APAR INDUSTRIES

LIMITED

MINOR PROJECT ON

Optimum Pipe Size Selection for Turbulent Flow

PROJECT GUIDE: SUBMITTED BY:

Mr. Anand Mishra Mr. Manoj Parab
Ms. Priyanka Sanap

Datta Meghe College of Engineering

Rajeshri Shahu Maharaj Marg, Sector 3, Airoli, Navi Mumbai,
Maharashtra 400708.

Submission date: 09/07/2015

BACKGROUND
Pipelines are normally designed to deliver fluid at the required head and flow
rate in a cost effective manner. Increase in diameter leads to increase in
annualmaterial costs, and decrease in operating costs.On the other hand
decrease in the pipe diameter leads to decrease in annual material cost but
increases the operating cost due to increase in different head losses occurring
within the pipe. Selection of an optimum conduit diameter for a particular fluid
flow will therefore be a vital economic decision.The optimum pipe size should
be based on minimizing the sum of energy cost and piping cost.This report
presents an optimization technique for determination of optimum pipe diameter
for a number of turbulent flow.

METHODOLOGY
The total annual cost,CT is the addition of the fixed cost and the piping cost,
i.e. CT = CM + CP
Where,
CM = Material cost
CP = Pumping cost

 Material cost can be calculated in the following manner:

M.C. = density (kg/m3)*volume of cylinder (m3)*cost (Rs/kg)

Density will depend on the type of material that is used for construction on pipe.
The volume of cylinder can be calculated in the following way.
Volume of cylinder = 𝜋𝑟 2 l

𝜋
V = ∗ 𝑙 ∗(d22 - d12) d2 => outer diameter of cylinder
4

d1 => inner diameter of cylinder

𝜋
= ∗ 𝑙 ∗(d2 + d1) (d2 - d1)
4
But,
d2 + d1 = 2D +2t , d2 – d1 = 2t t => thickness

𝜋
[V = ∗ 𝑙 ∗(2D +2t)*2t] m3
4

Hence yearly material cost is given by,

𝝅
{Material cost (yearly)= ( *L*(2D+2t)*2t*ρ*c1*5*0.17)}Rs.
𝟒

Where,
 c1 is unit cost /kg
Factor of 0.17 denotes Capital investment {Interest per year 12%, 5%
Depreciation}
Once the equation has been formulated final step is to select different pipe
diameter and determine corresponding material cost.

 Pumping cost can be calculated in the following manner:

P.C. = Operating time (h) * Power (KW) * Unit cost (Rs/KWh)

Power required for pumping is calculatedby,
Power = (v*ρ*g*h)/t W
= (q*ρ*g*h)/103 KW
Where,
 q is flow rate in m/s
 ρ is density in kg/m3
 h = (hl + hv), is total head loss in meter

The head losses in piping installations include the energy or head required to
overcome resistance of the pipeline and fitting in the pumping system. Friction
exists on both the discharge and suction sides of a pump and energy loss in pipe
flow depends on the fluid velocity, density, viscosity, and conduit dimension. A
number of equations governing fluid flow in pipelines have been developed by
authors but most widely used is Darcy-Weisbach equation. Darcy–Weisbach
equation is aphenomenological equation, which relates the head loss-r pressure
loss — due to friction along a given length of pipe to the average velocity of the
fluid flow for an incompressible fluid. It is given by,

Head loss can be calculated with

hl = f *L/D*v2/2g

Where,

 hl is the head loss due to friction (SI units: m);

 L is the length of the pipe (m);
 D is the hydraulic diameter of the pipe (for a pipe of circular section, this
equals the internal diameter of the pipe) (m);
 V is the average flow velocity, experimentally measured as the
volumetric flow rate per unit cross-sectional wetted area (m/s);
 g is the local acceleration due to gravity (m/s2);
 f is a dimensionless coefficient calledthe Darcy friction factor.

Friction factor is calculated using following formula:

{f= 1.325/ {ln[(e/3.7D)+(5.74/Re0.9)]}

Where,
 e is absolute roughness
 Re is Reynold’s number for turbulent flow
 e/D is relative roughness.
Hence yearly pumping cost is given by,
{Pumping cost = (T* q*ρ*g*h*c2)/103} Rs.
Where,
 c2 =unit cost/ KWH
 T =operating time in hr
∴Total annual cost = material cost + pumping cost
= {(𝝅/4*L*(2D+2t)*2t*ρ*c1*5*0.17) + (T*q*ρ*g*h*c2)/103} Rs.
FINDINGS

Material cost =>

Given Data:
Length (L) =150m
Thickness (t) = schedule 40 pipe
Density (ρ) =0.85*103 kg/ (m^3)
Cost (c1) =50 Rs/kg

Calculations:
Material cost = (𝜋/4)*L*(2d+2t)*2t*ρ* c1
= (𝜋/4)*150*(2d+2t)*2t*0.85*103*50
= 5006913*(2d+2t)*2t

Material cost (yearly) = 5006913*(2d+2t)*2t*5*0.17

Calculation table:

c D t 2d 2t 2d+2t (2d+2t)2t M.C.

5006913 0.08 0.05 0.15 0.11 0.26 0.029 122208
0.1 0.06 0.2 0.12 0.32 0.039 165777
0.15 0.07 0.3 0.14 0.44 0.062 270618
0.2 0.08 0.41 0.16 0.57 0.091 396744
0.25 0.09 0.51 0.19 0.7 0.137 547195
Pumping cost=>
Given Data:
Operating time (T) = 12 hrs. /day *26days/month
Flow rate (q) =0.028 (m3)/sec
Cost (c2) =7.50 Rs/KWH
Vertical height (hv) =8m
Viscosity (µ) =0.015 kg/ (m.sec)
Absolute roughness (e) = 4.57*10-5m

Calculations:
Pumping cost =(T*q*ρ*g*( hv + hl)*c2)*10-3
= 6404.55*(8+hl)
Where,
hl = f*(L/D)*(v2/2g)
friction factor(f) = 1.325/{ln[(e/3.7D)+(5.74/Re0.9)]}
Hp = power/ (0.746*12*26*12*7.5)

Calculation table :

d d^2 a v d*v re f v^2 (v^2)*f/d hl h p.c hp

0.08 0.01 0.005 6.09 0.464 26307 0.17 37.12 83.18 636 644 4188460 205
0.1 0.01 0.008 3.43 0.348 19730 0.21 11.74 24.51 187 195 1270884 65
0.15 0.02 0.018 1.52 0.232 13153 0.3 2.32 4.61 35 43 279696 13
0.2 0.04 0.032 0.86 0.174 9865 0.41 0.73 1.46 11 19 123586 6
 COST vs DIAMETER
4500000

4000000

3500000

3000000
Cost (Rs/year)

2500000

2000000

1500000

1000000

500000

0
0 0.05 0.1 0.15 0.2 0.25 0.3
Dia. (m)

m.c vs dia.Sheet1!$M$2:$O$6 p.c vs dia.Sheet1!$M$2:$O$6

FROM GRAPH :

OPTIMUM PIPE SIZE = 0.15 m

OPTIMUM COST = 275000 Rs/year

CONCLUSION
Model for determining optimum pipe size was developed .Graph of cost versus
diameter was plotted .It was observed that there was rise in material cost along
with the increase in the diameter but on the other hand pumping cost decreased.
The intersection of the material and pumping cost yielded the optimum point.

REFRENCES
1. Handbook of Pumps and Pumping: Pumping Manual
International By Brian Nesbitt
2. McGraw Hill Professional, 31-Dec-2004 - Technology &
Engineering.