LECTURE- 5

HYDRAULIC CIRCUIT
DESIGN AND ANALYSIS

By G/michael G/mariam
 Learning objectives
 Differentiate b/n laminar and turbulent flow
 Understand the significance of the Reynolds number

 Determine the Reynolds number at any location in a

pipeline
 Explain friction factor and determine it for laminar and

turbulent flow
 Evaluate the head loss in a pipeline undergoing laminar

or turbulent flow
 Calculate frictional losses in valves and fittings

 Discuss the significance of the term equivalent length

 Perform an energy analysis of a complete hydraulic

circuit
 What are the Hydraulic
components Cylinder
called?

Direction
al valve

Pressure
Gauge Relief
valve

Hydraulic
Pump
Reservoir
Or tank
Electric
motor www.hydrexa.com 589067
Start up Hydraulic
Cylinder

Direction
al valve

Pressure
Gauge Relief
valve

Hydraulic Hydraulic
Pump Reservoir
/oil tank
Electric
motor 589067
Extend
Retract
FRICTIONAL LOSSES IN
HYDRAULIC PIPE LINES
 INTRODUCTION
 The resistance to flow is essentially a measure of the
viscosity of the liquid.
 The greater the viscosity of the fluid, the less readily it
flows and the more energy is required to move it.
 This energy is loss because it is dissipated in to
environment in the form of heat and thus represents wasted
energy.
 Energy losses also occur in valves and fittings. A fitting is a
component (other than a straight pipe) that is used to carry
the fluid.
 Examples: -Bends, couplings, tees, elbows, filters, and strainers.
 Intro…
 The nature of the flow path through valves and fittings
determines the amount of energy losses.
 Generally speaking the more tortuous the path, the greater
the losses.
 In many fluid power applications, energy losses due to
flow in valves and fittings exceed those due to flow in
pipes.
 It is very important to keep all energy losses in a fluid
power system to a minimum acceptable level.
 This requires the proper selection of the sizes of the
pipes, valves, and fittings that make up the system.
 Intro…
 In general, the smaller the pipe diameter as well as valve
and fitting size, the greater the losses.
 However, using large-diameter pipes, valves, and fittings
results in greater cost and poor utilization.
 Thus, the selection of component sizes represents a
compromise b/n energy losses and component cost and
space requirements.
 Bernoulli‘s equation & Continuity equation used to
perform analysis of Fluid Power System and calculating
Pressure drops, flow rates, HP losses for all components.
 REYNOLDS NUMBER
 The experiments performed by Osborne Reynold in 1833 to
determine the conditions governing the transition from
laminar to turbulent flow.
 The nature of the flow depends on the dimensionless
parameter , Re :
Re = υDρ/μ
where: - υ = fluid velocity
D = pipe inside diameter
ρ = Fluid density
μ = Absolute(dynamic) viscosity
 Laminar or Turbulent Flow
 Re <2000 : LAMINAR
 2000< Re < 4000 CRITICAL ZONE
 Re >4000 : TURBULENT
 It is not possible to predict the type of flow that will exist
within the critical zone. Thus if Re lies in critical zone,
turbulent flow should be assumed.
 Greater losses in Turbulent flow
 Fluid power system designed to operate in LAMINAR flow
region.
 Friction Losses
 Friction – Main cause of energy losses in fluid power
systems.
 The result is a loss of potential energy in the system, and
this shows up as a loss in Pressure or head
 The Head Loss (H ) in a system….
L

Losses in Pipes
Losses in Valves & Fittings
 Head loss in Pipes can be found by DARCY’s Equation
 DARCY’s Equation
 HL = f (L/D)(v2/2g)
◦ f = friction factor (dimensionless)
◦ L = length of pipe
◦ D = pipe inside diameter
◦ v = avg. fluid velocity
◦ g = Acceleration due to gravity
 Darcy’s equation can be used to calculate the head loss due
to friction in pipes for both laminar and turbulent flow.
 The difference b/n the two lies in the evaluation of the
friction factor f.
Frictional Losses in Laminar Flow
 Friction
Factor f = 64/(Reynolds Number)
 Hagen-Poiseuille Equation

HL = (64/Re)(L/D)(v /2g) 2
 Frictional Losses in Turbulent Flow

 In this case, the friction factor can not be represented by a

simple formula as was the case of laminar flow.
 This is due to the random and fluctuating movement of the
fluid particles.
 For turbulent flow, experiments have shown that the
friction factor is a function of not only the Reynolds
number but also the relative roughness of the pipe.
Frictional Losses in Turbulent Flow
 Relative roughness = ε/D
◦ ε = absolute roughness
◦ D = Pipe inside diameter
 Typical values of Absolute Roughness (mm)

◦ Glass or plastic = Smooth

◦ Drawn tubing = 0.0015
◦ Commercial steel/wrought iron = 0.046
◦ Asphalted Cast Iron = 0.12
◦ Galvanized Iron = 0.15
◦ Cast iron= 0.26
◦ Riveted Steel = 1.8
 Moody diagram used to calculate friction factor
Moody Diagram
Losses in Valves & Fittings
 Energy losses in valves and fittings such as Tees,
Elbows, and Bends
 Nature of flow through Valves and Fittings is very
complex.
 Head Loss H = Kv2/2g k = loss coefficient
L

 K factor for Valves and Fittings (dimensionless)

Gate Valve ---- (wide open) = 0.19
¾ open = 0.90 ½ open = 4.5
¼ open = 24.0
 K-Factor

Return Bend = 2.2

Standard Tee = 1.8
Standard Elbow = 0.9
90 deg Elbow = 0.75
45 deg Elbow = 0.42
Ball Check valve = 4.0
Globe Valve:
wide open = 10
½ open = 12.5
 Equivalent Length Technique
 Darcy’s Equation
◦ Friction head loss in pipes proportional to
 Square of Fluid Velocity
 Length of Pipe
 Head Loss in valves & fitting
◦ Proportional to square of fluid velocity
We can find a length of pipe that for the same flow
rate would produce same head loss as a valve or fitting.
This length of pipe, which is called the equivalent length
of a valve or fitting
 Equivalent Length Technique
 HL(valve or Fitting) = HL(Pipe)
 K(v2/2g) = f(Le/D)(v2/2g)
 Since velocities are equal
 Equivalent Length L = KD/f
e

 Where the equivalent length of a valve or fitting whose k

factor is k.
 Convenient method for analyzing hydraulic circuits
where frictional energy losses are to be taken in to
account.
 Exercise
 For the Hydraulic System shown, the following data are
given:
 Pump is adding 3.730 kW to fluid
 Pump flow is 0.0019m3/s
 Pipe has 0.0254 m inside diameter
 Sp. Gravity of oil = 0.9
 Kinematic viscosity of oil is 100 cS.
 Find the pressure at the inlet to the hydraulic motor

(station 2). The pressure at the oil top surface level in the
hydraulic tank is atmospheric (0 Pa gage). The head loss H L
due to friction between station 1 and station 2 is not given.
Thank you