T04: Internal Flow

2D steady, viscous laminar flow between 2

parallel plates
y=h
• No local nor convective acceleration
• No hydrostatic effects
𝜕𝜕𝜕 𝜕𝜕2 u y=0
• − +μ =0
𝜕𝜕𝜕 𝜕𝜕𝜕2
𝜕𝜕𝜕 𝜕𝜕𝜕 𝜕𝜕𝜕
• + + = 0 → u = u(y) y=-h
𝜕𝜕𝜕 𝜕𝜕𝜕 𝜕𝜕𝜕
d2 u 1 dp du 1 dp 1 dp
• = · → = · · y + C1 → u = · · y 2 + C1 · y + C2
dy2 μ dx dy μ dx 2·μ dx
1 dp
• u = 0 if y = ±h → C1 = 0; C2 = − · · h2
2·μ dx
1 dp
• u(y) = · · (y 2 − h2 )
2·μ dx
h 2 h3 dp 2·h3 ·∆p
• q= ∫−h u · dy = − · · =
3 μ dx 3·μ·L
q h2 ·∆p 3
• u� = = ; uMAX = · u�
2·h 3·μ·L 2
2
 Pipe flow

• Navier-Stokes equations for Cylindrical Coordinates

𝜕𝜕𝜕 1 𝜕𝜕 𝜕𝜕𝑢𝑢𝑟𝑟 𝜕𝜕2 𝑢𝑢𝑟𝑟
𝑢𝑢𝑟𝑟 1
2 𝜕𝜕𝑢𝑢𝜃𝜃 𝜕𝜕2 𝑢𝑢𝑟𝑟
• ρ · g 𝑟𝑟 − +μ· ·· 𝑟𝑟 · − + · 2 − 2· + 2
𝜕𝜕𝑟𝑟 𝑟𝑟 𝜕𝜕𝜕𝜕 𝜕𝜕𝑟𝑟 𝑟𝑟 2
𝜕𝜕𝜃𝜃 𝑟𝑟 2
𝑟𝑟 𝜕𝜕𝜃𝜃 𝜕𝜕𝜕
2
𝜕𝜕𝑢𝑢𝑟𝑟 𝜕𝜕𝑢𝑢𝑟𝑟 𝑢𝑢𝜃𝜃 𝜕𝜕𝑢𝑢𝑟𝑟 𝑢𝑢𝜃𝜃 𝜕𝜕𝑢𝑢𝑟𝑟
= ρ·( + 𝑢𝑢𝑟𝑟 · + · − + 𝑢𝑢𝑧𝑧 · )
𝜕𝜕𝜕 𝜕𝜕𝑟𝑟 𝑟𝑟 𝜕𝜕𝜃𝜃 𝑟𝑟 𝜕𝜕𝜕
1 𝜕𝜕𝜕 1 𝜕𝜕 𝜕𝜕𝑢𝑢 𝑢𝑢 1 𝜕𝜕2 𝑢𝑢 2 𝜕𝜕𝑢𝑢𝑟𝑟 𝜕𝜕2 𝑢𝑢𝜃𝜃
• ρ · g 𝜃𝜃 − ·
+μ· · · 𝑟𝑟 · 𝜃𝜃 − 𝜃𝜃2 + 2 · 2𝜃𝜃 + · + 2
𝑟𝑟 𝜕𝜕𝜃𝜃 𝑟𝑟 𝜕𝜕𝜕𝜕 𝜕𝜕𝑟𝑟 𝑟𝑟 𝑟𝑟 𝜕𝜕𝜃𝜃 𝑟𝑟 2 𝜕𝜕𝜃𝜃 𝜕𝜕𝜕
𝜕𝜕𝑢𝑢𝜃𝜃 𝜕𝜕𝑢𝑢𝜃𝜃 𝑢𝑢𝜃𝜃 𝜕𝜕𝑢𝑢𝜃𝜃 𝑢𝑢𝜃𝜃 · 𝑢𝑢𝑟𝑟 𝜕𝜕𝑢𝑢𝜃𝜃
= ρ·( + 𝑢𝑢𝑟𝑟 · + · − · +𝑢𝑢𝑧𝑧 · )
𝜕𝜕𝜕 𝜕𝜕𝑟𝑟 𝑟𝑟 𝜕𝜕𝜃𝜃 𝑟𝑟 𝜕𝜕𝜕
𝜕𝜕𝜕 1 𝜕𝜕 𝜕𝜕𝑢𝑢𝑧𝑧 1 𝜕𝜕2 𝑢𝑢𝑧𝑧 𝜕𝜕2 𝑢𝑢𝑧𝑧
• ρ · gz − +μ· · · 𝑟𝑟 · + 2· 2 + 2
𝜕𝜕𝜕 𝑟𝑟 𝜕𝜕𝜕𝜕 𝜕𝜕𝑟𝑟 𝑟𝑟 𝜕𝜕𝜃𝜃 𝜕𝜕𝜕
𝜕𝜕𝑢𝑢𝑧𝑧 𝜕𝜕𝑢𝑢𝑧𝑧 𝑢𝑢𝜃𝜃 𝜕𝜕𝑢𝑢𝑧𝑧 𝜕𝜕𝑢𝑢𝑧𝑧
= ρ·( + 𝑢𝑢𝑟𝑟 · + · + 𝑢𝑢𝑧𝑧 · )
𝜕𝜕𝜕 𝜕𝜕𝑟𝑟 𝑟𝑟 𝜕𝜕𝜃𝜃 𝜕𝜕𝜕

