Table of Contents. Table of Contents. Pipeline Results Contents. Best Selections Introduction System Results...

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1 Slysel Manual The contents of this document are the copyrighted intellectual property of GIW Industries. It is intended for the sole purpose of evaluating and applying GIW slurry pumps to slurry applications of GIW s customers or prospective customers. This document may not be copied or disclosed to any additional parties without the written authorization of GIW Industries.

2 Table of Contents Contents Introduction... 5 Getting Started... 7 Overview... 7 Quick Start Standard Pump Selection...9 Quick Start Standard Pump Selection Continued...11 Options Pipeline System Pipeline System for a Mining Application...17 Pipeline System for a Dredge Application...19 Pump Duty Horizontal Pipe Friction... Configurator Table of Contents Pipeline Results Best Selections System Results Sheave Duty Final Results Pump BOM Appendix I Example of a Pipeline System for a Dredge Application...45 Appendix II Further Information for System Evaluation...49 Appendix III Multistage Pipeline System Evaluation...51 GIW Slysel Users Manual - RevC 3

3 Introduction Creation and History of Slysel Slysel was originally developed as a water pump computer selection program in 1975 selecting for a given duty the highest efficiency pump from a database file of available standard end suction pumps. In those days, computer size limited what was possible, but the program did include a rudimentary pipeline system head calculation and a limited number of configurable options for the pump range employed. Slysel is now a complete slurry pump selection program that chooses and recommends the best GIW pump for a given solids transport rate case duty. The program has an optional slurry pipeline friction module that determines the necessary head for a variety of settling and non-settling types of slurries for conventional sump fed or dredge (ladder) arrangements. The selection approach, and in particular the service wear class determination, is completely in accordance with the American National Standard for Rotodynamic (Centrifugal) Slurry Pumps ANSI/HI For the pumps that Slysel selects, the solids effect for head and efficiency, rotating shaft assembly, shaft deflection, shaft stress, and bearing life checked (and if necessary the pump rejected) along with the NPSH and pressure rating are included. Selection may include all available pumps and/or be restricted to specific pumps. The speed may be fixed and an impeller turndown calculated. It is even possible (in the case of a specific pump) to provide speed, head, and slurry particulars and have the operating flow calculated. If required, the shell and suction liner wear life can be estimated and the annual cost of wear parts and total operating cost calculated. The database of available pumps includes over 800 distinct hydraulic types which, including the different configurations such as mechanical seals, expands to over 2,000 types. Where applicable the necessary expeller submergence is calculated. A pump for selection may have its type, impeller diameter, and branches specified ahead of time. For standard LSA, LCC, and LCV non-standard pumps, different bearing housing type (oil or grease) and other options may also be configured. Output is in conventional tabular printed or plotted form as appropriate. For every pump selected, a full parts list is available and a link is provided to provide access to the technical booklet and maintenance manuals. Selection Limits and Acceptance While Slysel is primarily a pump selection program, it is important to be aware of the checks it performs and that the pumps chosen are hydraulically and mechanically suitable for the service conditions as noted. Slysel selects, rejects, and accepts from a file of preconfigured (BOM) pumps. The acceptance criteria (along with warnings and rejections) are in accordance with the Centrifugal Slurry Pump Standard ANSI/HI The following figures and tables are available in the previously referenced standard. The service class selected by Slysel is in accordance with Figure of the Standard. The maximum impeller peripheral speed is according to Table 12.6, and flow operating limits are according to Table 12.7 pro-rated linearly from the maximums. For every selection and each condition, the shaft deflection, shaft stress, and bearing life are checked. Acceptable bearing life is in accordance with Table 12.9 of the Standard. Shaft deflection limits are set for the stuffing box location at.015 for mechanical seals and.040 for regular packed boxes. Shaft stress is determined for every change of cross section location and compared with an endurance limit for the preconfigured bill of material to establish a safety factor where anything greater than 1 is expected to give infinite fatigue life. The maximum (bearing) rotating assembly speed is set by the bearing manufacturer and experience relative to the class of service. For the vertical pumps, the critical speed is checked against pre-calculated configurations. Pumps are rejected where they operate near (+or- 10%) the critical speed. The assembly pressure rating noted is for the preconfigured BOM components and the standard materials noted. A limited number of material family variations are allowed, such as T90G and 40G for LCC and FGD type pumps. For non-standard variations, users must consult Engineering. The maximum particle size allowed for rubber lined pumps is checked against a special chart developed by Chief Engineer Bob Visintainer. This and other limits can be provided by special request. How to Use this Manual The Getting Started section of this manual provides general information in downloading and navigating in Slysel as well as a quick start guide for a basic pump selection. Quick Tips are provided on the lower left hand side of each page throughout the manual and are designed to be helpful hints. Directly following the Getting Started Section are the Example Pages and the Detail Tab Explanations. One selection example is followed all the way through the manual with step-by-step instructions and screen shots for each tab. This example begins on page 12 and continues through page 42 as applicable. Detail Pages provide in-depth explanations of each field by Tab. The detail pages begin on page 13 and continue through page 43. GIW Slysel Users Manual - RevC 5

4 Overview Getting Started Software Installation A 7-day trial version of Slysel can be downloaded at: GIWSLYSELusers.htm. Detailed instructions are available on the web site. When Slysel is opened for the first time, a reminder dialog box will be displayed. To register for a permanent version of Slysel, click the enter key dialog box. Registration information will be displayed. An 8 digit alpha numeric hardware fingerprint will be displayed. To obtain the key, the hardware fingerprint to: engineering@ giwindustries.com. A key will be ed to you within 72 hours. NOTE: Slysel trial version can be used for 7 days without entering a key by clicking the okay button on the reminder dialog box. The okay button may take up to 30 seconds to be available. Menus Slysel has been modeled from the Windows operating environment. Drop-down menus work similarly to Windows applications. For any field, click on the File menu to display your current options (pictured to the left). Standard Values Standard operating values have been loaded for many fields in Slysel. To select a common value from a list, select the field (it will turn blue), right click inside the field and select the field name or value from the list. A second menu will be displayed; click on the appropriate value, and the field will be updated. How the Software Works A slurry pump always operates where the system curve and the pump curve intersect. System information can be entered in detail on the Pipeline System Tab or can be entered as a single duty point on the Pump Duty Tab. Without entering any slurry properties on the Pump Duty Tab, a water curve for the system entered will be the basis for pump selection and evaluation. Entering the slurry information on the Pump Duty Tab uses the Solids Effect Efficiency % and Solid Effect Head % to generate the curves used for pump selection and evaluation. Knowing the slurry properties is crucial in selecting and evaluating the correct pump for any system. Based on the information entered on the Pump Duty Tab, Slysel will calculate which pumps are best suited for the application and display them in order by BEPQ on the Best Selections Tab. More detailed information about this process is provided in each specific tab section of this manual. To update Slysel, select the Help menu and then click on Update SLYSEL. Update Slysel at least once a month. If it is used less than once a month, update before each use. GIW Slysel Users Manual - RevC 7

5 Quick Start Standard Pump Selection Getting Started This section provides a quick overview for a standard pump selection and is not intended to be all-inclusive. More detailed field and screen information is provided on the individual tab detail pages. An example is also provided to guide the user through the entire pump selection process, and can be found on the even pages of this manual. Options Tab (not pictured) Report Title Information will print on the final report. Reference - Enter the specific project name Item # - Enter the tag number Application - Enter the specific application this report applies to Input/Output Units - Select unit of measure Slysel Program Options Leave default boxes checked Select the Pump Duty Tab Pump Duty Tab (pictured to the left) Slurry Mixture Properties Enter either the Slurry SG, % of Solids by Volume, or the Solids by Weight Slurry Solids Properties S.G. Solids - Enter the Solids SG (standard values available) D50 - Enter a value for D50 in microns (D85 will be calculated based on the default ratio). Note: Changes to D85 will result in the D50 being recalculated. Fines % - Enter an estimate of the percent fines Miller Number (G75) - Enter Miller number (standard values available) Hydraulic Duty Details Flow - Enter flow required by the pump Total Head - Enter head required by the pump NPSHA - If this information is not entered, a warning will be printed on the reports Best Selections Tab (not pictured) Read notification box and click ok Best Hydraulic Choices (top window) Displays the best pumps to fit the application as defined. The pumps are listed in order of efficiency Click on the pump that appears to be the best choice (look at pump efficiency and BEPQ) Performance Basis (middle window) Pump assemblies will be displayed in the window The assemblies are mechanical variations of the pump selected in the Best Hydraulic Choices window Select the best standard assembly (an S pump in the LCC or LSA range) Click in the Operating Data field to scroll through the report To do a quick selection, you need: Slurry SG (concentration), Solids SG, particle D50, Flow and Head. Additional detailed information will improve the accuracy of the results. GIW Slysel Users Manual - RevC 9

