HEAD LOSSES IN THE PIPELINE

INTRODUCTION
Lesson 2 deals with the two main classes of head losses in the pipeline, namely,
the major losses and the minor losses. Specifically, it discusses the methods of
calculating head losses using Moody's chart and the Darcy-Weisbach equation, as well
as determining pipe sizes according to the standard schedule numbering system. The
Crane chart is likewise explained in determining the equivalent length of fittings and
valves. These topics are accompanied by sample problems and corresponding
solutions.
Again, there are self-tests and additional problems which students can use as practice
exercises.

LESSON OBJECTIVES
At the end of this lesson, the students should be able to:
• enumerate the two main classes of head losses and the different fittings and valves;
• use the Darcy-Weisbach equation in calculating head losses;
• use Moody's chart in determining the Darcy-Weisbach friction factor;
• calculate the equivalent length of fittings and valves;
• use the Crane chart in determining the equivalent length of fittings and valves;
• use the tables in the selection of pipe sizes based on the standard schedule number;
and
• solve problems involving head losses in the pipeline.

CLASSIFICATIONS OF LOSSES
1. Major head losses are head losses due to fluid friction because of viscosity and pipe
roughness.
2. Minor losses are head losses or turbulence losses due to pipe fittings and valves.
a. Entrance loss is the flow of fluid from tank to pipe. It is a head loss because velocity
is being created.
 Pipe
Fluid
Tank
Figure 2.1. Entrance Loss
b. Exit loss is the flow of fluid from pipe to tank. It is a head loss because velocity is
being destroyed.
Pipe
Fluid
Tank
Figure 2.2. Exit Loss
c. Sudden expansion is the flow of fluid in a suddenly increasing pipe diameter. It is a
head loss due to the decrease in velocity.

Figure 2.3. Sudden Expansion

d. Sudden contraction is the flow of fluid in a suddenly decreasing pipe diameter. It is a
head loss due to the sudden increase in velocity.

Figure 2.4. Sudden Contraction

e. Bends (elbows), fittings, and valves are head losses due to the change in the
magnitude and direction of velocity. Gate valve

Elbow Check Valve

Figure 2.5. Elbows and Valves

f. Gradual expansion and gradual contraction are head losses due to the gradual
increase or gradual decrease in fluid velocity.
Figure 2.6. Gradual Expansion and Contraction
g. A nozzle at the end is a head loss due to the very high velocity at the nozzle outlet.

Figure 2.7. Nozzle at the End

EQUATIONS FOR THE COMPUTATION OF MAJOR HEAD LOSSES
DUE TO FRICTION
Major head losses are mainly due to friction because of the fluid viscosity and pipe
material roughness. Head losses, h, are computed particularly in a long straight pipe (L
> 500D).
1. Darcy-Weisbach Equation
a. For a circular pipe
𝐿 𝑉2
ℎ𝑓 = 𝑓
𝐷 2𝑔
b. For a non-circular pipe
𝐿 𝑉2
ℎ𝑓 =
4𝑅𝑚 2𝑔
where, ℎ𝑓 = head loss due to friction, m

L = length of pipe, m
D = inside diameter of pipe, m
V = velocity of fluid, m/s
g = acceleration due to gravity, m/s?
= 9.8066 m/s?
𝑅𝑚 = hydraulic radius

𝐶𝑟𝑜𝑠𝑠 − 𝑆𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐴𝑟𝑒𝑎

𝑅𝑚 =
𝑊𝑒𝑡𝑡𝑒𝑑 𝑃𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟 𝑂𝑓 𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛
• Value of f for laminar flow:
64
Hagen-Poiseuille equation, 𝑓 = 𝑅𝑒 < 2 000
𝑅𝑒

0.316
Blasius equation, 𝑓 = → 𝑅𝑒 < 105
(𝑅𝑒 )0.25

where 𝑅e = Reynolds number

• Friction factor fin laminar flow is a function of Reynolds number, 𝑅e′ and
independent of the pipe roughness.
• Value of f for transition and turbulent flows:
𝜀
𝑓 = 𝜙(𝑅𝑒 ′ )
𝐷
Where ϕ = is a function of
𝜀
𝑒= = relative roughness
𝐷

