Professional Documents
Culture Documents
MECHANICS
K URDISTAN – I RAQ
by
HELENA LAAVI
Duhok Polytechnic University
Zakho Technical Institute
Zakho
2015
Preface
This material is made for the course Fluid Mechanics for 2nd stage stu-
dents to be taught in Zakho Technical Institute, Duhok Polytechnic Uni-
versity in Kurdistan-Iraq during the academic year 2015-2016.
This material gives an introduction to the fluid mechanics that is needed
in petrochemistry. It is divided in sections:
1. Introduction
• This part gives introduction to fluid mechanics and what does it contain.
The definition of the fluid is given. Standard units, dimensions and mea-
surement systems are presented.
2. Fluid Properties
• In this part, fluid properties are illustrated with practical examples. Also
flow characteristics are defined with practical examples.
3. Fluid statics
• In this part, fluid at rest are presented. Pressure and its different forms
are presented. Pressure gauges are discussed with examples.
4. Fluid dynamics
• In this part, fluid in motion are presented. Flow rate is introduced with
examples with Reynold’s number. As the flow of gases is presented, the
basic principles how to write balances is given. The equation of continuity
is presented with examples of mass balance. Energy Conservation Law
i
Preface
• In this part, the causes of pressure losses in pipes are given with exam-
ples. Also friction coefficient and the pressure losses caused by friction in
pipes are presented with examples.
6. Pumps
• In this part, different types of pumps and their use are presented. Pump
is a crucial part of a piping system. The NPSH (Net Positive Suction
Head) and its requirements are presented in order to avoid pump cavita-
tion.
7. Valves
• In this part, parts of valves and different types of valves with their main
use are presented.
Helena Laavi
ii
Contents
Preface i
Contents iii
1. Introduction 1
1.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Compressibility . . . . . . . . . . . . . . . . . . . . . . 1
2. Fluid Properties 3
2.0.1 Example on Properties . . . . . . . . . . . . . . . . . . 3
2.1 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.1 Example on Viscosity . . . . . . . . . . . . . . . . . . . 4
2.2 Flow Characteristics . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.1 Newtonian Fluids . . . . . . . . . . . . . . . . . . . . . 6
2.2.2 Non-Newtonian Fluids . . . . . . . . . . . . . . . . . . 6
2.3 Ideal Gas Law . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Example on Ideal Gas Law . . . . . . . . . . . . . . . 8
3. Fluid Statics 9
3.1 Hydraulics and Pneumatics . . . . . . . . . . . . . . . . . . . 9
3.2 Pressure in Fluids at Rest . . . . . . . . . . . . . . . . . . . . 10
3.2.1 Hydrostatic Pressure . . . . . . . . . . . . . . . . . . . 10
3.2.2 Atmospheric Pressure . . . . . . . . . . . . . . . . . . 12
3.2.3 Buoyancy . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.4 Capillary Forces and Surface Tension . . . . . . . . . 14
4. Fluid Dynamics 15
4.1 Flow Rate – Reynolds Number . . . . . . . . . . . . . . . . . 15
4.1.1 Laminar Flow . . . . . . . . . . . . . . . . . . . . . . . 16
iii
Contents
6. Pumps 37
6.1 Introduction to Pumps . . . . . . . . . . . . . . . . . . . . . . 37
6.1.1 Parts of Pumps . . . . . . . . . . . . . . . . . . . . . . 38
6.2 Pump Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.1 Pump Operation Point . . . . . . . . . . . . . . . . . . 40
6.3 Pump Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.1 Net Positive Suction Head (NPSH) . . . . . . . . . . . 41
6.3.2 Net Positive Suction Head Required (NPSHR) . . . . 41
6.3.3 Net Positive Suction Head Available (NPSHA) . . . . 42
6.3.4 Pumping of Boiling Liquid . . . . . . . . . . . . . . . . 42
6.4 Pump types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.4.1 Centrifugal Pump . . . . . . . . . . . . . . . . . . . . . 43
6.4.2 Diaphragm Pump . . . . . . . . . . . . . . . . . . . . . 43
6.4.3 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . 43
6.4.4 Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . 43
iv
Contents
7. Valves 45
7.1 Introduction to Valves . . . . . . . . . . . . . . . . . . . . . . 45
7.1.1 Parts of Valves . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Valve Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2.1 Ball Valve . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2.2 Butterfly Valve . . . . . . . . . . . . . . . . . . . . . . 48
7.2.3 Check Valve . . . . . . . . . . . . . . . . . . . . . . . . 48
7.2.4 Choke Valve . . . . . . . . . . . . . . . . . . . . . . . . 48
7.2.5 Control Valve . . . . . . . . . . . . . . . . . . . . . . . 48
7.2.6 Diaphragm Valve . . . . . . . . . . . . . . . . . . . . . 49
7.2.7 Disc Valve and Gate Valve . . . . . . . . . . . . . . . . 49
7.2.8 Globe Valve . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2.9 Knife Gate Valve . . . . . . . . . . . . . . . . . . . . . 50
7.2.10 Needle Valve . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2.11 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . 50
v
Contents
vi
1. Introduction
Fluid mechanics deals with a huge range of topics which deal with the
behaviour of gases and liquids.
