PIPE SIZING AND PRESSURE DROP

CALCULATIONS

Compressible fluid

Incompressible fluid

Steam Service

Equivalent Length

NETWORK SOLUTION BY HARDY CROSS

METHOD

A. Compressible fluid
Density changes with change in pressure
Line sizing
Q = AV

d 1.157

QT
VP

Where, d = Calculated ID in mm.

Q = Flow in Nm3/hr.,
T = Fluid temperature in K
P = Fluid pressure in Kg/cm2a ( Kg/cm2g + 1.0332)
V = Velocity in m/s

Recommended velocities for compressible fluids

SL.Nu.
1
2
3
4
5
6
7

Service
Compressed air
Nitrogen
Argon
Oxygen
Acetylene
LPG(Gas)
BF,Coke Oven,Mixed Gas

Velocity
10
10
10
8
6
8
12

Conversion of m3/hr. to Nm3/hr.

RH

P1V1
100

V
T1
273 t 2 ) 2
P2 Pv

Vapour Pressure Table

Where,
V1
P1
T1
V2

= Nm3/hr
= Atmospheric pressure = 1.0332 Kg/cm2a
= 0 C = 273 K
= m3/hr.
P2 = System pr. Kg/cm2g +1.0332
t2 = Fluid temperature in C
RH = Relative humidity
Pv = Vapor pressure at temperature t2 C

Tempr.

Pr.

Tempr.

Pr.

Tempr.

kg/cm2(a
)
0.00622
0.00669
0.00719
0.00772
0.00829
0.00889
0.00953
0.01021
0.01093
0.0117
0.01251
0.01338
0.01429
0.01526
0.01629
0.01738
0.01853
0.01975
0.02103
0.02239
0.02383
0.0254
0.027
0.0286
0.0304
0.0323
0.0343

kg/cm2(a
)
0.0363
0.0385
0.0408
0.0433
0.0459
0.0485
0.05135
0.0542
0.0574
0.0606
0.0641
0.0676
0.0714
0.0752
0.0794
0.0836
0.0882
0.0928
0.0978
0.1028
0.1083
0.1138
0.1198
0.1258
0.1323
0.1388
0.1459

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53

54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100

kg/cm2(a
)
0.153
0.1607
0.1684
0.1767
0.185
0.19405
0.2031
0.233
0.244
0.267
0.291
0.318
0.346
0.377
0.41
0.445
0.483
0.523
0.567
0.613
0.662
0.715
0.771
0.831
0.894
0.962
1.033

Pressure Drop Calculation

i) Weymouth equation (for gas transmission lines)

0.3 x L x Q 2 xSxT
P
Px d 5.33
Where,
P = Pressure drop in kgf/cm2
Q = Discharge in Nm3/hr
P = Average line pressure, in
kgf/cm2a
(P1 + P2)/2
=

P1
P2
L
D
S
T

=
=
=
=
=
=

Initial pressure in kgf/cm2 a

Final pressure in kgf/cm2a
Equivalent length in meter
Pipe bore in mm
Sp. gr. of gas
Actual Gas temp. oK

ii) Fritzsche Equation

0.15 x L x Q1.875 xS 1.857 xT
P
Px d 5
Where,
P = Pressure drop in kgf/cm2
Q = Discharge in Nm3/hr
P = Average line pressure, in
kgf/cm2a
(P1 + P2)/2
=

P1 =
kgf/cm2 a
P2 =
kgf/cm2a
L
=
meter
D
=
S
=
T
=

Initial pressure in
Final pressure in
Equivalent length in
Pipe bore in mm
Sp. gr. of gas
Actual Gas temp. oK

B. Incompressible fluid
Density does not changes with change in pressure

Line sizing
d 1128 .38

Q
V

Where,
d = Calculated ID in mm.,
Q = Flow in lit/min., V=
Velocity in m/s

OR

d 18.8

Q
V

Where,
d = Calculated ID in
m,
Q = Flow in m3/hr.,
V = Velocity in m/s

Recommended velocity
SL.N
o.
1
2
3
4
5
5
6
7
8
9
10
11
12
13
14
15
15

Service
Feed Water
LPG (Liquid)
Condensate(Pressure)
Condensate(Gravity)
Hydraulic Fluid(7Kscg)
Hydraulic Fluid(70 Kscg)
Hydraulic Fluid(140 Kscg)
Hydraulic Fluid(210 Kscg)
Roll Coolant
Oil Lubricant
Grease
Fuel oil/LSHS
Water-Discharge line/General service
Water-Pump suction line
Water-Pump suction line(Boiling
water)
Water- Gravity line
Water-Sewere system

