Introduction

Pumps are essential components in industrial processes, facilitating the movement of

fluids for various manufacturing and processing tasks. These mechanical devices
employ different mechanisms, such as centrifugal force or positive displacement, to
impart energy to fluids and propel them through pipelines. Centrifugal pumps, for
instance, are favored for their ability to handle high flow rates, while positive
displacement pumps offer precise control over flow and pressure, making them suitable
for various fluids, including viscous or abrasive ones. When selecting pumps for a plant
process system, factors such as fluid properties, flow requirements, and operational
conditions must be carefully considered to ensure optimal performance and efficiency.
Ultimately, pumps play a pivotal role in maintaining the smooth operation of industrial
processes, contributing to productivity, reliability, and overall system effectiveness.

This report focuses on calculating the necessary amount of pumps for two distinct plant
setups in a company, one with pumps set in a series and the other with pumps set in
parallel Its main aim is to obtain understandings from the principles of various pump
configuration solutions to solving hydrodynamic variables for fluid flow in pipelines.. The
objective is to guarantee that both plants satisfy their specific flow rate and pressure
needs by taking into account different operational factors and limitations.

In plant processing systems, effective fluid management is essential for maximum

performance. Series and parallel pump setups provide different methods to attain the
required flow rates and pressures. Multiple pumps are arranged in a series to boost the
total system pressure, making this setup ideal for applications that demand high-
pressure output. On the flip side, parallel pumping includes running multiple pumps at
the same time to boost the overall flow rate capacity, perfect for situations that require
high flow rates. Factors such as system requirements, fluid characteristics, and
maintenance considerations should be carefully considered when deciding between
series and parallel configurations. Engineers and operators can effectively design and
operate plant process systems, ensuring smooth operations and maximizing
productivity by grasping the principles and considerations related to series and parallel
pumping.
In Plant 1, developed for transferring oil, requires a thorough assessment of the quantity
of pumps needed to be set up consecutively. The system requirements consist of a flow
rate of 3000 L/min, a specific gravity of 0.85, a pressure need of 120 kPa, and a total
pipe length of 900 m. Other considerations include a height variance of 25 meters
between the entrance and exit points, a pipe width of 0.2 meters, an 80% efficiency
rating for the pump, and a pump pressure of 40 meters. The difficulty is in determining
the exact amount of pumps required to address these physical and operational factors.

Plant 2, the water treatment facility, has a distinct set of demands. A flow rate of 5000
L/min is needed at a pressure of 300 kPa, with a total pipe length of 800 m and a height
difference of 12 m. Each pump in this configuration can produce a head of 35 m, with an
efficiency of 85%, and the pipe diameter is 0.3 m. The objective is to figure out the
number of pumps set up in parallel needed to meet the required flow rate and pressure.

This report thoroughly examines both situations, discussing the basic principles of fluid
dynamics, the utilization of system equations, as well as the application of appropriate
formulas and functions to determine the necessary amount of pumps. By taking into
account the characteristics of both Newtonian and non-Newtonian fluids, this study
guarantees a strong and flexible solution that can be used in a range of industrial
settings.
Methodology

The approach used in this report follows a systematic method for determining the
necessary number of pumps for every plant setup. The procedure involves providing
precise details of system equations, inputs, and assumptions to guarantee a thorough a
80%nd dependable analysis.

The following parameters are taken into account for Plant 1:

• Flowrate (Q) → 3000 L/min = 0.05 m3/s

• Pressure (P) → 120 kPa = 120 000 Pa
• Specific gravity of oil (SG) → 0.85
• Total pipe length (L) → 900 m
• Pipe diameter(d) → 0.2 m
• Height difference between the inlet and outlet of the pipe (∆z) → 25 m
• Pump efficiency (ɳ) → 80% = 0.80
• Viscosity (µ) → 0.0595 Pa.s

The following parameters were considered for Plant 2:

• Flowrate (Q) → 5000 L/min = 0.0833 m3/s

• Pressure (P) → 300 kPa = 300 000 Pa
• Total pipe length → 800 m
• Height difference of 12 m between the inlet and outlet of the pipe (∆z) → 12 m
• Pump efficiency (ɳ) → 85% = 0.85
• Pipe diameter (d) → 0.3 m

The following was assumed for plant 2:

• Water density (ρ) → 1000 kg/m3

• Water viscosity (µ) → 10-3Pa.s
Calculations require applying both the Bernoulli equation and the Darcy-Weisbach
equation to find the overall head loss in the system.

Figure 1: Bernoulli’s Equations

The following formulas were used for plant 1 and plant 2:

 Area: The area of a two-dimensional shape is known as the cross-sectional

area, which is obtained by slicing a three-dimensional object, like a cylinder,
perpendicular to a specified axis at a point. For instance, if you were to slice a
cylinder parallel to its base, the cross-section would be a circle.

2
πd
A=
4

Where:

• A → cross-sectional area of the pipe (m2)

• d → diameter of pipe (m)
  Specific gravity: Specific gravity (SG) is a unit less measure that shows the
relationship between a fluid's density and that of a standard substance (typically
water at 4°C for liquids). Specific gravity plays a crucial role in fluid mechanics by
affecting fluid behavior and system design.