Fluid statics deals with fluids that are at rest. In other, it deals with
fluids that do not move.
Fluid dynamics deals with fluids in motion. In other words, it deals
with fluids that move.
1.1 Definitions
The three forms of matter, solid, liquid and gas, can be divided into two
groups. Solids are the matters that don’t freely change shape if force is
focused onto them. Fluids include gases and liquids. They freely change
shape if force is focused onto them.
1.1.1 Fluid
An attempt to change the shape of a fluid leads that the fluid layers slide
over each other until the new shape is achieved. During the transforma-
tion, shear stress affect the fluid layers. The value of the shear stress
depends on the viscosity of the fluid and the velocity how fast the layers
move in respect to each other. At rest, there is no shear stress in the fluid.
1.1.2 Compressibility
1
Introduction
2
2. Fluid Properties
In studying properties of fluids, one must always include the unit which
is used in describing the property. Often there are different units for the
same property. In such cases, one must convert the units of the property
to be the same. Otherwise the properties can’t be compared or used in the
same calculation.
Viscosity (µ or ν) viscosity of a fluid is a measure of its resistance to
gradual deformation by force (shear stress). For liquids, viscosity is com-
monly understood as the ”thickness” of the liquid. For example, honey has
a much higher viscosity than water. The standard SI unit for viscosity is
Pa · s = kg / (m · s).
Pressure (P ) is the force / area acting normal to a surface. The standard
SI unit for pressure is Pa (Pascal). 1 Pa = 1 kg/(m·s2 )
Density (ρ) is defined as the mass / volume. The standard SI unit for
density is kg/m3 . One cubic meter equals volume of a cube of which the
three sides are 1m each.
1 m3 = 1000 l (litres). One litre equal volume of a cube of which the three
sides are 10 cm each. Ten centimeter is 0.1 m (10cm = 0.1m) so one litre
cube is (0.1m)3 = 0.001m3 .
Velocity (v) describes how fast does the object move. Velocity has al-
ways a direction. The standard SI unit for velocity is m / s. For vehicles,
such as cars, a velocity unit km/h is often used.
1 km/h = 1000 m/3600s = 1/3.6 m/s
The flow of a fluid is steady if the pressure, density and velocity of the
fluid don’t change in time at any point. It they change, then the flow is
unsteady.
3
Fluid Properties
2.1 Viscosity
Viscosity is quantity that describes the friction between the fluid particles
(molecules). Friction tries to prevent the fluid particles to move. Viscosity
is the ”stickiness” of liquid.
Viscosity is defined by the Newton’s equation of viscosity.
dv
τ =µ (2.1)
dy
where τ is the shear stress [Pa], µ is (dynamic) viscosity [Pa · s], and
dv/dy is strain rate (velocity gradient) [s−1 ].
Figure 2.1. Two rectangular parallel plates and liquid between them. The upper plate is
pulled forward with force F .
There is liquid between two parallel plates as shown in Figure 2.1. The
distance between the plates is d. The lower plate doesn’t move. The upper
plate of which the area is A is pulled with force F . This creates a velocity
v for the upper plate.
After a while, the liquid that was located between the plates has moved
(2.2).
4
Fluid Properties
Figure 2.2. The upper plate has moved forward and has dragged the upper layers of
liquid forward, too.
The liquid close to the upper plate has moved with a velocity v. The
liquid close to the lower plate has not moved: v = 0. This has created a
velocity difference in the fluid between the two plates.
F
The
upper
plate
is
pulled.
Figure 2.3. The velocity profile in the liquid between two plates at different time step.
F dv
τ= =µ (2.2)
A dy
where µ is dynamic viscosity [kg / ms], F is force [N], A is area [m2 ], and
dv/dy is velocity gradient [1/s].
Other units for dynamic viscosity µ are 1 kg / m s = 1 PI (Poiseulle) = 1
Pa s = 1 N s / m2 = 10 P (Poise) = 10 g / cm s = 1000 cP (centipoise).
5
Fluid Properties
At room temperature, typical viscosity for gases is about 0.01 mPas and
for liquids about 1 mPas.
Kinematic viscosity is defined as follows
µ
ν= (2.3)
ρ
As seen in the equation 2.3, kinematic viscosity is the dynamic viscosity
divided by the density of the fluid. The unit for kinematic viscosity is m2 /s.
Often centistokes (cSt) are used: 1 cSt = 1 · 10−6 m2 /s.
Fluids can be divided into two groups based on their flow characteristics.
Newtonian fluids are named after Isaac Newton, who first derived the
relation between the rate of shear strain rate and shear stress.
Newtonian fluids follow the equation 2.1. It means that shear stress is
linearly proportional to the strain rate (velocity gradient). In other words,
viscosity is constant despite strain rate.
All gases and most liquids are Newtonian fluids. Especially those liquids
that are ”thin” i.e. that have low viscosity are Newtonian. These include
water, benzine, thin motor oil, etc.
Non-Newtonian fluids do not follow equation 2.1 but their viscosity de-
pends on the strain rate.
