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CEM4M1C-102-0-2010

CHEMICAL ENGINEERING TECHNOLOGY


CEM4M1C

ASSIGNMENT 2

Question 1

In the case of a runaway temperature in a reactor, cooling water (10oC) flows


from a tank (vented to the atmosphere, 100 kPa) through the reactor to a waste
system at 50 kPa (a). The piping (L = 200 m) is 150 mm diameter smooth pipe
containing two gate valves, three standard 90o elbows and three couplings.
Assume the pressure loss through the reactor is equivalent to another 450 m of
this pipe. The difference in elevation from the liquid level in the tank to the
discharge point into the waste system is 40 m. What will be the rate of water flow
in an emergency (m3.hr-1)?
(10)
ρ = 10 kg/m
3 3

µ = 1.00 × 10-3 kg/ms


gate valves L/D = 7
standard 90o elbows L/D = 30
couplings L/D = 0

ANSWER:
(1) 100 kPa(a)

Tank

40 m

Reactor

(2)
Waste 50 kPa(a)

ME balance

p1 u12 p2 u22
+ z1g + + ws = + z 2g + +f
ρ 2 ρ 2

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assume u1 is negligible and no mechanical work.

P1 − P2 u 2
+ (z1 − z 2 )g = 2 + f
ρ 2
(100 − 50 )10 3
+ 40(10 ) =
u22
+f
103 2
u22
∴ + f = 450Jkg−1
2

L 2
f = 4θ u (equation 3.19 from Coulson & Richardson, 6th edition)
d

u22 L
i.e. + 40/ u2 = 450Jkg−1
2 d

L = 200m + (0.15 )(2 × 7 + 3 × 30 + 0 ) + 450m


= 665.6m

Assume u such that LHS = RHS

u 2 4
Re 3 x 105 6 x 105
0/ 0.00175 0.00155
u2 Lu2
/
+ 40 126.2 448.2
2 d

U = 4m.s-1 is close enough

ρud
Re =
µ
For a smooth pipes θ = 0.0396 Re −0.25 (equation 3.11 from Coulson & Richardson,
6th edition)

π (0.15 )
2

∴ flow rate through reactor = 4 m/s


4
= 0.0706m .s-1
3

= 254.5m3hr--1

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Question 2

A non-Newtonian Fluid is cooled in a jacketed pipe with cooling water. The non-
Newtonian fluid flows through the annulus. Calculate the pressure drop of the
fluid if the jacketed pipe is 30 m long. The flowrate is 10 m3.hr-1. The inside pipe
is a 40 mm outside diameter pipe, and the outside pipe is an 80 mm inside
diameter. The physical properties of the fluid are:
k = 0.208 Pa.sn (fluid consistency index)
n = 0.28 (flow behaviour index (-))
density = 1685 kg.m-3
(15)

ANSWER:

4 × ( x sec tion )
de =
wetted perimeter

=
(
4π D 2 − d 2 )
4π (D + d )
de = D − d
= 80 − 40
= 40mm = 0.04m

k = 0.208 n = 0.28

µ app : apparent viscosity (N.s.m-2)

n −1
 8u 
µ app = k   (3.2.2.4 in Study Guide)
 di 

Q
Q = Au ⇒ u=
A

10  4 
u=  2 
3600  π 0.04  ( )
= 2.21m.s −1

8u 8(2.21)
Flow characteristic: = = 442s −1
di 0.04

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µ app = 0.208(442 )0.28 −1


= 0.208(0.012 )
= 2.60 × 10− 3 = 0.0026( Ns / m 2 )

ρdu (1685)(0.04 )(2.21)


Re n = =
µ app 0.0026
= 5729

Turbulent flow

a
Now f = (3.2.3.2.1 in Study Guide)
Rebn

From Table (3.1 in Study Guide) a = 0.0677 and b = 0.33 for n = 0.28

0.0677
∴f = = 0.0039
(5729)0.33
L 2
∆Pf = 2 f ρu (3.2.3.1 in Study Guide)
di
L ρu 2
∆Pf = 4 f
di 2

L ρu 2 30 1685(2.21)
2
∆Pf = 4 f = 4(0.0039 )
di 2 0.04 2
= 48144( Pa )
= 48.144kPa

Question 3

Calculate the required pressure at the delivery flange of a pump which feeds an
organic mixture to a distillation column (elevation = 16 m). The feed is pumped
from a feed tank that consists of 90 % carbon tetrachloride and a 10 % perchloro
ethylene. Physical properties given below.

