Rheo[.
Acta 20, 4 8 7 - 496 (1981)
1981 Dr. Dietrich Steinkopff Verlag, Darmstadt
ISSN 0035-4511 / ASTM-Coden: RHEAAK
Petroleum Engineering Department, Technical Universityfor Heavy Industries, Miskolc-Egyetemvros
(Hungary)
Determination of turbulent pressure loss of non-newtonian oll flow in rough pipes
A. P. Szilas, E. B o b o k , a n d L. N a v r a t i l
With 6 figures and 2 tables
Summary
A detailed theoretical analysis is carried out of the
turbulent flow of non-newtonian fluids in rough
pipes in which approximate assumptions are of negli-
gible importance. A new friction-factor equation
(BNS-equation) is obtained which is valid for
turbulent flow of "power-law type" non-newtonian
fluids in the transition region between smooth and
wholly rough wall turbulence.
The accuracy of the deduced formula was checked
by in situ measurements on a crude oll pipeline having
a diameter of 305 mm and a length of 161 km. For
this pipeline the Reynolds numbers ranged between
104 and 105. The computed and the measured friction
factors showed good agreement. The mean of the
absolute values of the relative error was 4.1%, while
the standard deviation was 0.8170, these results
appear to give better fitting than other similar
equations published earlier.
The BNS-equation is the first analytically deduced
relationship for non-newtonian crude oils which in-
cludes the effects of both Reynolds number and
relative roughness of the pipe.
Zusammenfassung
Es wird eine ausfhrliche theoretische Analyse der
turbulenten Strmung nicht-newtonscher Flssigkei-
ten in rauhen Rohren durchgefhrt, wobei Nhe-
rungsannahmen nur eine untergeordnete Rolle spie-
len. Ein neues, fr die turbulente Strmung von
Potenz-Gesetz-Flssigkeiten gltiges Reibungsgesetz
(BNS-Gle!chung) wird abgeleitet, welches fr den ge-
samten Ubergangsbereich zwischen der Strmung
durch hydraulisch-glatte Rohre und der vollkomme-
nen Rauhigkeitsstrmung anwendbar ist.
Die Genauigkeit der abgeleiteten Gleichung wird
durch in-situ-Messungen an einer Rohl-Pipeline von
305 mm Durchmesser und 161 km Lnge getestet.
Hierbei bewegen sich die Reynolds-Zahlen zwischen
104 und 105. Die berechneten und d!e gemessenen Rei-
bungsbeiwerte zeigen eine gute Ubereinstimmung.
Das Mittel des Absolutwerts der relativen Fehler be-
trgt 4,1%, die Standard-Abweichung 0,8170. Hier-
durch wird eine bessere Anpassung erreicht als mit
hnlichen frher verffentlichten Formeln.
702
(Received February 9, 1981)
Die BNS-Gleichung ist die erste analytisch abgelei-
tete Beziehung fr nicht-newtonsche Rohle, die so-
wohl den Einflu der Reynolds-Zahl als auch den der
relativen Rohrrauigkeit bercksichtigt.
Key words
Turbulent flow, non-newtonian fluid, flow in rough
pipe, friction factor, pressure loss
1. Introduction
A l l over the w o r l d there a r e a g r e a t n u m b e r o f
pipelines t r a n s p o r t i n g p s c u d o p l a s t i c oils. I n the
design m c t h o d s o f pipelines it is vcry i m p o r t a n t
to k n o w an a d e q u a t e r e l a t i o n s h i p for resistance
to t u r b u l e n t f l o w o f p s e u d o p l a s t i c fluids. T h e
key p r o b l e m is the d e t e r m i n a t i o n o f the friction
f a c t o r in the W e i s b a c h o r the F a n n i n g - c q u a f i o n
for p r a c t i c a l l y i m p o r t a n t flow regions. T h e
p r e s e n t f o r m u l a s a r e n o t s a t i s f a c t o r y in every
respect.
There exist correct equations for the laminar fric-
tion factor. For turbulent flow a number of advances
have been made in our understanding of the resis-
tance of power-law pseudoplastics. Dodge and
Metzner (3) carried out a semitheoretical
investigation, applying techniques of dimensional
analysis. Shaver and Merril extended the weil known
Blasius-formula to pseudoplastic polymeric solutions
