Piping Design

CALCULATION COVER SHEET PROJECT LAS BAMBAS

JOB NO.

SUBJECT Cu-Concentrate Thickener Underflow Pump Calc CALCULATION STATUS PRELIMINARY DESIGNATOR X

25635 (0410-PPS-0123/0124)

CALC. NO.

SHEET 1 of 10

25635-220-M0C-0410-10011 DISCIPLINE MECHANICAL

CONFIRMED

SUPERSEDED

VOIDED

COMPUTER PROGRAM/TYPE

SCP

PROGRAM NO.

VERSION/RELEASE

OPERATING SYSTEM

SCP RUNTIME VALIDATION

AUTOMATIC

MANUAL

SUCCESSFUL TEST COMPLETION YES NO

COMPUTER TYPE

Table of Contents Section

Titles

1.0 2.0 3.0 4.0 5.0 6.0

Page No.

PURPOSE BASIS OF DESIGN ASSUMPTIONS REFERENCES CALCULATIONS CONCLUSIONS

2 2 2 2 3 10 Appendices

Appendix A Appendix B Appendix C

( 1 sheet ) ( 1 sheet ) ( 1 sheet )

Efficiency and Head Ratio Chart Viscosity Chart Durand Factor Chart

Appendices Attachment 1

B

( 3 sheets )

Plant GA Drawings & Plot Plan

Issued for Design

16

A

Issued for Review

8

REV. NO.

REASON FOR REVISION

TOTAL NO. OF SHEETS

Attachment 1 Sheet 3 of 3 Attach. 2 sheet 3 of 3 LAST SHEET

BS

SM

PKM

20-Feb-12

BS

SG

PKM

30-Nov-11

BY

CHECKED

APPROVED/AC CEPTED

Date

RECORD OF REVISIONS

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CALCULATION SHEET Subject : By :

1.0

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date : 20-Feb-12

Project : Job no. : Calc. no. : Sheet rev. :

Las Bambas 25635 25635-220-M0C-0410-10011 00B

PURPOSE To determine: 1.1 Slurry transport critical velocity (limiting settling velocity). 1.2 Pipe sizes with transport velocity above the critical velocity for lines from Thickener Underflow Pumps (0410-PPS-0123 & 0124) to Filter Feed Tank (Facility 0420). 1.3 Head, NPSHa and Power rating of Thickener Underflow Pumps (0410-PPS-0123/0124).

2.0 BASIS OF DESIGN Durand’s modified by JRI equation for Limiting settling velocity as Wilson Nomogram does not cover settling velocity estimation for slurry with D50 = 30 µm. 2.2 Darcy-Weisbach equation used for computing pressure loss due to friction 2.3 Colebrook-White equation for friction factor. 2.4 Slurry is treated as a homogeneous, Newtonian equivalent fluid of apparent viscosity 8 cP. (ref. 4.1) (ref. 4.3) 2.5 Design flow is 1.3 times of Balanced flow. 2.6 20% margin considered on frictional head loss, in view of preliminary ISO's. 2.7 2 X 100% Thickener Underflow Pumps (1W + 1S) (Reference 4.4) 2.8 C.S., neoprene lined pipes 150 # class used for slurry transportation 2.9 Longest path of flow has been considered for frictional loss. 2.10 Drive type - VFD 2.11 Thickener Underflow Level has been considered as 1.5 m for Head Calculation. 2.12 Piping length, elevations and routing are based on preliminary input from plant design. 2.1 Thickener Underflow withdraw lines are defined as Part-1 and Manifold is defined as Part-2. 2.1 Total underflow is distributed equally in open lines of Part-1 and Part-2 is carrying total under flow. 2.1

