10.0 Pump Design & Pump System Design Preface: Bechtel Confidential

10.
0 PUMP DESIGN & PUMP SYSTEM DESIGN
PREFACE
This section details the method of calculating pressure profiles, determination of net positive
suction head (NPSH), and establishment of pressure drops through control valves for various
pumping systems.
INTRODUCTION
The rules included in this section for pump design and pump system design should be
followed, unless specified otherwise by job (Client) requirements. Pressure Profile Program is
mandatory for generating the “Pump and Control Valve Calculation Sheet.”
For convenience and ease in maintaining records, the pump calculation has been prepared to
indicate the original Calculation Level I, the purchase Calculation Level II, and the final
Calculation Level III. On a normal project, Calculations I, II, and III are performed by the
Project Engineer.*
* Unless it is a conceptual design in which case the process engineer carries out Level I
calculations.
Note: Level III Calculation shall be done only for pumps in critical service. For non-critical
service pumps, Calculations I and II alone will be performed. After Calculation II has been
done and changes occur in plot plan or system design by addition or deletion of equipment, by
a change in delivery point or pipe rack elevation affecting a non-critical pump circuit, the
necessity of Calculation III should be explored. A decision can be taken in a short time (less
than an hour) by re-running the PPS program and by substituting new values in Calculation II.
If results indicate even a doubt in the adequacy of contingency, Level III Calculations shall be
performed.
Pumps that are in critical service will be defined at the beginning of each project. These
critical services normally involve more than one destination, multiple heat exchangers in
series/parallel, and a multitude of control valves. Any shortfall in flow or head of such
applications will not allow sustained plant operation.
Typical critical services may include:
· Pumparound circuits
· Furnace Charge loops
· Complex Reactor Charge loops
· Complex Boiler Feedwater circuits
· High Horsepower (above 500HP) pumps
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to the electronic documents in BecRef for current revisions.
Bechtel Confidential
© Bechtel Corporation 2002. Contains confidential and/or proprietary information to Bechtel and its affiliated companies which shall not be
used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission. All rights reserved.
3DG-M11-J0001-003 PAGE 1 OF 54
The following groups shall be consulted on identifying critical pump service applications:
· Process
· Project
· Process Licensor (if any)
· Machinery
Project Engineering will facilitate identification of critical service applications.
Application of the Pressure Profile Program precludes showing all three (3) calculations on the
same sheet. Each calculation requires a new sheet and revision similar to any
drawing/calculation of computer origin.
Level I Calculation
In order to provide preliminary data for vendor quotations, pump specifications must normally
be developed before equipment layouts are available. A method of estimating pump
requirements for preliminary design is detailed below. While making the pump calculations,
equipment design pressures can be determined by development of the system pressure
profile.
The Project Engineer will obtain the data to perform Level I Calculations from appropriate
documents such as stream properties, steam balance, utility balance and pump datasheet
issued by Process Engineering.
It is important that any alternate service conditions be specified as different cases. These
alternate service conditions should be shown as a range of flowrates (min., normal and max.)
or different process cases. The Pump and Control Valve Design Sheet is numbered by the
Project Engineering Group. A systematic review is made by the Project, Instrument Engineer
and Rotating Equipment Specialist Engineers according to the requirement of the job.
The Unit/Project Engineer will refine the calculations by estimating the NPSHR (Net Positive
Suction Head Required) based on the pump suction specific speed, r.p.m., flow rate and
estimated head. The calculated NPSHR shall be confirmed with the Rotating Equipment
Specialist. Alternatively, if NPSHR calculation is not done it may be read from Chart G 1.1 or
obtained from the Rotating Equipment Specialist. Using a margin for NPSH specified for the
project, NPSHA (Net Positive Suction Head Available) shall be calculated and the elevation of
the source vessel fixed. The calculation shall then be adjusted for the new elevation. The
Unit/Project Engineer will prepare the pressure profile in psia on the lower graph section of the
Pump and Control Valve Design Sheet showing the maximum pump discharge and maximum
pump suction pressures. Maximum pump suction pressure is based on suction vessel high-
high liquid level and relief valve set pressure plus accumulation unless dictated otherwise by
Bechtel Confidential © Bechtel 2002. All rights reserved.
PUMP DESIGN & PUMP SYSTEM DESIGN

