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Topic 4: Head Losses Calculation

Classification of Losses
• There are two main classifications of head losses in the piping line. These are the:
1. Major head losses are head losses due to fluid friction because viscosity and or head
losses due to friction because of pipe roughness.
2. Minor Losses are head losses or turbulence Losses due to pipe fittings and valves.

MINOR AND MAJOR LOSSES

MINOR LOSSES
a. Entrance loss in the flow of fluid from tank to pipe, head loss because velocity
is being created.

Figure 1. Entrance Loss

b. Exit loss – flow of fluid from pipe to tank, head loss because velocity is being
destroyed.
Figure 2. Exit Loss

c. Sudden Expansion is the flow of fluid in a sudden increase of pipe diameter,

head loss due to the decrease in velocity.
Figure 3. Sudden Expansion
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d. Sudden Contraction is the flow of fluid in sudden decrease in pipe diameter,

head loss due to the sudden increase of velocity.
Figure 4. Sudden Contraction

e. Bends (elbows), fittings and valves is head loss due to the change in magnitude
and direction of velocity.
Figure 5. Elbow & Valves

f. Gradual Expansion and gradual contraction are head loss due to gradual
increase or gradual decrease of fluid velocity.
Figure 6. Gradual Expansion & Contraction

g. A nozzle at the end is head loss due to the very high velocity at the nozzle outlet.
Figure 7. Nozzle at the End
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MAJOR LOSSES DUE TO FRICTION

▪ Major head losses are mainly due to friction because of the fluid viscosity and pipe
material roughness. Head losses, ℎ𝑓 , are computed particularly in a Long Straight
Pipe (say L > 500D)
▪ The following equations are used to computed head losses due to friction:

Darcy-Weisbach Equation
a. Darcy-Weisbach equation for circular pipe

𝐋 𝐕𝟐
𝐡𝐟 = 𝐟
𝐃 𝟐𝐠
b. For non-circular pipe
𝐋 𝐕𝟐
𝐡𝐟 = 𝐟
𝟒𝐑 𝐦 𝟐𝐠

Where, hf = Head loss due to friction, m. L = length of the pipe, m.

D = inside diameter of pipe, m. V = velocity of fluid, m/s
g = acceleration due to gravity, 9.8066 m/s2 R m = Hydraulic radius, m

Cross Sectional Area

Rm =
Wetter Peremeter of Cross Section

▪ Value of 𝑓 for laminar Flow:

Hagen-Poiseuille Equation,
64
f= → R e < 2000
Re

Blasius Equation,
0.316
f= → R e < 105
(R e )0.25
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where, R e = Reynolds Number

o Friction factor f in laminar flow is a function of Reynolds number, R e , and
independent of the pipe roughness.

▪ Value of 𝑓 for Transition and Turbulent Flows:

ε
𝑓 = ϕ (R e , )
D

Where, ϕ = is a function of R e = Reynolds Number

ε
e = D = relative roughness
𝜀 = Absolute roughness of a pipe material, m.
o Relative roughness is a better indicator of pipe roughness
o Darcy friction factor is one of the parameters used to calculate friction loss
o Absolute roughness or specific roughness is a parameter that measures the
average size of imperfection inside the pipe.

Important Notes:
1. Values of friction factor, f, may be obtained by the use of Moody’s Chart, from the
following references:
a. Page 105, Refrigeration and Air Conditioning, 2nd Edition, By Stoecker & Jones.
b. Pages 61-62, Power Plant Theory and Design, 2nd Edition by Potter.
c. Page 12, Centrifugal Pumps and Blowers. By: Church.
d. Page 119, Mechanical Engineering Tables & Charts, 5th Edition. By MRII

2. Friction factor, f, may also be obtained using Colebrook Equation

1
f=
√ D 9.3
1.14 + 2 log ( ) − 2 log [1 + ε ]
ε R e ( ) √f
D

3. Friction Factor, f, may also be determined using Moody’s Equation, for turbulent flow.
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1
ε 106 3
f = 0.0055 [1 + (20 000 + ) ]
D Re

