Fluid Flow Velocity Head. Piping Pressure Drop... Equivalent Length. Control Valves Safety Relief Valves.Fluid Flow 3 Velocity Head ‘Two of the most useful and basic equations are a @ ad loss in feet of flowing fluid elocity in f/sec g=32.2fusec P= Pressure in Ib/ft? specific volume in fb Z = Elevation in feet E = Head loss due to friction in feet of flowing fluid In Equation 1 Ah is called the “velocity head.” This expression has a wide range of utility not appreciated by many. It is used “as is” for 1. Sizing the holes in a sparger 2. Calculating leakage through a small hole 3. Sizing a restriction orifice 4, Calculating the flow with a pitot tube With a coefficient itis used for 1. Orifice calculations 2. Relating fitting losses, ete For a sparger consisting of a large pipe having small holes drilled along its length Equation 1 applies directly. This is because the hole diameter and the length of fluid travel passing through the hole are similar dimensions. An orifice on the other hand needs a coefficient in Equation 1 because hole diameter is a much larger dimen- sion than length of travel (say & in. for many orifices). Orifices will be discussed under “Metering” in this chapter, For compressible fluids one must be careful that when sonic or “choking” velocity is reached, further decreases in downstream pressure do not produce additional flow. This occurs at an upstream to downstream absolute pres sure ratio of about 2: 1. Critical flow due to sonic veloc ity has practically no application to liquids. The speed of sound in liquids is very high. See “Sonic Velocity” later in this chapter. Still more mileage can be gotten out of Ah = u'/2g when using it with Equation 2, which is the famous Bernoulli equation, The terms are 1. The PV change 2. The kinetic energy change or “velocity head” 3. The elevation change 4. The friction loss ‘These contribute to the flowing head loss in a pipe. However, there are many situations where by chance, or on purpose, w’/2g head is converted to PV ot vice versa, inge w'/2g to PV gradually in the fol- |. Entering phase separator drums to cut down turbu- lence and promote separation 2. Entering vacuum condensers to cut down pressure drop We build up PV and convert it in a controlled manner to w2g in a form of tank blender. These examples are dis- cussed under appropriate sections. Source Brenan, C. R. The Process Engineer's Pocket Handbook, ‘Vol. 1, Gulf Publishing Co., Houston, Texas, p. 1, 1976,4 Rules of Thumb for Chemical Engineers, Piping Pressure Drop A handy lationship for turbulent flow in commercial steel pipes is AP, = W'§y"? /20.000d"%p where AP; = Frictional pressure loss, psi/100 equivalent ft of pipe W = Flow rate, lb/hr = Viscosity, ep p = Density, lb/ft? d = Internal pipe diameter, in This relationship holds for a Reynolds number range of 2,100 to 10°, For smooth tubes (assumed for heat exchanger tubeside pressure drop calculations), a con- stant of 23,000 should be used instead of 20,000. Branan, Carl R. “Estimating Pressure Drop.” Chemical Engineering, August 28, 1978. Equivalent Length ‘The following table gives equivalent lengths of pipe for various fitting Table 1 Equivalent Length of Valves and Fittings in Feet : Sree tos wy | Soe g | rad. M2" SO iuterbonds | Sudden | SY | suddon | St st gS x en) | F + re ——_|_ee_ eg s 318 Equiv. Lin terms of small d ee 2 £3 III ~ TTT 28 Plog . . ls T e =| 8 Beige 2/8 Fry papa Tala ae \+ SPEED Eee sigie ig gals (al | | Waa zs] e 33 Tri 14) 2) 2 34/1011 34 vata wl) al 4 3 | 2) 8 ala}a clin) fae [EL S/o] Sh s}=|= la /a/B]s) 2) 8] e)2 alal= 95 [a8 | 65 | 220 | 65/112) #1 | 40 | 90 | 70 | 250) 70 |126] 90 18/88] 2 [8] 8]Fluid Flow 5 Sources 1. GPSA Engineering Data Book, Gas Processors Sup- pliers Association. 