Pumps ’n Pipeline (PnP v1.1) Help

i2D’s Doc No: i2D-PnP-MAN-001

0 27/10/17 ISSUED FOR USE SBU RBR SBU

A 17/10/17 ISSUED FOR COMMENTS SBU RBR SBU

REV DATE DESCRIPTION OF REVISION Auteur Checker Approver

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Contents Introduction ...................................................................................................................................... 4

General ........................................................................................................................................ 4 Quick Introduction ........................................................................................................................ 5 Getting Started ............................................................................................................................. 5 Abbreviations ............................................................................................................................... 5

1 Pumps ...................................................................................................................................... 6 1.1.1 Name Fields ................................................................................................................. 7 1.1.2 Open and Save Pump File........................................................................................... 7 1.1.3 Constant Power or Torque........................................................................................... 7 1.1.4 Power Nominal [kW] .................................................................................................... 7 1.1.5 RPM Nominal [1/min] ................................................................................................... 7 1.1.6 RPM Minimum [1/min] ................................................................................................. 7 1.1.7 RPM Maximum [1/min] ................................................................................................ 7 1.1.8 Head Regression Coefficients [kPa] ............................................................................ 7 1.1.9 Efficiency Regression Coefficients [-] .......................................................................... 8

2 Pipeline ..................................................................................................................................... 9 2.1 General ............................................................................................................................ 9

2.1.1 Wall Roughness [mm] .................................................................................................. 9 2.2 Suction Side ..................................................................................................................... 9

2.2.1 Diameter of Suction Line [m] ....................................................................................... 9 2.2.2 Suction Pipeline Length [-] ........................................................................................... 9 2.2.3 Friction Loss Water [-] .................................................................................................. 9 2.2.4 Friction Loss Mixture [-] ............................................................................................. 10

2.3 Discharge Side .............................................................................................................. 10 2.3.1 Diameter of Discharge Line [m] ................................................................................. 10 2.3.2 Discharge Pipeline Length [-] .................................................................................... 10 2.3.3 Friction Loss Water [-] ................................................................................................ 10 2.3.4 Friction Loss Mixture [-] ............................................................................................. 10

2.4 Vertical Distances .......................................................................................................... 10 2.4.1 Suction Depth [m] ...................................................................................................... 11 2.4.2 Waterline Pump Axle Depth [m] ................................................................................ 11 2.4.3 Geodetic Height [m] ................................................................................................... 11

3 Mixture .................................................................................................................................... 12 3.1.1 Mixture Density [kg/m3] .............................................................................................. 12 3.1.2 Water Density [kg/m3] ................................................................................................ 12 3.1.3 In-situ Density [kg/m3] ................................................................................................ 12 3.1.4 Solids Density [kg/m3] ................................................................................................ 13 3.1.5 Shape Factor [-] ......................................................................................................... 13 3.1.6 Temperature [deg C] .................................................................................................. 13 3.1.7 Determining Particle Size [µm] .................................................................................. 13

4 Diagrams ................................................................................................................................ 14 4.1 Calculation Parameters ................................................................................................. 14

4.1.1 Maximum Discharge [m3/s] ....................................................................................... 14 4.1.2 Minimum Vacuum [kPa] ............................................................................................. 14 4.1.3 Maximum Vacuum [kPa] ............................................................................................ 15 4.1.4 Maximum Pipeline Length [m] ................................................................................... 15

4.2 Display Parameters ....................................................................................................... 15 4.2.1 Maximum Head [kPa] ................................................................................................ 15 4.2.2 Maximum Power [kW] ................................................................................................ 15 4.2.3 Maximum Production [in-situ m3/hr] .......................................................................... 15 4.2.4 Minimum Efficiency [%] .............................................................................................. 15

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4.2.5 Maximum Efficiency [%]............................................................................................. 15 4.3 Show Labels .................................................................................................................. 15

