Professional Documents
Culture Documents
TE CH l\ll CA L
DE VE LD PM El\ IT
PR Dli RA M
DESIGN FACTORS
SIZING PROCEDURES
PUMP SELECTION &
APPLICATION
Copyright ,c Carrier Corporation 1965, 1986 Printed in U.SA 791-033 Section T200-33
T200-33
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
FORMUI..AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SUPPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VALVES . . . . . . . . . . . . . . . . . . . . . 9
STRAINERS ............. .. ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EXPANSION TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AIR VENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OTHER ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PIPE SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2
PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2. Capacity 28
3. Head .... ... ... . 28
4. ............................ ...
Suction Head Page 28
............................... .
5. Discharge Head 29
6. ....................................... .
Total Head 29
29
7. Liquid Horsepower ................ ..................
8. Brake Horsepower ............................... . 30
9. ............................... .
Net Positive Suction Head 30
TECHNICAL DEVELOPMENT PROGRAM
INTRODUCTION
chiller. The water is often recirculated so that the pick up and re-
The piping and pumping systems used to transport the water to and from
the various heat exchangers are usually relatively simple and straight
between 40F and lOOF, although year-round air conditioning may require
hot water piping for heating. The motive force for circulating or
The design of piping systems is an old art and much has been written
here .
FORMULAS
to the heat carry ing
A revie w of some of the form ulas perta ining
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sizes, lower operating costs, and lower energy requiremen ts. For
towers
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SUPPLY
RETURN
RETURN
SUPPLY
RETURN
n~BB I
RETURN. UNITS Pl PED HORIZONTALLY
UNITS PIPED HORIZONTALLY
FIG. 1
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If the pressure drops through the units are identical, then in the
case of the direct return system, each of the first five units will
time to insure the same flow through all units. In the reverse return
system, however, the pressure difference from supply line through the
unit to return line is the same for all units. Each unit will, therefore,
The cost of the extra length of return pipe is probably less than the
cost of valves and balancing, and much time and trouble will be saved.
drop.
GENERAL CONSIDERATJONS
cleaned, and cooling coils, control valves and pumps will eventually
- 6 -
isolating valves so that the entire system does not have to be drained
can be isolated and worked on while the remainde r of the system con-
balance convenie nce in servicing against first cost and maintena nce
MATERIALS
The usual piping materials are black steel for the large sizes say
1 1/2" and above and hard copper for the smaller sizes. Galvaniz ed
steel may be used, but usually only for drainage lines. It is now
Fittings for black steel pipe are usually welded for larger sizes or
malleable iron screwed type for smaller sizes. Hard copper fittings
The weight of the pipe and fittings will depend on the pressures and
something to say about this and the ones that apply must be.
consulted .
SUPPORTS
Manual.
See tables 7 and 8 in the Design
changes can be taken care of in this way. The hangers for chilled
insulation and the hanger. For hot water service, the hanger is
usually around the pipe and pipe and hanger are insulated together.
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prevent the transmission of vibration into the piping system, but they
liquid and vibrations from the pump are transmitted through the water
are best handled with spring type pipe hangers and by providing a good
mass under pumps or other vibrating components in a piping system.
which goes from the bottom to the top of the building. In large sizes,
the pipe and water represent a very large weight. The accompanying
dirt leg with cleanout and a solid support with a minimum of hangers
.
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VALVES
Gate valves are usually used for this function, because when wide
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With stem extend ed, these valves Gate Valve - Rising Stem
to install them in such a positio n in the piping that the stem does
A plug cock has the same low
simulta neousl y.
Plug Cock
.
FIG. 5 ~
T'I
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Globe valves or angle valves are usually used for this service.
Globe valves have a relatively high pressure drop when open, but
Angle Valve
FIG. 7
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coming popular for this use, especia lly in the larger sizes.
3. Preventi ng Back_ Flow.
the reversa l of flow in piping. The 15 swing check is the usual type,
with lift checks often used at pump dischar ge. If a pump operate s
between two water levels in an open system, the water will surge
pump discharg e to perform all three function s so far conside red. For
this multiple use, the valve is a normally closed type so that when air
is bled from the branch air line the valve goes to the closed position .
rated flow in the piping system, then after use as a shut off, the
pump seal, where the pressure must be regulated to about 5 psi above
the downstream flow rate and not to suit the pipe size
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accidentally valved off at each end. The water trapped between the
extensive system in which all the control valves are the throttling
type rather than three-way valves, the pump can build up a high
pressure when all valves are nearly closed, and a relief valve is often
installed at the pump discharge to relieve the excess pressure into the
pump suction.
STRAINERS
can circulate without doing any great harm. In such cases, the need
human like the rest of us and if the task of cleaning strainers becomes
too irksome, the strainer basket will get punched full of holes or be
removed.
In a condenser water system using a cooling tower and not using control
considered sufficient. A mud ring is sometimes installed around the
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at frequent intervals.
FIG. 13
EXPANSION TANKS
usually placed at the top of the return main closest to the pump so
VALVE
collapse of the tank if the system is
GATE GAGE
VALVE-.... GLASS
DRAIN VALVE-....
(GATE VALVE)
TRAP
be calculat ed by obtainin g the total inter- ENLARGED PORTION OF
EXPANSION LINE
( I r MIN.)
