PressureDrop Calculation AdditionalProblems

EXAMPLES FOR SINGLE PHASE PRESSURE DROP CALCULATIONS: EXAMPLE 1: Let us consider a piping route as shown.
The route shows all components present from entry nozzle to exit nozzle. It is a dedicated pipeline taking a mixture of two completely miscible organic compounds from a storage tank entry nozzle to a distillation column feed tray for separation process. Estimate the minimum pressure at the inlet of the pipe (i.e. the outlet nozzle of the storage tank) when pressure at distillation feed tray is given to be 1 atma. Relevant specifications of the pipe route are given below.
No. 1 2 3 4 5 6 7 8
Components Inlet Nozzle Expander Gate valve Tee Elbow LR Elbow LR Elbow LR Elbow LR
Size (inch) 4 64 6 6 6 6 6 6
No. 9 10 11 12 13 14 15 16
Components Elbow LR Elbow LR Reducer Tee Elbow SR Tee Elbow SR Exit Nozzle
Size (inch) 6 6 64 4 4 4 4 4
Pipe: Commercial Steel with surface roughness approximately 0.05 mm For 6 NB, SCH 40, OD = 6.625 in (168.27 mm), Wall thickness = 0.280 in (7.112 mm) For 4 NB, SCH 40, OD = 4.500 in (114.30 mm), Wall thickness = 0.237 in (6.020 mm) Fluid: Density = 900 kg/m3, Viscosity = 1.45 cP, Mass Flow Rate = 110000 kg/hr
EXAMPLE 2: Let us consider a piping route as shown. The route shows all components present from entrance nozzle to exit nozzle. It is a dedicated pipeline taking cyclohexane from its over head storage tank to the reactor for production of nylon-6. Estimate the exit pressure (i.e. at the entry nozzle of the reactor) when storage tank pressure is about 5 atma. Relevant specifications of the pipe route are given below.
No. 1 2 3 4 5 6 7 8
Components Inlet Nozzle Fully open globe valve Elbow SR Bend Bend Reducer Bend Exit Nozzle
Size (inch) 6 6 6 6 6 64 4 4
Pipe: Commercial Steel with surface roughness approximately 0.05 mm For 6 NB, SCH 40, OD = 6.625 in (168.27 mm),Wall Thickness = 0.280 in (7.112 mm) For 4 NB, SCH 40, OD = 4.500 in (114.30 mm), Wall Thickness = 0.237 in (6.020 mm) Fluid: Density = 779 kg/m3, Viscosity = 1.02 cP, Mass Flow Rate = 80000 kg/hr
EXAMPLE 3: Let us consider a route as shown. The route connects the outlet nozzle of the storage tank to the reactor inlet. The discharge end is 20 m below the outlet nozzle of the storage tank. The pressure at the tank discharge is 3 atma. Estimate the pressure at the reactor inlet? Relevant specifications of the pipe route are given below.
No. 1 2 3 4 5 6 7
Components Inlet Nozzle Gate Valve Expander Elbow SR Elbow SR Reducer Exit Nozzle
Size 4 4 6x4 6 6 6x4 4
Pipes: 4 NB, SCH 40 and 6 NB, SCH 40, Commercial Steel with surface roughness approximately 0.05 mm. Tank has a Flush nozzle of 4 NB, while the reactor inlet nozzle is of size 4 NB, also there are one fully open gate valve, one reducer and one expander in the route as shown in the figure. Fluid: Density = 1000 kg/m3, Viscosity = 1 cP, Mass Flow Rate = 50000 kg/hr All liquid properties are given at flow conditions and elbows used are short radius.
EXAMPLE 4: Let us consider a route as shown. The route connects the discharge nozzle of the condenser to a storage tank inlet nozzle. The tank inlet nozzle is 130 m below discharge nozzle of the condenser. The pressure at the condenser discharge nozzle is 6 atma. Estimate the pressure at the storage tank inlet? Relevant specifications of the route are given below.
No. 1 2 3 4 5 6 7 8 9
Components Inlet Nozzle Gate Valve Reducer Tee-1 Elbow LR Tee-2 Gate Valve Elbow LR Exit Nozzle
Size 6 6 6x4 4 4 4 4 4 4
Pipe: 6 NB, SCH 40 and 4 NB, SCH 40, Commercial Steel Pipe with surface roughness approximately 0.05 mm. Condenser discharge has a Protruding nozzle of 6 NB, while storage tank inlet nozzle is of size 4 NB. Also there are two fully open Gate Valve, one Reducer (6 to 4), three large radius Elbows and two Tees as shown in the figure. Fluid: Density () = 779kg/m3, Viscosity () =1.02cP, Mass Flow Rate (W) = 77900kg/hr
EXAMPLE 5: Let us consider a route as shown in the figure. There is a network along the ground. Pressure at inlet of the pipe is 15 atma. Due to some new requirement, one need to draw some liquid from the pipeline at outlet pressure between 1.5 atma to 3 atma. Find out segment numbers in which these pressures can be measure.
No. 1 2 3 4
Components Elbow Reducer Elbow Tee
Size (inch) 6 6x4 4 4
No. 5 6 7
Components Expander Elbow Tee
Size (inch) 6x4 6 6
Each tees, expander, reducer are in the middle of every branch. Each segment contain one reducer (6 x 4), one expander (6 x 4), one tee and four 900 elbows. All distance are in meters. The service and the pipe specifications are as given below. Pipes used in the route are 6 NB SCH 40 and 4 SCH 40. Pipe made of Commercial Steel with surface roughness approximately 0.05 mm Fluid: Density () = 1000 kg/m3, Viscosity () = 1 cP, Flow Rate (W) = 100000 kg/hr
EXAMPLE 6: Let us consider a route as shown. . The route connects the outlet nozzle of the reactant storage tank to the reactor inlet. The discharge end is at a height of 4 m from the outlet nozzle of the storage tank. The pressure at the inlet of the reactor should not be less than 3 atma. Can this system deliver the pressure more than 3 atma? Pressure at Pump Discharge: P1 = 4 atma upstream of discharge nozzle. The service and the pipe specifications are given below.
No. 1 2 3 4 5
Components Inlet nozzle Reducer Tee Elbow Elbow
Size (inch) 8 8x6 6 6 6
No. 6 7 8 11 12
Components Gate Valve Elbow Elbow Reducer Exit nozzle
Size (inch) 6 6 6 6x4 4
Pipes: 8 NB, SCH 30, 6 NB, SCH 40, 4 NB, SCH 60 Commercial Steel with surface roughness approximately 0.05 mm. Entry nozzle is 8 protruding nozzle. Fluid: Density () = 878.6 kg/m3, Viscosity () = 0.652 cP, Flow Rate (W) = 79074 kg/hr
EXAMPLE 7: Let us consider a route as shown. It is a dedicated pipeline taking liquid from an over head tank nozzle to an outlet. Relevant specifications of the pipe route are given below.
No. 1 2 3 4 5
Components Vertical Inlet Elbow Gate Valve Reducer Tee Section
Size (inch) 3 3 3 3x2 2
No. 6 7 8 9 10
Components Elbow Elbow Elbow Globe Valve Horizontal Inlet
Size (inch) 2 2 2 2
Pipe: 3 NB, SCH 40, and 2 NB, SCH 40, Commercial Steel with surface roughness approximately 0.05 mm. Fluid: Density () = 1000 kg/m3, Viscosity () = 1 cP, Mass Flow Rate (W) = 15688 kg/hr Head at Inlet = 10 m of liquid column. Find the delivery Head at outlet.
EXAMPLE 8: Let us consider a route as shown. It is a dedicated pipeline taking liquid from an underground tank to an outlet. Relevant specifications of the pipe route are given below.
No. 1 2 3 4 5 6 7
Components Elbow Gate Valve Elbow (45) Butterfly Valve Elbow (45) Tee Section Bend
Size (inch) 4 4 4 4 4 4 4
No. 8 9 10 11 12 13
Components Globe Valve Expander Elbow Ball Valve Tee Section Globe Valve 60
Size (inch) 4 6x4 6 6 6 6
Pipe: 4 NB, SCH 40, and 6 NB SCH 40, Commercial Steel with surface roughness approximately 0.05 mm. Liquid: Density = 817.15 kg/m3, Viscosity = 1.64 cP, Mass Flow Rate = 88252.2 kg/hr. Head at inlet is 25 m of liquid column. Find the delivery Head at outlet.
EXAMPLE 9: Let us consider the piping route as shown. The route connects the outlet nozzle of the reactant storage tank to the reactor inlet. The discharge end is at a height of 20 m from the outlet nozzle of the storage tank. The pressure requirement at the reactor inlet is 2 atm (absolute). Estimate the minimum pressure at the inlet of the pipe (i.e. the outlet nozzle of the storage tank). Relevant specifications of the pipe route are given below. Pipe: 8 NB, SCH 30, commercial steel pipe with surface roughness approximately 0.05 mm. Tank has a nozzle of 8 NB, while the reactor inlet nozzle is of size 6 NB. Fluid: Density = 873.5 kg/m3, Viscosity = 0.604 cP, Mass Flow Rate = 131025 kg/hr
No. Component Size (inches) 1 Entry Nozzle 8 2 Gate Valve 8 3 Elbow LR 8 4 Elbow LR 8 5 Elbow LR 8 6 Elbow LR 8 7 Elbow LR 8 8 Ball Type Check Valve 8 9 Elbow LR 8 10 Reducer 8x6 11 Exit Nozzle 6
EXAMPLE 10: Let us consider the piping route as shown. The route connects the outlet nozzle of the overhead tank to the shell side Nozzle of the shell and tube heat exchanger. The discharge end is 30 m below from the outlet nozzle of the storage tank. The pressure at the inlet nozzle is 10.5 m of liquid column (absolute). Estimate the pressure at the exit of the pipe (i.e. at the inlet nozzle of the shell and tube heat exchanger). Relevant specifications of the pipe route are given below. Pipe: 6 NB, SCH 40, 4 NB SCH 40, commercial PVC pipe with surface roughness approximately 0.0015 mm. Tank has a nozzle of 4 NB, while the heat exchanger has a nozzle of size 2 NB. Fluid: Density = 997.13 kg/m3, Viscosity = 0.891 cP, Mass Flow Rate = 34900 kg/hr
No. Component Size (inches) 1 Entry Nozzle 4 2 Expander 6x4 3 Elbow LR 6 4 Elbow LR 6 5 Elbow LR 6 6 Globe valve 6 7 Elbow LR 6 8 Elbow LR 6 9 Reducer 6x4 10 Elbow LR 4 11 Elbow LR 4 12 Elbow LR 4 13 Ball Type Check Valve 4 14 educer 4x2 15 Exit Nozzle 2
EXAMPLE 1: Let us consider a piping route as shown. The route shows all components present from entry nozzle to exit nozzle. It is a dedicated pipeline taking a mixture of two completely miscible organic compounds from a storage tank entry nozzle to a distillation column feed tray for separation process. Estimate the minimum pressure at the inlet of the pipe (i.e. the outlet nozzle of the storage tank) when pressure at distillation feed tray is given to be 1 atma. Relevant specifications of the pipe route are given below.
No. 1 2 3 4 5 6 7 8
Components Inlet Nozzle Expander Gate valve Tee Elbow LR Elbow LR Elbow LR Elbow LR
Size (inch) 4 64 6 6 6 6 6 6
No. 9 10 11 12 13 14 15 16
Components Elbow LR Elbow LR Reducer Tee Elbow SR Tee Elbow SR Exit Nozzle
Size (inch) 6 6 64 4 4 4 4 4
Pipe: Commercial Steel with surface roughness approximately 0.05 mm For 6 NB, SCH 40, OD = 6.625 in (168.27 mm), Wall thickness = 0.280 in (7.112 mm) For 4 NB, SCH 40, OD = 4.500 in (114.30 mm), Wall thickness = 0.237 in (6.020 mm) Fluid: Density = 900 kg/m3, Viscosity = 1.45 cP, Mass Flow Rate = 110000 kg/hr
SOLUTION 1: The route involves two sizes, 4 and 6. First step should be to find the equivalent length of the entire route in terms of straight pipe length of 6 NB and 4 NB, SCH 40 pipe. Route Analysis: Equivalent Length/ Component ft Size 4 10 4 Total Contribution ft (m) Size 4 10 (3.05 ) 4 (1.22 ) 6.5 30 10 4 7 20 10.5 20 4 (1.22) 7 (2.13) 20 (6.10) 21 (6.40) 20 (6.10) 406.56 (123.92) 492.56 (150.14) 642.22 (195.75) 738.72 (225.16) 6.5 (1.98) 30 (9.14) 60 (18.29) Equivalent Length/ Component ft Size 6
Piping Component Entry Nozzle (4) Expander (6 4) Gate Valve (6) Tee(6) Elbow LR (6) Reducer (6 4) Tee (4) Tee (4) Elbow SR (4) Exit Nozzle (4) Pipe TOTAL
Numb er 1 1 1 1 6 1 1 1 2 1
Total Contribution ft (m) Size 6
NOTE: The lengths in parenthesis are in m.
The route analysis says that the route with its pipes, fittings and valves is equivalent to 150.14 m of 4 straight pipe and 225.16 m of 6 straight pipe. These lengths should be used in overall frictional pressure drop calculations.
Calculation of the Inside Diameter of Pipe with 4 NB, SCH 40 The actual outside diameter of the pipe = 4.5 Thickness of the pipe The inside diameter of the pipe = 114.30 - (2 6.02) The equivalent length of 4 pipe components Actual length of 4 straight pipe Total equivalent length of the 4 pipe (L) = 26.22 + 123.92 = 114.30 mm = 6.02 mm = 102.26 mm = 26.22 m = 123.92 m = 150.14 m
Pressure Drop Calculations For 4 pipe Mass Flow Rate (W) = 110000 kg/hr Flow Rate (Q) Diameter (D) = W/ = 122.22 m3/hr = 102.26 mm
The Linear Velocity (v) =
4Q D 2
4 122.22 3.14 (60 60) 102.26 2 10 -6
= 4.14 m/s
Reynolds Number (Re) =
D v 102.26 10 3 4.14 900 = 1.45 10 3
= 262773
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation = 0.316 Re 0.25 = 0.316 262773 0.25 = 0.013957 The Colebrook and White equation for calculating the friction factor is as follows:
2.51 = 2 log10 + f 3.71 D Re f
Solving this equation using the friction factor from Blazius equation as the initial guess, the iterative values are
Iteration No. 0 1 2 3 4
1/sqrt(f)
7.34469 7.38952 7.38768 7.38775
f 0.013957 0.018538 0.018313 0.018322 0.018322
As can be seen, the iterative procedure converges after 3-4 iterations. Generally, 3 - 4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.018322 is accepted as the friction factor value in further calculations. Frictional Head Loss per unit length = 0.018322 4.14 2 P f v 2 = = g 2gD 2 9.81 102.26 10 -3 = 0.157 m/m Total Frictional Head Loss for a pipe length of 150.14 m = 0.157 150.14 = 23.57 m
Calculation of the Inside Diameter of Pipe with 6 NB, SCH 40

The actual outside diameter of the pipe = 6.625 in Thickness of the pipe The inside diameter of the pipe = 168.27 - (27.112) The equivalent length of 6 pipe components Actual length of 6 straight pipe = 168.27 mm = 7.112 mm = 154.05 mm = 29.41 m = 195.75 m
Total equivalent length of the 6 pipe (L) = 29.41 + 195.75 = 225.16 m
Pressure Drop Calculations For 6 pipe

Mass Flow Rate (W) = 110000 kg/hr Flow Rate (Q) Diameter (D) = 122.22 m3/hr = 154.05 mm
4 122.22 3.14 (60 60) 154.05 2 10 -6
= 1.82 m/s
154.05 10 3 1.82 900 Reynolds Number (Re) = 1.45 10 3
= 174023
Darcy Friction Factor (f) calculated as per (Blazius Equation) f = 0.316 174023 0.25 = 0.015472
Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 4 iterations giving a friction factor value of 0.018153
Iteration No. 0 1 2 3 4 5
1/sqrt(f)
7.38312 7.42451 7.42184 7.42201 7.42200
f 0.015472 0.018345 0.018141 0.018154 0.018153 0.018153
Frictional Head Loss per unit length =
0.018153 1.82 2 2 9.81 154.05 10 -3
= 0.02 m/m
Total Frictional Head Loss for a pipe length of 225.16 m = 0.02 225.16 = 4.50 m Now, Total Head Loss due to friction in the piping system = (23.57 + 4.50) m = 28.07 m Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows.
P1 g
2 v1 2g
+ Z1 =
P2 g
v2
2g
+ Z2 +
P g friction
P g friction
P1 P2 g
v2
v1 2g
+ (Z 2 Z1 ) +
4.14 2 4.14 2 = + (10 4) + 28.07 2 9.81 = 34.07 m

P1 P2
= pressure equivalent to 34.07 m of liquid column = 34.07 900 9.81
P1 P2
= 300804.03 Pa = 2.97 atma.
The net pressure drop along the pipe route is 2.97 atma. If we want to maintain a pressure of 1 atma. at the feed tray of distillation column, the pressure at the inlet of the pipe should be at least 3.97 atma.
Summary of Solution 1: For 4 pipe

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Head Loss = 4.14 m/s = 262773 = 0.018322 = 23.57 m
For 6 pipe
The Total Head Loss due to friction = 28.07m The Pressure Drop in the entire pipe section (because of Velocity head, Gravitational head and Frictional head) = 34.07 m = 300804.03 Pa = 2.97 atma. The minimum required pressure at the inlet of the pipe = 3.97 atma.
EXAMPLE 2:
Let us consider a piping route as shown. The route shows all components present from entrance nozzle to exit nozzle. It is a dedicated pipeline taking cyclohexane from its over head storage tank to the reactor for production of nylon-6. Estimate the exit pressure (i.e. at the entry nozzle of the reactor) when storage tank pressure is about 5 atma. Relevant specifications of the pipe route are given below.
No.
1 2 3 4 5 6 7 8
Components
Inlet Nozzle Fully open globe valve Elbow SR Bend Bend Reducer Bend Exit Nozzle
Size (inch)
6 6 6 6 6 64 4 4
Pipe: Commercial Steel with surface roughness approximately 0.05 mm

For 6 NB, SCH 40, OD = 6.625 in (168.27 mm),Wall Thickness = 0.280 in (7.112 mm) For 4 NB, SCH 40, OD = 4.500 in (114.30 mm), Wall Thickness = 0.237 in (6.020 mm)
Fluid: Density = 779 kg/m3, Viscosity = 1.02 cP, Mass Flow Rate = 80000 kg/hr
SOLUTION 2:
The route involves two sizes, 4 and 6. First step should be to find the equivalent length of the entire route in terms straight pipe length of 6 and 4, SCH 40 pipe.
Route Analysis: Equivalent Length/ Component ft Size 4 Total Contribution ft (m) Size 4 Equivalent Length/ Component ft Size 6
18 175 15 8.5 4 5.5 20 4 (1.22) 5.5 (1.68) 20 (6.10) 298.56 (91) 328.06 (100) 431.17 (131.42) 656.17 (200)
Piping Component
Inlet (6) Fully Open Globe Valve (6) Elbow SR (6) Bend (6) Reducer (6 4) Bend (4) Exit Nozzle (4) Pipe TOTAL
Number
1 1 1 2 1 1 1

18 (5.49) 175 (53.34) 15 (4.57) 17 (5.18)

The route analysis says that the route with its pipes, fittings and valves is equivalent to 100 m of 4 straight pipe and 200 m of 6 straight pipe. These lengths should be used in overall frictional pressure drop calculations.

The actual outside diameter of the pipe = 4.500 in = 114.30 mm
Thickness of the pipe The inside diameter of the pipe = 114.30 - (26.020) The equivalent length of 4 pipe components Actual length of 4 straight pipe Total equivalent length of the 4 pipe (L) = 9 + 91
= 6.020 mm = 102.26 mm =9m = 91 m = 100 m

Mass flow rate (W) = 80000 kg/hr Flow Rate (Q) Diameter (D) = W/ = 102.70 m3/hr = 102.26 mm
4Q D 2
4 102.70 = 3.48 m/s 3.14 (60 60) 102.26 2 10 -6

= 271783
D v 102.26 10 -3 3.48 779 = Reynolds Number (Re) = 1.02 10 3
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.35434 7.39919 7.39739 7.39746 7.39746
f 0.01384 0.018489 0.018265 0.018274 0.018274 0.018274
As can be seen, the iterative procedure converges after 3-4 iterations. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.018274 is accepted as the friction factor value in further calculations. P fv 2 0.018274 3.48 2 = = g 2gD 2 9.81 102.26 10 -3 = 0.11 m/m Total Frictional Head Loss for a pipe length of 150.14 m = 0.11 100 = 11 m

Total equivalent length of the 6 pipe (L) = 68.58 + 131.42 = 200 m

Mass flow rate (W) = 80000 kg/hr Flow Rate (Q) Diameter (D) = 102.70 m3/hr = 154.05 mm
4 102.70 = 1.53 m/s 3.14 (60 60) 154.05 2 10 -6

= 180007
154.05 10-3 1.53 779 1.02 10 3
Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 Re 0.25 = 0.316 180007
0.25
= 0.015341
1/sqrt(f)
7.39767 7.43958 7.43693 7.43709 7.43708
f 0.015341 0.018273 0.018068 0.018081 0.01808 0.01808

= 0.014 m/m
0.01808 1.53 2 2 9.81 154.05 10 -3
Total Frictional Head Loss for a pipe length of 200 m = 0.014 200 = 2.80 m Now, the total head loss due to friction in the piping system = (11 + 2.80) m = 13.80 m Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows. 2 2 P1 v1 P2 v 2 P + + Z1 = + + Z2 + g 2g g 2g g friction
P1 P2 g v2 2 v1 2g 2
+ (Z 2 Z1 ) +
P g friction
3.48 2 1.53 2 = + (0 5) + 13.80 2 9.81 = 9.30 m

P1 P2
= pressure equivalent to 9.30 m of liquid column
=9.30 779 9.81

P1 P2
= 71070.51 Pa = 0.70 atma.
P2
= 4.3 atma
The net pressure drop along the pipe route is 0.70 atma. The pressure at the entry nozzle to the will be about 4.3 atma.

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Head Loss = 3.48 m/s = 271783 = 0.018274 = 11 m
For 6 pipe
Total Head Loss due to friction = 13.80 m The Pressure Drop in the entire pipe section (because of Velocity Head, Gravitational Head and Frictional Head) = 9.30 m = 71070.51 Pa = 0.70 atma. The pressure at the entry nozzle to the will be about 4.3 atma.
EXAMPLE 3:
Let us consider a route as shown. The route connects the outlet nozzle of the storage tank to the reactor inlet. The discharge end is 20 m below the outlet nozzle of the storage tank. The pressure at the tank discharge is 3 atma. Estimate the pressure at the reactor inlet? Relevant specifications of the pipe route are given below.
No. 1 2 3 4 5 6 7
Size 4 4 6x4 6 6 6x4 4
Pipes: 4 NB, SCH 40 and 6 NB, SCH 40, Commercial Steel with surface roughness approximately 0.05 mm. Tank has a Flush nozzle of 4 NB, while the reactor inlet nozzle is of size 4 NB, also there are one fully open gate valve, one reducer and one expander in the route as shown in the figure.
Fluid: Density = 1000 kg/m3, Viscosity = 1 cP, Mass Flow Rate = 50000 kg/hr
All liquid properties are given at flow conditions and elbows used are short radius.
SOLUTION 3:
Let us analyze the route to get equivalent length of the same.
Route Analysis:
Piping System Component

Pipe Elbow SR Expander (6 x 4) Reducer (6 x 4) Gate Valve (4) Entry Nozzle (4) Exit Nozzle (4)
Equivalent Length/ Component ft Number Size 4

164 2 1 1 1 1 1 4 4 4.5 10 20

164 (50)
Equivalent Length/ Component ft Size 6

164 15

164 (50) 30 (9.15)
4 (1.22) 4 (1.22) 4.5 (1.37) 10 (3.05) 20 (6.10)
TOTAL
206.5 (62.96)
194 (59.15)

The route analysis says that the route with its pipes, fittings and valves is equivalent to 62.96 m of 4 straight pipe and 59.15 m of 6 straight pipe. These lengths should be used in overall frictional pressure drop calculations. The equivalent length for the two nozzles is in terms of straight length of pipe of same size as the nozzle.

