INDUSTRIAL

PLANT
ENGINEERING
ME 523

RAYMUNDO M. MELEGRITO
Mechanical Engineering dept.
INDUSTRIAL PLANT
ENGINEERING

A. PUMPS
B. FANS AND BLOWERS
C. AIR COMPRESSORS
D. COOLING TOWERS
E. MACHINERY FOUNDATIONS
F. PIPES AND INSTRUMENTATIONS
INDUSTRIAL PLANT ENGINEERING
Plant services – interdisciplinary nature since they
provide the essential services for the location:
- heat
- process steam if facility is a process plant.
- water and waste disposal
- electric power
- power generation
- compressed air
- refrigeration
- air conditioning
INDUSTRIAL PLANT ENGINEERING

Keeping the many services in a facility

functional requires a broad knowledge of
the equipment involved as well as how
vital this services may be to the
commercial building, institution,
manufacturing operation, or other activity
for which the facility may have been
designed.
PUMPS
 The purpose of a pump is to transfer a fluid from a region of low pressure
to another region at the same or higher pressure.
 A pump is a machine that imparts energy into a liquid to lift the liquid to a
higher level, to transport the liquid from one place to another, to pressurize
the liquid for some useful purpose, or to circulate the liquid in a piping
system by overcoming the frictional resistance of the piping system.

All types of pumps are used in manufacturing process flow, power plants, and
irrigation systems; Pumps supply water to a plant for domestic, process, or
fire fighting purposes, as well as pumps for chilled water flow, condensing
water flow, condensing water flow, condensate return, boiler feedwater, and
drainage.
CLASSIFICATION OF PUMPS
RECIPROCATING PUMPS
- Direct-acting steam type: Simplex and duplex
- Power machine driven; single-acting simplex and triplex
CENTRIFUGAL PUMPS
- single and multistage
- Volute and turbine type
ROTARY PUMPS
- Gear and screw pumps
- Propeller pumps
JET PUMPS
- Steam jet injectors and ejectors
- Water jet ejectors
PUMP SELECTION
Determined by the service if corrosive or
abrasive fluids are to be handled.
Usually starts with determining basic data
such as head in feet, capacity, power
required, speed and direction of rotation.,
properties of fluids to be handled
(viscosity, temperature, corrosiveness, and
abrasiveness).
PUMPING TERMS
Head – liquid pressure in pump application is
considered equivalent to a column of liquid of a
height sufficient because of the weight of the
column to produce this pressure.
Velocity – of flow per the velocity head equation is
expressed in fps or mps.
Work in Pumping – is the work required of a pump
is influenced by the amount of head the liquid will
be raised, to force required to pump it into a
higher-pressure system, required to overcome
friction.
Static head- height of ft of fluid above a
designated gage point.
Pressure head – is the static head plus the gage
pressure expressed in feet plus the friction head
(if the fluid is flowing).
Velocity head – the vertical height or feet
required to produce a certain speed of flow.
Pump operating head – the difference between
the pressure and suction head.
Friction head – the feet of liquid required to
overcome the resistance to fluid flow in pipes
and fittings.
Viscosity – term used to indicate the internal friction of a
fluid.

Suction – total suction lift is the reading of the gage at

suction flange of pump, which is converted to feet (or
meter) minus the velocity head at that point.
Total suction head is the same lift except the velocity head
is added. Pumps have suction limitations even though in
theory they should lift a liquid to the feet height
represented by atmospheric pressure, or 14.7 psi x 2.31 ft
= 34 ft of lift possible.
Cavitation – can occur on pumps when the fluid pressure
equals the vapor pressure at the existing temperature, and
as a result vapor bubbles alternately form and collapse.
 - to prevent cavitation, most pump manufacturers
indicates the NPSH, which should not be
exceeded in order to avoid cavitation damage.
Useful pump data:
1 psi gage = 2.31 ft of water
1 ft of head = 0.434 psi
1 ft3 of water = 62.4 lb in weight
1 U.S. Gal = 8.33 lb in weight
1 imperial gallon = 10 lb in weight
1 U.S. Gal = 231 in3
1 imperial gal = 277 in3
1 hp = 33,000 ft-lb/min of work
RECIPROCATING PUMPS
Are positive displacement pumps and can
be used to obtain very high pressures by
staging the cylinders or by using more
than one pump. In staging, the discharge
pressure from one cylinder is the suction
pressure for the next cylinder and this can
be carried out with each cylinder boosting
the pressure to the desired result.
Reciprocating pumps
Its use is ordinarily dictated by service needs. The
advantage of a reciprocating pump is its flexibility in
achieving desired pressures, capacity, and speed. They
are more expensive than centrifugals, require more floor
space, can be noisy, and need more maintenance.
Simplex double acting pumps are used for water service
and moderate capacity boiler feed.

