Pipeline System Design

Worked example 4.1

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

(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

Frictional and pressure losses of the system

thicknesses as: -

Pumping power requirement

(i) D = 63mm and e = 3.8mm.

Pressure transients (i.e. water hammer)

(ii) D = 75mm and e = 4.5mm respectively.

The above parameters are shown and worked examples are

provided to demonstrate the calculation

Solution

procedure for each aspect.

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

4.1 Pipe diameter calculation

d = 35.68

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: -

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: 2

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

This is clearly over the recommended design limit

internal pipe diameter (d in m): -

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

recommended value of 3m/s and is therefore

of flow velocity: -

acceptable. Remember that lower flow velocity

In order to avoid increasing pressure losses due to friction,

means proportionately lower pressure losses,

if the pipe internal diameter is reduced the flow velocity

therefore, always go for the next size up if your

should be proportionately reduced.

calculated size is not available.

Noise generation increases rapidly with velocity,

especially for gas flow applications and the following
limiting velocities are accepted for the general design

Flow regimes in a pipe were classified by Osborne Reynolds

of pipeline systems: -

(in the early twentieth century) into three categories: -

Table 4.1 Noise limiting flow velocities in

plastic pipeline systems
Medium carried
Liquid under suction
Liquid under delivery
Gas
12

4.2 Flow regimes in pipeline system

Maximum velocity (m/s)

1
3
25

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.

Reynolds identified these categories by calculating a

The friction factor ( f ) can also be determined graphically

dimensionless group of three flow parameters, later given

using the Moody diagram (Chart 4.1) shown at the end of

the name Reynolds number, which is defined by:-

this chapter.
DArcy presented the following relationship to determine the
Head loss ( H ) due to frictional resistance to the flow
f

Where

in pipelines: -

Re

Reynolds number

Flow velocity (m/s)

Pipe internal diameter (m)

2
Hf = 4 f L u
2g
d

Kinematic viscosity (m/s), see table 4.2 below

Where

Table 4.2 Kinematic viscosity of water

Coefficient of friction

Length of pipe (m)

Acceleration due to gravity (9.81m/s)

Temperature

Kinematic viscosity (m/s x 10-6)

Flow velocity (m/s)

1.752

Pipe internal diameter (m)

1.501

Usually hydraulic loss is evaluated in metres per 100m length

10

1.300

(i.e. L = 100) so the above formula can be simplified to: -

15

1.137

20

1.004

25

0.893

30

0.800

35

0.722

40

0.656

45

0.600

50

0.551

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

HO ) is calculated as the

Reynolds concluded that if Re is less than 2000 the flow is

and the associated hydraulic loss (

clearly laminar and when Re is over 4000 the flow is clearly

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

turbulent. However when Re is between 2000 and 4000 the

approaching fluid: -

flow is transient and the flow prediction is not reliable.

HO = ( k i )

Table 4.3 Reynolds flow regimes

Regime
Laminar

Reynolds number (Re )

<2000

Transient

2000 - 4000

Turbulent

>4000

u2
2g

Acceleration due to gravity (9.81m/s)

Characteristics

Flow velocity (m/s)

Streamline flow

Where

Unsettled flow
Very mixed flow

4.3 Pressure losses due to friction

in pipelines

The sum of k-values for fittings and valves for

the pipe system, see tables 4.5 and 4.6

Table 4.5 Obstruction loss coefficient for fittings

Obstruction

Pipe entry

0.5

The coefficient of friction which is an indication of the

Pipe exit

resistance the pipe surface offers to the flow is dependent on

90 elbow

0.40

the value of the Reynolds number and the roughness of the

45 elbow

0.30

90 bend

0.60

45 bend

0.40

Tee straight through

0.80

Tee branch 90

0.95

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 4.4 Friction coefficients

Regime
Laminar

Reynolds number (Re)

