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DESIGN OF COMMON HEADER LINE FOR REDUCTION OF PROCESS TIME IN
PUMP TESTING
Article in International Journal of Engineering and Technology · February 2018
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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 01 | Jan -2017 [Link] p-ISSN: 2395-0072
DESIGN OF COMMON HEADER LINE FOR REDUCTION OF PROCESS TIME IN
PUMP TESTING
V.Naveenprabhu1,*,F.JustinDhiraviam2, A.Vimal3and K.Kumarrathinam4
1,2,3 Assistant professor, Department of mechanical Engineering, Sri Eshwar College of engineering, Coimbatore, India.
4 Executive engineer, Enmas GB Power systems projects limited, Chennai, India.
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ABSTRACT pumps serve in a wide range of applications such as
Groundwater is frequently chosen as the most suitable pumping water from wells, aquarium filtering, pond
source of drinking water. Hence it is necessary to conduct filtering and aeration, in the car industry for water-
various tests to analyze the various parameters while cooling and fuel injection, in the energy industry for
abstracting the water. Pumping tests are a practical way of pumping oil and natural gas or for operating cooling
obtaining the results pertaining to the water abstraction. towers. The every pump has to test the capacity
Much of the specialized knowledge and technical expertise
before implement into in action of actual load.
needed for this purpose can be gained from the standard
literature. However, field operations in remote areas or in
difficult conditions often require flexibility to solve technical Testing of pumps to check whether that it
problems. The end result should be a cost-effective facility meets the manufacture specification is the area that
capable of supplying water for many years. The main needs [Link] problem identified is the
objective of the project is to test the operation of the time taken for testing of the pump is quite long and
pumping and monitoring equipment, to make sure that work is found tedious, in addition to huge manpower
employed method is been a sophisticated, effective and is needed while mounting and demounting of the
efficient method which will bring down the process timing [Link] wide range of pumps are been tested, It
and manual labor. Industries plunged towards technological
is often found that the old method is time consuming
development such as automation, superior material
management etc., which brings down the manual labor and taken a dig at manual [Link] is observed that
work and most important factor, Time. This work is also a the present method employed for the testing of
technique which reduces the handling time and handling pumps need [Link] separate
effort in the process of testing the pump for its specifications. suction line and delivery line are used for testing the
pumps of suction separately for lengths 1”, 1.5”, 2”,
KEYWORDS: pumping test, common header, 2.5” and for lengths 3”, 4”, 6”. Such a kind of design
delivery line and suction line takes huge time in testing and also requires high man
power.
INTRODUCTION LITERATURE REVIEW
Randall W. Whitesides, PE et alThere are many
A pump is a device that moves fluids (liquids or factors that affect the operation of a pump. Important
gases), or sometimes slurries, by mechanical action. factors are total head, speed, liquid properties, and
Pumps can be classified into three major groups physical arrangement/system connection. Included
according to the method they use to move the fluid: in the category of arrangement and connection are
direct lift, displacement, and gravity pumps. Pumps the suction conditions.
operate by some mechanism and consume energy to Excessive suction lift, shallow inlet submergence, or
perform mechanical work by moving the fluid. Pumps insufficient
operate via many energy sources, including manual Net Positive Suction Head available (NPSHA), all spell
operation, electricity, engines, or wind power, come serious trouble from vibration, cavitation, lowered
in many sizes, from microscopic for use in medical capacity, and reduced efficiency. While the Engineer
applications to large industrial [Link] may not have large control over some of the inherent
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 969
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 01 | Jan -2017 [Link] p-ISSN: 2395-0072
process factors, with planning and foresight many as the work piece in this type of welding and
times the pump suction conditions can be optimized weldingparameters such as welding current.
in the design stage.
Gokilakrishnan.g et al.[10] torque required to open EXPERIMENTAL SETUP
the valve in the fluid system needs some separate
external mechanical equipment for easier the Theproposed common header line system is
operation of valve. implemented in the pump testing line. Thebed used
Naveenprabhu et al. [6] and [7] deals with the fluid for the mounting of the pumps is the same as used
flow over the closed pipe environment to enhance before for testing individual pumps.
the fluid heat transfer characteristics nano sized After mounting the pump, the common header line
materials like aluminium are mixed with the water by for suction and delivery are engaged to the pump’s
means of separate mechanical process of chemical suction and delivery port respectively. Thisdesign is
decomposition to enhancement of thermal used for both common header lines and the working
conductivity of water. These chemical composition of common header line is explained in the following:
will increase the density of water that result decrease
the flow due to increase viscosity as well as pressure Operation of 1” Pump
drop in flow.
When a pump of suction capacity 1” is to be tested,
Baskaran.s et al.[8] experimental setup has explained
the 1” suction pump is mounted on the bed and the
with help of ic engines with different fuel for the flow
common header line assembly is mounted .When test
analysis of fuel through the different flow of diesel
is to be started the following arrangements are made
with different blending.