𝜀 = absolute roughness of a pipe material, m

𝑅𝑒 = Reynolds number
• Relative roughness is a better indicator of pipe roughness.
• The Darcy friction factor is one of the parameters used to calculate friction loss.
• Absolute roughness or specific roughness is a parameter that measures the average
size of imperfections inside the pipe.
Important Notes:
• Values of friction factor, f, may be obtained using Moody's chart, from the following
a. JW Jones and WF Stocker, Refrigeration and Air Conditioning, 2nd Edition,
(USA: McGraw-Hill Book Company, 1982), p. 105.
b: Philip Potter, Power Plant Theory and Design, 2nd Edition. (New York: The Ronald
Press Company), pp. 61-62.
c. AH. Church, Centrifugal Pumps and Blowers. (USA: McGraw-Hill Book Company,
1944), p. 12.
d. Manila Review Institute, Inc., Mechanical Engineering Tables and Charts, (Manila,
Philippines: MRII, 2004), p. 119.
• Friction factor f may also be obtained using the Colebrook equation.
 1
𝑓=
√1.14 + 2 log (𝐷) − 2 log[1 + 9.3
]
𝜀 𝜀
𝑅𝑒 (𝐷) √𝑓

• Friction factor f for turbulent flow may also be determined using Moody's equation.
1
𝜀 106 3
𝑓 = 0.0055[1 + (20000 𝐷 + )]
𝑅𝑒

• Values of absolute roughness of selected materials

Material 𝒆 (𝒎𝒎)
Glass, spun cement, brass, copper, plastic, bituminous lining 0.002
Commercial steel or welded steel 0.05
Riveted steel 0.90 to 9.0
Galvanized Iron (G.I.) 0.15
Cast Iron (C.I) 0.25
Concrete 0.30 to 3.0
Wet-mix spun precast concrete 0.60
Timber 0.20 to 0.60
Plastic (PVC, ABS) 1.5 𝑥 10−3
Copper & brass 1.6 𝑥 10−3
Steel 0.06 (0.00002 ft)
C.I (Plain) 0.24 (0.0008 ft)
Concrete 1.2 (0.004 ft)

• Equivalent lengths of valves and fittings are obtained using the Crane chart,
formulated by Dean, and charted by the Crane Co., from the following
references:
a. Philip Potter, Power Plant Theory and Design, 2nd Edition (New York: The
Ronald Press Company), Figure 2-21, p. 70.
b. Frederick Morse, Power Plant Engineering (USA: Litton Educational
Publishing.Inc., 1953), Figure 14-23, p. 607.
c. Manila Review Institute, Inc., Mechanical Engineering Tables and Charts,
5th Edition (Manila, Philippines: MRIl, 2004), Chart (S. L.), p. 90; Table, p. 112.
d. Manila Review Institute, Inc., Mechanical Engineering Tables and Charts,
3rd Edition (Manila, Philippines: MRIl, 2004), p. 136, Chart (English Units), p.
91.
• Physical Properties of Pipe (Schedule Number)
 a. Philip Potter, Power Plant Theory and Design, 2nd Edition (New York: The
Ronald Press Company), Plate 1, pp. 674-677.
b. Frederick Morse, Power Plant Engineering (USA: Litton Educational
Publishing, Inc., 1953), Figure A-6, p. 665.
c. Wilbert F. Stocker, Refrigeration and Air Conditioning, 2nd Edition, (USA:
McGraw-Hill Book Company, 1982), Table 7-2, p. 136.
d. Manila Review Institute, Inc., Mechanical Engineering Tables and Charts,
5th Edition (Manila, Philippines: MRII, 2004), Table, p. 114.
• Recommended Flow of Fluid in Pipe, obtained from the following references:
a. Frederick Morse, Power Plant Engineering (USA: Litton Educational
Publishing, Inc., 1953), Table 14-6, p. 603.
b. Philip Potter, Power Plant Theory and Design, 2nd Edition (New York: The
Ronald Press Company), Table 2-6, p. 72.
2. Morse Equation
The following equations, to determine head losses, are currently used in power
plant engineering calculations and adopted in Power Plant Engineering (mks Units) by
Morse. It is called Morse equation in this book.
𝐿 𝑉2
ℎ𝑓 = 2𝑓
𝐷 𝑔

