1. CHEMCAD Seminar Transport and Storage John Edwards, P&I Design Ltd
January 2015 1

2. HANDLING AND STORAGE SESSION OBJECTIVES
Review energy balance theory
Understand derivation of resistance coefficients
Develop user resistance coefficients
Control valve characteristics & sizing parameters
Centrifugal pump sizing and rating
Design and rate piping distribution networks
Design and rate complex networks using Nodes
Reference: Crane, “Flow of Fluids through Valves, Fittings and Pipes”, 410M
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3. HANDLING AND STORAGE FLUID FLOW BASIC THEORY
Continuity Equation
Q volume flow
a pipe area
v velocity
p pressure
w density
z height
h line losses
Bernoulli’s Equation
Combining for p1= p2 and z1 = z2

4. HANDLING AND STORAGE CIRCULAR PIPE FRICTION FACTORS
Darcy Equation Form (CHEMCAD & CRANE 410M)
L pipe length
D pipe diameter
f friction factor
v velocity
G 9.81 m/s2
Darcy > Fanning Friction Factor
Fanning Friction Factor Equation Form

5. HANDLING AND STORAGE FRICTION FACTORS IN CHEMCAD
Jain Equation Solves Darcy Friction Factor
Matches Colebrook equation within 1.0% for
10-6 < ε / D < 10-2 and 5000 < Re < 108
Jain is CHEMCAD default method
Churchill Solution Validity
Applicable for all values of ε / D and Re

6. MOODY DIAGRAM (DARCY f)

7. HANDLING AND STORAGE FRICTION FACTOR CORRELATIONS
Blasius more accurate for smooth pipe

8. CHEMCAD LOSSES IN PIPES AND FITTINGS ROUGHNESS COEFFICIENTS ε

9. Pressure Loss Coefficient Darcy Gradual Enlargement Kr
LOSSES DUE TO FITTINGS
Pressure Loss Coefficient Darcy
Gradual Enlargement Kr
Entry to pipe K = 0.5
Exit from pipe K = 1.0
Sudden enlargement
Sudden contraction
L pipe length
D pipe diameter
f friction factor
v velocity
G 9.81 m/s2

10. CHEMCAD LOSSES IN PIPES AND FITTINGS DARBY 3K METHOD

11. CHEMCAD LOSSES IN PIPES AND FITTINGS
STANDARD L/D VALVE AND FITTING LOSSES FROM CRANE 410
USER SPECIFIED OPTIONS INCLUDE
L/D Manufacturers’ data
Kr Derived from orifice calculation
KS Sudden expansion or contraction coefficient (Crane K1)
3K Darby Method Enter appropriate K1 Ki KD
L/D methods tend to under predict friction loss for larger D pipes.
3K method is most accurate for all Re and fitting sizes.

12. TEES STRAIGHT AND REDUCING
“Tee Flow Thru Run” in pipe with largest flow rate
L/D CHEMCAD=8.4 DARBY 3K=17
Flow-out Branch
Flow-thr Run
Flow-thr Run
Flow-in Branch
“Tee Flow Thru Run”
CHEMCAD in both pipes
Equates to DARBY 3K
“Flow Out Branch” in branch pipe
L/D CHEMCAD=58 DARBY 3K=51.2
“Flow In Branch” in branch pipe
L/D CHEMCAD=43.2 DARBY 3K=51.2
UnitOp 1
UnitOp 2
UnitOp 3
Expansion Contractions always In smallest diameter pipe
Unequal Tees install reducer in branch pipe
UnitOp 1
UnitOp 2
UnitOp 3

13. CHEMCAD LOSSES IN PIPES AND FITTINGS

14. CRYOGENIC BATCH REACTOR OPTIMISATION
PIPE DESIGN ECONOMIC VELOCITIES
CRYOGENIC BATCH REACTOR OPTIMISATION

15. ORIFICE PLATE TAPPINGS
2½D – 8D taps for
flow restriction

16. EXPANSIONS AND CONTRACTIONS

17. CRYOGENIC BATCH REACTOR OPTIMISATION
FLOW SCALERS WITH PRESSURE NODES
CRYOGENIC BATCH REACTOR OPTIMISATION
Flows calculated from PIN and POUT
Pipe (PIPE) Valve (VALV)
Control Valve (CVAL) Pump (PUMP)
Compressor (COMP) Expander (EXPN)

18. CRYOGENIC BATCH REACTOR OPTIMISATION
PIPE NETWORKS - NODES(CALCULATORS)
CRYOGENIC BATCH REACTOR OPTIMISATION
All Network Flows and Pressures are interdependent
Junction pressures are equal and flows balance
Flows are calculated as a function of :
Inlet Pressure (Pin) & Outlet Pressure (Pout)
Flow Scalers calculate flow as a function of :
Nodes link all Flow Scaling UnitOps
Elevation of node entered > elevation change calculated