Non-Newtonian fluids include many slurries, colloidical solutions, paints,
resins, lubricants, etc.
Non-Newtonian fluids are classified into three classes: Bingham plas-
6
Fluid Properties
dv/dy
Newtonian
Bingham
plastic
Pseudoplastic
Dilatant
Strain
rate τ
τ0 Shear
stress
Figure 2.4. The relation between strain rate and shear stress of pseudoplastic, Newto-
nian, dilatant, and Bingham plastic fluids.
tic fluids, pseudoplastic fluids and dilatant fluids. In addition, there are
other non-Newtonian fluids that don’t belong into these categories. their
viscosity may be a function of mixing time. It means that the viscosity is
not constant but changes if the fluid is mixed for a long time.
Pseudoplastic Fluids
The viscosity of pseudoplastic fluid decreases (the fluid becomes ”thinner”)
when the shear stress increses. The shear stress is non-linearly propor-
tional to the strain rate.
Pseudoplastic fluids include polymer solutions, tomato juice, blood, quick-
sand, etc. Most non-Newtonian fluids are pseudoplastic.
Dilatant Fluids
Dilatant fluids become more viscous under pressure. Their viscosity in-
creases with increasing strain rate.
Dilatant fluids include PVC (poly vinyl chloride) paste, sand-water sus-
7
Fluid Properties
The ideal gas law is called the equation of state of ideal gas. In prac-
tise, gases are non ideal but real. The ideal gas las is still often a good
approximation to the behaviour of many gases.
Typically, if the pressure is low and temperature is high gases behave
close to ideally. At low pressures and high pressures, the ideal gas law is
a good approximation.
If temperature is low and pressure high, gases behave non-ideally. At
these conditions, ideal gas law gives unreliable results for gas behaviour.
The ideal gas law is written
P V = nRT (2.4)
8
3. Fluid Statics
9
Fluid Statics
Advantages of Pneumatics
• Simplicity of design and control – Machines are easily designed using stan-
dard cylinders and other components, and operate via simple on-off control.
• Safety – There is a very low chance of fire compared to hydraulic oil. Newer
machines are usually overload safe.
Advantages of Hydraulics
• Liquid does not absorb any of the supplied energy.
• Capable of moving much higher loads and providing much higher forces
due to the incompressibility.
• When hydraulic fluid flow is stopped, the slightest motion of the load re-
leases the pressure on the load; there is no need to "bleed off" pressurized
air to release the pressure on the load.
A fluid cannot remain at rest under the presence of a shear stress. How-
ever, fluids can exert pressure normal to any contacting surface. This
allows fluids to transmit force.
The force applied to a fluid in a pipe is transmitted, via the fluid, to the
other end of the pipe. This principle was first formulated by Blaise Pascal,
and is now called Pascal’s law.
10
Fluid Statics
p = ρgh (3.1)
F1/ F2 = A1 / A2
F2
F1
A1 A2
Figure 3.1. In hydraulic press, the pressure is constant. Higher lifting forces are created
if the surface area A2 is larger than the input area A1 .
11
Fluid Statics
ilarly, the shape of the container does not affect the hydrostatic pressure.
If external pressure on a liquid is changed, the change is immediately
valid throughout the liquid. It is called Pascal’s Law. Pascal’s Law is
due to the incompressibility of liquid and it is utilized in hydraulics.
Atmospheric pressure is the mass of the air above the measurement point
focused on area. Atmospheric pressure is the weigh of ”an air column”
that you feel on top of your head.
The definition of pressure and force are given in equations 3.2 and 3.3.
F
p = (3.2)
A
F = mg (3.3)
where F is force [N] and A is area [m2 ]. The force F is caused by the
gravity as g is gravitational constant [9.81 m/s2 ] and m is the mass of the
air [kg].
The unit for atmospheric pressure is Pa (Pascal). Also hPa (hehtopascal)
or mbar (millibar) is used. Earlier, mmHg (millimeter of mercury) was
also used.
Normal atmospheric pressure at sea level is 101325 Pa = 1.01325 bar
that corresponds 760 mmHg. The atmospheric pressure at sea level varies
between 0.9 kPa and 1.1 kPa. The lowest values are measured in tropical
storms.
Atmospheric pressure decreases the higher the measurement point is
from sea level. A rise of 8 m corresponds approximately 1 mBar decrease
in atmospheric pressure.
12
Fluid Statics
3.2.3 Buoyancy
Any body which is immersed in a fluid will experience a net force in the
opposite direction of the local pressure gradient i.e. towards the lower
pressure. If this pressure gradient is caused by gravity, the net force is
in the vertical force upwards. This vertical force is called buoyancy (or
buoyant force) and buoyancy is equal in magnitude, but opposite in direc-
tion, to the weight of the displaced fluid.
Mathematically,
F = ρgV (3.4)
where F is the force [N], ρ is the density of the fluid, g is the gravitational
constant [9.81 m/s2 ], and V is the volume of the displaced fluid [m3 ].
Discovery of the principle of buoyancy is attributed to Archimedes of
Syracuse and it is dated 212 B.C.