Duplex double acting pumps, are used to pump viscous

type fluids such as oils and tars. Triplex pumps are used
for constant type loads, such as pumping water to a
higher pressure.
Reciprocating pump
This type of pumps must have packing to prevent
water from leaking past the piston or plunger and
also where any rod comes out of the cylinder, called
gland packing. The packing depends upon the fluid
being handled, temperatures, pressures, and pump
materials.

Foot valves are used for pumps under suction pressure

to prevent backflow on the suction line.

Aspirators are used to drain air out of suction lines to

prevent the pump from becoming air bound (a form
of pump priming).
Reciprocating pumps

PLAN
Water pressure calculation:
Steam piston area x steam pressure =

ihp 
Water piston area x water pressure

Horsepower calculation:
PLAN
ihp 

33000
33000
ihp = indicated horsepower
P = mean effective pressure
L = length of stroke
A = piston area
N = number of strokes per minute
CENTRIFUGAL PUMPS
Most frequently used pumps. Used for all types of
service, including industrial manufacturing
applications, in addition to the traditional ones of
pumping water, condensate, boiler feed, and
chilled water.

Sizes can go up to 20,000 hp, as used for utility

boiler feed. Centrifugal pump application is due to
lower cost, smaller floor space, non-pulsating flow,
relatively quiet operation, and adaptability to drive
the pump by motors and gas and steam turbines.
Multistage centrifugal pumps
Used for service pressures not attainable from single
stage pumps and are found in such service as water
supply, fire, boiler feed, and charge pumps in the
refinery and petrochemical industry.

Multistage pumps can be of the volute or diffusor

type. (Volute – convert the velocity energy to
pressure energy; Diffusor type – or turbine pumps,
guide vanes are placed between the impeller and
casing chamber, but the transformation of velocity
energy to pressure follows the volute casing design.)
Centrifugal pump vs. Reciprocating
pump
 Reciprocating pumps are positive discharge pump while
Centrifugal pumps are not.

 If the discharge valve of centrifugal pump is completely

closed, the pressure will only rise to a limited pump value
with the rotating impeller churning the fluid and the work on
the fluid being converted to heat. No rise in the head on the
discharge end of the pump.
 In reciprocating pumps (discharge valve closed), pressure
continues to build up unless a pressure control stops the
pump or a relief valve opens or the overload protection on
the driver stops the pump.
PUMP LAWS
For pumps operating at constant speed:

 Total head varies directly as the pump

impeller diameter squared, D2
 Capacity of the pump varies as the pump
impeller cubed, D3
 Fluid power developed by the pump
varies by D5 with D = pump impeller
diameter
Pump Laws
For a centrifugal pump operating at
different speeds:

- Pump capacity varies directly as the

speed, N
 Total head varies directly as N 2
 Fluid power developed by the pump
varies directly as N3
Some operating problems on centrifugal
pumps are:
 Low water flow can be caused by improper speed, plugged
suction strainer, air bound pump, open air vent valves used
to prime the pump, worn wearing rings, damaged impeller.

 Vibration can be caused by misalignment, bearing wear,

impeller unbalance due to wear, and corrosion on pump
parts.

 Progressive shaft thinning and cracking can be caused by

improperly installed shaft packing or chemical attack on the
material from the liquid handled that may cause stress-
corrosion cracking to occur.
ROTARY PUMPS
Rotary pumps are considered positive displacement
pumps because they can build pressure by the action of
two rotating meshing pump components.

 The flow form a rotary pump is not pulsating, but is

fairly steady.

- They are designed for certain services up to a medium

head. Some are designed with stainless steel
components and have large cavities for the fluid
between the rotating rotor which permit pumping of
high viscous fluids.
Rotary pump
The absence of entry and discharge valves
is another advantage of this type of pump.
Generally, rotary pumps are not well
suited for pumping fluids containing grit
or abrasives because of the close
clearance between rotating elements and
the pump casing.
PROPELLER PUMPS

Propeller pumps are usually immersed in

the liquid to be pumped and are used for
drainage of for large volume circulating
service such as condensers in steam or
refrigeration service. The propeller pump
is considered an axial flow pump.
Propeller pumps
Considered as an axial flow pump. The
fluid enters the pump at the bottom, and
then the rotating impellers on the shaft lift
the fluid along the pump length to be
discharged axially from the impellers. The
total head developed comes from the
dynamic lifting action between the vanes
or impellers and the fluid.
DIAPHRAGM PUMPS
Primarily used for controlled volume pumping and
for precise feeding of chemicals in manufacturing
or as the equivalent of a meter.
- Considered to be the positive displacement type
with low-volume flows and essentially consist of
a flexible diaphragm enclosed in a pressure casing
called a head with the pump being considered as
single acting.
- The diaphragms can be pushed back and forth
mechanically or by air or liquid on the other side
of the fluid being pumped.
COMPRESSED AIR SYSTEMS
Plant services includes air systems that are used
extensively for the following applications:

1. To provide air for pneumatic controls for air

conditioning, heating systems, and other such
controls in process applications.