The actual outside diameter of the pipe = 4.5 Thickness of the pipe The inside diameter of the pipe = 114.30 (2 6.02) Total equivalent length of the 4 pipe (L) = 114.30 mm = 6.02 mm = 102.3 mm = 62.96 m

Flow Rate (Q) =
50000 = 50 m3/hr 1000
Diameter (D) = 0.1023 m Viscosity () = 1 cP Density () = 1000 kg/m3
Linear Velocity (v) =
4Q D 2
4 50 3.14 3600 0.1023 2
= 1.69 m/s
D v 0.1023 1.69 1000 = 10 3
= 172887
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation = 0.316 (R e ) 0.25 = 0.316 (172887) 0.25 = 0.01549
The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log + f 3.71D Re f
Iteration No. 0 1 2 3 4 5 6
1/sqrt(f)
7.209951 7.252788 7.250506 7.250628 7.250621 7.250622
f 0.0154969 0.0192369 0.0190103 0.0190223 0.0190216 0.0190217 0.0190217
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.01902 is accepted as the friction factor value in further calculations. P fv 2 0.01902 1.69 2 = = g 2gD 2 9.81 0.1023
Frictional Head Loss per unit length
= 0.02707 m/m
Frictional Pressure Drop per unit length, P = 0.002655 bar/m
Total Frictional Pressure Drop for a pipe length of 62.96 m =
0.002655 62.91 = 0.165 atma 1.013


Flow Rate (Q) = 50 m3/hr Diameter (D) = 0.1541 m Viscosity () Density () = 1 cP = 1000 kg/m3
4 50 3.14 3600 0.15412 0.1541 0.75 1000 10 3
= 0.75 m/s
= 115575
Initial guess of Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 (R e ) 0.25 = 0.316 (115575) 0.25 = 0.0171384 Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 4 iterations giving a friction factor value of
0.01918. Iteration No. 0 1 2 3 4 5 6 7 1/sqrt(f)

7.189273 7.223 7.220386 7.220588 7.220573 7.220574 7.220574
f 0.0171384 0.0193477 0.0191674 0.0191813 0.0191802 0.0191803 0.0191803 0.0191803
Frictional Head Loss per unit length Frictional Pressure Drop per unit length
0.01918 0..75 2 2 9.81 0.1541
= 0.003568 m/m
= 0.000350 bar/m
Total Frictional Pressure Drop for a pipe length of 59.15 m =
0.000350 59.15 1.013
= 0.0205 atma
Now, the Total Pressure Drop due to friction in piping system (P) friction = 0.165 + 0.0205 = 0.1855 atma Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows.
2 2 P1 v1 P2 v 2 P + + Z1 = + + Z2 + g 2g g 2g g friction
P1 P2 g
2 2 v2 v1 P = + (Z2 Z1) + 2g g friction
The elevation difference between the two ends of the route is 20 m. Inlet is at higher elevation than outlet. So, if inlet is taken as basis, Z1 = 0, Z2 = -20 m in the Bernoullis equation. The nozzles are of the same size, so velocity and the kinetic head is the same at both the ends and cancels out.
P P = (Z Z ) g + (P 1 2 2 1
P P = 1 2
) friction
20 1000 9.81 + 0.1855 1.013 10 5
P P = 1 . 937 + 0 . 1855 1 2
P P = 1 . 752 atma. 1 2
The net pressure gain along the pipe route is 1.752 atma. So, the pressure at the inlet of the reactor will be 4.752 atma.

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop per unit length = 0.75 m/s = 115575 = 0.01918 = 0.000350 bar/m
For 4 pipe
Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop per unit length = 1.69 m/s = 172887 = 0.01902
= 0.002655 bar/m
The Total Frictional Pressure Drop (P) friction = 0.1855 atma
EXAMPLE 4:
Let us consider a route as shown. The route connects the discharge nozzle of the condenser to a storage tank inlet nozzle. The tank inlet nozzle is 130 m below discharge nozzle of the condenser. The pressure at the condenser discharge nozzle is 6 atma. Estimate the pressure at the storage tank inlet? Relevant specifications of the route are given below.
No. 1 2 3 4 5 6 7 8 9
Size 6 6 6x4 4 4 4 4 4 4
Pipe: 6 NB, SCH 40 and 4 NB, SCH 40, Commercial Steel Pipe with surface roughness
approximately 0.05 mm. Condenser discharge has a Protruding nozzle of 6 NB, while storage tank inlet nozzle is of size 4 NB. Also there are two fully open Gate Valve, one Reducer (6 to 4), three large radius Elbows and two Tees as shown in the figure. Fluid: Density () = 779kg/m3, Viscosity () =1.02cP, Mass Flow Rate (W) = 77900kg/hr
SOLUTION 4:
Route analysis

Pipe Elbow LR Reducer (6 x 4) Gate Valve (6) Gate Valve (4) Tee-1 Tee-2 Entry Nozzle (6) Exit Nozzle (4)
Number

164 (50)

623.40 (190)
2 1 1 1 1 6.5 6.5 (1.98)
7 4
14 (4.27) 4 (1.22)
4.5 7 20
4.5 (1.37) 7 (2.14) 20 (6.10)
1 1
29
29 (8.84) 20 20 (6.10)
TOTAL 199.5 (60.82) NOTE: The lengths in parenthesis are in m.
692.9 (211.2)
The equivalent length for the two nozzles is in terms of straight length of pipe of same size as the nozzle.


Flow Rate (Q) =
77900 = 100 m3/hr 779
Diameter (D) = 0.154 m The Linear Velocity (v) =
4Q D 2
D v
4 100 3.14 3600 0.154 2

0.154 1.49 779 1.02 10 3
= 1.49 m/s
= 175244
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation
0.25 = 0.316 (175244) 0.25 = 0.01544 = 0.316 (R e )
The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log + f 3.71D Re f
Solving this equation using the friction factor from Blazius equation as the initial guess, the iterative values are:
1/sqrt(f)
7.386579 7.428093 7.425426 7.425597 7.425586
f
0.0154417 0.0183279 0.0181236 0.0181366 0.0181358 0.0181358
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.01814 is accepted as the friction factor value in further calculations. P fv 2 0.01814 1.49 2 = = = 0.01333 m/m g 2gD 2 9.81 0.154
Frictional Pressure Drop per unit length, P = 0.00102 bar/m Total Frictional Pressure Drop for a pipe length of 60.82 m =
0.00102 60.82 = 0.0612 atma 1.013


Flow Rate (Q) = 100 m3/hr Diameter (D) = 0.1023 m
4 100 3.14 3600 0.1023 2
= 3.38 m/s
0.1023 3.38 779 1.02 10 3
= 264076
Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 (R e ) 0.25 = 0.316 (264076) 0.25 = 0.013940 Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 4 iterations giving a friction factor value of 0.01831
Iteration No.
0 1 2 3 4 5
1/sqrt(f)
f
0.0139400 0.0185287 0.0183046 0.0183137 0.0183133 0.0183133
7.346432 7.39127 7.389436 7.389511 7.389508
0.01831 3.38 2 = 0.1042 m/m 2 9.81 0.1023
Frictional Pressure Drop per unit length, P = 0.007965 bar/m Total Frictional Pressure Drop for a pipe length of 211.2 m =
0.007965 211.2 = 1.66 atma 1.013
Now, the total pressure drop due to friction in piping system (P) friction = 0.0612 + 1.66 = 1.72 atma Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows.
P1 P2 g 2 2 v 2 v1 P = + (Z 2 Z1 ) + 2g g friction
2 2 v 2 v1 g + (Z 2 Z1 ) g + (P )friction P P = 1 2 2g
The elevation difference between the two ends of the route is 130 m. Inlet is at higher elevation than outlet. So, if inlet is taken as basis, Z1 = 0, Z2 = -130 m in the Bernoullis equation.
2 2 (3.38 1.49 ) 779 9.81 130 779 9.81 P P = + 1.72 1 2 5 5 1.013 10 2 9.81 1.013 10
P P = 0.0354 9.8071 + 1.72 1 2
P P = 8.052 1 2
P = P + 8.052 2 1 P = 14.052 atma 2
So pressure at the storage tank inlet is 14.052 atma.

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop per unit length = 1.49 m/s = 175244 = 0.01814 = 0.00102 bar/m = 3.38 m/s = 264076
For 4 pipe
Linear Velocity (v) Reynolds Number (Re)
Darcy Friction Factor (f) Frictional Pressure Drop per unit length
= 0.01831 = 0.007965 bar/m
The Total Frictional Pressure Drop (P) friction = 1.72 atma
EXAMPLE 5:
Let us consider a route as shown in the figure. There is a network along the ground. Pressure at inlet of the pipe is 15 atma. Due to some new requirement, one need to draw some liquid from the pipeline at outlet pressure between 1.5 atma to 3 atma. Find out segment numbers in which these pressures can be measure.
No.
1 2 3 4
Components
Elbow Reducer Elbow Tee
Size (inch)
6 6x4 4 4
No.
5 6 7
Components
Expander Elbow Tee
Size (inch)
6x4 6 6
Each tees, expander, reducer are in the middle of every branch. Each segment contain one reducer (6 x 4), one expander (6 x 4), one tee and four 900 elbows. All distance are in meters. The service and the pipe specifications are as given below.
Pipes used in the route are 6 NB SCH 40 and 4 SCH 40. Pipe made of Commercial Steel
with surface roughness approximately 0.05 mm Fluid: Density () = 1000 kg/m3, Viscosity () = 1 cP, Flow Rate (W) = 100000 kg/hr
SOLUTION 5:
The route involves two sizes, 6 and 4. First step should be to find the equivalent length of the entire route in terms of straight pipe length of 6 and 4, SCH 40 pipe. The equivalent length of the route is calculated as follows.
Route Analysis:

Pipe (6) Pipe (4) Elbow(6) SR 900 Elbow(4) SR 900 Expander (4 x 6) Reducer (6 x 4) Tee (4) Tee (6) TOTAL
Equivalent Length/ Component (ft) Number Size 4

n n 3n n n n n n
0

0 246.06n (75n) 0 10.5n (3.20n) 4n (1.22n) 4n (1.22n) 7n (2.13n) 0 271.56n (82.77n)
Equivalent Length/ Component (ft) Size 6

574.15n (175n)
0 15 0 0 0 0 10
0 45n (13.72n) 0 0 0 0 10n (3.05n) 629.15n (191.77n)
10.5
4 4 7 0

The route analysis says that the each segment with its pipes, fittings and valves is equivalent to 191.77 m of 6 straight pipe and 82.77 m of 4 straight pipe. These lengths should be used in overall frictional pressure drop calculations.

The actual outside diameter of the pipe = 6.625 Thickness of the pipe The inside diameter of the pipe = 168.27 (2 x 7.112) The equivalent length of 6 pipe components Actual length of 6 straight pipe Total equivalent length of the 6 pipe (L1) = 175 + 16.77 = 168.27 mm = 7.112 mm = 154.05 mm = 16.77 m = 175 m = 191.77 m
Pressure Drop Calculations: For 6 pipe

Flow Rate (Q) = W 100000 = 100 m3/hr = 1000
4 100 4Q = = 1.49 m/s 2 D 3.14 (60 60) 0.154 2 D v 0.154 1.49 1000 = = 229460 1 10 3
2.51 = 2 log10 + f 3.71 D Re f
Iteration No.
0 1 2 3 4 5
1/sqrt(f)
f
0.014438 0.017794 0.017582 0.017594 0.017593 0.017593
7.496484 7.541581 7.539057 7.539198 7.53919
As can be seen, the iterative procedure converges after 3 - 4 iterations. The change in the friction factor value is only after 4 significant digits after the second iteration. A value of 0.01759 is accepted as the friction factor value in further calculations. Frictional Pressure Drop per unit length P = fv 2 2d 0.01759 1.49 2 1000 2 0.154046
= 126.75 Pa/m The Total Frictional Pressure Drop due to 6 pipe = P x L1 = 126.75 x 191.77 = 24306.85 Pa
For 4 pipe Calculation of the Inside Diameter of Pipe with 4 NB, SCH 40
The actual outside diameter of the pipe = 4.5 Thickness of the pipe The inside diameter of the pipe = 114.30 - (2 x 6.020) The equivalent length of 4 pipe components Actual length of 4 straight pipe Total equivalent length of the 4 pipe (L2) = 75 + 5.64 = 114.30 mm = 6.020 mm = 102.26 mm = 5.64 m = 75 m = 80.64 m

Flow Rate (Q) Diameter (D) = 100 m3/hr = 0.102 m
4 100 = 3.4 m/s 3.14 (60 60) 0.102 2
0.102 3.4 1000 = 346800 1 10 3
Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 Re 0.25 = 0.316 346800 0.25 = 0.013022 Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 2 iterations giving a friction factor value of 0.01796.
Iteration No.
0 1 2 3 4
1/sqrt(f)
f
0.013022
7.417469 7.461848 7.460348 7.460398
0.018176 0.01796 0.017967 0.017967
Frictional pressure drop per unit length P
0.017964 3.4 2 1000 2 0.102
= 1017.96 Pa/m The total frictional pressure drop due to 4 pipe = P x L2 = 1017.96 x 82.77 = 84256.55 Pa Total pressure drop across one segment P = 24306.85 + 84256.55 = 108563.4 Pa
Now applying Bernoullis equation in the network from initial point to end of nth segment.
2 2 P P1 v1 P2 v 2 + + Z1 = + + Z2 + g g 2g g 2g friction
For P2 = 3 atma (P1 P2) = P x n 12 x 105 = 108563.4 x n n = 11.05 In the 12 segment pressure will be 3 atma For P2 = 1.5 atma, n = 12.44 In the 13th segment pressure will be 1.5 atma
th

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) = 1.49 m/s = 229460 = 0.017593
Frictional Pressure Drop per unit length = 126.75 Pa/m
For 4 pipe
Frictional Pressure Drop per unit length = 1017.96 Pa/m In the 12th segment pressure will be 3 atma In the 13th segment pressure will be 1.5 atma
EXAMPLE 6:
Let us consider a route as shown. . The route connects the outlet nozzle of the reactant storage tank to the reactor inlet. The discharge end is at a height of 4 m from the outlet nozzle of the storage tank. The pressure at the inlet of the reactor should not be less than 3 atma. Can this system deliver the pressure more than 3 atma? Pressure at Pump Discharge: P1 = 4 atma upstream of discharge nozzle. The service and the pipe specifications are given below.
No.
1 2 3 4 5
Components
Inlet nozzle Reducer Tee Elbow Elbow
Size (inch)
8 8x6 6 6 6
No.
6 7 8 11 12
Components
Gate Valve Elbow Elbow Reducer Exit nozzle
Size (inch)
6 6 6 6x4 4
Pipes: 8 NB, SCH 30, 6 NB, SCH 40, 4 NB, SCH 60 Commercial Steel with surface
roughness approximately 0.05 mm. Entry nozzle is 8 protruding nozzle. Fluid: Density () = 878.6 kg/m3, Viscosity () = 0.652 cP, Flow Rate (W) = 79074 kg/hr
SOLUTION 6:
Let us analyze the route to get the equivalent length of the same.
Route Analysis:
Equivalent Length/ Component (ft) Size 4 Equivalent Length/ Component (ft) Size 6 Equivalent Length/ Component (ft) Size 8
Piping System Component Pipe (4) Pipe (6) Pipe (8) Elbow LR (6) Reducer (8 x 6) Reducer (6 x 4) Gate Valve (6) Tee (6) Entry Nozzle (8) Exit Nozzle (4) TOTAL
Number 1 1 1 4 1 1 1 1 1 1
Total Contribution ft (m) Size 4 98.4 (30)
433 (132)
164 (50) 10 7 4 4 (1.2) 175 10

175 (53.34)
40 (12.19) 7 (2.13)
10 (3.05) 38 38 (11.58)
20
20 (6.1) 122.4 (37.3) 665 (202.71) 202 (61.58)

The route analysis says that the route with its pipes, fittings and valves is equivalent to 37.3 m of 4 straight pipe, 202.71 m of 6 straight pipe and 61.58 m of 8 straight pipe. These lengths should be used in overall frictional pressure drop calculations.

The actual outside diameter of the pipe = 4.5 Thickness of the pipe = 114.30 mm = 7.137 mm
The inside diameter of the pipe = 114.30 - (2 x 7.137) The equivalent length of 4 pipe components Actual length of 4 straight pipe Total equivalent length of the 4 pipe (L1) = 30 + 7.3
= 100.026 mm = 7.3 m = 30 m = 37.3 m

Flow Rate (Q) =
79074 W = 90 m3/hr = 878.6 4 90 4Q = = 3.18 m/s 2 D 3.14 (60 60) 0.100 2 D v 0.100 3.18 878.6 = 0.652 10 3
= 428520
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation = 0.316 Re 0.25 = 0.316 428520 0.25 = 0.012351
The Colebrook and White equation for calculating the friction factor is as follows:
2.51 = 2 log10 + f 3.71 D Re f
Iteration No. 0 1 2 3 4 5 1/sqrt(f) 7.454107 7.497053 7.495829 7.495864 7.495863 f 0.012351 0.017997 0.017792 0.017798 0.017797 0.017797
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the first iteration. Generally, 3-4
iterations are sufficient irrespective of the quality of the initial guess. A value of 0.01779 is accepted as the friction factor value in further calculations. Frictional pressure drop per unit length P = = fv 2 2d 0.01779 3.18 2 878.6 2 0.100
= 790.3 Pa/m The total frictional pressure drop due to 4 pipe = P x L1 = 790.3 x 37.30 = 29478.19 Pa


4 90 3.14 (60 60) 0.154 2 0.154 1.34 878.6 0.652 10 3
= 1.34 m/s
= 278080
Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 Re 0.25 = 0.316 278080 0.25 = 0.013761
Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 3 iterations giving a friction factor value of 0.01725.
Frictional pressure drop per unit length P
0.01725 1.34 2 878.6 2 0.154
= 88.36 Pa/m The total frictional pressure drop due to 6 pipe = P x L2 = 88.36 x 202.71 = 17911.5 Pa

The actual outside diameter of the pipe = 8.625 Thickness of the pipe The inside diameter of the pipe = 219.08 2 x 7.036 The equivalent length of 8 pipe components Actual length of 8 straight pipe Total equivalent length of the 8 pipe (L3) = 50 + 11.58 = 219.08 mm = 7.036 mm = 205.008 mm = 11.58 m = 50 m = 61.58 m

4 90 = 0.76 m/s 3.14 (60 60) 0.205 2
0.205 0.76 878.6 0.652 10 3
= 209948
Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 Re 0.25 = 0.316 209948 0.25 = 0.014762
Iteration No. 0 1 2 3 4 1/sqrt(f) 7.569576 7.612422 7.609579 7.609767 f 0.014762 0.017452 0.017257 0.017269 0.017269
0.01726 0.76 2 878.6 Frictional pressure drop per unit length P = 2 0.205 = 21.36 Pa/m The total frictional pressure drop due to 6 pipe = P x L3 = 21.36 x 61.58 = 1315.35 Pa Now, the total pressure drop due to friction in the piping system = 1315.35 + 17911.5 + 29478.19 = 48705.04 Pa Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows: P P1 v1 P v + + Z1 = 2 + 2 + Z 2 + pg g 2g g 2g friction
2 2
878.6 3.182 878.6 0.76 2 P1 P2 = + 878.6 9.81 4 + 48705.04 2 = 87369.9 Pa P2 = 3.13 atma Pressure at the outlet is 3.13 atma which is approximately equal to required value for the reactor inlet pressure.

