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Fluid Engineering Flow in pipes

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Home Fluids Index Fluid Flow in pipes

Pump Notes and Calculations Pumps Valve Notes Valves Fluid Power Notes Fluid Power Introduction..... Symbols..... Fluid Flow..... Modified Bernoulli's Equation..... Pipe Flow Calculations..... Moody chart..... Pipe roughness values..... L/ D values for fittings..... K values for Sudden Expansion -Contraction & Orifice..... Pipe flow velocities..... Introduc tion The following notes should enable a mechanical engineer to establish basic flow conditions and head losses along pipe routes in which fluids are flowing. The equations are most relevant to liquids although approximate sizing for gases can be carried out if appropriate correction factors are used,where necessary, and low gas velocities are considered.

Symbols p = Absolute Pressure N / m2 Pr = Prantl Number =c p. mu / k (Dimensionless) Q = Volume flow Rate (m3 /s ) q = Heat Input per unit mass ( kJ /kg ) R = Gas Constant = R o / M (kJ /(kg.K) Re = Reynolds Number = v.D/ t = Temperature (C ) T = Absolute Temperature (K) u = Specific Internal Energy (kJ/kg) v =Fluid Velocity (m/s) w = Work Output per unit mass (kJ/kg)

A = Pipe Cross Section Area (m2) a = Velocity of sound ( m /s) c p = Specific Heat Capacity at Constant pressure (kJ/(kg K)) c v = Specific Heat Capacity at Constant Volume (kJ/(kg K))

= Pipe roughness (m) mm = Pipe roughness (mm)

D = diameter (m) f = friction factor f T = friction factor (flow in zone of complete turbulence). h = Specific Enthalpy (kJ/kg ) k = Thermal Conductivity (W/(m K)) r = radius of pipe bend (m) K = f (L/D ) L = Pipe Length (m)

= Density ( kg /m3 ) =Fluid Viscosity = (Ns/m2 = Pa s) z = Elevation (m )

g = gravitational acceleration ( 9.81 m /s 2)

Fluid Flow Fluid flowing in pipes has two primary flow patterns. It can be either laminar when all of the fluid particles flow in parallel lines at even velocities and it can be turbulent when the fluid particles have a random motion interposed on an average flow in the general direction of flow. There is also a critical zone when the flow can be either laminar or turbulent or a mixture. It has been proved experimentally by Osborne Reynolds that the nature of flow depends on the mean flow velocity (v), the pipe diameter (D), the density () and the fluid viscosity Fluid Viscosity( ). A dimensionless variable for the called the Reynolds number which is simply a ratio of the fluid dynamic forces and the fluid viscous forces , is used to determine what flow pattern will occur. The equation for the Reynold Number is

For normal engineering calculations , the flow in pipes is considered laminar if the relevant Reynolds number is less than 2000, and it is turbulent if the Reynolds number is greater than 4000. Between these two values there is the critical zone in which the flow can be either laminar or turbulent or the flow can change between the patterns... It is important to know the type of flow in the pipe when assessing friction losses when determining the relevant friction factors

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Fluid Engineering Flow in pipes

Steady Flow Equation.... Reference : The steady flow equation steady flow equation (energy per unit mass ) for a system is identified below... Reference... Steady Flow

If q = w = 0 and the fluid is incompressible and frictionless and if the variables are converted to measured heads of the fluid , that is the units are per unit weight (g) - then the Bernoulli's equation results .. Reference .. Bernoulli's Equation ideal fluids ..

In real flow systems there are losses due to internal and wall friction which result in increase in the internal energy of the fluid. (q > 0). Reference Bernoulli's Equation real Fluids . The bernoulli equation is modified to reflect these losses by adding a term h f = Head loss due to friction.= (u2 -u1 - q) The modified bernoullis equation is therefore ..

The object of most pipe flow head loss calculations is to determine the friction head loss and allow estimation of the pump / compressor power required to pump the fluid along the piping. In most fluid transfer cases the fluid is a incompressible (a liquid) and the flow rate (Q) is constant along the pipe run and therefore the velocity at any point can easily be calculated. The head (z) can also be easily obtained from the pipeline geometry. The system pressure and head loss are therefore the variables generally subject to the detailed pipeline calculations....

Pipe Flow Calc ulations In determining the head loss (pressure drop) along a pipe as a result of friction losses it is first necessary to determine the following: Diameter (m), Length (m), Fluid Viscosity( ), Fluid density () and the fluid velocity (v). It is then necessary to obtain the relevant Reynolds number.. The equation for the Reynold Number

Consistent units to be used i.e Typically = kg/ m3, v = m/ s, D= m, = Ns/ m2 ( 1 Ns/ m2 = 103cP) The value for the Reynold number is to be used to evaluate if the flow is laminar or turbulent and can be used to obtain the friction factor " f " from a moody chart. The moody chart plots the friction factor (f) against the Reynold number with a number of different plotted lines for different values of absolute roughness/ Diameter . The head loss along the pipe can now be calculated using the Darcy-Weisbach equation

The result of the calculation is in units of head of the fluid. . It is based on the pipe being all one dia and the fluid is incompressible For a single pipe line with a number of fittings the total head loss is calculated as

K p = f (L/ D) for the length of pipe. ( this may be made up of f(L/ D). for a number of different pipe lengths of different diameters ) K 1..n = fT(L/ D) equivalent for each fitting

A Moody chart (see below) is used to determine the turbulent flow friction factor from the Reynolds number and the relative roughness of the pipe. If the flow is laminar then the fricton factor is 64/ Re.