6 Quick Start Standard Pump Selection Continued Getting Started Right click on your document/spreadsheet Select paste Operating Data (bottom window) Scroll through the report specifically looking for warnings and rejections (may be listed under each individual heading) Other things to look for include Pump Speed and throughput To view results for a different pump, select a different pump from the list in the best hydraulic basis section. Select the Final Results tab Final Results Tab (pictured above) To print the final report, select file, then select print final report. To use the information in another application (including Lotus Notes): Right click on the screen Select copy to clipboard»» Open the program you want to use (Word, Excel, Lotus Notes etc.) Always Double - Check NPSHR. GIW Slysel Users Manual - RevC 11

7 Example - Options Tab Information used to create this example will be shown in the top left-hand corner of each example page (even pages) as appropriate. A screen shot showing how the Slysel screen should look after the steps have been followed is provided in the lower right-hand corner of each page. Step-by-step instructions given on the example page are for this example only. More detailed options for each field may be found on the Instruction pages (odd pages). This example is a pump being used to move a Options Tab sand slurry from a tank to a pipeline. The pipeline In the Reference field type Example 1 dimensions and slurry information have been provided. Slysel will calculate the TDH required In the Item field type #1 from the pump. A pump selection and V-belt drive In the Application field type Sand Slurry selection will then be calculated. Ensure that the Auto Update box is checked Check the Create Extra Comma Separated Value (CSV) Output Files (not required, but helpful if using output data for further analysis) Ensure that Novice Mode is checked Example continued on page 16 (Pipeline System Tab). GIW Slysel Users Manual - RevC 12

8 Options Report Title Information (optional) This information will print on the report. Reference - Enter the specific customer/project name. Item # - Enter the tag number. Application - Enter the specific application this report applies to. Today s Date and Time of Day - Leave Update Date and Time box checked to have the report automatically print the current date and time of report. Uncheck the box to assign a specific date and time to the report. Comments - notes typed in this box will print on the final report. Input/Output Units Select the unit of measure for the project. US units are the default. Field titles will show the appropriate unit of measure in [ ]. Slysel Program Options Auto update D85 from D50 using the default D85:D50 ratio This box is checked by default. Unless both the actual D50 and D85 are known, this box should remain checked. Create extra Comma Separated Value (CSV) output files - Writes a CSV file with the output information which is used in some internal GIW applications. GIW employees are encouraged to select this option. Append Horizontal Pipe Friction results to final results - Final results page will display and print the information provided on the Horizontal Pipe Friction Tab. Append pipeline system results to final results - Pipeline System and Pipeline Results will be displayed, and will print at the bottom of the Final Results. Pipeline results do not include pump information, but can be used to present the pipeline data with the pump selection and/ or to determine operating conditions for the pump. Append best pump selection results to final results - Final Results page will display and print the list of pump choices from the Best Selections tab in its entirety. This option should be used if multiple pumps are being considered. Append hydraulic equivalent pump assemblies to final results - Displays all pump assemblies that have the same hydraulic configuration (shell, impeller type, etc.) on the Final Results. Append pump/system results to final results- System Results (which uses the pipeline information and pump to suggest how the pump might operate in the system) will be displayed and print with the Final Results. Append sheave selection results to final results- Displays and prints selected V-belt drive from the Sheave Duty Tab with the Final Results (only selected drive will be displayed). Append sheave selection list to final results- Displays and prints all V-belt drive options as displayed on the Sheave Duty Tab with the Final Results. Append pump assembly s bill of materials to final results - Bill of materials (BOM) for the pump selected on the Best Selections Tab will be displayed and printed with the Final Results. Novice Mode - Automatically eliminates mechanical options that don t meet recommended requirements. (By default this option is selected. It is not recommended that this option be deselected.) Novice Mode should only be unchecked if establishing a baseline or performing a comparison. Novice mode eliminates mechanical options that are beyond the default safety limits. Deselecting Novice mode is only done for special situations, such as when selecting a fire pump that will only be used in case of emergency where unreasonable wear is not an issue. GIW Slysel Users Manual - RevC 13

9 Enable Manual Sheave Selection - Allows a sheave selection without selecting a pump. Disable LCC Rubber Preference Selection - When the wear for a rubber pump would be at least 3 times better than a metal pump Slysel automatically places the rubber pumps at the top of the list on the Best Selections Tab. Checking this box will disable the sorting preference for rubber pumps. Total Cost of Ownership Shown as the total yearly cost. The cost here is the sum of the (electric) driver cost, the wear parts (consumed) cost, the rotating assembly rebuild cost and the capital cost. Capital Cost % - Represents the interest on the money required to purchase the pump. Enter the percentage of the pump list price (usually 10%) to be included in the total cost of ownership for the year. Mechanical end rebuild cost % - Assumed to be 10% of the pump assembly cost, and is prorated down linearly from the maximum speed head. Operational hours per year - Default is 6,000 hours, but may be varied to reflect actual operating hours. Motor/ Driver efficiency % - The driver efficiency has a default of 90%, but may be varied to reflect actual efficiency. KW/hr. cost [U.S. Dollars] - The driver cost is assumed to be electrical. A default value of $.05 a KW/hr. is shown as the default, but may be varied to reflect actual electric costs. Pipeline head loss per unit length - Used to calculate energy cost per ton per mile (or metric equivalent). Enter the horizontal pipeline head loss per unit length of pipe if known. Maintenance labor is not taken into account in the Total Cost of Ownership Calculations. Wear parts cost assumes parts are changed out as they reach a nominated thickness. Downtime is not included. For most applications / selections, the default boxes as checked are appropriate. Options Check additional options to add information to the output report. GIW Slysel Users Manual - RevC 15

10 Example: Pipeline System Section vertical rise / fall = rise of 40 feet (number is entered as a positive number because it is a rise). Total K value of this discharge section includes 1 gate valve and three 90 degree bends. Pipe diameters in the K value table jump from 8 to 10 to 16 to 18. For this example, use the smaller (higher K value) diameter pipe. The K value for the gate valve is 0.11 and each 90 bend has a K value of The total K value must be entered into the field (0.34) = To add the second discharge section, click on the 03 and then click on the Pipeline Section Name field. Enter the pipeline section name as Disch #02 and press tab. Follow steps 2-6 using the following input information: pipe section diameter = pipeline section length = 400 section vertical rise = 30 Total K = 1.00 for a pipe exit. Your screen should look like the one below. Example continued on page 20 (Pump Duty Tab). On the Pipeline System Tab: 1) Enter 15 in the (ft) box on the diagram to represent the height of the liquid level above the pump center line. Tab to the Pipe Section Roughness field. 2) This example will use the default roughness factor for the suction section (for a table right click in this field). Press Tab. 3) Right click in the Pipe Section Diameter field and select Standard Pipe Diameters (other options are available if the type of pipe is known). Click on 13.25: nominal 14. Press Tab. 4) Enter 15 in the Pipeline Section Length. Press Tab. 5) This example assumes no vertical change in the suction section of pipe. Enter zero in the Section Vertical Rise and Fall field. Press Tab. 6) Right click in the Total K value of section field. Select total K value to display the K value table. This suction section has no valves or bends, but will have friction losses as the slurry enters the pipeline. Select a 0.78: pipe entrance (projecting). Press Tab. Click on Disch #01 in the table. Follow steps two through six using the following criteria: pipe diameter = pipe section length = 100. GIW Slysel Users Manual - RevC 16

11 Pipeline System for a Mining Application Pipeline System Pipeline section name - Reference name used to distinguish pipe sections; it can be changed as needed. Pipe Section Roughness - Standard roughness co-efficients are used to calculate friction. Right click on the field for common values (common E values) based on type of pipe used. Pipe Section Diameter - Internal diameter (ID) of pipe section. Right click on field for common piping schedules. If pipe with multiple IDs are used, each ID should be listed as a separate pipe section. Pipeline Section Length - Length of pipe section. Section Vertical Rise + / Fall - Total vertical change over pipe section (from the pump suction center line) + indicates rise and - indicates fall. Total K value of section - This field is a sum of all losses (pipe fittings, valves, elbows, etc.). Right click on the field to view standard losses per fitting. Enter total of all values per fitting for the pipe section. (For example, 2 elbows and 1 entrance, add 2(elbow)+ 1(entrance loss) = the total. ) The total is to be entered in field. Click on line 02 and follow steps above for each section of discharge pipe. Note: For each pipe diameter or type of pipe, a separate discharge pipe section must be entered. Up to 49 discharge sections are allowed. To add additional discharge pipe sections, click on the next line or use the down arrow key. Make sure to name each section for future reference. Repeat steps above for each additional discharge pipe section. Click on the Pump Duty Tab. See Pump Duty Tab Detail for more information. This section is used to run a pipeline calculation for a mining application (see next page for dredge). (ft) - This field represents the tank liquid level. Enter the distance from the top of the liquid level in the tank to the center line of the pump suction. Suction pipe inlet altitude - Enter location altitude for high elevations. This field adjusts the NPSHA calculation. Fixed final discharge pressure (psi) - Enter value if a fixed discharge pressure is required at the end of the discharge pipe (example cyclone feed application). Pipeline Information The line that is highlighted in the window will be changed by the information entered in the fields listed below. Click on the desired line or use the arrow keys to move between pipeline sections. The default line is 01 Suction. Slysel will only use information entered on line 01 as suction pipe section even if the name of the pipeline section is changed. Slysel assumes all other lines are discharge sections. Place the cursor over an input box to view an explanation of what should be entered. If the TDH (total dynamic head) required by the pump is known, a pipeline calculation is not required. Skip straight to the Pump Duty Tab. GIW Slysel Users Manual - RevC 17