3DG-M11-J0001-003 PAGE 2 OF 54
Client practices.
It is important to remember that vessels, exchangers, heaters, etc., are normally longer
delivery items than pumps. Therefore, good engineering judgment is required to set design
pressures of equipment at an early date.
If the Project Engineer has used the Pressure Profile Program, the pressure profile will be
drawn and the results issued as Level I Calculation.
Level II Calculation
The second phase of calculations is made by the Unit/Project Engineer just prior to purchase
of the pumps. Pump quotations will have been received complete with estimated performance
curves. Pressure drops for exchangers and heaters will have been quoted by their vendors.
Timing is of importance at this stage. Ideally, purchase of pumps should be done at the same
time or before the rest of the equipment in the system. However, this is considered impractical
because of unequal delivery time. Therefore, changes in equipment design pressures caused
by pump heads shall be made as early as possible and prior to start of equipment vendor’s
engineering and fabrication to minimize extras.
The differences between Level I and II Calculations are:
(1) Required NPSH is quoted by the pump vendors which allows verification of skirt heights
(2) Equipment (exchangers, heaters, etc.) pressure drops are based on purchased
equipment
As part of Level II Calculation, verify the Dp across the control valve based on the minimum
process flow (turndown flow) and minimum (non-fouled, without contingency) pressure drop
through equipment and piping. This condition will result in maximum Dp across the control
valve.
Revise the pump shutoff pressure based on vendor’s quoted pump performance curve.
For pumps in non-critical service where Level III Calculation is not to be performed, special
attention needs to be made to ensure vendor pressure drop data is obtained for heat
exchangers, filters, heaters, nozzles, static mixers, flow orifices before Level II Calculation is
completed and issued. If for some reason vendor pressure drop data is available only after
completion of Level II Calculation, the vendor data shall be compared to the assumed
pressure drop data and the difference verified against the contingency. If an inadequacy is
determined, Level III Calculation shall be performed.

3DG-M11-J0001-003 PAGE 3 OF 54
Level III Calculation
Once equipment layouts and isometric drawings are available, the Unit/Project Engineer is
responsible for verifying specification of the pump selected, using the manufacturer’s
equipment pressure drops and line losses calculated by the Linesize program in PPS using
the length and fittings taken from isometric drawings. The line loss calculations from simplified
piping sketch can also be used if isometric drawings are not available. The pressure profile is
firmed up to indicate final design and final data as developed in the Level II Calculation Pump
and Control Valve Design Sheet.
If, however, the Pressure Profile computer program is used, line sizing can be done internally
and the final design may be produced in design sheet form. Pressure Profile can generate the
system sketch and produce pressure profile on the design sheet as needed.
Important Note Pertinent to all Three Calculations
It is most important to check pump shutoff head versus design pressure of all affected
systems, specially when revisions are made to the system. Rising head curves for pumps in
series must also be considered.
10.1 Criteria for Pump Design
10.1.1 Design Flow or Rated Flow
All pumps, except those used in reflux and furnace charge services, should be rated for 110%
of normal flow. Reflux pumps and furnace charge pumps should be designed to handle 120%
of normal flow. This is Bechtel’s standard practice and must be implemented, unless specified
otherwise by the Client.
Normal flow is the flow specified on the PFD or stream property tables that will give the
throughput that the plant/unit is designed to produce.
For pumps in boiler feedwater and condensate systems for design margin between the
“normal” flow and “rated” flow, reference shall be made to Mechanical Engineering Design
Guide No. 3DG-M43G-00001 titled, “Design Guide for Design Margins for Pumps in
Condensate and Feedwater Systems.”
10.1.2 Minimum Flow
To protect pumps from thermal and instability problems minimum flows are specified by
vendors. The minimum flow can vary from 10 percent to 50 percent of the rated flow. If a
continuous minimum flow is provided by means of a continuous flow recirculation line with a
restriction orifice, the recirculating flow should be added to the rated flow defined in Paragraph

