Energy Conversion

Piping systems

dr. B.P.M. van Esch

Piping systems

Contents
System analysis
Bernoulli equation
Hydrostatics
Hydrodynamics
Pressure loss
Pipe friction
Minor losses
Pipe characteristic
Pipe selection

Energy conversion : Piping systems

1 / 25

Piping systems

Contents
System analysis
Bernoulli equation
Hydrostatics
Hydrodynamics
Pressure loss
Pipe friction
Minor losses
Pipe characteristic
Pipe selection

2 / 25

Energy conversion : Piping systems

Piping systems

Contents
System analysis
Bernoulli equation
Hydrostatics
Hydrodynamics
Pressure loss
Pipe friction
Minor losses
Pipe characteristic
Pipe selection

Energy conversion : Piping systems

3 / 25

Piping systems

Contents
System analysis
Bernoulli equation
Hydrostatics
Hydrodynamics
Pressure loss
Pipe friction
Minor losses
Pipe characteristic
Pipe selection

4 / 25

Energy conversion : Piping systems

System analysis
System with through-flow

Nomenclature

dU
------- = Q + W +  E i +  W v i (conservation of energy)
dt

U internal energy
Q heat flow rate
W work rate

(note: uniform velocity)

u
v

and FLOW WORK

p
W v = F p  v =  pAv =  m --

v1 , p1
Q

For steady system

1 2
Q + W +  m i  h i + --- v i + gz i
 = 0
2
i

p
with h = u + --

Energy conversion : Piping systems

[J/s]

E energy flow (rate) [J/s]

W v flow work (rate) [J/s]

with ENERGY FLOW

kin
pot
1 2
E = m  u + e + e  = m u + --- v + gz



2

[J]
[J/s]

z
m
h
p


spec. int. energy [J/kg]

velocity
[m/s]
elevation
[m]
mass flow rate
spec. enthalpy
pressure

[kg/s]
[J/kg]
[Pa]

density

[kg/m3]

z1
v2 , p2
z2

5 / 25

System analysis

Intermezzo : non-uniform velocity profiles

Flow work :

W v =

p
1
 pv dA = pA --A-  v dA = pAvavg = m ---

laminar pipe flow

2

r

v  r  = v max  1 ------
2

R 

Kinetic energy flow :

kin
E
=

 --2- v

1 2
v dA  m --- v avg
2
r
turbulent pipe flow v  r  = v max 1 ---


R

with the kinetic-energy correction factor

1n

laminar

turbulent

n=6

1.077

n=7

1.058

n=10

1.031

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Energy conversion : Piping systems

System analysis
Steady system with through-flow but without
external heat flux and work
dU
------- = 0 ; Q = 0 ; W = 0
dt

i
+ --- v
 m i  ui + --- 2 i i
i

Nomenclature

U internal energy
Q heat flow rate
W work rate

[J]
[J/s]
[J/s]

E energy flow (rate) [J/s]

W v flow work (rate) [J/s]

+ gz i = 0


u
v

if NO CHANGE IN SPECIFIC ENERGY

(no energy losses)

v1 , p1

pi 1

2
+ --- v + gz i = 0
 m i  ---i 2 i i


v3 , p3

z1

z
m
h
p


spec. int. energy [J/kg]

velocity
[m/s]
elevation
[m]
mass flow rate
spec. enthalpy
pressure

[kg/s]
[J/kg]
[Pa]

density

[kg/m3]

z3
v2 , p2
z2

Energy conversion : Piping systems

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Bernoulli equation
Nomenclature

pi 1

2
+ --- v + gz i = 0
 m i  ---i 2 i i

i

U internal energy
Q heat flow rate
W work rate

steady flow

For

pipe flow

(conservation of mass)

v1 , p1

i = 1 2

spec. int. energy [J/kg]

velocity
[m/s]
elevation
[m]

z
m
h
p


streamtube

[J/s]

E energy flow (rate) [J/s]

