piping design

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CALCULATION COVER SHEET

PROJECT JOB NO. CALC. NO. SHEETLAS BAMBAS 25635 25635-220-M0C-0410-10011 1 of 10

SUBJECT Cu-Concentrate Thickener Underflow Pump Calc (0410-PPS-0123/0124) DISCIPLINE MECHANICAL

CALCULATION STATUS PRELIMINARY CONFIRMED SUPERSEDED VOIDEDDESIGNATOR

COMPUTER PROGRAM/TYPE SCP PROGRAM NO. VERSION/RELEASE OPERATING SYSTEM

SCP RUNTIME VALIDATION AUTOMATIC MANUAL COMPUTER TYPE

YES NO

Table of Contents

Section Titles Page No.

1.0 PURPOSE 22.0 BASIS OF DESIGN 23.0 ASSUMPTIONS 24.0 REFERENCES 25.0 CALCULATIONS 36.0 CONCLUSIONS 10

Appendices

Appendix A Efficiency and Head Ratio Chart ( 1 sheet )Appendix B Viscosity Chart ( 1 sheet )Appendix C Durand Factor Chart ( 1 sheet )

Appendices

Attachment 1 Plant GA Drawings & Plot Plan ( 3 sheets )

B Issued for Design 16 BS SM PKM 20-Feb-12

A Issued for Review 8 BS SG PKM 30-Nov-11

REV. NO. REASON FOR REVISION LAST SHEET BY CHECKED Date

RECORD OF REVISIONS

SUCCESSFUL TEST COMPLETION

Attachment 1 Sheet 3 of 3

Attach. 2 sheet 3 of 3

TOTAL NO. OF SHEETS

APPROVED/ACCEPTED

X

Electronic documents, once printed, are uncontrolled and may become outdated.Refer to the electronic documents in Project InfoWorks ® for current revision

Confidential. © 2011,2012 Bechtel Chile Limitada. All rights reserved.2 of 16

CALCULATION SHEET Project : Las BambasJob no. : 25635

Subject : Cu-Concentrate Thickener Underflow Pump Calc Calc. no. : 25635-220-M0C-0410-10011By : Biswanath Sen Date : 20-Feb-12 Sheet rev. : 00B

1.0 PURPOSE

To determine:1.1 Slurry transport critical velocity (limiting settling velocity).1.2 Pipe sizes with transport velocity above the critical velocity for lines from Thickener

Underflow Pumps (0410-PPS-0123 & 0124) to Filter Feed Tank (Facility 0420).1.3 Head, NPSHa and Power rating of Thickener Underflow Pumps (0410-PPS-0123/0124).

2.0 BASIS OF DESIGN

2.1 Durand’s modified by JRI equation for Limiting settling velocity as Wilson Nomogram does not

2.2 Darcy-Weisbach equation used for computing pressure loss due to friction2.3 Colebrook-White equation for friction factor.2.4 Slurry is treated as a homogeneous, Newtonian equivalent fluid of apparent viscosity 8 cP. (ref. 4.1)2.5 Design flow is 1.3 times of Balanced flow. (ref. 4.3)2.6 20% margin considered on frictional head loss, in view of preliminary ISO's.2.7 2 X 100% Thickener Underflow Pumps (1W + 1S) (Reference 4.4)2.8 C.S., neoprene lined pipes 150 # class used for slurry transportation2.9 Longest path of flow has been considered for frictional loss.2.10 Drive type - VFD 2.11 Thickener Underflow Level has been considered as 1.5 m for Head Calculation.2.12 Piping length, elevations and routing are based on preliminary input from plant design.2.13 Thickener Underflow withdraw lines are defined as Part-1 and Manifold is defined as Part-2.2.14 Total underflow is distributed equally in open lines of Part-1 and Part-2 is carrying total under flow.

3.0 ASSUMPTION

3.1 All four thickener outlet lines are working during normal operation.

4.0 REFERENCES

4.1

4.2

4.3

4.4

4.5(Rev D).