4. Values absolute roughness for some selected materials

Materials 𝜺 (mm)

Glass, spun cement, brass, copper, plastic, bituminous lining 0.002

Commercial steel or welded steel 0.05

Riveted Steel 0.9 to 9.0

Galvanized iron (G.I.) 0.15

Cast iron (C.I.) 0.25

Concrete 0.30 to 3.0

Wet-mix spun precast concrete 0.60

Timber 0.20 to 0.60

Plastic (PVC, ABS) 1.5 x 𝟏𝟎−𝟑

Copper & brass 1.6 x 𝟏𝟎−𝟑

Steel 0.06 (0.0002 ft)

C.I. (Plain) 0.24 (0.0008 ft)

Concrete 1.2 (0.004 ft)

5. Equivalent length of valves and fittings. Equivalent lengths of valves and fittings are
obtained using Crane Chart, formulated by Dean, and charted by the Crane Co., from
the following references:
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a. Fig. 2-21, p70, Power Plant Theory and Design, 2nd Edition. By Potter.
b. Figure 14-23, p607, Power Plant Engineering, By Morse (Metric Unit)
c. Chart, p113 (S.I.), Mechanical Engineering Tables and Charts, 5th Edition. By MRII.
d. Chart, p91 (English Units), Mech. Engineering Tables & Charts, 3rd Edition. By MRII
e. Table, p112, Mech. Engineering Tables & Charts, 5th Edition. By MRII.

6. Physical Properties of Pipe (Schedule Number)

a. Plate 1, p674-677, Power Plant Theory and Design, 2nd Edition. By Potter
b. Figure A-6, p665, Power Plant Engineering. By: Morse
c. Table 7-2, p136, Refrigeration and Air Conditioning, 2nd Edition. By Stoecker.
d. Table, p114, Mechanical Engineering Tables & Charts, 5th Edition. By MRII.

7. Recommended Flow of Fluid in Pipe, obtained from the following references:

a. Table 14-6, p603, Power Plant Engineering. By Morse.
b. Table 2-6, p72, Power Plant Theory and Design, 2nd Edition. By Potter.

MINOR LOSSES (EQUATIONS) IN PIPE LINES

▪ Minor losses are head losses called turbulence Losses because of the fittings and
valves installed in the piping line or flow line.
1. Entrance – tank to pipe,
𝐕𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠
Where, V = velocity of fluid in the pipe, m/s
k = coefficient of minor losses, depends on the condition at the entrance,
For the bell mouth, k ≈ 5

2. Exit – pipe to tank,

𝐕𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠
Where, V = velocity of fluid in the pipe, m/s k≈1

3. Sudden enlargement,
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𝐕𝟐 𝟐 − 𝐕𝟏 𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠

Where, k ≈ 1
V1 = velocity at upstream, m/s
V2 = downstream velocity, m/s
4. Gradual Enlargement,
𝐕𝟐 𝟐 − 𝐕𝟏 𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠

Where, k is a function of angle ∝ k≈1

V1 = velocity at upstream, m/s

V2 = downstream velocity, m/s

5. Sudden Contraction,
𝐕𝟐 𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠

Where, V2 = downstream velocity, m/s; k = depends on the ratio D2 ⁄D1

k ≈ 0.375 or 0.40 D1 = inside diameter of the upstream pipe,
m.
D2 = inside diameter of the downstream pipe, m

6. Gradual Contraction,
𝐕𝟐 𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠
Where, k = depends on the cone angle ∝. ≈ 0.10 to 0.04

7. Bends and Elbows,

𝐕𝟐 𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠
Where, k = is a function of the angle bend, θ and the ratio r⁄D
k = 0.5 for 90°, smooth bend
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8. Nozzle (orifices, Venturi meter),

𝐕𝟐 𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠
Where, k ≈ 0.04 V2 = velocity, m/s

9. Pipe Fittings and Valves,

𝐕𝟐 𝟐
𝐡𝐋 = 𝐤 ( )
𝟐𝐠
Where, k = depends on the fittings and valves.

