Pipeline System Design

4. Pipeline system design

This chapter describes the design calculations for a plastic pipeline system by using the following criteria: Pipeline diameter for a given fluid flow rate Frictional and pressure losses of the system Pumping power requirement Pressure transients (i.e. water hammer) The above parameters are shown and worked examples are provided to demonstrate the calculation procedure for each aspect.

Worked example 4.1

(a) What size of HPPE pipe should be used if the volumetric flow rate is 10 l/s and the flow velocity is restricted to 3m/s? (b) What is the effect of using a smaller or larger size pipe to do the job? Take pipes of external diameters and wall thicknesses as: (i) D = 63mm and e = 3.8mm. (ii) D = 75mm and e = 4.5mm respectively.

Solution
(a) The pipe internal diameter formula is used:-

4.1 Pipe diameter calculation

Pipeline sizing is a three-way relationship between the internal pipe flow area (A in m), the flow velocity (u in m/s) and the volumetric flow rate (Q in m/s) as given by: -

d = 35.68

10 Q = 35.68 = 65 mm 3 u

(b) In case the suppliers do not have the exact diameter determined above (65mm), let us examine two options: (i) When the flow area is decreased by selecting a 63mm diameter pipe, then the velocity will increase as shown by the Continuity equation in

Where the cross-section of the pipes internal flow area (A) is

terms of velocity: -

35.68 35.68 = 10 u=Q d 63 - 7.6

= 4.15 m/s

The above relationship can be expressed in terms of the internal pipe diameter (d in m): -

This is clearly over the recommended design limit of 3m/s for flow velocity of liquids in this pipeline system and is not advisable. (ii) When the flow area is increased by selecting a 75mm diameter pipe, then the velocity will decrease as shown by the Continuity equation: -

If the flow rate is expressed in litres per second (l/s), then the pipe diameter (mm) relation can be simplified to: -

35.68 u=Q d

= 10

35.68 75 - 9

= 2.92 m/s

This flow velocity is lower than the maximum Note that there are two factors which influence the selection of flow velocity: In order to avoid increasing pressure losses due to friction, if the pipe internal diameter is reduced the flow velocity should be proportionately reduced. Noise generation increases rapidly with velocity, especially for gas flow applications and the following limiting velocities are accepted for the general design of pipeline systems: Table 4.1 Noise limiting flow velocities in plastic pipeline systems Medium carried Liquid under suction Liquid under delivery Gas
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recommended value of 3m/s and is therefore acceptable. Remember that lower flow velocity means proportionately lower pressure losses, therefore, always go for the next size up if your calculated size is not available.

4.2 Flow regimes in pipeline system

Flow regimes in a pipe were classified by Osborne Reynolds (in the early twentieth century) into three categories: Laminar: Where the flow behaves in an orderly manner running in parallel stream lines. Turbulent: Where the flow streams are interlinked. Transient: An intermediate condition where the flow is neither Laminar nor Turbulent. 1

Maximum velocity (m/s) 1 3 25

Reynolds identified these categories by calculating a dimensionless group of three flow parameters, later given the name Reynolds number, which is defined by:-

The friction factor ( f ) can also be determined graphically using the Moody diagram (Chart 4.1) shown at the end of this chapter. DArcy presented the following relationship to determine the Head loss ( H ) due to frictional resistance to the flow
f

Where

Re u d v

Reynolds number Flow velocity (m/s) Pipe internal diameter (m) Kinematic viscosity (m/s), see table 4.2 below

in pipelines: 2 Hf = 4 f L u 2g d

Where

f L g u d

Coefficient of friction Length of pipe (m) Acceleration due to gravity (9.81m/s) Flow velocity (m/s) Pipe internal diameter (m)

Table 4.2 Kinematic viscosity of water Temperature 0 5 10 15 20 25 30 35 40 45 50 Kinematic viscosity (m/s x 10-6) 1.752 1.501 1.300 1.137 1.004 0.893 0.800 0.722 0.656 0.600 0.551