4.6

4.7

4.8

cover settling velocity estimation for slurry with D50 = 30 µm.

Fluid and Slurry Handling Design Criteria, Doc No : 25635-220-3DR-M11-00001-000.

Design Guide for Hydraulics of Slurry Flow, Doc No : 3DG-K04-00007-000.

Process Design Criteria, Doc No : 25635-220-3DR-V01-00003-000.

Cu-Concentrate Thickener PFD, Doc No : 25635-220-M5-0410-00001-002.

P&ID : Thickener and Thicnener Underflow Pumps, Doc No : 25635-220-M6-0410-00002 & 3

Plot Plan for Moly Plant, Doc No : 25635-220-P1-0370-0202-00B

Cu-Concentrate Thickener and Tank Area GA, Doc No : 25635-220-P1-0410-00201 & 202 (Rev A).

Concentrate Holding Tank and Filter Plant GA, Doc No : 25635-220-P1-0420-00202 Rev B.



CALCULATION SHEET Project : Las Bambas

Job no. : 25635Subject : Cu-Concentrate Thickener Underflow Pump Calc Calc. no. : 25635-220-M0C-0410-10011By : Biswanath Sen Date 20-Feb-12 Sheet rev. : 00B

Balance Design

5.0 CALCULATIONSSummary

Solid Feed Rate TPH 127 165Pulp Volumetric flow 98.00 127.40Design factor - - 1.30Concentration by weight, Cp % 65.0 65.0Specific gravity of solids, SGs - - 4.32Specific gravity of slurry, SGm - 2.00 2.00

μm - 12Suction nominal diameter-Part1 in No. of U/F 4Suction flow velocity m/s Lines in 2.13 2.77

Service: -

Durand's modified by JRI m/s 2 ###Suction nominal diameter-Part2 in - 6Suction flow velocity m/s 1.72 2.23

Durand's modified by JRI m/s - #ADDIN?Discharge nominal diameter in - 6Discharge flow velocity m/s 1.72 2.23

Durand's modified by JRI m/s #ADDIN?Total Dynamic Head m #ADDIN? #ADDIN?Hydraulic power kW #ADDIN? #ADDIN?

hp #ADDIN? #ADDIN?Brake power kW #ADDIN? #ADDIN?

hp #ADDIN? #ADDIN?Calculated Motor Power kW - #ADDIN?

hp - #ADDIN?

Figure 1-1. Duty Point Curve

m3/h

Average particle size, d50

Limiting settling velocity, vL



0 20 40 60 80 100 120 140 1600.00

2.00

4.00

6.00

8.00

10.00

12.00

ΔH Pump (B) ΔH Pump (D) System curve Balance Design

Pump Curve Head for waterFlow rate (m3/h)

Hea

d (

m)





5.1 Operating DataConcentration by volume, Cv % 30.1 30.1

μm 75Froth factor - 1.00Fluid temperature °C 25Fluid pH - 7 - 8

- #ADDIN? #ADDIN?

Viscosity (Kinematic) cSt 4.00 4.00Viscosity (Dynamic) cP 8.00 8.00Pump CL elevation masl 4,135.4Discharge elevation masl 4,170.3Tank/Sump liquid level masl 4,140.9Pressure Required at Destination barg 0.00

psig 0.0msc 0.0

Vapor pressure bar #ADDIN?msc #ADDIN?

Barometric pressure bar 0.607msc 3.10

5.2 Preliminary Pump Selection ( for the purpose of power estimation only)

Impeller in 10Suction in 4Discharge in 3Revolutions per minute rpm 1850 1,900Pump efficiency % 62.0 65.0Tip speed m/min 1,477 1,517

m/s 25 25Pump Discharge Pressure m #ADDIN? #ADDIN?

