08 Pipeflow

Pipe flow
April 8 and 15, 2008
Pipe Flow
Larry Caretto Mechanical Engineering 390
Outline
Laminar and turbulent flows Developing and fully-developed flows Laminar and turbulent velocity profiles: effects on momentum and energy Calculating head losses in pipes
Major losses from pipe only Minor losses from fittings, valves, etc.
Fluid Mechanics
Noncircular ducts
2
Piping System
Fundamentals of Fluid Mechanics, 5/E by Bruce Munson, Donald Young, and Theodore Okiishi Copyright 2005 by John Wiley & Sons, Inc. All rights reserved.
What We Want to Do
Determine losses from friction forces in straight pipes and joints/valves
Will be expressed as head loss or pressure drop hL = P/
Will show that this is head loss in energy equation if variables other than pressure change
System consists of
Straight pipes Joints and valves Inlets and outlets Work input/output
Losses in straight pipes are called major losses Losses in fittings, joints, valves, etc. are called minor losses Minor losses may be greater than major losses in some cases
Pipe Cross Section

Most pipes have circular cross section to provide stress resistance Main exception is air conditioning ducts Consider round pipes first then extend analysis to non-circular cross sections
Extension based on using same equations as for circular pipe by defining hydraulic diameter = 4 (area) / (perimeter), which is D for circular cross sections
5
The Pipes are Full

Consider only flows where the fluid completely fills the pipe Partially filled pipes are considered under open-channel flow
Driving force is pressure
Fundamentals of Fluid Mechanics, 5/E by Bruce Munson, Donald Young, and Theodore Okiishi. Copyright 2005 by John Wiley & Sons, Inc. All rights reserved.
Driving force is gravity

6
ME 390 Fluid Mechanics
Pipe flow
Laminar vs. Turbulent Flow
Laminar vs. Turbulent Flow II

Most flows of engineering interest are turbulent
Analysis relies mainly on experimentation guided by dimensional analysis Even advanced computer models, called computational fluid dynamics (CFD) rely on turbulence models that have large degree of empiricism
Laminar flows have smooth layers of fluid
Turbulent flows have fluctuations
Can get some (very limited) analytical results for laminar flows
8
7 Fundamentals of Fluid Mechanics, 5/E by Bruce Munson, Donald Young, and Theodore Okiishi. Copyright 2005 by John Wiley & Sons, Inc. All rights reserved.
Laminar vs. Turbulent Flow III

Condition of flow as laminar or turbulent depends on Reynolds number For pipe flows
Re = VD/ < 2100 is laminar Re = VD/ > 4000 is turbulent 2100 < Re < 4000 is transition flow
Flow Development
Other flow geometries have different characteristics in Re = VLc/ and different values of Re for laminar and turbulent flow limits
9 10 Fundamentals of Fluid Mechanics, 5/E by Bruce Munson, Donald Young, and Theodore Okiishi. Copyright 2005 by John Wiley & Sons, Inc. All rights reserved.
Developing Flows
Entrance regions and bends create changing flow patters with different head losses Once flow is fully developed the head loss is proportional to the distance Entrance pressure drop is complex
Complete entrance region treated under minor losses Will not treat partial entrance region here
11
Developing Flows II
Entrance regions and bends create changing flow patters with different head losses Once flow is fully developed the head loss is proportional to the distance
12 Fundamentals of Fluid Mechanics, 5/E by Bruce Munson, Donald Young, and Theodore Okiishi. Copyright 2005 by John Wiley & Sons, Inc. All rights reserved.
Pipe flow
Developing Flows III

After development region, pressure drop (head loss) is proportional to pipe length Equations for entrance region length, e
Laminar flow: Turbulent flow:
le = 0.06 Re D le = 4.4 Re1 6 D
13
Fluid Element in Pipe Flow
Turbulent flow rule of thumb e 10D
Look at arbitrary element, with length , and radius r, in fully developed flow What are forces on this element?
14
Fully Developed Flow