(9). Tomita, on the basis of similarity considerations
derived a friction factor equation, which has been
confirmed by measurements with lime slurries (4).
Clapp derived a dimensionless velocity profile of
pseudoplastics for turbulent flow in smooth pipes
and, from this, a friction factor equation (4). Clapp
made extensive velocity profile measurements to
evaluate his constants of integration. His experiments
were probably influenced by pipe wall roughness.
These correlations were verified for CMC solutions in
small diameter pipes in a limited range of Reynolds
numbers. The respective formulae are given in an
Appendix.
488
There is lack of sufficient experimental data
obtained b y / n situ measurements of crude oil
pipelines in a wide range of Reynolds-numbers.
On the other hand, determination of the fric-
tion factor equations is based on doubtful
velocity measurements.
In the present paper we show another pos-
sible way to determine the friction factor rela-
tionship for turbulent flow of pseudoplastic oil
in rough pipes at the "partially rough wall"
region, where friction factor is affected by both
relative roughness and Reynolds number.
In order to get such a relationship:
- w e deduced a theoretical expression, in
which approximate assumptions play a negli-
gible role;
- we made a great number of in situ measure-
ments on a 305 mm diameter crude oil
pipeline in a wide range of Reynolds num-
ber;
- we compared the accuracy of our (BNS) for-
mula with the previous equations. The ac-
curacy and utility of the BNS equation are
clearly demonstrated.
2. F o r m u l a t i o n o f the p r o b l e m
We consider a homogeneous, isotropic turbu-
lent flow in a cylindrical tube of radius R and of
infinite length. The fluid is incompressible, and
its rheological behaviour is pseudoplastic. On
the pipe wall a thin viscous (often called
"laminar") sublayer occurs, in which turbulent
fluctuations are negligible. On the other hand,
in the core flow viscosity is assumed to have a
negligible effect on the random turbulent fluc-
tuations. A cylindrical coordinate system is
chosen as it is shown in figure 1.
v(r} ~ ~ " , , ~ T u' w'
Laminor subtayer
Fig. 1. Velocity profile of pseudoplastic flow in a pipe
Rheologica Acta, Vol. 20, No. 5 (1981)
The time-averaged velocity field is steady and
axisymmetric. Its only component v lies in the
direction of the pipe axis. It is assumed that the
distributions of the velocity fluctuations u' and
w' are axisymmetric, too. When using these re-
strictions the equation of momentum balance is
as follows:
pgJr
2 ~1' d_~r n - pu' w' = 0. [1]
The first term of the equation is the driving
force of motion, in which J i s the dimensionless
hydraulic gradient. The second is the resistance
due to viscous shear stress, in which t/' is the
index of consistency and n is the so-called flow
index. The third term is the resistance due to an
additional virtual stress, caused by momentum
flux due to turbulent fluctuations.
It is necessary to distinguish between two
regimes when solving the above differential
e q u a t i o n , in accordance with experimental
data.
In the viscous sublayer turbulent fluctuations
practically disappear, thus the third term of the
equation may be omitted. We get the following
simple form:
pgJr _ ~, dv n.
dr [21
Since the viscous sublayer is very thin, an
additional assumption may be accepted that the
shear stress r is constant throughout the
sublayer:
where
rR_ R.!pg_~. [3]
2
Dimensional considerations show that
v,= V OJR2 [4]
z
Turbu[ent
core f[ow has the dimension of velocity. It will be called
friction velocity. Thus
/ 2 \l/n
d~ - I ~*P) ,
[5]
 SziIas et al., Determination of turbulent pressure loss of non-newtonian oil flow in rough pipes 489