3DG-M11-J0001-003 PAGE 4 OF 54
10.1.1 to arrive at a new rated flow. As an illustration if the rated flow without recirculation is
100 GPM and the minimum flow required is 20 GPM, then the rated flow should be revised to
120 GPM with the recirculating flow line recirculating 20 GPM continuously back to the source
of pump suction.
If, however, the recirculating flow line derives flow from an automatic recirculation valve or a
control valve, the minimum flow is not to be added to the rated flow. In such cases, flow
through the recirculating line occurs only when flow across the main line drops below that
needed for proper operation of the pump.
10.1.3 Pressure Drops through Equipment at Normal Flow
For first guesses needed in Level I Calculations, the Engineer should use the allowable
pressure drops in equipment data sheets to vendors for bids. If these are not issued yet, the
following values can be used.
(a) Exchangers
A 10 psi pressure drop per exchanger unit may be assumed for liquids having a
viscosity less than 10 cP, and 15 psi between 10 and 25 cP and 25 psi above 25 cP.
(b) Air Coolers
A 15 psi pressure drop may be assumed for liquids having viscosities of 10 cP or less,
and 20-50 psi for liquids with viscosities between 10 and 100 cP (upper limit for refinery
vacuum tower bottoms).
(c) Plate Air Exchangers
An 8 psi pressure drop may be used.
Multiplier factors for fouled heat exchanger and air cooler pressure drops should be
used if specified by Project Procedures. If not, use the following multipliers. These are
based on process side fouling factors.
Fouling Factor Multiplier

Process Side < 0.001 1.15
< 0.0029 1.29
> 0.003 1.5

3DG-M11-J0001-003 PAGE 5 OF 54
(d) Orifice Meter
A nominal pressure drop of 2 psi (corresponds to 100-inch meter orifice) shall be used
for all orifice meters.
(e) Other Equipment
For equipment in which pressure losses vary considerably (heaters, mixers, filters,
centrifuges, etc.), consult Vendor specifications, if available.
10.1.4 Control Valves in Pump Discharge Systems
The selection of the pressure drop through control valves is a function of the dynamic losses in
the system. The dynamic losses are the pressure drops which vary with flow, such as through
piping, heat exchangers, heaters, mixing and spray nozzles, etc. (These do not include the
pressure drop through the control valves).
The Chart below is a guide indicating the lowest permissible percentages of the dynamic
losses (with a minimum of 10 psi) shall be used to establish the pressure drop through the
control valve under normal flow condition.
In practice, the losses in most pump discharge systems are in a range that result in using the
basis of 50% of the system dynamic loss for total dynamic loss less than 50 psi. The lower
percentage values shown in the Chart may require upward adjustment using engineering
judgment and considering the following criteria:
(a) Decreasing the percentage of the system dynamic loss used for the control valve also
decreases the ability of the valve to control.
(b) The Chart will give the optimum valve size for a given horsepower.
(c) The Chart refers to a system dynamic loss in fouled condition (e.g., heater coils just
before decoking, etc.)

3DG-M11-J0001-003 PAGE 6 OF 54
For systems using high horsepower pumps, the control valve sizing must be thoroughly
studied to obtain the required control action using minimum horsepower. Consultation with the
Control System Engineer and the Rotating Equipment Specialist will aid to determine an
optimum design. Do not use the Chart to estimate ΔP’s across control valves in service other
than pump discharge systems.
Turndown Flow and Control Valve Rangeability
In order to specify proper control valve rangeability, an analysis should be done at turndown
flow to determine control valve pressure drop. This will allow the Systems Engineer to
determine a new Cv at turndown flow to be incorporated in the control valve M/R. The
Pressure Profile Program is used to estimate control valve pressure drop at minimum, normal
and maximum (pump rated) flows. These values are useful for the Control Systems Group to
specify control valve rangeability. There may be cases when the large required range cannot
be covered by one valve. Two parallel valves could be required to cover both the high and low
end of the required control range.
10.1.5 Dynamic Head
Allow 2 psi minimum for dynamic head loss due to acceleration of fluid through the pump.

3DG-M11-J0001-003 PAGE 7 OF 54
10.1.6 Friction Losses in Flow Lines
Suction Lines
Pump suction line sizing is based on the rated flow (i.e., 110 or 120% of normal), per
Paragraph 10.1.1 for NPSH purposes.
The total friction loss in suction lines should generally not exceed 0.5 psi. However, NPSH is
the only criterion. An evaluation of the NPSHA and NPSHR may allow a greater loss provided
other pump requirements such as the velocity criteria set in Paragraph 2.3 are satisfied.
Discharge Lines
Two Options are possible:
Option 1:
For pumping circuits where project procedures require the system to be designed for normal
flow and the rated flow is provided as a contingency for the pump, the pump differential head
is determined based on pressure drop and velocity criteria for process liquid lines based on
normal flow. Pressure drop through equipment is based on normal flow. The control valve
pressure drop selected is based on dynamic losses at normal flow as given in Chart in
Paragraph 10.1.4, or 10 psi, whichever is higher.
Note that PPS has the capability to calculate the % of total dynamic loss and the control valve
ΔP based on the calculated total dynamic loss per the Chart in Paragraph 10.1.4.
Option 2:
For pumping circuits where project procedures require the system to be designed to push the
rated flow of the pump, the pump differential head is determined based on pressure drop and
velocity criteria for process liquid lines based on rated flow rate. Pressure drop through
equipment is determined based on rated flow. At rated flow a minimum pressure drop of 10
psi (0.69 bar) through the control valve shall be provided. Pressure drop through control valve
at normal flow is determined from the specific pump curve provided by Mechanical group. A
check should be made to ensure that the control valve pressure drop recommended by the
Chart in Paragraph 10.1.4 is also satisfied (50% of total dynamic losses = Line loss + loss
through the equipment). If the check reveals a deficiency, the pressure drop at normal flow
should be increased and the pressure drop at rated flow increased accordingly. If the check
shows the available pressure drop at normal flow greater than that given in Chart in Paragraph
10.1.4, no change needs to be made.