Frictional pressure drop per unit length = 790.3 Pa/m
For 6 pipe
Frictional pressure drop per unit length = 88.36 Pa/m
For 8 pipe
Frictional pressure drop per unit length = 21.36 Pa/m The Pressure Drop in the entire pipe section (because of Velocity Head, Gravitational Head and Frictional Head) = 0.87 atma Pressure at the outlet of the pipe = 3.13 atma
EXAMPLE 7:
Let us consider a route as shown. It is a dedicated pipeline taking liquid from an over head tank nozzle to an outlet. Relevant specifications of the pipe route are given below.
No.
1 2 3 4 5
Components
Vertical Inlet Elbow Gate Valve Reducer Tee Section
Size (inch)
3 3 3 3x2 2
No.
6 7 8 9 10
Components
Elbow Elbow Elbow Globe Valve Horizontal Inlet
Size (inch)
2 2 2 2
Pipe: 3 NB, SCH 40, and 2 NB, SCH 40, Commercial Steel with surface roughness
approximately 0.05 mm.
Fluid: Density () = 1000 kg/m3, Viscosity () = 1 cP, Mass Flow Rate (W) = 15688 kg/hr
Head at Inlet = 10 m of liquid column. Find the delivery Head at outlet.
SOLUTION 7:
The route involves two pipe sizes, 3 and 2 NB. First step should be to find the equivalent length of the entire route in terms of straight pipe length of 3 and 2 NB, SCH 40 pipe. The equivalent length of the route is calculated as follows.
Route Analysis:
Piping Component Number

Pipe (3)
Equivalent Length/ Component, ft Size 3

20

20 (6.096)

---

---
Vertical Inlet (3) Elbow LR Reducer (3 2) Gate Valve (3) Pipe (2) Tee Globe Valve 90 Elbow SR Horizontal Outlet (2) TOTAL
1 1 1
7.5 5 ---
7.5 (2.286) 5 (1.524) ---
---
---
2.3
2.3 (0.70)
3.5 ---
3.5 (1.067) -----------
--24 11 60 5.25 9
--24 (7.32) 11 (3.35) 60 (18.29) 15.75 (4.80) 9 (2.74)
1 1 3 1
---------
---
36 (10.97)
---
122 (37.2)
The route analysis says that the route with its pipes, fittings and valves is equivalent to 10.97 m of 3 straight pipe and 37.2 m of 2 straight pipe. These lengths should be used in overall frictional pressure drop calculations. The next step is to calculate head loss per unit length of 3 and 2 pipes.
Calculation of the Inside Diameter of Pipe

The actual outside diameter of the pipe 3 NB pipe = 3.5 Thickness of the pipe (SCH 40) The inside diameter of the pipe = 88.9 - (2 5.49) = 88.9 mm = 5.49 mm = 77.92 mm
The actual outside diameter of the pipe 2 NB pipe = 2.375 = 60.3 mm Thickness of the pipe (SCH 40) The inside diameter of the pipe = 60.3 - (2 3.91) = 3.91 mm = 52.48 mm
Pressure Drop Calculations For 3 NB pipe

Flow Rate (Q) = W 15688 = 15.688 m3/hr = 1000
Diameter (D) = 0.0779 m Linear Velocity (v) =
4Q D2
4 15.688 3.14 0.0779 2 60 2
= 0.9144 m/s
0.0779 0.9144 1000 Dv = 71232 = 0.001
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation = 0.316 Re-0.25 = 0.019341
The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log 10 + f 3.71 D Re f
1/sqrt(f)
6.740625 6.773534 6.771084 6.771266
Friction Factor 0.019341 0.022009 0.021796 0.021811 0.021811
The iterative procedure converges after 3 - 4 iterations. A value of 0.021811 is accepted as the friction factor value in further calculations. Frictional Head Loss (m /m) = P fv 2 0.021811 0.9144 2 = = g 2gD 2 9.81 0.0779 = 0.011932 1000 9.81 = 0.011932 = 117.05 = 0.13089 m
Frictional Pressure Drop (Pa /m)
Total Frictional Head Loss over 10.97 m of 3 pipe = 0.011932 10.97

4 15.688 3.14 0.0525 2 60 2
= 2.013 m/s
= 105686 = 0.017525
Reynolds Number (Re) Initial guess = 0.316 Re-0.25
Friction Factor Frictional Head Loss (m /m) Frictional Pressure Drop (Pa /m)
1/sqrt(f)
6.720979 6.761299 6.759304 6.759402 = 0.021887 = 0.0861 = 844.641
Friction Factor 0.017525 0.022138 0.021875 0.021887 0.021887
Total Frictional Head Loss over 37.2 m of 2 pipe = 0.0861 37.2 = 3.2 m Now applying Bernoullis equation to calculate total Head Loss in the entire route
2 P P1 v 1 P2 v 2 + + Z1 = + 2 + Z2 + g g 2g g 2g friction
The elevation difference between the two ends of the route is 10 ft (3.048 m). Inlet is at higher elevation than outlet. So, if inlet is taken as basis, Z1 = 0, Z2 = -3.048 m in the Bernoullis equation. Bernoullis equation also needs consistent units. Give a set of consistent units and work in that set of units. P1 0.9144 2 P 2.014 2 + + 0= 2 + 3.048 + (0.13089 + 3.2) g 2 9.81 g 2 9.81
P1 P2 = 0.45 m g
P1 P2 = 4383.17 Pa
P2 = 9.55 m g
The Head at outlet is 9.55 m of liquid column
Summary of Solution 7: For 3 NB, SCH 40 pipe

Frictional Head Loss (m/m) = 0.011932 Total Frictional Head Loss (m) = 0.13089
For 2 NB, SCH 40 pipe

Overall Route:
Total Frictional Head Loss = 3.33 m The net Head at outlet is 9.55 m of liquid column
EXAMPLE 8:
Let us consider a route as shown. It is a dedicated pipeline taking liquid from an underground tank to an outlet. Relevant specifications of the pipe route are given below.
No.
1 2 3 4 5 6 7
Components
Elbow Gate Valve Elbow (45) Butterfly Valve Elbow (45) Tee Section Bend
Size (inch)
4 4 4 4 4 4 4
No.
8 9 10 11 12 13
Components
Globe Valve Expander Elbow Ball Valve Tee Section Globe Valve 60
Size (inch)
4 6x4 6 6 6 6
Pipe: 4 NB, SCH 40, and 6 NB SCH 40, Commercial Steel with surface roughness
Liquid: Density = 817.15 kg/m3, Viscosity = 1.64 cP, Mass Flow Rate = 88252.2 kg/hr.
Head at inlet is 25 m of liquid column. Find the delivery Head at outlet.
SOLUTION 8:
The route involves two sizes, 4 and 6 NB. First step should be to find the equivalent length of the entire route in terms of straight pipe length of 4 and 6 NB, SCH 40 pipe. The equivalent length of the route is calculated as follows.
Route Analysis: Equivalent Length/ Component ft Size 4 Equivalent Length/ Component ft Size 6
-----------------
Piping Number Component

Pipe (4) Globe Valve 90(4) Butterfly Valve(4) Tee(4) Elbow SR 90(4) Elbow SR 45(4) Bend 90 (4) Expander (6 x 4) Gate Valve (6) Pipe (6) Tee (6) 1 1 1 1 1 2 1 1 1

72.18 (22)

-----------------
120 15 7 10.5 5.25 5.5 4 4.5 -----
120 (36.58) 15 (4.572) 7 (2.1336) 10.5 (3.2) 10.5 (3.2) 5.5 (1.6764) 4 (1.2192) 4.5 (1.3716) -----
52.49 30
52.49 (16) 30 (9.144)
Globe Valve 60 (6) Elbow LR (6) Ball Valve (6)
1 1 1
-------
-------
88 10 75 ---
88 (26.8224) 10 (3.048) 75 (22.86) 255.49 (77.87)
--249.18 (75.95) TOTAL NOTE: The lengths in parenthesis are in m.
The route analysis says that the route with its pipes, fittings and valves is equivalent to 75.95 m of 4 straight pipe and 77.87 m of 6 straight pipe. These lengths should be used in overall frictional pressure drop calculations. The next step is to calculate Head loss per unit length of 4 and 6 pipes.

The actual outside diameter of the pipe 4 NB pipe = 4.5 Thickness of the pipe (SCH 40) The inside diameter of the pipe = 114.3 - (2 6.02) The actual outside diameter of the pipe 6 NB pipe = 6.625 Thickness of the pipe (SCH 40) The inside diameter of the pipe = 168.3 - (2 7.11) = 114.3 mm = 6.02 mm = 102.3 mm = 168.3 mm = 7.11 mm = 154.1 mm
Head Loss per unit length of 4 pipe is calculated as follows.

Diameter (D) = 0.1023 m Volumetric Flow Rate (Q) = Linear Velocity (v) = W
88252.2 = 108 m3/hr 817.15
4Q 4 108 = = 3.652 m/s 2 D 3.141 0.1023 2 60 2
Dv 0.1023 3.6517 817.15 = = 186135 0.00164
To calculate Darcy friction factor (f) the initial guess is calculated from Blazius equation. f = 0.316 Re-0.25 = 0.015213 Using Colebrook and White equation the friction factor is calculated. 1 2.51 = 2 log 10 + f 3.71 D Re f
On iterative calculation the friction factor is given as follows:
1/sqrt(f)
7.235723 7.279146 7.276931 7.277044
Friction Factor 0.015213 0.019100 0.018873 0.018884 0.018884
The iterative procedure converges after 3 - 4 iterations. A value of 0.018884 is accepted as the friction factor value in further calculations. Friction Factor = 0.018884 P fv 2 0.018884 3.652 2 Frictional Head Loss (m/m) = = = g 2gD 2 9.81 0.1023 Frictional Pressure Drop (Pa/m)
= 0.12548
= 0.12548 1000 9.81 = 1005.744
Total Frictional Head Loss over 75.95 m of 4 pipe = 0.12548 75.95 = 9.53 m
Head loss per unit length of 6 pipe is calculated as follows.

Diameter (D) = 0.1541 m Linear Velocity (v) = 1.609 m/s Reynolds Number (Re) = 123542 Initial guess of friction factor = 0.316 Re-0.25 = 0.016855
The iterative calculation using Colebrook and White equation the friction factor is given as:
Friction Factor = 0.018982 Frictional Head loss (m/m) = 0.01626
1/sqrt(f)
7.225506 7.26073 7.25808 7.258279 7.258264
Friction Factor 0.016855 0.019154 0.018969 0.018983 0.018982 0.018982
Frictional Pressure Drop (Pa/m) = 130.3455 Total Frictional Head Loss over 77.87 m of 2 pipe = 0.01626 77.87 = 1.266 m Now let us apply Bernoullis equation to calculate total Head loss in the entire route.
2 P P2 v 2 P1 v1 + + Z1 = + 2 + Z 2 + g g 2g g 2g friction
The elevation difference between the two ends of the route is 10 m. Inlet is at lower elevation than outlet. So, if inlet is taken as basis, Z1 = 0, Z2 = 10 m in the Bernoullis equation. Bernoullis equation also needs consistent units.
P1 3.652 2 P 1.609 2 + + 0= 2 + + 10 + (9.49 + 1.266) g 2 9.81 g 2 9.81
P1 P2 = 20.21 m g
P1 P2 = 161993.6 Pa
P2 = 4.79 m g
The Head at outlet is 4.79 m of liquid column.
Summary of Solution 8: For 4 NB, SCH 40 pipe

For 6 NB, SCH 40 pipe

Entire Route:
The Total Head Loss due to friction = 10.756 m The Net Head at outlet is 4.79 m of liquid column.
EXAMPLE 9:
Let us consider the piping route as shown. The route connects the outlet nozzle of the reactant storage tank to the reactor inlet. The discharge end is at a height of 20 m from the outlet nozzle of the storage tank. The pressure requirement at the reactor inlet is 2 atm (absolute). Estimate the minimum pressure at the inlet of the pipe (i.e. the outlet nozzle of the storage tank). Relevant specifications of the pipe route are given below.
Pipe: 8 NB, SCH 30, commercial steel pipe with surface roughness approximately 0.05
mm. Tank has a nozzle of 8 NB, while the reactor inlet nozzle is of size 6 NB.
Fluid: Density = 873.5 kg/m3, Viscosity = 0.604 cP, Mass Flow Rate = 131025 kg/hr
SOLUTION 9:
Let us analyze the route to get the equivalent length of the same
Route Analysis Equivalent Length/ Component (ft) Size 8 Total Contribution ft (m) Size 8
689 (210) 6 1 1 1 1 1 1 14 6.5 100 24 0 0 --84 (25.60) 6 (1.98) 100 (30.48) 24 (7.32) 0 0 903 (275.38) 0 0 7 36 ---0 0 7 (2.13) 36 (10.98) 43 (13.11)
Piping System Number Component

Pipe Elbow LR (900) Gate Valve Ball Check Valve Entry Nozzle Reducer (8x 6) Exit Nozzle TOTAL

0 0 0
Total Contribution (m) Size 6

0 0 0


The actual outside diameter of the pipe = 8.625 Thickness of the pipe The inside diameter of the pipe = 219.08 - (2 7.036) = 219.08 mm = 7.036 mm = 205.008 mm
The equivalent length of 8 pipe components Actual length of 8 straight pipe Total equivalent length of the 8 pipe (L) = 210 + 65.38
= 65.38 m = 210 m = 275.38 m

Volumetric Flow Rate (Q) Diameter (D) The Linear Velocity (v) = W 131025 = = 150 m3/hr 873.5
= 0.205 m =
4Q D 2
4 150 = 1.263 m/s 3.14 (60 60) 0.205 2

= 374441
Reynolds Number (Re)
D v 0.205 1.263 873.5 = 0.604 10 3
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation = 0.316 Re 0.25 = 0.316 3744410.25 = 0.0127744
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.805827 7.855744 7.853286 7.853406 7.853400 7.853401
f 0.0127744 0.0164120 0.0162041 0.0162142 0.0162137 0.0162137 0.0162137
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the third iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.01621 is accepted as the friction factor value in further calculations. P fv 2 0.01621 1.263 2 = = g 2gD 2 9.81 0.205
= 0.006431 m/m
Total Frictional Head Loss for a pipe length of 275.38 m = 0.006431 275.38 = 1.77 m

The equivalent length of 6 pipe components
= 13.11 m

Volumetric Flow Rate Diameter (D) =
131025 = 150 m3/hr 873.5
= 0.154 m
4 150 = 2.238 m/s 3.14 (60 60) 0.154 2 0.154 2.238 873.5 0.604 10 3
= 498433
Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 498433 0.25 = 0.0118928
1/sqrt(f)
7.747799 7.795614 7.793963 7.79402 7.794018
f 0.0118928 0.0166587 0.0164550 0.0164620 0.0164617 0.0164617
0.01646 2.238 2 2 9.81 0.154
= 0.02728 m/m
Total Frictional Head Loss for a pipe length of 13.11m

= 0.02728 13.11 = 0.36 m
Now, the Total Head Loss due to friction in the piping system = (1.77 + 0.36) = 2.13 m Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows.
2 2 P P1 v1 P2 v2 + + Z1 = + + Z2 + g g 2g g 2g friction
P1 P2 g
2 2 P v 2 v1 = + (Z2 Z1 ) + g 2g friction
2.238 2 1.263 2 + (20 0) + 2.13 2 9.81
= pressure equivalent to 22.30 m of liquid column
P1 P2
= 22.30 873.5 9.81 = 191089.5 Pa =1.89 atma.
The net pressure drop along the pipe route is 1.89 atma. If we want to maintain a pressure of 2 atma at the reactor inlet, the pressure at the inlet of the pipe should be at least 3.89 atma.

For 6 pipe
The Total Head Loss due to friction = 2.13 m The Pressure Drop in the entire pipe section (because of Velocity Head, Gravitational Head and Frictional Head) = 22.30 m of liquid column = 191089.5 Pa = 1.89 atma. The minimum pressure required at the inlet of the pipe = 3.89 atma
EXAMPLE 10:
Let us consider the piping route as shown. The route connects the outlet nozzle of the overhead tank to the shell side Nozzle of the shell and tube heat exchanger. The discharge end is 30 m below from the outlet nozzle of the storage tank. The pressure at the inlet nozzle is 10.5 m of liquid column (absolute). Estimate the pressure at the exit of the pipe (i.e. at the inlet nozzle of the shell and tube heat exchanger). Relevant specifications of the pipe route are given below.
Pipe: 6 NB, SCH 40, 4 NB SCH 40, commercial PVC pipe with surface roughness
approximately 0.0015 mm. Tank has a nozzle of 4 NB, while the heat exchanger has a nozzle of size 2 NB.
Fluid: Density = 997.13 kg/m3, Viscosity = 0.891 cP, Mass Flow Rate = 34900 kg/hr
No. Component Size (inches) 1 Entry Nozzle 4 2 Expander 6x4 3 Elbow LR 6 4 Elbow LR 6 5 Elbow LR 6 6 Globe valve 6 7 Elbow LR 6 8 Elbow LR 6 9 Reducer 6x4 10 Elbow LR 4 11 Elbow LR 4 12 Elbow LR 4 13 Ball Type Check Valve 4 14 Reducer 4x2 15 Exit Nozzle 2
SOLUTION 10:
Route Analysis:
Equivalent Length/ Component ft (Number) Number Size 6 Total Contribution ft (m) Size 6 Equivalent Length/ Component ft ( Number) Size 4 Total Contribution ft (m) Size 4 Equivalent Length/ Component (ft) (Number) Size 2 Total Contribution ft (m) Size 2
Piping Component
Pipe Elbows LR 900 Expander Globe valve Reducer Check Valve ball type Entry Nozzle Exit Nozzle Total (m)
8 1 1 2 1 1 1
10 (5) 175 (1) 0
672.57 (205) 50.0 (15.24) 175 (53.34) 0
7 (3) 4 (1) 4 (1) 50 (1) 10 (1) 0
508.53 (155 ) 21 (6.4) 4 (1.22) 4 (1.22) 50 (15.24) 10 (3.05) 0 597.53 (182.13) 3.2 (1) 0 0 9 3.2 (0.98) 0 0 9 (2.74) 12.2 (3.72)
0 895.57 (273.58)
Note: 1. The lengths in parenthesis are in m (total contribution)

2. The values in Parenthesis number of pieces of particular component (equivalent length/component column) The route analysis says that the route with its pipes, fittings and valves is equivalent to 273.58 m of 6 straight pipe, 182.13 m of 4 straight pipe and 3.72 m of 2 straight pipe. These lengths should be used in overall frictional pressure drop calculations.

The equivalent length of 6 pipe components Actual length of 6 straight pipe Total equivalent length of the 6 pipe (L) = 205 + 68.58
= 68.58 m = 205 m = 273.58 m

Volumetric Flow Rate (Q) = Diameter (D) = 0.154 m The Linear Velocity (v) = W 34900 = = 35 m3/hr 997.13
4Q D 2
D v
4 35 = 0.522 m/s 3.14 (60 60) 0.154 2

0.154 0.522 997.13 0.891 10 3 = 89963
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.359080 7.364210 7.363613 7.363682 7.363674 7.363675
f 0.018246 0.018465 0.018439 0.018442 0.018442 0.018442 0.018442
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.018442 is accepted as the friction factor value in further calculations. P fv 2 0.018442 0.522 2 = = g 2gD 2 9.81 0.154 = 0.001661 m/m Total Frictional Head Loss for a pipe length of 273.58 m = 0.001661 273.58 = 0.45 m

The equivalent length of 4 pipe components Actual length of 4 straight pipe Total equivalent length of the 4 pipe (L) = 152.5 + 27.13
= 27.13 m = 155 m = 182.13 m

Volumetric Flow Rate (Q) Diameter (D) The Linear Velocity (v) = = 35 m3/hr = 0.1023 m
4 35 = 1.184 m/s 3.14 (60 60) 0.1023 2
0.1023 1.184 997.13 0.891 10 3
= 135550
Darcy Friction Factor (f) as per one of the empirical equations given in the notes (Blazius Equation) = 0.316 Re 0.25 = 0.316 135550 0.25 = 0.016469 The Colebrook and White equation for calculating the friction factor is as follows:
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.657974 7.672669 7.671049 7.671227 7.671207 7.67121
f 0.016469 0.017052 0.016987 0.016994 0.016993 0.016993 0.016993
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.016993 is accepted as the friction factor value in further calculations. 0.016993 1.184 2 = 0.011868 m/m 2 9.81 0.1023
Total Frictional Head Loss for a pipe length of 182.13 m = 0.011868 182.13 = 2.16 m

The actual outside diameter of the pipe = 2.375 Thickness of the pipe The inside diameter of the pipe = 60.33 - (2 3.912) = 60.33 mm = 3.912 mm = 52.51mm
The equivalent length of 2 pipe components Total equivalent length of the 2 pipe (L)
= 3.72 m = 3.72 m

Volumetric Flow Rate (Q) Diameter (D) = 0.0525 m The Linear Velocity (v) = = 35 m3/hr
4 35 3.14 (60 60) 0.0525 2
= 4.493 m/s
0.0525 4.493 997.13 0.891 10 3
= 263979
Darcy Friction Factor (f) as per one of the empirical equations given in the notes (Blazius Equation) = 0.316 Re 0.25 = 0.316 263979 0.25 = 0.013941 The Colebrook and White equation for calculating the friction factor is as follows:
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
8.108756 8.143188 8.139842 8.140166 8.140135 8.140138
f 0.0139410 0.0152086 0.0150803 0.0150927 0.0150915 0.0150916 0.0150916
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.015092 is accepted as the friction factor value in further calculations.
0.015092 4.493 2 = 0.2958 m/m 2 9.81 0.0525
Total Frictional Head Loss for a pipe length of 3.72 m = 0.2958 3.72 = 1.10 m Now, the total head loss due to friction in the piping system = (0.45 + 2.16 + 1.10) = 3.71 m Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows.
2 2 P P1 v1 P2 v2 + + Z1 = + + Z2 + g 2g g 2g g friction
P1 P2 g
2 2 P v 2 v1 = + (Z2 Z1 ) + g 2g friction
4.493 2 0.522 2 + (0.0 - 30.0) + 3.71 2 9.81
10.5
P2 = -25.27 m of liquid column g
P2 = 35.77 m of water column g

P2 = 349896.60 Pa = 3.45 atma.
The pressure at the exit of the pipe = 3.45 atma.

Linear Velocity (v) Reynolds Number (Re) = 0.522 m/s = 89963
Darcy Friction Factor (f) Frictional Head Loss
= 0.018422 = 0.45 m = 1.184 m/s = 135550 = 0.016993 = 2.16 m = 4.493 m/s = 263979 = 0.015092 = 1.10 m
For 4 pipe
Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Head Loss
For 2 pipe
Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Head Loss
The Total Head Loss due to friction = 3.71m The pressure at the exit of the pipe = 349896.60 Pa = 3.45 atma.
EXAMPLES FOR TWO PHASE PRESSURE DROP CALCULATIONS: EXAMPLE 11:

Let us consider a piping route as shown. The route shows all components present from entry nozzle to exit nozzle. It is a dedicated pipeline taking a liquid-gas mixture from a storage tank entry nozzle to a distillation column feed tray for separation process. Estimate the minimum pressure at the inlet of the pipe (i.e. the outlet nozzle of the storage tank) when pressure at distillation feed tray is given to be 1 atma. Relevant specifications of the pipe route are given below.
No.
1 2 3 4 5 6 7 8
Components
Inlet Nozzle Expander Gate Valve Tee Elbow LR Elbow LR Elbow LR Elbow LR
Size (inch)
4 64 6 6 6 6 6 6
No.
9 10 11 12 13 14 15 16
Components
Elbow LR Elbow LR Reducer Tee Elbow SR Tee Elbow SR Exit Nozzle
Size (inch)
6 6 64 4 4 4 4 4

For 6 NB, SCH 40, OD = 6.625 in (168.27 mm), Wall thickness = 0.280 in (7.112 mm) For 4 NB, SCH 40, OD = 4.500 in (114.30 mm), Wall thickness = 0.237 in (6.020 mm)
Liquid: Mass Flow Rate (Wl) = 100000 kg/hr, Density (l) = 1000 kg/m3, Viscosity (l)
= 1.02 cP, Surface Tension (l) = 18.7 dyne/cm
Gas: Mass Flow Rate (Wv) = 850 kg/hr, Density (v) = 2.16 kg/m3, Viscosity (v) = 0.135 cP
EXAMPLE 12:
No.
1 2 3 4 5 6 7 8
Components
Inlet Nozzle Fully open Globe Valve Elbow SR Bend Bend Reducer Bend Exit Nozzle
Size (inch)
6 6 6 6 6 64 4 4

