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GRAVITY FLUID FLOW DESIGN GUIDE
PROCEDURE NO.
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PREPARED BY
PROCESS TECHNOLOGY PROCEDURES
PAGE
OF
13
DATE
Edited from existing
doc by J.R. Barnhart
April 30, 2000
APPROVED BY
DEPARTMENT:
SUBJECT:
PROCESS ENGINEERING
JRB
GRAVITY FLUID FLOW DESIGN GUIDE
REVISION DATE
REV.
11/01/02
TABLE OF CONTENTS
Section
1.0
SCOPE.............................................................................................................
2.0
RESPONSIBILITIES........................................................................................
3.0
DEFINITION OF SYMBOLS............................................................................
4.0
CALCULATIONS..............................................................................................
4.1
4.2
Discussion Guidelines.............................................................................
Calculation Methods................................................................................
LIST OF ILLUSTRATIONS
Figure
1
2
3
4
5
Cross Section of Pipe Flowing Full..................................................................
Cross Section of Pipe Flowing Partially Full....................................................
Cross Section of Open Launder......................................................................
Pipe Flowing Full..............................................................................................
Pipe Flowing Partially Full...............................................................................
GRAVITY FLUID FLOW DESIGN GUIDE
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GRAVITY FLUID FLOW DESIGN GUIDE
1.0
SCOPE
This design guide1 describes the procedure for sizing gravity flow lines.
2.0
RESPONSIBILITIES
The process section is responsible for the hydraulic analysis and line sizing of
aboveground gravity flow piping systems.
3.0
DEFINITION OF SYMBOLS
Symbols used in this design guide are listed in Table 1.
Table 1 - Definition of Symbols
Symbols
Ce
Definition
Coefficient for entrance loss
(0.5 for sharp edge entrance)
Inside diameter of pipe or liner, feet
Flow depth, feet
32.17 feet/second2
Liquid head required at entrance, feet
hv
Velocity head, feet
Roughness coefficient
Differential pressure, pi
Quantity, cubic feet/second
Ve
Velocity at inlet, feet/second
V1
Velocity in elevated tank, feet/second
V2
Velocity in pipe, feet/second
Rev. 0 of the Design Guide was adapted with minimal changes from a Pasadena document, DSG-MP6K, 11/92
GRAVITY FLUID FLOW DESIGN GUIDE
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4.0
CALCULATIONS
4.1
Discussion Guidelines
Calculations are recorded on the preprinted company standard calculation sheet.
Variations in flow, slurry concentration, particle size, specific gravity, fluid viscosity,
scaling, internal pipe surface roughness, etc., make accurate gravity flow predictions
difficult.
This guide presents a simplified approach, resulting in approximate but adequate results
for most in-plant design.
If accuracy is required in a specific case, refer to textbooks.
4.2
Calculation Methods
The following steps are used to determine gravity flow:
1. Determine maximum flow (gallons per minute [gpm]) and minimum flow (gpm).
2. Establish (from process data) if liquid is:
a. Clear liquid with viscosity of water
b. Clear liquid with viscosity greater than water
c. Slurry
d. Froth
e. Scaling
f. Any combination of the above
3. Determine (from project design criteria) the maximum allowable velocity in
feet/second and the minimum allowable velocity in feet/second.
4. Decide if flow is to be by pipe flowing full (Figure 1), pipe flowing partially full
(Figure 2), or open launder (Figure 3).
In most cases design for pipe flowing full. Partially full pipe or open launder design
may be considered in particular circumstances, such as:
a. Top of pipe to be free for venting of gases
b. Wide fluctuation in flow (pipe may run full at maximum flow and partially full at
minimum flow)
c. Velocity limitations
d. In most cases, the slope of a partially full pipe or launder requires less head
than a full pipe.
e. Froth
f. Scaling
g. Any combination of the above (e.g., long distance tailings disposal lines)
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5. Select pipe diameter (or launder size).
For full flowing pipe, the allowable velocities usually govern pipe diameter. For
partially full pipes or open launders, use the gravity flow tables available from the
mechanical process clerk (be sure to correct for proper internal pipe roughness);
also, these tables are for liquids with a viscosity of water.