where L = pipe length, m

D = inside diameter of pipe, m
V = fluid velocity, m/s
𝑔 = acceleration due to gravity, m/s?
= 9.8066 m/s?
𝑓 = friction factor
Important Notes:
• Values of fare obtained from Morse's Power Plant Engineering.
1. Table 14-7, p. 605. Friction factor ffor water flow in iron and steel pipes
2. Equations of f, p. 605
 𝑍
a. Turbulent flow: 𝐷𝑉𝑆 < 1163.5

For copper, brass 7 lead pipe,

𝑍
𝑓 = 0.0081 + 0.0011787(𝐷𝑉𝑆)0.55 → eq. 14-12

For iron and steel pipe,

𝑍
𝑓 = 0.0035 + 0.007562(𝐷𝑉𝑆)0.424 → eq. 14-13

b. Viscous flow or laminar flow in all pipes

𝑍
𝑓 = 0.000016026( ) → eq. 14-14
𝐷𝑉𝑆

c. Flow of steam and air in pipes (Turbulent flow)

𝑍
𝑓 = 0.0054 + 0.0465(𝐷𝑉𝑆)

where Z = absolute viscosity or fluid viscosity, centipoise

V= velocity of flow, m/s
D = internal diameter of pipe, m
d = density of fluid, 𝑘𝑔/𝑚3
S = specific gravity, water referred to
3. Fluid viscosities are obtained from the following table and equation:
a. Table 14-8, p. 606. Viscosities of Water and Other Viscous Fluids, in
centiPoise
b. Viscosity of steam, in centiPoise
𝑍 = 0.00894 + 3.6 𝑥 10−5 𝑡
where t = steam temperature, °C
3. Hazen-Williams Formula
The Hazen-Williams formula is used for fluid flowing in a pipe with D > 50
mm and velocity of V < 3 m/s.
a. Fluid velocity, V = 0.848 𝐶𝑅 0.63 𝑆 0.54
𝜋
b. Volume rate (circular pipe), 𝑄 = 𝐷2 𝑉 = 0.2785𝐶𝐷2.63 𝑆 0.54
4

𝐷
where R = hydraulic mean radius, 𝑅 = 4
 ℎ𝐿
S = slope of the energy-gradient line, 𝑆 = 𝐿

ℎ𝐿 = head loss, m
L = length of pipe, m
C = roughness coefficient which depends only on the relative
roughness of the pipe materials
c. Head loss h, in m (Hazen-Williams equation)
6.78𝐿 𝑉 1.85
ℎ𝐿 = ( )
𝐷 1.17 𝐶

Important Notes:
• Values of Hazen-Williams coefficient, C, for some selected materials:
C.I. pipe, new 130
old 100
New riveted steel 110
Vitrified sewer pipe 110
C.I. pipes in bad condition 80 to 90
Pipes, very smooth and straight 140
• The Hazen-Williams formula is more advantageous than Darcy's formula.
because the coefficient C is independent of Reynolds number that trial solutions
for finding fare eliminated.
EQUATIONS FOR THE COMPUTATION OF MINOR LOSSES IN PIPE LINES
Minor losses are head losses called turbulence losses because of the fittings and
valves installed in the piping line or flow line.
𝑉2
1. Entrance - tank to pipe, ℎ𝐿 = 𝑘(2𝑔)

Where V = velocity of fluid in the pipe, m/s

k = coefficient of minor losses, depends on the condition at the
entrance. For bell mouth, k = 0.05
𝑉2
2. Exit - pipe to tank, ℎ𝐿 = 𝑘(2𝑔)

Where V = velocity of fluid in the pipe, m/s

k = 1.0
 𝑉22 −𝑉12
3. Sudden Enlargement, ℎ𝐿 = 𝑘( )
2𝑔

Where k = 1.0
𝑉1 = velocity at upstream, m/s
𝑉2 = downstream velocity, m/s
𝑉22 −𝑉12
4. Gradual Enlargement, ℎ𝐿 = 𝑘( )
2𝑔