3
 Pipe flow

• Velocity is a function of the radius

1 𝜕𝜕𝜕
• vz (r) = · · (r 2 − R2 )
4·μ 𝜕𝜕𝜕
2π R π·R4 𝜕𝜕𝜕
• q= ∫0 ∫0 vz · r · dr · dθ = − 8μ ·
𝜕𝜕𝜕

• Hägen-Poiseuille law
π·R4 ·∆p
• q=
8·μ·L
q R2 ·∆p
• v�z = =
π·R2 8·μ·L
R2 ·∆p
• vzMAX =
4·μ·L
• vzMAX = 2 · v�z

4
 Shear stress in a pipe
• Laminar flow (Re<2300)
r
• Parabolic flow: vz r = vzMAX · (1 − ( )2 )
R
• Shear stress:
dvz
τ =µ· dr
dvz −2·vzMAX ·r −4·vz ·r
= − = −
dr R2 R2
8·μ·v
τ|r=R = τw = − d z
dvz −4·v ·r R2 ·∆p
= − 2z ;v�z =
dr R 8·μ·L
R2 ·∆p r
τ r = −μ · 4 · ·
8·μ·L R2
∆p·d
τ|r=R = τw = −
4·L 5
 Shear stress in a pipe
• Laminar flow (Re<2300)
∆p·d 8·μ·vz
τw = − =−
4·L d
v
∆p = 32 · μ · L · dz2
π·d4 ∆p
q= ·
128·μ L
v�z = v
∆p 32·μ·L·v ∆p 64 L 64
1⁄ ·ρ·v2 = 1⁄ 2 2 → 1⁄ ·ρ·v2 = · →f=
2 2·ρ·v ·d 2 Re d Re
L ρ·v2
∆p = f · · 2
d
L v2
hfp = f · · Primary head loss (in m)
d 2·g
6
 Shear stress in a pipe
• Turbulent flow (Re>4000)
r 1
• Non-parabolic flow: vz r = vzMAX · (1 − ( )n ) n=6-10
R
d�
u
• Shear stress: τ = μ · − ρ · u′ · v′
dy
• Colebrook-White (1939)
1 ϵ⁄ 2,51
• = −2 · log d
+
f 3.7 Re· f
0,25
• f0 = ϵ� 2
d 5,74
log[ + ]
3.7 Re0,9

7
 Shear stress in a pipe
• Turbulent flow (Re>4000)
• Haaland (1983)
ϵ⁄ 1,11
1 d 6,9
• = −1,8 · log +
f 3.7 Re

1,11 −2
ϵ⁄ 6,9
d
• f = −1,8 · log[ + ]
3.7 Re

8
Moody’s diagram

9
 Typical values in industry

• Velocities
– Liquids: 1-3 m/s
– Liquid-liquid separators: 0.1-0.5 m/s
– Gases: 10-30 m/s
• Head loss
Flow (m3/h) ΔP (kPa/m pipe)
0-20 0.2-1.2
20-100 0.2-0.8
>100 <0.4

10
Optimal pipe diameter

Economic balance
Total Energy Equipment

Optimal
Cost

Pipe diameter

11
 Optimal pipe diameter

• Optimal pipe diameter estimation

• d = c · ρ0.15 · Q0.5
– d is the diameter, in mm
– ρ is the density, in kg·m-3
– Q is the volumetric flow, in m3·h-1
– c depends on the impulsion method

Method c (dimensional)
Centrifugal pump 5.0
Compressor 3.7
Vapor generator 2.3

12
 Minor losses

• Due to pipe accessories

v2
– hfs = K · 2·g
Secondary head loss (in m)