5 Results .................................................................................................................................... 16 5.1 Pump # Range Diagram ................................................................................................ 16 5.2 Pump and Pipeline Characteristic (QHL-Diagram) ........................................................ 16 5.3 Production Limitations (PrQ-Diagram) ........................................................................... 16 5.4 Discharge Production Limitation (PrLd-Diagram) .......................................................... 17

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Introduction

General Pumps ’n Pipeline (PnP) can estimate suction and discharge production for any dredging or mining equipment that hydraulically transports soil like materials. PnP is generic and powerful, but still simple and intuitive for the user. Any production for dredging or mining equipment can be accurately and robustly estimated. The Graphical User Interface is derived from decades of estimating experiences. PnP uses a unique collection of empirical relationships based on decades of field measurements. Extensive literature on hydraulic transport is available. However, all this information complicates the practical production estimate. Literature is often very specific and includes many hidden model scale effects. Therefore, PnP only applies empirical relationships which have proven themselves in the field. PnP can be practically used to support:

Designing pump-drive systems and pipeline configurations

Selecting equipment feasibility for projects

Estimating suction and discharge production

Selecting gear(s) or e.g. the rainbow nozzle diameter for a project

Evaluating performance of pump-drive systems

The program has five tabs / submenu pages giving the user an easy overview:

Pumps

Pipeline

Mixture

Diagrams

Results

All input parameters are in SI units. All input fields show the SI unit. For some input parameters, typical values or ranges are provided. i2D can help to ensure your calculations are realistic. PnP can estimate production for the majority of projects. PnP has the following limitations to ensure its user friendliness:

Maximum three pumps in series

No increase of viscosity due to mud or clay is taken into consideration

Impeller diameter or the number of vanes are not included as variables

Limiting vacuum of only Pump #1 is taken into consideration and is independent of

RPMs. Incoming pressure for Pump #2 and Pump #3 is not considered.

i2D can use PnP Expert to overcome these limitations and for special, advanced projects, which are less typical. PnP Expert has no graphical user interface. Therefore, it is very flexible, fast to develop and easy to integrate with another estimation tool. Both tools share the same library. If you have any questions, comments, ideas or feedback please contact i2D via www.in2Dredging.com/contact or support@in2dreding.com.

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Quick Introduction PnP’s Graphical User Interface has five tabs / submenus. The first four submenus request input parameters and the last submenu (Results) shows several graphs to check the input deck and to find the end results: the suction or discharge production. The results are given when the calculation button or short key F9 has been pressed and no error message is given. If an error message shows up, the user has to fill in more data in the specified input box. The user is unable to input values outside a typical / logical range. If the graphs are out of range, then the user can tweak the values in the Diagram submenu. The user can open or save each pump in a *.pmp file and build their own pump database. Project files are opened and saved as *.pnp files. You can find more detailed help in this document. Press crtl + F1 or press Help and then PnP Document to come back to this file.

Getting Started You can download a demo or licensed version from the PnP web page. The demo version allows for unlimited trial use of PnP v1.1 during a trail period of 7 days. This version is fully functional except for the pumps submenu, which is disabled. To run the licensed version the user has to obtain a licence key. The following steps are required:

1. Pay for the licence key online

2. Download and install the PnP licensed version

3. Send Registration Number and Username to support@in2Dredging.com

4. Receive Unlock Code from support@in2Dredging.com to unlock PnP licensed version

5. Estimate suction and discharge production reliably

6. Load the project file example.pnp to get started even faster

Abbreviations CSD Cutter Suction Dredger i2D in2Dredging Pty Ltd PnP Pumps ‘n Pipeline RPM Revolutions per Minute SI Système International (International System of Units) TSHD Trailer Suction Hopper Dredger UWP Under Water Pump

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1 Pumps Above the pumps tab page you will find typical program buttons such as New Project File, Open Project File, Save Project File, Print and Run Project. The project files have the extension *.pnp. On the pumps tab page, it is possible to select up to three pumps in series. Pump #1 is at the suction inlet end. Pump #1 always has to be specified. Pump #2 has to be specified if Pump #3 is specified. PnP v1.1’s graphical user interface is limited to three pumps because the majority of projects use a maximum of three pumps. i2D can perform calculations with PnP Expert using an unlimited number of pumps. Each dredge pump can be saved in a *.pmp file. Users can create their own pump database.

