Case Study: Application of numerical

methods in finding a solution for

industrial piping application
Presented by:
Hrushikesh Ajit Kulkarni
Roll: 193110054
M. tech 1st year
MM3 [Steel technology]
MEMS, IIT Bombay
Flow-sheet applied in the metallurgical plant
 Design of piping system for furnace

Ground level

Sump
Problem Statement
 Find diameter of pipe suitable for this application

Given data
 Length of pipe = 50m

 Eight 900 bends of short radius

 Flow rate = 50 LPM

Solution
 Applying energy balance equation:

P1/dg + v12 / 2g + Z1 = P2/dg + v22 / 2g + Z2 + Ef / g

Where,
 P1, P2 are the pressures at point 1 and 2 respectively
 v1,v2 are the velocities at point 1 and 2 respectively
 Ef is the energy loss due to friction
 d is the density of fluid = [1000 kg/m3]
 g is acceleration due to gravity = 9.81 m/s2
 Solving, we get:
Ef = 14.715 J/kg

 The equation for Ef is:

Ef = 2 f [L/D] v2

Where,
 f is the friction factor
 L is length of pipe required = 50m [given]
 D is diameter of pipe
 v = velocity of fluid in pipe
 Now, we can write velocity as:
v = volume flow rate / area ……[continuity equation]

 Choose a smooth pipe [preferably plastic]

 For a smooth pipe, friction factor is given as:

f = 0.0791 / [Re]0.25
Where,
Re stands for Reynold’s number = dvD / µ
µ is dynamic viscosity of fluid [= 0.001 kg/ms]
Governing equation:

 After solving the data and expressing each terms in terms of

D in the Ef equation, we get:

f[D] = 14.715 D5.75 – [7.474816 * 10-6] D – [1.5572 * 10-6]

 We will use Newton- Raphson method for solving this

equation
Newton Raphson method

 f [D] = 14.715 D5.75 – [7.474816 * 10-6] D – [1.5572 * 10-6]

 f ’ [D] = 84.61125 D4.75 – [7.474816 * 10-6]

 Dnew = D0 – f [D] / f ’ [D]…….[Newton Raphson formula]

Iterations:
Srno. D f [D] f ‘ [D] Dnew €relative [%]
1 1 14.71499 84.61124 0.8261 `-
2 0.8261 4.9056 34.1454 0.6824 21.06
3 0.6824 1.6349 13.7757 0.5637 21.06
4 0.5637 0.544856 5.55783 0.46566 21.06

Observations:

 The €relative remains constant. Hence, change the initial

guess.
Iterations:
Srno. D f [D] f ‘ [D] Dnew €relative [%]
1 0.1 2.386 × 10-5 1.49715 × 10-3 0.08406 -
2 0.08406 7.456 × 10-6 6.52 × 10-4 0.07262 15.75
3 0.07262 2.057 × 10-6 3.217 × 10-4 0.06622 9.66
4 0.06622 3.9377 × 10-7 2.049 × 10-4 0.064298 2.989
5 0.064298 2.71 × 10-8 1.7718 × 10-4 0.0641450 0.2385

 The €relative < 1 %. Stop the iterations. The solution has been
reached
 Diameter to be selected = 6.42 cm
Conclusion

 Newton Raphson method can be successfully used in finding

solutions of complex algebraic equations provided finding the
derivative is easy

 Newton Raphson works well when the initial guess taken is

close to the true value
References:

 Transport Phenomena and Kinetics in Process Metallurgy –

[Peter Hayes (School of Chemical engineering, The
University of Queensland, Australia)]

 Numerical methods for engineers [Steven P. Chapra,

Raymond P. Canale]