PUMP (P-100):

Pumps are basically machines that can add energy to fluids. As a result, they can increase the
pressure, velocity, or elevation of the fluid so that it can either be taken to a different place or
circulated within a system. According to their working principle, the first level of classification of
these devices includes two main types, namely: Centrifugal (Dynamic) pumps and Positive
Displacement pumps.

Centrifugal Pumps
The theory of these pumps, which are the most common in processing industries, is based on
transferring kinetic energy into the fluid. The fluid enters the center (eye) of a rotating impeller.
The impeller vanes accelerate the fluid outward due to centrifugal force.
When the fluid goes from the small passages of the impeller to the larger volume of the casing
(volute or diffuser), its velocity is changed into static pressure according to the Bernoulli equation.
Some of the major parameters to monitor are Head (H), which is the height the pump can lift the
fluid, and Net Positive Suction Head (NPSH), which is the condition that allows the pressure at
the impeller eye to be high enough to prevent cavitation (the formation and collapse of vapor
bubbles, which causes the pump to wear). The connection between head, flow rate (Q), efficiency,
and power is core to their working and determining their size.

Positive displacement pumps

Positive displacement pumps are devices that work on the idea of capturing a specific amount of
fluid and then pushing (displacing) that same amount into the outlet pipe. Their flow rate is in
theory fixed even if the output pressure changes, thus they can be used as a source of high pressure
and low- flow with great success. The list of such pumps comprises piston, plunger, diaphragm,
and different types of rotary ones (gear, screw, vane). They differ from centrifugal pumps in that
their operation is mainly dependent on the speed and the volume of the chambers, and they have
to be equipped with a relief valve for safety purposes in case of an overpressure condition.

Mixed Refrigerant (MRL) - Calculation Data

Property Symbol Value Unit Value Unit

specific heat capacity Cp 2.554152 KJ/kg. K 141.5 KJ/kgmole. ̊C

dynamic viscosity μ 0.00012 Pa. S

density ρ 532.8 Kg/m3

temperature T 40 ̊C

Pressure inlet P1 21.007 Barg 2202 kPa

Pressure outlet P2 59.627 Barg 6064 kPa

pipe length L 30.48 m 100 ft

roughness of pipe
ε 4.572E-05 m 0.0018 in
material

Pipe diameter D 0.2032 m 8 in

efficiency np 0.75

flowrate Q 0.064501 m3/s 123719 kg/hr

g g 9.81 m2/s

Step-by-Step Calculations:

STEP 1: Calculate Pipe Cross-Sectional Area (A)

𝐴 = 𝜋𝐷² / 4
Substituting values:
A = π × (0.2032) ² / 4
A = π × 0.04129024 / 4
A = 0.129734 / 4
A = 0.032433 m²
STEP 2: Calculate Flow Velocity (V)
𝑉 = 𝑄/𝐴
Where:
Q = Volumetric flowrate = 0.064501 m³/s
A = Cross-sectional area = 0.032433 m²

Substituting values:
V = 0.064501 / 0.032433
V = 1.988725 m/s

STEP 3: Calculate Reynolds Number (Re)

𝑅𝑒 = (𝜌 × 𝑉 × 𝐷) / 𝜇

ρ × V × D = 532.8 × 1.98872 × 0.2032 = 215.5

Re = 215.5 / 0.00012 = 215.5 / 1E-04
Result: Re = 2.155 × 10⁶ = 2E+06

Flow is TURBULENT (Re > 4000)

STEP 4: Calculate Darcy Friction Factor (f)

Note: The friction factor is calculated using the Colebrook equation method or Moody diagram.
For this calculation, it was determined using a calculator/iterative method.
𝜀/𝐷 = 5𝐸 − 05 / 0.203 = 0

Relative roughness:
ε/D = 4.572E-05 / 0.2032
ε/D ≈ 0.000225 ≈ 0 (very smooth pipe)

f = 0.014585 (from calculator/Colebrook equation)

STEP 5: Calculating Total Head loss (m)