The pressure in the feed tank is 100 kPa (g) while the column is pressurised at
585 kPa (a). The proposed pipe outlay is:

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Length Ball Gate Elbows Strainer Diaphragm


valves valves valve
Suction 5m 1 4 X 90o 1 1
Discharge 45 m 1 1 12 X 90o - -

Internal diameter of the pipeline on the delivery end of the pump is 40 mm. The
flow in the pipeline must be 10 m3.hr-1.
The roughness of the pipe is 0.000046 m.

Physical properties of the fluid:


Density = 1589 kg.m-3
Viscosity = 0.08 mPa.s
Temperature = 100 oC
Vapour pressure = 90 kPa (a)
Atmospheric pressure = 85 kPa
(15)
Ball valves L/D = 13
Gate valves L/D = 7
90o elbows L/D = 60
Diaphragm valves L/D = 40
Strainer L/D = 130

ANSWER:

ME balance :

 ud 2 Pd   us 2 Ps 
 + + Z − + + Z  = ∆hp + h f (4.1.1.3 in study guide)
 2 g ρg d   2 g ρg s 
   

Ps
Suction head : hs = Z s + − h fs (4.1.1.1in study guide)
ρg

Pd
Discharge head : hd = Z d + + h fd (4.1.1.2in study guide)
ρg
Pd
hd = Z d + + h fd
ρg
we need to caculate h fd
le u 2
h fd = 4φ
di g

Q = 10m3hr −1 = 2.78 × 10 −3 m3 .s−1

Q 2.78 × 10 −3 × 4
Q = uA ⇒ u = Q = = = 2.212m.s −1
A π (di )2 π (0.04 )2
4
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CEM4M1C-102-0-2010

ε 0.000046
= = 0.00115
d 0.04

ρdu 1589 × 0.04 × 2.212


∴ Re = =
µ 0.08 × 10 − 3
= 1.757 × 106
From chart φ = 0.0025

le= 45 + [ (1 × ball valve) + (1 × gate valve) + (12 × 90° elbows) ] × di


= 45 + [(1 × 13) + (1 × 7 ) + (12 × 60 )]× 0.04
= 74.6 m

le u 2
h fd = 4φ
di g
74.6 (2.212 )
2

h fd = 4(0.0025)
0.04 9.81
= 9.30 m

Pd
hd = Z d + + h fd
ρg
585 × 103
hd = 16 + + 9.30
1589 × 9.81
hd = 16 + 37.53 + 9.30
= 62.83 m

∆Pd = ρg∆hp = 1589 × 9.81 × 62.83


= 9.8 × 105 Pa(a )

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Question 4

Water flows at a rate of 10 m3/s in a channel shown in the Figure below. If the
canal is weedy (n=0.03) with a slope of 0.0014, determine the depth of flow.
[10]

y
40o 40o

3.66 m

ANSWER:

1 2 1
Q= ARh 3 S0 2
n

A : area
A
Rh = ( P : wetted perimeter)
P

A=2( )+

1 
A = 2 bh  + y (3.65)
2 
A = bh + y (3.66 )
 y 
A = y  + y (3.66 )
 tan 40 
y2
A= + 3.66 y
tan 40
A = 1.19 y 2 + 3.66 y

 y 
P = 3.66 + 2 
 sin 40 
2
P = 3.66 + y
0.6427
P = 3.66 + 3.11 y

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CEM4M1C-102-0-2010

A 1.19 y 2 + 3.66 y
Rh = =
P 3.66 + 3.11 y

1 2 1
Q= ARh 3 S0 2
n
Q = 10 m3.s-1

2
1.19 y 2 + 3.66 y 
( )
3
1
10 = 1.19 y 2 + 3.66 y   (0.0014 )12
0.03  3.66 + 3.11 y 

) ( )
 1.19 y 2 + 3.66 y 2 3 
(
10 = (33.33) 1.19 y + 3.66 y 2
3
3   (0.0014 ) 2
1

 (3.66 + 3.11y ) 3 
2
 

10 = 1.2471
(1.19 y 2
+ 3.66 )
5
3

(3.66 + 3.11y )2 3

(1.19 y ) − 8.018(3.66 + 3.11y )


5 2
2
+ 3.66 3 3 =0

(1.19 y 2
)
+ 3.66 − 515(3.66 + 3.11 y ) = 0
5 2

by trial and error y = 1.5 m

Question 5

Water flows uniformly in a rectangular channel of width b and depth y.