W v flow work (rate) [J/s]

inviscid (no losses)

m i = 0

[J]
[J/s]

mass flow rate

spec. enthalpy
pressure

[kg/s]
[J/kg]
[Pa]

density

[kg/m3]

so
2
--p- + 1
--- v + gz = const
 2

z1
v2 , p2

--> BERNOULLI EQUATION

z2

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Energy conversion : Piping systems

Hydrostatics
No fluid velocity :

p + gz = const

Pressure in (incompressible) fluid

patm
z2

p atm +  w gz 2 = p +  w gz 1
so

p = p atm +  w g  z 2 z 1 

z1

p = p atm +  w gh

z=0

Buoyancy force
patm

p t = p atm +  w gh t
p b = p atm +  w gh b
F buo =  p b p t A =  w g  h b h t A =  w gV

Fbuo

pt
pb

ht

A
hb
A

so, buoyancy force is equal to weight of displaced water

F buo = m w g

(Archimedes)

Energy conversion : Piping systems

9 / 25

Hydrostatics
No fluid velocity :

p + gz = const

Examples

z2

Barometer :

p atm + gz 1 = p 2 + gz 2

p 2 = p v  T  p atm
p atm = gh

z1 = 0

Manometer :

p A +  1 gz 1 = p B
pB = pC
p D +  2 gz 2 = p C

z1

p A = p atm +   2 z 2  1 z 1 g

( p D = p atm )

z2
C

2
z=0

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Energy conversion : Piping systems

Hydrodynamics
p1

Bernoulli equation
2
1
p + ---  v + gz = const
2

(no losses , assume = 1 )

p1
g

v1

v1
2g

p2

z1

p2
g
2

v2

z1

z2

v2
2g

z2

Examples
Fountain :

z2

1 2
p atm + --- v + gz 1 = p atm + gz 2
2

v
h = -----2g

z1

Pump :

1 2
p atm + gh = p s + --- v + gH
2
1 2
p s = p atm g  H h  --- v
2

Energy conversion : Piping systems

v
patm

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Pressure loss
Inviscid flow asssumed (no losses)

patm

1 2
p atm + gh 1 = p 1 + --- v
2

h1

p1
H

1 2
1 2
p 1 + --- v + g  H h 1 + h 2  = p 2 + --- v
2
2

gH = 0

patm

1 2
p 2 + --- v = p atm + gh 2
2

p2

h2

No losses invalid assumption

p


1 2
2

Conservation of energy states u + --- + --- v + gz = const

p1 1 2
p2 1 2
p1 1 2
p loss
p2 1 2
u 1 + ----- + --- v 1 + gz 1 = u 2 + ----- + --- v 2 + gz 2 or ----- + --- v 1 + gz 1 = ----- + --- v 2 + gz 2 + --------------- with p loss =   u 2 u 1 
 2
 2
 2
 2

modified Bernoulli equation
In the example above : p loss = gH

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Energy conversion : Piping systems

Pressure loss

Modified Bernoulli equation

p1 1 2
p loss
p
2
----- + --- v 1 + gz 1 = ----2- + 1
--- v + gz 2 + ------------- 2
 2 2


p1

p1
g

v1
z1

p2

ploss

p2
g

z1

v2
2g
z2

v1
2g

v2

Energy conversion : Piping systems

z2

13 / 25

Pressure loss
v

Viscosity leads to shear stress

v
F = A with  =  --h
or in general

(Newtonian fluid)

dv
 =  -----dy

fluid-wall and fluid-fluid shear stress

Couette flow

Force balance in pipe flow

 p  p + dp  r = 2rdx
dv
 =  -----dr

D
(laminar flow)

pr2

(p+dp)r2

leads to

dx
2

2
R 

velocity profile v  r  = v max  1 ------

L1
D2

pressure loss p loss = f ---- --- v

laminar pipe flow

64
Re

vD


with friction factor f = ------ ; Re = -----------

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Energy conversion : Piping systems