1. Friction Head Loss (hf)
ℎ𝑓 = 𝑓 × (𝐿/𝐷) × (𝑉²/2𝑔)
Given:
f = Darcy friction factor = 0.014585
L = Pipe length = 30.48 m
D = Pipe diameter = 0.2032 m
V = Flow velocity = 3.95503 m/s (from velocity calculation)
g = Gravitational acceleration = 9.81 m/s²

Step 1a: Calculate L/D

L/D = 30.48 / 0.2032
L/D = 150

Step 1b: Calculate V²

V² = (3.95503)²
V² = 3.95503 m²/s²

Step 1c: Calculate 2g

2g = 2 × 9.81
2g = 19.62 m/s²

Step 1d: Calculate V²/2g

V²/2g = 3.95503 / 19.62
V²/2g = 0.20158 m

Step 1e: Calculate hf

hf = 0.014585 × 150 × 0.20158
hf = 2.188 × 0.20158
hf = 0.4410096 m

2. Minor Losses (h_minor)

Note: Minor losses include losses due to fittings, valves, bends, expansions, contractions, etc.
The loss coefficient K is estimated as 2.0 for this calculation.
ℎ𝑚𝑖𝑛𝑜𝑟 = 𝐾 × 𝑉² / 2𝑔
Given:
K = Minor loss coefficient = 2.0 (estimate)
V = Flow velocity = 3.95503 m/s
g = Gravitational acceleration = 9.81 m/s²

Step 2a: Calculate V²

V² = (3.95503)²
V² = 3.95503 m²/s²

Step 2b: Calculate 2g

2g = 2 × 9.81
2g = 19.62 m/s²

Step 2c: Calculate hminor

hminor = 2 × 3.95503 / 9.81
hminor = 2 × 3.95503 / 9.81
hminor = 0.4031627 m

3. Velocity Head (hv)

ℎ𝑣 = 𝑉² / 2𝑔
Given:
V = Flow velocity = 3.95503 m/s
g = Gravitational acceleration = 9.81 m/s²

Step 3a: Calculate V²

V² = (3.95503)²
V² = 3.9550264 m²/s²

Step 3b: Calculate 2g

2g = 2 × 9.81
2g = 19.62 m/s²

Step 3c: Calculate hv

hv = 3.9550264 / 19.62
hv = 0.2015814 m

4. Elevation Head (h_z)

Elevation head (static height difference) = hz = 1 m. This represents the vertical height
difference between the inlet and outlet of the pipe system.

5. Total Head (H)

𝐻 = ℎ𝑓 + ℎ𝑧 + ℎ𝑚𝑖𝑛𝑜𝑟 + ℎ𝑣
Where:
hf = Friction head loss = 0.4410096 m
hz = Elevation head = 1 m
hminor = Minor losses = 0.40316 m
hv = Velocity head = 0.2016 m

Substituting values:
H = 0.4410096 + 1 + 0.40316 + 0.2016
H = 2.0457537 m

• Required Hydraulic Head

H pump = 2.0457537 m

STEP 6: Calculation of Required Pump Power

1. Hydraulic (Shaft) Power

The hydraulic (shaft) power required by the pump is calculated using the following equation:

𝑃shaft = 𝜌 × 𝑔 × 𝑄 × 𝐻
Where:
ρ= Fluid density = 532.8 kg/m³
g= Acceleration due to gravity = 9.81 m/s²
Q= Volumetric flow rate = 0.064501274 m³/s
H= Total pump head = 2.045753735 m

Substituting the values:

𝑚 × ∆𝑃
𝑃_𝑠ℎ𝑎𝑓𝑡 =
𝜌 × 𝜂
 34.366279 × 3862
𝑃_𝑠ℎ𝑎𝑓𝑡 =
532.8 × 0.75

P_shaft = 332.13856 kW
P_shaft = 332,138.6 W

Hence, the hydraulic (shaft) power required by the pump is approximately 332.1 kW.