• Equivalent length
K
– Le = · d
f
Le v2
– hfs = f · ·
d 2·g

• Minor losses are additive

v2
– hfs = ∑ K · 2·g
∑ Le v2
– hfs = f · d
· 2·g
13
 Bends and curves
Flow Flow
• Threaded elbows
• 45º : K = 16·f
• 90º : K = 30·f
• Welded bends Flow
– Curved
• 180º : K = 50·f
r d
• 90º : K = fn (r/d)
r/d 1.0 2.0 4.0 6.0 8.0 10 12 14 16 20

– Angled K 20·f 12·f 14·f 17·f 24·f 30·f 34·f 38·f 42·f 50·f

• K = fn (α)
Flow α
α 0º 15º 30º 45º 60º 75º 90º
K 2·f 4·f 8·f 15·f 25·f 40·f 60·f
14
 T fittings

• T fittings
– Direct flow : K = 20·f Flow
– 90º flow: K = 60·f

Flow

15
 Change of diameter Flow
d1 d2

• Expansions
– Abrupt: K1 = 1 − β2 2 Flow
– Smooth: K1 = Ce · 1 − β2 2 d1 d2
• If α < 45°; Ce = 2,6 · sin α⁄2 α
• If 45° < α < 180º ; Ce = 1
• Contractions Flow
2
– Abrupt: K1 = 0,5 · 1 − β d2 d1
– Smooth: K1 = 0,5 · Cc · 1 − β2
• If α < 45°; Cc = 1,6 · sin α⁄2
• If 45° < α < 180° ; Cc = sin α⁄2
d1
Flow d2 d1
• β= α
d2
K1
• K2 =
β4
 Valves
• Control Valves
– Gate: K = 8·f
– Plug: K = 18·f
– Globe
• Straight: K = 340·f
• 90º: K = 150·f
• 45º: K = 55·f
– Ball: K = 3·f
– Butterfly: K = 45·f
• Stop Valves
– Swing check
• Inclined: K = 100·f
• Perpendicular: K = 50·f
– Shutter
• Rising: K = 600·f
• Inclined: K = 55·f
– Footvalve: K = 420·f 17
Centrifugal Pump

18
Pump Unit

19
Centrifugal Pump

20
Velocity triangles (inlet)

21
Velocity triangles (outlet)

22
 Velocity triangles (combined)

• General case • Centrifugal Pump 23

 General case

• W=V−U
• Euler’s equation
• T = ṁ · (r2 · V2t − r1 · V1t )
• T = Q · ρ · (r2 · V2t − r1 · V1t )
• Pot = ω · Q · ρ · (r2 · V2t − r1 · V1t )
• u=ω·r=π·n·d
• Pot = Q · ρ · u2 · V2t − u1 · V1t
• Pot = Q · ρ · g · Wp
u2 ·V2t −u1 ·V1t
• Wp =
g

24
 Centrifugal pumps
u2 ·V2t −u1 ·V1t
• Wp =
g
u2 ·V2t
• V1t = 0 → Wp =
g
V2r
• tan β2 =
u2 −V2t
V2r
• V2t = U2 −
tan(β2 )

• V2r = Q�A2
• A 2 = 2 · π · r2 · b
u22 u2 ·Q
• Wp = −
g 2·g·π·r2 ·b·tan(β2 )
25
 Wp vs Q – Blade Design
u22 u2 ·Q
• Wp =
g
−
2·g·π·r2 ·b·tan(β2 )
in centrifugal pumps

Wp Wp Wp

26
Q Q Q
 Energy consumption

• PIDEAL = Q · ρ · g · Wp

27
 Energy losses
Wp

• Flow friction
– Proportional to v2
• Recirculation
– When Q is below design
• Incidence
– Due to difference between blade angle and fluid angle

Wp Wp

28
Impeller choice

29
 Energy consumption

• Electric work does not convert totally into pressure

– First law of thermodynamics
– Losses due to friction, recirculation and incidence
• Efficiency (η) takes losses into account
PIDEAL
– PREAL =
η
• 0<η<1
• Typically between 0.5 and 0.8
– ECONS = PREAL · t WORK
• Typically in kWh

30
Cavitation

31
32
Cavitation

33
 NPSHa and cavitation

• Net Positive Suction Head

p1 −psat u21 −u22
• NPSHa m = +α + z1 − z2 − hf
ρ·g 2·g
• If NPSHa < NPSHr → CAVITATION!

– https://www.youtube.com/watch?v=oRYYP4F8LTU

34
 Choosing the pump

• Wp required?
• Q required?
• NPSH required?
• Power + Impeller

35
Characteristic curve example

36
 Other considerations

• Friction factor
– Darcy-Weisbach
– Fanning
fD
• fF =
4
L v2 L v2
• hfp = fD · · = fF · · 2·
D 2·g D g

• Water hammer
– Sudden pressure change
– Dangerous to piping and equipment
37
 Multiple-pipe systems

• Increasing complexity
• In series
• In parallel
• Networks
• Mass and energy are still
conserved!!