No change in momentum Flow Direction
Extend Relation to Wall
= r 2 p1 r 2 ( p1 p ) 2rl = 0
2l p = r
Pressure drop is due to viscous stresses
Have p = 2/r for any r: 0 < r < R = D/2 For wall r = R = D/2 and = w = wall shear stress: p = 2w/R = 4w/D
Fundamentals of Fluid Mechanics, 5/E by Bruce Munson, Donald Young, and 15 Theodore Okiishi. Copyright 2005 by John Wiley & Sons, Inc. All rights reserved.
16
Fully Developed Laminar Flow

Can get exact equation for pressure drop
p = 128lQ D 4
Fully Developed Laminar Flow II

r 2 u = uc 1 R
Laminar shear stress profile found from du = dr
uc
Laminar r 2 velocity u = uc 1 R profile 17
du 2r 8u = uc 2 = 2c r dr R D
18
Pipe flow
Fully Developed Laminar Flow III

r Q = VA = VR 2 = udA = u 2rdr = uc 1 2rdr R 0 0 A
Effect of Velocity Profile

Momentum and kinetic energy flow for mean velocity, V
& FlowMomentum = m V = VAV = V2(R2) & V2/2 = VAV2/2 = V3(R2)/2 FlowKE = m
What is centerline velocity, uc?
R R 3 R r2 R2 r4 r dr = 2uc 2 = 2uc Q = 2uc rdr 4 R2 0 2 4R 0 0
Accurate representation uses profile

R r 2 4 FlowMomentum = udAu = uc 1 2 2rdr = V 2 A R 3 A 0 2
R2 Q = uc 2
uc =
2Q R 2
2VA R 2
2VR 2 R 2
= 2V
FlowKE = udA
A
Centerline uc is twice the mean velocity, V 19
R V3 u 2 1 r 2 = uc 1 2 2rdr = 2A R 2 2 2 0
20
Turbulent Flow
For laminar and turbulent flows, the velocity at the wall is zero
This is called the no-slip condition Momentum is maximum in the center of the flow and zero at the wall
Laminar flows: momentum transport from wall to center is by viscosity, = du/dr Turbulent flows: random fluctuations exchange eddies of high momentum from the center with low momentum flow from near-wall regions
21
Turbulent Flow Quantities

Velocities at one point as a function of time
u=
1 T
t0 +T t0
u(t )dt
u(t) = instantaneous velocity u = velocity fluctuation = u u
Momentum Exchange
Turbulence Regions/Profiles
turbulent eddy viscosity,
= ( + )
du dr
Laminar flow random molecular motion
Turbulent flow eddies have structure
Very thin viscous sublayer next to wall 0.13% of R = 3 in for H20 at u = 5 ft/s Flat velocity profile in center of flow
Pipe flow
Profile
u r = 1 Vc R
1n
Effect of Velocity Profile

Analysis similar to one used for laminar flow profile
Determine momentum and kinetic energy flow for mean velocity Correction factor multiplies average V results to give integrated u2 and u3 values n Re 6 1.5x104 8 4x105 10 3x106 Momentum 1.027 1.016 1.011 KE 1.077 1.046 1.031
n = 6: Re = 1.5x104; Vc/V = 1.264 n = 8: Re = 4x105; Vc/V = 1.195 n = 10: Re = 3x106; Vc/V = 1.155 Laminar: Vc/V = 2 V = Q/A
Turbulent velocity profiles with n a function of Reynolds number

25
26
Pipe Roughness
Effect of rough walls on pressure drop may depend on surface roughness of pipe Typical roughness values for different materials expressed as roughness length, , with units of feet or meters Only turbulent flows depend on roughness length, laminar flows do not
27
Pipe roughness effects in viscous sublayer affects pressure drop in turbulent flow No effect on laminar flow
28
Use this table (p 433 of text) to find
Energy Equation
Energy equation between inlet (1) and outlet (2) p V2 p V2 z2 + 2 + 2 = z1 + 1 + 1 + hs hL 2g 2g Previous applications allowed us to compute the head loss from all other data in this equation
Call this the measured head loss
We can compute it, but we have no way of knowing its cause
30
29
Pipe flow
Pressure Drop/Head Loss

We now seek a design calculation for hL Use level pipe (z1 = z2) with constant area (V1 = V2) and no shaft head (hs = 0)
p2 V22 p V2 + = z1 + 1 + 1 + hs hL 2g 2g p1 p2 p hL = = Calculated p for z1 = z2, V1 = V2, and hs = 0 gives hL for more general flows z2 +
31
Pressure Drop/Head Loss