Where k = 1.0
𝑉1 = velocity at upstream, m/s
𝑉2 = downstream velocity, m/s
𝑉2
5. Sudden Contraction, ℎ𝐿 = 𝑘(2𝑔
2
)
𝐷
Where k depends on the ratio 𝐷2
1

k = 0.375 or 0.40
𝑉2= downstream velocity, m/s
𝐷1 = inside diameter of the upstream pipe, m
𝐷2 = inside diameter of the downstream pipe, m
𝑉2
6. Gradual Contraction, ℎ𝐿 = 𝑘(2𝑔
2
)

Where k depends on the cone angle, k = 0.10 to 0.04

𝑉2
7. Bends and Elbows, ℎ𝐿 = 𝑘(2𝑔)
𝑟
Where k is a function of the angle of bend, q and the ratio 𝐷

K = 0.5 for 90°, smooth bend

𝑉2
8. Nozzle (orifices, Venturi meter), ℎ𝐿 = 𝑘(2𝑔
2
)

Where k = 0.04
𝑉2= Velocity, m/s
𝑉2
9. Pipe Fittings and Valves, ℎ𝐿 = 𝑘(2𝑔)

Where k depends on the fittings and valves

 Important Notes:
Values of k
45° Bend (elbow) 0.35 to 0.45
90° Bend (elbow) 0.50 to 0.75
Tees 1.5 to 2.0
Gate valve:
Fully open 0.25
Half-open 5.6
¼ open 24
Check valve (open) 3.0
Globe valve:
Fully open 10
Half-open 20
DETERMINATION OF MAJOR LOSS AND MINOR LOSS COMBINED
• To make the solution simple, only one equation may be used to compute for the
combined major and minor head losses.

𝐿𝑓 𝑉 2
ℎ𝑓 = 𝑓
𝐷 2𝑔
Where 𝐿 𝑇 = total length of pipe, m
𝐿 𝑇 = 𝐿𝑠𝑝 + 𝐿𝑒𝑞

𝐿𝑠𝑝 = Length of straight pipe, m

𝐿𝑒𝑞 = equivalent length of fittings and valves into straight pipe

ℎ𝑓 = major loss + minor loss

ℎ𝑓 = Friction loss ℎ𝑓 (straight pipe) + Turbulence loss ℎ𝑓

(fittings & valves)

𝐿 𝑉2 𝐿 𝑉2
ℎ𝑓 = ℎ𝑓 + ℎ𝑓 = 𝑓 𝐷 2𝑔
= 𝑓 ( 𝐷𝑇 ) 2𝑔
Ex. 21] A pump delivering 230 Ips of water whose absolute viscosity is 0.0114 Poise
has a 300-mm diameter suction pipe and a 254-mm diameter discharge pipe as shown
in the figure below. The suction pipe is 3.5 m long and the discharge pipe is 23m long.
The water is delivered 16 m above the intake water level. Considering the head losses
in fittings and valves, find the head which the pump must supply. If the motor brake
power of the driving motor is 75 kW, what is the efficiency of the pump? Assume the
pipe material as cast iron.
Given: A figure showing a pumping installation
Q = 230 lps BP = 75 kW
𝐷𝑠 = 300 mm 𝐷𝑑 = 254 mm
𝜇 = 0.00114 Poise = 0.00114 Pa-s Standard elbow

Long sweep elbow Standard Elbow Discharge

reservoir
2
1
z = 𝑧A + 𝑧B

A Pump

Source Foot valve & strainer

Required:
a) The total dynamic head
b) The pump efficiency
Solution:
• Considering the Suction Pipe Line

Q 4Q 4(0.23)
Solving for the suction velocity, 𝑉1 = = = = 3.254 𝑚/𝑠
A 𝜋D21 𝜋(0.30)2
Solving for the Reynolds number,

𝜌D1 V1 1000(0.30)(3.254)
R 𝑒1 = = = 856 315.79 = 8.6 x 105
𝜇 0.00114

Solving for the relative roughness of the pipe material,

 𝜀 0.00025 m
e1 = = = 0.00083
D1 0.30 m

Where 𝜀 = 0.25 mm = 0.00025 m (for C.I pipe)

Solving for the value friction factor f using Moody’s chart (MRII, p.119)

fs

e = 0.00083

Then, from Moody’s chart, fs = 0.0193.

