Professional Documents
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DATE : 1/12/2010
PROJECT : xx
SYSTEM : xx
Prepared ,& Calc. by : Eng. Faisal Rai
PSI 185.48
Bar 12.79
11/04/2021
Faisal Rai
ARABTEC
PIPE FRICTION CALCULATION
PROJECT : DATE : 1/12/2010
xx SYSTEM : xx
INPUT DATA from Summary
Liquid type Water
q = flow rate 500 GPM
D = pipe diameter 8 Inch
L = pipe length 420.00 Feet
TYPE K
Pipe entrance,inward proj. 0.78
Pipe entrance, Flush 0.5
Pipe Exit , all 1 OR
Ka 1.5 1.78
ESTIMATING PIPELINE HEAD LOSS AND PUMP SELECTION USING DARCY WEISBACH METHOD
Project : xx Date : 1/12/2010
System : xx Done By: FR
Page 2 of 4
kc for Equipment
Equipment kc
Equip. Qty. kc kc
CHIL. COIL 0 11 0
AHU COIL 0 0 0
H.Exch. 0 0 0
0
0
0
Equip.kc = 0
K = Ka + Kb + Kc = 6.765
Hf = K X V² / 2g 1.07
Hf = f X L /100 2.63
Hv = V² / 2g 0
Static Head 320.78
HEAD ( TDH ) = Static head (Hs) + friction head (Hf) + pressure hesd ( Hp) + velocity head(Hv)
Static head ( Hs) = is measured from the surface of the liquid in the section vessel to the surface
of the liquid in the vessel where the liquid is being delivered. In closed-loop system ,
the total static head = 0 .
NOTES :
1. To use this table, one must first have calculated the design flow (DF) and the design head (DH).
2. In closed systems, the friction head is the total head as well, so the values in the right
hand column represent the heads for the system curve.
3. Total System Head = Friction Head
Velocity head appears in italics to remind us that velocity head is generally ignored, as it is insignificant
in hydronic applications
4.5
4
HEAD ( Ft.)
3.5
2.5
1.5
0.5
0
0 100 200 300 400 500 600
FLOW (GPM)
SYSTEM CURVE
FR11/04/2021
OPEN SYTEM CURVE
430
429
428
TH (FEET)
427
426
425
424
423
422
0 100 200 300 400 500 600
FLOW ( GPM )
SYSTEM CURVE
FR11/04/2021
The Friction Coefficient - λ
where
Note that the friction coefficient is involved on both sides of the equation and that
the equation must be solved by iteration.
The Colebrook equation is generic and can be used to calculate the friction
coefficients in different kinds of fluid flows - air ventilation ducts, pipes and tubes with
water or oil, compressed air and much more.
The friction coefficient can also be estimated with the Moody diagram:
NPSH (Net Positive Suction Head)
NPSH is undoubtedly one of the most misunderstood factors in pump selection. The pump NPSH consideration
is actually not a difficult concept once you understand two essential concepts:
1. We tend to think that water boils at 212° F, which is true at atmospheric pressure at sea level. In reality, water
boils at different temperatures, depending upon its pressure. The table below shows the relationship. The pressure at
which water boils at a given temperature is called its vapor pressure.
Under certain operating conditions, as the pump attempts to pull water into the eye of the impeller, it can create a
negative pressure (vacuum). If the pressure created drops to the water’s vapor pressure, the water will begin to boil.
Obviously, this is more likely to happen if the pump is pumping hot water than if it is pumping cool water.
2. The second principle is that a pump is designed to handle pure liquid, not boiling liquid, which is a mixture of
liquid and vapor. (The vapor is steam in the case of water).
What happens when water begins to vaporize as it is drawn into the pump? Vapor bubbles begin to form, just
as they do when you boil water on your stove. As the fluid moves into the vanes of the impeller, it picks up energy
from centripetal acceleration ("centrifugal force"). This causes an increase in the pressure of the boiling liquid. This
causes the bubble to implode (collapse violently). The process of bubbles forming then collapsing violently is called
cavitation. When a pump experiences cavitation:
1. Performance deteriorates.
2. The pump sounds as if it is pumping marbles or gravel (Some people have actually opened up their pumps to find
out how the heck the gravel got in!).