– Archimedes of Syracuse
13
Fluid Statics
14
4. Fluid Dynamics
vDρ
Re = (4.1)
µ
where ρ is density [kg/m3 ], D is diameter of the pipe [m], v is (average)
velocity [m/s], and µ is dynamic viscosity [kg/ms]. If the fluid velocity is
not known but the volumetric flow V̇ [m3 /s] and cross-sectional area A
[m2 ] of the pipe is known, the fluid velocity can be calculated based on
equation 4.2
15
Fluid Dynamics
v = V̇ /A (4.2)
The critical value for the Reynolds number is about 2100–2300. Below
the value flow is laminar and above it is turbulent.
Turbulent
flow
profile
Laminar
flow
profile
Figure 4.1. Laminar and turbulent flow profiles differ from each other.
The flow profile of an incompressible liquid is not flat. Closest to the wall,
the flow rate is close to zero. The flow rate increases towards the centre
of the flow where it achieves its maximum as seen in Figure 4.1. The
laminar flow can be thought to be flow of independent fluid payers that
move parallel in the same direction. Only the velocity of the fluid levels
varies as seen in Figure 4.2a.
16
Fluid Dynamics
Laminar flow is typical at conditions where the flow rate is small, the
diameter of the tube is small, and the viscosity is high.
(a) (b)
Figure 4.2. Flow profiles. (a) Laminar. (b) Turbulent flow contains eddies.
17
Fluid Dynamics
The Mach Number (M ) is defined as the ratio of the speed of an object (or
of a flow) to the speed of sound. For instance, in air at room temperature,
the speed of sound is about 340 m/s. M can range from 0 to ∞. It is
divided into several flow regimes. These regimes are subsonic, transonic,
supersonic, hypersonic, and hypervelocity flow. Figure 4.4 illustrates the
Mach number ”spectrum” of these flow regimes.
At very slow flow speeds the speed of sound is so much faster that the
Mach number is irrelevant. Once the speed of the flow approaches the
18
Fluid Dynamics
Figure 4.4. The speed of flow in comparison to the speed of sound waves.
speed of sound, the Mach number becomes crucial. This is when shock
waves begin to appear. In the supersonic regime, the flow is dominated
by wave motion. The waves have smaller angles than 90◦ . The higher the
speed, the smaller the angle.
Above about Mach 5, these wave angles grow so small that it is called hy-
personic speed regime. Finally, at speeds comparable to that of planetary
atmospheric entry from orbit, in the range of several km/s, the speed of
sound is now comparatively so slow that it is called hypervelocity regime.
19
Fluid Dynamics
In fluid dynamics, the continuity equation states that, in any steady state
process, the rate at which mass enters a system is equal to the rate at
which mass leaves the system.
The differential form of the continuity equation is shown in equation 4.6
∂ρ
+ ∇ · (ρu) = 0 (4.6)
∂t
where ρ is fluid density [kg/m3 ], t is time [s], u is the flow velocity vector
field.
If ρ is a constant, as in the case of incompressible flow, the mass conti-
nuity equation simplifies to a volume continuity equation
∇·u=0 (4.7)
20
Fluid Dynamics
For a component x,
the amount that accumulates inside the balance area =
+ how much x comes into the balance area
- how much x goes away from the balance area
+ how much x is generated inside the balance area.
The balance is done for a specific balance area that has borders.
The process can be at steady state or at unsteady state. Steady state
means that there are no changes in time. In other words, the flows prop-
erties are the same all the time. At unsteady state there are changes in
time. For example when a tank full of water is emptied through a hole at
the bottom of the tank the flow rate of water changes. First, the flow is
very fast. But then, the flow gets slower as there is less water in the tank.
The last drops of water come out very slowly.
21
Fluid Dynamics
Solution: ṁ1 = 10.0 kg/h, ṁ2 = 16.1 kg/h, ṁ3 = 15.0 kg/h, ṁ4 = 10.5 kg/h,
ṁ5 = 0.5 kg/h, ṁ6 = 1.6 kg/h, ṁ7 = 4.5 kg/h.
22
Fluid Dynamics
1
p + ρgy + ρv 2 = constant (4.11)
2
where p is the pressure of the fluid [Pa], ρ is the density of the fluid
(constant) [kg/m3 ], g is the gravitational constant [9.81 m/s2 ], y is the
height of the tube [m], and v is the velocity of the fluid [m/s].
Often the change in height along the streamline is so small that it can be
ignored. Then, the simplified form of Bernoulli’s equation can be written
as follows:
Air plane wing is more round on the upper side than on the lower side.
When the engines push the wing forward, the air must go around the
wing. The distance on the upper side of the wing is longer so the air
moves faster. It creates smaller pressure on the air wing that lifts the
wing upwards.
In a tube where fluid flows inside, the velocity increases and pressure
decreases if the tube gets narrower.
23
Fluid Dynamics
24
5. Pressure Drop in Pipes
There is pressure drop in pipes just because of the friction between the
fluid and the pipe inner wall. The smoother the wall is, the less the pres-
sure decreases.
The roughness expresses the average height of the small bumps on the
wall. The more friction the wall creates the rougher the surface is.
roughness
Relative roughness = = (5.1)
diameter D
In the table 5.1 some roughnesses for typical pipe materials are pre-
sented.