5.3 Pipe SelectionSuction Discharge

Material pipe

Par

t -

1

Carbon steelPipe Schedule STDOutside Diameter 4.500Nominal Wall Thickness 0.237Internal Diameter m 0.0903Length m 8.0Lining thickness mm 6.0Pipe Roughness , Ks mm 0.20Reynolds's no. 62,343Friction factor, Colebrook-White Equation (λ) 0.029

1.04Material pipe

Par

t -

2

Carbon steel Carbon steelPipe Schedule STD STDOutside Diameter 6.625 6.625Nominal Wall Thickness 0.280 0.280Internal Diameter m 0.142 0.142Length m 6.00 480Lining thickness mm 6.0 6.0Pipe Roughness , Ks mm 0.20 0.20Reynolds's no. 79,227 79,227Friction factor, Colebrook-White Equation (λ) 0.024 0.024

Average particle size, d80

fL factor





1.00 1.00





5.4 Equivalent lengthsSuction Discharge

Elbow 45°

Par

t -

1

1Elbow 90° short 1Elbow 90° long 0Elbow angled 0Tee run 4Tee branch 0Gate Valve 2Globe Valve 0Plug Valve 0Angle Valve 0Butterfly Valve 0Orifice plate, diameter 0Tank Output / Input 1Margin on frictional loss % 20Equivalent length m ###Fittings losses m ###Line friction losses m 1.18Line friction plus fittings losses m ###

Elbow 45°

Par

t -

2

0 8Elbow 90° short 0 22Elbow 90° long 0 0Elbow angled 0 0Tee run 4 4Tee branch 1 1Gate Valve 1 1Globe Valve 0 0Plug Valve 0 0Angle Valve 0 0Butterfly Valve 0 0Contraction / Expansion 1 1Orifice plate, diameter 0 0Tank Output / Input 0 1Margin on frictional loss % 20 20Equivalent length m ### ###Fittings losses m #ADDIN? #ADDIN?Line friction losses m 0.31 24.7Line friction plus fittings losses m #ADDIN? #ADDIN?

5.5 Total dynamic head

Head static suction m 5.5Head static discharge m 34.9Head total static m 29.4HR #ADDIN?ER #ADDIN?Pump Curve Head for water m #ADDIN?

m #ADDIN?NPSHAvailable





5.6 Calculation Formula

5.6.1 Slurry Properties and Data :

Specific gravity of slurry, SGm

=1

= 2.000.65+

1-0.654.32 1

Concentration by volume, Cv

=0.65 · 2.00

= 30.1 %4.32

Chart method

( __ sheets )

Durand Factor, fL

0.01 0.10 1.00 10.000.45

0.55

0.65

0.75

0.85

0.95

1.05

1.15

1.25

1.3520

d50, mm

fL

SGs

SGmCpCv

SGm=1

CpSGs

+ 1−Cp1





The slurry viscocity is obtained from Fluid and Slurry Handling Design Criteria. The Chart Method are provided for comparison only.

8 Attach. 2 sheet 3 of 3

BS Biswanath Sen

12Cv, % = 30.1

2.00#ADDIN?

cP = #ADDIN?cSt = #ADDIN?

Steam pressure

Chart method

Barometric pressure

= 1.013 · [(288-6.5·4,135/1,000)/288]^5.255

d50, mic=

rm, t/m3 =μ, mPa·s =

30 40 50 60 70 80 90 1000.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Steam table

Temperature, °F

Pre

ssu

re,

ps

i

AV

ER

AG

E P

AR

TIC

LE S

IZE

MIC

RO

ME

TE

RS

0 10 20 30 40 50 60 70

1

10

100

1000

1

Volume Percent Solids

Ap

pa

ren

t V

isc

os

ity

mP

a·s

AV

ER

AG

E P

AR

TIC

LE S

IZE

MIC

RO

ME

TE

RS

PBAR=1 . 013⋅(288−6 . 5⋅ELPump

1000288 )

5.255





= 0.61 barPBAR=1 . 013⋅(288−

6 . 5⋅ELPump

1000288 )

5.255





Let's use discharge for example.