ρ subtance
SG=
ρreference

Where:

• SG → Specific gravity
• ρ subtance→ density of oil (kg/m3)
• ρreference → density of water (kg/m3)

 Velocity: velocity refers to the rate of motion in a specific direction

Q
v=
A

Where:

• v→ velocity (m/s)
• Q→ Flowrate (m3/s)
• A→ Area (m)

 Reynolds number: The Reynolds number (Re) is a unit less measure utilized
in fluid dynamics to forecast flow behaviors in various fluid flow scenarios. It
shows if the flow will be smooth or chaotic. The equation used to determine the
Reynolds number is:
ρvd
Re =
μ
 Where:
• Re → Reynolds number
• ρ → density(kg/m3)
• v→ velocity (m/s)
• d → diameter of pipe (m)
• μ → viscosity (Pa.s)

 Frictional factor: The friction factor indicates the pressure drop of a liquid in a
tube because of the friction between the liquid and the tube.

2d
f= 2
∆P
ρv l

Where:

• f→ frictional factor
• d→ diameter (m)
• ρ→ density of fluid (kg/m3)
• v→ velocity (m/s)
• l→ length of pipe (m)
• ∆P→ Pressure (Pa)

 Frictional head loss: The head loss measures the decrease in the total head
of the fluid while it travels through a pipeline. Friction loss or head loss caused by
friction occurs along the pipe wall.

[ ]
2
l v
H L=f ( )( )
d 2g

Where:

• HL→ frictional head loss (m)

 • f→ frictional factor
• l→ length of pipe (m)
• d→ diameter (m)
• v→ velocity (m/s)
• g→ gravitational acceleration (m2/s)

 Total head of pump: The total pump head is the total discharge head (point 2)
minus the total suction head (point 1). The word "total" means it encompasses
the static pressure head, the velocity head, and the elevation head.

P
HT= +∆ z
ρg

Where:

• HT→ Total head of pump (m)

• P→ Pressure (Pa)
• ρ→ density of fluid (kg/m3)
• g→ gravitational acceleration (m2/s)
• ∆z→ height difference (m)

 Effective pump head: H P× ɳ

Where:

• Hp → effective pump (m)

• ɳ → pump effeciency

HT
N=
Hp

Where:

• HT→ Total head of pump (m)

 • H p→ Effective pump head

 Calculations
Plant 1: For plant 1 we are required to calculate the number of pumps needed in a
series to meet the process requirements of a chemical plant.
3000 l
∗1m3
min
• Flowrate(Q)= ∗1 min
1000 l
60 s
=0.05m3/s
kg
• Density=0.85∗1000 3
m
=850kg /m3
• Viscosity= 0.0595Pa.s
2
πd
• Area=
4
2
π ( 0.2 m )
¿
4
= 0.0314m3
Q 0.05 2
• Velocity= = =1.592 m /s
A 0.0314

ρ∗v∗d ( 850 )( 1.592 ) ( 0.2 )

• Re= =
μ 0.0595

¿ 4548.57
Therefore flow is Turbulent ,[Re¿ 4000 ¿ .

 Assuming we have a smooth pipe

0.316
For smooth pipe turbulent flow : f = 1/4
ℜ
0.316
Friction Factor = 1
4548.57 4
¿ 0.04

L
• Frictional Head Loss(HL) = f ( )¿ )
d
( 0.04 )∗900
= ∗¿ ¿
0.2
=23.25m

• Pressure head (Pa)=120 kPa∗1000=120 000 Pa

P 120 000
• Head Total (HT) = + z= + 25
ρ∗g 850∗9.81
=14.39m + 25m
=39.39m
• Static Head(Hs) = Height difference = 25m
• Total Dynamic Head(TDH) = HT+HL
¿ 39.39+23.25
=62.64m
TDH 62.64
Number of pumps(n)¿ =
Pump per head∗η 40∗0.8
¿ 1.95

Therefore ≈ 2 pumps are needed in series to meet the requirements of the plant.

Plant 2 : We are required to determine the number of pumps needed in parallel to

meet the requirements of the plant.

5000 l 3
∗1m
min
• Flowrate = ∗1 min
1000 l
60 s
 3
¿ 0.083 m /s
• Density of water = 1000kg/m3
• Viscosity of water = 1.26x10-6 Pa.s
2 2
πd π ( 0.3 )
• Area= =
4 4
3
¿ 0.0707 m
Q 0.083
• Velocity = =
A 0.0707
¿ 1.174 m/ s
ρ∗v∗d ( 1000 ) ( 1.174 )( 0.3 )
Re= =
μ 1 ×10
−3

¿353700

Turbulent flow [Re¿ 4000 ¿

2d
• Friction Factor= 2
∆P
ρV l
2 ( 0.3 )
= ∗(300 000)
( 1000 ) (1.174 )2 ( 800 )
= 0.164 =0.2
L
• Frictional Head Loss(HL) = f ( )¿ )
d
800
=0.2( )¿ )
0.3
=37.47m
P 300 000
• Head Total (HT) = + z= +12
ρ∗g 1000∗9.81
¿ 42.58 m
• Total Dynamic Head(TDH) = HT+HL
=32.47+42.58
=80.05m
Pump Head 35
Effective head= = =41.18 m
Pump Efficiency 0.85
 Total Head 80.05
Number of pumps = = =1.94
Effective Head 41.18

Therefore ≈ 2 pumps are required in parallel to meet the conditions of the plant.

Discussion