25
Pressure Drop in Pipes
L v2
hf = fD · · (5.2)
D 2g
where hf is the head loss due to friction [m], L is the length of the pipe
[m], D is the hydraulic diameter of the pipe [m], v is the average flow
velocity, (the volumetric flow rate per unit cross-sectional wetted area)
[m/s], g is the gravitational constant [m/s2 ], and fD is a dimensionless
parameter (Darcy) friction factor, resistance coefficient. Friction factor fD
can be found from a Moody diagram (see Figure 5.1) or calculated.
26
Pressure Drop in Pipes
fD = f Re, (5.4)
D
For turbulent flow, methods for finding the friction factor fD include
using a diagram such as the Moody diagram.
The head loss hf expresses the pressure drop (pressure decrease) in me-
ters [m]. The pressure drop expressed in meters can be converted into
pressure drop in pascals by using equation 5.5, into meters by using equa-
tion 5.6, and into energy per mass by using equation 5.7.
L ρv 2
∆p = fD · · (5.8)
D 2
where the pressure drop due to friction ∆p [Pa] is a function of L/D, the
ratio of the length to diameter of the pipe [m/m]; ρ the density of the fluid
[kg/m3 ]; v, the mean flow velocity [m/s]; and fD friction factor [no unit].
27
Pressure Drop in Pipes
Figure 5.1. Moody diagram showing the Darcy-Weisbach friction factor fD plotted
against Reynolds Number Re for various relative roughness / D.
28
Pressure Drop in Pipes
fluid is
a) water at 20◦ C.
b) water at 50◦ C.
c) oil at 20◦ C and ρ = 940 kg/m3 and µ = 0.54 Pa s.
Solution: a) ∆p = 43 kPa, b) ∆p = 40 kPa, c) ∆p = 144 kPa.
When the flow meets a change in the flow direction or in the cross-sectional
area of the pipe, there is locally extra pressure drop caused by local resis-
tance factor ζ. Pressure drop is calculated by the equation 5.10
v2
∆p = ζρ (5.10)
2
The value of the ζ depends on the type and quality of the local resis-
tance. Local resistance is caused by valves, turns, T-joints, divergence,
convergence, pipe fittings, measurement equipment, and inputs or out-
puts to vessels.
T–joint
The pressure drop for a t-joint depends on the flow direction. Below are
listed ranges for ζ for T–joint flows.
flow through ζ = 1.0 – 1.15
divide flow ζ = 1.5 – 1.9
combine flow ζ = 4.3 –5.3
29
Pressure Drop in Pipes
Pressure drop in turns increases if the turn gets sharper. In Table 5.2,
estimates of the friction losses in round turns of 90◦ and in sharp turns
are listed.
In round turns, the R is the radius from the centre of the turn to the
centre line of the flow and d is the diameter of the pipe as shown in Figure
5.2.
Roundness ζi Angle ζi
R=d 0.51 15◦ 0.1
R = 1.5d 0.40 30◦ 0.2
R = 2d 0.30 45◦ 0.35
R = 4d 0.23 60◦ 0.7
R = 6d 0.18 90◦ 1.3
There is pressure drop when the fluid leaves the vessel and when the fluid
enters the vessel. The pressure drop increases if the tube end is partly
inside the vessel.
Simple outlet (pipe entrance sharp corner) ζ = 0.5
Outlet (pipe entrance, tube partly inside) → ζ = 1.0
Simple feed (pipe exit) ζ = 1.0
The flow resistance decreases, if the pipe widens inside the vessel.
30
Pressure Drop in Pipes
There is pressure drop in valves. Below are listed some typical friction
losses for different valve types.
Butterfly valve ζ = 0.8
Knife gate valve ζ = 0.2
Needle valve ζ = 30–300
Check valve ζ = 2–4
Diaphragm valve ζ = 2.3
Ball valve ζ = 0.8
a
hb
ha
Wp
31
Pressure Drop in Pipes
Ea = Eb (5.11)
where Ea is the total energy entering the balance area and Eb is the
total energy exiting the balance area. The change in total energy depends
typically on the following changes:
1. Static pressure p
2. Potential energy Epot = ρgh
3. Kinetic energy Ekin = 21 αρv 2
4. Friction and flow resistances hf
5. Heat q
6. Work W
1 ∆L X 2
hf = ξ + ζi v (5.14)
2 D
The values for ξ and ζ can be taken from tables.
Often it is reasonable to calculate the work of pump W .
The kinetic energy correction factor α takes into account the viscous
effects of the flow. It has two values: one for turbulent flow and one for
laminar flow:
32
Pressure Drop in Pipes
33
Pressure Drop in Pipes
1
ρηp Wp = pb − pa + ρg hb − ha + ρ αb vb2 − αa va2 + ρhf
2
Energy/Mass [J/kg] : (5.18)
pb − pa 1
η p Wp = + g hb − ha + αb vb2 − αa va2 + hf
ρ 2
Height [m] : (5.19)
ηp W p pb − pa 1 h
f
= + hb − ha + αb vb2 − αa va2 +
g g 2·g g
where !