We now seek a design calculation for hL Use level pipe (z1 = z2) with constant area (V1 = V2) and no shaft head (hs = 0)
Will use friction factor f for p in such flows, but we are really getting hL
Extend to more general flows later
hL =
p1 p2 p =
32
Head Loss in Pipes

Dimensional analysis shows that dimensionless pressure drop, p/V2, is a function of Reynolds number, VD/, the /D ratio and relative roughness, /D Expressed in terms of friction factor, f
f = p = 1 l V 2 2D hL f = 1 l V 2 2D VD f ,D
hL = f l V 2 D 2g
33
How do we get f?
Have said that f = f(Re, /D) What is form of this relationship? For laminar flow we will later show that f = 64/Re Relationship determined experimentally with empirical fit to equations for turbulent flows Results expressed as Moody diagram
34
Moody Diagram
Moody Diagram Equations

Colebrook equation 1 (turbulent) f Haaland equation (turbulent)
D 2.51 = 2.0 log10 + 3.7 Re f
6.9 D 1.11 1 1.8 log10 + Re 3.7 f
128lQ 256 2 V D 64 64 p D 4 = D 3 4 f = = = = VD Re 1 l 1 l 2 2 V 2 V V 2D 2D
35 36
Laminar
Pipe flow
Wholly Turbulent Flows

Large Reynolds numbers: f independent of Re depends only on /D
p = f l V 2 D 2 V= Q Q = A D2 4 V2 = 16 Q 2 2 D 4
Pressure Drop Problems

Find the pressure drop given fluid data, pipe dimensions, , and flow (volume flow, mass flow, or velocity)
Get A = D2/4 & Get V = Q/A or V = m/A if not given V Find and for fluid at given T and P Compute Re = VD/ and /D Find f from diagram or equation
Laminar f = 64/Re; Colebrook for turbulent
p = f
& l 2 l 16 Q 2 8 fl Q 2 8 fl m 2 V = f = 2 = 2 2 4 5 D2 D2 D D D 5
Pressure drop varies as D-5

Similar to D-4 dependence in laminar flow
37
Compute p = f (/D) V2/2

38
Sample Problem
You have been asked to size a pump for an airport fuel delivery system. JP-4 fuel ( = 1.50 slug/ft3, = 1.2x10-5 slug/fts) has to travel 0.5 mi through commercial steel, schedule 40 pipe with a nominal 6 in diameter. The flow rate is 5 slug/s. What is the head loss? Schedule 40 pipe: OD = 6.625 in; thickness = 0.280 in; ID = 6.065 in
39
Sample Problem Solution

D = (6.065 in ) ft = 0.5054 ft 12 in A=
5 slug & m 16.61 ft s = = V= s A 1.50 slug 0.2006 ft 3 ft 3
2 D = (0.5054 ft )2 = 0.2006 ft 2 4 4
VD Re = =
1.50 slug 16.61 ft (0.5054 ft ) s ft 3 = 1.05 x106 > 4100 1.2 x10 5 slug ft s Since Re >
4,100, flow is turbulent
40
Sample Problem Solution II

0.00015 ft = 0.00015 for commercial = = 0.000297 steel (Table 8.1, page 433) D 0.5054 ft
Sample Problem Solution III

P = f
2 2 l V 2 0.0156 0.5 mi 5280 ft 1.50 slug 1 lb f s 16.61 ft = 3 D 2 2 0.5054 ft mi slug ft s ft
Find f from Moody diagram (page 434)
P =
& Wshaft & mg
16876 lb f ft 2
117.2 lb f in 2
= 117.2 psi
f (Re = 1.05 x106 , D = 0.000297) = 0.0155

Check f value with Colebrook equation
D 2.51 1 = 2.0 log10 + 3.7 Re f f 2.51 = 2.0 log10 0.000297 + 3.7 1.05 x106 0.0155 1 1 = 8.005 f = = 0.0156 f 8.0052
For shaft head to overcome this lead loss

net in
= hs hL =
P P = g
& mP & Wshaft net in
& Wshaft
net in
& mP =
Use f = 0.0156
41
5 slug 16876 lb f s hp s ft 2 = 102 hp 1.50 slug 550 ft lb f 3 42 ft
Pipe flow
Pressure Drop Problems II

