Hydraulics Suite & Pump Sizing Calculator

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.

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.

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.

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

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).

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 F_L and the liquid critical pressure ratio.

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.

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

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)

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”).

Actionable Findings & Recommended Actions

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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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.

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.

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)

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

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.

Heat-Loss Summary (10-m segments)

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)