Checking for the value of friction factor using Moody’s equation.
1
𝜀 106 3
f = 0.0055[1 + (20000 D + )]
Re
1
0.00025 106
fs = 0.0055 + 0.0055[20000 ( ) + 8.6 x 105]3 = 0.0199
0.30

Solving for the equivalent length of fittings and valves using the Crane chart
(MRII, p. 113),
Fittings & Equivalent Inside

valves Length Diameter

6.9m
Long Sweep

Elbow 300 mm

Gate Valve 2.0 m

From the Crane chart,

Long sweep elbow 6.9 m
Gate valve (fully open) 2.0 m
Then, Leq1 = 6.9 + 2.0 = 8.9 m.

For the total length of suction line,

L𝑠 = Lsp + Leq1 = 3.5 + 8.90 = 12.4 m

Solving for the head loss at the suction line,

 L2 V12 12.4 (3.254)2
hf s = fs = (0.0199) ( ) = 0.444 m
D1 2g 0.30 2(9.8066)
• Considering the Discharge Pipe Line

Q 4Q 4(0.23)
Solving for the discharge velocity, V2 = = = = 4.539 m/s
A2 πD22 𝜋(0.254)2

Solving for the Reynolds number,

𝜌D2 V2 (1000)(4.539)(0.254)
R 𝑒2 = = = 1011321.05 = 1.01 x 106
𝜇 0.00114

Solving for the relative roughness e21

𝜀 0.00025 m
e2 = = = 0.00098 = 0.001
D2 0.254 m

Solving for the value friction factor f using Moody’s chart,

fd e2 =0.001

Then, from the Moody’s chart, fs = 0.02

Checking for the value of friction factor f using Moody’s equation
𝜀 106 1
fd = 0.0055 + 0.0055[20000 (D ) + R ]3
2 e2

1
0.00025 106
fd = 0.0055 + 0.0055[20000 ( ) + 1.01 x 106]3 = 0.021
0.254

Solving for the equivalent length of valves and fittings, using the Crane chart
Fittings & Equivalent Inside
valves Length Diameter
Check valve 20 m

Standard elbow 8.3m 254 mm

Gate valve 1.6 m

Full open

From the Crane chart,

Gate valve: (fully open) 1.60 m
Check valve 20.0 m
 Standard elbow (3pcs x 8.3 m) 24.9 m
Then, Leq2 = 1.60 + 20.0 + 24.9 = 46.5 m

Solving for the total length,

Ld = L2 + Leq2 =23 + 46.5 = 69.5 m

Solving for the head loss at the discharge line,

Ls V22 69.5 (4.539)2
hf 𝑑 = f𝑑 = (0.021) ( )[ ] = 6.04 m
D2 2g 0.254 2(9.8066)
a) Solving for the total dynamic head (TDH),

TDH = (zS + zA ) + HLAB = 16 + 0.444 + 6.04 = 22.484 m

b) For the pump efficiency,

WP 𝜌𝑔Q (TDH)(100%) 1000(9.8066)(0.23)(22.484)(100%)
ηp = (100%) = =
BP 1000 BP 1000(75)
= 67.62%

Ex. 2.2] What is the power of the pump required to draw 50 lps of water from
reservoir A to reservoir B, as shown below? Assume a 70% overall efficiency of the
pump, and an average relative roughness for cast iron of 0.50 mm. The absolute
viscosity of water is 0.001002 Pa-s.
Given: Pumping installation shown
Suction line Discharge Line
Straight pipe 18 m 50 m
Nominal diameter 8 inches 6 inches
Schedule number 80 40
Pipe material Cast iron Cast iron
Absolute roughness 0.50 mm 0.50 mm
Water viscosity 0.001002 Pa-s 0.001002 Pa-s
Q = 50 lps
Pump efficiency = 70%

