Head Loss Calculation

Once the system minor and friction losses are determined, they can be entered into Bernoullis equation to calculate the external energy required to drive the system.

Energy from a pump is designated as Ep and minor and pipe friction losses are represented as head losses hm and hf respectively.

Head Loss Calculation

Example The pumping system shown in the figure below is required to transfer fresh water from the lower storage tank to the upper gravity tank. The bore size of all pipes and fittings are of 80mm. Pipes used are of API Schedule 40 black steel and connected to the fittings by flanges. Using the data provided, find out the minimum pumping head.

Head Loss Calculation

Solution Applying Bernoulis Equation and including Hpump and Hlosses, V12 P1 V22 P2 Z1 + ------ + ------ + Hpump = Z2 + ------ + ------ + Hlosses 2g g 2g g But V1 and V2 are small (assuming tanks have large surface) and P1 = P2 = Patmosphere Pumping head Hpump = Static head (Hstatic) + Pipe friction losses (Hf)+ Losses through fittings (Hm) Static head Hstatic = Z2 Z1 = 13 (-2) m = 15 m Flow Quantity Q = 800 litres/min = (800 x 10-3)/60 m3/s = 13.33 x 10-3 m3/s

Head Loss Calculation

Diameter of pipe D = 0.080 m Area of pipe section a = 5.03 x 10-3 m2 Since Q = a V Therefore Q 13.33 x 10-3 V = ---- = ----------------------- = 2.65 m/s a 5.03 x 10-3 Taking the temperature of fresh water to be 20o, from the kinematic viscosity table, we can get = 1.007 x 10-6 m2/s Therefore, Vd Re = ------ =

2.65 x 0.080 ------------------- = 2.1 x 105 1.007 x 10-6

It is turbulent flow.

Head Loss Calculation

For commercial steel, wall roughness = 0.046 mm Pipe diameter D = 80 mm Relative roughness /D = 0.046/80 = 0.000575 From Moodys diagram, when Re = 2.1 x 105 and /D = 0.000575, we get friction factor f = 0.019 From the pumping system figure, we get the straight pipe length: Pipe A B 3m B C 10m D F 10m F G 7.5m Total Pipe L = 30.5m Using Darcy-Weisbach Equation: L V2 30.5 x 2.65 x 2.65 Hf = f ----- ----- = 0.019 -------------------------- = 2.59 m D 2g 0.080 x 2 x 9.81

Head Loss Calculation

Minor Losses Calculation: Fitting Coefficient K Foot Valve 10.0 Standard 90o Elbow 0.90 Pump Entry (pipe exit) 1.00 Pump Exit (enter pipe) 0.50 Globe Valve (Fully Open) 10.0 Standard 90o Elbow 0.90 Upper Tank Entry (pipe exit) 1.00 Total 24.3 V2 24.3 x 2.65 x 2.65 Hm = K ------- = -------------------------2g 2 x 9.81 = 8.70 m

Head Loss Calculation

The minimum pump head = Hstatic + Hf + Hm = 15 + 2.59 + 8.70 = 26.29 m If it is converted to bar:

P = gH = 1000 x 9.81 x 26.29 = 257904 Pa

= 2.579 bar

Measures to Reduce Head Losses

Based on the equations of minor losses and friction losses, the following measures can be considered to reduce head losses in pipe line. V2 L V2 Hm = K ------Hf = f ----- ----2g D 2g - Use biggest possible pipe diameter D V Hm Hf - Use smoothest possible pipes /d f Hf - Layout shortest possible pipe lines L Hf - Minimize the number of elbows/bends in pipelines K Hm - Use valves with smaller K value if possible - Keep the temperature of liquids higher if possible T Re

Hf