2. Motor (Electrical) Power Requirement

To account for pump efficiency, the motor power is calculated using:

𝑃shaft
𝑃motor =
𝜂𝑝
Where:
𝑃shaft= 332138.6 W
𝜂𝑝 = Pump efficiency = 0.75

P motor= 332138.6/0.75
P_motor= 442851.41 W
P_motor= 442.9 kW
P_motor= 593.864 hp

STEP 7: Calculation of Net Positive Suction Head Available (NPSHA)

2.31(𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 𝑣𝑒𝑠𝑠𝑒𝑙 − 𝑃𝑣𝑎𝑝𝑜𝑟)

𝑁𝑃𝑆𝐻𝐴 = + 𝐻𝑠𝑢𝑐𝑡𝑖𝑜𝑛 𝑛𝑜𝑧𝑧𝑙𝑒 − ℎ𝑓
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐺𝑟𝑎𝑣𝑖𝑡𝑦

1. Given Data

• Suction pressure (gauge): 21.007 barg

• Suction pressure (absolute): 22.02025 bar
• Suction pressure (absolute): 319.36 psi
• Fluid vapor pressure, 𝑃𝑣 : 219.5 psi
• Fluid density, 𝜌: 532.8 kg/m³
• Specific gravity, 𝑆𝐺: 1.2545
• Suction nozzle elevation relative to pump centerline: 0 ft
• Suction line losses:
o 1.0458 m
o 3.431 ft

2. Pressure Difference at Pump Suction

The effective pressure available at the pump suction is calculated as the difference between the
suction vessel pressure and the fluid vapor pressure:
 Δ𝑃 = 𝑃suction − 𝑃𝑣
ΔP=319.36 – 219.5
ΔP=99.86 psi

3. Calculation of NPSHA

The Net Positive Suction Head Available (NPSHA) is calculated by converting the available
pressure difference into an equivalent liquid head and accounting for suction losses.

NPSHA = 180.45 ft

Converting feet to meters:

180.45
NPSHA =
3.28084
NPSHA = 55 m

This value represents the net suction head available at the pump inlet and should be compared
with the pump manufacturer’s NPSH required (NPSHR) to ensure cavitation-free operation.

STEP 8: Electrical Rating and Motor Selection

1. Electrical Rating Margin

An electrical rating margin of 1.10 is applied in accordance with Table 4.2.4 (B).

2. Electrical Power Requirement

Electrical Rating = 653.3 hp

3. Motor Power Selection

Based on standard motor sizes and as per Table 4.2.4 (C), the selected motor rating is:

Motor Power Selection = 670 hp

This selection provides adequate margin for startup conditions, service factors, operational
reliability, and future system degradation.
• Pump type: single-stage centrifugal pump (horizontal or vertical inline) — a low-head,
high-flow single-stage centrifugal is appropriate.
• Motor: choose a 1.0 kW motor (3-phase), IEC frame, with appropriate V & RPM (e.g.,
1450 or 2900 rpm). The pump curve will tell whether 1450 or 2900 rpm is better to reach
0.06 m³/s at 1.36 m head with good efficiency.
• Margins: add 10–20% head margin in selection to allow for fouling, uncertainty in K, and
future minor head additions. Likewise select motor with service factor (1.15–1.25) as
required by site practice.
References:

1. R. H. Perry, D. W. Green, and J. O. Maloney, Perry's Chemical Engineers' Handbook,

8th ed. New York, NY, USA: McGraw-Hill, 2008.
2. F. M. White, Fluid Mechanics, 7th ed. New York, NY, USA: McGraw-Hill, 2011
3. J. H. Ferziger, R. L. Panton, A. T. McDonald, and R. W. Fox, Fox and McDonald's
Introduction to Fluid Mechanics, 9th ed. Hoboken, NJ, USA: Wiley, 2015.
4. R. B. Bird, W. E. Stewart, and E. N. Lightfoot, Transport Phenomena, 2nd ed. New
York, NY, USA: Wiley, 2002.
5. Crane Co., Flow of Fluids Through Valves, Fittings, and Pipe (Technical Paper 410),
20th ed. Stamford, CT, USA: Crane Co., 2018.
6. I. J. Karassik, Centrifugal Pumps: Design and Application, 2nd ed. New York, NY, USA:
Gulf Publishing, 1998.
7. Gas Processors Suppliers Association, GPSA Engineering Data Book, 12th ed., Tulsa,
OK, USA: GPSA, 2004.