which after integration leads to a linear velocity arbitrary additional term. i t is obvious that
distribution velocities are equal on both sides of the
bounding surface of the core flow and the sub-
layer. Thus from eqs. [61 and [10] we get:

Outside the viscous sublayer the effect of

viscous shear stress diminishes and the role of
the turbulent momentum flux increases. It is
convenient to consider eq. [1] omitting the sec-
ond term:
Since d / R ~ 1, we obtain, using the binomial

In order to determine the velocity distribution

of the turbulent core flow it is necessary to find
an expression for the turbulent momentum Generalizing Prandtl's (8) well-known as-
flux, which would relate it to the main velocity. sumption, that
K/trmfin proposed the following relationship
(5):

for newtonian fluids, we may assume the fol-

lowing to hold true:
He did not evaluate the numerical constant ~
of the equation; this was done by Nikuradse (7),
based on his own experimental data. Now we
assume K to be, temporarily, undetermined.
Substituting eq. [8] into eq. [7] we get:

Expressing from eq. [14] the thickness fi of

the viscous sublayer and substituting it into eq.
[12], the dimensionless velocity maximum is ob-
After some manipulations, integrating twice, tained:
and taking of following boundary conditions:

we obtain the following dimensionless velocity

profile:
In this equation

This is a formula for the velocity distribution means the so-called Metzner-Reed Reynolds
of the core flow, but with Vmax as an unknown number (7), D = 2R is the diameter of the pipe.
490 Rheologica Acta, Vol. 20, No. 5 (1981)

The cross-sectional average velocity may be equation, analogously to the Colebrook-equa-

computed as: tion (2):
c 1 _ 2 lg ( 10 fl/2 "~
_ __1 ~ v 2nrdr. [171 -

+ [22]
v, R27r o v , \ R e * t? (2-n)/2n 3.71 D /

Substituting v/v, from eq. [10], and Vmax/V , where fl consists of the last three terms of eq.
from eq. [15] we get after integration: [20]. This is a generalization of the Colebrook-
formula and clearly demonstrates how friction
c _ 1 In Re* 1 factor depends on the pseudoplastic Reynolds-
V, K K number, the flow index and the relative rough-
[181 ness of the pipe. The BNS-eqution is a friction
. 548 + In a + factor relationship is valid for turbulent flow of
non-newtonian fluids flowing in rough pipe at
\ 240 n n
the transition region between the wholly rough
It is clear that the quantity c / v , depends only and the smooth pipe character.
on the Reynolds number. On this base the
friction factor can be deduced similarly to the 3. Experimental results
newtonian case:
A significant series of experimental verifica-
__1 _ __0"8141lg(Re,21_(n/2)) + 0.7532__n-2 tions of the BNS-equation were made on the
]/2 nK 2nK Algy-Szzhalombatta crude oll pipeline having
a diameter of 305 mm and a length of 161.3 km.
The temperature of pseudoplastic oll decreased
[19]
in the direction of flow, thus the corresponding

(~;~6n+~3 n
value of flow index also decreased with tem-
perature. Test stations were designed and equip-
ped using a number of precision instruments for
pressure, temperature and flow rate measure-
Substituting n = 1 into this equation we may ments along the pipeline at eight several points
evaluate constants a and x from the Prandtl- (see tble 1). Flow rate was controlled by gate
Nikuradse equation. Thus we get valves, thus Reynolds numbers varied w i t h i n
the range: 10 4 < Re* < 105.
= 2.087, K = 0.407. Measurements were repeated five times ac-
cording to the different temperatures of the
In this way the friction factor equation is ground (1). At the same time rheological prop-
obtained for hydraulically smooth pipes: erties of the oil were measured by a rotational
viscometer at the corresponding temperature.
1 2 lg(Re*21-(n/2)) + 1.511/n The interpretation of the laboratory measure-
ments involved the calculation of points to

(;07)40,,
.0"__ + 2.12
/7
[20]
1.057 .
determine the flow curve of the oil at the
adequate temperature. The parameters t/' and n
were determined from the flow curves. Know-
ing the flow rate and the rheological parameters
of the oil, the pseudoplastic Reynolds-number
It is obvious, that ;, can be determined for Re* can be determined. The interval between
rough wall turbulence as 10 4 and 10 indicated the transition nature of
the flow.
[21] Pressure loss per unit length was determined
from pressure measurements, as it is demon-
strated in figure 2. The series of measured
In the transition region between the smooth points were interpolated by a linear function
and rough wall case may propose the-following using the method of the least squares fitting.
 Szilas et al., Determination o f turbulent pressure loss o f non-newtonian oil f l o w in rough pipes 491

Table 1. Measured pressure gradients at Algy-Szzhalombatta crude oll pipeline

Test sections Pressure loss gradient (bar/km)

