Pipe Sizing Basics

Major & Minor Losses

Under Supervision of:

Prof. Dr. Mahmoud Fouad
By students:
Mahmoud Bakr 533 Mohammed Abdullah 511
Moaz Emad 619 Mohammed Nabil Abbas 525
Applications
How big does the pipe
have to be to carry a
flow of x m /s?
3
 Bernoulli's Equation
The basic approach to all piping systems is to write the 
Bernoulli equation between two points, connected by a
streamline, where the conditions are known. For
example, between the surface of a reservoir and a pipe
.outlet
The total head at point 0 must match with the total
head at point 1, adjusted for any increase in head due to
pumps, losses due to pipe friction and so-called "minor
losses" due to entries, exits, fittings, etc. Pump head
developed is generally a function of the flow through the
system
Bernoulli's Equation
 Friction Losses in Pipes
Friction losses are a complex function of the system
geometry, the fluid properties and the flow rate in the
system. By observation, the head loss is roughly
proportional to the square of the flow rate in most
engineering flows (fully developed, turbulent pipe
flow). This observation leads to the Darcy-Weisbach
equation for head loss due to friction
which defines the friction factor, f. f is insensitive
to moderate changes in the flow and is constant
for fully turbulent flow. Thus, it is often useful to
estimate the relationship as the head being
directly proportional to the square of the flow
rate to simplify calculations.
Reynolds Number is the fundamental dimensionless group in
viscous flow. Velocity times Length Scale divided by Kinematic
Viscosity.
 
Relative Roughness relates the height of a typical roughness
element to the scale of the flow, represented by the pipe diameter,
D.
 
Pipe Cross-section is important, as deviations from circular cross-
section will cause secondary flows that increase the pressure drop.
Non-circular pipes and ducts are generally treated by using the
hydraulic diameter,
in place of the diameter and treating the pipe as if it were round
For laminar flow, the head loss is proportional to
velocity rather than velocity squared, thus the friction
factor is inversely proportional to velocity
Turbulent flow
For turbulent flow, Colebrook (1939) found an implicit
correlation for the friction factor in round pipes. This
correlation converges well in few iterations.
Convergence can be optimized by slight under-
relaxation.
The familiar Moody Diagram is a log-log plot of the Colebrook
correlation on axes of friction factor and Reynolds number,
combined with the f=64/Re result from laminar flow. The plot
below was produced in an Excel spreadsheet
An explicit approximation
Pipe roughness
pipe material pipe roughness  (mm)
glass, drawn brass, copper 0.0015
commercial steel or wrought iron 0.045
asphalted cast iron 0.12

d Must be
galvanized iron 0.15 dimensionless!
cast iron 0.26
concrete 0.18-0.6
rivet steel 0.9-9.0
corrugated metal 45
PVC 0.12
Calculating Head Loss for a Known Flow

From Q and piping determine Reynolds Number,

relative roughness and thus the friction factor.
Substitute into the Darcy-Weisbach equation to obtain
head loss for the given flow. Substitute into the
Bernoulli equation to find the necessary elevation or
pump head
Calculating Flow for a Known Head
Obtain the allowable head loss from the Bernoulli
equation, then start by guessing a friction factor. (0.02
is a good guess if you have nothing better.) Calculate
the velocity from the Darcy-Weisbach equation. From
this velocity and the piping characteristics, calculate
Reynolds Number, relative roughness and thus friction
.factor
Repeat the calculation with the new friction factor until
sufficient convergence is obtained. Q = VA
"Minor Losses"
Although they often account for a major portion of the head loss,
especially in process piping, the additional losses due to entries and
exits, fittings and valves are traditionally referred to as minor losses.
These losses represent additional energy dissipation in the flow,
usually caused by secondary flows induced by curvature or
recirculation. The minor losses are any head loss present in addition
.to the head loss for the same length of straight pipe

Like pipe friction, these losses are roughly proportional to the square of
the flow rate. Defining K, the loss coefficient, by
. K is the sum of all of the loss coefficients in the
length of pipe, each contributing to the overall head
loss