Required: The pump brake power if the pump efficiency is 70%

 Figure:
B
Standard elbow

Standard elbow zA = 20 m
2

1
Standard elbow

z1 = 4.5 m Pump
A

Solution:
• Considering the Suction Pipe Line
From the Pipe Table (MRII, p.114), the inside diameter is D1 = 193.7 mm
for 8” nominal diameter suction pipe.
Q 4Q 4(0.050)
Solving for V1′ V1 = = = 𝜋(0.1937)2 = 1.70 m/s
A1 𝜋D21

Solving for the Reynolds number,

𝜌D1 V1 1000(1.70)(0.1937)
R 𝑒1 = = = 328 632.73 = 3.3 x 105
𝜇 0.001002

𝜀 0.0005 m
Solving for the relative roughness, e1 = = = 0.00258 = 0.003
D1 0.1937 m

Solving for the value of friction factor f using Moody’s chart,

 fd

e2 = 0.003

R e2 = 3.3 x 105
Then, f1 = 0.026

Checking for the value of friction factor f using Moody’s equation,

1
𝜀 106 3
𝑓1 = 0.0055[1 + (20000 D + )]
Re

1
0.0005 106
f1 = 0.0055 + 0.0055[20000 (0.1937) + 3.3 x 105]3 = 0.0264

Solving for the equivalent length of fittings and valves using the Crane chart,

Fittings & Equivalent Nominal

valves length diameter

Standard Elbow 21 ft

8 inches

Gate valve fully open 4.5 ft

Elbow = (21 ft)(1 m/3.28 ft) 6.40 m

Gate valve (fully open) = (4.5 ft)(1 m/3.28 ft) 1.37 m

Then, Leq1 = 6.40 + 1.37 = 7.77 m

For the total length of the sunction line,

L𝑠 = L1 + Leq1 = 18 + 7.77 = 25.77 m

Solving for the head loss hf1′

Ls V12 25.77 (1.70)2
hf 1 = f1 = (0.026) ( )[ ] = 0.51 m
D1 2g 0.1937 2(9.8066)
• Considering the Discharge Pipe Line
 From the Pipe Table (MRII, p. 114), for 6” nominal diameter, the inside diameter is
D2 = 154.1 mm
Q 4Q 4(0.050)
Solving for the velocity, V2 = = = = 2.68 m/s
A2 πD22 𝜋(0.1541)2

Solving for the Reynolds number R e2′

𝜌D2 V2 (1000)(2.68)(0.1541)
R 𝑒2 = = = 412163.67 = 4.1 x 105
𝜇 0.001002

𝜀 0.0005 m
Solving for the relative roughness, e2 = = = 0.00324
D2 0.1541 m

Solving for the friction factor f using Moody’s chart,

𝑓d e2 = 0.00324

R e2 = 4.1 x 105
Then, 𝑓d = 0.027
Checking for the value of friction factor f using Moody’s equation,
1
𝜀 106 3
𝑓d = 0.0055[1 + (20000 D + R ) ]
e2

1
0.0005 106
fd = 0.0055 + 0.0055[20000 (0.1541) + 4.1 x 105]3 = 0.0279

Solving for the equivalent length of fittings and valves using the Table for the Equivalent
Length (MRII, p.112), for 6” nominal diameter

Elbow (2 x 4.88) 9.76 m

Gate valve (fully open) 1.07 m
Check valve 10.67 m
 Then, Leq2 = 9.76 + 1.07 + 10.67 = 21.5 m

Solving for the total length,

Ld = L2 + Leq2 = 50 + 21.5 = 71.5 m

Solving for the head loss at the discharge line,

Ld V22 71.5 (2.68)2
hf 2 = f𝑑 = (0.027) ( )[ ] = 4.59 m
D2 2g 0.1541 2(9.8066)
Solving for the total dynamic head (TDH),

TDH = (zS + zA ) + HLAB = (zB + zA ) + (hf1 + hf2 )

TDH = (20 + 4.5) + (0.51 + 4.59) = 29.6 𝑚
Solving for the pump brake power (BP),
𝜌𝑔Q (TDH) 1000(9.8066)(0.05)(29.6)
BP = = = 20.73 kW
1000 η 1000(0.70)

• Therefore, use a 25-kW motor, if the pump is directly coupled to the motor.