For 6 NB, SCH 120, OD = 6.625 in (168.27 mm), Wall Thickness = 0.562 in (14.275 mm) For 4 NB, SCH 120, OD = 4.5 in (114.30 mm), Wall Thickness = 0.437 in (11.10 mm)
Liquid: Mass Flow Rate (Wl) = 80000 kg/hr, Density (l ) = 750 kg/m3,Viscosity (l )
= 0.48 cP, Surface Tension (l ) = 18.7 dyne/cm
Vapor: Mass Flow Rate (Wv ) = 9000 kg/hr, Density (v ) = 11.9 kg/m3, Viscosity (v )=
0.0138 cP
EXAMPLE 13:
No. 1 2 3 4 5 6 7
Size 4 4 6x4 6 6 6x4 4
Pipe: 4 NB, SCH 40 and 6 NB, SCH 40, Commercial Steel with surface roughness
approximately 0.05 mm. Tank has a Flush nozzle of 4 NB, while the reactor inlet nozzle is of size 4 NB, also there are one fully open gate valve, one reducer and one expander in the route as shown in the figure.
Liquid: Density (l) = 1000 kg/m3, Viscosity (l) = 1 cP, Mass Flow Rate (Wl) = 50000
kg/hr, Surface Tension (l) = 72.3 dynes/cm.
Gas:
kg/hr
Density (v) = 1.184 kg/m3, Viscosity (v) = 0.0184 cP, Mass Flow Rate (Wv) = 828.8
All fluid properties are given at flow conditions and elbows used are short radius. Let us analyze the route to get equivalent length of the same.
EXAMPLE 14:
Let us consider a route as shown. The route connects the discharge nozzle of the condenser to a storage tank inlet nozzle. The tank inlet nozzle is 130 m below discharge nozzle of the condenser. The pressure at the condenser discharge nozzle is 16 atm absolute. Estimate the pressure at the storage tank inlet? Relevant specifications of the route are given below.
No. 1 2 3 4 5 6 7 8 9
Size 6 6 6x4 4 4 4 4 4 4
approximately 0.05 mm. Condenser discharge has a Protruding nozzle of 6 NB, while storage tank inlet nozzle is of size 4 NB. Also there are two fully open Gate Valve, one Reducer (6 to 4), three large radius Elbows and two Tees as shown in the figure.
Liquid: Density (l) = 779 kg/m3, Viscosity (l) = 1.02 cP, Mass Flow Rate (Wl) = 77900
Gas:Density(v) =1.145 kg/m3, Viscosity (v) = 0.0178 cP, Mass Flow Rate(Wv)=1145 kg/hr
All fluid properties are given at flow conditions and elbows used are long radius.
EXAMPLE 15:
Let us consider a route as shown in the figure. There is a network along the ground. Pressure at inlet of the pipe is 19 atma. Due to some new requirement, one needs to draw some liquid from the pipeline at outlet pressure between 1.5 atma to 3 atma. Find out segment numbers in which these pressures can be measured.
No.
1 2 3 4
Components
Size (inch)
6 6x4 4 4
No.
5 6 7
Components
Expander Elbow Tee
Size (inch)
6x4 6 6
Pipes: used in the route are 6 NB SCH 40 and 4 SCH 40. Pipe made of Commercial Steel
with surface roughness approximately 0.05 mm
Liquid: Density (l) = 1000 kg/m3, Viscosity (l) = 1 cP, Flow Rate (Wl) = 100000 kg/hr,
Surface Tension (l) = 71.97 dyne/cm
Gas: Density (v) = 1.184kg/m3, Viscosity (v) = 0.01837 cP, Flow Rate (Wv) = 1302.4 kg/hr
EXAMPLE 16:
Let us consider a route as shown. . The route connects the outlet nozzle of the reactant storage tank to the reactor inlet. The discharge end is at a height of 4 m from the outlet nozzle of the storage tank. The pressure at the inlet of the reactor should not be less than 5 atma and greater than 10 atma. Can this system deliver the pressure more than 5 atma? Pressure at Pump Discharge: P1 = 15 atma upstream of discharge nozzle. The service and the pipe specifications are given below:
No.
1 2 3 4 5
Components
Size (inch)
8 8x6 6 6 6
No.
6 7 8 11 12
Components
Size (inch)
6 6 6 6x4 4
roughness approximately 0.05 mm. Entry nozzle is 8 protruding nozzle.
Liquid: Density (l) = 878.6 kg/m3, Viscosity (l) = 0.652 cP, Flow Rate (Wl) = 79074
kg/hr, Surface Tension (l) = 28.88 dyne/cm
Gas: Density (v) = 5.389 kg/m3 at 25oC, Flow Rate (Wv) = 5389 kg/hr, Viscosity (v) =
0.0238 cP
EXAMPLE 17:
Let us consider a route as shown. It is a dedicated pipeline taking fluid from an over head tank nozzle to your basin outlet. Relevant specifications of the pipe route are given below.
No.
1 2 3 4 5
Components
Size (inch)
3 3 3 3x2 2
No.
6 7 8 9 10
Components
Size (inch)
2 2 2 2 2
kg/hr, Surface Tension (l) = 72 dynes/cm.
Gas: Density (g) = 1.184 kg/m3, Viscosity (g) = 0.01983 cP, Mass Flow Rate (Wv)
=255.744 kg/hr. Pressure Head at inlet is 25 m of liquid column. Find the delivery Pressure Head at outlet.
EXAMPLE 18:
Let us consider a route as shown. It is a dedicated pipeline taking fluid from an underground tank to your over head tank. The service and the pipe specifications are as given below.
No.
1 2 3 4 5 6 7
Components
Size (inch)
4 4 4 4 4 4 4
No.
8 9 10 11 12 13
Components
Size (inch)
4 6x4 6 6 6 6
Liquid: Density (l) = 878.6 kg/m3, Viscosity (l) = 0.652 cP, Mass Flow Rate (Wl) = 87860
kg/hr, Surface Tension (l) = 28.88 dynes/cm
Gas: Density (v) = 1.184 kg/m3, Viscosity (v) = 0.01827 cP, Mass Flow Rate (Wv) = 473.6 kg/hr
Head at inlet is 40 m of liquid column. Find the delivery pressure at outlet.
EXAMPLE 19:
Let us consider the route shown; carrying a two phase mixture of hydrocarbon oil and gas. The service requirements and the specifications are given below. The discharge end is at an elevation of 20m. Gas and Liquid both are flowing at a flow rate of 5000 kg/hr and 45000 kg/hr respectively. Calculate the two phase pressure drop if the pressure at the inlet of the pipe is 5 atma.
Pipe: 8 NB, SCH30, commercial steel pipe with Surface roughness approx 0.05 mm; Liquid: Density (l) = 740 kg/m3, Viscosity (l) = 4.96 cP, Surface Tension (l)= 25
dynes/cm, Mass Flow Rate(Wl )= 45000 Kg/hr
Gas: Density (v) = 2.73 kg/m3, Viscosity (v) = 0.0135 cP, Mass Flow Rate (Wv ) = 5000
Kg/hr.
EXAMPLE 20:
Let us consider the route shown; carrying a two phase mixture of air and water. The service requirements and the specifications are given below. Air and water both are flowing at a flow rate of 15,000 kg/hr and 60,000 kg/hr respectively. Calculate the two phase pressure drop if the pressure at the inlet of the pipe is 5 atma.
No.
1 2 3 4 5
Components
Globe Valve Elbow Elbow Elbow Expander
Size (inch)
10 10 10 10 12 x 10
No.
8 9 10 11 12
Components
Elbow Elbow CheckValve Elbow Reducer
Size (inch)
12 12 x 10 12 12 12 x 10
Pipe: 10, NB, SCH 40 commercial PVC pipe with roughness 0.0015mm.
12, NB, SCH 40 commercial PVC pipe with roughness 0.0015mm.
Liquid: Density (l) = 996 kg/m3, Viscosity (l) = 0.798 cP, Surface Tension (l) =71.2
dynes/cm, Mass Flow Rate (Wl) = 60,000 Kg/hr.
Gas: Density (v) = 1.166 kg/m3, Viscosity (v) = 0.0187 cP, Mass Flow Rate (Wv) =
15,000 Kg/hr.
EXAMPLE 11:
Let us consider a piping route as shown. The route shows all components present from entry nozzle to exit nozzle. It is a dedicated pipeline taking a liquid-gas mixture from a storage tank entry nozzle to a distillation column feed tray for separation process. Estimate the minimum pressure at the inlet of the pipe (i.e. the outlet nozzle of the storage tank) when pressure at distillation feed tray is given to be 1 atma. Relevant specifications of the pipe route are given below.
No.
1 2 3 4 5 6 7 8
Components
Inlet Nozzle Expander Gate Valve Tee Elbow LR Elbow LR Elbow LR Elbow LR
Size (inch)
4 64 6 6 6 6 6 6
No.
9 10 11 12 13 14 15 16
Components
Elbow LR Elbow LR Reducer Tee Elbow SR Tee Elbow SR Exit Nozzle
Size (inch)
6 6 64 4 4 4 4 4

For 6 NB, SCH 40, OD = 6.625 in (168.27 mm), Wall thickness = 0.280 in (7.112 mm) For 4 NB, SCH 40, OD = 4.500 in (114.30 mm), Wall thickness = 0.237 in (6.020 mm)
Liquid: Mass Flow Rate (Wl) = 100000 kg/hr, Density (l) = 1000 kg/m3, Viscosity (l)
= 1.02 cP, Surface Tension (l) = 18.7 dyne/cm
Gas: Mass Flow Rate (Wv) = 850 kg/hr, Density (v) = 2.16 kg/m3, Viscosity (v) = 0.135 cP
SOLUTION 11:
The route involves two sizes, 4 and 6. First step should be to find the equivalent length of the entire route in terms of straight pipe length of 6 NB and 4 NB, SCH 40 pipe.
Route Analysis:
Equivalent Length/ Piping Component Component Number ft Size 4

Entry Nozzle(4) Expander (6 4) Gate Valve (6) Tee(6) Elbow LR (6) Reducer (6 4) Tee (4) Tee (4) Elbow SR(4) Exit Nozzle (4) Pipe TOTAL 1 1 1 1 6 1 1 1 2 1 --10 4 ---4 7 20 10.5 20 ---

10 (3.05 ) 4 (1.22 ) ---4 (1.22) 7 (2.13) 20 (6.10) 21 (6.40) 20 (6.10) 406.56 (123.92) 492.56 (150.14)

--6.5 30 10 --------

--6.5 (1.98) 30 (9.14) 60 (18.29) -----642.22 (195.75) 738.72 (225.16)

The actual outside diameter of the pipe = 4.5 Thickness of the pipe The inside diameter of the pipe = 114.30 - (2 6.02) The equivalent length of 4 NB pipe components Actual length of 4 straight pipe Total equivalent length of the 4 pipe (L) = 26.22 + 123.92 = 114.30 mm = 6.02 mm = 102.26 mm = 26.22 m = 123.92 m = 150.14 m
Pressure Drop Calculations: Pressure Drop for liquid phase per unit length of 4NB pipe is calculated as follows:
Flow Rate (Ql) = Diameter (D) Linear Velocity (vl) Wl 100000 = 100 m3/hr = l 1000 = 102.26 10 3 m =
4Q l 4 100 = = 3.38 m/s 2 D 3.14 (60 60) (102.26 10 3 ) 2 D v l l 102.26 10 3 3.38 1000 = l 1.02 10 3 = 338862
To calculate Darcy Friction Factor (f) the initial guess is calculated from Blazius equation f = 0.316 Re 0.25 = 0.316 229460 0.25 = 0.013097
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.41321 7.45770 7.45617 7.45622
f 0.013097 0.018197 0.01798 0.017987 0.017987
As can be seen, the iterative procedure converges after 3 - 4 iterations. A value of 0.017987 is accepted as the friction factor value in further calculations.
f vl 0.017987 3.38 2 P = = Frictional Head Loss per unit length = l g 2gD 2 9.81 102.26 10 -3
= 0.102 m/m Pressure drop per unit length (PL) = 0.044 psi/ft
Pressure Drop for gas phase per unit length of 4NB pipe is calculated as follows:
Flow Rate (Qv) =
850 = 393.52 m3/hr 2.16
Diameter (D) = 102.26 10 3 m Linear Velocity (vv) =
4 393.52 = 13.32 m/s 3.14 (60 60) (102.26 10 3 ) 2

102.26 10 3 13.32 2.16 = 21794 0.135 10 3
Initial guess of friction factor (f) calculated as per Blazius Equation f = 0.316 21794 0.25 = 0.026008 The iterative calculation using Colebrook and White equation the friction factor is given:
Friction factor Frictional Head Loss per unit length =
1/sqrt(f)
6.145325 6.151912 6.151127 6.151221 6.15121
f 0.026008 0.02648 0.026423 0.02643 0.026429 0.026429

= 0.026429
0.026429 13.32 2 = 2.34 m/m 2 9.81 102.26 10 -3 = 0.0022 psi/ft
Frictional Pressure drop per unit length (PV)
The fluid properties in FPS system of units are as follows:
Properties
Mass Flow Rate (lb/hr) Density (lb/ft3) Viscosity (cP) Surface Tension (dynes/cm)
Fluid 1
220462.25 61.80 1.02 18.7
Fluid 2
1873.93 0.135 0.135
Lockhart Martinellis Modulus (X) = {(P) L / (P) V } 0.5 PL = 0.044 psi/ft PV = 0.0022 psi/ft X = 4.47 Y(v or l) = exp
a (ln X )
i =1 i
i 1
where, for Yl: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002.
for Yv: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002.
Yl = 2.26, Y V = 10.10 Two Baker parameters BX and BY are calculated as follows:

A = 0.09 ft2 W ( v ) 0.5 11 3 BX = 531 l l 2/3 WV 1 1
220462.25 BX = 531 1873.93

Wv BY = 2.16 0.5 A( l v )
(61.80 0.135) 0.5 1.021 3 = 621.40 2/3 18.7 61.80
1873.93 BY = 2.16 0.09 (61.80 0.135)
0.5
= 15570.05
From the Baker flow regime map, we see that the flow regime is bubble and the correlation for Bakers modulus is given by Bakers Modulus () = 14.2X 0.75 (Wl / A) 0.1
= 10.03
Pressure Drop Calculation: Lockhart Martinellis Method:

(P) LV = Yv2 (P )V = 10.102 0.0022 (P) LV = Yl 2 (P )l = 2.262 0.0044 = 0.225 psi/ft = 0.225 psi/ft
Total Frictional Pressure Drop in 4 pipe = 0.225 492.56 = 110.83 psi
Bakers Method:
PLV = 2 PV PLV = 0.221 psi/ft Total Frictional Pressure Drop in 4 pipe = 0.221 492.56 = 108.86 psi

Total equivalent length of the 6 pipe (L) = 29.41 + 195.75 = 225.16 m
Pressure Drop for liquid phase per unit length of 6NB pipe is calculated as follows:
Flow Rate (Ql) Diameter (D) Linear Velocity (vl) =
100000 = 100 m3/hr 1000
= 154.05 10 3 m =
4 100 = 1.49 m/s 3.14 (60 60) (154.05 10 3 ) 2

= 225034
Initial guess of friction factor (f) calculated as per Blazius Equation f = 0.316 225034 0.25 = 0.014509 The iterative calculation using Colebrook White equation the friction factor is given as:
Friction Factor
1/sqrt(f)
7.48904 7.53392 7.53138 7.53153 7.53152
f 0.014509 0.01783 0.017618 0.01763 0.017629 0.017629
= 0.017629 0.017629 1.49 2 2 9.81 154.05 10 -3
= 0.013 m/m Pressure Drop per unit length (PL) = 0.0056 psi/ft
Flow Rate (Qv) Diameter (D) =
850 = 393.52 m3/hr 2.16
= 154.05 10 3 m
4 393.52 3.14 (60 60) (154.05 10 3 ) 2
= 5.87 m/s
154.05 10 3 5.87 2.16 Reynolds Number (Re) = 0.135 10 3
= 14468
Initial guess of Friction Factor (f) calculated as per Blazius Equation f = 0.316 14468 0.25 = 0.028813
The iterative calculation using Colebrook White equation the friction factor is given as:
Friction factor
1/sqrt(f)
5.909717 5.907212 5.907552 5.907506
f 0.028813 0.028633 0.028657 0.028654 0.028654

= 0.028654
0.028654 5.87 2 Frictional Head Loss per unit length = = 0.33 m/m 2 9.81 154.05 10 -3 Pressure drop per unit length (PV) = 0.00031 psi/ft
Lockhart Martinellis Modulus (X) = {(P) L /(P) V } 0.5 PL = 0.0056 psi/ft PV = 0.00031 psi/ft X = 4.28 Y(v or l) = exp
a (ln X )
i =1 i
i 1
Yl = 2.3, Y V = 9.81 Two Baker parameters BX and BY are calculated as follows:

Bakers parameters Bx and BY are calculated as follows: A = 0.20 ft2
220462.25 BX = 531 1873.93

BX = 621.40
(61.80 0.135) 0.5 1.021 3 61.80 2/3 18.7
1873.93 BY = 2.16 0.20 (61.80 0.135) BY = 7006.74
0.5
From the Baker flow regime map, we see that the flow regime is bubble and the correlation for Bakers modulus is given by 14.2X 0.75 = (Wl / A) 0.1 = 10.51
.
Pressure Drop Calculation: Lockhart Martinellis Method pressure drop:

(P) LV = Yv2 (P )V = 9.812 0.00031 = 0.03 psi/ft (P) LV = Yl 2 (P )l = 2.32 0.0056 = 0.03 psi/ft Total Frictional Pressure Drop in 6 pipe = 0.03 738.72 = 22.16 psi
Bakers Method:
PLV = 2 PV PLV = 0.034 psi/ft Total Frictional Pressure Drop in 6 pipe = 0.034 738.72 = 25.12 psi Total maximum frictional pressure drop in entire piping network = 134.02 psi The mixture density is give n by
1 mix
Mg g
Ml l
Where M g and M l are mass fractions of the two fluids mix = 204.5 kg/m3 Mixture velocity in 4 pipe vmix = Total mass of the mixture Flow area mixture density
vmix = (105 + 850)/(0.0082 204.51)
vmix = 16.68 m/s Mixture velocity in 6 pipe vmix = (105 + 850)/(0.0186 204.5) vmix = 7.352 m/s Now applying Bernoullis equation at the entry and the exit point:
P1 2 v1 2g P2 v2 2
mix g
+ Z1 =
mix g
2g
+ Z2 +
P g friction
P1 = 1.01 105 + 204.5 9.81 (10-4) +924035.37
P1 = 1037072.22 N/m2 P1 = 10.3 atma The minimum required pressure at the inlet of the pipe = 10.3 atma
Summary of Solution 11: For 4 NB, SCH pipe Liquid Phase

The Linear Velocity (vl) Reynolds Number (Re) Darcys friction factor Pressure drop per unit length (PL)
= 3.38 m/s
= 338862 = 0.017987 = 0.044 psi/ft
Gas Phase
The Linear Velocity (v) Reynolds Number (Re) Darcys friction factor
= 13.32 m/s
= 21794 = 0.026429
Pressure drop per unit length = PV
= 0.0022 psi/ft
Total frictional pressure drop in 4 pipe using Lockhart Martinellis Method = 110.83 psi Total frictional pressure drop in 4 pipe using Bakers Method = 108.86 psi
For 6 NB, SCH pipe Liquid Phase

= 1.49 m/s
= 225034 = 0.017629 = 0.0056 psi/ft
Gas Phase
The Linear Velocity (vv) Reynolds Number (Re) Darcys friction factor Pressure drop per unit length = PV
= 5.87 m/s
= 14468 = 0.028654 = 0.00031 psi/ft
Overall Route:
Total frictional pressure drop in entire piping network using Lockhart Martinellis Method = 133 psi Total frictional pressure drop in entire piping network using Bakers Method = 134.02 psi The minimum required pressure at the inlet of the pipe = 10.3 atma.
EXAMPLE 12:
No.
1 2 3 4 5 6 7 8
Components
Inlet Nozzle Fully open Globe Valve Elbow SR Bend Bend Reducer Bend Exit Nozzle
Size (inch)
6 6 6 6 6 64 4 4

For 6 NB, SCH 120, OD = 6.625 in (168.27 mm), Wall Thickness = 0.562 in (14.275 mm) For 4 NB, SCH 120, OD = 4.5 in (114.30 mm), Wall Thickness = 0.437 in (11.10 mm)
Liquid: Mass Flow Rate (Wl) = 80000 kg/hr, Density (l ) = 750 kg/m3,Viscosity (l )
= 0.48 cP, Surface Tension (l ) = 18.7 dyne/cm
Vapor: Mass Flow Rate (Wv ) = 9000 kg/hr, Density (v ) = 11.9 kg/m3, Viscosity (v )=
0.0138 cP
SOLUTION 12:
The route involves two sizes, 4 and 6 NB. First step should be to find the equivalent length of the entire route in terms straight pipe length of 6 and 4 NB, SCH 120 pipe.
Route Analysis: Equivalent Length/ Component ft Size 4

----4 5.5 20 ---
Piping Component
Inlet (6) Fully Open Globe Valve (6) Elbow SR(6) Bend SR (6) Reducer (6 4) Bend SR (4) Exit Nozzle (4) Pipe TOTAL
Number
1 1 1 2 1 1 1 ---

----4 (1.22) 5.5 (1.68) 20 (6.10) 298.56 (91) 328.06 (100)

18 175 15 8.5 ------

18 (5.49) 175 (53.34) 15 (4.57) 17 (5.18) ---431.17 (131.42) 656.17 (200)

The route analysis says that the route with its pipes, fittings and valves is equivalent to 100 m of 4 straight pipe and 200 m of 6 straight pipe. These lengths should be used in overall frictional pressure drop calculations.

The actual outside diameter of the pipe = 4.500 in Thickness of the pipe The inside diameter of the pipe = 114.30 - (211.10) The equivalent length of 4 NB pipe components Actual length of 4 straight pipe Total equivalent length of the 4 pipe (L) = 9 + 91 = 114.30 mm = 11.10 mm = 92.1 mm =9m = 91 m = 100 m
Pressure Drop Calculations: Pressure Drop for liquid phase per unit length of 4NB pipe is calculated as follows:
Flow Rate (Ql) Diameter (D) Linear Velocity (vl) = Wl 80000 = 106.7 m3/hr = l 750
= 92.1 10 3 m = 4Q l 4 106.67 = 2 D 3.14 (60 60) 92.12 10 -6 D v l l 92.1 10 -3 4.45 750 = l 0.48 10 3
= 4.45 m/s
= 640383
To calculate Darcy Friction Factor (f) the initial guess is calculated from Blazius equation f = 0.316 Re 0.25 = 0.316 640383 0.25 = 0.011171
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.47313 7.51084 7.51011 7.51012
f 0.011171 0.017906 0.017726 0.01773 0.01773
As can be seen, the iterative procedure converges after 3 - 4 iterations. A value of 0.01773 is accepted as the friction factor value in further calculations.
fv l 0.01773 4.45 2 P = = = 0.194 m/m Frictional Head Loss per unit length = l g 2gD 2 9.81 92.1 10 -3
Pressure drop per unit length (PL) = 0.063 psi/ft
Flow Rate (QV) Diameter (D) Linear Velocity (vv) =
9000 = 756.30 m3/hr 11.9
= 92.1 10 3 m =
4 756.30 3.14 (60 60) (92.1 10 3 ) 2
= 31.55 m/s
= 2505687
Initial guess of friction factor (f) calculated as per Blazius Equation f = 0.316 2505687 0.25 = 0.007942
The iterative calculation using Colebrook and White equation the friction factor is given:
Iteration No. 1/sqrt(f) f 0 0.007942 1 7.605047 0.01729 2 7.625245 0.017199 3 7.625131 0.017199
Friction Factor
= 0.017199
0.017199 31.55 2 Frictional Head Loss per unit length = = 9.47 m/m 2 9.81 92.1 10 -3 Frictional Pressure drop per unit length (PV) The fluid properties in FPS system of units are as follows: = 0.05 psi/ft
Properties
Liquid
176369.8 46.82 0.48 18.7
Gas
19841.6 0.74 0.0138
Lockhart Martinellis Modulus (X) = {(P) L /(P) V }0.5 PL = 0.063 psi/ft PV = 0.05 psi/ft X = 1.12 Y(v or l) = exp
a (ln X )
i =1 i
i 1
where for Yl: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002. for Yv: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002.
Yl = 4, Y V = 4.47 Two Baker parameters BX and BY are calculated as follows:

A = 0.072 ft2 W BX = 531 l WV ( l v ) 0.5 2/3 1
11 3 1
176369.8 BX = 531 19841.6
(46.82 0.74) 46.82 2/3
0.5
0.481 3 = 90 18.7
19841.6 BY = 2.16 0.072 (46.82 0.74)
0.5
= 101127
From the Baker flow regime map, we see that the flow regime is dispersed and the correlation for Bakers Modulus () is given by For X2>0.3 and X2 <2.5, = (7.844X + 9.1477)0.5, = 4.23

(P) LV = Yv2 (P )V = 42 0.063 (P) LV = Yl 2 (P )l = 4.472 0.05 = 1.01 psi/ft = 1 psi/ft = 331.34 psi
Total frictional pressure drop in 4 pipe = 1.01 328.06
Bakers Method:
PLV = 2 PV PLV = 0.9 psi/ft Total frictional pressure drop in 4 pipe = 0.9 328.06 = 295.25 psi

Total equivalent length of the 6 pipe (L) = 68.58 + 131.42 = 200 m
Pressure Drop for liquid phase per unit length of 6NB pipe is calculated as follows:
80000 750
= 106.7 m3/hr
= 139.72 10 3 m =
4 106.67 = 1.93 m/s 3.14 (60 60) (139.72 10 3 ) 2

