ChE 216

Optimization in Flow of Fluids

Determination of the Optimum Pipe Diameter (Di)

Evelyn R. Laurito
University of Santo Tomas

Economic Analysis
• Direct Cost, CD = Cost of Power (pump)
• Fixed Cost, CF = Cost of maintenance and depreciation

TotalCosts
CT=CF+CD
Annual Cost, C
Fixed
CTmin
Costs, CF

Variable
Diopt Costs, CD
Pipe Diameter (Di)
1/2/2011 216- Plant Design Course Notes by 2
Evelyn R. Laurito

Nomenclature
f = fanning friction factor
V= ave linear velocity of fluid, m/s
L = length of pipe, m
Le=equivalent length of valves,
fittings,m
Di = inside pipe diameter, m
qf = volumetric flow rate, m3/s
 = density of fluid, kg/m3
c= viscosity of fluid, Pa.s
K = cost of power, $/kWh
Hy = hours of operation/yr
J= Le/L
gc = conversion factor in Newton’s
Law, kg.m/s2N
E = pump and motor efficiency
X = purchase cost of pipe per m if
the diameter is 0.0254 m
n = cost correlation index for pipe
F = cost of installation and fittings/
purchase cost of pipe
KF = Annual fixed cost/ cost of
installed pipe
W = mechanical work added to the
system, J/kg

1/2/2011 216- Plant Design Course Notes by 3

Evelyn R. Laurito

1
  .16 1.84 
  qf

K .12478
 4.84

.16

 L ( 1.  J)    q f Hy
 
Cpumping 
 Di    B1
E 1000

1/2/2011 216- Plant Design Course Notes by 4

Evelyn R. Laurito

Optimum Economic Pipe Diameter

• Turbulent Flow (9-70/403 PTW)
1
( 4.84 n)
 6.04x10 4 ( 0.0254) n q 2.84  0.84  0.16 K ( 1  J) Hy 
 f c 
Di opt  n  ( 1  F) X E K F 
 

• Viscous Flow (9-71/403 PTW)

1/(4.0  n )
 0.1628(.0254) n q f 2 c K (1  J ) Hy 
Diopt   
 n(1  F ) XEK F 

1/2/2011 216- Plant Design Course Notes by 5

Evelyn R. Laurito

Constants Under Ordinary

Industrial Conditions
• n = 1.5 for steel if Di ≥ 0.0254 m EQN. 9-72
• n = 1 for steel if Di < 0.0254 m To 9-75
• K = $ 0.05/kWh
• J = 0.35 or 35%
• Hy = 8760 h/yr EQN. 9-76
• E = 0.5 or 50% To 9-79
• F = 1.4
• KF = 0.20 or 20%
• X = $ 2.43 per m for a 0.0254 m Di Steel
pipe
1/2/2011 216- Plant Design Course Notes by 6
Evelyn R. Laurito

2
 Example 1
A flotation plant requires water amounting to 25 m3/h
at 276 kPa. The water must be pumped from a lake
600 m from the plant and the total pump lift is 10 m;
neglect entrance and exit losses, friction due to the
meter. Calculate the optimum pipe diameter (Std steel
pipe) if the initial cost is $ 2.5/m-in diameter; power
cost is $ 0.01/kWh. Pump efficiency is 60%; money
is worth 8% with life of installation equal to 20 years.

1/2/2011 216- Plant Design Course Notes by 7

Evelyn R. Laurito

SOLUTION
3
m
flowrate  25 X  2.5 K  0.01 E  .6
hr
i  .08 n  20
.158
.025 
 1.63 10  K ( 1  J)  Hy 
Assume 6
.448 .132
a) Turbulent Flow Diopt qf   c 
 ( 1  F)  X E KF 
b) Di > 0.0254 m  

1 m3 62.244 0.898
q f  flowrate  q f  0.00694 at 25o C    1000  c 
3600 s 62.4 1000

For common industrial conditions

J  0.35 Hy  8760 F  1.4 i
KF  KF  0.022
n
( 1  i)  1

.158
 6 
.448 .132 .025  1.63 10  K ( 1  J)  Hy  Substitute and Solve:
Diopt  q f   c 
 ( 1  F)  X E KF  Diopt
  Diopt  0.087 greater than 0.0254
Diinches  Diinches  3.431
.0254

qf
Check Reynolds Number: Diopt  

4

 Diopt 2
NRe  NRe  112705.267 greater than 2100
c

1/2/2011 216- Plant Design Course Notes by 8

Evelyn R. Laurito

SOLUTION
qf
V1  0 V2  V2  1.164 L  610 g  32.2 g c  1 z  10 g  32.2 P2  276 P1  101

4

 Diopt 2

 2 2 
1  V2  V1
1
Vol  g
 B    Vol  P2  P1  z B  0.529
L  2 g c g c
 

4 2.84 0.84 .16

n  1.5 
1.24810  qf   c  K ( 1  J)  Hy n
CT   B  ( 1  F)  X Diopt  KF
4.84 CT  0.797
Diopt E

3 inch Sch 40 has a Di = 3.068 inches

Check for min total cost based on std pipe: 4 inch Sch 40 has a Di = 4.026 inches

Di  3.068 4 2.84 0.84 .16

If 
1.24810  qf   c  K ( 1  J)  Hy n
CT   B  ( 1  F)  X Di  KF CT  1.23
4.84
Di E

If Di  4.026 4 2.84 0.84 .16


1.24810  qf   c  K ( 1  J)  Hy n
CT   B  ( 1  F)  X Di  KF
4.84 CT  1.59
Di E

ANSWER : a) 3" Sch 40 steel pipe

b) Min total cost = $1.23/m

1/2/2011 216- Plant Design Course Notes by 9

Evelyn R. Laurito