6. Ascertain that available head is sufficient to overcome friction losses, (i.e.,
entrance loss, velocity head, pipe friction loss, control valve and factor of safety).
a. Pipe Flowing Full
The following factors must be considered for gravity flow by pipe flowing full
(Figure 4):
Figure 1 - Cross Section of Pipe Flowing Full
Figure 2 - Cross Section of Pipe Flowing Partially Full
Figure 3 - Cross Section of Open Launder
(1.) Available Head
Available head is the vertical distance, in feet, from the lowest operating
liquid level in the elevated tank to the highest operating liquid level in the
lower tank, if pipe outlet is submerged, or pipe outlet.
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(2.)
Entrance Loss
Entrance loss =
Ce V2 V1
2g
) , feet
(Eq. 5-1)
(3.)
Velocity Head
2
V
Velocity head, hv = 2 , feet
2g
(Eq. 5-2)
(4.) Friction Loss
To arrive at a figure for friction loss, complete the following calculations:
(a.) Determine the equivalent length of pipe, elbows, fittings, etc.
(b.) The pipe diameter has previously been selected in Step 5, above;
using Cameron hydraulic data, read friction loss in feet per 100 feet for
the required flow.
(c.) Multiply (a.) times (b.) to obtain the pipe friction loss, feet
(5.)
(Eq. 5-3)
Control Valve
Control Valve =
P ( psi ) x 2.31
= loss, in feet liquid (or slurry)
specific gravity liquid (orslurry )
(Eq. 5-4)
(6.) Factor of Safety
Factor of safety usually equals 3 or 4 feet or 20 percent of friction loss for
pipe flows less than 100 feet. For long distance pipe lines, more detailed
analysis is required (these are generally computed by the civil engineer).
When liquid is of an undetermined viscosity (e.g., slurry or froth), increase
the factor of safety. A rule of thumb is to add 50 percent to the friction loss.
b. Pipe Flowing Partially Full
The following factors must be considered for gravity flow by pipe flowing
partially full (Figure 5):
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(1.) Available Head
Available head equals the vertical distance (feet) from the lowest operating
liquid level in the elevated tank to the highest operating liquid level in the
lower tank, if pipe outlet is submerged, or the pipe outlet. The available
head shall be greater than the head required at entrance (h) plus the
vertical drop due to slope.
(2.) Liquid Head Required at Entrance
h is the head required to allow the necessary flow to enter the pipe. This is
important because if h is not sufficient, the actual flow into the pipe will
always be less than the required flow. h controls the quantity of liquid
entering the pipe. h is measured from the top of the liquid level at the
entrance to the pipe. It is not measured from pipe centerline.
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Figure 4 - Pipe Flowing Full
Figure 5 - Pipe Flowing Partially Full
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h=
velocity head (hv) + the entrance loss
2
Ce Ve V1
V
h= e +
2g
2g
1.5 Ve
h=
2g
(Eq. 5-5)
h = 1.5 ( hv )
Freeboard is the distance from the liquid level to the top of the tank. It
does not affect head loss calculations. Allow 9 inches for most cases,
except if liquid is agitated; then allow 12 to 18 inches.
If liquid is frothy, allow maximum froth buildup plus 9 inches. These
freeboard dimensions are a guide. Other cases may exist where greater or
lesser freeboard is required. Freeboard should be sufficient to include a
factor of safety on the computed value of h.
(3.) Slope
To arrive at slope, obtain gravity flow tables from the mechanical process
section. Read the required slope for the selected pipe diameter flow and
velocity.
NOTE
Gravity flow tables are for water in steel pipe. In the case of
slurries or froth, check with process and/or project to
determine if the fluid viscosity is significantly greater than
water. Then adjust the slope accordingly.
(4.) The following is an example of the calculation of pipe flowing partially full,
in sequence.
Given flow = 743 gpm
d/D = 0.5
Convert gpm to cubic feet per second by dividing by 7.48 gallons per cubic
foot times 60 seconds per minute.
Q=
743
= 1.65ft 3 / sec.
( 7.48 x 60 )
Find D:
Enter Table 2 at d/D = 0.5 and read 1.3955 under Q/D 5/2.
