Water Loop Calculations

Process Engineering

WATER LOOP DISTRIBUTION

Simultaneous usage within a minuteNeed to identify users for a distribution loop Water quality Temperature

WATER DELIVERY OPTIONS

Basic Distribution – delivered/received at same temperature as storedCool/ReheatPoint-of-use heat exchangers“Chase the tail”

BASIC DISTRIBUTION

COOL / REHEAT

POINT-OF-USE EXCHANGERS

“CHASE THE TAIL”

Line Sizing Calc Guide

Factors to consider include: Economics (capital cost, energy) Pressure frop Velocity Turbulence Length of pipe run Pipe run components Noise Space Plant expansion Pump/compressor capability

Pressure Drop/Velocity Guidelines

Service velocity, pressure drop,ft / sec PSI / 100 ft

Pump Suct., General Service, low visc. ----- 0.5 to 1.0Pump Suct., Gen. Serv., near boiling pt. ----- 0.2 to 0.4Pump Discharge, General Service ----- 1.0 to 3.0WFI / USP Water, 1" to 1 1/2" 2 to 4 1 to 4WFI / USP Water, 2" to 4" 3 to 7 1 to 3CIP Solutions, 1/2" to 1 1/2" 2 to 5 1 to 4CIP Solutions, 2" to 3" 3 to 7 1 to 3Compressed Air / N2, 15 psig ----- 0.25 to 0.5Compressed Air / N2, 50 psig ----- 0.5 to 1.0Compressed Air / N2, 100 psig ----- 1.0 to 2.0Saturated Steam, 15 psig ----- 0.5 to 1.0Saturated Steam, 50 psig ----- 0.5 to 1.0Saturated Steam, 100 psig ----- 1.0 to 2.0

(Re > 3000)

f = a function of Reynolds Number and

Relative Roughness; see Crane Technical Paper

No. 410

ε = 0.00015 for commercial steel

ε = 0.000005 for drawn tubing

Pressure Drop - Incompressible Turbulent Flow

5 0 . 6 Q ρd µ

R e =

0 . 0 0 0 2 1 6 f L Q 2 ρ

d 5∆ P =

Re = Reynolds Numberd = inside diameter, inchesL = length of pipe, feetQ = flowrate, gpmρ = density, lb/cfm = viscosity, cp∆P = pressure drop, psiε/D = relative roughnessD = inside diameter, feet

Line Sizing Guidelines

Maximum flow rate of 7-8 ft/secMaximum pressure drop of 2 lb per 100 feet Evaluate the “Equivalent Length”

Minimum flow rate 3 ft/sec Turbulent flow (Reynolds Number > 3000 is

turbulent. >10,000 – 15,000 is preferred)

Line Loses - Equivalent Length

Typically done when you can only estimate the linear footage of the systemOther resistances to be considered include manual valves, elbows, tees, reducers, entrances/exits, etc.Difficult to tabulate the resistances at this stage of designRule of thumb - allow the equivalent length to be twice the linear footage for the purpose of the initial pump head calculation

PUMP HEAD CALCULATION - CONSIDERATIONS(CIRCULATION LOOP)

F I

s u c t i o nt e r m i n a l

p r e s s u r e

s u c t i o ns t a t i ch e a d

m e t e rl o s s

e x c h a n g e rl o s s

c o n t r o lv a l v e l o s s

d i s c h a r g es t a t i c h e a d

s p r a y b a l ll o s s

d i s c h a r g et e r m i n a l

p r e s s u r e

s u c t i o n l i n e l o s s

p u m p w e a rl o s s

d i s c h a r g e l i n el o s s

u s e p o i n t s

N O T E : c o n s i d e r d i f f e r e n t f l o w s c e n a r i o s f o rp r e s s u r e d r o p c a l c ( n o u s e , p e a k u s e , e t c . )

note: check these values as the vendor information comes in

TYPICAL EQUIPMENT LOSSES(for pump head calculations)

In-line filter - allow 3 to 5 psiFlowmeter - allow 3 to 5 psiControl valve - allow 10 psiHeat exchanger - allow 3-5 psi shellside, 3-5 psi tubesideTank jacket - allow 5-10 psiSprayball - allow 25-30 psiPump wear - allow 5 psi

EVALUATE TWO SCENARIOS

Hot WFI LoopAmbient WFI Loop

WATER USE-POINT LAYOUT

QC Lab Buffer Prep Buffer Prep PurificationA-10 Fractionation Purification A-7, A-8, A-13

A-6 A-9 H-1, H-2

Fractionation InactivationA-4, A-5, A-12 A-1, A-2, A-3C-1 C-2

Utility

WFI CIP Ambient LoopA-11 Hot LoopH-3

HOT WFI LOOP

HWFI System Use-Point Matrix Estimated Estimated

UsePoint

RoomName

Use-Pt.Temp.