Determine the aspect ratio for the best hydraulic cross-section.
[15]

ANSWER:

Uniform flow
1 2 1
Q = ARh 3 S0 2
n
A=by
p = b + 2y

A by
Rh = =
P b + 2y

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CEM4M1C-102-0-2010

in term of A

A A A Ay
Rh = = = =
(b + 2 y )  A  A 2y
 +
2
A + 2 y2
y + 2 y 
  y y
2
1  Ay  3 12
∴ Q = A  S0
n  A + 2 y2 

3
 nQ  2

Rearrange and let K =  1 


 S0 2 
Then:

2
nQ  Ay  3
= A 2
 A + 2y 
1
S0 2

nQ
=A
3
3
( Ay )2 3
S0
1
2
(A + 2 y ) 2
2
3

( y )2 3
5
nQ A 3
=
S0
1
2
(A + 2 y ) 2
2
3

3
( y )2 3 ×
5 ×3
 nQ  2
A 3 2
3
2
  =
 S 12 
 0  (A + 2 y ) 2 3
2 3× 2

3
A 2 (y)
5
 nQ  2
  =
 S 12 
 0  (
A + 2 y2 )
5

K=
A 2y
A + 2y 2
5
⇒ A 2 y = K 2 y2 + A
( ) ( )

best hydraulic section is when A is minimum for all y

dA
∴ =0
dy
5 5 2  dA  5   dA  
∴ A   y + A 2 = K  4 y +   
2  dy    dy  

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CEM4M1C-102-0-2010

dA
For =0
dy

5
5 A2
A 2
= 4 Ky ⇒ K =
4y
5
A 2y
K=
A + 2 y2 ( )
5 5
A2 A 2y
∴ =
4y A + 2 y2 ( )
A 2 y (4 y ) A 2 4 y 2
5 5
5
=
A
(A + 2 y 2 ) = 2 y 2 + A
2

A
5
2
(2 y 2
)
+ A = 4 A 2 y2
5

5 7 5
2 A 2 y2 + A 2
= 4 A 2 y2

2 y2 + A = 4 y2

A = 4 y2 − 2 y2 = 2 y2

1
 A 2
⇒ y= 
2

A = by

1
 by  2
⇒ y= 
 2

by
y2 = ⇒ 2 y 2 = by ⇒ 2 y = b
2

b
∴ =2
y

Gives smallest A & smallest wetted perimeter.

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CEM4M1C-102-0-2010

ASSIGNMENT 3

Question 1

Water is to be pumped from a dam at the rate of approximately 75 m3.hr-1


through a pipeline 1 km in length and internal diameter 100 mm, and delivered at
atmospheric pressure to a point 30 m higher than the surface of the dam.
Homologous pumps are available for this duty with the impeller sizes of 100 mm,
150 mm and 200 mm. Determine:

1.1. Which pump should be selected.


1.2. The actual flowrate of water
1.3. The maximum distance at which the pump can be situated from the
pipeline inlet without cavitation.
(25)
Performance data for the 100 mm impeller pump are given below:

Q (m3.hr-1) Head (m) NPSH (m)


0 30 0.5
5 28 0.75
10 25 1.5
15 17.5 5.0

Suction line: 1 strainer, 1 check valve, 2 X 90 o bends


Pump is 3 m above the dam water level.
Discharge line: 2 globe valves, 5 X 90 o bends
Pipe roughness = 0.1 mm
Equivalent lengths: strainer = 130 d
Check valve = 50 d

Assume all pumps run at same speed


Viscosity of water = 1 mPa.s
Vapour pressure of water = 3 kPa (abs)
Atmospheric pressure = 101.3 kPa.