12 Dredge Pipeline does not apply in example scenario. For a dredge example, see Appendix I.

13 Pipeline System for a Dredge Application Pipeline System Pipeline section name - Reference name used to distinguish pipe sections; can be changed as needed. Pipe Section Roughness - Standard roughness co-efficients are used to calculate friction. Right click on the field for common values (common E values) based on type of pipe used. Pipe Section Diameter - Internal diameter (ID) of pipe section. Right click on field for common piping schedules. If pipe with multiple IDs is used, each ID should be listed as a separate pipe section. Pipeline Section Length - Length of pipe section. Section Vertical Rise + / Fall - Total vertical change over pipe section (from the pipe section inlet to the pipe section outlet) + indicates rise and - indicates fall. Total K value of section - This field is a sum of all losses (pipe fittings, valves, elbows, etc.). Right click on the field to view standard losses per fitting. Enter total of all values per fitting for the pipe section. (For example, 2 elbows and 1 entrance, add 2(elbow)+ 1(entrance loss) = total to be entered in field.) Click on line 02 and follow steps above for each section of discharge pipe. Note: For each pipe diameter or type of pipe, a separate discharge pipe section must be entered. Up to 49 dishcarge sections are allowed. To add additional discharge pipe sections, click on the next line or use the down arrow key. Make sure to name each section for future reference. Repeat steps above for each additional discharge pipe section. Click on the Pump Duty Tab. See Pump Duty Tab Detail for more information. This section is used to run a pipeline calculation for a dredge (suction lift) application. Select Dredge Application (ft) - Enter the vertical distance from the water surface to the suction pipe inlet (+ indicates rise and - indicates fall) in the unit of measure shown. If the pump is under water, this number will be greater than the distance from the pump center line to the suction pipe inlet. (ft) - Enter the vertical distance from the pump center line to the suction pipe inlet (+ indicates rise and - indicates fall) in the unit of measure shown. Pipeline Information The line that is highlighted in the window will be changed by the information entered in the fields listed below. Click on the desired line or use the arrow keys to move between pipeline sections. The default line is 01 Suction. Slysel will only use information entered on line 01 as the suction pipe section even if the name of the pipeline section is changed. Slysel assumes all other lines are discharge sections. A vertical pipe section will have the pipe section length equal to the section vertical rise/fall value. Hold the cursor over the two boxes in the diagram for a description of the input required. GIW Slysel Users Manual - RevC 19

14 Example: Pump Duty Information was entered to allow for the calculation of friction losses and total static head in the pipeline on the Pipeline System Tab. The result is the TDH required of the pump. The next step is to enter the information about the slurry on the Pump Duty Tab. Slurry Information: Slurry SG = 1.10 D50 = 175 microns Flow = 8,000 gpm Note: Any rounding of numbers on either the pipeline tab or the pump duty page (or if a Slysel update has modified any of the calculations) there may be a very small difference in the calculated head. To see the impact of the Slurry Properties on the TDH, enter a higher slurry SG (such as 1.5 and look at the recalculated head. Be sure to go back to the example values before moving on to the next tab. Your screen should look like the one pictured below. Example continued on page 26 (Horizontal Pipe Friction). On the Pump Duty Tab: Liquid properties Use defaults Slurry Mixture Properties Enter a slurry SG of Press Tab. Tab to the S.G. Solids field. Slurry Solids Properties Right click in the Solids SG field and select SG Solids to display the standard list of values for this field. Select 2.65: sand. Press Tab. Enter 175 in the D50 field. Press Tab. The D85 is automatically calculated based on the D50 entered above and the ratio on the options tab. Press Tab. Largest Fines - use default of 2000 microns. Press Tab. Enter 5.0 in the Fines % (<74 microns) field. Press Tab. Leave large particle type & Miller number as defaults. Tab to the Flow field. Hydraulic duty details Enter 8,000 in the Flow (gpm) field. Press tab. Total head (ft) - The pipeline information entered on the Pipeline System tab will be used in lieu of entering a total head. Leave the total head box blank and check the Utilize pipeline system to determine the head required box at the bottom of the column. Pump Search Filters Use defaults Customize pump selection Use defaults GIW Slysel Users Manual - RevC 20

15 Pump Duty This section is used to input duty information. Slurry Type - Select Settling, Non-Settling, or Newtonian (contact GIW for Non-Settling Slurries). Liquid Properties These fields refer to the carrier fluid. Default values provided are for water. Values entered in this section are used to determine material selection and acceptable wear. Gravity - Accept default value unless local gravity for the site location is known [field accepts 32-33]. ph - Enter the LOWER (acidic) numeric value for the ph range provided. For a ph below 5, please contact GIW for assistance [field allows values from 0 to 14]. Chlorides - Enter the HIGHEST chloride value provided, for a chloride level above 20,000 please contact GIW for assistance [field allows 0-250,000 ppm]. Temperature - Enter operating temperature for the carrier liquid during system operation. Note: the maximum operating temperature for rubber pumps is 140 F [field allows ]. Viscosity - Default value is calculated based on the water table. If carrier liquid is not water, the new viscosity value should be entered [field allows 0-1]. Specific Gravity - Default value calculated based on water. If carrier liquid is not water, new specific gravity value should be entered. Disable automatic temperature calculation of SG and viscosity - Check box if carrier liquid is not water to manually enter viscosity and specific gravity information. Slurry Mixture Properties These fields refer to the mixture of the carrier fluid and solids to be transported. S.G. Slurry - Specific gravity of slurry (density of slurry divided by the density of water at 39 F / 4 C) concentration (volume) and concentration (weight) will be automatically calculated from specific gravity. Specific gravity of slurry can be automatically calculated by entering concentration (volume) or concentration (weight) [field allows ]. Concentration (volume) - The percentage of the slurry volume that is particles (not carrier fluid). If S.G. slurry above is input, concentration (volume) will be automatically calculated. If concentration (volume) is known, it can be entered to automatically calculate S.G. slurry and concentration (weight) [field allows 0-100]. Concentration (weight) - The percentage of the slurry weight that is particles (not carrier fluid). If either the S.G. slurry or concentration (volume) are entered (above) the concentration (weight) will be automatically calculated. If concentration (weight) is known, it can be entered to automatically calculate S.G. slurry and concentration (volume) [field allows 0-100]. Non-settling viscosity for pump solids effect- Applies only to non-settling applications. For common values, right click on the field and select non-settling viscosity. Minimum required for pump selection: Slurry SG (or the concentration), Solids SG, and Particle sizes (or the defaults), Flow, and Total Head. Non-Settling Slurries and pastes will require review by GIW prior to any quotes being generated or orders being accepted. GIW Slysel Users Manual - RevC 21

16 Pump Duty Slurry Solids Properties The default values for sand are shown. To view common values for other slurry: right click on the field click on the field name to display list of options select best value S.G. Solids - Specific gravity of solids is calculated as the density of the solid divided by the density of water at 39 F / 4 C. For default values of Solids S.G., right click in the field and select S.G. solids and choose the solid being pumped [manual entries between 1.21 and 10 are accepted in this field]. D50 - Enter the particle size where 50% of particles are smaller than this size. D85 can be automatically calculated from the D50. Either the D50 or the D85 must be entered. D85 - Enter the particle size where 85% of the particles are smaller than this size. D50 can be automatically calculated from the D85. Either the D50 or the D85 must be entered. Largest - Enter the largest particle size expected to be pumped in the system. This field is used for calculating wear and sphere passage. Fines % (<74micron) - % of particles smaller than 74 microns [field allows 0-100% to be entered]. Large particle type - Select the shape of the largest particle; click on the arrow and choose from the list shown. Miller number - A measure of relative abrasitity of a slurry used to predict wear. Common values available (right click on the field). Hydraulic Duty Details Enter the information that is available; two out of three fields listed below are required to solve for the remaining one: Flow, Head, and Pump RPM (if this information is not available, use the pipeline system tab). If all three fields are fixed values (existing system), see Turn Down section below. A slysel report must be run for each individual duty point. Flow - If the flow requirement of the system is known, enter it here (volumetric flow rate through the pump). Total head - If the flow requirement of the system is known, enter it here (Differential pressure measured between the discharge (outlet) and the suction (inlet) of the pump). Pump RPM - Typically left as 0 to allow Slysel to calculate. Data is only entered in the case where the pump speed is known [field will allow 0-3,600]. NPSHA (Net Positive Suction Head Available from the System) Total pressure (absolute) at the suction inlet of the pump. NPSHA must be greater than the NPSHR to avoid cavitation [field will allow 0-9,999]. NPSHR margin (Net Positive Suction Head Required by the Pump) Safety factor in calculating the amount of pressure required at the inlet of the pump to operate without cavitation at a particular duty point (entered above); default is 3 [field will allow 0-33]. Maximum motor power - Maximum power available (enter if limited). Enter a value here to eliminate pumps exceeding the power available from the best selection list. Operating pressure - Used to filter pump selections by pressure rating. Sphere size - Used to filter pump selection by the largest particle required to pass through the pump (minimum sphere passage required through the pump based on particle size and shape). Service class - GIW classification based on particle size and shape. See appendix C. Do not modify. Utilize pipeline system to determine the head required - Check this box to use data entered on the Pipeline System tab. See Pipeline System Detail section of this manual for more information. Pump Search Filters (To search for a pump based on one or more criteria below, only pumps meeting all criteria selected will be displayed on the best selections list.) Turn Down - To calculate an impeller turn down, solve for the impeller diameter (see below. Flow, Total Head, and Pump RPM must be input in the appropriate field). Pump Selection Quantity - Number of identical pumps in a series. Vertical Pump Application - Check this box to select only vertical pumps (on the Pump Configurator Tab). If unchecked pumps selected will be, by default, only horizontal. Discharge - To choose a required discharge size, click on the drop down arrow and select the appropriate size. Suction - To choose a required suction size, click on the drop down arrow and select the appropriate size. Pump class - To specify a pump class, click on the drop down arrow and select the appropriate class. Impeller diameter - Click on the arrow to display the drop down box of impeller sizes available [field allows manual entry from 1-115]. NPSHA is not required for the pump selection, but note that a warning will appear on the output if this information is not included. To evaluate a multistage piping system with different pumps see Appendix III. GIW Slysel Users Manual - RevC 23

