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HOW TO CALCULATE PIPE SIZE Engineers use the formula below (1) to calculate pressure loss in liquid carrying pipelines. Its use requires specialised knowledge. However an easier method is to calculate the pipe velocity from the flow rate using various pipe diameters in the much simpler second formula (2). Then select the diameter that produces a liquid velocity between 1.5 m/s (5 ft/s) to a maximum of 3 m/s (10 ft/s). Hl = f l V 2 d2g Where (1)
Hl is the head loss (m or ft) f is the pipe wall friction factor depending on the liquids viscosity (dimensionless) l is the equivalent pipe length (m or ft) V is the liquid velocity (m/s or ft/s) d is the pipe diameter (m or ft) g is the gravitational constant (9.8 m/s2 or 32 ft/s2) Q=VA (2)
Where Q is the volume flow rate (m3/s or ft3/s) V is the velocity (m/s or ft/s) A is the area of the pipe bore (m2 or ft2) Once the flow rate is decided or known, the pipe diameter can be calculated from the area. Minimise the cost of discharge pipelines by using smaller bore pipe with velocities at the high end of the recommended range. But to keep pressure loss low on suction piping use velocities from the lower end of the range. WHERE PRESSURE LOSSES COME FROM IN PIPES Liquid moving in a pipe has to push its way along pipe walls, around bends, through valves, past projections and enclosed items. Throughout its progress friction robs energy. Three factors affect pressure loss in pipes. Surface Friction Along walls the liquid has to overcome friction. Wall friction depends on surface roughness. The higher the projections into the liquid the more the friction. At low velocities a laminar sub layer of slow flowing liquid covers the roughness. But at high velocities the sub layer thins as eddies in the turbulent center flow extend to the projections. Figure 1 shows the flow at the pipe wall. Direction Changes Liquid that is forced to change direction loses energy. When a liquid goes around a 90o bend its momentum
has to be redirected. From going at velocity in one direction it now has to go at the same velocity in a completely different direction. To do this it converts pressure into the energy it needs to change direction. A pressure loss results. The more sudden the change in direction the greater the energy it needs and the higher the corresponding pressure losses. Liquid viscosity A liquid that easily slides requires less energy to move than one that does not want to flow. Honey is thousands of times more viscous than water. Pushing honey through pipes, around corners and past valves requires far more energy than for water. If the honey was warmed it would then flow easier and the pressure loss would be less.
SURFACE ROUGHNESS
PIPE WALL
LAMINAR SUBLAYER
Figure 1 Effects of Surface Roughness on Liquid Flow MINIMISE FRICTION IN PIPELINE CONSTRUCTION During design, procurement and installation of a pipeline follow the recommendations in Table 1.
Select smooth bore pipes. 100 meters of 100mm (4) plastic pipe containing water moving at 1 m/s (3.25 ft/s) will lose 900mm (35) of pressure. The same flow in a 100mm steel seamless pipe will lose 1000mm (39) pressure. Use long radius elbows; use pipe reducers; minimise the number of flanges; use full bore straight through valves; use pipe size branch tees and reduce down on the branch (a must on suction lines); use instrumentation which does not project into the flow. Select pipe sizes that are practicable while keeping flow velocities reasonable. Make the gasket bore hole to the pipe bore diameter. Do not let the gasket project into the liquid flow path as it will cause unnecessary friction and turbulence. Weld splatter sits on the pipe surface and disrupts the liquid flow pattern. The splatter can come lose and damage down stream instruments and equipment. Like gaskets cut with the diameter less than the pipe bore, welds with high peaks project into the liquid flow. Try keep welds below the height of the sublayer thickness. Lobster back 90o bends are used when large diameter long radius bends are not available. Make them out of equal sized 15o segments instead of the usual 22.5o segments
DESIGN CONSTRUCTION
Minimise flow disruptions. Keep flow velocities low. Cut gasket holes to the bore diameter. Clean off weld splatter. Keep butt weld peaks low. Make multiple segment mitered bends.
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