(Eq. 5-6)
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1.65
D=
1.3955
2/5
= 1.07 feet
(Eq. 5-7)
Select a 12-inch pipe (D = 1.0 feet).
Find h:
Compute Q / D
5/2
1.65
=
1.0
5/2
= 1.65
(Eq. 5-8)
Enter Table 2 under column Q/D 5/2 at 1.65, read horizontally to column
hv
and find 0.2224.
D
therefore:
hv = 0.2224 x D = 0.2224 x 1 = 0.2224 foot
(Eq. 5-9)
And from equation 5-8:
h = 1.5 x 0.2224 = 0.33 foot
(Eq. 5-10)
To establish liquid level above the pipe invert:
Q/D5/2 was previously computed at 1.65.
Go to Table 2 and read down column Q/D 5/2 to the number closest to 1.65
(which is 1.6735). Read horizontally to d/D and find 0.55.
d = 0.55 x 1.0 = 0.55 foot
Liquid level in tank above the pipe invert =
=
=
(Eq. 5-11)
d+h
0.55 + 0.33
0.88 foot
(Eq. 5-12)
c. Selection of Pipe Slope
To select pipe slope, refer to gravity flow tables, 12-inch pipe. At d/D of 0.55,
flow 743 gpm, the approximate velocity is 4.2 feet/second. In order to avoid
unstable flow, it is advisable to select a slope that will correspond to a velocity
30 percent greater than the 4.2 feet/second = 5.5 feet/second. Therefore, in the
d/D column at 0.38 depth, at a velocity of 5.5 feet/second, 743 gpm requires a
slope of 0.02 feet/foot.
This would be the design slope for pipe with an n value of 0.013 (the commonly
accepted value for carbon steel pipe).
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d. Additional Relations
Table 3 provides additional relations that are of use in other gravity flow
problems.
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Table 2 Hydraulic Radius and Flow of Partially Filled Circular Conduit Sections
hv
D
Q
D5/2
P
D2
hv
D
Q
D5/2
P
D2
hv
D
Q
D5/2
P
D2
0.01
0.02
0.03
0.04
0.05
0.0033
0.0067
0.0101
0.0134
0.0168
0.0006
0.0025
0.0055
0.0098
0.0153
0.0000
0.0000
0.0001
0.0002
0.0003
0.34
0.35
0.36
0.37
0.38
0.1243
0.1284
0.1326
0.1368
0.1411
0.6657
0.7040
0.7433
0.7836
0.8249
0.0332
0.0356
0.0381
0.0407
0.0434
0.67
0.68
0.69
0.70
0.71
0.2974
0.3048
0.3125
0.3204
0.3286
2.4464
2.5182
2.5912
2.6656
2.7414
0.1644
0.1700
0.1753
0.1816
0.1875
0.06
0.07
0.08
0.09
0.10
0.0203
0.0237
0.0271
0.0306
0.0341
0.0220
0.0298
0.0389
0.0491
0.0605
0.0005
0.0007
0.0010
0.0013
0.0017
0.39
0.40
0.41
0.42
0.43
0.1454
0.1497
0.1541
0.1586
0.1631
0.8671
0.9103
0.9545
0.9396
1.0458
0.0462
0.0491
0.0520
0.0551
0.0583
0.72
0.73
0.74
0.75
0.76
0.3371
0.3459
0.3552
0.3648
0.3749
2.8188
2.8977
2.9783
3.0607
3.1450
0.1935
0.1996
0.2053
0.2121
0.2185
0.11
0.12
0.13
0.14
0.15
0.0376
0.0411
0.0416
0.0482
0.0517
0.0731