17 Pump title substring [field will allow 10 characters]. Reset all search filters - Click button to set all fields in the Pump Search Filter section back to the default. Calculate the relative suction liner wear for the best pump selection option - Calculates the relative wear hours for the suction liners for standard pump selections. These calculatons are displayed in the uppermost section of the Best Selections Tab in the column labeled Wear_khr, and can take up to forty seconds to appear. Lock Wear Thickness between sections - Used for wear analysis studies. Customize Pump Selection This section allows you to solve for different variables based on a single specific pump assembly number. Select the best pumps - (Default) selects the best pumps for the duty information you have entered. Single pump solve for pump speed - Enter a head and flow and Slysel will solve for rpm using the assembly # in the Pump Assembly Drawing box. Single pump solve for impeller diameter - Enter desired head, flow, and speed and Slysel will solve for specific impeller diameter in the specific pump assembly - useful for turndown calculations. Single pump solve for head - Enter flow and speed and Slysel will solve for head using the specific pump in the Pump Assembly Drawing box. Single pump solve for flow - Enter head and speed and Slysel will solve for flow using the specific pump in the Pump Assembly Drawing box. Single pump solve system Pump assembly drawing - Use when a Specific GIW Assembly number is to be viewed in the results section. A single pump assembly number can be entered to solve the criteria, or double click in this box for pump search. Pump search - Click to search for pumps. Not used for entering assembly numbers in Pump Assembly Drawing box. Solids Effect Efficiency % - Calculates the reduction in efficiency based on values of D50, solids concentration, impeller diameter, % fine particles, and solids specific gravity. [If Disable automatic update of solids effect box is checked, field will allow 0-70]. Solids Effect Head % - Calculates the reduction in head based on values of D50, solids concentration, impeller diameter, % fine particles, and solids specific gravity. Disable automatic update of solids effect - Impeller Diameter - Pump Duty Pump Search Filters and Customize Pump Selection are advanced options and require a certain amount of knowledge regarding GIW pump assemblies. Apply these options with care and contact GIW Sales with questions. GIW Slysel Users Manual - RevC 25

18 Example: Horz Pipe F This example will look at solving for one problem type only. Known Constant: Feed concentration of Cw 15% or 1.1 SG. On the Horizontal Pipe Friction Tab This section allows the user to look at the transport of solids on a unit horizontal case basis to establish the optimum pipe diameter that will operate free of particle deposit. A dialog box will open with a reference for additional information on subjects covered on this tab. Click ok. In the Horizontal Pipe Calculation Problem Type field select Concentration constant with Slurry Flow varying from the drop down menu. Pipe Diameter - Enter Select Desired Method for Slurry Concentration Input field select Cw from the drop down menu. Constant Cw% - enter 15. Flow Minimum Flow (GPM) - enter Flow Increment Flow - enter 500. The table shows key comparison with deposit velocity printout that no deposit occurs and the horizontal pipe friction, energy transport rate and concentration for the 8000 GPM example case. It also shows that lower flows are possible without deposit of solids. By running constant throughput with varying concentration it can be seen that higher concentrations require less energy. If the concentration were variable, this option should be explored. GIW Slysel Users Manual - RevC 26

19 Horz Pipe Friction Cw- Concentration by Weight Constant Flow - Enter the flow Minimum - This number will used to show the first or lowest value in the table. Depending on Problem Type field may be: SGM Cv Cw Throughput Flow Increment - Used to determine the increase from the minimum entered above for each calculation. Number of Increments - Select number of results based on the minimum and increment fields to be displayed in the table. Note: results may be limited due to maximum limits. Results will not be displayed outside of allowed parameters. Reading the Report Looks at the transport rate of solids on a unit horizontal case basis to establish the optimum pipe diameter to operate without particles depositing. The top section of the report entitled Particle Deposit Velocity Check, provides information on the deposit velocity for different size particles at different concentrations in the given pipe diameter. The bottom section entitled Settling Slurry Information provides a summary of the velocity, pipe friction, specific energy, flow, transport rate and concentration gpm for the chosen pipe diameter and solids. Utilizing this information it is possible to determine the pipe diameter, concentration, and flow rate that is most cost efficient. Utilizing information provided on the Pump Duty Tab and data input in the left column of the Horz Pipe F Tab, this section solves for several different types of situations depending on what constant data is available. Pipe Diameter - Enter the pipe diameter for the section of pipe being analyzed. Right click to select standard values. Pipe Slope - Enter slope in degrees. Positive number indicates a rise in the pipe. Pipe Roughness - Right click to select common E values for the pipe roughness. Mechanical Sliding Friction - Used only for very coarse slurries. This value may be measured or calculated as outlined in Wilson 2006 ISBN Horizontal Pipe Calculation Problem Type - Determines which variable Slysel will solve for. Data fields available in the right column will change based on the problem type selected. Select Desired Method for Slurry Concentration Input - Units used to input information in the right hand column. SGM- Specific Gravity of Mixture Cv - Concentration by Volume See Algorithm for coarse-particle transport in horizontal and inclined pipes by Kenneth C. Wilson, Professor Queens Universtiy for more information on horizontal pipe friction. Check Append Horizontal Pipe Friction results to final results on the Options Tab to print results with the Final Results GIW Slysel Users Manual - RevC 27

20 Example: Pipeline Results Flow 8,000 gpm On the Pipeline Results Tab: This page shows the calculated results of the pipeline information and duty information. Because the example flow is 8,000 gpm, enter an initial flow of 6,000 in the initial flow box. Enter a flow increment of 1,000 Leave number of flow increments as 10 (default) The information entered above creates the table that is pictured to the right. System Evaluation This is the most important section. This section displays the calculated settling information. For review see the Pipeline System Detail page. To avoid settling of the 500 microns particles, the minimum recommended flow is 5,700 gpm. The table of pipeline information (see arrow) shows a summary of pipeline information including NPSHA at various flows and the pipeline velocity and friction losses per foot in each section. Your screen should look like the one below. Example is continued on page 30. The settling slurry information section reviews the slurry information from the Pump Duty Tab. The Coefficient of mechanical-sliding friction is calculated based on particle and slurry input. Conduit Information This section summarizes the pipeline information input on the Pipeline System Tab. Static Head Information This section reviews the static information input on the Pipeline System Tab. Table created by information entered at the top of the screen as described to the left. It shows velocity and friction losses in each section of pipeline. GIW Slysel Users Manual - RevC 28