PIPE SIZE SPECIFICATIONS

• If the requirement is to specify the pipe sizes, take the following example:
Ex. 2.3] A pump is to draw water from reservoir A to reservoir B, as shown in the figure
on the next page. Recommend the sizes of the pipes and the size of motor to be used
for the following specifications:
Suction Pipe Line:
Length of straight pipe 100 m
Pipe material Cast Iron
Absolute roughness 0.50 mm
Schedule number Sch. 40
Discharge Pipe Line:
Length of straight pipe 400 m
Pipe material Cast Iron
Absolute roughness 0.50 mm
 Schedule number Sch. 40
Other Data:
Pump capacity 40 lps
Pump efficiency 78%
Water viscosity 0.001002 Pa-s
Allowable velocity 1.0 m/s to 2.50 m/s
Pipe sizes D1 > D2
Specify the pipe size.
Figure:
B
Standard elbow

Standard elbow zB = 12 m
2

1
Standard elbow

z1 = 3.5 m Pump
A

Solution:
• Considering the Suction Pipe Line
Solving for the pipe inside diameter
Try Vs1 = 1.25 m/s

4Q 4(0.040)
Ds1 = √𝜋V = √ 𝜋(1.25) = 0.2019 m = 201.9 mm
s1

Then, referring to the Pipe Table (MRII, p. 114), the nearest ID = 0.2027 m, with nominal
diameter of 8” for Sch. 80 pipe.
Checking the actual velocity for 8” nominal diameter, D1 = 0.2027 m,
4Q 4(0.040)
V1 = = 𝜋(0.2027)2 = 1.24 m/s
𝜋D21
 Since 1.0 m/s < 1.24 m/s < 2.50 m/s, the assumption is correct. Therefore, use
the following pipe specification for the suction line:
8” nominal diameter
Sch. 40 cast iron pipe
(ID = 0.2027 m)
If the computer velocity V is outside the given velocity range, try another value of
velocity. Then, refer to the Pipe Table and check the actual velocity.
• Considering the Discharge Pipe Line
Solving for the discharge pipe inside diameter;
Try Vs2 = 2.0 m/s

4Q 4(0.040)
Ds2 = √ =√ = 0.1596 m = 159.6 mm
𝜋Vs2 𝜋(2.0)

Then, referring to the Pipe Table (MRII, p. 114), the nearest ID = 0.1541 m, with
nominal diameter of 6” for Sch. 40 pipe.
Checking the actual velocity for 6” nominal diameter, D2 = 0.1541 m,
4Q 4(0.040)
V2 = = 𝜋(0.1541)2 = 2.14 m/s
𝜋D22

Since 1.0 m/s < 1.24 m/s < 2.50 m/s, the assumption is correct. Therefore, use the
following pipe specification for the suction line:
6” nominal diameter
Sch. 40 cast iron pipe
(ID = 0.1541 m)
If the computer velocity V is outside the given velocity range, try another value of
velocity. Then, refer to the Pipe Table and check the actual velocity.

Determination of the BP of the Pump

• Considering the Suction line
𝜌V1 D1 1000(1.24)(0.2027)
R e1 = = = 2.51 x 105
𝜇 0.001002
𝜀 0.0005
e1 = = = 0.0025
D1 0.2027
 𝜀 106 1
𝑓1 = 0.0055 + 0.0055[20000 ( ) + ]3
D1 R e1
0.0005 106 1
f1 = 0.0055 + 0.0055[20000 ( )+ ] 3 = 0.0262
0.2027 2.51 x 105
Equivalent length using the Crane chart,
Standard elbow 6.40 m
Gate valve (fully open) 1.37 m
Then, Leq1 = 7.77 m