2. To operate punch presses; rotating hand tools such

as grinders, wrenches, drills, screwdrivers,
reamers; and similar tools powered by
compressed air.
3. To provide air for cleaning machine tools
and other work stations.
4. To aerate and agitate liquids, operate paint
spray guns, and spray oils and insecticides.
5. To inflate tires, charge shock absorbers,
and act as a cushioning device for many
compressed fluids, such as expansion
tanks on hot water heating systems.
6. To start diesel engines and for pumped air
storage for operating combined-cycle
electric power generating plants.
Compressed..

The chief advantage of using air is that it is

available from the earth’s atmosphere,
which consist of a mechanical mixture of
gases, mostly oxygen and nitrogen, as
well as inert gases, such as argon, helium,
neon, krypton, radon, and xenon.
AIR FILTERING
Dust and moisture must be at minimum
in compressed air system. All air contains
suspended solid particles, or dust,
composed of various substances. Dust
can obstruct compressor passages, block
heat transfer, and cause sludge to form in
the compressor lubricating system. Filters
are used to block out the dust from the
intake of compressors.
Filtering...
Water vapor is compressed with the air as it
goes through the compressor and then
condenses in the piping or air receiver. It can
cause corrosion on metal parts if not removed
and eventual thinning due to corrosion, can
cause explosions.

Air dryers are used in certain compressed air

applications in order to reduce the moisture
content in the compressed air to a minimum.
COMPRESSED AIR
DYNAMICS
Compressed air is considered a working
substance which carries energy to and
from a machine. The working substance,
or air, may absorb or reject energy, do
work, or have work done on it.

Perfect gas laws are used to solve many

compressed air problem, as well as
Boyle’s and Charles’ Law.
AIR COMPRESSORS
RECIPROCATING COMPRESSORS
- these compressors may be double acting:
can also be single or multistage units.
SLIDING – VANE ROTARY
Air is trapped between the vanes as it
passes the suction openings and is
compressed as the volume between the
vanes decreases to the discharge pressure.
TWO-LOBE TYPE COMPRESSOR
Consists of two impellers mounted on
parallel shafts that rotate in opposite
directions, drawing air into the pockets
between the impellers and the casing and
then carrying this compressed air to the
outlet at design pressure.
LIQUID-PISTON COMPRESSOR
Liquid-piston rotary units have a multiblade
rotor revolving in an elliptical casing that
is partly filled with a liquid which acts as
a piston. The blades form a series of
buckets. The liquid follows the contour of
the casing and alternately leaves from and
returns to the space between the blades
twice per revolution.
CENTRIFUGAL
COMPRESSOR
Centrifugal compressor takes air at the eye
of the impeller and then accelerates it
outward radially. The velocity of the air
is converted to static pressure. These
units can be staged to obtain different
discharge pressures. These units can be
staged to obtain different discharge
pressures. Used for large volume air
flows at moderate pressure.
AXIAL COMPRESSOR

The axial compressor takes air in at one end

and discharges it at the other axial end
after it passes through a series of rotary
and stationary blades. Each row on the
rotor increases the pressure; thus the
number of stages of compression required
will be influenced by the final pressure
needed.
SCREW COMPRESSOR
Is a twin shaft positive displacement unit.
The air is slowly compressed from the
suction end to the discharge port by ever-
diminishing space between the
convolutions of the two helical rotor as
the air is compressed to the final design
pressure before leaving the discharge port.
Selection of compressor type
Selection of compressor is determined by:
PRESSURE
CAPACITY
- depends on load and whether it is
steady or intermittent. Capacity is
measured in CFM and the corresponding
pressure that is needed.
CONTROL
COMPRESSOR
EFFICIENCIES
1. Volumetric efficiency = actual air delivered, ft 3/
theoritical air delivery, or piston displacement
2. Isothermal compression efficiency = theoretical
isothermal hp / indicated hp
3. Adiabatic compression efficiency = theoretical
adiabatic hp / indicated hp
4. Mechanical efficiency = indicated hp / actual hp input
(brake hp)
5. Overall efficiency = compression efficiency x
mechanical efficiency (state if compression efficiency
is isothermal or adiabatic) / actual hp input (brake hp)
 FANS AND BLOWERS: AIR MOVERS

Fan and blowers are extensively used in all types of

occupancies and service requirements, such as draft for
boilers, ventilation, supplying conditioned air to offices, and
supplying combustion air for ovens and similar industrial
equipment.

 Fans and blowers move air at desired volumes and pressure;

however, the pressure is not measured in psi but rather in
inches of water.