21 Pipeline Results Deposit Data - Deposit velocity and flow calculated at design D50 and design SG (information entered on the Pump Duty tab). Deposit Data (Worst Case) - Deposit velocity and flow calculated using design SG (entered on Pump Duty tab) and worst case particle size (D50 = 500 micron). Deposit Data (Worst Case ) - Deposit velocity and flow calculated using worst case SG (28%) and worst case particle size (D50= 500 microns). Minimum Recommended Flow - Calculated value approximately 10% above worst case value above. Note: All values have to be considered. Minimum recommended flow value is a safe operating point taking into account all possibilities. If the slurry (particle size and SG) is well defined and consistent, operating nearer to the Deposit Data may be possible. An output table at the bottom of the Pipeline Results Tab shows the velocity and friction losses in each section of pipeline. Note: Losses are listed per foot or per meter of length. This tab displays the output from the pipeline calculation tab. Following fields are used to format data shown in the output window (and printed report). Initial Flow - Enter the beginning flow (first flow shown in output). Flow Increment - Distance between the data points shown in output. Number of Flow Increments - Default is 10, use the arrow button to change the number of data points shown in the output window. Settling Slurry Information Information as entered on the Pump Duty Tab Conduit Information Information as entered on the Pipeline System Tab System Evaluation Minimum Friction Point - Minimum head loss. Particles begin to fall out of the slurry and settle. System should be designed to run at a minimum of 10% above the minimum friction point velocity. This point is calculated based on concentration, pipe size, and mean particle size. This tab is useful for determining the minimum velocity required to avoid particle settling and also to make sure velocities aren t excessively high leading to unnecessary wear. To include the Pipeline Results in the Final Report, check the Append pipeline system results to final results box on the Options Tab. GIW Slysel Users Manual - RevC 29

22 Example: Configurator For this example, assume that an all-metal LCC pump with a standard KE stuffing box, closed impeller and an oil lubricated CBA is required. The Configurator Tab narrows the pumps displayed in the Best Selections Tab. On the Configurator Tab: Uncheck LCV Vertical Metal Construction Uncheck MEG Small, Back Pull-out, Metal Construction Uncheck LSA Standard Metal Construction Uncheck Standardized Custom GIW Pump Knowing that an LCC pump is required, LCV and LSA pumps are eliminated by unchecking the above. Under LCC uncheck the following options Rubber Lined Construction Shaft Seal Type Expeller Shaft Seal Type Mechanical Impeller Shroud Open The selections that will be shown on the Best Selection Tab are now limited to LCC pumps in Metal and Extra Heavy Construction and LCC s with KE stuffing boxes (LCC default) and Throat Busings and Closed Shroud Impellers (LCC default) and Oil and Grease CBA Lubrication Your screen should look like the one to the right. Example continued on page 34 (Best Selections Tab). GIW Slysel Users Manual - RevC 30

23 Configurator This tab acts as a filter for the Best Selections tab. Features with a next to them will be INCLUDED in the pump list on the Best Selection Tab. To exclude a feature, remove the. (If a customer requires oil bearing assembly lubrication, uncheck the grease box to eliminate grease bearing assemblies from the Pump Selection list.) Standard GIW Pump - S standard technical documentation, patterns exist, updated BOMs maintained. LCC Pump Configuration Options LCC Metal, Rubber, Expeller, and Heavy Duty Construction - Includes all options. Chemical (MC2, T90G) - For applications with a corrosive carrier fluid. Metal Construction - Single wall casing, impeller, and suction liner of high-chrome white iron. Rubber Lined Construction - Radially split construction with ductile iron outer casing and molded elastomer inner liners. Heavy Duty Construction - All-metal pump similar to Metal Construction, but with heavier sections and hydraulics suited to severe slurry duties. Shaft Seal Type Limited Flow KE - Minimum amount of water required. Throat Bushing - Designed for higher slurry concentrations (1.2 SG or higher). Mechanical - Delicate seal, applications where no leaking or diluting of product is allowed. Expeller - Used for applications where no seal water is available or dilution is not allowed. Impeller Shroud Open - No front shroud, used with stringy or frothy slurries. Closed - Standard impeller, front and rear shrouds. Bearing Assembly Lubrication Oil - Oil lubrication in CBA. Grease - Standard LCC, grease lubrication in CBA. Bearing Type (defaults to standard) Back to Back - Inch Series drive end bearing. Face to Face - Metric Series drive end bearing. LCV Pump Configuration Options LCV Vertical, Metal Construction - Unchecking this box excludes entire LCV class from selection. Chemical (MC2, T90G) - Checking this box will only show pumps available in the chemical configuration of T906, Chemical packing, and Upgraded shafts. Lower Seal - Non contacting type seals Plate - Standard. Prevents excess leakage. Throttle Bushing - Option. Good for abrasive or corrosive materials or SG>1.25. Impeller Shroud Open - No front shroud, used with stringy or frothy slurries. Closed - Standard impeller, front and rear shrouds. Motor Mount - Each LCV has a motor mount attached, and there are limitations to the size motor that can be installed. The default settings allow for searching the widest pump range. This section is useful when a specific pump feature is required (mechanical seal, vertical pump, etc.). GIW Slysel Users Manual - RevC 31

24 Small - Smaller NEMA frame motors, varies by pump size. Large - Larger NEMA frame motors, varies by pump size. MEG Small Back Pull-out Metal Construction - Uncheck to leave the small mega pump out of the selection pool. LSA Pump Configuration Options LSA Standard Metal Construction - Unchecking this box excludes entire LSA class from selection. Shaft Type Stiffened - Limits sections to pumps with stiffened shafts, useful when shaft deflection and bearing life are issues. Required for mechanical seals. Normal / One Diameter - Traditional GIW shaft type with no upsets between the bearings. Bearing Assembly Conventional - Traditional bearing assembly with some play or float in the thrust bearing. Do not use with mechanical seals. Limited End Play - No play or float in thrust bearing; required with mechanical seals. Stuffing Box Lantern Ring. Teflon - Standard Material Metal - Useful when abrasion, temperature, etc. is not compatible with a Teflon Ring Shaft Seal Type Normal - Forward Flush standard on LSA pumps. Highest volume seal water requirement. Limited Flow KE - Minimum amount of seal water required. Standard on LCC pumps. Throat Bushing - Modified KE, first row of packing replaced with bushing. Mid seal water requirement. Standardized Custom GIW Pump Standardized Custom GIW Pump - SC made to order, standard technology; patterns exist or are planned; updated BOMs maintained. Following section is used to filter specialized GIW pumps. LSA Specials or High Pressure LSR, Rubber Lined, Heavy Duty FGD, Split Rubber or Metal (28G) (40G) Option - High corrosion applications TBC, High Pressure, Metal Tie Bolt LHD, Metal, Low Head Wet End Conversion (Competitor) (40G) Option - High corrosion applications TBC, High Pressure, Metal Tie Bolt Configurator Selecting different materials (T90G, 40G) will lower the MAWP. Please contact GIW Sales for assistance. Selecting a stiffened shaft on LSA Pumps can eliminate rejections and warnings regarding shafts and bearings. GIW Slysel Users Manual - RevC 33

25 Example: Best Selections Requirements: LCC Pump Oil CBA Stuffing Box The Pump Product Codes screen appears when the Best Selections Tab is first selected. Provided here for reference. Select assembly number 4007x-00 in the middle box. Review the information displayed in the bottom box. Note this is a standard LCC metal pump. Select assembly number 4007x-01 in the middle box. This pump is an oil lubricated pump with a 100 mm shaft. Scroll down through the bottom window looking for rejections and warnings. This pump is a good fit for the example; however, for demonstration purposes, a pump with a longer bearing life/larger shaft size is required. Select the basis curve is B in the top box. Select assembly number 5001x-00 in the middle box. Review the information displayed in the bottom box. Note that this pump is a good fit, but is grease lubricated which does not meet the example specifications. To select the oil lubricated variation of this pump, select assembly number 5001x-01 in the middle box. This is the pump that will be used for the example. Make a note of the rpm, motor HP, and shaft size. They will be used for a V-belt drive selection. Your screen should look like the one below. Example continued on page 36. On the Best Selections Tab: The top box lists pump selections (that are hydraulically different from each other) by best efficiency. For this example a pump meeting the requirements listed above should be chosen. To begin reviewing the pumps, follow the steps below. Select the basis curve B329A-93 (you may have to scroll down to locate it). The middle box shows mechanical variations for the hydraulic chosen in the top box. To review the mechanical options, follow the steps below. Select the first pump in the middle box (assembly number 4040x-00). The bottom box displays performance information. This information must be carefully reviewed for the specific needs of the application. The (XH) displayed on the Second Line (S 12x14 LCC 28(XH)) means this pump is an Extra Heavy assembly which is not appropriate for the example application. All of the items shown in the middle window are mechanical variations of the same extra heavy pump and do not need to be reviewed. Select the pump with basis curve B330B-93 in the top window. Select assembly number 5011x-00 in the middle box. Review the information displayed in the bottom box. Note that this pump is also an Extra Heavy pump (XH). Continue this process of reviewing pumps by clicking on basis curve B317A-93 in the top box. GIW Slysel Users Manual - RevC 34