Usually hydraulic loss is evaluated in metres per 100m length (i.e. L = 100) so the above formula can be simplified to: 2 Hf = 20.4 f u d 4.4 Pressure losses due to obstructions in pipeline systems

Obstruction losses are due to the presence of valves and fittings in pipeline systems. These losses are grouped into one lot and the associated hydraulic loss ( approaching fluid: -

Reynolds concluded that if Re is less than 2000 the flow is clearly laminar and when Re is over 4000 the flow is clearly turbulent. However when Re is between 2000 and 4000 the flow is transient and the flow prediction is not reliable.

HO ) is calculated as the

sum of all loss coefficients multiplied by the velocity head of the

HO = ( k i )
Where g u
k
i

u2 2g

Table 4.3 Reynolds flow regimes Regime Laminar Transient Turbulent Reynolds number (Re ) <2000 2000 - 4000 >4000 Characteristics Streamline flow Unsettled flow Very mixed flow

Acceleration due to gravity (9.81m/s) Flow velocity (m/s) The sum of k-values for fittings and valves for the pipe system, see tables 4.5 and 4.6

4.3 Pressure losses due to friction in pipelines

The coefficient of friction which is an indication of the resistance the pipe surface offers to the flow is dependent on the value of the Reynolds number and the roughness of the pipe internal surface. Plastics have a unique advantage over metal pipes in that they are considered perfectly smooth when new and do not suffer from the build up of rust or coagulation; thus their original internal dimension is retained. The friction factor for plastic pipes is given in table 5.4

Table 4.5 Obstruction loss coefficient for fittings Obstruction Pipe entry Pipe exit 90 elbow 45 elbow 90 bend 45 bend Tee straight through Tee branch 90 1:2 1:3 1:4 k 0.5 1.0 0.40 0.30 0.60 0.40 0.80 0.95 0.15 0.19 0.24 0.30 Sudden contraction diameter ratio 5:1 4:1 3:1 2:1 0.40 0.37 0.33 0.30

Sudden enlargement diameter ratio

Table 4.4 Friction coefficients Regime Laminar Transient Turbulent Reynolds number (Re) <2000 2000 - 4000 >4000 Coefficient of friction ( f ) 16/Re No data 0.079 Re -0.25

1:5

2
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Pipeline System Design

Table 4.6 Obstruction loss coefficient for valves Valve Ball Diaphragm Butterfly Non-return 25% Open 10.53 1.94 3.74 6.37 50% Open 5.54 1.59 0.42 3.5 75% Open 1.25 1.39 0.14 2.1 100% Open 0.28 1.25 0.10 1.0

Worked example 4.2

A HPPE pipeline system, pumping water, comprises the following items: Pipe Length Outside diameter Wall thickness Fittings 2x 90 bends 1x pipe entry 1x pipe exit 200m 110mm 10mm k = 0.6 k = 0.5 k = 1.0

4.5 Pump rating

4.5.1 Hydraulic losses in pipeline systems
The pump in a fluid pipeline system has to: Overcome frictional losses, Overcome obstruction losses due to valves and fittings, The total hydraulic loss (metres) is therefore given by

1x butterfly valve (25% open) k = 3.74 (a) Determine the total hydraulic and pressure losses of this system when the flow rate of water is 30 l/s if the operating temperature is 10C. (Take the viscosity of water from table 4.2) (b) Determine the pump power to deliver this flow rate to a

Transfer the fluid at the required flow rate between two stations, The static-lift is the physical difference in elevation between the two stations in metres.

point situated 20m above the source given the pumps hydraulic efficiency is 80%.

Solution
(a)

4.5.2 Pressure losses in pipeline systems

The relationship between head loss and pressure loss is given by: Hence flow is turbulent.