10th Ed. 1987, 2. Branan, C. R, The Process Engineer's Pocket Hand- book, Vol. 1, Gulf Publishing Co., p. 6, 1976, Recommended Velocities Here are various recommended flows, velocities, and Slzing Cooling Water Piping in New Plants Maximum pressure drops for various piping services. Allowable Flow, Velocity and Pressure Drop arenas [wan pe See | Row we Fow ve | Gem psec, #100" GPa fee, #100 2 | aa aa?) 7 aot ah Sizing Steam Piping in New Plants Maximum Allowable 4 2005.05 429 wo 3850 222 ping In bw ants Raa 6 | ko Sse aia | amaze 12 5 foo bt buses ar 138 - — - 1350 B10 ano awe 9 Laterals Mains 12 2400 «6812.10 1,800 5.11 1.23 Prossue PSG 600175 — 10% P,, either break into sections where AP < 10% P, or use ih ose tas] AP=P,~ BaP, rary) from Maxwell! which assumes isothermal flow of ideal where: AP = Line pressure drop, psi P,, P= Upstream and downstream pressures in psi ABS S$) = Specific gravity of vapor relative to water 0.00150MP,/T d= Pipe diameter in inches U, = Upstream velocity, flsee f= Friction factor (assume .005 for approximate work) L=Length of pipe, fet AP = Pressure drop in psi (rather than psi per standard length as before) M = Mol. wt For “long’” pipelines, use the following from McAllister: Equations Commonly Used for Calculating Hydraulic Data for Gas Pipe Lines xDPEXEX Q, = 435.87 (Ty/Ps)! Qp =737x(T,/P,) x D*" XE 0.0375 GX (hy =f) Paes” Tae XZ, GRD M Tyg XZ PB Weymouth. Q=483.5(TH/B)X| “Gra | xD XE = 2/3[P,+P)—(P x P,)/P, +P] Pap is used to calculate gas compressibility factor Z Nomenclature for Panhandle Equations Q = flow rate, SCFD P= base pressure, psia base temperature, °R average gas temperature, °R P, = inlet pressure, psia P)= oullet pressure, psia gas specific gravity (air = 1.0) Tine length, mil Z-= average gas compressibility D = pipe inside diameter, in, elevation at terminus of line, ft clevation at origin of line, f average line pressure, psia = efficiency factor E= 1 for new pipe with no bends, fittings, or pipe diameter changes10 Rules of Thumb for Chemical Engineers E = 0.95 for very good operating conditions, typically through first 12-18 months E 0.92 for average operating conditions E = 0,85 for unfavorable operating conditions Nomenciature for Weymouth Equation Q= flow rate, MCFD Ty = base temperature, °R Py = base pressure, psia G = gas specific gravity (air = 1) L = line length, miles T = gas temperature, °R ‘Z= gas compressibility factor D ipe inside diameter, in. ficiency factor. (See Panhandle nomenclature for suggested efficiency factors) Sample Calculations 06 100°F 20 miles 2,000psia 1,500psia 1008 E=10 Prey = 2/3(2,000 + 1,500 ~ (2,000 x 1,500/2,000 + 1,500) = 1,762psia Z at 1,762psia and 100°F = 0.835. Panhandle A. Q x (4.026)"*"" x1 x 9587 520/14.) 2 20.0375 x06 (2,000)" -(1,500)° ~ 560 (0.6) x20 560°x.835 Q, = 16577 MCFD (4.026) x1. Q, = 737 x (520/14.7) = gp)? _9:0375 0.6 x 100 x1, 762)" ] (2.000) (500) 0.835 X 20 x 560 x.835 (0.6) Q, = 17,498 MCFD Weymouth. Q=0.433 x (520/14.7) x[(2,000)° — (1,500)'/ (04x 20 x 560 x 0.835)}” x (4.026) Q= 11,101 MCFD ‘Source Pipecale 2.0, Gulf Publishing Company, Houston, ‘Texas. Note: Pipecale 2.0 will calculate the compressibil- ity factor, minimum pipe ID, upstream pressure, down- stream pressure, and flow rate for Panhandle A, Panhandle B, Weymouth, AGA, and Colebrook-White equations. The flow rates calculated in the above sample calculations will differ slightly from those calculated