26 Best Selections This tab shows the best pumps based on the duty conditions entered on the Pump Duty Tab, the mechanical requirements, and within the pump service class. This list is restricted to S, SC, and C pumps unless options are changed on the Configurator Tab. Read notification box and click ok. Best Hydraulic Choices (top window) Displays the best pumps to fit the application as defined. The pumps are listed in order of efficiency based on hydraulic basis curve. Click on the pump that appears to be the best choice (look at pump efficiency and BEPQ). Performance Basis (middle window) Displays all pump assemblies with the same performance capability (basis curve) selected above. The pump assemblies are listed by assembly or drawing number. Select the best standard assembly (an S pump in the LCC or LSA range). Select Operating Data. Operating Data (bottom window) Displays mechanical information for the pump assembly selected. The first line shows the option or difference between the assemblies. Scroll through the printout information specifically looking for warnings and rejections (may be listed under each individual heading). Other things to look for include Pump Speed and throughput. To view results for a different pump, select a different pump from the list in the performance basis section. Check Boxes Display Mechanical Calculation Details - By default the Operating Data window only displays warnings and details outside the safety limits. To see all mechanical options, check this box. Shaft Material Options - Manually overrides the shaft material to increase plug and shaft stress excess safety factor. Enable Wear and Total Cost of Ownership Calculations - Used to compare pumps based on downtime and wear rate. This calculation is required if the pump service class is reduced to increase the pump selection options. Manual Entry of Wear Thickness - Enables manual override of the wear thickness for suction liner, impeller, and shell during a TCO calculation. Contact GIW for more details. Effective Liner Particle Size - Provides a way to manually adjust the particle size to be representative of actual known field conditions for pump comparison. The actual wear hours for the suction liner must be known and the enable wear and total cost of ownership box must be checked. Show Flange Load Diagram - This link launches a dialog box showing the Flange Load Diagram. Elastomer Friendly icon - This symbol will be displayed if the operating conditions input into Slysel are suitable for an LCC elastomer pump. To evaluate a pump s ability to meet future needs, check the Display Mechanical Calculations Box to see how close current conditions are to the safety factor. Rubber lined pumps are only appropriate with solids up to 1/4 which are not sharp or angularly shaped. GIW Slysel Users Manual - RevC 35

27 Example: System Results Flow 8,000 gpm On the Pipeline Results Tab: Accept the defaults for the Initial Flow, Flow Increment and Number of Flow Increments. This information is used to create the table at the bottom of the screen. Reading the report: System Analysis This section combines the pipeline data, pump duty information, and the specific pump selection. The Settling Slurry Information is a review of the slurry information entered on the Pump Duty Tab. The Conduit Information section is a review of the pipeline data entered on the Pipeline System Tab. Static Head Information This table displays the static head information entered for the system on the Pipeline System Tab. System Evaluation This section reviews the settling information that is also output in the pipeline data see that section for review. The operating point is for the specific pump chosen on the Best Selections Tab for the system entered on the Pipeline System Tab. The throughput is the calculated solids throughput based on the slurry SG and duty point. The pump curve and system curve table is located at the bottom of the report. Graphing the flow versus the system resistance produces the system curve and graphing the flow versus the pump head produces the pump curve. Your screen should look like the one below. Example continued on page 38. GIW Slysel Users Manual - RevC 36

28 System Results The fields below are used to establish the pipe friction and head for different flows. A table is produced with the flow, system resistance, and pump based on the information entered below: Initial Flow - Field is populated with a system generated number. Enter the beginning flow (used as the starting point for graphing). Flow Increment - Distance between the data points generated. Typical number used is 100 (used to determine the distance between points on the graph). Number of Flow Increments - Default is 10, use the arrow button to change the number of data points in the table shown (determines the number of points graphed). Settling Slurry Information Slurry details displayed as entered on the Pump Duty Tab. Conduit Information System information displayed as entered on the Pipeline System Tab. Static Head Information Input values from the Pipeline System Tab (Note: Dredge pipeline evaluations include a calculation for a ladder). System Evaluation Minimum Friction Point - Calculated point of minimum head loss. It is the lowest friction point, and at this flow particles begin to fall out of the slurry and settle. The system should be designed to run at a minimum of 10% above the minimum friction point velocity. This point is calculated based on concentration, pipe size, and mean particle size. Deposit Data - Data calculated using the information provided on the Pump Duty Tab. Using the actual D50 and SG for the slurry, Slysel calculates the velocity and flow where settling will begin. Deposit Data (Worst Case) - Deposit velocity and flow calculated using design SG (entered on Pump Duty Tab) and worst case particle size (D50 = 500 micron). Deposit Data (Worst Case ) - Deposit velocity and flow calculated using worst case SG (28% by weight) and worst case particle size (D50= 500 microns). Minimum Recommended Flow - Calculated value approximately 10% above worst case value above. Note: All values have to be considered. Minimum recommended flow value is a safe operating point taking into account all possibilities. If the slurry (particle size and SG) is well defined and consistent, operating nearer to the Deposit Data may be possible. An output table at the bottom of the Pipeline Results Tab shows the velocity and friction losses in each section of pipeline. Note: Losses are listed per foot or per meter of length. Pipeline Results and System Results repeat much of the same data. Seldom will both be needed in the Final Report. It is critical to know the solids size to avoid settling and pipeline blockages. GIW Slysel Users Manual - RevC 37

29 Example: Sheave Duty Motor Mount Limitations Chart Basic Overhead Offset Overhead Shaft Size Weight Limit Max. NEMA Max. NEMA Limited By Weight Limit Frame Frame Limited By 35mm 750 lbs 256T Motor Length 1500 lbs Approx. 405T Motor Weight 50mm 750 lbs 256T Motor Length 1500 lbs Approx. 405T Motor Weight 70mm 1500 lbs 365T Motor Length 2755 lbs Approx. 449T Motor Weight 100mm 1500 lbs 405T Motor Length 2755 lbs Approx. 449T Motor Weight 125mm 1500 lbs 405T Motor Length 2755 lbs Approx. 449T Motor Weight Your screen should look like the one below. Example continued on page 40. On the Sheave Duty Tab: This tab is used to narrow the sheave selections that appear on the Sheave Results Tab. In the first drop-down box on the left side of the screen, select GIW Standard Overhead Mount. This selection will be used for all overhead mounted motors. Center Distance Minimum, Center Distance Maximum, and Service Factor will all auto populate. In the large box on the lower left hand side of the screen, select LCC: mm 7780D (offset). This means the offset overhead mount per the motor mount limitations chart located in the yellow box above. The Pump RPM Min and Max will auto populate. Make sure the shaft size is correct. Motor Power (BHP) is the HP from the Slysel of the motor that was chosen. RPM, frame, and shaft size will auto populate for NEMA motors. Make changes if required for actual motor usage. GIW Slysel Users Manual - RevC 38

30 Sheave Duty This tab is used to select the V-belt drive equipment. Mount Orientation / Selection The default is GIW Custom Designated Mount which allows complete manual entry. GIW Standard Overhead Mount populates the box on the lower left side with all the standard GIW overhead mount options. Selecting a mount option from the list will populate the center distance min and max fields with the appropriate information based on the sheave selected. GIW Standard Side by Side Mount populates the box on the lower left side with all the standard GIW side-by-side mount options. Selecting a mount option from the list will populate the center distance min and max fields with the appropriate information based on the sheave selected. Center Distance min & max fields are populated with defaults based on the mount type selected in the drop-down box and the pump type/shaft diameter combination selected in the window. Center Distance (minimum) - Minimum center distance between motor and pump shafts at the lowest (nearest) adjustment of the motor to the pump. Center Distance (maximum) - Maximum center distance between motor and pump shafts at the highest (farthest) adjustment of the motor to the pump. Service Factor - Minimum safety factor required, the default is 1.5. Sheave type - Fixed versus Variable. Pump RPM min & max and Pump Shaft Size fields are populated based on the pump selection made on the Best Selections Tab. If a sheave selection is being done without a pump selection, this information must be entered manually. Pump RPM (minimum) - Pump RPM (maximum) - Pump Shaft Size - Motor Frequency - Motor Power - Includes safety factor and information populated based on the pump selection made on the Best Selections Tab. If a sheave selection is being done without a pump selection, this information must be entered manually. Motor RPM - Includes safety factor and information populated based on the pump selection made on the Best Selections Tab. If a sheave selection is being done without a pump selection, this information must be entered manually. NEMA Frame - Determined based on the information entered in the Motor Power and Motor RPM fields. Motor Shaft Size - Based on NEMA frame. Price Markup - Margin or profit used in determining the cost of the sheave that is printed on the Sheave Results Tab. List price is 1. Cost/List Price Ratios - Ratio used to determine price listed on the Sheave Results Tab. For list price, use 1. Select the Sheave Results Tab. To complete a sheave selection without selecting a pump, the Enable Manual Sheave Selection must be checked on the Options Tab. Enter as much information as is available to allow the program to weed out options. To view more options, enter less restrictive information on this tab. GIW Slysel Users Manual - RevC 39

31 Example: Sheave Results On the Sheave Results Tab: This tab displays the Sheave options based on the criteria as input on the Sheave Duty Tab. In this case only two options are shown. The first option (motor sheave 17.00) shows that it is rejected at the end of the first line of the top box. Scroll through the bottom box to view the rejections. Select the second option (motor sheave 13.20). Notice there are no rejections for this selection. Looking in the lower window, review the selection details. For this example, selection is easy as there is only one option that is not rejected. For situations where several options without rejects are listed, select a drive based on the RPM being close, but slightly above the pump RPM (to cover drive losses) and Sheave Size. Your screen should look like the one below. Example continued on page 42. GIW Slysel Users Manual - RevC 40