Where

Pressure loss (N/m or Pa) Density of fluid (kg/m) Acceleration due to gravity (9.81m/s)

4.5.3 Energy loss in pipeline system

The aforementioned hydraulic losses in a pipeline system are to be accommodated in the design process and these losses should be considered when selecting the correct pump size (duty). The pumps rating (power requirement in Watts) is given by: Total hydraulic losses

Where Q Volumetric flow rate Hydraulic efficiency of pump (Refer to manufacturers data) Htotal Total effective head Htotal =Hstatic-lift+ Hlosses (Due to pipe-friction, fittings, plus static-lift)

Hlosses = Hf + Ho = 33 + 7.2 = 40.2 m

Total pressure losses

P = g Hlosses = 10 3 9.81 40.2 = 394 kPa

(b) Total effective head

Htotal = Hstatic- lift + Hlosses = 20 + 40.2 = 60.2 m

Pump power

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= Q g Htotal / 3 -3 = 10 30 10 9.81 60.2 / 0.8 = 22.1 kW

4.6 Pressure transients in pipeline systems (water hammer)

There are times when either by poor design or abrupt changes in the flow condition the pipeline system undergoes a pressure surge, this phenomenon known as Water Hammer, may be initiated by any of the following actions in the pipeline system: Abrupt valve closure Pump start up, shutdown or an abrupt change in speed Entrapped gas in the liquid flow There are four important parameters to be considered at the design stage so that the effect of water hammer is minimised: 1. The velocity of the pressure wave (m/s)

Worked example 4.3

A HPPE pipeline system, PN10 rated, 300m in length, with an outside diameter of 50mm and a wall thickness of 3 mm with an operational pressure of 4.4 bar, has an actuated valve with a closing time of 2 seconds. Where HPPEs Youngs modulus (E) is 900 MPa and its circumferential stress is 10 MPa; and waters bulk modulus of elasticity (K) is 2.05 GPa and its density of 1000 kg/m. Determine the water hammer characteristics where the flow rate is 10m/h and 20m/h.

Solution Property 1. Pressure wave velocity 244 m/s 244 m/s Flow rate (m/h) 10 20

2. Initial wave velocity

Where

K E d e

Bulk modulus of elasticity for fluid (Pa) Fluid density (kg/m3) Modulus of elasticity of pipe material (Pa) Pipe inside diameter (mm) Pipe wall thickness (mm)
3. Pressure fluctuation

1.83 m/s

3.65 m/s

u
3.1 Maximum pressure

4.46 bar

8.92 bar

8.86 bar

13.32 bar

2. Pressure fluctuation consists of both an upper and lower pressure limit and these must be kept within the pipes pressure characteristics, such that the upper limit is within the pipes maximum operating pressure and the lower limit is above the pipes collapsing pressure, in order to avoid permanent damage to the pipe system. The pressure fluctuation is given by
Collapsing pressure -4.63 bar -4.63 bar 4. Critical wave period 2.46 second 2.46 second 3.2 Minimum pressure -0.06 bar -4.52 bar

Where u is the velocity change (m/s). The pressure fluctuation results in upper and lower limits of operation and is defined as:The maximum pressure: The minimum pressure: 3. The effective safety factor for frequent surges should be higher than the materials safety factor. Where is circumferential stress (MPa)
Statement
P min is within the Pe parameter, hence the system will withstand the negative pressure. P min is outside the Pe parameter, hence the pipe will collapse.

Maximum allowable negative pressure -2.31 bar -2.31 bar

Effective safety factor 1.54 1.02

4. Critical wave period (seconds) given by Where L is pipe length (m) Note: In cases of negative pressure C has a value of 2.

Actuated valves must have closure times greater than this wave period in order to minimise the effect of water hammer. 4
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Pipeline System Design

Chart 4.1 The Moody diagram
0.08 0.07 0.06 0.05 0.04 Friction factor Transient zone 0.05 0.04 0.03 0.02

0.01 Relative roughness

5

0.03

0.005

0.02

0.001

0.0005 0.0001 0.01 Laminar flow 0.008 103 104 105 Reynolds number 106 107 108 Turbulent flow 0.00001

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