38
 Pipes in series

• (Nothing new)
• Mass and volumetric flow are conserved
• Q = Q1 = Q 2 = Q 3
• Pressure losses are additive
• hf = hf1 + hf2 + hf3

39
 Pipes in parallel

• Energy is conserved!
• Δp between A and B is the same independently of the path
PA α·u2A PB α·u2B
• + + zA − hf1 = + + zB
ρ·g 2·g ρ·g 2·g
PA α·u2A PB α·u2B
• + + zA − hf2 = + + zB
ρ·g 2·g ρ·g 2·g
PA α·u2A PB α·u2B
• + + zA − hf3 = + + zB
ρ·g 2·g ρ·g 2·g
• hf1 = hf2 = hf3
• Mass is conserved!
• Q = Q1 + Q 2 + Q 3
• L, Le, d, v, Re, ε/d, f may change for each pipe!!

40
 Pipe networks

• Mass is conserved!
• Q1 + Q 2 + Q 3 = 0
• Flow could be negative!!
• Energy is conserved!
• The pressure (PJ) at the junction is unknown
• The velocity term at the junction is negligible
P1 α·u21 PJ α·u2J PJ
• + + z1 − hf1 = + + zJ = + zJ
ρ·g 2·g ρ·g 2·g ρ·g

P2 α·u22 PJ α·u2J PJ
• + + z2 − hf2 = + + zJ = + zJ
ρ·g 2·g ρ·g 2·g ρ·g

P3 α·u23 PJ α·u2J PJ
• + + z3 − hf3 = + + zJ = + zJ
ρ·g 2·g ρ·g 2·g ρ·g

• Iterate PJ until Q1 + Q 2 + Q 3 = 0
41
 Pipe networks

• Increasing complexity
• Needs simulation software
• Basic rules
• The net flow into any junction is zero.
• The net pressure change around any closed loop must be
zero. In other words, apply Bernoulli between junctions.
• Have fun.

42
 Open-Channel Flow
Figure Section Area (A) Wet perimeter (Pw)

b
Rectangle y b·y b+2·y

2·y
Triangle y y 2 · cot(α)
α sin(α)

2·y
Trapezoid y b y(b + y · cot α ) b+
α sin(α)

R R2
Circle · (α − sin α ) R·α
2
α
43
 Open-channel flow

• Hydraulic radius and diameter

• R h = A�Pw
• dh = 4 · R h !!
• Velocity estimation
8·g·Rh ·S
• v= Chézy formula
f
2
Rh �3 · S
• v= Manning formula
n
– f is the friction factor, calculated using dh
– S is the slope of the channel, in m/m
– n is the Manning coefficient, in s·m-1/3

44
 Open-channel flow

• Manning’s coefficient n

Conduct Material n (s·m-1/3)

Iron 0.012
Pipe Clay 0.011
Glass 0.010
Brick 0.016
Channel Corrugated metal 0.023
Stony, cobbles 0.035
Clean, straight 0.030
Natural channel Sluggish 0.040
Light brush 0.050

45
 Open-channel flow

• Optimal cross-sectional area

n·Q 3/5
• A=( ) · Pw 2/5
S
– A is the cross-sectional are, in m2
– Q is the volumetric flow, in m3·s-1
– S is the slope of the channel, in m/m
– n is the Manning coefficient, in s·m-1/3
– Pw is the wet perimeter, in m

46
 Agitation

• Applications
– Mixing miscible liquids
– Dissolving solids
– Dispersing gases
– Increasing heat transfer
• Tanks curved at the bottom
• Types of movement
– Axial
– Radial
47
 Axial agitation
• Type of agitator
– Helices
• High speed
• Low viscosity
• For big tanks

48
 Radial agitation
• Type of agitator
– Blade / anchor
– Turbine
• Low speed
• Range of viscosities
• For big tanks
• Vorticity!

49
 Vorticity
• Deflectors
• Multiple agitators
• …

Viscosity Number of
(kg·m-1·s-1) deflectors
0-0.5 4

0.5-10 2

10-20 1

>20 0

50
 Typical design (turbine)
Da
• S1 = = 1/3
Dt
E
• S2 = =1
Da
L
• S3 = = 0.25
Da
W
• S4 = = 0.2
Da
J
• S5 = = 1/12
Dt
H
• S6 = =1
Dt
51
 Power consumption

n·Da2 ·ρ
• Re =
μ
P
• Φ=
n3 ·Da5 ·ρ

Re 52
 T04: Internal Flow

Vía Augusta, 390 · 08017 Barcelona

T. (34) 932 672 020
www.iqs.edu