| Temp (°C) | Density (kg/m³) | μ (cP) | ν (m²/s) | Pv (kPa) | σ (N/m) |
|---|
Suction-side losses are calculated dedicated and independent from the discharge path — no allocation factor. The full suction friction is consumed in the NPSHa computation per HI 9.6.1. Keep suction velocity ≤1.5 m/s preferred to maximize NPSH margin.
Suction Fittings & Valves
| Fitting | K-value | Qty | Σ K | |
|---|---|---|---|---|
| Total Σ K (suction): | 0.00 | |||
Discharge pipe sizing balances capital cost (larger pipe) against energy cost (smaller pipe = more friction). Target velocity 1.5–3 m/s for water service per HI guidelines.
Discharge Fittings & Valves
| Fitting | K-value | Qty | Σ K | |
|---|---|---|---|---|
| Total Σ K (discharge): | 0.00 | |||
Friction Method Comparison
| Method | f | Head Loss (m) | Δ vs Colebrook |
|---|
Flow Regime Map
TDH Breakdown
| Component | Value (m) | % of TDH |
|---|---|---|
| Total Dynamic Head | — | 100% |
Waterfall Visualization
NPSH Component Breakdown
| ± | Component | Value (m) |
|---|
NPSH Margin Gauge
API 610 / HI define three operating zones around the Best Efficiency Point (BEP): POR (Preferred Operating Region) 70–120% of BEP — recommended for sustained operation; AOR (Allowable Operating Region) typically 50–130% of BEP — maximum allowed range; MCSF (Minimum Continuous Stable Flow) — manufacturer-specified low limit below which recirculation, vibration, and overheating occur.
Operating-Region Map
API 610 Compliance Checklist
| Criterion | Limit | Actual | Status |
|---|
ISO 9906 defines acceptance tolerances for hydraulic performance during factory acceptance testing. Grade 1B (precise) is for safety-critical service; 2B (standard) for general industrial; 3B (relaxed) for low-spec applications. Enter test results below to verify acceptance.
Acceptance Test Results
| Parameter | Guaranteed | Tested | Deviation | Tolerance | Verdict |
|---|
Operating Point
Static vs Friction Split
Pump Characteristics
Affinity Laws
| Variable | Original | Speed Change | Trim |
|---|
Parallel Pump Combined Curve
Series Pump Combined Curve
Select a pre-loaded manufacturer model to replace the synthesized curve in Tab 9, or import a custom curve from CSV. CSV format: Q,H,Eta,NPSHr with one row per data point (Q in m³/hr, H in m, Eta in %, NPSHr in m).
Active Curve Data
| Point | Q (m³/hr) | H (m) | η (%) | NPSHr (m) |
|---|
Computes required valve flow coefficient Cv (US units) or Kv (metric) for incompressible liquid service per IEC 60534-2-1. Checks choked-flow conditions using the pressure recovery factor FL and the liquid critical pressure ratio.
Commissioning Schedule
| Phase | Standard | Turnovers | Volume (L) | Duration | Status |
|---|
Cumulative LCC — Base vs VFD
Annual Cost Breakdown
Computes maximum surge pressure using Joukowsky’s equation (sudden closure) or Michaud’s formula (slow closure), with elastic-pipe wave-speed correction. Includes wave reflection time, pressure attenuation, and a pipe-class compatibility check against the peak transient pressure.
Transient Pressure vs Time
Mitigation Options Matrix
| Mitigation | Effectiveness | Cost | Recommended? |
|---|
AI Engineering Recommendations
Audit Trail (last 12 entries)
For polymer solutions, drilling muds, sludges, paints, foodstuffs, and slurries the Newtonian assumption fails. Select a rheology model and the apparent viscosity is computed for the design shear rate; the friction factor uses the Metzner–Reed generalized Reynolds number. Slurry mode adds the Durand critical settling velocity to ensure solids stay in suspension.