<2000

Transient

2000 - 4000

Turbulent

>4000

1.0

Sudden enlargement diameter ratio

1:2

0.15

1:3

0.19

1:4

0.24

1:5

Coefficient of friction ( f )

0.30
Sudden contraction diameter ratio

16/Re

5:1

0.40

No data

4:1

0.37

0.079 Re -0.25

3:1

0.33

2:1

0.30

2
13

Pipeline System Design

Worked example 4.2

Table 4.6 Obstruction loss coefficient for valves

Valve

25% Open

50% Open

75% Open

100% Open

10.53

5.54

1.25

0.28

Diaphragm

1.94

1.59

1.39

1.25

Butterfly

3.74

0.42

0.14

0.10

Non-return

6.37

3.5

2.1

1.0

Ball

A HPPE pipeline system, pumping water, comprises the

following items: Pipe

Length

200m

Outside diameter

110mm

Wall thickness

10mm

Fittings 2x 90 bends

k = 0.6

1x pipe entry

k = 0.5

1x pipe exit

k = 1.0

4.5 Pump rating

4.5.1 Hydraulic losses in pipeline systems

1x butterfly valve (25% open) k = 3.74

The pump in a fluid pipeline system has to: Overcome frictional losses,

(a) Determine the total hydraulic and pressure losses of this

system when the flow rate of water is 30 l/s if the

Overcome obstruction losses due to valves and fittings,

operating temperature is 10C. (Take the viscosity of

The total hydraulic loss (metres) is therefore given by

water from table 4.2)

(b) Determine the pump power to deliver this flow rate to a
point situated 20m above the source given the pumps

Transfer the fluid at the required flow rate between

hydraulic efficiency is 80%.

two stations,
The static-lift is the physical difference in elevation between

Solution

the two stations in metres.

(a)

4.5.2 Pressure losses in pipeline systems

The relationship between head loss and pressure loss is
given by: -

Where

Hence flow
is turbulent.

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: -

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

Where
Q

Volumetric flow rate

Total pressure losses

Hydraulic efficiency of pump

P = g Hlosses = 10 3 9.81 40.2

= 394 kPa

(Refer to manufacturers data)

Htotal

Total hydraulic losses

Total effective head Htotal =Hstatic-lift+ Hlosses

(Due to pipe-friction, fittings, plus static-lift)

(b) Total effective head

Htotal = Hstatic- lift + Hlosses

= 20 + 40.2
= 60.2 m
Pump power

14

= 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: -

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.

Abrupt valve closure

Determine the water hammer characteristics where the

Pump start up, shutdown or an abrupt change in speed

flow rate is 10m/h and 20m/h.

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

Solution
Property

is minimised: 1. The velocity of the pressure wave (m/s)

Flow rate (m/h)

10

20

1. Pressure wave velocity

244 m/s

244 m/s

1.83 m/s

3.65 m/s

4.46 bar

8.92 bar

8.86 bar

13.32 bar

-0.06 bar

-4.52 bar

2.46 second

2.46 second

-4.63 bar

-4.63 bar

-2.31 bar

-2.31 bar

1.54

1.02

2. Initial wave velocity

Where

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

u
3.1 Maximum pressure

2. Pressure fluctuation consists of both an upper and lower

pressure limit and these must be kept within the pipes

3.2 Minimum pressure

pressure characteristics, such that the upper limit is within

the pipes maximum operating pressure and the lower

4. Critical wave period

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

Where u is the velocity change (m/s).

The pressure fluctuation results in upper and lower limits of

Maximum allowable
negative pressure

operation and is defined as:The maximum pressure:

Effective safety factor

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.

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
15

Pipeline System Design

Chart 4.1 The Moody diagram
0.08
0.05

0.07

0.04

0.06

0.02

0.01

0.03

0.005

0.02

Relative roughness

0.04
Friction factor

0.03

Transient zone

0.05

0.001

0.0005
0.0001
0.01
Laminar flow

Turbulent flow
0.00001

0.008
103

104

105

106

107

108

Reynolds number

5
16