with Pipecale 2.0 since the viscosity used in the examples was extracted from Figure 5, p. 147. Pipecale uses the Dranchuk etal ‘method for calculating gas compressibility Equivalent Lengths for Multiple Lines Based on Panhandle A A single pipe line which consists of two or more dif- ferent diameter lines. Let Le wba Ly equivalent length length of each diameter Dy, Day... Da internal diameter of each separate line corresponding to Ly. Ls, L De = equivalent internal diameterExample. A single pipe line, 100 miles in Tength con- sists of 10 miles 10%-in. OD; 40 mites 12¥-in, OD and 50 miles of 22-in, OD lines. Find equivalent Jength (L¢) in terms of 22-in. OD pipe. aus rays qt ooelizs) {ina 50+ 614 + 364 1,028 miles equivalent length of 22-in, OD Condition ‘A multiple pipe line system consisting of two or more parallel lines of different diameters and different lengths. Let length of various looped sections internal diameter of the individ- ual line corresponding to length Ly, Loy Ly & Ly dp +d, +d3 equivalent length length of various looped sections ids & d,=internal diameter of individual line corresponding to lengths L,, aby &Ly dd dy Hedy Fluid Flow 11 length of unlooped section = length of single looped section length of double looped section 4)=4; then: Lest s02T66t nei ft =| 2a 44, when de = d, ds then Ly = Ly + 0.27664 L; + 0.1305 Ly Example. A multiple system consisting of a 15 ile section of 3-8%-in, OD lines and 1-10%-in. OD line, and a 30 mile section of 2-8-in. lines and 1—10¥-in. OD Tine Find the equivalent length in terms of single 12-in, ID Tine, | ss Ls Sat ——__ 3¢7.981) + 10.022" r 1 $3 0| ie “Lagos 100 =59+181 = 24.0 miles equivalent of 12-in, LD pipe Example. A multiple system consisting of a single 12-in. ID line 5 miles in length and 30 mile section of 312-in. ID lines. Find equivalent length in terms of a single 12-in, ID line. Lc=5 +.0.1305 x 30 8,92 miles equivalent of single 1 in, ID line 1. Maxwell, J. B., Data Book on Hydrocarbons, Van Nostrand, 1965. 2. McAllister, EW., Pipe Line Rules of Thumb Handbook, 3rd Ed,, Gulf Publishing Co., pp. 247-248, 1993. 3. Branan, C. R., The Process Engineer's Pocket Hand- book, Vol. 1, Gulf Publishing Co., p. 4, 1976.12 Rules of Thumb for Chemical Engineers Sonic Velocity ‘To determine sonic velocity, use V,=VKeRT where ‘onic velocity, f/sec WC. the ratio of specific heats at constant pressure to constant volume. This ratio is 14 for most diatomic gases. 32.2 filsec? 544/mol. wt. Dbsolute temperature in °R Hae To determine the critical pressure ratio for gas sonic velocity across a nozzle or orifice use 0) critical pressure ratio= [2/(K + )} If pressure drop is high enough to exceed the critical ratio, sonic velocity will be reached. When K = 1.4, ratio = 0.53. Source Branan, C. R., The. Process Engineer's Pocket Hand- book, Vol. 1, Gulf Publishing Co., 1976. Metering Orifice C,(2gAn)" Permanent head loss % of Ah Permanent Dud, Le 02 95 oa 82 06 63 08 40 One designer uses permanent loss = Ah (1 — C,) where U, = Velocity through orifice, ft/sec U, = Velocity through pipe, ft/sec 2g = 64.4 ft/sec” Ah = Orifice pressure drop, ft of fluid D = Diameter C, = Coefficient, (Use 0.60 for typical application where DP, is between 0.2 and 0.8 and Re at vena con- tracta is above 15,000.) Venturi Same equation as for orifice: C 98 Permanent head loss approximately 3-4% Ah, Rectangular Weir R 33(L~0.2H)H™* where low in f/see L= Width of weir. ft H = Height of liquid over weir, ft Pitot Tube ah=u'/2g Source Branan, C. R., The Process Engineer's Pocket Handbook Vol. 1, Gulf Publishing Co., 1976.