L X v2
hf = ξ + ζi (5.20)
D 2
Pressure Difference
Pressure difference is the difference of the static pressures on the liquid
surfaces at a and b.
∆p = pb − pa (5.21)
Height Difference
The height difference is the difference of the liquid surfaces a and b.
∆h = hb − ha (5.22)
1. If both balance area borders are next to the same pipe line and the diam-
eter of the pipe doesn’t change the velocity doesn’t change:
∆v = 0 → ∆pkin = 0.
34
Pressure Drop in Pipes
2. If both balance area ends are far from the pipe exit/entrance, the velocity
doesn’t change:
∆v = 0.
However, the local resistances for the pipe exit and entrance into the con-
tainer/tank need to be taken into account in head losses hf .
3. If one end of the balance area is at the pipe and the other far from the pipe
exit/entrance, there is a velocity difference:
∆pkin 6= 0.
35
Pressure Drop in Pipes
36
6. Pumps
A pump is a device that moves fluids by mechanical action. There are six
methods how to transfer the fluid:
• Centrifugal force
• Displacement
• Mechanical impuls
• Electromagnetic field
• Gravity
There are some criteria set for the fluid transfer. Some of them are triv-
ial such as the pump must not accumulate fluid (it must not leak) or the
consistency of the fluid must maintain the same. Often, the temperature
of the fluid should also be kept constant by using insulation. Also the
discharge pressure may be set.
Often pumps are classified based on their function or type into three cat-
egories: centrifugal pumps, displacement pumps and other pumps. Cen-
trifugal pumps include e.g. radial and axial flow pumps. Displacement
pumps are further classified into three categories based on the type of
moving the fluid. Back and forth movement is the basis of piston pumps
and diaphragm pumps. Rotating movement is the basis of screw pumps.
Other displacement pumps include e.g. impulsing displacement pumps.
Other pumps include e.g. impulse pumps.
37
Pumps
The main components in a pump are the casing, impeller, backing plate,
shaft and shaft seal, and the motor adapter. Some pumps have the back-
ing plate as part of the casing in which case you would have a removable
cover.
probrewer.com
In centrifugal pumps, the fluid flows from the suction head to the im-
peller. The fluid goes through the impeller blades to the discharge head.
The pump motor transfers the input energy into kinetic energy. the ef-
ficiency η tells how much of the input energy is transferred into kinetic
energy. Always some energy is lost (as heat).
38
Pumps
learneasy.info
Figure 6.2. Pump curves that show the performance of specific pumps.
39
Pumps
when
a) total head (∆h) is 30 m and φ = 291 mm?
b) total head (∆h) is 30 m and φ = 342 mm?
6. What impeller size should you select for a pumping task where the
total head ∆h is 35 m? What is the volumetric flow rate then?
Solution: 1.a) 35 m (115 ft), b) 20.5 m (62 ft) 2.a) 21.5 m, 73%, b) 23.5 m,
77 % 3.a) 3.5 m, b) φ=274 mm → 8.5 m, φ=342 mm → 4.5 m 4.a) 22 kW,
b) 32 kW 5.a) 26 kW, 73%, 64 l/s, b) 48 kW, 76%, 127 l/s 6. Option 1:
φ=325 mm and V̇ =68 l/s, Option 2: φ=342 mm and V̇ =100 l/s.
Operating point
System curve
Figure 6.3. The operation point is where the selected pump performance curve and the
piping performance curve cross each other.
V̇ V̇ 4 · V̇
v = = πd2 = (6.1)
A πd2
4
40
Pumps
h m3 /s i
For the units : [m/s] = = [m/s] (6.2)
m2
The operation point is at the point where the two curves cross each other
(see Figure 6.3). The volumetric flow at the operation point can then be
read from the figure.
For a centrifugal pump, it is mandatory that the static pressure (ps )in the
liquid at the suction head is larger than the vapour pressure (pv ) of the
liquid.
ps > pv (6.3)
The liquid begins to boil if its vapour pressure is equal to the static pres-
sure. When the boiling begins, vapour bubbles are formed in the liquid.
However, in the pump, the pressure rapidly increases. It means that the
vapour bubbles turn back to liquid and take much less space. This creates
pressure shocks inside the pump that makes terrible noise and causes ero-
sion. This is called cavitation. Cavitation also takes down the efficiency
of the pump. Therefore, vapour bubbles must not be formed in the suction
head so as to avoid cavitation.
In order to avoid cavitation, one must design the piping pressures so that
there is enough pressure in the liquid when it goes to the pump. The
pressure is called Net Positive Suction Head.
The NPSH can be expressed in pressure [Pa], energy/mass [J/kg], or
height [m]
N P SH = ps − pv (6.4)
ps − pv
N P SH = (6.5)
ρ
ps − pv
N P SH = (6.6)
ρg
41
Pumps
NPSHA (Net Positive Suction Head Available) is the actual pressure at the
suction of the pump. The process designer must calculate this pressure.