Flow velocity

=4 · 127

= 2.23 m/sπ · 0.14² · 3,600

Reynold's no.

=2.00 · 2.23 · 0.14

= 79,2278.00x10-6

Limiting settling velocity

Durand's eq. modified

= ###

= #ADDIN?5.6.2 Frictional Losses (Discharge)

Equivalent length

= ###

Friction factor, Colebrook - White equation :

λ = 0.024

Friction losses

= #ADDIN?

5.6.3 Total Dynamic Head

Total Static Head

= 4,170 - 4,141

= 29.4 msc

Total Dynamic Head

###

###

DPDischargeSuctionlossesFrictionTSHTDH

vL=1 . 25⋅f L⋅(2⋅g⋅DI⋅SGs−11 )

0 .25

Leq=∑ Ki

TSH=ED−ES

v=4⋅Q

π⋅DI2⋅3600

Re=ρ⋅v⋅D IμP

Friction losses=λ⋅((L+Leq .)*%margine ). v2

2⋅g⋅D I





NPSH Available

= ###

= ###

Hydraulic Power

=#ADDIN?

3,600

= ###

Head Ratio (HR) and Efficiency Ratio (ER)

Chart method

Hr : ###Er : ###

Brake power :

=#ADDIN?#ADDIN?

= ###

Calculated Motor Power : Brake Power x Transmission Loss : ### X 1.1 : ###

7

7

7

7

5

3

2

0.01 0.1 1 10

115

7

0.5 0.6 0.7 0.8 0.9 1.0

0.5

0.6

0.7

0.8

0.9

1

1

1

1

ER

HR

NPSH A=PBAR−PSTEAM+SHSUCTION−Friction lossesSUCTION

PB=PH

ER⋅ηPump⋅¿¿

PH=Q⋅TDH⋅ρw⋅SGm⋅PCF





6.0 CONCLUSIONS

6.1 Limiting Settling Velocitya) Suction : 1.49 m/secb) Discharge : 1.49 m/sec

6.2 Pipe sizesa) Suction : 6 inch, Sch STD ( lining thickness = 6 mm), L1E0VJb) Discharge : 6 inch, Sch STD ( lining thickness = 6 mm), L1E0VJ

a)

b)c) Motor Calculated Power is 45 kW. After considering derating factor and selecting

standard size, motor rating comes as 75 kW.

TDH : 29 m (@ 98 m3/hr) / 38 m ( @ 128 m3/hr)

NPSHa : 7.0 m


Confidential. © 2011, 2012, Bechtel Chile Limitada. All rights reserved.1 of 16


Job no. : 25635Subject : Cu-Conc. Thickener U/F Pump Calc Calc. no. : 25635-220-M0C-0410-10011By : Biswanath Sen Date 20-Feb-12 Sheet rev. : 00B

Appendix A: Efficiency and Head Ratio Chart

LEGEND

HR = Head on slurry Balance Design

Head on water 0.012 0.012

4.32 4.32

ER = Efficiency on slurry Cv, % = 30.1 30.1

Efficiency on water D, mm = 254 254

0.00005 0.00005

Cv = % Concentration of solids in slurry HR = #ADDIN? #ADDIN?

by true volume ER = #ADDIN? #ADDIN?