Velocity
1
1.5
2
1.5
2
2.5
3
3.5
2
2
2
1.5
2
1 to 0.5
0.5
0.3
1 to 0.5

Table for Hydraulic Radius (RH)

Pressure Drop Calculation

(Incompressible fluid)
i) DArcy Equation
hf

4000 fLv
2 gd

OR

1000 fLv 2
hf
2 gRH

Where,
d = ID in mm. ;
hf = Pressure drop in MLC,
L = Equivalent length in m.,
V= Velocity in m/s ,
g = 9.81 m/s2
f = Friction factor ;
RH = Hydraulic Radius (See table below)

Table for Hydraulic Radius (RH)

Shape

Hydraulic Radius

Circle, dia= d

d/4

Square, side = D

D/4

Rectangle, side a & b

ab
2 a b)

NETWORK SOLUTION BY HARDY CROSS METHOD

Procedure :
i) Number each circuit from left to right and then downward.
ii) Put diameter, direction of flow, flow and equivalent length of
each line.
iii) Calculate as per the table below
iv) Manipulate the data to make the desired flow as desired
point so that the value of the last but before column becomes
nearer to zero.

Line
No.
ab
bc
cd
de
ef
bh
hi
if
fg
dj
ik

NB
m
m
100
50
50
50
50
50
50
50
100
25
25

ID
(d)
mm
106
53.6
53.6
53.6
53.6
53.6
53.6
53.6
106
27.8
27.8

Direction

+
+
+
+
+
+
+

Flow
(Q)
m3/hr
.
50
25
25
21
21
25
25
21
42
4
4

hf

hf

m/s
1.57
3.08
3.08
2.58
2.58
3.08
3.08
2.58
1.32
1.83
1.83

m
50
25
25
25
25
25
50
25
50
10
10

m
1.32
5.07
5.07
3.67
3.67
-5.1
-10
-3.7
0.96
-1.7
1.67

Q
0.0264
0.2026
0.2026
0.1747
0.1747
0.2026
0.4053
0.1747
0.0228
0.4163
0.4163

0.88

2.419

hf hfQ

m3/h
r
-0.2
-0.2
-0.2
-0.2
-0.2
-0.2
-0.2
-0.2
-0.2
-0.2
-0.2

Q1
m3/h
r
49.8
24.8
24.8
20.8
20.8
-25.2
-25.2
-21.2
41.8
-4.2
3.804

Working
formulae :

i) v = (4 x 7 x 106 x Q)/( 3600 x 22 x

d2)
1.852

77511.6Q
Cd 2.63

ii )hf L

iii )

hf
hf
1.85
Q

iv)Q1=Q+

Pressure Drop Calculation

(Incompressible fluid), Contd
Friction factor can be found out from Moody Diagram or by
Colebrook & White version equation :
a. Moody Chart :

Where, e = Linear measurement of absolute roughness, which can be found out from the
table :
Pipe Quality

Cast Iron
Commercial black steel
Steel (Smooth)
Steel (light rust)
Steel(Galvanized)
Plastic

Roughness factor (e)

:
:
:
:
:
:

0.2
0.046
0.025
0.25
0.15
0.002

Pressure Drop Calculation

(Incompressible fluid), Contd

b. Colebrook & White version equation

Inertia Force Vd Vd

Viscous Force

Where,
Density
; V= Velocity of fluid, m/s
Kinematic Vis cos ity .001xstoke

d= ID, m

If RN < 2000, the flow is laminar and then f =16/R

If R > 3000, the flow is turbulent and f can be calculated by Colebrook & White
Version Equation as given below :

e
1
1.255
4 log10

f
3.7 d R f

If 3000> RN > 2000, the flow is in Transition zone and pressure

drop calculation result are better, if turbulent condition is
assumed.

Pressure Drop Calculation

(Incompressible fluid), Contd
ii)

Williams and Hazen Formula

hf L

77511.6Q
Cd 2.63

1.852

Where, hf=head loss in metre

Q=flow in m3/hr
d=pipe bore in mm
L=equivalent length in
metre
C=a co-efficient
representing the roughness of
the interior surface of the pipe

Value of C
C
=
140 for extremely smooth and straight pipes with continuous interior and welded or
coupled joints, such as new brass, copper, lead, tin, new cast iron, new welded or seamless steel, smooth
cement - lined cast iron or steel pipe.
C
=
130 for very smooth pipes, such as Welded or seamless steel with continuous interior in
fair conditions, New Welded-Steel Pipe with riveted girth joint, new cast iron, old brass, copper, lead, tin.
C

120 for smooth pipes, such as smooth wooden pipes or wood-stave pipes ordinary concrete.