DesignFlow Daily Volume

PeakUsage

H-1 Purification Autoclave 80 Deg C 5 gpm 150 gals 5 gpmH-2 Purification Washer 80 Deg C 5 gpm 200 gals 5 gpmH-3 CIP 80 Deg C 10 gpm 500 gals 10 gpm

Maximum Possible Draw: 20 gpm 850 gals 20 gpm

From To DistanceTank H-3 20 ftH-3 H-1 / 2 80 ft

H-1 / 2 Tank 120 ft

TOTAL 220 ft

HOT WFI CONSIDERATIONS

Maximum Demand - 20 GPMMinimum Return Flow Future ExpansionStorage Tank Sprayball flowrate (???) 2.5 - 3 GPM / ft of circumference 400 Gal Tk, 4 ft diameter -> 30 - 40 GPM

EconomicsFDA Approval

Service: HWFI Engineer:Line No.

INPUTFlow (GPM) 20.00Pipe Length (feet) 440Specific Gravity 0.97Viscosity (centipoise) 0.35Roughness (ft) 0.00005

Nominal Actual ID Reynolds ∆P Velocity FrictionSize (in) (inches) Number Flow Region (psi/100ft) (ft/sec) Factor

0.500 0.37 473982 Turbulent 1,717.8892 59.68 0.02270.750 0.62 282860 Turbulent 118.2286 21.25 0.02071.000 0.87 201578 Turbulent 20.8810 10.79 0.0199

>>>> 1.500 1.37 128010 Turbulent 2.1202 4.35 0.01952.000 1.87 93782 Turbulent 0.4538 2.34 0.01983.000 2.87 61106 Turbulent 0.0559 0.99 0.02084.000 3.83 45742 Turbulent 0.0138 0.56 0.02186.000 5.78 30331 Turbulent 0.0019 0.24 0.02378.000 7.98 21974 Turbulent 0.0004 0.13 0.025410.000 10.02 17502 Turbulent 0.0001 0.08 0.0269

note : Clean Tubing

Service: HWFI Engineer:Line No.

INPUTFlow (GPM) 45.00Pipe Length (feet) 440Specific Gravity 0.97Viscosity (centipoise) 0.35Roughness (ft) 0.00005

Nominal Actual ID Reynolds ∆P Velocity FrictionSize (in) (inches) Number Flow Region (psi/100ft) (ft/sec) Factor

0.500 0.37 1066459 Turbulent 8,585.3781 134.28 0.02240.750 0.62 636435 Turbulent 581.2814 47.82 0.02011.000 0.87 453551 Turbulent 100.8326 24.29 0.01891.500 1.37 288022 Turbulent 9.9066 9.79 0.0180

>>>> 2.000 1.87 211011 Turbulent 2.0675 5.26 0.01783.000 2.87 137488 Turbulent 0.2470 2.23 0.01814.000 3.83 102919 Turbulent 0.0598 1.25 0.01876.000 5.78 68245 Turbulent 0.0082 0.55 0.01998.000 7.98 49441 Turbulent 0.0017 0.29 0.021110.000 10.02 39380 Turbulent 0.0006 0.18 0.0222

note : Clean Tubing

AMBIENT WFI LOOPAWFI System Use-Point Matrix Estimated Estimated

UsePoint

RoomName

Use-Pt.Temp.

DesignFlow Daily Volume

PeakUsage

A-1 Inactivation Wash Room CIP 25 Deg C 5 gpm 200 gals 5 gpmA-2 Inactivation Wash Room 25 Deg C 4 gpm 100 gals 4 gpmA-3 Inactivation Wash Sink 25 Deg C 2 gpm 50 gals 0 gpmA-4 Fractionation Wash Room 25 Deg C 5 gpm 100 gals 5 gpmA-5 Fractionation Wash Sink 25 Deg C 2 gpm 50 gals 0 gpmA-6 Fractionation Buffer Prep 25 Deg C 2 gpm 100 gals 2 gpmA-7 Purification Wash Room 25 Deg C 4 gpm 50 gals 0 gpmA-8 Purification Wash Sink 25 Deg C 2 gpm 50 gals 0 gpmA-9 Purification Buffer Prep 25 Deg C 4 gpm 200 gals 4 gpmA-10 Q.C. Lab 25 Deg C 2 gpm 10 gals 0 gpmA-11 CIP 25 Deg C 10 gpm 500 gals 10 gpmA-12 Fractionation Diafiltration 25 Deg C 4 gpm 50 gals 4 gpm