3.0 ASSUMPTION 3.1 All four thickener outlet lines are working during normal operation.

4.0 REFERENCES Fluid and Slurry Handling Design Criteria, Doc No : 25635-220-3DR-M11-00001-000. Design Guide for Hydraulics of Slurry Flow, Doc No : 3DG-K04-00007-000. Process Design Criteria, Doc No : 25635-220-3DR-V01-00003-000. Cu-Concentrate Thickener PFD, Doc No : 25635-220-M5-0410-00001-002. P&ID : Thickener and Thicnener Underflow Pumps, Doc No : 25635-220-M6-0410-00002 & 3 (Rev D). 4.6 Plot Plan for Moly Plant, Doc No : 25635-220-P1-0370-0202-00B 4.7 Cu-Concentrate Thickener and Tank Area GA, Doc No : 25635-220-P1-0410-00201 & 202 (Rev A). 4.8 Concentrate Holding Tank and Filter Plant GA, Doc No : 25635-220-P1-0420-00202 Rev B. 4.1 4.2 4.3 4.4 4.5

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CALCULATION SHEET Subject : By :

Project : Job no. : Calc. no. : Sheet rev. :

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date 20-Feb-12

Las Bambas 25635 25635-220-M0C-0410-10011 00B

Balance

Design

127 98.00 65.0 2.00 2.1

165 127.40 1.30 65.0 4.32 2.00 12 4 2.77

1.72

### 6 2.23

m/s in m/s

1.72

#NAME? 6 2.23

m/s m kW hp kW hp kW hp

#NAME? #NAME? #NAME? #NAME? #NAME? -

#NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME?

5.0 CALCULATIONS Summary Solid Feed Rate Pulp Volumetric flow Design factor Concentration by weight, Cp Specific gravity of solids, SGs Specific gravity of slurry, SGm Average particle size, d50 Suction nominal diameter-Part1 Suction flow velocity Limiting settling velocity, vL Durand's modified by JRI Suction nominal diameter-Part2 Suction flow velocity Limiting settling velocity, vL Durand's modified by JRI Discharge nominal diameter Discharge flow velocity Limiting settling velocity, vL Durand's modified by JRI Total Dynamic Head Hydraulic power Brake power Calculated Motor Power

TPH 3 m /h % μm in m/s

No. of U/F Lines in Service: -

m/s in m/s

2

1.0 0.9 0.8

Head (m)

0.7

0.6 0.5 0.4 0.3

0.2 0.1 0.0

0

20

40

60

80

100

120

140

160

ΔH Pump (B)

ΔH Flow Pump rate (D) (m3/h)

System curve

Balance

Design

Pump Curve Head for water

Figure 1-1. Duty Point Curve

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CALCULATION SHEET Subject : By :

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date 20-Feb-12

5.1 Operating Data Concentration by volume, Cv Average particle size, d80 Froth factor Fluid temperature Fluid pH fL factor Viscosity (Kinematic) Viscosity (Dynamic) Pump CL elevation Discharge elevation Tank/Sump liquid level Pressure Required at Destination

Vapor pressure Barometric pressure

Project : Job no. : Calc. no. : Sheet rev. :

30.1

% μm °C cSt cP masl masl masl barg psig msc bar msc bar msc

#NAME? 4.00 8.00

5.2 Preliminary Pump Selection ( for the purpose of power estimation only) Impeller in Suction in Discharge in Revolutions per minute rpm 1850 Pump efficiency % 62.0 Tip speed m/min 1,477 m/s 25 Pump Discharge Pressure m #NAME?

Las Bambas 25635 25635-220-M0C-0410-10011 00B

30.1 75 1.00 25 7-8 #NAME? 4.00 8.00 4,135.4 4,170.3 4,140.9 0.00 0.0 0.0 #NAME? #NAME? 0.607 3.10

10 4 3 1,900 65.0 1,517 25 #NAME?

Material pipe Pipe Schedule Outside Diameter Nominal Wall Thickness Internal Diameter m Length m Lining thickness mm Pipe Roughness , Ks mm Reynolds's no. Friction factor, Colebrook-White Equation (λ)

Part - 2

Material pipe Pipe Schedule Outside Diameter Nominal Wall Thickness Internal Diameter m Length m Lining thickness mm Pipe Roughness , Ks mm Reynolds's no. Friction factor, Colebrook-White Equation (λ)

Part - 1

5.3 Pipe Selection Suction Carbon steel STD 4.500 0.237 0.0903 8.0 6.0 0.20 62,343 0.029 1.04 Carbon steel STD 6.625 0.280 0.142 6.00 6.0 0.20 79,227 0.024 1.00