ANSWER:

1.1.
Use equations for centrifugal pump relationships:
For 200 mm impeller:
For N1 = N2
3 3
Q1  N1  D1   D1 
=   =  
Q2  N 2  D2   D2 

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CEM4M1C-102-0-2010

3
Q1  100 
 = (0.5) = 0.125
3
=
Q2  200 
Q1
Q2 =
0.125
2 2
∆h1  D1   100 
=   =   = (0.5) = 0.25
2

∆h2  D2   200 

∆h1 ∆h1
= 0.25 ⇒ ∆h2 =
∆h2 0.25
2 2
NPSH11  D1   100 
=   =   = (0.5) = 0.25
2

NPSH 2  D2   200 
NPSH1 NPSH1
= 0.25 ⇒ NPSH 2 =
NPSH 2 0.25

For 200mmm impeller For 150mm impeller


 m3  NPSH  m3  NPSH
Q   h(m) (m) Q   h(m) (m)
 hr   hr 
0 120 2 0 67.5 1.13
40 112 3 16.9 63 1.69
80 100 6 33.8 56.3 3.38
120 70 20 50.6 39.4 11.25

For Q = 75m3.hr-1
75 4
u= .
3600 π (0.1)2
= 2.65m.s −1

ρdu 1000(0.1)(2.65 )
Re = =
µ 0.001
= 2.65 × 105

e 0.0001
= = 0.001
d 0 .1

φ = 0.0024

l u2
∴ h f = 4φ
d g

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CEM4M1C-102-0-2010

le = 1000 + [ (2 × globe valve) + ( 5 × 90° bends) + (strainer) +


(check valve) ] di
= 1000 + [ (2 × 300) + (5 × 20) + 130 + 50 ] 0.1 = 1088 m

l u2
∴ h f = 4φ
d g
1088 (2.65)
2
= 4(0.0024 )
0.1 9.81
= 74.76m

P −P u2 − u2
∆h =  2 1  + (δ 2 − z1 ) + 2 + hf
 ρg  g
= 30 + 74.76
= 104.76m

For Q = 80m3.hr-1

80
Re = 2.65 × 105 × = 2.85 × 10 6
75

φ = 0.0024
2
 80 
∴ h f = 74.76  = 85.06m
 75 

∆h = 30 + 85.06 = 115.06m

2
3 -1  70 
Q = 70m .hr hf = 74.76   = 65.12m
 75 

∆h = 30 + 65.12 = 95.12m

Only the 200mm impeller can provide sufficient head.

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1.2
System head:

Pd − Ps u 2 − us2
∆h = + (Z d − Z s ) + d + h fd + h fs
ρg 2g

l u2
∆h = (Z d − Z s ) + 4φ
d g

2
1088  Q  1
∆h = 30 + 4(0.0024)  
0 .1  A  g

π
A= (0.1)2 = 0.008
4
2
1088  Q  1
∆h = 30 + 4(0.0024)  
0.1  0.008  9.81

∆h = 30 + 13.04 × 10−3 Q 2

From the pump curves and system curves the actual flowrate is 74m3.hr-1

74  4 
u=  
3600  π (0.1)2 
= 2.62m.s −1

1.3 Corresponding NPSH = 5.4m

Ps − Pvp
NPSH = + Z s − h fs (4.1.2.1. in study guide)
ρg

5 .4 =
(101.3 − 3)103 + 3 − h
fs
9.81 × 103
h fs = 10.02 + 3 − 5.4
l s u2
= 7.62hr = 4φ
d g

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7.62dg
⇒ ls =
4φu 2
7.62(0.1)(9.81)
=
4(0.0024 )(2.62 )
2

= 297.20m

Now fittings account for:


0.1 [ 1 strainer + 1 check valve + 2 × 90° bends ] =
0.1[130 + 50 + 2 × 20] = 22m

∴Max length at suction line = 297.20 - 22


= 275.20 m

Assigment 3, Question 1, 2007

150

125

100
Head (m)

75

50

25

0
0 10 20 30 40 50 60 70 80 90 100 110 120 130

Q (m 3/h)

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Question 2

A centrifugal pump is used to extract water from a cooling tower operating at


atmospheric pressure (101.3 kPa).