I. II. III. IV. V.

Algy-Svnyhza 0.314 0.345 0.200 0.300 0.305

Svnyhza-Kiskun-
flegyhza 0.310 0.340 0.205 0.306 0.304
Kiskunflegyhz-
Kecskemt 0.305 0.332 0.205 0.315 0.302
Kecskemt-Lajosmizse 0.302 0.328 0.205 0.320 0.300
Lajosmizse-Pusztavacs 0.300 0.325 0.205 0.325 0.300
Pusztavacs-csa 0.300 0.320 0.207 0.330 0.300
csa-Szzhalombatta 0.295 0.318 0.210 0.335 0.300

0,5
Ap
L
[~r 1 0,4
kmJ

--o ~
0,3 ~0 r mO

0,2

0,1

I I
0 50 100 150

L [ kml
Fig. 2. Measured and calculated flow gradients

Pressure gradients of the five test series are de-
monstrated in table 1. The temperature distri-
bution was also linear along the pipe length,
thus is had been convenient to take the arith-
metic mean for any tested section of the pipe-
line. Friction factor values were determined by
the Weisbach-equation:
2D Apv
pc 2 L the Clapp-formula intersects some k / d =
There were seven tested sections of the pipe-
line, thus 35 measured friction factor values
were obtained f r o m the five test series. These
values were compared with computed friction
factors obtained by the Dodge-Metzner,
Shaver-Merrill, Tomita, Clapp, as weil as the
BNS-equation. Scattering, absolute and relative
mean errors were determined for every case. At
the end it appears that BNS-equation provides
the best results. It is interesting to see that the
Clapp-formula is successful to predict 2 values
for only one value of relative roughness. As is
shown in figure 3, the curve corresponding to
const, curves on the M o o d y ' s diagram (assum-
ing the case n = 1). It can be evidenced that
such a relationship is obtained evaluating the
constant of the smooth pipe friction factor
equation f r o m experimental data of rough
pipes.
492 Rheologica Acta, Vol. 20, No. 5 (1981)

T h e m e a n relative roughness o f the in- I n the course o f the c o m p a r i s o n o f different

vestigated pipeline is k / d = 4 10 -4. This friction factor e q u a t i o n s the a b o v e relative
r o u g h n e s s , s u b s t i t u t i n g n = I to the BNS-equa- r o u g h n e s s was t a k e n for the BNS f o r m u l a . T h e
t i o n leads to the curve 2 in figure 3 fitting o n the c o m p u t e d friction factor values are d e m o n s t r a t -
c o r r e s p o n d i n g curve of M o o d y ' s d i a g r a m . ed in table 2. B N S - e q u a t i o n appears to be m o r e

Table 2. Measured and calculated friction factors at Algy-Szzhalombatta crude oil pipeline

Friction factor

Measured S- M D- M TOMITA CLAPP B- N - S

0.0208 0.0190 0.0191 0.0191 0.0189 0.0208

0.0204 0.0205 0.0205 0.0207 0.0204 0.0218
0.0200 0.0192 0.0206 0.0220 0.0201 0.0212
0.0216 0.0180 0.0183 0.0183 0.0180 0.0201
0.0212 0.0183 0.0193 0.0200 0.0188 0.0205

0.0207 0.0165 0.0201 0.0230 0.0192 0.0200

0.0238 0.0204 0.0204 0.0204 0.0202 0.0218
0.0242 0.0217 0.0220 0.0228 0.0219 0.0228
0.0242 0.0208 0.0240 0.0276 0.0234 0.0226
0.0201 0.0196 0.0198 0.0198 0.0195 0.0212

0.0204 0.0203 0.0206 0.0209 0.0204 0.0217

0.0209 0.0196 0.0212 0.0228 0.0207 0.0215
0.0191 0.0166 0.0172 0.0174 0.0168 0.0193
0.0189 0.0167 0.0177 0.0182 0.0172 0.0194
0.0187 0.0169 0.0185 0.0196 0.0179 0.0197

0.0198 0.0178 0.0210 0.0239 0.0202 0.0206

0.0196 0.0173 0.0211 0.0243 0.0202 0.0205
0.0196 0.0181 0.0220 0.0255 0.0211 0.0210
0.0193 0.0142 0.0207 0.0247 0.0194 0.0193
0.0204 0.0154 0.0215 0.0264 0.0204 0.0199