Figure 1 Pump specification input panel

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The panel for Pump #1 specifications is discussed from the top and shown in Figure 1. The Pump #1 panel is identical to the Pump #2 and Pump #3 panels.

1.1.1 Name Fields The pump specifications can include an equipment and pump name e.g. CSD 01 (Cutter Suction Dredger 01) and e.g. UWP (Under Water Pump).

1.1.2 Open and Save Pump File The pump file with specifications shown in the panel above can be opened and saved with the typical open and save buttons. An empty pump file can be opened to erase all the fields at once. A pump without any specifications is not taken into account. Pump #1 always has to be specified. Pump #2 has to be specified if Pump #3 is specified.

1.1.3 Constant Power or Torque A radio button enables a choice between constant power and constant torque. A pump driven by an electrical engine typically generates constant power when the pump load on the engine reaches the nominal power. A pump driven directly by a diesel engine is typically constant torque.

1.1.4 Power Nominal [kW] The nominal power is the maximum power of the engine on the shaft. The hydraulic power is limited by the entered nominal power depending of the pump efficiency. The nominal engine power can be reduced for various reasons. Ideally a torque and revolutions per minute (RPM) measurement is performed regularly to check the engine performance.

1.1.5 RPM Nominal [1/min] The nominal revolutions per minute (RPM) should match the RPMs used to obtain the pump regression coefficients.

1.1.6 RPM Minimum [1/min] The minimum RPMs are typically 70 to 80% of the nominal RPM.

1.1.7 RPM Maximum [1/min] The maximum RPMs can typically be 120% of the nominal RPMs. The maximum RPMs of a dredge pump directly driven by a diesel engine match the nominal RPMs and therefore this field is disabled when constant torque is selected.

1.1.8 Head Regression Coefficients [kPa] The three head regression coefficients (C1, C2 and C3) describe a second order polynomial.

𝑦 = 𝐶1 + 𝐶2 ∗ 𝑥 + 𝐶3 ∗ 𝑥2 (1) The coefficients can easily be found using the curve fitting equation (1) on the water operating points. A minimum of three points, but ideally at least five operating points are used to fit the polynomial curve. In this case x is the discharge in m3/s and y is the manometric head in kPa.

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1.1.9 Efficiency Regression Coefficients [-] The efficiency is described with the same second order polynomial as shown in equation (1). In this case, x is the discharge in m3/s and y is the dimensionless efficiency [-]. Efficiency is defined as hydraulic power divided by engine power.

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2 Pipeline

Figure 2 Tab menu for pipeline specifications

The pipeline page is divided into four sections.

2.1 General

2.1.1 Wall Roughness [mm] The wall roughness is typically 0.01 mm. This relatively high value takes the flanges that are typically present in the pipeline into account.

2.2 Suction Side Suction side is only the suction side of Pump #1.

2.2.1 Diameter of Suction Line [m] The diameter of the suction line.

2.2.2 Suction Pipeline Length [-] Total length of the pipeline at the suction side of Pump #1.

2.2.3 Friction Loss Water [-] Typical local friction losses in the suction pipeline are shown in Table 1.

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Table 1 Typical friction losses at the suction side

Description Friction Loss [-]

Accelerating water/mixture

1.0

Inlet 0.5

Drag or cutter head (also soil dependent)

0.7-7.0

Significant friction losses in the suction pipeline can affect the pump performance.

2.2.4 Friction Loss Mixture [-] The mixture could increase the local friction losses. A typical value for TSHD and CSD is in between 1 and 2.

2.3 Discharge Side The discharge side starts upstream of Pump #1.

2.3.1 Diameter of Discharge Line [m] The diameter of the discharge line.

2.3.2 Discharge Pipeline Length [-] The length of the pipeline upstream of Pump #1. PnP v1.1 does not take the location of Pump #2 and Pump #3 into account.