Average particle size (mm)

D = Impeller diameter (mm)

Specific gravity of solids

d50, mm=

SGS =

d50/D =

d50 =

SGS =

0.01 0.1 1 10

15

7

7

7

7

5

3

2

7

0.5 0.6 0.7 0.8 0.9 1.0

0.5

0.6

0.7

0.8

0.9

1.0

1

1

1

1

ERH

R




Job no. : 25635Subject : Cu-Conc. Thickener U/F Pump Calc Calc. no. : 25635-220-M0C-0410-10011By : Biswanath Sen Date 20-Feb-12 Sheet rev. : 00B

Appendix B: Viscosity Chart

0 10 20 30 40 50 60 701

10

100

1000

1

Volume Percent Solids

Ap

pa

ren

t V

isc

os

ity

mP

a·s

AV

ER

AG

E P

AR

TIC

LE S

IZE

MIC

RO

ME

TE

RS




Job no. : 25635Subject: Cu-Conc. Thickener U/F Pump Calc Calc. no. : 25635-220-M0C-0410-10011By: Biswanath Sen Date 20-Feb-12 Sheet rev. : 00B

Appendix C : Durand Factor Chart

LEGEND

Modified Durand's limiting settling velocity parameter (for particles of widely graded sizing)= #ADDIN?

Average particle size (mm)= 0.012 mm

Cv = % Concentration of solids in slurry by true volume= 30.1 %

fL =

d50 =

0.01 0.10 1.00 10.000.45

0.55

0.65

0.75

0.85

0.95

1.05

1.15

1.25

1.3520

d50, mm

fL

Tabla de vapor Commercial Pipe Sizes and Wall Thicknesses, NPSsaturado Nominal Outside Nominal Wall Thickness For pipe size

Elbow 45° Tee runTemp Presión Pipe Diameter Sched. Sched. Sched. Sched. Sched. Standard Sched. Sched. Extra Strong Sched. Sched. Sched. Sched. Sched. XX Strong d (in)°F PSI Size 5S 10S 10 20 30 STD 40 60 XS 80 100 120 140 160 XXS 1/2 0.4 0 0.7 1.1 3.3 0.7 17 0.9 7.3