Discharge

Carbon steel STD 6.625 0.280 0.142 480 6.0 0.20 79,227 0.024 1.00

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CALCULATION SHEET Subject : By :

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date 20-Feb-12

Project : Job no. : Calc. no. : Sheet rev. :

Las Bambas 25635 25635-220-M0C-0410-10011 00B

5.4 Equivalent lengths

Elbow 45° Elbow 90° short Elbow 90° long Elbow angled Tee run Tee branch Gate Valve Globe Valve Plug Valve Angle Valve Butterfly Valve Contraction / Expansion Orifice plate, diameter Tank Output / Input Margin on frictional loss Equivalent length Fittings losses Line friction losses Line friction plus fittings losses

% m m m m

0 0 0 0 4 1 1 0 0 0 0 1 0 0 20 ### #NAME? 0.31 #NAME?

8 22 0 0 4 1 1 0 0 0 0 1 0 1 20 ### #NAME? 24.7 #NAME?

Part - 1

Discharge

% m m m m

Suction 1 1 0 0 4 0 2 0 0 0 0 0 1 20 ### ### 1.2 ###

Part - 2

Elbow 45° Elbow 90° short Elbow 90° long Elbow angled Tee run Tee branch Gate Valve Globe Valve Plug Valve Angle Valve Butterfly Valve Orifice plate, diameter Tank Output / Input Margin on frictional loss Equivalent length Fittings losses Line friction losses Line friction plus fittings losses

5.5 Total dynamic head Head static suction Head static discharge Head total static HR ER Pump Curve Head for water NPSHAvailable

m m m

m m

5.5 34.9 29.4 #NAME? #NAME? #NAME? #NAME?

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CALCULATION SHEET Subject : By :

5.6

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date 20-Feb-12

Project : Job no. : Calc. no. : Sheet rev. :

Las Bambas 25635 25635-220-M0C-0410-10011 00B

Calculation Formula

5.6.1 Slurry Properties and Data : Specific gravity of slurry, SGm

SGm 

1 = 0.65 Cp 1  Cp4.32  SGs 1

1 +

1-0.65 1

=

2.00

=

30.1 %

Concentration by volume, Cv

Cv  Cp 

SGm SGs

=

0.65 · 2.00 4.32

Durand Factor, fL Chart method Cv=30 25 20 15 10 5

1.35 1.25

0

1.15

( __ sheets )

fL

1.05 0.95 0.85 0.75

0.65 0.55 0.45 0.01

0.10

1.00

10.00

d50, mm

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CALCULATION SHEET Subject : By :

Project : Job no. : Calc. no. : Sheet rev. :

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date 20-Feb-12

Las Bambas 25635 25635-220-M0C-0410-10011 00B

The slurry viscocity is obtained from Fluid and Slurry Handling Design Criteria. The Chart Method are provided for comparison only.

Apparent Viscosity mPa·s

100

8

Attach. 2

320

160

80

60

40

30

20

AVERAGE PARTICLE SIZE MICROMETERS PARTICLE SIZE AVERAGE MICROMETERS

12

1000

sheet 3 of 3

10

BS

Biswanath Sen

30.1 1 0

10

20

30 40 Volume Percent Solids

50

60

70

d50, mic= 12 Cv, % = 30.1 rm, t/m3 = 2.00 μ, mPa·s = #NAME? cP = #NAME? cSt = #NAME? Steam pressure Chart method Steam table 0.9

0.8 Pressure, psi

0.7 0.6

0.5 0.4 0.3 0.2 0.1 0.0

0.00 30

40

50

60

70

77

80

90

100

Temperature, °F

Barometric pressure

PBAR

6.5  EL Pump    288  = 1000   1.013    = 288    

5.255

1.013 · [(288-6.5·4,135/1,000)/288]^5.255 0.61 bar

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CALCULATION SHEET

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6.5  EL   288 Pump Calc Pump Cu-Concentrate Thickener Underflow 1000 Biswanath Sen 1.013   Date 20-Feb-12 PBAR  288  

     

Project : Job no. : Calc. no. : Sheet rev. :

5.255

Las Bambas 25635 25635-220-M0C-0410-10011 00B

Let's use discharge for example. Flow velocity

v

4Q π

 D I2

=

4 · 127 π · 0.14² · 3,600

=

2.23 m/s

=

2.00 · 2.23 · 0.14 8.00x10-6

=

79,227

 3600

Reynold's no.