Slurry Mode — Durand Critical Settling Velocity
API 682 (5th edition) defines standardized piping plans for mechanical-seal flushing and cooling. Heat generated by seal-face friction must be removed or the seal faces will overheat and fail. This module computes required flush flow and cooling-water rate for the selected plan.
Plan-Specific Bill of Materials
| Component | Specification | Notes |
|---|
Carbon steel and cast iron pipes accumulate tuberculation, scaling, and biofilm over time. Friction losses can increase by 50–200% over 10–20 years. Apply an age factor to the roughness ε and Hazen-Williams C to simulate brownfield performance vs new design conditions.
Aging Reference Table (typical)
| Service | New C | 5-yr C | 10-yr C | 20-yr C | ε multiplier (10-yr) |
|---|---|---|---|---|---|
| Carbon Steel (clean) | 130 | 125 | 115 | 105 | 3× |
| Carbon Steel (aggressive) | 130 | 110 | 95 | 75 | 8× |
| Cast Iron (clean) | 130 | 120 | 110 | 95 | 4× |
| Cast Iron (untreated) | 130 | 100 | 80 | 55 | 12× |
| Galvanized Steel | 120 | 110 | 100 | 85 | 5× |
| HDPE / PVC | 150 | 148 | 145 | 140 | 1.2× |
| Stainless Steel | 130 | 128 | 125 | 120 | 1.3× |
| Concrete | 130 | 122 | 113 | 100 | 2.5× |
A Restriction Orifice (RO) is a fixed pressure-letdown device. Used here for two purposes: MCSF bypass line (recirculates flow back to suction to keep the pump above its Minimum Continuous Stable Flow) and multi-stage pressure letdown (splits a high ΔP into N stages to keep each stage below the cavitation index).
The diagnostics engine inspects the full system model and produces actionable, quantified recommendations — not just findings. For each detected issue, it computes the specific change required to bring the design back into compliance (e.g. “Increase suction pipe from NPS 4 to NPS 6 to add 1.8 m NPSH margin”).
System Health Index
Diagnostic Summary
| Domain | Status | Score |
|---|
Actionable Findings & Recommended Actions
Compliance Heatmap
| Standard | Criteria Met | Verdict |
|---|
Recommended Next Steps
Export the pump and piping data in formats compatible with AutoCAD Plant 3D, Smart 3D, and PDMS. The PCF (Piping Component File) format is the de-facto standard for piping isometric data interchange. The XML export captures the full project including the EPC-grade audit trail.
Full Session Audit Trail (every formula & standard logged)
Preview — PCF Output (first 30 lines)
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Preview — XML Output (first 30 lines)
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High-level project KPIs synthesized from all 31 modules. Refreshed automatically on each recalculation.
⚡ System Metrics
⚡ Energy & Economics
🌱 Environmental
🛡 Reliability
📋 Standards Compliance Summary
| Standard | Topic | Status |
|---|
Full compressible flow framework for natural gas, air, N₂, O₂, H₂, steam, and user-defined gases. Computes variable density, pressure drop, choked flow, sonic velocity, Mach number, and Z-factor along the pipeline.
Pressure & Density Profile
Velocity & Compressibility Profile
Liquid-gas multiphase analysis for steam-water, gas-liquid pipelines, aerated liquids, and reactor service. Computes regime (bubble/slug/plug/stratified/wavy/annular/mist), pressure drop, holdup, void fraction, and slip ratio.
Flow Regime Map (Baker)
Pipeline Flow Visualization
Solves parallel piping systems, ring mains, distribution networks, header/lateral systems, cooling-water loops, firewater networks, and process utility networks using the Hardy Cross iterative method. Define nodes, branches, demands, and sources below.
Network Branches (editable)
| # | From | To | L (m) | D (mm) | C (HW) | Initial Q (m³/hr) | Solved Q (m³/hr) | Velocity (m/s) | h_f (m) | Action |
|---|
Interactive Network Diagram
Hydraulic / Energy Grade Lines
Evaluates all available pump models against the current duty point. Ranks by composite score combining hydraulic performance, reliability, and 20-year lifecycle cost. Top-3 candidates shown below with full audit.