. The valve engaged with the 1” suction line is opened
Saravanakumar.N et al. [9] nano materials is mixed
and the 1.5”, 2”, 2.5” valves are closed. This, in turn
with the cutting fluid used in the conventional as well
makes the suction only through the 1” line.
as CNC machines for the efficient heat transfer, when
Eventually the flow takes place through the 1”
introduction of these types of fluids in application
suction line and flows through the common 2.5”
main problem arising is the flow to application is not
header line and reaches the pump. From there by the
as original because of alter the mother fluid by some
pump mechanism, the water is fed into the delivery
of the additives.
line. Similar to suction line the delivery line too
Sathiseelan.N et al. [11] Advanced materials
comprises of valves. In the delivery line, the
exhibitvery excellent technical properties. However,
arrangement similar to suction is made i.e. 1” valve is
the high costof both raw materials and processing
opened, 1.5”, 2”and 2.5” are closed. And the flow
limit their [Link] material such asnickel-base
measurement devices integrated with the 1” delivery
alloys, titanium alloys and stainless steel can beused
line is used to find out different flow parameters.
Fig 1 :Common Header , Delivery and Assembly line
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 970
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 01 | Jan -2017 [Link] p-ISSN: 2395-0072
Operation of 1.5” Pump Eventually the flow takes place through the 2”
When a pump of suction capacity 1.5” is to be tested, suction line and flows through the common 2.5”
the 1.5” suction pump is mounted on the bed and the header line and reaches the pump. From there by the
common header line assembly is mounted .When test pump mechanism, the water is fed into the delivery
is to be started the following arrangements are made line. Similar to suction line the delivery line too
. The valve engaged with the 1.5” suction line is comprises of valves. In the delivery line, the
opened and the 1”, 2”, 2.5” valves are closed. This, in rrangement similar to suction is made i.e. 2” valve is
turn makes the suction only through the 1.5” line. opened” and 1”, 1.5”, 2.5” are closed. And the flow
Eventually the flow takes place through the 1.5” measurement devices integrated with the 2” delivery
suction line and flows through the common 2.5” line is used to find out different flow parameters.
header line and reaches the pump. From there by the
pump mechanism, the water is fed into the delivery Operation of 2.5” Pump
line. Similar to suction line the delivery line too When a pump of suction capacity 2.5” is to be tested,
comprises of valves. In the delivery line, the the 2.5” suction pump is mounted on the bed and the
arrangement similar to suction is made i.e. 1.5” valve common header line assembly is mounted .When test
is opened, 1”, 2” and 2.5” are closed. And the flow is to be started the following arrangements are made
measurement devices integrated with the 1.5” . The valve engaged with the 2.5” suction line is
delivery line is used to find out different flow opened and the 1”, 1.5”, 2” valves are closed. This, in
parameters. turn makes the suction only through the 2.5” line.
Operation of 2” Pump Eventually the flow takes place through the 2.5”
suction line and flows through the common 2.5”
When a pump of suction capacity 2” is to be tested, header line and reaches the pump. From there by the
the 2” suction pump is mounted on the bed and the pump mechanism, the water is fed into the delivery
common header line assembly is mounted .When test line. Similar to suction line the delivery line too
is to be started the following arrangements are made comprises of valves. In the delivery line, the
. The valve engaged with the 2” suction line is opened arrangement similar to suction is made i.e. 2.5” valve
and the 1”, 1.5”, 2.5” valves are closed. This, in turn is opened” and 1”, 1.5”, 2” are closed.
makes the suction only through the 2” line.
Fig 3 : Final Assembly of Common HeaderLine 3” to
Fig 2 6”
: Final Assembly of Common HeaderLine 1” to 2.5”
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 971
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 01 | Jan -2017 [Link] p-ISSN: 2395-0072
FOR COMMON HEADER LINE OF LENGTH 3” TO 6” delivery line, the arrangement similar to suction is
made i.e. 4” valve is opened, 3”and 6” is closed. And
Operation of 3” Pump the flow measurement devices integrated with the 3”
When a pump of suction capacity 3” is to be tested, delivery line is used to find out different flow
the 3” suction pump is mounted on the bed and the parameters.
common header line assembly is mounted .When test Operation of 6” Pump
is to be started the following arrangements are made
. The valve engaged with the 3” suction line is opened When a pump of suction capacity 6” is to be tested,
and the 4”, 6” valves are closed. This, in turn makes the 6” suction pump is mounted on the bed and the
the suction only through the 3” line. Eventually the common header line assembly is mounted .When test
flow takes place through the 3” suction line and flows is to be started the following arrangements are made
through the common 4” header line and reaches the . The valve engaged with the 6” suction line is opened
pump. From there by the pump mechanism, the and the 3”, 4” valves are closed. This, in turn makes
water is fed into the delivery line. Similar to suction the suction only through the 6” line. Eventually the
line the delivery line too comprises of valves. In the flow takes place through the 6” suction line and flows
delivery line, the arrangement similar to suction is through the common 6” header line and reaches the
made i.e. 3” valve is opened, 4”and 6” is closed. And pump. From there by the pump mechanism, the
the flow measurement devices integrated with the 3” water is fed into the delivery line. Similar to suction
delivery line is used to find out different flow line the delivery line too comprises of valves. In the
parameters. delivery line, the arrangement similar to suction is
made i.e. 6” valve is opened, 3”and 4” is closed. And
Operation of 4” Pump the flow measurement devices integrated with the 6”
When a pump of suction capacity 4” is to be tested, delivery line is used to find out different flow
the 3” suction pump is mounted on the bed and the parameters.