At the rated discharge, the net positive suction head must be at least 4 m. If the
frictional head loss in the suction line is 5.5. m, what must be the least height of
the liquid level in the cooling tower above the pump inlet? The vapour pressure of
the water is 25 kPa at the operating temperature.
(10)

ANSWER:

NPSHR = 4m
hfs = 5.5m

Pvp
NPSH A = h s − (4.1.2.2. in study guide)
ρg
Ps
hs = + Z s − h fs (4.1.1.1. in study guide)
ρg
Ps P
NPSH A = + z s − h fs − vp
ρg ρg
P − Pvp
= s + z s − h fs
ρg

=
(101.3 − 25)103
+ z s − 5 .5
(9.81)103
= 7.77 + z s − 5.5
= 2.27 m + z s

But NPSHA ≥ NPSHR


2.27 + zs ≥ 4m
zs ≥ 1.72m

Question 3

A vacuum system is required to handle 10 g.s-1 of vapour (MW = 56 kg.kmol-1) so


as to maintain a pressure of 1.5 kPa in a vessel situated 30 m from the vacuum
pump. If the pump is able to maintain a pressure of 0.15 kPa at its suction point,
what diameter pipe is required? The temperature is 290 K, and the isothermal
conditions may be assumed in the pipe, whose surface can be taken as smooth.
The ideal gas law is followed.
µgas = 0.01 mPa.s
(15)

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Isothermal Flow
2 2
 G   P1  P2 − P1
2 2
l G
  ln  + + 4φ   = 0 K(1) (4.57) in Coulson &
 A   P2  2 P1V1 d  A
Richardson, 6th Edition

RT 8.314 × 290
P1V1 = = kJ.kg−1
MM 56
= 43.05kJ.kg−1

Since A, φ, d are unknown

Assume d = 0.1m
⇒ A = π (0.1)
2
= 7.85 × 10 − 3 m2
4

4G d G
Re = =  
πµd µ  A 
d G
∴ Re =   =
0 .1

(
 10 × 10 − 3 kg.s −1 ) 
µ  A  0.01 × 10− 3  7.85 × 10 − 3 

= 12740

From friction chart

φ = 0.0035

Substitute in equation (1)

 
2

ln   +
(
 10 × 10−3   1.5  0.152 − 1.52 106
+ 4()
0.0035 ) 30  10 × 10−3 

2

 =0
−3 
 7.85 × 10   0.15  (
2 43.05 × 103 ) (0.1)  7.85 × 10− 3 

∴diameter too large

Assume d = 0.08

A = π (0.08 )
2
= 5.027 × 10 − 3 m2
4

Re =
0.08 (
10 × 10 −3 )
0.01× 10 − 3 5.027 × 10 − 3
= 16000

From chart φ = 0.00325 for smooth pipe.

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 
2

ln   +
(
 10 × 10 −3   1.5  0.152 − 1.52 106 )+ 4 (0 . 00325 ) 30  10 × 10 −3 
 
2

−3 
 5.027 × 10   0.15  ( )
2(43.05) 103 0.08  5.027 × 10− 3 
= 2 2 × 2.3 − 25.87 + 19.5
= 2.83 ≈ 0

∴diameter of pipe is 0.08m = 80mm

Question 4

Determine the conditions (i.e. volumetric flowrate, density and pressure) at the
suction flange of a vacuum pump. The vacuum pump must maintain the pressure
in a stripping column at 5 kPa (a).

The 150 mm ID alloy pipeline between the vacuum pump and the column is 50 m
long and contains five 90o elbows and one ball valve. The absolute roughness (e)
of the pipeline is 0.0003 m. The stripped gas is chlorine with a flowrate of 200
kg.hr-1 and a temperature of 50 oC. Assume isothermal flow in the pipeline. MW
of Chlorine is 72 and Cp/Cv =1.3.
(20)

ANSWER:

m = 200kg.hr −1 = 0.056kg.s−1
π (0.15 )
2

A= = 0.0177m2
4
µ = 0.015 cp from tables

G d 0.056  0.15 


Re =   =  −3 
 A  µ 0.0177  0.015 × 10 
= 31638

e = 0.0003 = 0.002
d 0.15

From chart φ = 0.0034


L = 50m + (5 × 60 + 1× 13 )0.15
= 50 + 46.95
= 96.95m

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Assuming isothermal flow and kinetic term is negligible

2
P22 − P12 l G
+ 4φ   = 0
2P1v1 dA

 l  G 2 
P − P = 2P1v1 4φ   
2
2 1
2

 d  A  
RT1
where P1v1 =
MM

2(8314 )(323)  96.95 (0.056 ) 