Ls = 100 + 7.77 = 107.77 m

L2 V12 107.77 (1.24)2
hf 1 = f1 = (0.0262) ( )[ ] = 1.09 m
D1 2g 0.2027 2(9.8066)
• Considering the Discharge Line
𝜌D2 V2 (1000)(2.14)(0.1541)
R 𝑒2 = = = 3.3 x 105
𝜇 0.001002
𝜀 106 1
𝑓2 = 0.0055 + 0.0055[20000 ( ) + ]3
D2 R e2
0.0005 106 1
fd = 0.0055 + 0.0055[20000 ( )+ 5
]3 = 0.0279
0.1541 3.3 x 10
Equivalent length using the Table for the Equivalent Length
Standard elbow = 3(4.88) 14.64 m
Gate valve (fully open) 1.07 m
Check valve 10.67 m
Then, Leq2 = 26.38 m

Ld = 400 + 26.38 = 426.38 m

Ld V22 426.38 (2.14)2
hf 2 = f2 = (0.0279) ( )[ ] = 18.03 m
D1 2g 0.1541 2(9.8066)
Solving for the total dynamic head (TDH),
TDH = (zA + zB ) + HLAB = 12 + 3.5 + 1.09 + 18.03 = 34.62 m
Solving for the pump brake power (BP),
𝜌𝑔Q (TDH) 1000(9.8066)(0.04)(34.62)
BP = = = 17.41 kW
1000 ηp 1000(0.78)

Use a 20-kW motor drive.

PROBLEMS
1. A pump is required to draw. 50 lps of water (SG = 0.988) from reservoir A, with static
suction lift of 4.5 m, to reservoir B, with static discharge head of 15 m. The pipe in the
suction line is a 6" nominal diameter, schedule 40, and 80 m long. The pipe in the
discharge side is a 4" nominal diameter, schedule 40, and 150 m long. The fittings and
valves installed in the suction line are one foot valve, one standard elbow, and one gate
valve; and in the discharge line are one check valve, one gate valve, two standard elbows.
Assuming an absolute roughness of 0.24 mm for a cast iron pipe, and an absolute
viscosity of water of 0.01002 Poise, and neglecting the head losses in the foot valve and
at the exit in the discharge reservoir, determine the pump brake power if the pump
efficiency is 82%.
2. A pump delivers 95 lps of water through a 203-mm diameter suction pipe and 152-mm
diameter discharge pipe. The suction and discharge pipes are 3 m and 21 m long.
respectively. The water is delivered to a reservoir 20 m above the intake water level. The
turbulence losses in the suction pipe are 0.10 m and 0.20 m in the discharge pipe.
Assuming that the friction factor for the pipe and fluid flow is 0.025, determine the a) total
dynamic head; and b) pump brake power if the pump efficiency is 75%.
3. A pump draws water (SG = 0.998) from reservoir A and transports it to reservoir B, with
a static suction head of 8m and a static discharge head of 28 m. The diameter of the
suction pipe is 15.24 cm, and the diameter of discharge pipe is 4 inches. The total head
loss from A to B is 25% of the total dynamic head (TDH), and the head loss at the
discharge line is 90% of the total head loss. If the pump capacity is 60 ips, determine the
following:
a) Pump brake power if the efficiency is 82%
b) Reading of the pressure gauge installed at the suction flange of the pump
c) Reading of the pressure gauge installed at the discharge flange of the pump
4. Specify the sizes of pipes (cast iron, schedule 40) and the size of the motor to be
used for a pump to lift water at 40 lps, from reservoir A to reservoir B.
Consider the following data:
Total static head 50 m
Fittings & valves;
Suction line 1 foot valve, 1 standard elbow, and 1
gate valve
Discharge line 1 check valve, 1 gate valve, 1 long
sweep elbow, and 2 standards elbows
Length of straight pipes:
Suction pipe 300 m
Discharge pipe 80 m
Absolute viscosity of water 0.001002 Pa-s
Absolute roughness of cast iron 0.00026 m
Darcy-Weisbach friction factor 0.025
Water velocity 1.0 m/s to 2.75 m/s

Neglect the head losses in the foot valve and at the pipe exit in the discharge
reservoir, and do not use equal sizes for the suction and discharge pipes.