RETURN LINE TO PERMIT
AIR SEPARATION~
nal volume of the system includin g (NOTE 2)
RETURN
ENLARGED TEE FOR
AIR SEPARATION
LINE
L:..-1
piping, heat exchang ers, pumps, etc. AT LEAST 4d .J NORMAL LINE SIZE
1% for chilled water systems and 3% for hot water systems . (See Table 15,
page 3-31 of the Design Manual) . A safety factor of about 25% should
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the expansion tank but the volume of the space above the normal water
'
level in the tank.
GATE
The equalizer line from the expansion / VALVE
FIG. 15
prevent sweating . .
AIR VENTS
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MAIN
plot showing head versus gpm and gages should be provided as close
pressure rise across the pump can be found. By referring to the charac-
teristic curve, the gpm can then be read from the chart. This will
orifice plate installed between two flanges, with the necessary auxiliary
to the 11
Flow Meter Computatio n
FIG. 17
Handbook 11
or the supplement to
ASME. Note that the orifice plate forms a dam across the pipe and
dirt can collect and restrict flow. This orifice type of flow meter
For these reasons, it is often removed after use and replaced with a
flat disc which has a hole equal in diameter to the inside diameter
of the pipe.
and will not be reliable for use in troubleshoo ting when needed. For
this reason, gages should be removed from the system except when readings
are being taken. Good practice is to install gage cocks and provide the
/
operator with (or request that he obtain) several good quality gages for
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troubleshoo ting.
Sleeves are usually provided at points where piping passes thru walls
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sheet metal. Wall sleeves are generally flush with both sides of
inches above the floor to prevent water leakage around the pipe in
case of flooding.
PIPE SIZING
.
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After a piping system has been laid out and the gpm figured it
becomes necessary to size the pipe and determine the total resistance
in the system so as to know what head the pump must work against.
and entrained air wearing away or eroding the pipe. Erosion is, of
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pipe size (or cost) and a reasonab le life before the pipe is eroded
away.
control valves; and pipe friction) cannot exceed the total pressure
Chart 3 applies to new, smooth, clean standard weight steel pipe and
Chart 4 applies to steel pipe which has been subjected to scaling and
friction loss rate in open recirculat ing type systems such as condense r
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Note that the friction loss or head is given in feet of water per
Manual. For instance, in Table 10, we note that a 4" globe valve
loss in one 4" globe is the same as that through 120 feet of 4"
straight pipe. Note that a 4" angle valve is equivalent to only 4 7 feet
~.
In a closed system, friction is the only loss or head which the pump
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has to overcome. The height of water on the suction side of the pump
the two sides of the pump. In a cooling tower, for instance, the
height between the water in the pan and the exit from the distribution
nozzles which require a pressure behind them to force water through the
pipe friction head, including entrance and exit losses; losses through
99
1
10 GPM = 1200
Pump - 8 1
suction connection
1
85
GATE VALVE 6" discharge
COND.
1
1--12 --i i-12'-I
FIG. 18
per sec. velocity and 3.8 ft. per 100 ft. friction loss.
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Total equiva lent length of straigh t pipe (Tables 10, 11, and 12)
Note that if we had used an angle lift check instead of one elbow
we could have reduce d the total equiva lent lengths by the followi ng:
Deduct one ell = 13'
148'
This is 5. 6 1 friction head or ..hQ. x 100 = 21% of the total friction head.
26
TOTAL 25 psi
have neglected the loss in the 6" to 8" increaser at the pump dis-
We
charge. On the other hand, we are starting out with clean pipe
gpm than needed which might overload the pump motor. Note that the
26' - 675
100 x 22 = 26 - 15' = 11'
total head.
the pressure drop through each circuit at its rated flow must equal
the available difference in pressure between the supply and return mains
vary with the distance from the pump, balancing valves may be required
PUM PS
ng syst em and figu red out the
Afte r the desi gne r has laid out the pipi
a pum p. The pum p (or pum ps)
tota l pum ping hea d, he mus t sele ct
shou ld be easy to serv ice,
mus t fit into the spa ce ava ilab le, and
aga inst the exis ting hea d
and be able to pum p the nec essa ry gpm
PUM P TERMS
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in the suction line; velocity head; and any positive pressure which may
pressure gage at the pump suction would indicate a positive static suction
head minus suction line friction head; minus velocity head. A vacuum
gage would read suction lift plus friction head plus velocity head.
static discharge head; plus any positive pressure existing at the discharge
fl
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Total head is the Jischarge head minus the suction head, or discharge
!
pressure.
a very small part of the total head (at 8 fps velocity it equals v2/2g
or 64/64. 4 = 1 ft.) Calculations of pumping head are not sufficiently
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I remembered, however, that the pump must furnish the additional energy
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Brake Horsepower - is the power required to drive the pump and equals
pressure of the liquid, vapor bubbles will form. When moved into
cavitation and is most apt to occur at the inlet to the pump impeller.
NPSH is equal to the pressure drop in feet of liquid from suction flange
to the point inside the impeller where pressure starts to rise. Available
NPSH at the pump suction must always be greater than NPSH required by
the pump.
NPSH = h - h + (h - h )
a vp e f