3. The impeller and perhaps the casing begin to suffer damage. This happens when the bubbles implode so violently
that the water chips away at the metal surfaces. In extreme cases, holes are worn in the impeller, eventually resulting
in a "Swiss Cheese" appearance. Figure1 below shows two identical impellers. The impeller on the left has been
subjected to cavitation. You can see the metal that has worn away at the edge and in the eye of the impeller. The
material at the edge is now extremely thin. Note at the 1:00 O'Clock position, that a hole has actually been worn
through the impeller, and at 9:00, a crescent is completely gone. Soon, this entire impeller would have had the "Swiss
Cheese" appearance had it stayed in service.
Figure 1
Cavitation normally takes place in open systems. Figure 2 below shows the forces that determine the
pressure on the water at the lowest pressure point of the system, the entrance to the impeller.
Figure 2
Atmospheric pressure: The pressure from the atmosphere is a positive force of 14.7 PSIA. The factor to convert PSI
to feet of water is 2.31, so the atmospheric pressure is 14.7 X 2.31 = 33.96 feet.
Static height: This is the height of the water level above the pump inlet. The greater this height, the more positive
force is exerted on the water. (Note that if the pump must lift water from a reservoir, that the static height becomes a
negative value).
Inlet friction: Strainers, piping, valves and other accessories all cause a pressure drop, contributing to a lower
pressure.
NPSHr (NPSH Required) of the pump: The NPSHr is a pressure drop within the pump inlet. The NPSHr for any given
pump depends only on the quantity of flow. The NPSHr is shown on the pump curve, either as a separate curve or as
a value printed across the top of the curve (Taco uses the latter method).
We can see from the diagram, that the following factors contribute to low pressure at the inlet:
To avoid cavitation, we must select the pump to ensure that the water does not fall below its vapor pressure.
From the pressure diagram above, and remembering that the NPSHr of a pump is essentially another pressure loss,
we can say:
Atmospheric Pressure + Static Height – Inlet Friction – NPSHr must be greater than the Vapor Pressure of the water
at the temperature being pumped.
Mathematically, with all values expressed in feet of head, this becomes
Equation 1:
33.96’ + Static Height-Inlet Friction-NPSHr >Vp
This equation is normally rewritten by rearranging terms:
Equation 2:
33.96’ + Static Height – Inlet Friction – Vp > NPSHr
We need one more modification to the formula to make it practical. We would like to have about a 2’ safety
factor. Therefore, we can modify the formula as follows:
Equation 3:
31.96’ + Static Height – Inlet Friction – Vp > NPSHr
The sum of the terms on the left of the equation is called the NPSH available or NPSHa. If this formula is
satisfied, that is if NPSHa > NPSHr, then the selected pump should be a good selection as far as NPSH and
cavitation are concerned.
Example 1:
You wish to use a Taco #VI 1507 to pump 190 ° -F water from a shallow tank having a water level of 2’ above the
pump inlet. You estimate that an inlet valve and strainer will have a pressure drop of about 4’. The pump is to handle
100 GPM. Is this pump suitable?
1. Per the discussion above, the pump selection must satisfy the following formula:
31.96 + 2’ (static height) – 4’(inlet friction) – 21.5’(vapor pressure) > NPSHr.
2. From the pump curve below you will note that the NPSHr at 100 GPM is 11 feet. From the vapor pressure curve,
you will note that the vapor pressure is about 21.5’. Summing the terms on the left (31.96 + 2 – 4 –21.5) yields an
NPSHa of 8.46’. This is not greater than the NPSHr of 11’, so this is not a suitable selection.
Use the same parameters as in Example 1, except use a water temperature of 85 ° -F. You will find that the
NPSHa is over 28’! The NPSHr remains at 11’, so the VI 1507 is definitely suitable for this application. This
demonstrates that it is critical to take into account the fluid temperature when considering NPSH.
When a Selection Is Not Suitable
If the initial pump selection is not suitable, there are a number of possible solutions:
Select a larger pump. Oversized pumps operate on the "left" areas of their curves, where NPSHr is lower.
Select a lower speed pump. Lower speed pumps usually have lower NPSHr requirements.
Reduce the inlet friction. Do away with unnecessary valves, accessories and fittings; oversize inlet piping.
Lower the temperature, if practical.
Raise the receiver to increase the static height.
Use a low NPSH pump with a propeller inducer. This is a small propeller installed before the eye of the main impeller.
Pumps made specifically for high temperature condensate often have such inducers.