3DG-M11-J0001-003 PAGE 8 OF 54
The Pressure Profile Program is set up to perform calculations for both options. The option to
be used has to be determined by the Unit/Project Engineer based on Project and Client
Systems Design Criteria.
In order to expedite pump data calculations, assume pressure drops in the discharge lines in
accordance with the following table, until lines are sized by rigorous calculations.
Minimum Pressure Drop,

psi
Reflux to Towers 5
Feed to Column 10
To Battery Limits 10
Fired Reboiler Loop 15
For viscous fluids, the pressure drop allowed may exceed the minimum suggested above.
Allow additional pressure drop for lines going off-plot.
If plot plan or model is available, the line length should be estimated and the pressure drop
calculated.
In this estimate include length for the following:
Lines going to and from pipe rack and equipment. Vertical length of line up and down from
pipe racks and up and down equipment.
Allowance for equivalent length of fittings.
If the calculated pressure drop is less than 5 psi, then use 5 psi as a minimum line loss.
10.1.7 Net Positive Suction Head (NPSH)
The Net Positive Suction Head (NPSH) is the suction head in feet or meters of liquid (absolute
at the pump centerline or impeller eye) less the absolute vapor pressure (in feet or meters) of
the liquid being pumped.
It is necessary to check the NPSH conditions for each pump application to determine whether
the liquid to be pumped will vaporize inside the pump. Vaporization within a pump is called
cavitation. Cavitation reduces a pump’s performance and can damage the pump.
It is known that a liquid can vaporize on reduction of pressure when it is close to its vapor
pressure. The pressure on a liquid entering a centrifugal pump is reduced as it moves from
the suction flange to the point at which it receives energy from the impeller. This reduced
pressure needs to be compared to the vapor pressure entering the pump to determine

3DG-M11-J0001-003 PAGE 9 OF 54
whether the liquid will vaporize. This is what is done when NPSH conditions on an application
are checked. The proximity of a fluid at the pump to its vapor pressure is its “available NPSH”
and the pressure reduction inside the pump is the “required NPSH.” It is normal to compare
the available NPSH to the required NPSH. When the available NPSH is equal to or greater
than the required NPSH the pump will not cavitate.
Sufficient NPSH should be made available to permit reasonable flexibility in pump selection.
Check NPSH available against typical NPSH requirements using the design flow rate for
pumps by acceptable vendor. Except in special cases, NPSH available should be at least 8
feet. For pumps requiring more than 8 feet, available NPSH should be at least two feet more
than indicated pump requirements. Do not use NPSH correction charts for hydrocarbons.
The NPSH available for pumps is set by skirt height of towers and elevations of vessels. The
skirt heights specified should be used for design and layout of affected equipment. Final
pump design must be coordinated with design of vessels.
10.1.8 Subcooled Liquids
Net positive suction head includes allowance for difference between system suction pressure
and vapor pressure of the liquid. Always indicate calculated NPSH.
10.1.9 Boiling Liquids
With liquids at their bubble point, static head is the only source of NPSH. Sufficient static
head must be maintained by elevating suction equipment. Chart G 1.1 provides a guide to
required NPSH for pumps up to 1000 gpm. Note that the ordinate is the required NPSH.
Refer to Paragraph 10.1.7. Also, refer to Paragraph 10.0 regarding calculation of NPSHR.
10.1.10 Brake Horsepower (BHP)
An initial design estimate of required BHP for centrifugal pumps may be derived by using
efficiencies found on Chart G 1.1.
10.1.11 Remarks
Special factors which may have affected pump calculation (change of viscosity with
temperature, etc.) and any factors which may influence pump selection (corrosive fluid, solid
objects in fluid, other severe conditions) should be noted on Form 62.
Alternate designs: A pump for several services may pump at different heads for each service.
In these cases, control valve pressure drop should be adjusted to match pump characteristics.