32 0.089 1/8 0.405 0.049 0.068 0.068 0.095 0.095 3/4 0.6 0 0.9 1.4 4.2 0.9 23 1.2 9.733 0.092 1/4 0.540 0.065 0.088 0.088 0.119 0.119 1 0.7 1.6 1.2 1.8 5.3 1.1 28 1.5 12.134 0.096 3/8 0.675 0.065 0.091 0.091 0.126 0.126 1 1/2 1.1 2.4 1.8 2.7 8.1 1.7 45 4 1935 0.100 1/2 0.840 0.065 0.083 0.109 0.109 0.147 0.147 0.188 0.294 2 1.5 3.1 2.3 3.5 10.4 2.2 59 3 2536 0.104 3/4 1.050 0.065 0.083 0.113 0.113 0.154 0.154 0.219 0.308 2 1/2 1.7 3.7 2.7 4.2 12.4 2.7 3.837 0.108 1 1.315 0.065 0.109 0.133 0.133 0.179 0.179 0.250 0.358 3 2.2 5 3.4 5.7 15.5 3.3 86 4.5 3838 0.112 1 1/4 1.660 0.065 0.109 0.140 0.140 0.191 0.191 0.250 0.382 4 3 7 4 7 20 4 112 6 48 739 0.117 1 1/2 1.900 0.065 0.109 0.145 0.145 0.200 0.200 0.281 0.400 6 5 10 7 10 30 7 170 9 73 2040 0.122 2 2.375 0.065 0.109 0.154 0.154 0.218 0.218 0.344 0.436 8 6 13 9 13 40 9 170 12 98 2841 0.126 2 1/2 2.875 0.083 0.120 0.203 0.203 0.276 0.276 0.375 0.552 10 7 16 11 17 52 12 170 15 121 3442 0.131 3 3.500 0.083 0.120 0.216 0.216 0.300 0.300 0.438 0.600 12 9 19 13 20 60 13 170 18 145 4043 0.137 3 1/2 4.000 0.083 0.120 0.226 0.226 0.318 0.318 14 10 21 15 22 66 15 170 21 169 4444 0.142 4 4.500 0.083 0.120 0.237 0.237 0.337 0.337 0.438 0.531 0.674 16 11 24 17 25 78 17 170 23 193 5045 0.147 5 5.563 0.109 0.134 0.258 0.258 0.375 0.375 0.500 0.625 0.750 18 13 27 19 28 85 19 170 27 218 5646 0.153 6 6.625 0.109 0.134 0.280 0.280 0.432 0.432 0.562 0.719 0.864 20 14 29 21 32 95 21 170 30 242 6047 0.159 8 8.625 0.109 0.148 0.250 0.277 0.322 0.322 0.406 0.500 0.500 0.594 0.719 0.812 0.906 0.875 24 17 35 26 40 120 25 170 36 290 7648 0.165 10 10.75 0.134 0.165 0.250 0.307 0.365 0.365 0.500 0.500 0.594 0.719 0.844 1.000 1.125 1.000 30 21 44 32 50 150 32 170 46 360 10049 0.171 12 12.75 0.156 0.180 0.250 0.330 0.375 0.406 0.562 0.500 0.688 0.844 1.000 1.125 1.312 1.000 36 25 53 39 60 175 38 170 53 435 12050 0.178 14 O.D. 14.0 0.156 0.188 0.250 0.312 0.375 0.375 0.438 0.594 0.500 0.750 0.938 1.094 1.250 1.406 42 30 63 45 68 200 46 170 62 508 14051 0.185 16 O.D. 16.0 0.165 0.188 0.250 0.312 0.375 0.375 0.500 0.656 0.500 0.844 1.031 1.219 1.438 1.59452 0.192 18 O.D. 18.0 0.165 0.188 0.250 0.312 0.438 0.375 0.562 0.750 0.500 0.938 1.156 1.375 1.562 1.781 Suction53 0.199 20 O.D. 20.0 0.188 0.218 0.250 0.375 0.500 0.375 0.594 0.812 0.500 1.031 1.281 1.500 1.750 1.96954 0.206 22 O.D. 22.0 0.188 0.218 0.250 0.375 0.500 0.375 0.875 0.500 1.125 1.375 1.625 1.875 2.125 Design 6'' #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN?55 0.214 24 O.D. 24.0 0.218 0.250 0.250 0.375 0.562 0.375 0.688 0.969 0.500 1.218 1.531 1.812 2.062 2.34456 0.222 26 O.D. 26.0 0.312 0.500 0.375 0.50057 0.230 28 O.D. 28.0 0.312 0.500 0.625 0.375 0.50058 0.238 30 O.D. 30.0 0.250 0.312 0.312 0.500 0.625 0.375 0.500 Discharge59 0.247 32 O.D. 32.0 0.312 0.500 0.625 0.375 0.688 0.50060 0.256 34 O.D. 34.0 0.312 0.500 0.625 0.375 0.688 0.500 Design 6'' #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN? #ADDIN?61 0.265 36 O.D. 36.0 0.312 0.500 0.625 0.375 0.750 0.50062 0.275 38 38.0 0.375 0.50063 0.285 40 40.0 0.375 0.50064 0.295 42 O.D. 42.0 0.375 0.750 0.50065 0.305 44 44.0 0.375 0.50066 0.316 46 46.0 0.375 0.50067 0.327 48 O.D. 48.0 0.375 0.50068 0.339 56 56.0 0.375 0.50069 0.351 60 60.0 0.375 0.50070 0.363

71 0.37572 0.38873 0.40274 0.41675 0.43076 0.44477 0.45978 0.47579 0.49080 0.50781 0.52482 0.54183 0.55984 0.57785 0.59686 0.61587 0.63588 0.65689 0.67790 0.69891 0.72092 0.74393 0.76794 0.79195 0.815

77 077 #ADDIN?

30 #ADDIN?

Longitudes equivalentes de accesorios y fittings en pies

Elbow 90° short

Elbow 90° long

Tee branch

Gate Valve

Globe Valve

Plug Valve

Angle Valve

Butterfly Valve

piping design

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