Re 

ρ  v  DI μP

Limiting settling velocity Durand's eq. modified

SGs  1   v L  1.25  fL   2  g  D I   1  

0.25

= ### = #NAME? 5.6.2 Frictional Losses (Discharge) Equivalent length

Leq 

 Ki =

###

Friction factor, Colebrook - White equation :

λ

=

0.024

Friction losses

Friction

losses

 λ  ((L  Leq.) * %margine)

.

v2 2 g DI

= #NAME? 5.6.3 Total Dynamic Head Total Static Head

TSH  E D  E S = 4,170 - 4,141 = 29.4 msc Total Dynamic Head TDH  TSH  Friction lossesSuction  Discharge   PD

### ###

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CALCULATION SHEET Subject : By :

Project : Job no. : Calc. no. : Sheet rev. :

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date 20-Feb-12

Las Bambas 25635 25635-220-M0C-0410-10011 00B

NPSH Available

NPSH A  PBAR  PSTEAM  SH SUCTION  Friction losses SUCTION =

###

=

###

Hydraulic Power

PH  Q  TDH  ρ w  SGm  PCF #NAME? 3,600

= = ###

Head Ratio (HR) and Efficiency Ratio (ER) Chart method

0.01

0.1

1

0.012

10 SGS=1.1

1.5 2.0

3.0

4.0

5.0

6.0

0.5

0.6

HR

0.7

0.8

0.9

0.015

0.015

0.015

1.0

0.015

0.5

Hr Er

: :

0.6

0.7

ER

0.8

0.9

1.0

### ###

Brake power :

PB  =

ER

PH  η Pump



#NAME? #NAME?

= ### Calculated Motor Power : : :

Brake Power x Transmission Loss ### X 1.1 ###

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CALCULATION SHEET Subject : By :

6.0

Cu-Concentrate Thickener Underflow Pump Calc Biswanath Sen Date 20-Feb-12

Project : Job no. : Calc. no. : Sheet rev. :

Las Bambas 25635 25635-220-M0C-0410-10011 00B

CONCLUSIONS

6.1 Limiting Settling Velocity a) Suction : 1.49 m/sec b) Discharge : 1.49 m/sec 6.2 Pipe sizes a) Suction b) Discharge

a) b) c)

: 6 inch, Sch STD ( lining thickness = 6 mm), L1E0VJ : 6 inch, Sch STD ( lining thickness = 6 mm), L1E0VJ

TDH : 29 m (@ 98 m3/hr) / 38 m ( @ 128 m3/hr) NPSHa : 7.0 m Motor Calculated Power is 45 kW. After considering derating factor and selecting next standard size, motor rating comes as 75 kW.

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CALCULATION SHEET

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Las Bambas 25635 25635-220-M0C-0410-10011 00B

Project : Job no. : Cu-Conc. Thickener U/F Pump Calc Calc. no. : Biswanath Sen Date 20-Feb-12 Sheet rev. :

Appendix A: Efficiency and Head Ratio Chart 0.01

0.1

1

0.012

10 SGS=1.1 1.5

2.0

3.0

4.0

5.0

6.0

0.5

0.6

HR

0.7

0.8

0.9

0.015

0.015

0.015

1.0

0.015

0.5

0.6

0.7

0.8

0.9

1.0

ER

LEGEND HR =

Head on slurry

Balance

Design

d50, mm=

0.012

0.012

SGS =

4.32

4.32

ER = Efficiency on slurry

Cv, % =

30.1

30.1

Efficiency on water

D, mm =

254

254

d50/D =

0.00005

0.00005

Head on water

Cv = % Concentration of solids in slurry by true volume

HR =

#NAME?