Pipe friction
Force balance in pipe flow

laminar pipe flow

 p  p + dp  r = 2rdx

2

r

v  r  = v max  1 ------
2

R 

Laminar flow Re  2300

dv
 =  -----dr

r
turbulent pipe flow v  r  = v max 1 ---


R

Turbulent flow Re  2300

dv
 =   +  t  -----dr

1n

 t =  t  Re r  R  turbulent viscosity

Presure loss in pipe flow

L 1 2
p loss = f ------- --- v
Dh 2
Laminar flow

64
vD
f = ------ ; Re = ----------Re


Turbulent flow f = f  Re D h   

Energy conversion : Piping systems

vD h
Re = -------------

4A
D h = ------O
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Pipe friction
Re - number
1 . 10 2
0.10
0.09
0.08
0.07
0.06

1 . 10 3

1 . 10 4

1 . 10 5

1 . 10 6

D/ = 20

0.05

50

0.04

friction factor f

1 . 10 7

100

0.03

200
500

0.02

1000
2000
5000
10.000
20.000
50.000
100.000
inf

0.01

Moody diagram

laminar

L 1 2
p loss = f ------- --- v
Dh 2

transition

f = f  Re D h   

turbulent
;

vD h
Re = -------------

4A
D h = ------O
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Energy conversion : Piping systems

Pipe friction
Pipe roughness

material

state

seamless metal pipe (copper,

brass, bronze, tin, aluminium)

new, smooth

0.0013-0.0015

plastic, glass, Plexiglas

rubber (high pressure)

new
new

0.0013-0.0015
0.0016

steel

rolled (seamless)
rolled (welded)
galvanized (seamless)
galvanized (welded)
corroded, moderate
corroded, extensive

0.02 - 0.06
0.04 - 0.1
0.07 - 0.16
0.008
0.15 - 0.2
tot 3

cast iron

new
new with bitumen
corroded, light
corroded, extensive

0.2 - 0.6
0.1 - 0.13
0.5 - 1.5
tot 3

concrete / clay

new

0.3 - 0.8

Energy conversion : Piping systems

[mm]

17 / 25

Minor losses
Minor losses I
p loss =

 Ki 1--2- vi2

square edged inlet

K = 0.5

basket strainer
K = 1.3

inward protruding inlet

K = 1.0

well rounded or bell mouth inlet

K = 0.05

foot valve
K = 0.8

exit
K = 1.0

convergent outlet or nozzle

D1

D2

K = 0.1 (1 - D2 / D1)
D2 / D1 from 0.5 to 0.9

90 elbow

threaded

flanged or glued

regular

long radius

regular

long radius

K = 1.4

K = 0.75

K = 0.31

K = 0.22

45 elbow
regular

regular

K = 0.35

K = 0.17

regular

regular

long radius

K = 1.5

K = 0.3

K = 0.2

return bend

T-joint

line flow

branch flow

line flow

branch flow

K = 0.9

K = 1.9

K = 0.14

K = 0.69

18 / 25

Energy conversion : Piping systems

Minor losses
coupling

check valves

Minor losses II
p loss =

 Ki 1--2- vi2

threaded

: K = 0.08

swing type

: K = 2.5

flanged or glued

: K = 0.08

ball type

: K = 70

reducing bushing
p = K 21 v22

K = 0.5 - 0.167 (D2 / D1) - 0.125 (D2 / D1)2 - 0.208 (D2 / D1)3
D1

D2

6 < D < 25 mm

sudden expansion

D1

D2

p = K 21 v22

K = 0.93 - 0.592 (D2 / D1) - 3.625 (D2 / D1)2 - 2.803 (D2 / D1)3
6 < D < 25 mm

angle valve

globe valve

fully open K = 10

gate valve

fully open K = 2

fully open K = 0.15

0

fraction closed :
K :

ball valve

1/4 3/8 1/2 5/8 3/4 7/8

0.26 0.81 2.06 5.52 17.0 97.8

fully open K = 0.05

Energy conversion : Piping systems

0.15

o :
K

10

20

30

40

50

60

: 0.05 0.29 1.56 5.47 17.3 25.6 206

70

80

485 inf

19 / 25

Remarks
Developed pipe flow
Friction factors f only valid for fully developed pipe flow.
Inlet length l A for circular pipes
b

l A  A Re D

v gem D
Re = -------------------

with

A  0.06 ; b  1

: laminair flow ( Re  2300 )