NPSHA describes the pressure difference ps -pv in the piping that is
available for the proper pump function. The NPSHA is temperature de-
pendent: the smaller the pressure difference available for the pumping,
the higher the temperature of the liquid.
The pressure requirements for the pump can be written
Preferably, there is also some extra pressure (a) to guarantee that the
pressure definitely is over the vapour pressure
Sometimes there is need to pump liquid at its boiling point. This happens
for example in distillation columns, where the pumps at the bottom lift
the liquid upwards. Then, the liquid level in the vessel must be higher
than the pump so that the hydrostatic pressure creates enough pressure
in the liquid.
Example on NPSH
300 m3 /h of water is pumped through a steel pipe (Din = 200mm) from an
open tank where the water level is 0.5 m. The suction line consist of a 1
m long vertical pipe and 15 m long horizontal pipe, one check valve (ζ =
2.5) and one round 90◦ turn (R=D). The pump described in Figure 6.2 (φ
= 274 mm) is used for the task.
a) What is the NPSHR of the pump?
b) If water is at 10 ◦ C what is the NPSHA? Is it enough?
c) If water is at 80 ◦ C what is the NPSHA? Is it enough?
d) In case c), how high water level in the tank would make NPSHA > NPSHR?
42
Pumps
Centrifugal pumps are often the best choice for low viscosity (thin) liquids
and high flow rates. The pump uses one or more impellers that attach to
and rotates with the shaft. The rotation of the impeller creates energy
that moves liquid through the pump and pressurizes the liquid to move it
through the piping system.
The benefits of a centrifugal pump are simplicity, low price, constant
flow rate, small space requirement, low maintenance costs, and quiet op-
eration.
Diaphragm pumps use a flexing diaphragm to move fluid into and out of
the pumping chamber. They are a type of reciprocating positive displace-
ment pump.
Piston pumps move and pressurize fluid using one or more reciprocat-
ing pistons, which are normally driven by an electric motor through a
crankshaft and connecting rod.
43
Pumps
44
7. Valves
Valves are found everywhere. There are many valves especially in indus-
trial processes e.g. in gas and petroleum industry. The typical size of a
valve varies from tiny (less than a millimeter) to large (half a meter).
The word ”valve” is derived from the Latin word valva which means the
moving part of a door. The verb volvere means to turn or to roll.
Valves can be classified by how they are actuated. Valves can be hy-
draulic, pneumatic, manually operated, eletromechanically operated through
a solenoid valve, or operated through a motor.
Valves consist of components. The main parts of the most usual type of
valve are the body and the bonnet. These two parts form the casing that
holds the fluid going through the valve.
Body
The valve’s body is the outer casing of the valve that contains the internal
parts. The bonnet is the part of the encasing through which the stem
passes and that forms a guide and seal for the stem. The bonnet typically
screws into to the valve body.
45
Valves
Figure 7.1. Cross-sectional diagram of an open globe valve: 1. body; 2. ports; 3. seat;
4. stem; 5. disc when valve is open; 6. handle or handwheel when valve is
open; 7. bonnet; 8. packing; 9. gland nut; 10. fluid flow when valve is open;
11. position of disc if valve were shut; 12. position of handle or if valve were
shut.
Bonnet
A bonnet acts as a cover on the valve body. Many valves do not have
bonnets; for example, plug valves usually do not have bonnets. Many
ball valves do not have bonnets since the valve body is put together in a
different style, such as being screwed together at the middle of the valve
body.
Ports
Ports are passages that allow fluid to pass through the valve. Ports are
obstructed by the valve member or disc to control flow. Valves most com-
monly have 2 ports.
Handle or Actuator
A handle is used to manually control a valve from outside the valve body.
Automatically controlled valves often do not have handles but they have
an actuator. An actuator is a mechanism or device to automatically or
remotely control a valve from outside the body.
Some valves have neither handle nor actuator because they automati-
cally control themselves from inside; for example, check valves and relief
valves may have neither.
Some automatically controlled valves may have a handle in addition to
46
Valves
Disc
A disc or valve member is a movable obstruction inside the stationary
body that adjustably restricts flow through the valve.
Seat
The seat is the interior surface of the body which contacts the disc to form
a leak-tight seal. The seat always remains stationary relative to the body
when the disc moves.
Stem
The stem transmits motion from the handle or controlling device to the
disc. The stem typically passes through the bonnet when present.
Gasket
Gaskets are the mechanical seals, or packings, used to prevent the leak-
age of a gas or fluids from valves.
Spring
Many valves have a spring for spring-loading, to normally shift the disc
into some position by default but allow control to reposition the disc. Re-
lief valves commonly use a spring to keep the valve shut, but allow exces-
sive pressure to force the valve open against the spring-loading.
Trim
The internal elements of a valve are collectively referred to as a valve’s
trim.
Valves can be categorised based on their function or the valve disc. The
valve disc may have various shapes as seen below.
Ball valves are used for on/off control without pressure drop. It is ideal
for quick shut-off, since a 90 degrees turn offers complete shut-off angle
in comparison to multiple turns required on most manual valves.