Field Considerations
Sometimes a properly selected pump will cavitate when placed in service. There are usually two conditions that
cause this:
1. The flow is not balanced, causing the pump to run out (to operate in the high flow areas of the curve). This is high
NPSHr territory. The situation can be resolved by throttling the discharge valve to reduce the flow to the design level.
2. The inlet strainer or filter becomes plugged. This is common in swimming pool applications where the resulting
extreme inlet pressure drop causes cavitation, even with 80° water. The solution is to keep the filters and strainers
clean.
Clarifications
The graph in Figure 4 applies to water only. For other fluids, contact FHI.
For most closed heating systems NPSH is not generally a problem. In a closed system, the expansion tank pressure
replaces atmospheric pressure (31.96’) in Equation 3. The fill valve setting establishes this pressure to a level high
enough to avoid cavitation.
Note that for closed (non-vented) process systems, such as deaerators and vacuum condensers, the
atmospheric pressure is replaced by vapor pressure. This changes the condition to be met to:
Equation 4:
Static Height – Inlet Friction – 2’ (safety) > NPSHr
Approx. Boiling
" Hg Vacuum PSIG Temp, Degrees
Fahrenheit
20 -9.8 157
15 -7.3 179
10 -4.9 192
5 -2.45 204
0 0 212
12 244
30 274
Calculating the Pump Head
Before we can discuss pump head, we must understand the difference between an open hydronic
system and a closed hydronic system. It is important to know whether the pump serves an open or
a closed system, because the pump head calculation depends on the type of system that the pump serves.
In a closed system, the fluid is not exposed to a break in the piping system that interrupts forced flow at any
point. In an open system, it is. In a closed system, the fluid travels through a continuous closed piping system
that starts and ends in the same place--- there is no break in the piping loop. The vast majority of hydronic
piping systems are closed. The most common open system is the cooling tower portion of a chilled water
system, as depicted below. A break in the piping system occurs where the water exits the spray nozzles, and
is exposed to air in the fill section of the tower. The water collects in the cooling tower sump before being
pumped around the loop again. Note that the chilled water side of this diagram (the right side) is closed.
Because it is closed, an expansion tank absorbs any thermal expansion of the fluid. Open systems don’t
require expansion tanks, as the fluid is naturally free to undergo thermal expansion.
Units of Measure: In the U.S. system, head is measured either in PSI or in "feet of head" (usually
abbreviated to "feet").
Pump Head is the total resistance that a pump must overcome. It consists of the following components:
Static Head: Static head represents the net change in height, in feet, that the pump must overcome.
It applies only in open systems. Note that in a closed loop system, the static head is zero because
the fluid on one side of the system pushes the fluid up the other side of the system, so the pump
does not need to overcome any elevation.
Friction Head: This is also called pressure drop. When fluid flows through any system component, friction
results. This causes a loss in pressure. Components causing friction include boilers, chillers,
piping, heat exchangers, coils, valves, and fittings. The pump must overcome this friction.
Friction head is usually expressed in units called "feet of head." A foot of friction head is equal
to lifting the fluid one foot of static height.
Pressure Head: When liquid is pumped from a vessel at one pressure to a vessel at another pressure,
pressure head exists. Common applications include condensate pumps and boiler feed pumps.
Condensate pumps often deliver water from an atmospheric receiver to a deaerator operating at
5 PSIG, meaning that in addition to the other heads, the pump must overcome a pressure head
of 5 PSIG. One PSIG equals 2.31 feet, so the differential head in this application is 5 X 2.31 = 11.6.’
Pressure head is a consideration only in some open systems.
Velocity Head: Accelerating water from a standstill or low velocity at the starting point to a higher velocity at
an ending point requires energy. In closed systems the starting point is the same as the ending
point. Therefore the beginning velocity equals the final velocity, so velocity head is not a
consideration. In an open system, the velocity head is theoretically a consideration, but the pipeline
velocities used in hydronics are so low that this head is negligible, and is ignored.
(Note that the velocity head is defined by the formula V2/2g where V is the fluid velocity in feet per
second and g is the gravitational constant 32 feet/second 2. Therefore at typical velocities of 2-6 fps,
the velocity head is a fraction of a foot. Since head loss calculations are really estimates, this
small figure becomes insignificant).
1. For closed systems: Pump head = the sum of all friction pressure drops
Where:
Friction pressure drop = piping pressure drop + terminal unit pressure drop
+ source unit pressure drop* + valve pressure drop + accessories pressure drop.