Although K appears to be a constant coefficient, it

varies with different flow conditions

: Factors affecting the value of K include

.,the exact geometry of the component
. the flow Reynolds number , etc
 Some types of minor losses
Head Loss due to Gradual Expansion (Diffuser)
V 1  V 2 2
hE  K E 
2g
2 2
V  A2 
hE  K E 
2
 1
2 g  A1 
0.8
0.7
0.6
0.5
KE 0.4
0.3
0.2
0.1
0
0 20 40 60 80
diffusor angle ()
Sudden Contraction
2
 1  V 2
hc    1 2
C  2g
 c 

V1 V2

flow separation

losses are reduced with a gradual contraction Ac

Cc 
A2
Sudden Contraction
1
0.95
0.9
0.85
Cc 0.8
0.75
0.7
0.65
0.6
0 0.2 0.4 0.6 0.8 1
A2/A1

Qorifice  CAorifice 2 gh
Entrance Losses 2
V
Losses can be he  K e
reduced by K e  1 .0 2g
accelerating the
flow gradually and K e  0 .5
eliminating the
vena contracta
K e  0 . 04
Head Loss in Bends
High pressure
Head loss is a function of
the ratio of the bend radius
Possible
to the pipe diameter (R/D)
separation
Velocity distribution R from wall
returns to normal several
pipe diameters downstream D
Low pressure
2
V
hb  K b
2g
Kb varies from 0.6 - 0.9
Head Loss in Valves
Function of valve type and valve
position 2
V
The complex flow path through hv  K v
valves can result in high head loss 2g
(of course, one of the purposes of
a valve is to create head loss when
it is not fully open)
To calculate losses in piping systems with both pipe
friction and minor losses use
Solution Techniques
Neglect minor losses
Equivalent pipe lengths
Iterative Techniques
Simultaneous Equations
Pipe Network Software
Iterative Techniques for D and Q (given total
head loss)
Assume all head loss is major head loss.
Calculate D or Q using Swamee-Jain equations
Calculate minor losses
Find new major losses by subtracting minor losses
from total head loss
Solution Technique: Head Loss
Can be solved directly

2
V 2 8Q
h minor  K h minor  K
2g g 2 D 4

0 . 25 2
4Q f  8 LQ
Re     5 . 74 
2
hf  f
 log    2
D 

 3 .7 D Re 0 . 9

 g D5

hl   hf   h minor
Solution Technique:
Discharge or Pipe Diameter
Iterative technique
Set up simultaneous equations in Excel

0 . 25 2
4Q f  8 LQ
Re     5 . 74  
2
hf  f
 log    2
D  

 3 .7 D Re 0 .9 

g D5
2
8Q Use goal seek or Solver to
h minor  K
g 2D 4 find discharge that makes the
calculated head loss equal
the given head loss.
hl   hf   h minor
Example: Minor and Major Losses
Find the maximum dependable flow between the
reservoirs for a water temperature range of 4ºC to 20ºC.

Water 25 m elevation difference in reservoir water levels

Reentrant pipes at reservoirs

Standard elbows
2500 m of 8” PVC pipe
Sudden contraction
Gate valve wide open
1500 m of 6” PVC pipe
Directions
Assume fully turbulent (rough pipe law)
find f from Moody (or from von Karman)
Find total head loss
Solve for Q using symbols (must include minor losses)
(no iteration required)
Obtain values for minor losses from notes or text
Example (Continued)
What are the Reynolds number in the two pipes?
Where are we on the Moody Diagram?
What value of K would the valve have to produce to
reduce the discharge by 50%?
What is the effect of temperature?
Why is the effect of temperature so small?
Example (Continued)
Were the minor losses negligible?
Accuracy of head loss calculations?
What happens if the roughness increases by a factor of
10?
If you needed to increase the flow by 30% what could
you do?
Suppose I changed 6” pipe, what is minimum
diameter needed?