32 Sheave Results Sheave / Belt Combo information is shown in a table below the selection requirements. This information is based on the selection from the Possible Selections box. Data Calculated based on the input data and sheave/belt combo information is displayed next and labeled as Calculated center distance, service factor, pump RPM. Rejections and Warnings if applicable are displayed at the bottom of the report. Sheave results can be printed by selecting File, Print Sheave Results. A Few Common Warnings & Rejections: Non-Standard guard required - GIW has non-standard guards for larger sheaves if this warning appears. Motor Sheave is below NEMA minimum - Larger sheave is required based on motor HP. SFPM too high use ductile iron - If the drive is selected, the added cost of ductile iron sheaves must be quoted. Possible Selections Displays possible sheave selections based on information entered on the Sheave Duty Tab. List is sorted by PRICE with the lowest price option at the top. Pump RPM may impact the sheave selection. Be sure to scroll through all possible selections to view all pump RPM choices. List is not grouped by RPM. If a yes is in the rejected column, the selection was rejected based on manufacturer s specifications but may be worth looking at anyway. The specific rejection information will be displayed in the Output for Sheave Selection Results box when the sheave /belt combo is selected. Output for Sheave Selection Results Sheave selection requirements show the input data from the Sheave Duty Tab. If a selection is not available because of the bore size of the bushing, contact GIW Sales for help. Non-Standard guards and variable pitch sheaves available by calling GIW Sales. For LCV guards and V-belts contact GIW. GIW Slysel Users Manual - RevC 41

33 Example: Final Results On the Final Results Tab: This tab displays the Slysel Report along with all the output options selected (Options Tab). Scroll through or right click to copy to another program. Your screen should look like the one below. Example continued on page 44. GIW Slysel Users Manual - RevC 42

34 Final Results Final Results Tab The final report by default includes the pump selection. Additional information can be included in the Final Results by using the Options Tab. Information on the final results tab is the same information that was displayed on the other tabs, with one exception: if a sheave selection has been done, the bearing life will be recalculated due to the belt load changing. The correct bearing life is displayed on the final results report. To print the final report, select File, then select Print Final Report. To use the information in another application (including Lotus Notes): Right click on the screen Select Copy to Clipboard Open the program you want to use (Word, Excel, Lotus Notes etc.) Right click on your document / spread sheet Select Paste To append additional data to this report, go straight to the Options Tab and check the appropriate boxes and then go straight back to the Final Results Tab. Clicking on any other tab may result in having to re-select or re-input some of the information. GIW Slysel Users Manual - RevC 43

35 Example: Pump BOM On the Pump BOM Tab: This tab displays the parts list and provides general pump drawings. Right click in the box for options. General layout drawing pictured to the right. Your screen should look like the one below. End of Example. GIW Slysel Users Manual - RevC 44

36 Pump BOM To print BOM with the final results, check the Append Pump Assembly s Bill of Material to final results box on the Options Tab. GIW Slysel Users Manual - RevC 45

37 Example of a Pipeline System for a Dredge Application Appendix I The Dredge (Suction Lift) example is for the below system. We are dredging out of a pond, and we know from experience that our range of conditions will be: Minimum SG = 1.13 with a D50 of 600 microns Maximum SG = 1.30 with a D50 of 150 microns The pump is located 1 m above the water line and our dredge depth is 10 meters below the water. Type 16 in the Pipeline Section Length field. Type 11 in the Section Vertical Rise / Fall field. Press Tab. Note: The vertical distances in the diagram are positive or negative in reference to the pump center line (in our example both are negative). In the table of pipeline sections, the Section Vertical dimension is positive if the pipeline is rising and negative if the pipeline is downhill (in our example both the suction and the discharge are positive). Type 2.1 in the Total K value of section field and press tab. Click on the 02 Disch #01 line in the table. Click in the Pipe Section Roughness field and right click. Select common E and then select smooth worn steel. Press Tab. Right click in the Pipe Section Diameter field. Select Standard Pipe Diameters. Select Nominal 20. Press Tab. Type 500 in the Pipeline Section Length field and press tab. Type 2 in the Section Vertical Rise and Fall field and press tab. Type 1.2 in the Total K Value of Section field and press tab. Your screen should look like the one below. Example continued on page 46. On the Options Tab: Select S.I. Units because this example is done using metric units. On the Pipeline System Tab: Select Dredge Application. Enter -10 in the vertical distance from water surface to suction pipe inlet box (left hand side). Enter -11 in the vertical distance from pump center line to suction pipe inlet box (on the right). Remember to hold the cursor over the field to see the field description. Tab to the Pipe Section Roughness field and right click. Select common E and then select steel or wrought iron. Tab to the Pipe Section Diameter Field. Right click in the Pipe Section Diameter field. Select Standard Pipe Diameters. Select Nominal 20. Press Tab. GIW Slysel Users Manual - RevC 47

38 Appendix I Continued Option 2 in the top box is 18x18 44 T 12-// 4HE and has the same issue as option 1. Option 3 is the 20x22 54 C 12-7/8/ 5ME. The TBC 8892D is a very high pressure design. This would be a costly option in a low pressure application. Option 4 (top box) is a 12x14 36 C H12-1/4/ 3ME. Click on the first option displayed in the middle box (Assembly No. 0569X-00). The BEPQ of this pump is very high, but for illustrative purposes, scroll through the Operating Data (bottom window). There are several warnings. The first one is due to the BEPQ being too high. The second one is for insufficient NPSHA. This is not a good selection. Option 5 (top box) is a 14x16 28 C 9- // 5ME. Again, this design is not appropriate for this type of application. Option 6 (top box) is an 18x18 44 C H16//3ME. The efficiency and BEPQ % are reasonable. There are several options displayed in the Performance Basis Window (middle box). The LSA product line is a good choice for severe duty. Click on 0539X-00. Scroll through the Operating Data (bottom box) looking for warnings or rejections. This is a good choice. Click on the Final Results Tab and print the results for comparison purposes. Click on the Pump Duty Tab to run a report for the second duty point. Because this example is dealing with an existing system, it is not necessary to review the pipeline information except to look for inconsistencies which might indicate that the data was entered incorrectly or that the information provided is inaccurate. Once the data makes sense, click on the Pump Duty Tab. On the Pump Duty Tab: S.G. Slurry - Enter Tab to the S.G. Solids field. S.G. Solids - Enter Tab to the D 50 field. D 50 - Enter 600 and tab to the Flow field. Flow (M^3/hr) - Enter 2840 and press Tab. Total head (m) - The pipeline information entered on the Pipeline System tab will be used in lieu of entering a total head. Leave the total head box blank and check the Utilize pipeline system to determine the head required box at the bottom of the column. Your screen should look like the one above. Click on the Best Selections Tab. On the Best Selections Tab: Reviewing results shows how some selections will be difficult. Best Hydraulic choices option 1 (top box) is the 18x20 44 T 12//5HE. This design is not appropriate for large solids or high wear applications. GIW Slysel Users Manual - RevC 48

39 On the Pump Duty Tab: S.G. Slurry - Enter Tab to the S.G. Solids field. S.G. Solids - Enter Tab to the D 50 field. D 50 - Enter 150 and tab to the Flow field. Flow (M^3/hr) - Enter 2840 and press Tab. Total head (m) - The pipeline information entered on the Pipeline System Tab will be used in lieu of entering a total head. Leave the total head box blank and check the Utilize pipeline system to determine the head required box at the bottom of the column. Click on the Best Selections Tab. On the Best Selections Tab: The first three options in the Best Hydraulic Choices Window (top box) are the same as the initial duty point. Option 1 (top box) is the 18x20 44 T 12//5HE. This design is not appropriate for large solids or high wear applications. Option 2 in the top box is 18x18 44 T 12-// 4HE and has the same issue as option 1. Option 3 is the 20x22 54 C 12-7/8/ 5ME. The TBC 8892D is a very high pressure design. This would be a costly option in a low pressure application. Option 4 (top box) is a 18x18 33 C H 11-17/32 5ME. This is an FGD pump and is not appropriate for this service. The Z0086 pump is a design only and cannot be a selection. Option 5 (top box) is a 18x20 52 C 17-19/32/ 5ME. This is a rubber lined pump and not appropriate for Dredge applications due to particle size and high abrasivity. Option 6 (top box) is an 18x18 44 C H16//3ME. The efficiency and BEPQ % are reasonable. There are several options displayed in the Performance Basis Window (middle box). The LSA product line is a good choice for severe duty. Click on 0539X-00. Scroll through the Operating Data (bottom box) looking for warnings or rejections. This is a good choice. Click on the Final Results Tab. Print the Slysel Report for the second duty point. Compare the two Slysel Reports for any warnings or rejections. This pump is a good selection at either duty point. End of Example. Appendix I Continued GIW Slysel Users Manual - RevC 49