2.3.3 Friction Loss Water [-] Typical local friction losses in the discharge pipeline are shown in Table 2.

Table 2 Typical friction losses in the discharge pipeline

Description Friction Loss [-]

90 deg bend 0.5

T-piece 1.2

Rubber hoses, man holes, straight Y-piece

0.05

2.3.4 Friction Loss Mixture [-] Additional friction loss due to mixture in the discharge pipeline.

2.4 Vertical Distances Definition of the vertical distances are given in the drawing next to the panel of the input field. The vertical positions of Pump #2 and Pump #3 are ignored in PnP v1.1.

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In the vast majority of projects, the incoming pressure for Pump #2 and #3 is not relevant or not an issue and therefore it is ignored as a production limitation. i2D can perform more detailed calculations with PnP Expert if the incoming pressure of Pump #2 or Pump #3 is a concern.

2.4.1 Suction Depth [m] The vertical distance between inlet (e.g. cutter head or drag head) and water level.

2.4.2 Waterline Pump Axle Depth [m] The vertical distance between pump axle level and water level. The waterline pump axle depth only affects suction production.

2.4.3 Geodetic Height [m] The vertical distance between the water and outlet levels (e.g. rainbow nozzle or outlet on sand fill)

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3 Mixture

Figure 3 Tab menu mixture specification

3.1.1 Mixture Density [kg/m3] The mixture density entered should be in the range of the Water Density and In-situ Density. The mixture density is applied in the Pump # Range Diagram. A range of mixture densities in between Water Density and Mixture Density in steps of 100kg/m3 is applied throughout the operating points calculations. The mixture density applied here can be related to the maximum production produced at e.g. the drag head, suction head, cutter head or in the hopper.

3.1.2 Water Density [kg/m3] The water density of seawater is typically 1025kg/m3.

3.1.3 In-situ Density [kg/m3] The in-situ density is found with an unstirred and fully saturated soil sample. Typical in-situ density ranges are given in Table 3.

Table 3 Typical in-situ density ranges

Soil Description In-situ Density [kg/m3]

Silt, mud and clay 1.3 – 2.2

Sand 1.8 - 2.0

Gravel 2.0 - 2.1

Rock 2.0 - 2.7

The productions (in-situ m3/hr) shown in the graph are given for the in-situ density.

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3.1.4 Solids Density [kg/m3] The solids density of the sand particles is typically 2700kg/m3. Clay or peat might have a lower density while rock might have a larger solids density.

3.1.5 Shape Factor [-] Various values for the shape factor are shown in Table 4.

Table 4 Typical shape factor

Soil Description Shape Factor [-]

Clay balls 1.0

Silica sand 0.7

Intact shells 0.5

Crushed shells 0.3

3.1.6 Temperature [deg C] The temperature should be given in degrees Celsius.

3.1.7 Determining Particle Size [µm] The determining particle size can be calculated with the following equation (2):

𝑑𝑚𝑓 =𝐷10+𝐷20+𝐷30+𝐷40+𝐷50+𝐷60+𝐷70+𝐷80+𝐷90

9 (2)

If the Particle Size Distribution (PSD) is not defined, then the average particle size (D50) can be applied as a best estimate.

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4 Diagrams

Figure 4 Tab menu diagrams specification

The specification of the diagram is divided in calculation parameters, display parameters and show labels.

4.1 Calculation Parameters

4.1.1 Maximum Discharge [m3/s] Maximum discharge determines the domain of the calculation, which is between zero and the entered value. The discharge is shown on various horizontal axes.

4.1.2 Minimum Vacuum [kPa] Minimum Vacuum is the lowest production parabola drawn in the Production Limitation (PrQ) Diagram. The typical limiting vacuum range for a pump is 60-80kPa. The value depends on the pump and RPMs. In order to make the program more user friendly PnP v1.1 ignores that the limiting vacuum depends of RPMs. With PnP Expert i2D can perform more advanced calculations that take the Nett Positive Suction Head (NPSH) characteristics of the pump into account (RPM dependency).

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4.1.3 Maximum Vacuum [kPa] Maximum vacuum is the highest production parabola drawn in the Production Limitation graph (PrQ-Diagram).