0.0203 0.0142 0.0220 0.0282 0.0206 0.0195

0.0199 0.0138 0.0220 0.0285 0.0206 0.0193
0.0198 0.0120 0.0217 0.0292 0.0201 0.0186
0.0241 0.0230 0.0260 0.0301 0.0256 0.0239
0.0241 0.0217 0.0262 0.0315 0.0256 0.0232

0.0243 0.0209 0.0264 0.0325 0.0257 0.0229

0.0247 0.0219 0.0272 0.0334 0.0266 0.0234
0.0212 0.0178 0.0215 0.0248 0.0207 0.0208
0.0215 0.0170 0.0217 0.0256 0.0207 0.0205
0.0218 0.0176 0.0222 0.0263 0.0212 0.0208

0.0222 0.0193 0.0232 0.0270 0.0224 0.0217

0.0185 0.0154 0.0159 0.0226 0.0185 0.0195
0.0185 0.0150 0.0199 0.0235 0.0188 0.0194
0.0185 0.0218 0.0196 0.0244 0.0182 0.0186
0.0186 0.0134 0.0204 0.0255 0.0191 0.0190

Standard 3.08% 1.31% 4.14% 1.11% 0.81%

deviation
Mean relative - 15.13% 1.93% 16.51% - 1.75% -0.39%
error
Mean of absolute 15.14% 6.39% 20.11% 4.70% 4.13%
values of
relative error
 Szilas et al., Determination of turbulent pressure loss of non-newtonian oil flow in rough pipes 493

0,0350

0,0300
2~

0,0 250
~ ~ ~ = -

-... ;. 70.4 -....~

~~, .10-4
0,0200 ~ :18:',
Smooth pipe '0"4 " ~

0,0150
104 2 3 4 5 6 7 8 9 105
. Re ~
Fig. 3. Friction factor cnrves according to C]app (1) and Bobok-Navratil-Szi]as (2) presented on the transi-
tional part o f M o o d y - d i a g r a m

0,50 n = 0,60
r~' = 0,0117 Ns/m z
bp = 820 kglm 3
L D = 0,3m

EN]
0,40
1. BNS, k/D=lO 3 1
2. Tomita /2
3. BNS~ k/D=5,1 4 //

0,30
~. 0-
5 CLAPP //
II 13
6. BNS~ k/D=3.1 5
7. S - M

0,20
6

0,10

t I , i J I Fig. 4. Calculated friction gradient

1oo 200 300 curves after formulas of different
q [m31h] authors at small flow index
494 Rheologica Acta, Vol. 20, No. 5 (1981)

favourable than the others from the point of
view of both scattering and absolute and
relative errors. In this special case BNS-equa-
tion is not very much better than Clapp's rela-
tionship. In spite of this, BNS equation is valid
for arbitrary relative roughnesses, at which the
error of Clapp's formula can be important.
4. Accuracy of pressure loss determination
In the following the accuracy of pressure loss
determination will be demonstrated at any sup-
posed transport conditions (flow rate, oil prop-
erties) as well as the error to be expected using
the earlier friction factor equations. We con-
sider the inner diameter of the pipe and the flow
curves of the psendoplastic oll to be given. Cha-
racteristic parameters are shown in figures 4
and 5 where pressure gradient A p / L is plotted
versus flow rate q. The three supposed different
relative roughnesses for the BNS-equation are
to be expected for commerical steel pipes (1).
The flow indices of the oil are n = 0.6 in the
case demonstrated in figure 4, and n -- 0.9 in
figure 5. Especially in figure 4, it is conspicious,
that deviation of pressure gradients determinat-
ed by different methods increases with the flow
rate (thus with the Reynolds number). From a
comparison of figures 4 and 5 it is evident that
~deviation of pressure gradients decreases with
:increasing flow index (i.e. approaching the
newtonian behaviour).
It is also evident that earlier friction factor
equations without reference to relative rough-
ness may lead to major errors. By chance it may
be possible to obtain a good result as is near the
only point of Tomita's curve, in which it is in-
tersected by the BNS curve of k / d = 10 -3. In
figure 6 BNS pressure gradients are compared
with Clapp's curves depending on the flow
index n, at some constant flow rate. It is