2
∴ P = 5 × 10
2
2
( )
3 2
+
72
4(0.0034 ) 
0.15 (0.0177 )2 

= 25 × 106 + 6.56 × 106
= 31.56 × 106
P2 = 5.62 × 103 Pa = 5.62kPa

From
RT
P2v2 =
MM
RT
v2 =
P2 MM
1
ρ=
v2
P2 MM
ρ=
RT
5.62 × 103 (72 )
= 3
10 × 8.314 × 323
= 150.68kg.m − 3

m& 0.056
∴ Volumetric flowrate = =
ρ 150.68 × 10 − 3
= 3.72 × 10−1 m3 .s −1

19
CEM4M1C-102-0-2010

Question 4 cont

In a synthetic ammonia plant, the hydrogen is fed from a reservoir at 2 MNm-2


pressure through a clean horizontal mild steel pipe 50 mm in diameter and 500 m
long to the synthesis converters. The hydrogen is required at a pressure of 2.5
MNm-2 and the pressure is raised to 3 MNm-2 by a single stage compressor at
the upstream end of the pipe. The index of compression is 1.45 and the
temperature of the gas at the exit of the compressor is 320 K. If the flow of gas in
the pipeline is isothermal, determine:

4.1 the mass flowrate of the hydrogen

4.2. the indicated power of the hydrogen.

e/d = 0.001
R = 8314 Jkmol-1K-1
(20)

ANSWER:

4.1 Flowrate unknown, need to assume φ and find G


A

2MPa

1 2
P3 = 2.5Mpa
T3
P1 P2 = 3MPa
T1 T2 = 320K

From tables µ of H2 at 320K = 0.009mPa.s

Since flow is isothermal

2 2
G P P2 − P22 l G
  ln 2 + 3 + 4φ   = 0
A P3 2P2 v 2 dA
where P2v2 = RT2 / 2

Assume φ = 0.0025

20
CEM4M1C-102-0-2010

G
 
2

l n
3
+ 4 (0 . 0025 ) +
[ ]
500  2.52 − 32 × 1012
=0
 2 .5 0.05  2 RT2
 A 
2
2
G 5.168 × 105 × 2
  = = 101.57 kgs −1m − 2
 A 100.18

Check φ

G d
Re = = 5.6 × 105
A µ

e = 0.001
d

From chart φ = 0.0024 ≈ φ assumed

∴Flowrate = 101.57kg.m-2.s-1

& = 0.199kg.s-1
m

4.2
 n −1

ip =
& RT1
zn m  P2  zn − 1
n −1 M  P  
 1  
n −1

T2 =  P2  n
T1  P 
 1
T2
T1 = n −1
 P2  n
 
 P1 
320
= 0.45
 3  1.45
 
2
= 282.16K
 0.45

1.45 (0.199 )(8314 )(282.16 )  3  1.45 
∴ ip =   −1
0.45 2  2  
 
= 101.4kW

21
CEM4M1C-102-0-2010

Question 5

A monolithic concrete inverted siphon on the Tugela River aqueduct is circular in


cross section and is 4.88 m in diameter. It is completely filled with water.

5.1. If n = 0.013, find the slope of the hydraulic grade line for a flow of 45 m3.s-
1
.
(5)
5.2. Solve the same problem using the friction factor charts, and assuming a
mean value of for concrete pipes. Compare your result with that of part
5.1.
(10)

ANSWER:

5.1
π
A= D2
4
π
= (4.88 )2
4
= 18.7m2

4.88
Rh = D = = 1.22m
4 4

2 1
1
Q = ARh3 So2
n
1
18.7 2
45 = (1.22)3 So2
0.013
∴ So = 0.00075 or 0.75m / km

5.2 Mean value of e for concrete

0 .3 + 3 .0
= 1.65mm
2

e = 1.65 = 0.000338
d 4880

45
u=Q = = 2.41m.s −1
A
18.7
υ = 1.139 × 10 − 6 at 15°C

22
CEM4M1C-102-0-2010

Du
Re =
υ
=
(4.88 )(2.41)
1.139 × 10 − 6
= 1.033 × 107

From chart f = 0.0153

l u2
hL = f
d 2g
2
hL  1  2.41
∴ = 0.0153 
R  4.88  2(9.81)
= 0.000924

∴within 23% of value found in 5.1

23

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