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Note: it is suggested that for laminar flow in pipe at Re number approaching 2000 the above K values are used for bends and fitting with reasonable accuracy A moody chart and tables for roughness values and (L/ D) factors for various fittings are provided below

Moody Chart

Various typic al v alues of hydraulic roughness ( ) Note: In the moody chart above ( / D ) is identified with both numerator and denominator in metres (for consistency with all other equations on this page. It is probably more convenient to express both in (mm).i.e a 50mm cast iron pipe ( mm ; / Dmm ) would simply be (0,203 / 50 ). Type of Pipe Cast Iron Galvanised Steel Steel/Wrought Iron Rivetted Steel Asphalted Cast Iron 0,203 0,152 0,051 0,91 - 9,1 0,12

.103..( = mm )

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Wood-Stave Concrete Spun Concrete

Fluid Engineering Flow in pipes

0,18 - 0,91 3,0 0,203 Smooth

Draw n Copper, Brass Steel,Glass

T ypic al Values of L/ D for Fittings The losses through fittings are generally evaluated by obtaining K = fT(L/ D) Table of pipe friction values for clean pipe in region of complete turbulence Nominal size(mm) fT 15 0,027 20 0,025 25 0,023 32 0,022 40 0,021 50 0,019 65,80 0,018 100 0,017 125 0,016 150 0,015 200,250 0,014 300,400 0,013 450,600 0,012

Fitting Fitting Globe Valve Gate Valve Lift Check Valve Sw ing Check Valve Ball Valve Butterfly Valve Flush Pipe Entrance Sharp Corner Flush Pipe Entrance radius >0,15 Pipe Exit Tee Through Tee- Branch flow Elbow -90 Elbow -45 340 8 600 50 - 100 6 35 K = 0.5 K = 0.04 K=1 20 60 30 16 L/ D Close Pattern Ret. Bend 90o Bend r /D=1 90o Bend r /D=2 90o Bend r /D=3 90o Bend r / D=6 90o Bend r / D=8 90o Bend r / D=10 90o Bend r / D=12 90o Bend r / D=14 90o Bend r / D=16 90o Bend r / D=16 90o Bend r / D=20 50 20 12 12 17 24 30 34 38 42 46 50

L/ D

The K180 value for a 180o bend may be derived from the equivalent K90 which is calculated from the above tables using the equation The K180 = 0,25. .fT . r/ D + 1,5.K90 For laminar fluids with low Re numbers ( "<" 500) the K values obtained using the above are probably very innaccurate. The table below illustrates how this affects the K values

Fitting 90 deg Elbow Short 0,9 Radius Gate Valve Globe Valve Plug Valve Angle Valve 1,2 11 12 8

K values for low Reynolds Number fluids Re = 1000 1 1,7 12 14 8.5 4,5 500 7,5 9,9 20 19 11 17 100 16 24 30 27 19 55 50

Swing check Valve 4

K v alues for Sudden Expansion-Contrac tion & Orific e The losses through these fitting are generally evaluated by first obtaining = d2 / d1 Important Note: the resulting K values as tabled below are based on the flow velocity in the larger pipe if the flow velocity in the small pipe is used to evaluate the head loss then the K values tabled below should be multiplied by ( ) 4 = (d2 / d1) 4

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Fluid Engineering Flow in pipes

T able of K e ,K c & K O against

= d2 / d1
Ke 1887.42 576 225 102.23 51.31 27.56 15.51 9 5.32 Kc 965.43 300 120 56.17 29.24 16.41 9.72 6 3.81 Ko 2852.85 876 345 158.4 80.55 43.97 25.23 15 9.13

0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55

0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1

Ke 3.16 1.87 1.08 0.6 0.32 0.15 0.06 0.01 0

Kc 2.47 1.62 1.06 0.69 0.44 0.27 0.14 0.06 0

Ko 5.63 3.49 2.14 1.29 0.76 0.42 0.2 0.07 0

Reasonable Veloc ities of fluid in Pipes Medium Steam (sat) Steam (sat) Steam (sup) Air Water Water Water Water Water Water Oil Ammonia Ammonia Pressure (bar) 0 - 1.7 over 1.7 over 14 Heating Process Process Forced Air Flow General Concrete Pipe Pump Suction Horizontal Sew er Pump discharge Boiler Feed Hydraulic Systems Compressor Suction Service Velocity (m/ s) 20 to 30 30 to 50 30 to 100 5 to 8 1 to 3 4,7 1,2 0,75 1,2 to 2,5 2,4 to 4,6 2,1 to 4,6 25 Minimum Minimum Minimum Minimum Max. Permissable Max. Permissible Notes + 100mm dia +150mm dia +150mm dia e.g. AC Reheat

Compressor Discharge 30

Useful Links 1. 2. 3. 4. 5. 6. 7. 8. Efluids .. Site includes lots of really useful information and calulculators Wikipedia Mechanics of Fluids .. Excellent source of information Efunda Pipe Pressure Loss Calculator .. Authoritative Calculator and notes 1MNO eng.. A site containing a large number of Fluid Flow Calculations and Calculators : Some of the calculators require registration for a fee; Engineering Page.. A site including various Engineering Calculators - Very good pump calculator ER_Online.. Useful software downloads - Very good pump calculator Piping Toolbox a wealth of information on piping design Spirax Sarco...Excellent Reference Site . Learning centre includes fluid flow reference information

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Fluid Engineering Flow in pipes

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