Find the diameter for a given pressure drop given fluid data, , and flow (volume flow, mass flow, or velocity)
Find and for fluid at given T and P Guess D; get A = D2/4 & Get V = Q/A or V = m/A if not given V Compute Re = VD/ and /D Find f from diagram or equation
A Harder Problem
You have a 200 hp pump to deliver 5 slug/s of JP-4 fuel ( = 1.50 slug/ft3, = 1.2x10-5 slug/fts) over 0.5 mi. What diameter of commercial steel, schedule 40 pipe should be used? Compute required p
& Wshaft prequired =
43
Compute pcalculated = f (/D) V2/2 Iterate on D until pcalculated = prequired
net in
& m
550 ft lb f 1.50 slug (200 hp ) 3 33000 lb f hp s ft = = 5 slug ft 2 s

44
Iterative Solution
The calculation we just did for D = 6.065 in gave p = 16876 psf an error of 16876 psf 33000 psf = 16124 psf
Count Dguess (in) pcomputed (psf) 1 6.065 16876 Error (psf) 16124
Iterative Problem Solution

D = (5 in ) ft = 0.4167 ft 12 in A=
5 slug & m 24.45 ft s V= = = s A 1.50 slug 0.1364 ft 3 ft 3
2 D = (0.4167 ft )2 = 0.1364 ft 2 4 4
Take second guess of D = 5 in and repeat calculations done previously to find pcomputed
45
VD Re = =
1.50 slug 24.45 ft (0.1364 ft ) s ft 3 = 1.27 x106 > 4100 1.2 x10 5 slug ft s Since Re >
4,100, flow is turbulent
46
Iterative Problem Solution II

0.00015 ft = = 0.00036 D 0.4167 ft
= 0.00015 for commercial steel (Table 8.1, page 433)
P = f
Iterative Problem Solution III

2 2 l V 2 0.0160 0.5 mi 5280 ft 1.50 slug 1 lb f s 24.45 ft = 3 D 2 slug ft s 2 0.4167 ft mi ft
f (Re = 1.27 x10 , D = 0.000297) = 0.0159

6
P =
45564 lb f ft
2
316.4 lb f in 2
= 316.4 psi

D 2.51 1 = 2.0 log10 + 3.7 Re f f 2.51 = 2.0 log10 0.00036 + 3.7 1.27 x106 0.0159 1 1 = 7.894 f = = 0.0160 f 7.8942
We now have two iterations

Count Dguess (in) pcomputed (psf) 1 2 6.065 5 16876 45564 Error (psf) 16124 12564
48
Use f = 0.0160
47
Pipe flow
Iterative Problem Solution IV

Use linear interpolation to get new guess, Di+1 that sets error ei+1 to zero
Di +1 = Di + Di +1 = Di ei
D D Di Di 1 (ei +1 ei ) = Di ei ei e i 1 ei ei 1 i i 1
Iterative Problem Solution V

Continue iterations until error is small
Count Dguess (in) pcomputed (psf) 1 2 3 4 5 6 6.065 5 5.466 5.349 5.321 5.323 16876 45564 28780 32176 33072 32999 Error (psf) 16124 12564 4219 823 72 1
50
Di Di 1 5 6.065 = 5 12564 = 5.466 ei ei 1 12564 ( 16124 )
Count Dguess (in) pcomputed (psf) 1 2 6.065 5 16876 45564
Error (psf) 16124 12564

49
Iterations and Reality

Commercial pipe and tubing only comes in fixed sizes
Extra iterations not needed once the minimally acceptable commercial size is found In this case available nominal diameters are 5 in and 6 in with actual inside diameters of 5.047 in and 6.065 in (for Schedule 40) Only choice is 6 in (nominal)
51
Pressure Drop Problems III

Find the flow rate for a given pressure drop given fluid data, , and diameter
Get A = D2/4 Find and for fluid at given T and P Guess V Compute Re = VD/ and /D Find f from diagram or equation
Compute pcalculated = f /D V2/2 Iterate on V until pcalculated = prequired & Compute Q or m as desired
52
Different Friction Factors