47
Valves
Butterfly valves are used for flow regulation in large pipe diameters.
polyprocessing.com
avtexas.com
(a) (b)
Check valves are also called non-return valves. It allows the fluid flow in
one direction only. This is called a check valve, as it prevents or "checks"
the flow in one direction.
Choke valve is a valve that raises or lowers a solid cylinder which is placed
around or inside another cylinder which has holes or slots. Used for high
pressure drops found in oil and gas wellheads.
Control valves are valves used to control conditions such as flow, pressure,
temperature, and liquid level. They open or close fully (or partially) in
response to signals received from controllers.
The opening or closing of control valves is usually done automatically by
electrical, hydraulic or pneumatic actuators. Positioners are used to con-
trol the opening or closing of the actuator based on electric, or pneumatic
signals.
48
Valves
globalspec.com
weiku.com
(a) (b)
Gate valve is mainly for on/off control. Usually it has low pressure drop.
en.wikipedia.org
(a) (b)
Figure 7.4. (a) Gate (or Disc) Valve. (b) Globe Valve.
49
Valves
Knife gate valve is similar to a gate valve, but usually more compact.
Often knife valves are used for slurries or powders for on/off control.
Needle valve has a long needle that moves slowly when the valve is opened
or closed. It requires many turnings to get closed. Needle valve is good
for accurate flow control.
www.dictionaryofconstruction.com
fnwvalve.com
(a) (b)
A safety valve is a valve which has the function of increasing the safety
of a plant. An example of safety valve could be a pressure safety valve
(PSV). They are also called a pressure relief valves (PRV). It automatically
releases the fluid from a pressurised vessel or pipeline if the pressure or
temperature exceeds preset limits.
50
A. Appendix A: Physical Constants and
SI Unit System Tables
i
Appendix A: Physical Constants and SI Unit System Tables
ii
Appendix A: Physical Constants and SI Unit System Tables
iii
Appendix A: Physical Constants and SI Unit System Tables
iv
B. Appendix B: Properties of Water
Ta Tb pc ρd µe λf cp g
◦C K MPa kg/m3 10−3 Pas W/(m·K) kJ/(kg·K)
0 273.15 0.000611 999.9 1.792 0.569 4.21
10 283.15 0.00123 999.7 1.308 0.587 4.19
20 293.15 0.00234 998.3 1.005 0.603 4.18
30 303.15 0.00425 995.7 0.801 0.618 4.18
40 313.15 0.00739 992.3 0.656 0.632 4.18
50 323.15 0.0124 988 .0 0.543 0.643 4.18
60 333.15 0.0200 983.2 0.468 0.654 4.19
70 343.15 0.0312 977.7 0.406 0.662 4.19
80 353.15 0.0474 971.6 0.357 0.670 4.20
90 363.15 0.0702 965.2 0.316 0.676 4.21
100 373.15 0.101325 958.4 0.284 0.681 4.22
a T = Temperature in Celsius, ◦ C
b T = Absolute temperature in Kelvin, K
c p = Saturated vapour pressure, MPa
d ρ = Density of water, kg/m3
e µ = Dynamic viscosity of water, 10−3 Pas
f λ = Thermal conductivity of water, W/(m·K)
g cp = Specific heat of water, kJ/(kg·K)
Reference: Kari I. Keskinen, Tables and Drawings for Chemical
Engineering, Otatieto Oy, Helsinki, 2000.
v
Appendix B: Properties of Water
Ta Tb ρ µ λ cp
◦C K kg/m3 10−3 Pas W/(m·K) kJ/(kg·K)
0 273.15 999.868 1.7921 0.5535 4.2169
5 278.15 999.992 1.5188 0.5655 4.2014
10 283.15 999.728 1.3077 0.5767 4.1914
15 288.15 999.127 1.1403 0.5873 4.1850
20 293.15 998.234 1.0049 0.5971 4.1811
25 298.15 997.077 0.8935 0.6063 4.1788
30 303.15 995.678 0.8007 0.6049 4.1777
35 308.15 994.061 0.7225 0.6229 4.1774
40 313.15 992.250 0.6560 0.6303 4.1778
45 318.15 990.251 0.5988 0.6371 4.1787
50 403.15 988.068 0.5494 0.6433 4.1800
55 408.15 985.729 0.5064 0.6490 4.1816
65 413.15 980.592 0.4355 0.6590 4.1860
70 423.15 977.813 0.4060 0.6633 4.1888
75 428.15 974.888 0.3799 0.6672 4.1920
80 453.15 971.829 0.3565 0.6706 4.1956
85 458.15 968.647 0.3354 0.6737 4.1997
90 463.15 965.343 0.3165 0.6764 4.2043
95 468.15 961.916 0.2994 0.6787 4.2095
100 373.15 958.381 0.2838 0.6808 4.2152
a T = Temperature in Celsius, ◦ C
b T = Absolute temperature in Kelvin, K
c ρ = Density of water, kg/m3
d µ = Dynamic viscosity of water, 10−3 Pas
e λ = Thermal conductivity of water, W/(m·K)
f cp = Specific heat of water, kJ/(kg·K)
Reference: Kari I. Keskinen, Tables and Drawings for
Chemical Engineering, Otatieto Oy, Helsinki, 2000.
vi