C
=
110 - 130 for new full reveted steel or wrought-iron pipe, depending on thickness of plate
and extent to which rivets are counter sunk.
C

110 for old cement-lined pipe, or vitrified-crock sewers in good condition.

C
=
100 for old cast-iron or old continuous interior steel pipes where the carrying capacity over
a long period of years is somewhat impaired through tuberculation or sedimentation. For sizes below 6 in,
somewhat lower valves should be used.

C. Steam
Line sizing

d 18.8

Where, d = Calculated ID in mm, Q = Flow in Kg/hr., V=

in m/s
Velocity
SpecificVo
lume, m3 / kg

Q*v
V

Recommended velocity for steam

service
SL.
No.
1
2
3
4
5
6

Service

Medium pressure saturated(20 to 40KScg)

Low pressure superheated(12Kscg & below)
High pressure saturated(100 KSCG)
High pressure superheated(100 KSCG)
Medium pressure saturated(20 to 40KScg)
Medium pressure superheated(20 to 40KScg)

Pressure Drop Calculation (Steam)

P

91.44

Where,

6.95 x V x L x W2
d5

P
d

=
=

L
W
V

Pressure drop in kgf/cm2

Pipe Bore in mm
=
=

Equivalent length of pipe in meter

Mass flow rate in kg/hr
Specific volume in m3/kg

Velocity
27
30
36
43
30
36

D. Equivalent Length
i) Equivalent Length of Fittings and Flanges
Fittings
90 S.R. Welding Elbow

Le/d
20

90 L.R. Welding Elbow

15

3D
90 Standard screwed
Elbow

10

180 return bend

65

Tee with flow through

Tee with flow through
branch
90 Mitre Bend- 3 cut
45 Elbow
45 Mitre

20

30

65
16
15
15

Fittings
Flange Joint
25%Expand
er
25%
Reducer
50%Expand
er
50%
Reducer
75 %
Reducer
75%
Expander
Vessel outlet
Vessel inlet
5D bend

Le/d
6
30
15
20
12
12
7
33
66
8

Ex. : Equivalent length of 1 no. 100 NB Flange joint = 6 x 100/1000

= 0.6 M

Equivalent Length (Contd)

ii) Equivalent Length of Valves and strainer
Valve
Type

25

Equivalent straight length in m. for NB valve size

40
50
80
100
125
150 200 250

300

Gate valve

0.17 0.25

0.35

0.5

0.67

0.84

1.0

1.33

1.67 2.0

(open)
Gate valve

1.0

1.5

2.0

3.0

4.0

5.0

6.0

8.0

10

12

(1/4th Close)
Globe valve

5.0

7.5

10

15

20

25

30

40

50

60

(1/2 close)
Globe Valve

20

30

40

60

80

100

120

160

200

240

(3/4 close)
Globe (Open)
Swing Check
Foot Valve
Strainer

8.3
2.07
0.62
1.2

12.5
3.12
0.93
1.4

16.7
4.17
1.25
1.5

25
6.5
1.87
1.8

33
8.25
2.47
2.4

41.7
10.4
3.12
3.0

50
12.5
3.15
3.3

66.7
16.6
5.0
4.2

83.3
20.8
6.24
4.8

100
25
7.5
5.5

( Basket)
Globe Check

3.8

5.75

7.68

11.5

15.2

14.2

23

30.7

38

Equivalent Length (Contd)

iii) Equivalent Length of composite network
d3, l3
d1, l1
d4, l4

d5, l5

d2, l2
de1, l2

Grid AB

l
d e1 d1 2
l1

3
16

= Eq. dia of l2 length

d 01 d e1 d 2
Now, eq. dia of single l2 long line becomes

d2, l2

8
3

3
16

d3, l3

Grid BC

de3, l3

d e3

de4, l3

3
16

l
d 4 3
l4

&

l3

l5

d e 4 d 5

d 02 d 3 d e 3 d e 4
Now equivalent dia of single l3 line becomes,

8
3

d01, l2
A

8
3

8
3

8
3

3
16

3
16

d02, l3
C

The equivalent length of section BC in terms of d01

d
Leq l 3 01
d 02

16
3

So, the whole system becomes equivalent to d01 dia and (l2+Leq)
length pipe.