* The "source unit" is defined as the boiler, chiller, or heat exchanger, which creates the hot or chilled water.
Step 1: Lay out the piping system using logical routing as determined by the building requirements.
Note each terminal unit and its GPM.
Step 2: Select pipe sizes for each segment, based on proper velocity and pressure drop.
The graphs below are from the ASHRAE Fundamentals Book. Recommended velocities are:
Where P is the head loss (also called friction loss or pressure drop).
The recommended ranges ensure that the piping system will be quiet, consume reasonable pump horsepower,
and be reasonably economical to install. Note that the minimum velocities are recommended based on the fact
that lower velocities will allow air to collect at high points, with the possible result of air binding.
Once the layout and pipe size for each section has been determined follow these steps:
Step 3: Determine Friction Due to Source, Terminal and Accessory Equipment Including:
Accessory items include filters, strainers, check valves or multi purpose valves that could have a significant
pressure drop that would not be covered under the equivalent feet of piping rule of thumb.
To determine valve D P refer to curves or Cv ratings. A Cv is defined as the flow at which the valve will have a
resistance of 1 PSIG (2.31 feet). Since the pressure drop is proportional to the square of the flow rate, use the
following formula to calculate the pressure drop through the valve for any flow rate:
Example: A valve has a Cv of 10. Flow through the valve is 21 GPM. What is the valve D P in feet of head?
Sometimes pressure drops will be given in PSI units instead of feet of head. To convert PSI units to feet of head:
Example: A plate and frame heat exchanger printout shows a pressure drop of 8.5 PSI. What P in feet must be
added to the pump for this item?
In the drawing below, showing a cooling tower, the static height might appear to be 40’. However, the water level in
the tower sump is 28’ above the pump, so the pump must only provide a net lift of 12’. Therefore, the static head is
12’.
Figure 2, Static Height Example
Step 6: Determine the "Worst Pressure Drop Loop" and Estimate the Friction Loss for that Loop by Using
‘Equivalent Feet"
Because fittings result in more pressure drop than plain pipe, we account for them by using "equivalent length."
The equivalent length of a piping circuit is the actual measured length plus an allowance for all the fittings (elbows,
tees, valves, etc.).
The table below lists the number of equivalent feet of piping for various fittings and accessories:
To use this method, add the equivalent length of each item in the fluid’s path to the actual length of piping to get
the total equivalent feet of piping.
Designers often skip the above method and simply multiply the actual piping length times 1.5 to 1.75 to get the
equivalent length. This provides speed and a reasonably accurate estimation for "typical" hydronic piping systems.
As with any rule of thumb, however, watch out for oddball situations (the boiler room is 2 blocks away from the
building, a piping system with an extreme number of fittings, etc). In such situations, the long method provides
better accuracy.
Now multiply the friction loss per 100’ of piping from the ASHRAE charts times the equivalent length in the
"worst" loop to get the total piping friction loss. Select the worst loop by inspection, if possible. Calculate
several branches if there is a doubt. The friction in the worst loop is used as the friction head.
Note that the worst loop is simply that the loop that results in the largest total pressure drop. Do not add
pressure drops from other parallel loops.
In the drawing above, assume that the pressure drop through Coil 3 and its valve are higher than the pressure
drop through Coils 1 and 2. Assuming that the branch piping for all three circuits is similar, the "worst case" total
friction loss loop is shown in light blue. It would be erroneous to add the pressure drops of the piping shown in
black.
Notes
1. Those circuits with less pressure drop than the "worst" circuit will be balanced in the field by partially closing
balancing valves (not shown above).
2. If there are different pipe sizes on the circuit, the circuit may have to be analyzed in sections, because the
pressure drop/foot may vary by section. This is one good reason for selecting all piping at the same pressure drop
per 100.’ It simplifies the calculations considerably.
Safety factors
You may wish to add a safety factor to the calculated head for two reasons:
Jobsite conditions may not allow direct routing of piping as shown on the plan. Extra length and extra elbows result
in added friction.
The interior pipe walls become rough over time due to corrosion, especially in open systems, where fresh water
makeup brings in a steady supply of corrosion-causing oxygen. This increases friction. Various sources
recommend total safety allowances of 15-25% for friction calculations. Note that the friction tables assume cold
water, which results in more friction than hot water. Therefore, if you are designing a hot water system, you
already have a safety margin of around 12%. Be careful of excessive safety factors. They result in oversized
pump impellers that cause wasted energy!