= 421343
Initial guess of friction factor (f) calculated as per Blazius Equation f = 0.316 421343 0.25 = 0.012403
Friction Factor
1/sqrt(f)
7.64812 7.69531 7.69359 7.69365
f 0.012403 0.017096 0.016887 0.016894 0.016894
= 0.016894
0.016894 1.93 2 Frictional Head Loss per unit length = 2 9.81 139.72 10 -3 = 0.023 m/m Pressure drop per unit length (PL) = 0.0075 psi/ft
Flow Rate (Qv) =
9000 = 756.30 m3/hr 11.9
Diameter (D) = 139.72 10 3 m
Linear Velocity (vl) =
4 756.30 3.14 (60 60) (139.72 10 3 ) 2
= 13.7 m/s
= 1650620
Initial guess of Friction Factor (f) calculated as per Blazius Equation f = 0.316 1650620 0.25 = 0.008816
Friction Factor
1/sqrt(f)
7.896513 7.929416 7.929015 7.92902
f 0.008816 0.016037 0.015904 0.015906 0.015906

= 0.015906
0.015906 13.7 2 Frictional Head Loss per unit length = = 1.09 m/m 2 9.81 139.72 10 -3 Pressure drop per unit length = PV Lockhart Martinellis Modulus (X) = {(P) L /(P) V } 0.5 PL = 0.0075 psi/ft PV = 0.0056 psi/ft X = 1.16 Y(v or l) = exp = 0.0056 psi/ft
a (ln X )
i =1 i
i 1
Yl = 3.92, Y V = 4.55
Two Baker parameters BX and BY are calculated as follows:

Bakers parameters Bx and BY are calculated as follows: A = 0.17 ft2
176369.8 BX = 531 19841.6

BX = 90
(46.82 0.74) 46.82 2/3
0.5
0.481 3 18.7
19841.6 BY = 2.16 0.17 (46.82 0.74) BY = 42830
0.5
From the Baker flow regime map, we see that the flow regime is dispersed and the correlation for Bakers modulus () is given by For X2 > 0.3 and X2 < 2.5, = 4.27 = (7.844X + 9.1477)0.5

(P) LV = Yv2 (P )V = 3.922 0.0075 = 0.12 psi/ft (P) LV = Yl 2 (P )l = 4.552 0.0056 = 0.12 psi/ft = 78.74 psi
Total frictional pressure drop in 6 pipe = 0.12 656.17
Bakers Method:
PLV = 2 PV PLV = 0.1 psi/ft Total frictional pressure drop in 6 pipe = 0.1 656.17 = 65.62 psi
Total Maximum Frictional Pressure Drop in entire piping network = 410.08 psi
The mixture density is given by
1 mix
Mg g
Ml l
Where M g and M l are mass fractions of the two fluids mix = 104.13 kg/m3 Mixture velocity in 4 pipe vmix = Total mass of the mixture Flow area mixture density
vmix = (80000 + 9000)/(0.0067 104.13) vmix = 35.43 m/s Mixture velocity in 6 pipe vmix = (80000 + 9000)/(0.015 104.13) vmix = 15.83 m/s Now applying Bernoullis equation:
P 1 g 2 v1 2g P2 g v2 2
+ Z1 =
2g
+ Z2 +
P g friction
1 P2 = 30 1.01 105 + 104.13 (15.83 2 35.43 2 ) + 104.13 9.81 5 2827402.07 2

P2 = 3030000 52309.5 + 5107.58 2827402.07 P2 = 155396.01 N/m2 P2 = 1.54 atma. The pressure at the exit nozzle = 1.54 atma.
Summary of Solution 12: For 4 NB, SCH pipe Liquid Phase

= 4.45 m/s
= 640383 = 0.01773 = 0.063 psi/ft
Gas Phase
The Linear Velocity (vv) Reynolds Number (Re) Darcys friction factor Pressure drop per unit length (PV)
= 31.55 m/s
= 2505687 = 0.017199 = 0.05 psi/ft
For 6 NB, SCH pipe Liquid Phase

= 1.93 m/s
= 421343 = 0.016894 = 0.0075 psi/ft
Gas Phase
The Linear Velocity (vv)
= 13.7 m/s
Reynolds Number (Re) Darcys friction factor Pressure drop per unit length (PV)
= 1650620 = 0.015906 = 0.0056 psi/ft
Overall Route:
Total frictional pressure drop in entire piping network using Lockhart Martinellis Method = 410.08 psi Total frictional pressure drop in entire piping network using Bakers Method = 360.87 psi The pressure at the exit nozzle = 1.54 atma.
EXAMPLE 13:
No. 1 2 3 4 5 6 7
Size 4 4 6x4 6 6 6x4 4
Pipe: 4 NB, SCH 40 and 6 NB, SCH 40, Commercial Steel with surface roughness
approximately 0.05 mm. Tank has a Flush nozzle of 4 NB, while the reactor inlet nozzle is of size 4 NB, also there are one fully open gate valve, one reducer and one expander in the route as shown in the figure.
Gas:
kg/hr
Density (v) = 1.184 kg/m3, Viscosity (v) = 0.0184 cP, Mass Flow Rate (Wv) = 828.8
All fluid properties are given at flow conditions and elbows used are short radius. Let us analyze the route to get equivalent length of the same.
SOLUTION 13: Route Analysis:

Pipe Elbow SR Expander (6 x 4) Reducer (6 x 4) Gate Valve (4) Entry Nozzle (4) Exit Nozzle (4)
Equivalent Length/ Component ft Number Size 4

164 2 1 1 1 1 1 4 4 4.5 10 20

164 (50)

164 15

164 (50) 30 (9.15)
4 (1.22) 4 (1.22) 4.5 (1.37) 10 (3.05) 20 (6.10)
TOTAL
206.5 (62.96)
194 (59.15)


Pressure Drop Calculations Pressure drop for liquid phase per unit length of 4 NB pipe is calculated as follows:
Wl
50000 = 50 m3/hr 1000
= 0.1023 m =
4Q D 2
4 50 3.14 3600 0.1023 2
= 1.69 m/s
D v l l 0.1023 1.69 1000 = l 10 3
= 172887
To calculate Darcy friction factor (f) the initial guess is calculated from Blazius Equation = 0.316 (R e ) 0.25 = 0.316 (172887) 0.25 = 0.01549 The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log + f 3.71D Re f Solving this equation using the friction factor from Blazius equation as the initial guess, the iterative values are
1/sqrt(f)
7.209951 7.252788 7.250506 7.250628 7.250621 7.250622
f 0.0154969 0.0192369 0.0190103 0.0190223 0.0190216 0.0190217 0.0190217
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.01902 is accepted as the friction factor value in further calculations.
Pl fv l 0.01902 1.69 2 = = Frictional Head Loss per unit length = l g 2gD 2 9.81 0.1023
Frictional Pressure Drop per unit length (Pl ) = 0.002655 bar/m
= 0.02707 m/m
Pressure drop for gas phase per unit length of 4 NB pipe is calculated as follows:
Flow Rate (Qv) Diameter (D) Linear Velocity (vv) =
828.8 = 700 m3/hr 1.184
= 0.1023 m =
4 700 3.14 3600 0.1023 2

0.1023 23.67 1.184 0.0184 10 -3
= 23.67 m/s
= 155815
Initial Guess of Friction Factor (f) calculated as per Blazius Equation = 0.316 (155815) 0.25 = 0.015905
Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 4 iterations giving a friction factor value of
0.01923. Iteration No. 0 1 2 3 4 5 6
1/sqrt(f)
7.171797 7.213633 7.211269 7.211402 7.211395 7.211395
f
0.01590527 0.01944214 0.01921728 0.01922988 0.01922917 0.01922921 0.01922921
Frictional Head Loss per unit length Frictional Pressure Drop per unit length (Pv) So in 4 pipe, flow is in Annular Regime
0.01923 23.67 2 2 9.81 0.1023
= 5.368 m/m
= 0.000623 bar/m

Wv BY = 2.16 0.5 A( l v ) W ( v ) 0.5 11 3 BX = 531 l l 2/3 WV 1 1
Properties
Liquid
110231 62.43 1 72.3
Vapor
1827.2 0.074 0.0184
110231 BX = 531 1827.2
(62.43 0.074) 0.5 62.43 2/3
11 3 72.3
= 60.52
1827.2 BY = 2.16 0.5 0.0884 (62.43 0.074)
= 20771.85
From the Baker flow regime map, we see that the flow regime is annular and the correlation for Bakers Modulus is given by ( ) = aX b Where, a = 4.8 0.3125d
b = 0.343 0.021d
d = I.D. of pipe in inches, So, a = 4.8 0.3125 4.028 = 3.54
b = 0.343 0.021 4.028 = 0.258
Pl Lockhart Martinellis Modulus (X) = P v

Bakers Modulus () = 3.54 x 2.0640.258 Y(L or V) = exp Where, for YL
0.5
0.002655 = 0.000623
= 4.27
0.5
= 4.26 0.5 = 2.064
a (lnX)
i =1 i
i 1
a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002 for YV a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
YL = 3.0254, YV = 6.2443
Lockhart Martinellis Method:

(P)LV = YL (P) L = 9.153 0.002655 = 0.0243 bar/m (P)LV = YV (P)v = 39 0.000623
2
= 0.0243 bar/m = 0.0243 62.96 = 1.53 bar
So Total Pressure Drop in 4 pipe
Bakers Method:
Pressure Drop per unit length due to two phase flow,
PLV = 2 (P )V = 4.27 2 0.000623 = 0.01136 bar/m

So, Total Pressure Drop in 4 pipe (L = 62.96 m) due to mixture = 0.7152 bar

Pressure drop for liquid phase per unit length of 6 NB pipe is calculated as follows:
Flow Rate (Ql) = 50 m3/hr Diameter (D) = 0.1541 m Viscosity (l) Density (l) = 1 cP = 1000 kg/m3
The Linear Velocity (vl) =
4 50 3.14 3600 0.15412
= 0.75 m/s
0.1541 0.75 1000 10 3
= 115575
Initial guess of Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 (115575) 0.25 = 0.0171384
0.01918. Iteration No. 0 1 2 3 4 5 6

1/sqrt(f)
7.189273 7.223000 7.220386 7.220588 7.220573 7.220574 =
f 0.0171384 0.0193477 0.0191674 0.0191813 0.0191802 0.0191803 0.0191803

= 0.003568 m/m
0.01918 0..75 2 2 9.81 0.1541
Frictional Pressure Drop per unit length (Pl) = 0.000350 bar/m
Pressure drop for gas phase per unit length of 6 NB pipe is calculated as follows.
Flow Rate (Q) = 700 m3/hr Diameter (D) = 0.1541 m Viscosity (v) Density (v) = 0.0184 cP = 1.184 kg/m3
The Linear Velocity (vv) =
4 700 3.14 3600 0.15412
= 10.43 m/s
0.1541 10.43 1.184 0.0184 10 -3
= 103424
Initial guess of Darcy Friction Factor (f) calculated as per Blazius Equation = 0.316 (103424) 0.25 = 0.0176212
0.01948. Iteration No. 0 1 2 3 4 5 6 1/sqrt(f)

7.136365 7.167886 7.165341 7.165546 7.165530 7.165531
f 0.0176212 0.0196357 0.0194634 0.0194772 0.0194761 0.0194762 0.0194762
0.01948 10.43 2 2 9.81 0.1541
= 0.7010 m/m
Frictional Pressure Drop per unit length (Pv ) = 0.000081 bar/m
Two Baker parameters Bx and By are calculated as follows:

BX = 60.52 BY = 9156 From the Baker flow regime map, we see that the flow regime is annular and the correlation for Baker Modulus is given by
= aX b
Pl = 0.000350 bar/m Pv = 0.000081 bar/m
0.000350 Lockhart-Martinellis Modulus (X) = 0.000081

a = 2.9 , b = 0.22, Bakers Modulus () = 3.40
0.5
= 4.32 0.5
= 2.079
Y(L or V) = exp
a (ln X )
i =1 i
i 1
For YL : a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002 For YV: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
YL = 3.0163 and YV = 6.271 Bakers Method:

(P)LV = 2Pv (P)LV = 0.00094 bar/m Total Pressure Drop in 6 pipe (L = 59.15 m) due to mixture = 0.0556 bar

Now unit pressure drop due to both liquid and gas (P)LV = YL (P) L = 9.1 0.000350 (P)LV = YV (P) V = 39.33 0.000081
2
= 0.003185 bar/m = 0.003185 bar/m
So Total Pressure Drop in 6 pipe due to two phase flow = 0.003185 59.15 = 0.1884 bar Now Total Frictional Pressure Drop in route = 1.53 + 0.1884 = 1.72 bar Now let us apply Bernoullis equation.
The elevation difference between the two ends of the route is 20 m. Inlet is at higher elevation than outlet. So, if inlet is taken as basis, Z1 = 0, Z2 = -20 m in the Bernoullis equation. Bernoullis equation also needs consistent units. The nozzles are of the same size, so velocity and the kinetic head is the same at both the ends and cancels out. Only thing is we have to calculate mix to use in Bernoullis equation
1 mix
M v fraction of air M l fraction of water + v l
50000 828.8 1 = 50828.8 + 50828.8 mix 1000 1.184 1 = 0.0163 0.9837 + 1.184 1000
mix
mix = 67.8 kg/m3

P = P + (Z1 Z ) g (P )friction 2 1 2 mix
P = 3+ 2
20 67.8 9.81 1.72 1.013 5 1.013 10
P = 3 + 0.13 1.70 2
P = 1.43 atma 2
Pressure at outlet is 1.43 atma.
Summary of Solution 13: For 4 NB, SCH 40 pipe Liquid Phase

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop = 1.69 m/s = 172887 = 0.01902 = 0.002655 bar /m
Gas Phase
Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop = 23.67 m/s = 155815 = 0.01923 = 0.000623 bar/m
Total frictional pressure drop in 4 pipe using Lockhart Martinelli Method = 1.53 bar Total frictional pressure drop in 4 pipe using Bakers Method = 0.7152 bar
For 6 NB, SCH 40 pipe Liquid Phase

Gas Phase
Linear Velocity (v) Reynolds Number (Re) = 10.43 m/s = 103424
Darcy Friction Factor (f) Frictional Pressure Drop
= 0.01948 = 0.000081 bar/m
Total frictional pressure drop in 4 pipe using Lockhart Martinelli Method = 0.1884 bar Total frictional pressure drop in 4 pipe using Bakers Method = 0.0556 bar
Overall Route:
Total frictional pressure drop in entire piping network using Lockhart Martinelli Method = 1.72 bar Pressure at outlet is 1.43 atma.
EXAMPLE 14:
Let us consider a route as shown. The route connects the discharge nozzle of the condenser to a storage tank inlet nozzle. The tank inlet nozzle is 130 m below discharge nozzle of the condenser. The pressure at the condenser discharge nozzle is 16 atm absolute. Estimate the pressure at the storage tank inlet? Relevant specifications of the route are given below.
No. 1 2 3 4 5 6 7 8 9
Size 6 6 6x4 4 4 4 4 4 4
approximately 0.05 mm. Condenser discharge has a Protruding nozzle of 6 NB, while storage tank inlet nozzle is of size 4 NB. Also there are two fully open Gate Valve, one Reducer (6 to 4), three large radius Elbows and two Tees as shown in the figure.
Liquid: Density (l) = 779 kg/m3, Viscosity (l) = 1.02 cP, Mass Flow Rate (Wl) = 77900
Gas:Density(v) =1.145 kg/m3, Viscosity (v) = 0.0178 cP, Mass Flow Rate(Wv)=1145 kg/hr
All fluid properties are given at flow conditions and elbows used are long radius.
SOLUTION 14:
Route Analysis:

Pipe Elbow LR Reducer (6 x 4) Gate Valve (6) Gate Valve (4) Tee-1 Tee-2 Entry Nozzle (6) Exit Nozzle (4)
Number

164 (50)

623.40 (190)
2 1 1 1 1 6.5 6.5 (1.98)
7 4
14 (4.27) 4 (1.22)
4.5 7 20
4.5 (1.37) 7 (2.14) 20 (6.10)
1 1
29
29 (8.84) 20 20 (6.10)
TOTAL
199.5 (60.82)
692.9 (211.2)

The equivalent length for the two nozzles is in terms of straight length of pipe of same size as the nozzle.

Flow Rate (Q) =
77900 = 100 m3/hr 779
4Q D 2
4 100 3.14 3600 0.1023 2

=
= 3.38 m/s
D v l l l
0.1023 3.38 779 = 269358 10 3
To calculate Darcy Friction Factor (f) initial guess is calculated from Blazius Equation = 0.316 (R e ) 0.25 = 0.316 (269358) 0.25 = 0.013871 The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log + f 3.71D Re f Solving this equation using the friction factor from Blazius equation as the initial guess, the iterative values are:
1/sqrt(f)
7.346432 7.39127 7.389436 7.389511 7.389508 7.389508
f 0.0138710 0.0185287 0.0183046 0.0183137 0.0183133 0.0183134 0.0183134
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.01831 is accepted as the friction factor value in further calculations. Frictional Head Loss per unit length
P fv l 0.01831 3.38 2 = = l g 2gD 2 9.81 0.1023
= 0.1042 m/m
Frictional Pressure Drop per unit length due to liquid, (P)l = 0.007963 bar/m
Flow Rate (Q) =
1145 = 1000 m3/hr 1.145
Diameter (D) = 0.1023 m The Linear Velocity (Vv) =
4 1000 3.14 3600 0.1023 2
= 33.81 m/s
0.1023 33.811.145 = 222488 0.0178 10 -3
Initial guess of Friction Factor (f) calculated as per (Blazius Equation) = 0.316 (222488) 0.25 = 0.0145500
0.01858. Iteration No. 0 1 2 3 4 5 6 1/sqrt(f)

7.294624 7.339053 7.337022 7.337115 7.33711 7.337111
f 0.0145500 0.0187929 0.0185660 0.0185763 0.0185758 0.0185759 0.0185759
0.01858 33.812 2 9.81 0.1023
= 10.582 m/m
Frictional Pressure Drop per unit length due to gas, (P)v = 0.001189 bar/m

Wv BY = 2.16 0.5 A( l v ) W ( v ) 0.5 BX = 531 l l 2/3 WV 1 In the above definitions, following units are used: WV - Vapor flow rate, lb/hr Wl v - Liquid flow rate, lb/hr - Vapor density, lb/ft
3
11 3 1
l - Liquid density, lb/ft
A - Internal cross-sectional area = 0.0884 ft l - Viscosity of liquid, cp l - Surface tension of liquid, dyne/cm
Properties
Liquid
171740 48.63 1.02 25.3
Vapor
2524.3 0.0715 0.0178
Calculation of pressure drop due to mixture for 4 pipe
171740 BX = 531 2524.3

BX = 201.17
(48.63 0.0715) 0.5 1.021 3 2/3 48.63 25.3
2524.3 BY = 2.16 0.5 0.0884 (48.63 0.0715) BY = 33077.85 From the Bakers flow regime map, we see that the flow regime is bubble or froth and the correlation for Bakers modulus is given by
14.2X 0.75 Bakers Modulus ( ) = W ( l ) 0.1 A

= 6.8
0.007963 Lockhart Martinellis Modulus (X) = 0.001189

Y(L or V) = exp
0.5
= 6.7 0.5 = 2.588
a (ln X )
i =1 i
i 1
Where for YL: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002 for YV: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
YL = 2.76 and YV = 7.14 Lockhart Martinellis Method:

(P)LV = YL (P) L = 7.618 0.007963 = 0.06066 bar/m (P)LV = YV (P) V = 51 0.001189
2 2
= 0.060639 bar/m
So total pressure drop in 4 pipe due to two phase flow = 0.06066 211.2 = 12.81 bar
Bakers Method:
Pressure drop per unit length due to two phase flow,
PLV = 2 (P )V = 6.8 2 0.001189 = 0.055 bar/m

So total pressure drop in 4 pipe (L = 211.2 m) due to mixture = 11.616 bar

Pressure drop for liquid phase per unit length of 6 NB pipe is calculated as follows:
Flow Rate (Q) = 100 m3/hr Diameter (D) = 0.1541 m The Linear Velocity (vl) =
4 100 3.14 3600 0.15412
= 1.49 m/s
0.1541 1.49 779 = 175358 1.02 10 3
Initial guess of Friction Factor (f) calculated as per (Blazius Equation) = 0.316 (175358) 0.25 = 0.0154421
0.01814. Iteration No. 0 1 2 3 4 5 6
1/sqrt(f)
7.386579 7.428093 7.425426 7.425597 7.425586 7.425586
f 0.0154421 0.0183279 0.0181236 0.0181367 0.0181358 0.0181359 0.0181359
0.01814 1.49 2 = 2 9.81 0.1541
= 0.01332 m/m
Frictional Pressure Drop per unit length (P)l = 0.00102 bar/m
Flow Rate (Q) = 1000 m3/hr Diameter (D) = 0.1541 m The Linear Velocity (Vv) =
4 1000 3.14 3600 0.15412 0.1541 14.90 1.145 0.0178 10 -3
= 14.90 m/s
= 147698
Darcy Friction Factor (f) calculated as per (Blazius Equation) = 0.316 (R e ) 0.25 = 0.316 (147698) 0.25 = 0.0161192 Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 4 iterations giving a friction factor value of
0.01853.
1/sqrt(f)
7.310038 7.348664 7.345975 7.346162 7.346149
f 0.0161192 0.0187137 0.0185175 0.0185311 0.0185302 0.0185302
0.01853 14.90 2 2 9.81 0.1541
= 1.3607 m/m = 0.000153 bar/m
Frictional Pressure Drop per unit length due to gas, (P)v So in 6 pipe, flow is in bubble or froth regime.

BX = 201.17 BY = 14620.4 From the Bakers flow regime map, we see that the flow regime is bubble or froth So,
14.2 X 0.75 W ( l ) 0.1 A
= 7.38
PL Lockhart-Martinellis Modulus ( X) = P V
0.5
PL = 0.00102 bar/m PV = 0.000153 bar/m X = 2.583 Y(L or V) = exp
a (ln X )
i =1 i
i 1
Where for YL : a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002
for YV: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
YL = 2.76 and YV = 7.14 Bakers Method:

Pressure drop per unit length due to two phase flow,
PLV = 2 (P )V = 7.38 2 0.000153 = 0.00833 bar/m

Total pressure drop in 6 pipe (L = 60.82 m) due to mixture = 0.507 bar

Now unit pressure drop due to both liquid and gas (P)LV = YL (P) L = 7.62 0.00102 (P)LV = YV (P) v = 51 0.000153
2
= 0.00777 bar/m = 0.00780 bar/m
So total pressure drop in 6 pipe due to two phase flow = 0.0078 60.82 = 0.48 bar
Now Total Frictional Pressure Drop in route = 12.81 + 0.48 = 13.29 bar
Now let us apply Bernoullis equation, to calculate P2

The elevation difference between the two ends of the route is 130 m. Inlet is at higher elevation than outlet. So, if inlet is taken as basis, Z1 = 0, Z2 = -130 m in the Bernoullis equation. The nozzles are of the different size, so there is pressure drop due to velocity also. Now to calculate density of mixture
1 mix
wt fraction of N 2 wt fraction of cyclohexane + N2 cyclohexane

1145 77900 1 = 79045 + 79045 mix 1.145 779
1 mix
0.0145 0.9855 + 1.145 779
mix = 71.8 kg/m3 Now for effective velocity calculation Velocity = mass flow rate mix A cross section
79045 3600 So velocity in 6 pipe, V6" = 2 71.8 ( d 6 ) 4 V6 = 16.43 m/sec 79045 3600 V4" = 2 71.8 ( d 4 ) 4 V4 = 37.22 m/sec The pressure P2 can be calculate using,
where, d6 = 0.154 m
And in 4 pipe,
where, d4 = 0.1023 m
P1 v 6" P v + + Z1 = 2 + 4" + Z 2 + h f g 2g g 2g
(v 6" v 4" ) (P P ) + (Z1 Z 2 ) h f = 2 1 2g mix g

P2 = P1 + (v 6" v 4" ) mix g + (Z1 Z 2 ) mix g h f mix g 2g
2 2
(16.43 2 37.22 2 ) 71.2 130 71.2 9.8 P2 = P1 + + h f mix g 2 1.013 10 5 1.013 10 5 P2 = P1 0.392 + 0.895 h f mix g
P2 = P1 + 0.503 h f mix g
P2 = 16 + 0.503 13.29 P2 = 3.213 atma Pressure at outlet is 3.213 atma.