#NAME?

ER =

#NAME?

#NAME?

d50 = Average particle size (mm) D = Impeller diameter (mm) SGS = Specific gravity of solids

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CALCULATION SHEET

Project : Job no. : Cu-Conc. Thickener U/F Pump Calc Calc. no. : Biswanath Sen Date 20-Feb-12 Sheet rev. :

Subject : By :

Las Bambas 25635 25635-220-M0C-0410-10011 00B

Appendix B: Viscosity Chart

320

160

80

60

40

30

20

AVERAGE PARTICLE SIZE MICROMETERS

1000

Apparent Viscosity mPa·s

100

10

1 0

10

20

30.1 30

40

50

60

70

Volume Percent Solids

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CALCULATION SHEET

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Project : Job no. : Cu-Conc. Thickener U/F Pump Calc Calc. no. : Biswanath Sen Date 20-Feb-12 Sheet rev. :

Las Bambas 25635 25635-220-M0C-0410-10011 00B

Appendix C : Durand Factor Chart Cv=30 25 20 15 10 5

1.35 1.25

0

1.15

fL

1.05 0.95 0.85 0.75 0.65 0.55 0.45 0.01

0.10

1.00

10.00

d50, mm

LEGEND fL = Modified Durand's limiting settling velocity parameter (for particles of widely graded sizing) = #NAME? d50 = Average particle size (mm) = 0.012 mm Cv = % Concentration of solids in slurry by true volume = 30.1 %

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Tabla de vapor saturado Temp Presión °F PSI 32 0.089 33 0.092 34 0.096 35 0.100 36 0.104 37 0.108 38 0.112 39 0.117 40 0.122 41 0.126 42 0.131 43 0.137 44 0.142 45 0.147 46 0.153 47 0.159 48 0.165 49 0.171 50 0.178 51 0.185 52 0.192 53 0.199 54 0.206 55 0.214 56 0.222 57 0.230 58 0.238 59 0.247 60 0.256 61 0.265 62 0.275 63 0.285 64 0.295 65 0.305 66 0.316 67 0.327 68 0.339 69 0.351 70 0.363 71 0.375 72 0.388 73 0.402 74 0.416 75 0.430 76 0.444 77 0.459 78 0.475 79 0.490 80 0.507 81 0.524 82 0.541 83 0.559 84 0.577 85 0.596 86 0.615 87 0.635 88 0.656 89 0.677 90 0.698 91 0.720 92 0.743 93 0.767 94 0.791 95 0.815 77 0 77 ######## 30 ########

Nominal Pipe Size 1/8 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 5 6 8 10 12 14 O.D. 16 O.D. 18 O.D. 20 O.D. 22 O.D. 24 O.D. 26 O.D. 28 O.D. 30 O.D. 32 O.D. 34 O.D. 36 O.D. 38 40 42 O.D. 44 46 48 O.D. 56 60

Outside Diameter 0.405 0.540 0.675 0.840 1.050 1.315 1.660 1.900 2.375 2.875 3.500 4.000 4.500 5.563 6.625 8.625 10.75 12.75 14.0 16.0 18.0 20.0 22.0 24.0 26.0 28.0 30.0 32.0 34.0 36.0 38.0 40.0 42.0 44.0 46.0 48.0 56.0 60.0

Sched. 5S

0.065 0.065 0.065 0.065 0.065 0.065 0.083 0.083 0.083 0.083 0.109 0.109 0.109 0.134 0.156 0.156 0.165 0.165 0.188 0.188 0.218

Sched. 10S 0.049 0.065 0.065 0.083 0.083 0.109 0.109 0.109 0.109 0.120 0.120 0.120 0.120 0.134 0.134 0.148 0.165 0.180 0.188 0.188 0.188 0.218 0.218 0.250

0.250

0.312

Sched. 10

0.250 0.250 0.250 0.250 0.250 0.250 0.312 0.312 0.312 0.312 0.312 0.312

Sched. 20

0.250 0.250 0.250 0.312 0.312 0.312 0.375 0.375 0.375 0.500 0.500 0.500 0.500 0.500 0.500