0.0868
0.1016
0.1176
0.1347
0.0021
0.0026
0.0032
0.0038
0.0015
0.44
0.45
0.46
0.47
0.48
0.1676
0.1723
0.1769
0.1817
0.1865
1.0929
1.1410
1.1899
1.2399
1.2988
0.0616
0.0650
0.0634
0.0720
0.0757
0.77
0.78
0.79
0.80
0.81
0.3855
0.3967
0.4085
0.4210
0.4343
3.2314
3.3200
3.4112
3.5050
3.6019
0.2249
0.2314
0.2380
0.2447
0.2525
0.16
0.17
0.18
0.19
0.20
0.0553
0.0589
0.0626
0.0862
0.0689
0.1530
0.1724
0.1828
0.2144
0.2371
0.0053
0.0061
0.0070
0.0080
0.0091
0.49
0.50
0.51
0.52
0.53
0.1914
0.1964
0.2014
0.2085
0.2117
1.3427
1.3955
1.4423
1.5041
1.5598
0.0795
0.0833
0.0873
0.0914
0.0856
0.82
0.83
0.84
0.85
0.86
0.4485
0.4633
0.4803
0.4982
0.5177
3.7021
3.3061
3.9144
4.0276
4.1465
0.2584
0.2653
0.2723
0.2794
0.2865
0.21
0.22
0.23
0.24
0.25
0.0736
0.0773
0.0811
0.0848
0.0887
0.2809
0.2857
0.3116
0.3326
0.3667
0.0103
0.0115
0.0128
0.0143
0.0157
0.54
0.55
0.56
0.57
0.58
0.2170
0.2224
0.2279
0.2335
0.2393
1.6164
1.6735
1.7327
1.7923
1.8530
0.0998
0.1042
0.1037
0.1133
0.1179
0.87
0.88
0.89
0.90
0.91
0.5002
0.5632
0.5900
0.6204
0.6555
4.2721
4.4056
4.5486
4.7033
4.8725
0.2933
0.3011
0.3064
0.3158
0.3233
0.26
0.27
0.28
0.29
0.30
0.0925
0.0963
0.1002
0.1042
0.1081
0.3857
0.4259
0.4571
0.4893
0.5225
0.0173
0.0190
0.0207
0.0226
0.0255
0.59
0.60
0.61
0.62
0.63
0.2451
0.2511
0.2572
0.2635
0.2699
1.9146
1.9773
2.0409
2.1057
2.1716
0.1227
0.1276
0.1326
0.1376
0.1423
0.92
0.93
0.94
0.95
0.96
0.6855
0.7159
0.8065
0.8841
0.9885
5.0603
5.2726
5.5183
5.8118
6.1787
0.3308
0.3011
0.3064
0.3158
0.3233
0.31
0.32
0.33
0.1121
0.1161
0.1202
0.5568
0.5921
0.6284
0.0666
0.0287
0.0309
0.64
0.65
0.66
0.2765
0.2833
0.2802
2.2386
2.3867
2.3760
0.1481
0.1534
0.1589
0.97
0.98
0.99
1.1410
1.3353
1.3700
6.8592
7.4063
8.8263
0.3692
0.3770
0.3818
GRAVITY FLUID FLOW DESIGN GUIDE
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--
--
--
--
--
--
--
--
1.00
--
--
0.3927
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d
D
area
D2
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12
0.13
0.14
0.15
0.16
0.17
0.18
0.19
0.20
0.21
0.22
0.23
0.24
0.25
0.26
0.27
0.28
0.29
0.30
0.31
0.32
0.33
0.34
0.35
0.36
0.37
0.38
0.39
0.40
0.41
0.42
0.43
0.44
0.45
0.46
0.47
0.48
0.49
0.50
0.0013
0.0037
0.0069
0.0105
0.0147
0.0192
0.0242
0.0294
0.0350
0.0409
0.0470
0.0534
0.0600
0.0668
0.0739
0.0811
0.0885
0.0961
0.1039
0.1118
0.1199
0.1281
0.1365
0.1449
0.1535
0.1623
0.1711
0.1800
0.1890
0.1982
0.2074
0.2167
0.2260
0.2355
0.2450
0.2546
0.2642
0.2739
0.2836
0.2934
0.3032
0.3130
0.3229
0.3328
0.3428
0.3527
0.3627
0.3727
0.3827
0.3927
See Section 3.0
wet.per.