19. PUMP NPSH

20. PUMP NPSH

21. PIPE SYSTEM SIMPLE DESIGN
Case 5.03 Piping Design
Section 5-p155
NPSH Nett Positive Suction Head

22. PIPING SYSTEM DESIGN CASE 5.03
Case 5.03 Piping Design
Section 5-p155
Objectives
Pipe UnitOp
Pump UnitOp
Elevation change
Pipe size(p121)
Suction ft/s
Diam 4 in
Discharge 10 ft/s
Diam 3 in
Simulation Basis
Units English
Component Glacial Acetic acid
Thermo H – UNIFAC L - LH
Feed Stream Q 220 gpm T 70°F P 20 psia
Discharge P P > 20 psia T 140°F
Pump Discharge T o be determined

23. PIPING SYSTEM DESIGN CASE 5.03
Case 5.03 Piping Design
Section 5-p155
Objectives
Pump selection
1.Manual method
2.Controller
Pipe UnitOp
Mode Single phase
Sizing Rating
Pipe Schedule Default Schedule 40 (p548)
Size Determined by velocity
Roughness Commercial steel Friction Churchill
Elevation change Down – Negative Up - Positive
Pump Discharge Initial trial 60 psia η 0.8 (Refinery p66)

24. PIPING DESIGN USING NODES CASE 5.04
Case 5.04 Pump Sizing and Pipe Branches
Section 5-p158

25. PIPING DESIGN USING NODES CASE 5.04
Case 5.04 Pump Sizing and Pipe Branches
Section 5-p158
Piping design
Deliver acetic acid
120 gpm 70 deg F
at 20 psia to process
Nodes
Set inlet state
Set elevations
Set outlet state
Flow scaler
Here the pump
Calculates
Flow

26. PIPING DESIGN USING NODES CASE 5.04 INLET AND OUTLET NODES
Case 5.04 Pump Sizing and Pipe Branches
Section 5-p158
Inlet Node
Outlet Node

27. PIPING DESIGN USING NODES CASE 5.04 PIPE FLOW AS FLOW SCALER
Case 5.04 Pump Sizing and Pipe Branches
Section 5-p158
Allows Flow to be set by UnitOp

28. PIPING DESIGN USING NODES CASE 5.04 NODE BETWEEN FLOW SCALERS
Case 5.04 Pump Sizing and Pipe Branches
Section 5-p158
P set Variable or Fixed
Flow set Fixed or Variable
Boundaries for the pressure

29. PIPING DESIGN USING NODES CASE 5.04 PUMP PERFORMANCE CURVE
Case 5.04 Pump Sizing and Pipe Branches
Section 5-p158

30. PIPING DESIGN USING NODES CASE 5.04 NODE BETWEEN FLOW SCALERS
Case 5.04 Pump Sizing and Pipe Branches
Section 5-p158
Excel Data Map Facility for Key Data Reporting

31. Piping Design and Rating
Simulation of more complex piping systems, as found in service distribution networks, to determine the pressure drops and the flows throughout the system. This case develops the design of a cooling water distribution system supplying three shell and tube heat exchangers.
CASE 5.05 COOLING WATER SYSTEM
PIPING SYSTEM RATING
Piping Design and Rating
Case 5.05 Cooling Water System
Section 5-p163
Simulation Basis
Units Common SI
Component Water
Thermo H – Ideal Vapor Pressure L - LH
Feed Stream W kg/h T 15°c P 5 bar
Heat Exchanger Duties 50 kW 100kW 150kW
Heat Exchanger ∆P 0.5 bar
Piping Design 3 m/s allow for upgrade to kg/h
Restriction Orifice 0.5 bar pressure drop in spillback line
Control Valve Sizing Flow based on 150kW POUT 3.5 bar
Control valves are adjusted manually to achieve required duty

32. Piping Design and Rating
PIPING SYSTEM RATING CASE 5.05
Piping Design and Rating
Case 5.05 Cooling Water System
Section 5-p163

33. Piping Design and Rating
CASE D2.04 DYNAMIC TANKER OFFLOAD
Piping Design and Rating
Case D2.04 Road Tanker Offload
Section 2-p25

34. Piping Design and Rating
CASE 5.02 VALVE SIZING TWO PHASE FLOW
Piping Design and Rating
Case 5.02 Control Valve Sizing and Flow Split
Section 5-p152
Liquid NH3
225 psig -9 deg F
Flow lb/h
50% split to two users
15 psig -1 deg F
0.2 psig -28 deg F
Size control valves