Commercial Pipe Sizes and Wall Thicknesses, NPS Nominal Wall Thickness For Sched. Standard Sched. Sched. Extra Strong Sched. 30 STD 40 60 XS 80 0.068 0.068 0.095 0.095 0.088 0.088 0.119 0.119 0.091 0.091 0.126 0.126 0.109 0.109 0.147 0.147 0.113 0.113 0.154 0.154 0.133 0.133 0.179 0.179 0.140 0.140 0.191 0.191 0.145 0.145 0.200 0.200 0.154 0.154 0.218 0.218 0.203 0.203 0.276 0.276 0.216 0.216 0.300 0.300 0.226 0.226 0.318 0.318 0.237 0.237 0.337 0.337 0.258 0.258 0.375 0.375 0.280 0.280 0.432 0.432 0.277 0.322 0.322 0.406 0.500 0.500 0.307 0.365 0.365 0.500 0.500 0.594 0.330 0.375 0.406 0.562 0.500 0.688 0.375 0.375 0.438 0.594 0.500 0.750 0.375 0.375 0.500 0.656 0.500 0.844 0.438 0.375 0.562 0.750 0.500 0.938 0.500 0.375 0.594 0.812 0.500 1.031 0.500 0.375 0.875 0.500 1.125 0.562 0.375 0.688 0.969 0.500 1.218 0.375 0.500 0.625 0.375 0.500 0.625 0.375 0.500 0.625 0.375 0.688 0.500 0.625 0.375 0.688 0.500 0.625 0.375 0.750 0.500 0.375 0.500 0.375 0.500 0.375 0.750 0.500 0.375 0.500 0.375 0.500 0.375 0.500 0.375 0.500 0.375 0.500

Sched. 100

0.594 0.719 0.844 0.938 1.031 1.156 1.281 1.375 1.531

Sched. 120

0.438 0.500 0.562 0.719 0.844 1.000 1.094 1.219 1.375 1.500 1.625 1.812

Sched. 140

0.812 1.000 1.125 1.250 1.438 1.562 1.750 1.875 2.062

Sched. 160

XX Strong XXS

0.188 0.219 0.250 0.250 0.281 0.344 0.375 0.438

0.294 0.308 0.358 0.382 0.400 0.436 0.552 0.600

0.531 0.625 0.719 0.906 1.125 1.312 1.406 1.594 1.781 1.969 2.125 2.344

0.674 0.750 0.864 0.875 1.000 1.000

Longitudes equivalentes de accesorios y fittings en pies Tee Gate Globe pipe size Elbow 90° Elbow 90° Elbow 45° Tee run branch Valve Valve d (in) short long 1/2 0.4 0 0.7 1.1 3.3 0.7 17 3/4 0.6 0 0.9 1.4 4.2 0.9 23 1 0.7 1.6 1.2 1.8 5.3 1.1 28 1 1/2 1.1 2.4 1.8 2.7 8.1 1.7 45 2 1.5 3.1 2.3 3.5 10.4 2.2 59 2 1/2 1.7 3.7 2.7 4.2 12.4 2.7 3 2.2 5 3.4 5.7 15.5 3.3 86 4 3 7 4 7 20 4 112 6 5 10 7 10 30 7 170 8 6 13 9 13 40 9 170 10 7 16 11 17 52 12 170 12 9 19 13 20 60 13 170 14 10 21 15 22 66 15 170 16 11 24 17 25 78 17 170 18 13 27 19 28 85 19 170 20 14 29 21 32 95 21 170 24 17 35 26 40 120 25 170 30 21 44 32 50 150 32 170 36 25 53 39 60 175 38 170 42 30 63 45 68 200 46 170

Plug Valve 0.9 1.2 1.5 4 3 3.8 4.5 6 9 12 15 18 21 23 27 30 36 46 53 62

Angle Valve 7.3 9.7 12.1 19 25 38 48 73 98 121 145 169 193 218 242 290 360 435 508

7 20 28 34 40 44 50 56 60 76 100 120 140

Butterfly Valve

Suction Design

6''

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

#NAME?

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Discharge Design

6''