Gas Phase
Total frictional pressure drop in 4 pipe using Lockhart Martinellis Method = 12.81 bar Total frictional pressure drop in 4 pipe using Bakers Method = 11.616 bar

Gas Phase
Total frictional pressure drop in 4 pipe using Lockhart Martinellis Method = 0.48 bar Total frictional pressure drop in 4 pipe using Bakers Method = 0.507 bar
Overall Route:
Total frictional pressure drop in entire piping network using Lockhart Martinellis Method = 13.29 bar Pressure at outlet is 3.213 atma.
EXAMPLE 15:
Let us consider a route as shown in the figure. There is a network along the ground. Pressure at inlet of the pipe is 19 atma. Due to some new requirement, one needs to draw some liquid from the pipeline at outlet pressure between 1.5 atma to 3 atma. Find out segment numbers in which these pressures can be measured.
No.
1 2 3 4
Components
Size (inch)
6 6x4 4 4
No.
5 6 7
Components
Expander Elbow Tee
Size (inch)
6x4 6 6
Pipes: used in the route are 6 NB SCH 40 and 4 SCH 40. Pipe made of Commercial Steel
with surface roughness approximately 0.05 mm
Liquid: Density (l) = 1000 kg/m3, Viscosity (l) = 1 cP, Flow Rate (Wl) = 100000 kg/hr,
Surface Tension (l) = 71.97 dyne/cm
Gas: Density (v) = 1.184kg/m3, Viscosity (v) = 0.01837 cP, Flow Rate (Wv) = 1302.4 kg/hr
SOLUTION 15:
The equivalent length of the route is calculated as follows.
Route Analysis:

Pipe (6) Pipe (4) Elbow(6) SR 900 Elbow(4) SR 900 Expander (6 x 4) Reducer (6 x 4) Tee (4) Tee (6) TOTAL
Equivalent Length/ Component (ft) Number Size 4

n n 3n n n n n n 0 246.06
0

0 246.06n (75n) 0 10.5n (3.20n) 4n (1.22n) 4n (1.22n) 7n (2.13n) 0 271.56n (82.77n)

574.15 0 15 0 0 0 0 10

574.15n (175n) 0 45n (13.72n) 0 0 0 0 10n (3.05n) 629.15n (191.77n)
10.5
4 4 7 0

The route analysis says that the each segment with its pipes, fittings and valves is equivalent to 191.77 m of 6 straight pipe and 82.77 m of 4 straight pipe. These lengths should be used in overall frictional pressure drop calculations.

Pressure Drop Calculations: Pressure Drop for liquid phase per unit length of 6 pipe is calculated as follows:
Flow Rate (Q) = Wl 100000 = = 100 m3/hr l 1000
Diameter (D) = 0.154 m Linear Velocity (vl) =
4 100 4Q = 2 D 3.14 (60 60) 0.154 2

D v l l 0.154 1.49 1000 = l 1 10 3
= 1.49 m/s
= 229460
To calculate Darcy Friction Factor (f) the initial guess is calculated from Blazius Equation = 0.316 Re 0.25 = 0.316 229460 0.25 = 0.014438 The Colebrook and White equation for calculating the friction factor is as follows:
2.51 = 2 log10 + f 3.71 D Re f
Iteration No.
0 1 2 3 4 5
1/sqrt(f)
7.496484 7.541581 7.539057 7.539198 7.53919
f
0.014438 0.017794 0.017582 0.017594 0.017593 0.017593
As can be seen, the iterative procedure converges after 3 - 4 iterations. The change in the friction factor value is only after 4 significant digits after the second iteration. A value of 0.01759 is accepted as the friction factor value in further calculations.
fv Frictional Pressure Drop per unit length (P) L = 1 l 2D

= 0.01759 1.49 2 1000 2 0.154046
= 126.75 Pa/m
Pressure Drop for gas phase per unit length of 6 pipe is calculated as follows:
Flow Rate (Q) =
1302.4 1.184
= 1100 m3/hr
Linear Velocity (vv)
4 1100 3.14 (60 60) 0.154 2 0.154 16.41 1.184 1.84 10 5
= 16.41 m/s
= 162616
Initial guess of Darcy Friction Factor (f) using Blazius Equation = 0.316 162616 0.25 = 0.015736
Iteration No. 1/sqrt(f)

0 1 2 3 4 5 7.353256 7.393556 7.390872 7.39105 7.391039
f
0.015736 0.018494 0.018293 0.018307 0.018306 0.018306
0.01830 16.412 1.184 Frictional Pressure Drop per unit length (P)V = = 18.94 Pa/m 2 0.154 The fluid properties in FPS system of units are as follows:
Properties
Mass Flow Rate (lb/hr) Density (lb/ft ) Viscosity (cP) Surface Tension (dynes/cm)
3
Liquid
220462 62.43 1 71.97
Gas
2871.8 0.074 0.0184

Bx Wl = 531 W v
[( l v ) 0.5 ] 2/3 1
11 3 1
220462 = 531 2871.28

= 77.37 By = 2.16
(62.43 0.074) 0.5 11 3 62.43 2/3 71.97
Wv 2871.28 = 2.16 = 14406.48 0.5 0.5 A( l v ) 0.20029 (62.43 0.074)
From the Baker flow regime map, we see that the flow regime is annular and the correlation for Baker parameter is given by = aX b
a = 4.8 - 0.3125 d
= 4.8 - 0.3125 6.065
= 2.904688 = 0.215635
b = 0.343 - 0.021 d = 0.343 - 0.021 6.065 where, d = I.D. of pipe in inches,
(P )L Lockhart Martinellis Modulus (X) = (P ) V
0.5
126.75 = 18.94
0.5
= 2.59
Bakers Modulus () = 2.904688 2.590.215635 = 3.56 2 = 12.66 Y(V or L) = exp
a (ln X )
i =1 i
i 1
where, for YL: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002 for YV: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
YL = 2.76, YV = 7.011 Lockhart Martinellis Method:

2 (P )L = 2.762 126.75 = 965.6 Pa/m (P)LV = YL
2 (P )V = 7.0112 18.94 = 967.23 Pa/m (P)LV = YV
Bakers Method:
(P) LV = 2(P) V = 12.66 18.94 = 239.78 Pa/m
Total Frictional Pressure drop over 191.77 m of 6 pipe = (P)LV L1 = 965.6 191.77 = 185173.11 Pa

Pressure Drop Calculations Pressure Drop for liquid phase per unit length of 4 pipe is calculated as follows:
Flow Rate (Q) Diameter (D) Linear Velocity (vl) = 100 m3/hr = 0.102 m =
4 100 3.14 (60 60) 0.102 2 0.102 3.4 1000 1 10 3
= 3.4 m/s
= 346800
Initial guess of Darcy Friction Factor (f) calculated as per Blazius Equation = 0.316 346800 0.25 = 0.013022
Iteration No.
0 1 2 3 4
1/sqrt(f)
7.417469 7.461848 7.460348 7.460398
f
0.013022 0.018176 0.01796 0.017967 0.017967
0.017964 3.4 2 1000 Frictional pressure drop per unit length (P)L = = 1017.96 Pa/m 2 0.102
Flow Rate (Q) Diameter (D) Linear Velocity (vv) = 1100 m3/hr = 0.102 m =
4 1100 3.14 (60 60) 0.102 2
= 37.41 m/s
0.102 37.41 1.184 1.84 10 5
= 245540

0 1 2 3 4 5 7.323384 7.368099 7.366183 7.366265 7.366261
f 0.014196 0.018646 0.01842 0.01843 0.018429 0.018429
Frictional Pressure Drop per unit length (P)V =
0.01830 37.412 1.184 = 148.64 Pa/m 2 0.102
Two Baker parameters B X and B Y are calculated as follows:

BX = 77.37 BY = 32839.69
From the Bakers flow regime map, we see that the flow regime is dispersed and the correlation for Bakers parameter is given by = (3.2967X + 24.738)0.5

For X2 > 2.5
0.5
1017.96 = 148.64
0.5
= 2.62
Bakers Modulus () = (3.2967X + 24.738)0.5
= 5.78
Liquid and gas flow rates are in turbulent region so YL and YV will be calculated as previously

2 (P )L = 2.752 1017.96 = 7698.3 Pa/m (P)LV = YL
2 (P )V = 7.22 148.64 (P)LV = YV
= 7659.4 Pa/m
Bakers Method:
(P)LV = 2(P) V = 5.782 148.64 = 4936.1 Pa/m
Total Frictional Pressure drop over 82.77 m of 4 pipe = 7698.3 82.77 = 637188.29 Pa Total Frictional Pressure Drop across one segment P = 185173.11 + 637188.29 = 822361.4 Pa Now applying Bernoullis equation in the network from initial point to end of nth segment.
2 2 P P1 v1 P v + + Z1 = 2 + 2 + Z 2 + g g 2g g 2g friction
(P1 P2) = P x n
Lockhart Martinellis method For P2 = 3 atma, 16 x 105 = 822361.4 x n n = 1.94 In the 2nd segment pressure will be 3 atma For P2 = 1.5 atma, n = 2.13 In the 3rd segment pressure will be 1.5 atma
Summary of Solution 15: For 6 pipe Liquid

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop per unit length = 1.49 m/s = 229460 = 0.017593 = 126.75 Pa/m
Gas
For 4 pipe Liquid

Gas
Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop per unit length The frictional Pressure Drop in one segment Lockhart Martinellis P = 822361.4 Pa = 8.22 atma In the 2nd segment pressure will be 3 atma In the 3rd segment pressure will be 1.5 atma = 37.41 m/s = 245540 = 0.018429 = 148.64 Pa/m
EXAMPLE 16:
Let us consider a route as shown. . The route connects the outlet nozzle of the reactant storage tank to the reactor inlet. The discharge end is at a height of 4 m from the outlet nozzle of the storage tank. The pressure at the inlet of the reactor should not be less than 5 atma and greater than 10 atma. Can this system deliver the pressure more than 5 atma? Pressure at Pump Discharge: P1 = 15 atma upstream of discharge nozzle. The service and the pipe specifications are given below:
No.
1 2 3 4 5
Components
Size (inch)
8 8x6 6 6 6
No.
6 7 8 11 12
Components
Size (inch)
6 6 6 6x4 4
roughness approximately 0.05 mm. Entry nozzle is 8 protruding nozzle.
Liquid: Density (l) = 878.6 kg/m3, Viscosity (l) = 0.652 cP, Flow Rate (Wl) = 79074
kg/hr, Surface Tension (l) = 28.88 dyne/cm
Gas: Density (v) = 5.389 kg/m3 at 25oC, Flow Rate (Wv) = 5389 kg/hr, Viscosity (v) =
0.0238 cP
SOLUTION 16:
Let us analyze the route to get the equivalent length of the same.
Route Analysis:
Equivalent Length/ Component (ft) Size 4 98.4 0 0 0 0 4 0 0 0 20 Equivalent Length/ Component (ft) Size 6 0 433 0 10 7 0 175 10 0 0 Equivalent Length/ Component (ft) Size 8 0 0 164 0 0 0 0 0 38 0
Piping System Component Pipe (4) Pipe (6) Pipe (8) Elbow LR (6) Reducer (8 x 6) Reducer (6 x 4) Gate Valve (6) Tee (6) Entry Nozzle (8) Exit Nozzle (4) TOTAL
Number 1 1 1 4 1 1 1 1 1 1
Total Contribution ft (m) Size 4 98.4 (30) 0 0 0 0 4 (1.2) 0 0 0 20 (6.1) 122.4 (37.3)
Total Contribution ft (m) Size 6 0

433 (132)
Total Contribution ft (m) Size 8 0 0 164 (50) 0 0 0 0 0 38 (11.58) 0 202 (61.58)
0 40 (12.19) 7 (2.13) 0
175 (53.34)
10 (3.05) 0 0 665 (202.71)

The route analysis says that the route with its pipes, fittings and valves is equivalent to 37.3 m of 4 straight pipe, 202.71 m of 6 straight pipe and 61.58 m of 8 straight pipe. These lengths should be used in overall frictional pressure drop calculations.

Pressure Drop Calculations: Pressure drop for liquid phase per unit length of 4 NB pipe is calculated as follows:
Flow Rate (Q) = Wl 79074 = = 90 m3/hr l 878.6
Diameter (D) = 0.100 m Linear Velocity (vl) =
4 90 4Q = 2 D 3.14 (60 60) 0.100 2

D v l l 0.100 3.18 878.6 = l 0.652 10 3
= 3.18 m/s
= 428520
To calculate Darcy friction factor (f) the initial guess is calculated from Blazius Equation = 0.316 Re 0.25 = 0.316 428520 0.25 = 0.012351 The Colebrook and White equation for calculating the friction factor is as follows:
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f) 7.454107 7.497053 7.495829 7.495864 7.495863
f 0.012351 0.017997 0.017792 0.017798 0.017797 0.017797
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 4 significant digits after the first iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.01779 is accepted as the friction factor value in further calculations. Frictional pressure drop per unit length (P) L =
fv l l 2D
0.01779 3.18 2 878.6 = 790.3 Pa/m 2 0.100
Flow Rate (Q) =
5389 = 1000 m3/hr 5.389
Linear Velocity (vv) =
4 1000 = 35.39 m/s 3.14 (60 60) 0.1002

0.100 35.39 5.389 2.38 10 5
= 801331
Initial guess of Darcy Friction Factor (f) using Blazius Equation = 0.316 8013310.25 = 0.010562
Iteration No.
0 1 2 3 4
1/sqrt(f)
7.56372 7.600146 7.599521 7.599532
f 0.010562 0.01748 0.017312 0.017315 0.017315
Frictional Pressure Drop per unit length (P)v =
0.01731 35.392 5.389 = 584.17 Pa/m 2 0.100
The fluid properties in FPS system of units are as follows:
Properties
Liquid
174328.1 54.85 0.652 28.88
Gas
11880.7 0.336 0.0238

Wl Bx = 531 W v
[( l v ) 0.5 ] 2/3 1
11 3 1
0.5 13 174328.1 (54.85 0.336) 0.652 = 531 = 69.57 54.85 2/3 11880.7 28.88
By = 2.16
Wv 11880.7 = 2.16 = 70742.62 0.5 0.5 A( l v ) 0.0845 (54.85 0.336)
From the Bakers flow regime map, we see that the flow regime is dispersed and the correlation for Bakers Modulus is given by = (7.844X + 9.1477)0.5

For X2 > 0.3 and X2 2.5
0.5
790.3 = 584.17
0.5
= 1.16
Bakers Modulus () = (7.844X + 9.1477)0.5 = 4.27 Y(V or L) = exp
a (ln X )
i =1 i
i 1
where, for YL: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002 for YV: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
YL = 3.92, YV = 4.55 Lockhart Martinellis Method:

2 (P )L = 3.922 790.3 = 12144.06 Pa/m (P)LV = YL
2 (P )V = 4.552 584.17 = 12093.78 Pa/m (P)LV = YV
Bakers Method:
(P) LV = 2(P) V = 4.272 584.17 = 10651.1 Pa/m Total Frictional Pressure drop over 37.3 m of 4 pipe = (P)LV x L1
= 12144.06 x 37.3 = 452973.43 Pa

Flow Rate (Q) Diameter (D) Linear Velocity (vl) = = 90 m3/hr = 0.154046 m
4 90 3.14 (60 60) 0.154 2 0.154 1.34 878.6 0.652 10 3
= 1.34 m/s
= 278080
0.01725 1.34 2 878.6 Frictional pressure drop per unit length (P)L = = 88.36 Pa/m 2 0.154
Flow Rate (Q) Diameter (D) Linear Velocity (vv) = 1000 m3/hr = 0.154 m =
4 1000 =14.92 m/s 3.14 (60 60) 0.1542
0.154 14.92 5.389 2.38 10 5
= 520260

0 1 2 3 4 5 7.758913 7.806552 7.804956 7.805009 7.805007
f 0.011766 0.016611 0.016409 0.016416 0.016415 0.016415
0.01641 14.92 2 5.389 = 63.92 Pa/m 2 0.154

BX = 69.57 BY = 29888.76 From the Bakers flow regime map, we see that the flow regime is annular and the correlation for Baker parameter is given by = aX b a = 4.8 - 0.3125 d = 4.8 - 0.3125 6.065 = 2.904688 = 0.215635
b = 0.343 - 0.021 d = 0.343 - 0.021 6.065 where, d = I.D. of pipe in inches,
0.5
88.36 = 63.92
0.5
= 1.18 = 3.01
Bakers Modulus () = 2.904688 1.180.215635
Liquid and gas flow rates are in turbulent region so YL and YV will be calculated as previously,

2 (P)LV = YL (P )L = 3.892 88.36 = 1337.1 Pa/m 2 (P )V = 4.592 63.92 (P)LV = YV
= 1346.7 Pa/m
Bakers Method:
(P)LV = 2(P) V = 3.012 63.92 = 579.12 Pa/m
Total Frictional Pressure drop over 202.71 m of 6 pipe = 1337.1 x 202.71 = 272989.6 Pa

The actual outside diameter of the pipe = 8.625 Thickness of the pipe The inside diameter of the pipe = 219.08 2 x 7.036 The equivalent length of 8 pipe components Actual length of 8 straight pipe Total equivalent length of the 8 pipe (L3) = 50 + 11.58 = 219.08 mm = 7.036 mm = 205.008 mm = 11.58 m = 50 m = 61.58 m
4 90 3.14 (60 60) 0.205 2
= 0.76 m/s
0.205 0.76 878.6 0.652 10 3
= 209948
Iteration No. 0 1 2 3 4 1/sqrt(f) 7.569576 7.612422 7.609579 7.609767 f 0.014762 0.017452 0.017257 0.017269 0.017269
0.01726 0.76 2 878.6 Frictional pressure drop per unit length (P)L = = 21.36 Pa/m 2 0.205
Flow Rate (Q) Diameter (D) Linear Velocity (vv) = = 1000 m3/hr = 0.205 m
4 1000 = 8.42 m/s 3.14 (60 60) 0.205 2

0.205 8.42 5.389 2.38 10 5
= 390838
Initial guess of Darcy Friction Factor (f) calculated as per Blazius Equation = 0.316 3908380.25 = 0.012638

0 1 2 3 4 0.05 7.821124 7.871309 7.868899 7.869014
f 0.012638 0.016348 0.01614 0.01615 0.01615
0.01615 8.42 2 5.389 = 15.05 Pa/m 2 0.205

BX = 69.57 BY = 16377.40 From the Bakers flow regime map, we see that the flow regime is annular and the correlation for Baker parameter is given by = aX b
(P )L Lockhart Martinelli Modulus (X) = (P ) V
0.5
21.36 = 15.05
0.5
= 1.19 = 2.35
Bakers Modulus () = 2.277813 1.190.173509
Liquid and gas flow rates are in turbulent region so YL and YV will be calculated as previously
YL = 3.88 and YV = 4.61

2 (P )L = 3.882 21.36 (P)LV = YL 2 (P )V = 4.612 15.05 (P)LV = YV
= 321.56 Pa/m = 319.8 Pa/m
Bakers Method:
(P)LV = 2(P) V = 2.352 15.05 = 83.11 Pa/m
Total Frictional Pressure drop over 61.58 m of 8 pipe = 321.56 61.58 = 19801.7 Pa
Density Calculation of a Mixture:

Mass fraction of gas Mg =
5389 = 0.064 79074 + 5389
Mass fraction of liquid Ml
79074 = 0.936 79074 + 5389

Mg g + Ml l
1 mix 1 mix
0.064 0.936 + 5.389 878.6
mix = 77.27
Velocity Calculation:
Total Mass Flow Rate (mix A v) = 90 878.6 + 1000 5.389 = 84463 v= Velocity for 4 pipe Velocity for 6 pipe Velocity for 8 pipe
84463 4 77.27 3600 3.14 d 2
= 38.68 m/s
v = 38.68 m/s v = 10.31 m/s v = 9.20 m/s
Using the Bernoullis equation, the total pressure drop in the entire pipe length is calculated as follows P P1 v1 P v + + Z1 = 2 + 2 + Z 2 + pg g 2g g 2g friction
2 2
77.27 38.68 2 77.27 9.20 2 P1 P2 = + 77.27 9.81 4 + (P )friction 2 P1 P2 = 57565.47 + (P )friction Total frictional pressure drop in the pipeline = 452973.43 + 272989.6 + 19801.7 = 745764.73 Pa P1 P2 = 803330.20 Pa P2 = 6.97 atm a Pressure at the outlet lies between 5 atma -10 atma which is approximately equal to required value for the reactor inlet pressure.
Summary of Solution: For 4 pipe Liquid

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional pressure drop per unit length = 3.18 m/s = 428520 = 0.017797 = 790.3 Pa/m
Gas
For 6 pipe Liquid

Linear Velocity (v) = 1.34 m/s
Reynolds Number (Re) Darcy Friction Factor (f) Frictional pressure drop per unit length
= 278080 = 0.017256 = 88.36 Pa/m
Gas
For 8 pipe Liquid

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional pressure drop per unit length = 0.76 m/s = 209948 = 0.017269 = 21.36 Pa/m
Gas
Total Frictional Pressure Drop in the route

P = 745764.73 Pa = 7.46 atma.
EXAMPLE 17:
Let us consider a route as shown. It is a dedicated pipeline taking fluid from an over head tank nozzle to your basin outlet. Relevant specifications of the pipe route are given below.
No.
1 2 3 4 5
Components
Size (inch)
3 3 3 3x2 2
No.
6 7 8 9 10
Components
Size (inch)
2 2 2 2 2
kg/hr, Surface Tension (l) = 72 dynes/cm.
Gas: Density (g) = 1.184 kg/m3, Viscosity (g) = 0.01983 cP, Mass Flow Rate (Wv)
=255.744 kg/hr. Pressure Head at inlet is 25 m of liquid column. Find the delivery Pressure Head at outlet.
SOLUTION 17:
The route involves two pipe sizes, 3 and 2 NB. First step should be to find the equivalent length of the entire route in terms of straight pipe length of 3 and 2 NB, SCH 40 pipe. The equivalent length of the route is calculated as follows.
Route Analysis: Equivalent Length/ Component, ft Size 3

20
Piping Component Number

Pipe (3)

20 (6.096)

---

---
Vertical Inlet (3) Elbow LR Reducer (3 2) Gate Valve (3) Pipe (2) Tee Globe Valve 90 Elbow SR Horizontal Outlet (2)
1 1 1
7.5 5 ---
7.5 (2.286) 5 (1.524) ---
---
---
2.3
2.3 (0.70)
3.5 ---
3.5 (1.067) -----------
--24 11 60 5.25 9 ---
--24 (7.32) 11 (3.35) 60 (18.29) 15.75 (4.80) 9 (2.74) 122 (37.2)
1 1 3 1
---------
--36 (10.97) TOTAL NOTE: The lengths in parenthesis are in m.
The route analysis says that the route with its pipes, fittings and valves is equivalent to 10.97 m of 3 straight pipe and 37.2 m of 2 straight pipe. These lengths should be used in overall frictional pressure drop calculations. The next step is to calculate head loss per unit length of 3 and 2 NB pipes.