A  0.6 ; b  0.25 : turbulent flow ( Re  2300 )

Interaction between accessories

K -factors cannot be added.
Example: two 90-bends close together

K = 2 fF K 90

20 / 25

Energy conversion : Piping systems

Pipe characteristic
Modified Bernoulli :

p atm gH s p loss + p pump = p atm

Hs
so

p pump = gH s + p loss

L

with p loss =  f ------- +

 Dh

 Ki 1--2- vi 2

i

pump

Q v = vi A : volume flow rate

ppump

ploss
gHs

Qv

Energy conversion : Piping systems

21 / 25

Pipe characteristic
Modified Bernoulli :

p atm gH s p loss + p pump = p atm

Hs
so

p pump = gH s + p loss

L

with p loss =  f ------- +

 Dh

 Ki 1--2- vi 2

i

pump

Q v = vi A : volume flow rate

gHs

pump

pipe

Qwp

Qv
22 / 25

Energy conversion : Piping systems

Pipe selection
Maximum system pressure
dF r = p L r d

; p = p i p o gauge pressure

dF x = p L r cos d
po

2

F x = p L r

cos d

= pLD i

-Fx

Fx

pi

  2

pD i
Fx
! = --------- = ------------- ; s pipe wall thickness
2sL
2s
2! max s
p max = -----------------Di

; ! max maximum normal stress

Nominal pressure PN

! 20 o C s
PN = ----------------cD i

dFr

; c safety factor

Energy conversion : Piping systems

23 / 25

Pipe selection
Economic pipe diameter
From max. system pressure

pDi
s = ------------2!
Material cost proportional with pipe cross section A p = Di s

fixed

p 2
A p = ---------- Di
2!

variable
Dopt

Variable cost = pump power + maintenance

C1 C2
L

1 2
P pump = Qv p pump = Qv  f ------- +  K i --- vi = ------- + ------5
4
D
2
 h

Di Di
i
4Q v

with vi = ----------

Di

24 / 25

Energy conversion : Piping systems

Pipe selection
100
80
60
50
40
30

Recommended speed in piping systems

h
hi g

avg. velocity
[m/s]

fluid

avg. velocity
[m/s]

acetone

1.0 - 3.0

glycerine

0.4 - 0.9

ethyl alcohol

1.5 - 3.0

heptane

1.5 - 3.0

methyl alcohol

1.5 - 3.0

hexane

1.6 - 3.2

benzene

1.4 - 2.8

kerosine

1.4 - 2.8

castor oil

0.5 - 1.0

propane

1.7 - 3.4

chloroform

1.5 - 3.0

propylene

1.7 - 3.4

ether

1.5 - 3.0

turpentine

1.4 - 2.8

water

1.4 - 2.8

ethylene glycol 1.2 - 2.4

average velocity [m/s]

20

fluid

10
8

low

6
5
4
3

p
re (
ssu
pre

p
re (
ssu
pre

>>

=1

1 ba

low

gas and vapor

)
bar

-6

y (
osit
visc

r)

.10
=1

2 )
m /s

liquid

1,0
0,8
0,6
0,5
0,4
0,3

s
isco
hv
hig

=
ity (

2
- 6 m / s)
.10
100

0,2

0,1
10

4 5 6 8 100

3 4 5 6 8 1000

pipe diameter [mm]

Energy conversion : Piping systems

25 / 25