40 Further Information for System Evaluation Appendix II This Appendix provides further explanation of the System Evaluation section of the Pipeline Results (shown in the box below). Numbers have been added to the four sections to allow for easy reference, and the pipe section names have been carried through for clarity. Deposit Data (represented by the number 2 in the diagram) Minimum Friction Point Section Review (represented by number 1 in the diagram) The minimum friction point is exactly what it sounds like: the flow and velocity in each pipe section that corresponds to the minimum friction in each pipe section. The minimum friction point is a calculated value based on the concentration, pipe diameter, and mean particle size. In theory, this would be the best point to operate at as it would minimize pipeline wear. The problem is that some or all of the particles may settle at that velocity and plug the pipe. The data in this column is the deposit velocity (velocity below which settling occurs) for the D50 size particle and flow within each section of the pipeline. These volumes are based on the actual duty information entered on the Pipeline Tab and the Pump Duty Tab. Large differences between the velocities in this column and the velocities in Column #1 would indicate the potential for settling or high wear. The Deposit Data (represented by the number 3 in the diagram) This section shows additional information that is not based strictly on the slurry. The velocities and flows in this column are based on a worst case D50 particle of 500 microns and the SG of the original slurry. Particles with a diameter of 500 microns will be the first to settle out and the velocity to keep these particles flowing must be considered. If the slurry has particles that are 500 microns in size, they will begin to settle below the listed velocities. If the presence of this size particle is limited or infrequent, settling is less of an issue. Caution - If particle settling occurs at a velocity greater than the minimum friction point, the velocity at which any particles begin to settle is the minimum flow rate. All slurries contain a distribution of particles. 500 micron particles settle first due to a larger velocity requirement. The velocity at which it settles varies with concentration, being higher at lower concentrations. If there are no 500 micron particles, the largest particle or the D50 must be considered. With no 500 micron particles, actual service and modeling suggest to target a velocity 10% above the minimum friction point. GIW Slysel Users Manual - RevC 51

41 Appendix II Continued The final piece of the Deposit Data is in Column #4. Slysel has calculated the velocities required to keep the worst case particle size (500 microns), at the worst case slurry S.G., moving along the pipeline. This scenario should be considered if the operating concentration will vary. A particle concentration of 28% by weight presents a unique problem. At lower concentrations there is less particle interaction, and settling is not heavily influenced. At higher concentrations the solids actually begin to have a carrying effect fewer solids settling even with higher concentrations. The data in Column #4 shows the velocities required if the D50 and the slurry SG approach this Worst Case condition. Slysel always presents a Recommended Minimum Flow value. This flow is calculated at 10% above the highest flow rate in the 4 columns above. This number is a safe flow, but it is not always practical. Good knowledge of the slurry is key to reviewing the data that Slysel generates and selecting a reasonable operating point. For further reading please see Chapter 5 of Slurry Transport Using Centrifugal Pumps Third Edition (Addie et.al). For particle settling information please review Figure 5.3 (pictured to the right) from Slurry Transport Using Centrifugal Pumps Third Edition. This figure shows how required velocity changes with particle size and pipe diameter. GIW Slysel Users Manual - RevC 52

42 Multistage Pipeline System Evaluation Appendix III To access the Multistage Pipeline System Evaluation feature, click on the file menu and select Multistage. A separate window will open (pictured above). This feature provides a means of evaluating a number of pumps located in series in a pipeline. Together with pipeline information entered on the pipeline system tab this feature can: Determine operating flow Tabulate steady state hydraulic gradient Summarize the system and its energy requirements Evaluate startup pressure gradients over time Indicate when cavitation and water hammer might occur Pumps Tab Pump Search List - (small window in the top left corner) displays the pumps from the Best Selection tab in order by impeller diameter. Pump Search - Selecting this button will display the GIW Pump Search dialog box which enables a search based on discharge, suction, pump class, impeller diameter, or pump title substring. Use the drop down menus to filter data based on your search criteria. Highlight the pump of choice and click okay to select. Pump selected will now be displayed in the pump search window. To include a pump in the Pump Series Table (bottom window) Highlight the pump in the Pump Search List (top) window Check the box corresponding with the series number in the table where you would like the pump to appear. For example, for the 3rd pump in the series, check the box next to 03. Note: Pumps will only be added to lines that are enabled with the check box checked. Multiple series locations can be selected (using the check box) at once to add the same pump multiple times. Disable automatic update of solids effect and impeller diameter - When checked, this box over-rides the data refresh in the Pump Series Table and saves the values manually entered. When left unchecked, the data that has been manually changed will be reset to the default values for pumps selected (check box) when a new pump is selected from the pump search list. Data Input Fields (center of screen) Information pertaining to the pump selected (check box) in the pump series table is displayed in the following fields and can be changed by the user. Only pumps selected (enabled with check box checked) will be updated. To change information for multiple lines all applicable boxes must be checked. Pump - To manually change the pump selection, type the pump assembly number and press tab. This will change the pump assembly displayed in the table for all selected series. Impeller Diameter - manually changes the impeller diameter for all pumps selected (check box). Check the series number you want to add prior to using the pump search feature to automatically update the Pump Series Table when selecting a pump from the Pump Search dialog box. Only highlighted lines will be updated. To highlight or enable a pump to be added or changed, select the check box next to the series number. Multiple pumps can be added / edited at once. GIW Slysel Users Manual - RevC 53

43 Appendix III Continued RPM - Manually enters RPM. Head % - Can be used to change the value for the pump solids effect on head. Eff % - Used to change the value for the pump solids effect on efficiency. Power - Motor power rating. To leave unlimited use zero. Motor Type - Use the drop down menu to select alternate motor type. Head - Calculated value from Steady State Hydraulic gradient tab and cannot be changed. Pump delayed startup time - Manually change the delay between startup. First pump in the series must be zero. Values are used in the start up analysis to check for potential cavitation, water hammer, and maximum operating pressure. Enable check on single click - Box is checked by default When checked, a pump in the Pump Series Table will be selected (check box enabled) by clicking once on the line associated with the pump or check box on the left. When unchecked, a pump in the Pump Series Table will be highlighted by clicking once on the line associated with the pump or check box on the left, but will not be selected (check box enabled). When highlighted, the information in the Data Input Fields will be displayed for the pump, but cannot be changed until the check box is enabled by clicking on the check box (or line associated with the pump) in the Pump Series Table a second time. Clear Pump - To remove a pump from the Pump Series Table, select the pump (check box enabled) and press the clear pump button. Multiple pumps may be cleared at once. GIW Slysel Users Manual - RevC 54

44 Appendix III Continued *Denotes pump or conduit is already used in the system and displayed in the System Window. Configuration Tab Pump Window (top window) - Displays pumps added on the Pumps tab along with their operating speed, RPM, Solids Effect, Available Motor Power etc. Pipeline Window (middle window) - Displays pipeline profile information as entered on the Pipeline System Tab. System Window (bottom window) - Shows the combined pump/pipeline profile information with the pipeline and pumps located correctly in sequence along the line. To add a pump in the series, click on pump in the Pump Window and press the add pump button. To add a section of pipe, click on the pipe section in the Pipeline Window and click the add conduit button. Note: The button changes names based on what is selected. To remove a pump or conduit from the series, click on the item to be removed in the System Window and click the Remove button. Note: each pump and conduit may only be added to the series once. If a pump or conduit is needed more than once it must be added on the Pump or Pipeline System tab. Double click the pump or conduit to add it to the System Window more quickly. Double clicking a line in the System Window will remove the item from the series. GIW Slysel Users Manual - RevC 55

45 Appendix III Continued Steady State Hydraulic Gradient This tab shows the hydraulic gradient along the line at each change of conduit section. Note: a pump location requires a change of conduit. Operating Point - When this Steady State Hydraulic Gradient tab is selected a dialog box with the Operating point, Flow, and Total head is displayed (pictured right) Pump Spacing and Steady Head Distribution table is shown in the window. This report can be printed by clicking on file and selecting print from the pull down menu. GIW Slysel Users Manual - RevC 56

46 Appendix III Continued Specific Energy This tab shows a summary of the energy requirements of the pipeline. The top section shows the pumps, their assembly descriptions and titles. The second section summarizes the impeller diameters, RPMs, location along the pipeline, motor KW and efficiency. The third section summarizes the pipeline lengths, diameters, pipe friction and average velocity. The last section provides overall flow, transport rate, SG, solids concentration, discharge elevation and specific energy consumption. GIW Slysel Users Manual - RevC 57

47 Appendix III Continued Startup Hydraulic Gradient Shows the water (only) pressure along the line for the total configuration after different times using the times entered on the configuration tab. Here different times (as entered on the pumps tab) after the first pump startup can be used to limit pressure in the line and to look for negative pressures that might cause cavitation. The pumps are assumed to come up to speed instantly. Pressure along the line at each location is shown along with the flow in the pipeline at different elapsed times. Pressure location times are after each pump starts and steady state for that condition. Where a negative pressure occurs a warning is flagged. The maximum and minimum pressures seen are tabulated at the end of the window. GIW Slysel Users Manual - RevC 58