The friction factor definition we are using here is the common one
Called the Darcy friction factor if clarification is needed
Minor Losses
Determine pressure drop (head loss) in a variety of flow passages
Entrance into a piping system Exit from a piping system Expansion in a piping system Contraction in a piping system Valves of various types (with different opening fractions) Fittings (elbows, tees, bends, unions)
53 54
Another definition, called the Fanning friction factor is sometimes seen

Fanning factor = w / (V2/2)
From the relationship that w = Dp/4 we get the result that the Fanning factor is one fourth of the Darcy factor
Pipe flow
Minor Losses
Fittings in pipe systems modeled as loss coefficients, KL
V2 hL = K L 2g p L V2 = KL 2g g V 2 p L = K L 2
pL = K L
V 2 V = Pipe velocity 2 Entrance Losses
Reentrant: KL = 0.8
Sharp edged: KL = 0.5
KL depends on geometry and Re

For flows dominated by inertia effects KL is a function of geometry only
r D
Alternative process, not given here, uses equivalent length for minor losses
55
Slightly rounded: KL = 0.2
Well rounded: 56 KL = f(r/D)
Rounded Inlet KL
Slightly rounded KL = 0.2 for r/D = 0.055
Full KE loss cannot be recovered in sharp-edged entrance

r/D = 0 is square inlet

58
New Area
Sudden contraction (left) Reentrant
KL = 1 for all exit flows
Sharp edged For sudden expansion (right) KL = ( 1 A1/A2)2
Slightly rounded
Well rounded
59
60
10
Pipe flow
61
62
Problem with Minor Losses

4 kg/s of oil with SG = 0.82 and = 0.05 kgm/s2 is pumped from one tank to another. The line of 2-in Schedule-40 pipe has a total length of 40 m, with two gate valves and six elbows (regular flanged 90o). The entrance is rounded with an r/D ratio of 0.1. Find pressure loss with both valves open 2-in schedule 40 pipe has OD = 2.375 in and thickness = 0.154 in, so ID = 2.067 in = 0.05250 m
63
Problem Solution
= (SG ) ref = A = D 2 = (0.05250 m )2 4 4 999 kg 819.2 kg 2 (0.82) = = 0.002165 m s s 4 kg & m 2.26 m s V= = = s A 819.2 kg 0.002165 m3 m3
VD Re = =
819.2 kg 2.26 m (0.05250 m ) s m3 = 1940 < 2100 0.050 kg ms Since Re <
2,100, flow is laminar
64
Problem Solution II
Find pmajor directly from laminar flow equation
Q= & 0.04883 m m 4 kg m = = s 819.2 kg s
3 3
Problem Solution III

pminor = (Loss coefficient sum) times V2/2
pminor =
Could also use f = 64/Re
pmajor
3 N (128) 0.05 2 s (40 m ) 0.004883 m 52369 N 128lQ s m = = = 52.369 kPa = D 4 m2 (0.05250 m )4
( K L ) V 2
3.07 819 kg 2.26 m 1 N s 2 6,397 N = 2 m3 s kg m m2
Minor losses coefficients: rounded entrance (r/D = 0.1), KL = 0.12; exit, KL = 1; fully open gate valve, KL = 0.15; 6 elbows, KL = 6(0.3) = 1.8. Total KL = 0.12 + 1 + 0.15 + 1.8 = 3.07
65
ptotal = pmajor + pminor = ptotal = 58,766 N m2
52,369 N m2
6,397 N m2
= 58.8 kPa
66
11
Pipe flow
Noncircular Ducts
Define hydraulic diameter, Dh = 4A/P
A is cross-sectional area for flow P is wetted perimeter For a circular pipe where A = D2/4 and P = D, Dh = 4(D2/4) / (D) = D
Dh =
Re h =
4A P
VD
For turbulent flows use Moody diagram with D replaced by Dh in Re, f, and /D For laminar flows, f = C/Re (both based on Dh) see next slide for C values
67
P = f
P =
l V 2 Dh 2
2C lQ 4 Dh
68
Problem
An 10-in-square, commercial steel air conditioning duct contains air at 80oF and atmospheric pressure and has a flow rate of 125 ft3/min. Find the pressure drop per unit duct length Property data at 80oF (Table B.3) = 0.002286 slug/ft3; = 1.69x10-4 ft2/s Solution: find Reh to see if flow is laminar or turbulent then find f and p
69
Solution
4 A 4 L2 = =L Dh = P 4L = 10 in = 0.8333 ft
V= Q = A 125 ft 3 min min 60 s
2 (10 in ) ft 2 144 in 2
3 ft s
Re h =
3 ft (0.8333 ft ) VDh = s = 1.78 x105 1.69 x10 4 ft 2 s
Turbulent flow for Reh > 4100
0.00015 ft = = 0.00018 D 0.8333 ft
= 0.00015 for commercial steel (Table 8.1, page 433)