4.1.4 Maximum Pipeline Length [m] The maximum discharge pipeline length is shown on the horizontal axis in the Discharge Production Limitations (PrLd) diagram.

4.2 Display Parameters The display parameters only affect the scales on the axes.

4.2.1 Maximum Head [kPa] The maximum head determines the vertical axis for the head in the Pump # Range Diagram and the Pump and Pipeline Characteristic (QHL) Diagram.

4.2.2 Maximum Power [kW] The maximum power determines the maximum on the vertical axis for the power.

4.2.3 Maximum Production [in-situ m3/hr] The maximum production determines the maximum on the vertical axis of the Production Limitations (PrQ) Diagram and the Discharge Production Limitation (PrLd) diagrams.

4.2.4 Minimum Efficiency [%] The minimum efficiency determines the vertical axis for the efficiency in the Pump # Range Diagram.

4.2.5 Maximum Efficiency [%] The maximum efficiency determines the vertical axis for the efficiency in the Pump # Range Diagram.

4.3 Show Labels A ticked box provides labels in the specified graphs indicating the mixture densities.

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5 Results The results are shown in four types of diagrams. Select the diagram you want to see in the drop-down menu. When the project is calculated and no input errors are found, then PnP automatically shows the results submenu. To run the simulation either press the calculator button or the short key F9.

5.1 Pump # Range Diagram The Pump # Range Diagram consists of three graphs:

Top graph: Discharge [m3/s] versus power on the shaft [kW]

Middle graph: Discharge [m3/s] versus efficiency [%]

Bottom graph: Discharge [m3/s] versus manometric head [kPa].

The scale of the axis can be changed in the diagram submenu. These Pump # Range graphs can be used to understand the pump characteristics for the specified mixture density and RPM range. The RPM range is from minimum to maximum. In order to obtain quick and accurate results it is best to check these graphs before proceeding to the estimate.

5.2 Pump and Pipeline Characteristic (QHL-Diagram) The Pump and Pipeline Characteristic (QHL-Diagram) shows the characteristics of the pumps and pipeline. If three pumps are specified Pump #1, Pump #1 + Pump#2 and a summation of all the pumps is displayed. The intersection of the pumps and pipeline characteristics or operating point are shown. This graph shows the user a range of mixture densities, a specific pipeline length and whether the pumps are able to pump the specified mixture through the specified pipeline. The pipeline could be too long or the number of specified pumps has to be reduced such that intersection points between the pumps and pipeline characteristics can be determined.

5.3 Production Limitations (PrQ-Diagram) The Production Limitations (PrQ) Diagram shows the limitations of the project in one go. The graph shows:

Critical discharge for the largest pipeline diameter, typically on the suction side

Vacuum production parabolas for a specified range of vacua

Operating points for a range of mixture densities

The velocity in the pipeline has to stay above the critical velocity to avoid a bed of solid material in the pipeline. Typically, a solid bed in the pipeline is avoided to reduce pressure losses. The discharge below the critical velocity is hatched red. The vacuum production is only applicable for Pump #1. Production above the vacuum range is not possible because the pump starts to cavitate and rapidly loses its efficiency. The area above the maximum vacuum parabola is hatched red. The operating points are an outcome of the pump-drive system and number of pumps specified. The area outside the working points is hatched red.

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Maximum production can be found at the top of the area that has no red hatching. The intersection of critical discharge with the working point parabola or vacuum parabola normally shows maximum production and also the critical components to make the project successful.

5.4 Discharge Production Limitation (PrLd-Diagram) The Discharge Production Limitation (PrLd) shows the pipeline length versus In-situ Production. The graph shows the maximum discharge production for the specified mixture density range and maximum discharge pipeline length. This graph shows if the project is feasible with the specified pumps, pipeline and mixture. The user might have to reconsider e.g. the pump-drive systems, a booster pump or even alternative equipment. Now that the pump power usage and production are well defined it becomes possible to perform an accurate and robust cost estimate or schedule.