 Blowers usually deliver large volumes of air at higher

pressure than fans, which are considered low pressure air
deliverers
FAN TYPES AND
CHARACTERISTICS
Classification for fans is by flow:
RADIAL OR CENTRIFUGAL
AXIAL
Propeller fan is used mostly for ventilation
and exhaust services.
Vane axial fan is a propeller fan set inside a
cylinder
Centrifugal fan

Radial (propeller)
Axial

Vaneaxial
Centrifugal fan performance law
Similar to centrifugal pumps, for a given fan size, duct system,
and air density, the following relationships exist on
performance:
1. Capacity varies directly as the speed ratio.
2. The static pressure varies as the speed ratio.
3. The speed and capacity vary as the square root of the static
pressure.
4. The horsepower varies as the cube of either the speed or
capacity ratio.
5. The horsepower varies as the 3/2 power of the static pressure
ratio.
6. The air velocity varies directly as either the speed or the
capacity ratio.
Fan performance..
Where the static pressure is constant at the fan outlet, the
following rules apply:

1. The capacity and the horsepower vary as the square of the

wheel diameter.
2. The speed ratio varies directly as the wheel diameter ratio.
3. At constant static pressure, the speed, capacity, and power
vary inversely as the square root of the ratio of the air
densities.
4. At constant capacity and speed, the horsepower and static
pressure vary directly as the ratio of the densities of the air.
Operation and maintenance
Fans and blowers should be started with
minimum flows and gradually brought to
full load to prevent shocking the
machine’s components and also to avoid
seriously overloading the driver. It should
be maintained clean and free of deposit, to
prevent any build up of corrosion attack
and imbalance with resultant vibration
may occur.
COOLING TOWERS
Cooling towers are a special type of heat
exchanger that allows water and air to
come in contact with each other to lower
the temperature of the hot water.
During the cooling tower working process,
small volumes of water evaporate,
lowering the temperature of the water
that’s being circulated throughout the
cooling tower.
COOLING TOWER PROCESS
What are cooling towers? Cooling towers are a special type of heat
exchanger that allows water and air to come in contact with each other to lower
the temperature of the hot water. During this process, small volumes of water
evaporate, lowering the temperature of the water that’s being circulated
throughout the cooling tower. In a short summary, a cooling tower cools down
water that gets over heated by industrial equipment and processes.
The hot water is usually caused by air conditioning condensers or other
industrial processes. That water is pumped through pipes directly into the
cooling tower. Cooling tower nozzles are used to spray the water onto to the “fill
media”, which slows the water flow down and exposes the maximum amount of
water surface area possible for the best air-water contact. The water is exposed
to air as it flows throughout the cooling tower. The air is being pulled by an
motor-driven electric “cooling tower fan”.
When the air and water come together, a small volume of water evaporates,
creating an action of cooling. The colder water gets pumped back to the
process/equipment that absorbs heat or the condenser. It repeats the loop over
and over again to constantly cool down the heated equipment or condensers.
EVAPORATIVE COOLING
Evaporative cooling is the process where
warm water from an industrial process is
pumped up to the top of the cooling tower
where the water distribution system is. The
water then gets distributed by cooling tower
nozzles to the wet deck. At the same time,
air is being drawn through the air-inlet
louvers forcing water to evaporate.
Evaporation causes the heat to be removed
from the make up water.
Cooling towers......
 Crossflow Cooling towers
 Counterflow Cooling towers
 Forced Draft & Induced Draft Cooling
Towers Process
 Factory Assembled Cooling towers (FAP)
Factory Assembled Product
 Fiel-Erected-Towers (FEP) Field Erected
Product
TYPES OF COOLING
TOWERS
Cross flow cooling Towers
In crossflow cooling tower systems the water vertically flows through the fill
media while the air horizontally flows across the falling water. That’s why
they call it “crossflow” because the air and water cross paths or flows.
Because of the crossing of flows, the air doesn’t need to pass through the
distribution system. This permits the use of hot water flow via gravity and
distribution basins on the top of the tower right above the fill media. The
basins are a standard of crossflow cooling towers and are applied on all
units.
Counterflow Cooling Tower Diagram
Difference between crossflow and counterflow cooling towers: In counterflow cooling tower system processes, the air
vertically flows upwards, counter to the water flow in the fill media. Due to the air flowing vertically, it’s not possible to
use the basin’s gravity-flow like in crossflow towers. As a substitute, these towers use pressurized spray systems, usually
pipe-type, to spray the water on top of the fill media. The pipes and cooling tower nozzles are usually spread farther apart
so they will not restrict any air flow.
Forced Draft & Induced Draft Cooling
Towers Process
Cooling tower fans are used on induced draft cooling
towers to pull air up through the fill media. On forced
draft cooling towers, the air is pushed/forced by blowers
at the bottom of the air inlet louver.
Natural Draft & Fan Assisted Natural
Draft Cooling Towers