Pressure Drop Calculations Pressure drop for liquid phase per unit length of 3 NB pipe is calculated as follows.
Flow Rate (Q) Diameter (D) Linear Velocity (vl) = = Wl l =
10800 1000 4 10.8 3.141 0.0779 2 60 2

0.0779 0.6294 1000 0.001
= 10.8 m3/hr
= 0.0779 m.
4Q D2
Dv l l l
= =
= 0.6294 m/s = 49030
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation = 0.316 Re-0.25 = 0.021235.
The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log10 3.71 D + f Re f
1/sqrt(f)
6.561131 6.587085 6.584821 6.585018 6.585001
f 0.021235 0.023230 0.023047 0.023063 0.023061 0.023062
The iterative procedure converges after 3 - 4 iterations. A value of 0.023062 is accepted as the friction factor value in further calculations.
P fv l 0.023062 0.6294 2 Frictional Head Loss (m /m) = = = l g 2gD 2 9.81 0.0779
= 0.00598
Frictional Pressure Drop (Pl) = 0.00598 1000 9.81 = 58.6638 Pa/m = 0.002593 psi/ft
Flow Rate (Q) Diameter (D) Linear Velocity (vv) =
255.744 = 216 m3/hr 1.184
= 0.0779 m = 12.5888 m/s
Reynolds Number (Re) = 58553 Initial guess of friction factor = 0.316 Re-0.25 = 0.020314 The iterative calculation using Colebrook and White equation the friction factor is given as:
1/sqrt(f)
6.649117 6.678484 6.6761 6.676294 6.649117
Friction Factor 0.020314 0.022619 0.02242 0.022436 0.022435 0.022435
Friction Factor Frictional Head Loss (m/m)
= 0.022435 = 2.32626
Frictional Pressure Drop (Pv) = 27.0196 Pa/m = 0.00119457 psi/ft The fluid properties in FPS system of units are as follows:
Properties
Mass Flow Rate (lb/hr) Density (lb/ft ) Viscosity (cP) Surface Tension (dynes/cm)
3
Water
23809.92 62.42794 1 72
Air
563.82 0.073915 0.01983

BY = 2.16
Wv 2.16 563.82 = = 11002 0.5 A( l v ) 0.0515 (62.43 0.074) 0.5
BX
Wl = 531 W v = 531
[( l v ) 0.5 ] 2/3 1
11 3 1
23809.92 (62.43 0.074) 0.5 11 / 3 = 42.54 563.82 62.43 2 / 3 72
From the Bakers flow regime map, we see that the flow regime is annular and the correlation for Bakers Modulus is given by = aX b a = 4.8 - 0.3125 d = 4.8-0.3125 3.068 = 3.84125
b = 0.343 - 0.021 d = 0.343-0.021 3.068 = 0.27857 where, d = I.D. of pipe in inches,
Lockhart Martinellis Modulus (X) = ((Pl) / (Pv))0.5
58.6632 = 27.0196
0.5
= 2.17110.5 = 1.4735
Bakers Modulus () = 3.84125 1.47350.27857 = 4.2793 2 = 18.3122 Y(v or l) = exp
a (ln X )
i =1 i
i 1
where, for Yl: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002 for Yv: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
Yl = 3.5058, Y V = 5.1662

2 (P )V = 5.16622 0.00119457 = 0.03188 psi/ft (P) LV = YV
(P) LV = Yl2 (P )l = 3.50582 0.00259268 = 0.03186 psi/ft
Bakers Method:
(P) LV = 2(P) V = 18.3122 0.00119457 = 0.02187 psi/ft The Total Frictional Pressure Drop over 10.97 m (36 ft) of 3 pipe = 0.031883 36 = 1.148 psi
Pressure Drop for liquid phase per unit length of 2 NB pipe is calculated as follows.
Diameter (D) Flow Rate (Q) = 0.0525 m = 10.8 m3/hr
Linear Velocity (vl)
4Q 4 10.8 = = 1.386 m/s 2 D 3.141 0.0525 2 60 2
1/sqrt(f)
6.592892 6.630243 6.627935 6.628078 6.628069
f 0.019240 0.023006 0.022748 0.022764 0.022763 0.022763
= 0.022763 = 0.042452
Frictional Pressure Drop (P)l = 416.454 Pa/m = 0.0184087 psi/ft
Pressure drop for gas phase per unit length of 2 pipe is calculated as follows.
Diameter (D) Linear Velocity (vv) Reynolds Number (Re) = 0.0525 m = 27.717 m/s = 86883
Initial guess of friction factor = 0.018406 The iterative calculation using Colebrook and White equation the friction factor is given as:
1/sqrt(f)
6.656625 6.695668 6.693490 6.693611 6.693605
f 0.018406 0.022568 0.022306 0.022320 0.022319 0.022319
= 0.022319 = 16.646
Frictional Pressure Drop (P)v = 193.344 Pa/m = 0.00854867 psi/ft

B Y = 24331 B X = 42.5124 From the Bakers flow regime map, we see that the flow regime is annular and the correlation for Bakers Modulus is given by = aX b a = 4.8-0.3125 2.067 = 4.154 b = 0.343-0.021 2.067 = 0.2996 Lockhart Martinellis Modulus (X) = ((P) L / (P) V ) 0.5 = (0.0184087/ 0.00854867) 0.5 = 1.46745 Bakers Modulus () = 4.154 1.473230.2996 = 4.6599 2 = 21.7146 Y(v or l) = exp
a (ln X )
i =1 i
i 1
where for Yl : a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002 for Yv: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002
Y V = 5.1552, Yl = 3.5121

(P) LV = Yv2 (P )V = 5.15522 0.00854867 = 0.227196 psi/ft (P) LV = Yl2 (P )l = 3.51212 0.0184087 = 0.227079 psi/ft
Bakers Method:
(P) LV = 2(P) V = 21.7146 0.00854867 = 0.185632 psi/ft
The Total Frictional Pressure Drop over 37.2 m (122.05 ft) of 2 pipe = 0.227196 122.05 = 27.729 psi Total Frictional Pressure Drop = 1.148 + 27.729 = 28.877 psi = 20.3 m of liquid column The mixture density is given by
1 mix
Mg g
Ml l
where, Mg and Ml are mass fractions of gas and liquid. mix = 48.75 kg/m3 Total Frictional Pressure Drop = P1 = 20.3 m P1 = 20.3 1000 g lg
P1 mix g
20.3 1000 g = 416.4 m of mixture column 48.75 g
Total Volumetric Flow Rate in 3 pipe (Q1) = (10800+255.744)/ 48.75 = 226.8 m3/hr Velocity in 3 pipe (v1) = 4 226.8 / (3.14 0.07792 602) = 13.218 m/s Velocity in 2 pipe (v2) = 4 226.8 / (3.14 0.05252 602) = 29.103 m/s Now applying Bernoullis equation:
P1 mix g
P 1 v1 1 v2 + Z1 = 2 + + Z2 + f h 2 g mix g 2 g
P2 13.218 2 29.103 2 + + 0= + 3.048 + 416.4 mix g 2 9.81 mix g 2 9.81 P1 P1 P2 = 447.6 m mix g
P1 P2 = 214059 Pa
Inlet Head is 25 m of liquid column i.e. P2 mix g
P1 P = 25 m 1 = 512.82 m lg mix g
= 65.22 m
P2 = 3.18 m lg
Head at outlet is 3.18 m of liquid column.

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop = 0.6294 m/s = 49030 = 0.023062 = 58.6638 Pa /m = 0.002593 psi/ft
Gas Phase
Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop = 12.5888 m/s = 58553 = 0.022435 = 27.0196 Pa/m = 0.00119457 psi/ft
Total frictional pressure drop in 3 pipe using Lockhart Martinellis Method = 0.03188 psi/ft Total frictional pressure drop in 3 pipe using Bakers Method = 0.02187 psi/ft
Total frictional pressure drop in 3 pipe using pressure drop obtained from Lockhart Martinellis Method = 1.148 psi

Gas Phase
Total frictional pressure drop in 2 pipe using Lockhart Martinelli Method = 0.227196 psi/ft Total frictional pressure drop in 2 pipe using Bakers Method = 0.185632 psi/ft Total frictional pressure drop in 2 pipe using pressure drop obtained from Lockhart Martinellis Method = 27.729 psi
Overall Route:
Total Frictional Head Loss = 28.877 psi = 20.3 m of liquid column The net Head at outlet is 3.18 m of liquid column.
EXAMPLE 18:
Let us consider a route as shown. It is a dedicated pipeline taking fluid from an underground tank to your over head tank. The service and the pipe specifications are as given below.
No.
1 2 3 4 5 6 7
Components
Size (inch)
4 4 4 4 4 4 4
No.
8 9 10 11 12 13
Components
Size (inch)
4 6x4 6 6 6 6
Liquid: Density (l) = 878.6 kg/m3, Viscosity (l) = 0.652 cP, Mass Flow Rate (Wl) = 87860
kg/hr, Surface Tension (l) = 28.88 dynes/cm
Gas: Density (v) = 1.184 kg/m3, Viscosity (v) = 0.01827 cP, Mass Flow Rate (Wv) = 473.6 kg/hr
Head at inlet is 40 m of liquid column. Find the delivery pressure at outlet.
SOLUTION 18:
The route involves two sizes, 4 and 6 NB. First step should be to find the equivalent length of the entire route in terms of straight pipe length of 4 and 6 NB, SCH 40 pipe. The equivalent length of the route is calculated as follows.
Route Analysis:
Equivalent Length/ Component ft Size 4 Total Contribution ft (m) Size 4 72.18 (22) 1 1 1 1 2 1 1 1 120 15 7 10.5 5.25 5.5 4 4.5 --1 1 1 1 ----------120 (36.58) 15 (4.572) 7 (2.1336) 10.5 (3.2) 10.5 (3.2) 5.5 (1.6764) 4 (1.2192) 4.5 (1.3716) ----------249.18 (75.95) 52.49 30 88 10 75 --52.49 (16) 30 (9.144) 88 (26.8224) 10 (3.048) 75 (22.86) 255.49 (77.87) Total Equivalent Length/ Contribution ft Component (m) ft Size 6 Size 6 ---------------------------------
Piping Component Pipe (4) Globe Valve 90 Butterfly Valve Tee Elbow SR 90 Elbow SR 45 Bend (90 ) Expander (6 x 4) Gate Valve Pipe (6) Tee Globe Valve 60 Elbow LR Ball Valve TOTAL
Number
The route analysis says that the route with its pipes, fittings and valves is equivalent to 75.95 m of 4 straight pipe and 77.87 m of 6 straight pipe. These lengths should be used in overall frictional pressure drop calculations. The next step is to calculate Head loss per unit length of 4 and 6 pipes.

Flow Rate (Ql) Diameter (D) Linear Velocity (vl) = Wl 87860 = = 100 m3/hr l 878.6
= 0.1023 m = 4 Ql 4 100 = 2 D 3.141 0.1023 2 60 2 = 3.379 m/s
Dv l l 0.1023 3.379 878.6 = = 466118 l 0.000652
To calculate Darcy friction factor (f) the initial guess is calculated as per Blazius equation f = 0.316 Re-0.25 = 0.316 x 466118-0.25 = 0.012094
The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.48605 7.528678 7.52752 7.527551
f 0.012094 0.017844 0.017643 0.017648 0.017648
The iterative procedure converges after 3 - 4 iterations. A value of 0.017648 is accepted as the friction factor value in further calculations. Frictional Head Loss (m /m) = Frictional Pressure Drop (Pl) 0.017648 3.379 2 P fv l = = l g 2gD 2 9.81 0.1023 = 0.100472 878.6 9.81
2
= 0.100472 = 0.017648 Pa /m = 0.0382725 psi/ft
Flow Rate (Q) Diameter (D) Linear Velocity (vv) Reynolds Number (Re) Initial guess = 0.316 Re-0.25 =
473.6 = 400 m3/hr 1.184
= 0.1023 m = 13.518 m/s = 82570 = 0.018261
The iterative calculation using Colebrook and White equation the friction factor is given as:
1/sqrt(f)
6.939883 6.973542 6.971035 6.971222
f 0.018261 0.020763 0.020563 0.020578 0.020577
= 0.020577
= 1.89578
Frictional Pressure Drop (Pv) = 22.0196 Pa/m = 0.000973179 psi/ft The fluid properties in FPS system of unit are as follows:
Liquid
Mass Flow Rate (lb/hr) Density (lb/ft3) Viscosity (cP) Surface Tension (dynes/cm) 193698.13 54.849 0.652 28.88
Gas
1044.10 0.073915 0.01983

B Y = 2.16
Wv 2.16 1044.1 = 0.5 A( l v ) 0.0885 (54.85 0.074) 0.5
= 12649
Wl B X = 531 W v = 531
[( l v ) 0.5 ] 11 3 2/3 1 1
193698.13 (54.85 0.074) 0.5 0.6521 / 3 = 412.77 1044.1 54.85 2 / 3 28.88
From the Baker flow regime map, we see that the flow regime is bubble or froth and the correlation for Bakers Modulus is given by
Bakers Modulus () =
14.2X 0.75 (Wl /A) 0.1
Where, Wl = Liquid Flow Rate, lb/hr A = Internal cross-sectional area, ft 2 Lockhart Martinellis Modulus (X) = ((P)l/ (P) V ) 0.5 = (0.0382725/0.000973179)0.5 = 6.27115 14.2 6.27 0.75 = 13.069 Bakers Modulus ( ) = (193698.13 / 0.0885) 0.1 2 = 170.818 Y(v or l) = exp
a (ln X )
i =1 i
i 1
where for Yl: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002. for Yv: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002. Y V = 12.7, Yl = 2.0284.

(P) LV = Yv2 (P )V = 12.72 0.000973179 (P) LV = Yl2 (P )l = 2.02842 0.0382725 = 0.156966 psi/ft = 0.157469 psi/ft
Bakers Method:
(P) LV = 2(P) V = 170.818 0.000973179 = 0.166237 psi/ft The Total Frictional Pressure Drop over 75.95 m (249.18 ft) of 4 pipe = 0.166237 249.18 = 41.423 psi
Pressure drop for liquid phase per unit length of 6 pipe is calculated as follows.
Diameter (D) Flow Rate (Q) Linear Velocity (vl) = 0.1541 m = 100 m3/hr = 1.489 m/s
1/sqrt(f)
7.605246 7.652769 7.650527 7.650633
f 0.013398 0.017289 0.017075 0.017085 0.017085
= 0.017085 = 0.0125394
Frictional Pressure Drop (P)l = 108.078 Pa/m = 0.00477662 psi/ft
Pressure drop for gas phase per unit length of 6 pipe is calculated as follows:
Diameter (D) Flow Rate (Q) Linear Velocity (vv) Reynolds Number (Re) = 0.1541 m = 400 m3/hr = 5.957 m/s = 59381
Initial guess of friction factor = 0.020231 The iterative calculation using Colebrook and White equation the friction factor is given as:
1/sqrt(f) 0.05 6.831521 6.850726 6.848855 6.849037
f 0.020231 0.021427 0.021307 0.021319 0.021318
= 0.021318 = 0.254009
Frictional Pressure Drop (P)v = 2.95033 Pa/m = 0.000130393 psi/ft Two Baker parameters B X and B Y are calculated as follows: BY BX = 5579.35 = 412.53
From the Bakers flow regime map, we see that the flow regime is bubble or froth and the correlation for Bakers Modulus is calculated as Bakers Modulus () = 13.813 2 = 190.803 Lockhart Martinellis Modulus (X) = ((P) L / (P) V ) 0.5 = (0.00477662/0.000130393)0.5 = 6.05249 Y(v or l) = exp
a (ln X )
i =1 i
i 1
Where, for Yl: a1 = 1.44065; a2 = -0.50445, a3 = 0.06212, a4 = -0.00106, a5 = -0.00101, a6 = 0.00003, a7 = 0.00002. for Yv: a1 = 1.44105; a2 = 0.49541, a3 = 0.06153, a4 = -0.00113, a5 = -0.00095, a6 = 0.00003, a7 = 0.00002.
Y V = 12.3932, Yl = 2.0507.

(P) LV = Yv2 (P )V = 12.39322 0.000130393 = 0.0200273 psi/ft (P) LV = Yl2 (P )l = 2.05072 0.00477662 = 0.0200892 psi/ft
Bakers Method:
(P) LV = 2(P) V = 1.90803 0.000130393 = 0.0248793 psi/ft
The Total Frictional Pressure Drop over 77.87 m (255.48 ft) of 6 pipe = 0.0248793 255.49= 6.356 psi Total Frictional Pressure Drop = 41.423 + 6.356 = 47.779 psi = 38.24 m of liquid column The mixture density is give n by
1 mix
Mg g
Ml l
Where, Mg and Ml are mass fractions of gas and liquid. mix = 176 kg/m3 Total Frictional Pressure Drop P1 P = 38.24 m 1 = 190.89 m of mixture column lg mix g
Total Volumetric Flow Rate in 4 pipe (Q1) = (87860 + 473.6)/ 176 = 501.89 m3/hr Velocity in 4 pipe (v1) = 4 501.89 / (3.14 0.10232 602) = 16.9631 m/s Velocity in 6 pipe (v2) = 4 501.89 / (3.14 0.15412 602) = 7.4757 m/s Now applying Bernoullis equation:
P 1 v1 1 v2 + + Z1 = 2 + + Z2 + f h mix g 2 g mix g 2 g
P1 mix g + P 16.96 2 7.4757 2 + 0= 2 + + 10 + 190.89 2 9.81 mix g 2 9.81
P1
P1 P2 = 189.08 m mix g
P1 P2 = 326454.15 Pa
Inlet Head is 40 m of liquid column i.e. P2 mix g
P1 P = 40 m 1 = 199.68 m lg mix g
= 10.6m
P2 = 2.12 m lg
Head at outlet is 2.12 m of liquid column.

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Pressure Drop = 3.379 m/s = 466118 = 0.017648 = 0.017648 Pa /m = 0.0382725 psi/ft
Gas Phase
Total frictional pressure drop in 4 pipe using Lockhart Martinellis Method = 0.156966 psi/ft Total frictional pressure drop in 4 pipe using Bakers Method = 0.166237 psi/ft
Total frictional pressure drop in 4 pipe using pressure drop calculated from Bakers Method = 41.423 psi

Gas Phase
Total frictional pressure drop in 6 pipe using Lockhart Martinellis Method = 0.0200273 psi/ft Total frictional pressure drop in 6 pipe using Bakers Method = 0.0248793 psi/ft Total frictional pressure drop in 6 pipe using pressure drop calculated from Bakers Method = 6.356 psi
Overall Route:
Total Frictional Head Loss = 47.779 psi = 38.24 m of liquid column The net Head at outlet is 2.12 m of liquid column
EXAMPLE 19:
Let us consider the route shown; carrying a two phase mixture of hydrocarbon oil and gas. The service requirements and the specifications are given below. The discharge end is at an elevation of 20m. Gas and Liquid both are flowing at a flow rate of 5000 kg/hr and 45000 kg/hr respectively. Calculate the two phase pressure drop if the pressure at the inlet of the pipe is 5 atma.
Pipe: 8 NB, SCH30, commercial steel pipe with Surface roughness approx 0.05 mm; Liquid: Density (l) = 740 kg/m3, Viscosity (l) = 4.96 cP, Surface Tension (l)= 25
dynes/cm, Mass Flow Rate(Wl )= 45000 Kg/hr
Gas: Density (v) = 2.73 kg/m3, Viscosity (v) = 0.0135 cP, Mass Flow Rate (Wv ) = 5000
Kg/hr.
SOLUTION 19:
Route Analysis: Equivalent Length/ Component (ft) Size 8 Total Contribution ft (m) Size 8
689 (210) 6 1 1 1 1 1 1 14 6.5 100 24 0 0 --84 (25.60) 6 (1.98) 100 (30.48) 24 (7.32) 0 0 903 (275.38) 0 0 7 36 ---0 0 7 (2.13) 36 (10.98) 43 (13.11)

Pipe Elbow LR (900) Gate Valve Ball Check Valve Entry Nozzle Reducer (8 x 6) Exit Nozzle TOTAL

0 0 0

0 0 0


The actual outside diameter of the pipe = 8.625 Thickness of the pipe The inside diameter of the pipe = 219.08 - (2 7.036) The equivalent length of 8 pipe components Actual length of 8 straight pipe Total equivalent length of the 8 pipe (L) = 210 + 65.38 = 219.08 mm = 7.036 mm = 205.008 mm = 65.38 m = 210 m = 275.38 m
Volumetric Flow Rate (Q) = Diameter (D) Linear Velocity (v) = Wl 45000 = = 60.81 m3/hr l 740
= 0.205 m
4 60.81 4Q = 2 3.14 (60 60) 0.205 2 D

D v l l 0.205 0.5120 740 = l 4.96 10 3
= 0.5120 m/s
= 15659
To calculate Darcy friction factor (f) the initial guess is calculated from Blazius Equation = 0.316 Re 0.25 = 0.316 15659 0.25 = 0.028248 The Colebrook and White equation for calculating the friction factor is as follows:
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
5.983342 5.978782 5.979402 5.979317 5.979329
f 0.028248 0.027933 0.027975 0.027969 0.02797 0.02797
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 5 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.02797 is accepted as the friction factor value in further calculations. Frictional Head Loss per unit length P fv l 0.02797 0.5120 2 = = g 2gD 2 9.81 0.205 = 13.23 Pa/m
2
= 0.001823 m/m
Frictional Pressure Drop per unit length (Pl)
Pressure drop for Gas phase per unit length of 8 NB pipe is calculated as follows
Volumetric Flow Rate (Q) = Diameter (D) Linear Velocity (vv) =
5000 2.73
=1831.5 m3/hr
= 0.205 m
4 1831.5 = 15.42 m/s 3.14 (60 60) 0.205 2

0.205 15.42 2.73 0.0135 10 3
= 639245
Initial guess of Darcy friction factor (f) calculated using Blazius Equation = 0.316 639245 0.25 = 0.011175
The Colebrook and White equation for calculating the friction factor is as follows: 1 2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.975328 8.025973 8.024196 8.024258
f 0.011175 0.015722 0.015524 0.015531 0.015531
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 6 significant digits after the third iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.015531 is accepted as the friction factor value in further calculations. Frictional Head Loss per unit length = 0.015531 15.42 2 2 9.81 0.205 = 0.91815 m/m = 24.59 Pa/m
Frictional Pressure Drop per unit length (Pv) The fluid Properties in FPS system are as follows Properties Mass Flow Rate (lb/hr) Density (lb/ft3) Viscosity (cP) Surface Tension (dynes/cm) Oil 46.196 4.96
Gas 0.1704 0.0139 25
992080.01 11023.11

BX = 531
13 Wl [( l v ) 0.5 ] 1 Wv 1 2 3 1
= 531
992080.01 (46.196 0.1704) 0.5 4.961/3 11023.11 46.196 2/3 25
= 71.14
B Y = 2.16
[A( ) ]
0.5
Wv
l
= 2.16
11023.11 0.355(46.196 0.1704) 0.5
= 23905.21
From the Baker flow regime map, we see that the flow regime is annular and the correlation for Bakers Modulus ( ) is given by
=aXb
a = 4.8 0.3125d
b = 0.343 0.021d where, d = I.D. of pipe in inches
a = 4.8 0.3125 8.07 = 2.278 b = 0.343 0.021 8.07 = 0.1735

PL Lockhart Martinellis Modulus (X) = P v Bakers Modulus ( ) = 2.278 0.7335 0.1735
0.5
13.23 = 24.59
0.5
= 0.538 0.5 = 0.7335
= 2.159
Since the flow of both gas and liquid are turbulent, the Parameters YL or YV can be calculated using the formula For Y(V or L) = exp ai ( LnX )
i =1 n i 1
For calculating YL: a1 = 1.44065 a5 = -0.00101 For calculating YV: a1 = 1.44105 a5 = -0.00095 a2 = 0.49541 a 6 = 0.00003 a3 = 0.06153 a4= -0.00113 a2 = -0.504445 a 6 = 0.00003 a3 = 0.06212 a4= -0.00106
YL = 4.9679, YV = 3.6453
Lockhart Martinelli Method

Two phase pressure drop based on YL is PlV = YL2 PL = 4.9679 2 13.23 = 326.51 Pa/m Two phase pressure drop based on YV is PlV = YV2 PV = 3.6453 2 24.59 = 326.75 Pa/m
Bakers Method:
Two Phase Pressure Drop (Plv) = 2 Pv
= 2.159 2 24.59 = 114.62 Pa/m
The Total Two Phase Pressure Drop over the 8 pipe section; By Bakers Method Plv = 275.38 114.62 = 31564.05 Pa. By Lockhart Martinellis Method Plv = 275.38 326.75 = 89980 Pa.