common header line assembly is mounted .When test CALCULATION
is to be started the following arrangements are made
. The valve engaged with the 4” suction line is opened CALCULATION OF ENERGY LOSSES
and the 3”, 6” valves are closed. This, in turn makes
the suction only through the 3” line. Eventually the Kinematic Viscosity
flow takes place through the 3” suction line and flows
⁄
through the common 4” header line and reaches the
pump. From there by the pump mechanism, the Kinematic Viscosity
water is fed into the delivery line. Similar to suction ⁄
line the delivery line too comprises of valves. In the
MAJOR ENERGY LOSS: L– Length of Pipe
V- Mean Velocity of Flow
Darcy- Weisbach Equation, d- Diameter of Pipe
P- Welded Perimeter of Pipe
Chezy’s Formula, ( ) √ A- Area of Cross section of Pipe
- Loss of Head due to Friction Q= Area * Velocity;
f- Coefficient of Friction which is a function of
Reynolds number
Reynolds number= , for Re < 2000 (Viscous Flow)
= ⁄
, for re varying from 4000 to
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 972
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 01 | Jan -2017 [Link] p-ISSN: 2395-0072
MINOR ENERGY LOSS: Pipe Fittings,
( )
Sudden Expansion of Pipe,
Obstruction in Pipe, ( )
Sudden Contraction of Pipe,
Entrance of the Pipe,
Bend in Pipe,
Exit of the Pipe,
RESULT AND DISCUSSION
ANALYSIS OF FLOW THROUGH COMMON HEADER LINE
Fig 4: Analysis of Various sizes of individual pipes
Fig 5 :Analysis of Common Header Line
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 973
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 01 | Jan -2017 [Link] p-ISSN: 2395-0072
PROCESSTIMECALCULATION
Table: 1 Present Method Table: 2 Developed Method
NUMBER SETUP OPERA TOTA NUMB NUM SETUP OPER TOTA NUMB
OF PUMPS TIME TION L ER OF BER TIME ATION L ER OF
(MOUNT TIME TIME LABO OF (MOUNT TIME TIME LABO
+DEMOU URS PUM +DEMOU URS
NT) PS NT)
1 1 Hr 30 1 Hr 30 3 Hrs 4 1 30 Mins 1 Hr 2 Hrs 2
Mins Mins 30
4 6 Hrs 6 Hrs 12 4 Mins
Hrs 4 2 Hrs 6 Hrs 8 Hrs 2
Max number of pumps tested/ Per day (8hrs) =2 Max number of pumps tested/ Per day (8hrs)
=4
COST ESTIMATION
Table3:Cost Estimation for 1” to 2.5” Common Header Line
COMPONENTS 1” 1.5” 2” 2.5” COST (IN
RUPEES)
PIPES (in meters) 1*86=86 1*139=139 1*186=186 3*300=900 1311
ELBOW - - - 2*125=250 250
TEE JOINT 2*25= 50 2*50= 100 2*80= 160 - 310
VALVE 2*212= 424 2*411= 822 2*629=1258 2*836=1672 4176
FLANGE 4*147= 588 4*196= 784 4*295=1180 4*447=1788 4340
REDUCER 1”*2.5”- 1.5”*2.5”= 2”*2.5”= 2*51= - 274
2*40= 80 2*46= 92 102
TOTAL COST Rs. 10661
Table 4: Cost Estimation for 3” to 6” Common Header Line
COMPONENTS 3” 4” 6” COST (IN RUPEES)
PIPES (in meters) 1.4*393= 550 2.4*555= 1330 1.7*1002= 1700 3580
ELBOW - 2*310= 620 2*820= 1640 2260
TEE JOINT - 2*414= 828 2*1115= 2230 3058
VALVE 2*1040= 2080 2*1430= 2860 2*1860= 3720 8660
FLANGE 4*480= 1920 4*600= 2400 4*850= 3400 7720
REDUCER 3”*4”- 2*90=180 - 4”*6”- 2*125=250 430
TOTAL COST Rs. 25708
CONCLUSION engineering sciences to the worker and his working
environment, so as obtain maximum satisfaction for
According to the International Labor Organization the worker which at the same time enhances
(ILO), “Ergonomics is defined as the application of productivity”.
human biological sciences in conjunction with
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 974
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 01 | Jan -2017 [Link] p-ISSN: 2395-0072
Thus by using the Common Header Line, it becomes 9. Sathiseelan.N and Baskaran.S, ( 2016) ,’
very much easier for the workers to do pump testing Optimization of welding parameters using
without mounting and de-mounting the suction and plasma arc welding for SS316 material’,
delivery lines [Link] the manual labor is IRACST – Engineering Science and
reduced thereby reducing the process time and end Technology: An International Journal,pp 26-
result cost is also minimized. 31.
[Link].F, NaveenPrabhu.V, Suresh.T
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© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 975
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