A-13 Purification Diafiltration 25 Deg C 4 gpm 50 gals 0 gpmC-2 Batching/Reactor Tanks 2 Deg C 7 gpm 1000 gals 7 gpmC-1 Fractionization Freezers 2 Deg C 7 gpm 200 gals 7 gpm

Maximum Possible Draw: 64 gpm 2710 gals 48 gpm

From To DistanceTank A-11 20 ftA-11 A-4 / 5 / 6 40 ft

A-4 / 5 / 6 C-1 10 ftC-1 A-1 / 2 / 3 90 ft

A-1 / 2 / 3 C-2 10 ftC-2 A-7 / 8 / 13 60 ft

A-7 / 8 / 13 A-9 30 ftA-9 A-6 20 ftA-6 A-10 40 ftA-10 Tank 60 ft

TOTAL 380 ft

AMBIENT WFI CONSIDERATIONS

Maximum Demand - 48 GPMMinimum Return FlowFuture ExpansionStorage Tank Sprayball flowrate 2.5 - 3 GPM / ft of circumference 1000 Gal Tk, 5.5 ft diameter -> 43 - 50 GPM

EconomicsFDA Approval

Service: AWFI Engineer:Line No.

INPUTFlow (GPM) 65.00Pipe Length (feet) 760Specific Gravity 1.00Viscosity (centipoise) 0.80Roughness (ft) 0.00005

Nominal Actual ID Reynolds ∆P Velocity FrictionSize (in) (inches) Number Flow Region (psi/100ft) (ft/sec) Factor

0.500 0.37 692053 Turbulent 18,442.8108 193.96 0.02260.750 0.62 412999 Turbulent 1,258.1437 69.08 0.02031.000 0.87 294321 Turbulent 220.1296 35.08 0.01941.500 1.37 186905 Turbulent 21.9881 14.15 0.01872.000 1.87 136930 Turbulent 4.6502 7.59 0.0188

>>>> 3.000 2.87 89219 Turbulent 0.5652 3.22 0.01944.000 3.83 66787 Turbulent 0.1383 1.81 0.02026.000 5.78 44286 Turbulent 0.0191 0.79 0.02188.000 7.98 32084 Turbulent 0.0041 0.42 0.023310.000 10.02 25555 Turbulent 0.0014 0.26 0.0245

note : Clean Tubing

Service: AWFI Engineer:Line No.

INPUTFlow (GPM) 17.00Pipe Length (feet) 760Specific Gravity 1.00Viscosity (centipoise) 0.80Roughness (ft) 0.00005

Nominal Actual ID Reynolds ∆P Velocity FrictionSize (in) (inches) Number Flow Region (psi/100ft) (ft/sec) Factor

0.500 0.37 180998 Turbulent 1,311.6706 50.73 0.02350.750 0.62 108015 Turbulent 93.3924 18.07 0.02211.000 0.87 76976 Turbulent 17.0159 9.17 0.0219

>>>> 1.500 1.37 48883 Turbulent 1.8080 3.70 0.02252.000 1.87 35813 Turbulent 0.3980 1.99 0.02353.000 2.87 23334 Turbulent 0.0506 0.84 0.02544.000 3.83 17467 Turbulent 0.0127 0.47 0.02716.000 5.78 11582 Turbulent 0.0018 0.21 0.03008.000 7.98 8391 Turbulent 0.0004 0.11 0.032710.000 10.02 6684 Turbulent 0.0001 0.07 0.0348

note : Clean Tubing

CONCLUSIONS

HWFI System 2” Line, 45 GPM (> 5 ft/sec)

AWFI System 2” Line, 65 GPM, Min Return Flow of 18 GPM

(2 ft/sec). May limit Expansion 3” Line if Expansion critical and Cost is not.

Tools: Pipe Sizing - Non Compressible Fluids, Pipe Sizing - MatrixCan use other tools for complicated systems Fluid Flow, Hydronet