0,50 n = 0,90
r~ = 0,0117 Nsn/m 2
Ap
= 820 kg/m 3
L D = 0,3 m

[ bar]
kmJ
0,40
1. BNS, k / D = 1 0 -3
2. Tomita

3. BNS, k / D = 5 ' I 4

4. D - M
0,30
5. C L A P P
6 BNS, k/D=3.1 s
7 S-M

0,20

0,10

0 I ] i i I
Fig. 5. Calculated friction gradient
0 100 200 3OO curves after formulas of different
q [m3/h] authors at great flow index
 Szilas et al., Determination of turbulent pressure loss of non-newtonian oil flow in rough pipes 495

0,50
1. k/D= 3.10
2 k/D = 5.1 4 st BNS
3. klo = l 3
t~p 300 m3/h
L
[bar]
-~mJ
0,40

0,30

zoo M/h
0,20

0,10

BLAPP ~ 3 100 m3/h

Fig. 6. Comparison of flow gradient
curves calculated with Clapp respec-
tively Bobok-Navratil-Szilas equa-
0 I I I I I
tions at different pipe surface rough-
0,5 0,6 0,7 0,8 0,9 1,O ness

obvious that Clapp's curve may approach a cer- (i) Dodge-Metzner formula:
tain BNS pressure gradient referring to some
relative roughness, for example the k / d = 3 1_ 2 / / ~ \ , (,,2q
10 -5 curve at flow rate 300 m3/h. In other situa- B nO.7~lg~Re, k__~) j n120"2"
tions, however, the discrepancy may be im-
portant. Here it can also be seen that the dif- (ii) Shaver-Merrill equation:
ference increases with growing flow rate q and 0.316
2-
with decreasing magnitude of n. n 5(Re*)m
BNS equation is slightly more complicate where
than earlier relationships, but this seems to be
2.63
quite unimportant when using digital com- m-
1.05 n "
puters. At is customary the necessary knowl-
edge of relative roughness for pipeline designing (iii) Tomita's formula:
can be taken from performance data of existing
similar pipelines, like in the newtonian case for B - 2lg e* - 0.2.
using the Colebrook formula.
(iv) Clapp's equation:
Appendix 2.27 [ //,& \1 (/2)1
1 _ 1.35__ l ' 4 8 + - - l g [ R e * [ k - 4 - B J
The investigated friction-factor relationships for B n n
time-independent visous non-newtonian fluids are as
follows. All equations are valid for hydraulically 5n - 8
+ 0.34--
smooth pipes. n
496 Rheologica Acta, Vol. 20, No. 5 (1981)
References
1) Bobok, E., L. Navratil, A. P. Szilas, In-
vestigation of turbulent pressure loss of pseudoplastic
crude oll (in Hungarian), Geonmia s Bnyszat
1980 (in the press).
2) Colebrook, C. F., Turbulent flow in pipes with
particular reference to the transition region between
the smooth and rough pipe laws. Vol. 11. Inst. Civ.
Eng. (London 1938/39).
3) Dodge, D. W., A. B. Metzner, Amer. Inst.
Chem. Eng. J. 5, 189 (1959).
4) Govier, G. W., K. Aziz, The Flow of Complex
Mixtures in Pipes. Van Nostrand Reinhold (New
York 1973).
5) v. Krmn, T., Mechanische hnlichkeit und
Turbulenz, Nachr. Ges. Wiss. Gttingen, Math.
Phys. Kl. (Gttingen 1930).
6) Loitsyansky, L. G., Mechanics of Fluids and
Gases (in Russian), Nauka (Moscow 1973).
7) Metzner, A. B., J. C. Reed, Amer. Inst. Chem.
Eng. J. 1, 434 (1955).
8) Prandtl, L., Fhrer durch die Strmungslehre,
Braunschweig (1956).
9) Shaver, R. G., E. W. Merrill, Amer. Inst.
Chem. Eng. J. Il, 181 (1959).
10) Szilas, A. P., Production and Transport of Oil
and Gas; Elsevier (Amsterdam 1975).
11) Varga, J., Handbook of Hydraulic and
Pneumatic Machines (in Hungarian), Mszaki
Knyvkiad (Budapest 1973).
Authors' address:
Prof. Dr. A. P. Szilas, Dr. E. Bobok, Dr. L. Navratil
Petroleum Engineering Department
Technical University for Heavy Industries
H-3515 Miskolc-Egyetemvros (Hungary)