Full Ranking Matrix
| Rank | Model | BEP Q (m³/hr) | BEP H (m) | η (%) | %BEP | NPSH Margin (m) | 20-yr LCC ($) | CO₂ (tCO₂) | API | Score |
|---|
Heat-transfer simulation along the pipeline. Recalculates fluid properties (density, viscosity, vapor pressure) every 10 m. Includes insulation modeling, ambient conditions, solar loading, and wind convection.
Temperature / Viscosity Profile
Pressure / Density Profile
Heat-Loss Summary (10-m segments)
| Segment | Position (m) | T (°C) | ρ (kg/m³) | μ (mPa·s) | q (W/m) |
|---|
Local-first collaboration framework with full revision history, undo/redo, change-approval workflow, and locked engineering baselines. The session state exports as JSON, ready for sync into a multi-user cloud backend.
Revision Timeline
Change Log (last 50)
| Timestamp | User | Module | Parameter | Old → New |
|---|
Unified site-safety command center. Live readouts from the v6.0 safety engines (vessels, exclusion zones, flange ratings, chemical PPE). Highest-severity items rise to the top.
⚠ Active Safety Alerts
🚧 Exclusion Zones Summary
🥽 Required PPE — Current Chemicals
📋 Site-Safety Compliance Matrix
| Domain | Standard | Status | Action |
|---|
📞 Emergency Response Checklist
- Establish exclusion zones with hard barriers + warning signs before any pressure test
- Brief all personnel; obtain signed permit-to-work for any chemical or pressure activity
- Confirm eyewash + safety shower within 10 s travel time of chemical work area
- Identify neutralizing agents and have first-aid responder on standby
- Post emergency numbers, MSDS, and chemical inventory at all access points
- Verify N₂/inerting equipment isolated; lockout-tagout (LOTO) all rotating equipment
Sizes suction and discharge vessels per ASME Section VIII Division 1 with anti-vortex liquid depth (HI 9.8) and de-aeration residence time. Outputs feed directly into the NPSHa calculation — adequate vessel head prevents vortexing and gas entrainment that destroys NPSH margin.
NPSH/Vortexing Coordination
Computes the stored energy in a system during pressure testing and the corresponding exclusion-zone radius. Pneumatic tests release energy on rupture orders of magnitude greater than hydrostatic (compressible vs incompressible) and require much larger safety zones per ASME PCC-2 Article 5.1.
Site Layout — Exclusion Zone
PCC-2 Compliance Checklist
| Requirement | Reference | Status |
|---|
Links the commissioning durations from the Commissioning module (flushing, cleaning, passivation) to a project-level Gantt. Detects whether pump commissioning sits on the critical path and recommends flow-rate adjustments to compress the schedule.
Critical-Path Gantt
Recommends ASME B16.5 flange class (150/300/600/900/1500/2500) based on the peak transient pressure from the Water Hammer Analysis at the design temperature. Suggests gasket material and validates flange-face compatibility against the active chemical service.
B16.5 Pressure-Temperature Rating Table
| Class | @ 38°C (kPa) | @ 100°C | @ 200°C | @ 400°C | vs Peak |
|---|
Gasket Chemical-Compatibility Matrix
Where a process requires letting down significant pressure (e.g. high-pressure separator → low-pressure flash drum, RO reject, amine regen), an HPRT can recover 50–80% of the otherwise wasted hydraulic energy. This module sizes the HPRT and computes payback against a baseline control valve.
🌱 Green Engineering Impact
Auto-generates a Safety Data Sheet summary and PPE requirements for every chemical in the dosing module. Lists required protective equipment and recommended neutralizing agents for spill response. Color-coded by NFPA 704 health/flammability/reactivity ratings.