3DG-M11-J0001-003 PAGE 10 OF 54
10.2 Sample Pump Calculations
A sample pump calculation is attached for a Lean Solvent Booster Pump of ALNG Train 2
Project at Rated Flowrate with Linesize outputs (PCI=01 and FVN=1). Only the Pump and
Control Valve Design Sheet, Hydraulic Circuit Sheet and CV Data Sheet for the Normal
Flowrate (PCI=01 and FVN=0) and Minimum Flowrate (PCI=01 and FVN=2) plus the Pump
Mechanical Datasheet are included for reference.
10.2.1 Level I Calculation
For this sample calculation, equipment arrangement, operating pressures and fluid properties,
etc. were obtained from the Process Flow Diagram and the Stream Property Data Sheets.
The height of the column was taken from the vessel sketch sheet. The pressure drop through
equipment and line losses were estimated by the methods outlined in Paragraph 10.1.
Suction Line Loss 0.034 bar or 0.5 psi

Discharge Line Loss 0.690 bar or 10 psi
Exchanger E-21203A 0.690 bar or 10 psi
Air Cooler E-21201 1.034 bar or 15 psi
Flow Element FE-212028 0.135 bar or 2 psi
Filter F-21201 0.069 bar or 1 psi Note 1
Contingency 0.345 bar or 5 psi
Total Dynamic Loss 2.756 bar or 40 psi
Control Valve FV-212028 1.378 bar or 20 psi (50% Total Dynamic Loss)
10.2.2 Level II Calculation
Quotations have been obtained and equipment purchased as follows:
Exchanger E-21203A 0.835 bar or 12.111 psi

Air Cooler E-21201 0.672 bar or 9.747 psi
Flow Element FE-212028 0.105 bar or 1.523 psi
Filter F-21201 0.254 bar or 3.684 psi Note 1
Contingency 0.138 bar or 2 psi
Note 1: It is suggested that for pressure drop through filters, an average of the clean and
dirty pressure drops at rated and normal flows should be used.

3DG-M11-J0001-003 PAGE 11 OF 54
Suction and discharge line losses were calculated by the Linesize program in PPS using the
isometric drawings taken from ALNG Train 1 Project.
Quotations have been obtained and the selected pump (not purchased to date) is as follows:
8 x 6 with bid impeller 305 mm (12"), efficiency 74.5%. Required NPSH equals 3.30 m (10.83
ft) and the shut-off head is 46.30 m (151.9 ft).
Note that ALNG Train 2 Project is the duplication of the ALNG Train 1 Project, the isometric
should be considered as identical and, therefore, it is not necessary to perform the
Calculation III.
The output of Pressure Profile program together with the Control Valve Data and Linesize
calculation output of Level II calculations are attached for reference.

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What are the different levels of pump calculations described?

What are the different levels of pump calculations described?

10.

0 PUMP DESIGN & PUMP SYSTEM DESIGN

Typical critical services may include:

Project Engineering will facilitate identification of critical service applications.

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

The differences between Level I and II Calculations are:

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

Important Note Pertinent to all Three Calculations

10.1 Criteria for Pump Design

10.1.1 Design Flow or Rated Flow

10.1.2 Minimum Flow

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

10.1.3 Pressure Drops through Equipment at Normal Flow

(b) Air Coolers

(c) Plate Air Exchangers

An 8 psi pressure drop may be used.

Fouling Factor Multiplier

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

(e) Other Equipment

10.1.4 Control Valves in Pump Discharge Systems

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

Turndown Flow and Control Valve Rangeability

10.1.5 Dynamic Head

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

Two Options are possible:

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

Minimum Pressure Drop,

In this estimate include length for the following:

Allowance for equivalent length of fittings.

10.1.7 Net Positive Suction Head (NPSH)

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

10.1.8 Subcooled Liquids

10.1.9 Boiling Liquids

10.1.10 Brake Horsepower (BHP)

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

10.2.1 Level I Calculation

Suction Line Loss 0.034 bar or 0.5 psi

10.2.2 Level II Calculation

Quotations have been obtained and equipment purchased as follows:

Exchanger E-21203A 0.835 bar or 12.111 psi

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN

Bechtel Confidential © Bechtel 2002. All rights reserved.

PUMP DESIGN & PUMP SYSTEM DESIGN