70
Solution II
Recommended Air Velocity

Air Ducts Combustion air ducts Air inlet to boiler room Warm air for house heating Vacuum cleaning pipe Compressed air pipe Ventilation ducts (hospitals) Ventilation ducts (offices) Air Velocity m/s ft/s 12 - 20 40 - 66 1-3 3.3 - 9.8 0.8 - 1.0 2.6 - 3.3 8 - 15 26 - 49 20 - 30 66 - 98 1.8 - 4 5.9 - 13 2.0 - 4.5 6.5 - 15
72
f (Re = 1.27 x10 , D = 0.00018) = 0.0172

6

D 1 2.51 = 2.0 log10 + 3.7 Re f f 1 = 7.611 f f = 1 7.6112 2.51 = 2.0 log10 0.00018 + 3.7 1.78 x105 0.0172 = 0.0173
Use f = 0.0173
5 2 2 P 1 V 2 0.0173 1 0.00229 slug 1 lb f s 3 ft 1.78 x10 lb f = f = = l D 2 2 0.8333 ft slug ft s ft 3 ft 3

71
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Pipe flow

April 8 and 15, 2008

Pipe Cross Section

The Pipes are Full

Driving force is pressure

Driving force is gravity

ME 390 Fluid Mechanics

April 8 and 15, 2008

Laminar vs. Turbulent Flow

Laminar vs. Turbulent Flow II

Laminar flows have smooth layers of fluid

Turbulent flows have fluctuations

Laminar vs. Turbulent Flow III

ME 390 Fluid Mechanics

April 8 and 15, 2008

Developing Flows III

Fluid Element in Pipe Flow

Turbulent flow rule of thumb e 10D

Fully Developed Flow

Extend Relation to Wall

Pressure drop is due to viscous stresses

Fully Developed Laminar Flow

Fully Developed Laminar Flow II

Laminar r 2 velocity u = uc 1 R profile 17

ME 390 Fluid Mechanics

April 8 and 15, 2008

Fully Developed Laminar Flow III

Effect of Velocity Profile

What is centerline velocity, uc?

R R 3 R r2 R2 r4 r dr = 2uc 2 = 2uc Q = 2uc rdr 4 R2 0 2 4R 0 0

Accurate representation uses profile

Centerline uc is twice the mean velocity, V 19

Turbulent Flow Quantities

u(t) = instantaneous velocity u = velocity fluctuation = u u

Laminar flow random molecular motion

Turbulent flow eddies have structure

ME 390 Fluid Mechanics

April 8 and 15, 2008

Effect of Velocity Profile

Turbulent velocity profiles with n a function of Reynolds number

Use this table (p 433 of text) to find

ME 390 Fluid Mechanics

April 8 and 15, 2008

Pressure Drop/Head Loss

Pressure Drop/Head Loss

Head Loss in Pipes

Moody Diagram Equations

6.9 D 1.11 1 1.8 log10 + Re 3.7 f

ME 390 Fluid Mechanics

April 8 and 15, 2008

Wholly Turbulent Flows

Pressure Drop Problems

Pressure drop varies as D-5

Compute p = f (/D) V2/2

Sample Problem Solution

4,100, flow is turbulent

Sample Problem Solution II

Sample Problem Solution III

Find f from Moody diagram (page 434)

f (Re = 1.05 x106 , D = 0.000297) = 0.0155

For shaft head to overcome this lead loss

& mP & Wshaft net in