The actual outside diameter of the pipe = 6.625 Thickness of the pipe The inside diameter of the pipe = 168.27 - (2 7.112) The equivalent length of 6 pipe components = 168.27 mm = 7.112 mm = 154.046 mm = 13.11 m
Volumetric Flow Rate = Diameter (D)
45000 = 60.81 m3/hr 740
= 0.154 m
4 60.81 = 0.9073 m/s 3.14 (60 60) 0.154 2 0.154 0.9073 740 = 20846 4.96 10 3
Initial guess of Darcy Friction Factor (f) is calculated as per Blazius Equation = 0.316 20846 0.25 = 0.026298 Solving the Colebrook White equation iteratively as done earlier, the iterative values are as follows. Again, convergence is obtained after 3 iterations giving a friction factor value of 0.026333
Iteration 1/sqrt(f) f No. 0 0.026298 1 6.161873 0.026337 2 6.162452 0.026333 3 6.162379 0.026333
0.026333 0.9073 2 2 9.81 0.154
= 0.0079 m/m
Frictional Pressure Drop per unit length (Pv)
= 57.40 Pa/m
Volumetric Flow Rate = Diameter (D)
5000 = 1831.5 m3/hr 2.73
= 0.154 m
The Linear Velocity (vv) =
4 1831.5 = 27.33 m/s 3.14 (60 60) 0.154 2
0.154 27.33 2.73 0.0135 10 3
= 851117
Initial guess of Darcy Friction Factor (f) is calculated as per Blazius Equation = 0.316 851117 0.25 = 0.0104
0.01598 Iteration No. 0 1 2 3 4
1/sqrt(f)
7.867878 7.911556 7.910546 7.910570
f 0.01040
0.016154 0.015976 0.015980 0.015980
0.015980 27.33 2 2 9.81 0.154
= 3.95 m/m = 105.79 Pa/m
Two Bakers parameters Bx and By are calculated as follows:

Bx = 71.14 By = 42386.25 From the Baker flow regime map, we see that the flow regime is dispersed and the correlation for Bakers Modulus is given by, If X2 > 0.3 and X2 < = 2.5, = (7.844 X + 9.1477) 0.5
PL Lockhart Martinellis Modulus(X) = P v
0.5
57.40 = 105.79
0.5
= 0.5425 0.5 = 0.7366
Bakers Modulus ( ) = (7.844 0.7366 + 9.1477) 0.5
=3.8633
Since the flow of both gas and liquid are turbulent, the Parameters YL or YV can be calculated using the previous method
YL = 4.9566, YV = 3.6523 Bakers Method:

= 3.8633 2 105.79 = 1579 Pa/m

The Total Two Phase Pressure Drop over the 6 pipe section; (PlV) = 13.11 1579
= 20700.7 Pa.
Lockhart Martinellis Method

Two Phase Pressure Drop based on YL is PlV = YL2 PL = 4.9566 2 57.40 =1410.2 Pa/m Two Phase Pressure Drop based on YV is PlV = YV2 PV = 3.6523 2 105.79 =1411.16 Pa/m The Total Two Phase Pressure Drop over the 6 pipe section; PlV = 13.11 1411.16 = 18500.30 Pa.
Now the Total Two Phase Frictional Pressure Drop due to all the piping components in the entire piping section By Bakers Method (PlV) = 31564.05 + 20700.7 = 52264.75 Pa.
By Lockhart Martinellis Method (PlV) = 89980 + 18500.30 = 108480.30 Pa.
The Two Phase Mixture Density is calculated using the formula 1 mix = Ml Mv + l v
Ml =
45000 = 0.9 (45000 + 5000)
Mv =
1 mix =
5000 = 0.1 45000 + 5000

0.9 0.1 + =0.03784 740 2.73
mix = 26.42 kg/m3 Total Mass Flow Rate = 50000 kg/hr Mixture Volumetric Flow Rate (Qmix) = The velocity at the inlet of the pipe
v1 = 4Q 4 1892.50 = 15.935 m/s = 2 3.14 D 3.14 0.205 2 (3600)
Mass Flow Rate 50000 = = 1892.50 m3/hr Density 26.42
The velocity at the exit of the pipe

v2 = 4Q 4 1892.50 = 28.237 m/s = 2 3.14 D 3.14 0.154 2 (3600)
Bernoullis Equation
2 2 P v1 P2 v2 + + Z1 = + + Z2 + g mix g 2g mix g 2g mix friction
P1
P1 P2 mix g
2 2 P v 2 v1 + (Z 2 Z1 ) + g 2g mix friction
Here the frictional pressure drop considered is the two phase frictional pressure drop by Lockhart Martinellis method. P1 P2 28.237 2 15.935 2 + (20 0.0) + 418.55 = 466.25 m = mix g 2 9.81
P2 = P1-(120842.76) Pa = P1- 1.193 atma The Pressure at the exit of the pipe P2 = 5-1.193 = 3.807 atma.
Summary of the Solution 19: For 8 pipe Liquid Phase

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Head Loss Frictional Pressure Drop = 0.5120 m/s = 15659 = 0.02797 = 0.001823 m/m = 13.23 Pa/m
Gas Phase
Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Head Loss Frictional Pressure Drop = 15.42 m/s = 639245 = 0.01553 = 0.91815 m/m = 24.59 Pa/m = 31564.05 Pa
Two Phase Pressure drop by Bakers Method
Two Phase Pressure drop by Lockhart Martinellis method = 89980 Pa
For 6 Pipe Liquid Phase

Gas Phase
Two Phase Pressure drop by Bakers Method
Two Phase Pressure drop by Lockhart Martinellis method = 18500.30 Pa
In the Entire Pipe Section

The Total Two Phase Frictional Pressure Drop due to all the piping components in the entire piping section By Bakers Method (PlV) = 31564.05 + 20700.70 = 52264.75 Pa.
By Lockhart Martinellis method (PlV) = 89980.00 + 18500.30 = 108480.30 Pa. The pressure at the exit of the pipe = 3.807 atma.
EXAMPLE 20:
Let us consider the route shown; carrying a two phase mixture of air and water. The service requirements and the specifications are given below. Air and water both are flowing at a flow rate of 15,000 kg/hr and 60,000 kg/hr respectively. Calculate the two phase pressure drop if the pressure at the inlet of the pipe is 5 atma.
No.
1 2 3 4 5
Components
Globe Valve Elbow Elbow Elbow Expander
Size (inch)
10 10 10 10 12 x 10
No.
8 9 10 11 12
Components
Elbow Elbow CheckValve Elbow Reducer
Size (inch)
12 12 x 10 12 12 12 x 10
Pipe: 10, NB, SCH 40 commercial PVC pipe with roughness 0.0015mm.
12, NB, SCH 40 commercial PVC pipe with roughness 0.0015mm.
Liquid: Density (l) = 996 kg/m3, Viscosity (l) = 0.798 cP, Surface Tension (l) =71.2
dynes/cm, Mass Flow Rate (Wl) = 60,000 Kg/hr.
Gas: Density (v) = 1.166 kg/m3, Viscosity (v) = 0.0187 cP, Mass Flow Rate (Wv) =
15,000 Kg/hr.
SOLUTION 20:
Route Analysis:

Pipe Elbows LR 900 Globe Valve 900, (Fully Open Type) CheckValve (Ball Type) Expander (12 x10) Reducer (12 x10) Entry Nozzle Exit Nozzle Total (m) 6 1
Equivalent Length/ Component (ft) Size12
Total Contribution ft (m) Size12

935.03 (285)
Equivalent Length/ Component (ft) Size10

442.91 (135)
21 (3)
63 (19.20)
16 (3)
48 (14.63)
280 (1)
280 (85.34)
1 1 1 1 1
150 (1)
150 (45.72) 6.5 (1) 6.5 (1) 31 (1) 62 (1) 1148.03 (349.92) 6.5 (1.98) 6.5 (1.98) 31 (9.45) 62 (18.90) 876.91 (267.28)
Note: 1.The lengths in parenthesis are in m (total contribution)

2.The values in Parenthesis number of pieces of particular component (equivalent length/component column)
The route analysis says that the route with its pipes, fittings and valves is equivalent to 349.92 m of 12 straight pipe and 267.28 m of 10straight pipe. These lengths should be used in overall frictional pressure drop calculations. The equivalent length for the two nozzles is in terms of straight length of pipe of same size as the nozzle.

The actual outside diameter of the pipe = Thickness of the pipe The inside diameter of the pipe = 323.85 - (2 10.312) The equivalent length of 12 pipe components Actual length of 12 straight pipe Total equivalent length of the 12 pipe (L) = 285 + 64.92 = 323.85 mm = 10.312 mm = 303.226 mm = 64.92 m = 285.0 m = 349.92 m
Volumetric Flow Rate (Q) = Diameter (D) The Linear Velocity (v) = Wl 60000 = = 60.24 m3/hr l 996
= 0.3032
4Q D 2
4 60.24 = 0.232 m/s 3.14 (60 60) 0.3032 2

= 87796
D v l l 0.3032 0.232 996 = l 0.798 10 3
To calculate Darcy Friction Factor (f) the initial guess is calculated from Blazius Equation = 0.316 Re 0.25 = 0.316 87796 0.25 = 0.01836
2.51 = 2 log10 + f 3.71 D Re f
1/sqrt(f)
7.345488 7.349537 7.349061 7.349117 7.349110
f 0.018360 0.018534 0.018513 0.018516 0.018515 0.018515
As can be seen, the iterative procedure converges after 3-4 iterations. The change in the friction factor value is only after 5 significant digits after the fourth iteration. Generally, 3-4 iterations are sufficient irrespective of the quality of the initial guess. A value of 0.018515 is accepted as the friction factor value in further calculations. P fv l 0.018515 0.232 2 Frictional Head Loss per unit length = = g 2gD 2 9.81 0.3032 Frictional Pressure Drop per unit length (Pl ) = 1.636 Pa/m
2
= 0.000167 m/m
Pressure drop for Gas phase per unit length of 12 NB pipe is calculated as Follows
Volumetric Flow Rate (Q) = Diameter (D) Linear Velocity (vl)
15000 = 12864.5 m3/hr 1.166
= 0.3032m =
4 12864.5 3.14 (60 60) 0.3032 2
= 49.52 m/s
0.3032 49.52 1.166 0.0187 10 3
= 936196
0.011886. Iteration No. 0 1 2 3 4 5
1/sqrt(f)
9.107655 9.178287 9.171923 9.172495 9.172443
f 0.010159 0.012056 0.011871 0.011887 0.011886 0.011886
0.011886 49.52 2 2 9.81 0.3032
= 4.90 m/m
= 56.04 Pa/m
The fluid Properties in FPS system are as follows Properties Mass Flow Rate (lb/hr) Density (lb/ft3) Viscosity (cP) SurfaceTension (dynes/cm) Oil 133277.34 62.18 0.798 71.2 Gas 33069.34 0.0728 0.0187

BX Wl [( l v ) 0.5 ] = 531 Wv 1 2 3 = 531
11 3 1
= 3.779
133277.34 (62.18 0.0728) 0.5 0.7981/3 71.2 33069.34 62.18 2/3
BY
= 2.16
[A( ) ]
0.5
l v
Wv
= 2.16
33069.34 0.7768(62.18 0.0728) 0.5
= 43219.43
From the Bakers flow regime map, we see that the flow regime is dispersed and the correlation for Bakers Modulus is given by If X2 >= 0.003 and X2 < = 0.3,
= (13.765X 0.2836 ) 0.5

0.5
PL Lockhart Martinellis Modulus (X) = P v
1.636 = 56.04
0.5
= 0.029 0.5 = 0.1710
Bakers Modulus ( ) = (13.765X 0.2836 ) 0.5 = 2.8882 Since the flow of both gas and liquid are turbulent, the Parameters YL or YV can be calculated using the formula For Y(V or L) = exp ai ( LnX )
i =1 n i 1
For calculating YL: a1 = 1.44065 a5 = -0.00101 For calculating YV: a1 = 1.44105 a5 = -0.00095 a2 = 0.49541 a 6 = 0.00003 a3 = 0.06153 a4= -0.00113 a2 = -0.504445 a 6 = 0.00003 a3 = 0.06212 a4= -0.00106
YL = 12.44, YV = 2.126 Bakers Method:

= 2.8882 2 56.04
= 467.47 Pa/m
The Total Two Phase Pressure Drop over the 12 pipe section; PlV = 349.92 467.47 = 163577.1 Pa.

Two phase pressure drop based on YL is PlV = YL2 PL = 12.44 2 1.636 = 253.176 Pa/m Two phase pressure drop based on YV is PlV = YV2 PV = 2.126 2 56.04 = 253.29 Pa/m The Total Two Phase Pressure Drop over the 12 pipe section; PlV = 349.92 253.29 = 88631.23 Pa.

The actual outside diameter of the pipe Thickness of the pipe The inside diameter of the pipe = 273.05- (2 9.271) The equivalent length of 10 pipe components Actual length of 10 straight pipe = 273.05 mm = 9.271 mm = 254.51 mm = 132.28 m = 135 m
Total equivalent length of the 10 pipe (L) = 135 + 132.28 = 267.28 m
Pressure Drop for liquid phase per unit length of 10 NB pipe is calculated as follows:
Volumetric Flow Rate (Ql) Diameter (D) The Linear Velocity (vl) = 60.24 m3/hr = 0.2545 m =
4 60.24 = 0.329 m/s 3.14 (60 60) 0.2545 2
0.2545 0.329 996 0.798 10 3
=104506
1/sqrt(f)
7.476479 7.484148 7.483266 7.483367
f 0.01757 0.01789 0.017853 0.017857 0.017857
0.017857 0.329 2 2 9.81 0.2545
= 0.000387 m/m = 3.78 Pa/m
Volumetric Flow Rate (Qv) Diameter (D) Linear Velocity (vl) = = 12864.5 m3/hr =0.2545m
4 12864.5 = 70.28 m/s 3.14 (60 60) 0.2545 2
0.2545 70.28 1.166 0.0187 10 3
= 1115261
Initial guess of Darcy Friction Factor (f) calculated as per Blazius Equation = 0.316 11152610.25 = 0.009724
0.011574 Iteration No. 0 1 2 3 4 5 1/sqrt(f)

9.224796 9.301443 9.294765 9.295345 9.295294
f
0.010400 0.011751 0.011558 0.011575 0.011574 0.011574
0.011574 70.28 2 2 9.81 0.2545
= 11.45 m/m
= 130.95 Pa/m

Bx = 3.75 By = 61312.84 From the Baker flow regime map, we see that the flow regime can is dispersed and the correlation for Bakers Modulus is given by: If X2 >= 0.003 and X2 < = 0.3, = (13.765 X 0.2836 ) 0.5 PL Lockhart Martinellis Modulus ( X) = P v
0.5
3.78 = 130.95
0.5
= 0.0288 0.5 = 0.1699
Bakers Modulus () = (13.765 0.1699 0.2836 ) 0.5 = 2.8855 Since the flow of both gas and liquid are turbulent, the Parameters YL or YV can be calculated using the previous method
YL = 12.498, YV = 2.122
Lockhart Martinellis Method

Two Phase Pressure Drop based on YL is PlV = YL2 PL = 12.498 2 3.78 = 590.43 Pa/m Two Phase Pressure Drop based on YV is PlV = YV2 PV = 2.122 2 130.95 = 589.65 Pa/m The Total Two Phase Pressure Drop over the10 pipe section; (PlV) = 267.28 590.43 = 157810.13 Pa.
Bakers Method:
= 2.8855 2 130.95 = 1090.35 Pa/m
The Total Two Phase Pressure Drop over the10 pipe section; (PlV) = 267.28 1090.35 = 291428.74 Pa.
Now the Total Two Phase Frictional Pressure Drop due to all the piping components in the entire piping section By Bakers Method (PlV) = 163577.10 + 291428.74 = 455005.84 Pa By Lockhart Martinellis Method (PlV) = 88631.23 + 157810.13 = 246441.36 Pa
The Two Phase Mixture Density is calculated using the formula 1 mix = Ml Mv + l v 60000 = 0.8 (60000 + 15000)
Ml =
Mv =
15000 = 0.2 60000 + 15000
1 mix
0.8 0.2 + =0.03784 996 1.166
mix = 5.803 kg/m3
Total Mass Flow Rate = 75000 kg/hr Mixture Volumetric Flow Rate (Qmix) = The velocity at the inlet of the pipe
V1 = 4Q 4 12924.35 = 70.61m/s = 2 3.14 D 3.14 .2545 2 3600
Mass Flow Rate 75000 = = 12924.35 m3/hr Density 5.803
The velocity at the exit of the pipe

V2 = 4Q 4 12924.35 = 70.61 m/s = 2 3.14 D 3.14 .2545 2 3600
Bernoullis Equation P1 mix g +

2 2 P v1 P v + Z1 = 2 + 2 + Z 2 + g 2g mix g 2g mix friction
2 2 P v 2 v1 + (Z 2 Z1 ) + g 2g mix friction
P1 P2 mix g
Here the frictional pressure drop considered is the two phase frictional pressure drop by Lockhart Martinellis method. P1 P2 mix g = 70.612 70.612 + 4329 = 4329 m 2 9.81
P2 = P1-(246441.36) Pa = P1- 2.43 atma The Pressure at the exit of the pipe P2 = 5-2.43 = 2.57 atma.
Summary of the Solution 20: For 12 pipe Liquid Phase

Linear Velocity (v) Reynolds Number (Re) Darcy Friction Factor (f) Frictional Head Loss Frictional Pressure Drop = 0.2320m/s = 87796 = 0.018515 = 0.000167 m/m = 1.636Pa/m
Gas Phase
Two Phase Pressure drop by Bakers method
For 10 Pipe Liquid Phase

Gas Phase
Two Phase Pressure drop by Bakers method
In the Entire Pipe Section

The Total Two Phase Frictional Pressure Drop due to all the piping components in the entire piping section By Bakers method (PlV) = 163577.10 + 291428.74 = 455005.84 Pa
By Lockhart Martinellis method (PlV) = 88631.23 + 157810.13 = 246441.36 Pa The pressure at the exit of the pipe = 2.57 atma.

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PressureDrop Calculation AdditionalProblems

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EXAMPLES FOR SINGLE PHASE PRESSURE DROP CALCULATIONS: EXAMPLE 1: Let us consider a piping route as shown.

Size 4 4 6x4 6 6 6x4 4

Components Elbow Reducer Elbow Tee

Size (inch) 6 6x4 4 4

Components Expander Elbow Tee

Size (inch) 6x4 6 6

Components Inlet nozzle Reducer Tee Elbow Elbow

Size (inch) 8 8x6 6 6 6

Components Gate Valve Elbow Elbow Reducer Exit nozzle

Size (inch) 6 6 6 6x4 4

Components Vertical Inlet Elbow Gate Valve Reducer Tee Section

Size (inch) 3 3 3 3x2 2

Components Elbow Elbow Elbow Globe Valve Horizontal Inlet

Size (inch) 4 6x4 6 6 6 6

Total Contribution ft (m) Size 6

NOTE: The lengths in parenthesis are in m.

The Linear Velocity (v) =

4 122.22 3.14 (60 60) 102.26 2 10 -6

Reynolds Number (Re) =

D v 102.26 10 3 4.14 900 = 1.45 10 3

2.51 = 2 log10 + f 3.71 D Re f

f 0.013957 0.018538 0.018313 0.018322 0.018322

Calculation of the Inside Diameter of Pipe with 6 NB, SCH 40

Total equivalent length of the 6 pipe (L) = 29.41 + 195.75 = 225.16 m

Pressure Drop Calculations For 6 pipe

The Linear Velocity (v) =

4 122.22 3.14 (60 60) 154.05 2 10 -6

154.05 10 3 1.82 900 Reynolds Number (Re) = 1.45 10 3

f 0.015472 0.018345 0.018141 0.018154 0.018153 0.018153

Frictional Head Loss per unit length =

0.018153 1.82 2 2 9.81 154.05 10 -3

4.14 2 4.14 2 = + (10 4) + 28.07 2 9.81 = 34.07 m

= pressure equivalent to 34.07 m of liquid column = 34.07 900 9.81

= 300804.03 Pa = 2.97 atma.

Summary of Solution 1: For 4 pipe

Pipe: Commercial Steel with surface roughness approximately 0.05 mm

Total Contribution ft (m) Size 6

NOTE: The lengths in parenthesis are in m.

Calculation of the Inside Diameter of Pipe with 4 NB, SCH 40

= 6.020 mm = 102.26 mm =9m = 91 m = 100 m

Pressure Drop Calculations For 4 pipe

The Linear Velocity (v) =

4 102.70 = 3.48 m/s 3.14 (60 60) 102.26 2 10 -6

D v 102.26 10 -3 3.48 779 = Reynolds Number (Re) = 1.02 10 3

2.51 = 2 log10 + f 3.71 D Re f

f 0.01384 0.018489 0.018265 0.018274 0.018274 0.018274

Frictional Head Loss per unit length =

Calculation of the Inside Diameter of Pipe with 6 NB, SCH 40

Total equivalent length of the 6 pipe (L) = 68.58 + 131.42 = 200 m

Pressure Drop Calculations For 6 pipe

The Linear Velocity (v) =

4 102.70 = 1.53 m/s 3.14 (60 60) 154.05 2 10 -6

Reynolds Number (Re) =

154.05 10-3 1.53 779 1.02 10 3

f 0.015341 0.018273 0.018068 0.018081 0.01808 0.01808

0.01808 1.53 2 2 9.81 154.05 10 -3

3.48 2 1.53 2 = + (0 5) + 13.80 2 9.81 = 9.30 m

= pressure equivalent to 9.30 m of liquid column

=9.30 779 9.81

= 71070.51 Pa = 0.70 atma.

Summary of Solution 2: For 4 pipe

Size 4 4 6x4 6 6 6x4 4

Piping System Component

Equivalent Length/ Component ft Number Size 4