D
0.2003
0.2838
0.3482
0.4027
0.4510
0.4949
0.5355
0.5735
0.6094
0.6435
0.6761
0.7075
0.7377
0.7670
0.7954
0.8230
0.8500
0.8763
0.9020
0.9273
0.9521
0.9764
1.0003
1.0239
1.0472
1.0701
1.0928
1.1152
1.1373
1.1593
1.1810
1.2025
1.2239
1.2451
1.2661
1.2870
1.3078
1.3284
1.3490
1.3694
1.3898
1.4101
1.4303
1.4505
1.4706
1.4907
1.5108
1.5308
1.5508
1.5708
hyd rad
D
0.0065
0.0130
0.0198
0.0261
0.0326
0.0388
0.0452
0.0513
0.0574
0.0636
0.0695
0.0755
0.0813
0.0871
0.0929
0.0985
0.1041
0.1097
0.1152
0.1206
0.1259
0.1312
0.1365
0.1415
0.1466
0.1517
0.1566
0.1614
0.1662
0.1710
0.1756
0.1802
0.1847
0.1891
0.1935
0.1978
0.2020
0.2062
0.2102
0.2143
0.2182
0.2220
0.2258
0.2294
0.2331
0.2366
0.2401
0.2435
0.2468
0.2500
d
D
area
D2
0.51
0.52
0.53
0.54
0.55
0.56
0.57
0.58
0.59
0.60
0.61
0.62
0.63
0.64
0.65
0.66
0.67
0.68
0.69
0.70
0.71
0.72
0.73
0.74
0.75
0.76
0.77
0.78
0.79
0.80
0.81
0.82
0.83
0.84
0.85
0.86
0.87
0.88
0.89
0.90
0.91
0.92
0.93
0.94
0.95
0.96
0.97
0.98
0.99
1.00
0.4027
0.4127
0.4227
0.4327
0.4426
0.4526
0.4723
0.4822
0.4920
0.5018
0.5115
0.5212
0.5308
0.5404
0.5499
0.5594
0.5687
0.5780
0.5872
0.5964
0.6054
0.6143
0.6231
0.6318
0.6404
0.6489
0.6573
0.6655
0.6736
0.6815
0.6893
0.6969
0.7043
0.7115
0.7186
0.7254
0.7320
0.7384
0.7445
0.7560
0.7504
0.7560
0.7642
0.7662
0.7707
0.7749
0.7785
0.7816
0.7841
0.7854
wet.per.
D
hyd rad
D
1.5908
1.6108
1.6308
1.6509
1.6710
1.6911
1.7113
1.7315
1.7518
1.7722
1.7926
1.8132
1.8338
1.8546
1.8755
1.8965
1.9177
1.9391
1.9606
1.9823
2.0042
2.0264
2.0488
2.0714
2.0944
2.1176
2.1412
2.1652
2.1895
2.2143
2.2395
2.2653
2.2916
2.3186
2.3462
2.3746
2.4038
2.4341
2.4655
2.4981
2.5322
2.5681
2.6061
2.6467
2.6906
2.7389
2.7934
2.8578
2.9412
3.1416
0.2531
0.2562
0.2592
0.2621
0.2649
0.2676
0.2703
0.2728
0.2753
0.2776
0.2799
0.2821
0.2842
0.2862
0.2881
0.2900
0.2917
0.2933
0.2948
0.2962
0.2976
0.2988
0.2998
0.3008
0.3017
0.3024
0.3031
0.3036
0.3040
0.3042
0.3043.
0.3043
0.3041
0.3038
0.3033
0.3026
0.3018
0.3007
0.2995
0.2980
0.2963
0.2944
0.2932
0.2895
0.2864
0.2829
0.2787
0.2735
0.2666
0.2499
PAGE OF
12
13
PROCEDURE NO.
REV.
DATE
PAGE OF
PTD-DGS-121
11/01/02
11
13
GRAVITY FLUID FLOW DESIGN GUIDE
Job Number
Cost Center
Pate Number
Sheet
of
Calculation Sheet
Rev
Date
By
Ck
Title
ENG-GE-30 (050492)
GRAVITY FLUID FLOW DESIGN GUIDE
PROCEDURE NO.
REV.
DATE
PTD-DGS-121
11/01/02
PAGE OF
13
17
Exhibit 1 Standard Calculation Sheet (ENG-GE-30)