Important Note: Values of k

45° Bend (elbow) 0.35 to 0.45
90° Bend (elbow) 0.50 to 0.75
Tees 1.5 to 2.0
Gate Valve:
Fully Open 0.25
Half Open 5.6
¼ Open 24
Check Valve (open) 3.0
Globe Valve:
Fully open 10
Half Open 20

DETERMINATION OF HEAD LOSS AND MINOR LOSS COMBINED

▪ To make the solution simple, only one equation may be used to compute for the
combined major and minor head losses.
𝐋𝐓 𝐕 𝟐
𝐡𝐟 = 𝐟
𝐃 𝟐𝐠

Where, LT = total length of pipe, m LT = Lsp + Leq

Lsp = length of straight pipe, m Leq = equivalent length of fittings and
valves into straight pipe
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hf = major loss + minor loss

hf = Friction loss, hf , (straight pipe) + Turbulence Loss, hf , (fittings & valves)

𝐋 𝐕𝟐 𝐕𝟐 𝐋𝐓 𝐕 𝟐
𝐡𝐟 = 𝐡𝐟 + 𝐡𝐭 = 𝐟 +𝐤 = 𝐟( )
𝐃 𝟐𝐠 𝟐𝐠 𝐃 𝟐𝐠

SAMPLE PROBLES:
#1. A pump delivering 230 lps of water whose absolute viscosity is 0.0114 poise has 300 mm
diameter suction pipe 254 mm discharge pipe as shown in the figure below. The suction pipe
is 3.5 m long and the discharge pipe is 23 m long. The water is delivered 16 m above the
intake water level. Considering the head losses in fittings and valves, find a) a head which
the pump must supply. b) If the motor brake power of the driving motor is 75 kW, what is the
efficiency of the pump? Assume pipe material as cast iron.
Given: A pumping installation shown

Q = 230 lps
BP = 75 kW
Ds = 300 mm
Dd = 254 mm
µ = 0.0114 Poise = 0.00114 Pa-s
Required:
a) The total dynamic head
b) The pump efficiency

Solution:
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▪ Consider the Suction Pipe Line

Solving for the suction velocity,

Q 4Q 4(0.23)
V1 = = = = 3.254 m/s
A πD1 2 π(0.30)2

Solving for the Reynolds Number,

ρD1 V1 1000(3.254)(0.30)
R e1 = = = 856315.79 ≈ 8.6 x 105
µ 0.00114

Solving for the relative roughness of the pipe material,

ε 0.00025 m
e1 = = = 0.00083
D1 0.30 m

Where, ε = 0.25 mm = 0.00025 m (for C.I. pipe)

Solving for the friction factor, f, using Moody’s Chart (p119, MRII)

Then, from Moody’s Chart, fs = 0.0193

Checking the value of friction factor, f, using Moody’s Equation,
1
ε 106 3
𝑓 = 0.0055 [1 + (20 000 + ) ]
D Re
1
0.00025 106 3
𝑓𝑠 = 0.0055 + 0.0055 [20 000 ( )+ ] = 0.0197
0.30 8.6 𝑥 105
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Solving for the Equivalent Length of fittings & valves, using the Crane Chart (p113,
MRII)

From the Crane Chart,

Long Sweep Elbow 6.9 m
Gate Valve (Fully open) 2.0 m
Then, Leq1 = 6.9 + 2.0 = 8.9 m
For the total length of suction line, Ls = Lsp + Leq1 = 3.5 + 8.90 = 12.4 m
Solving for the Head Loss at the suction line,
Ls V1 2 12.4 (3.254)2
hfs = fs = (0.0193) ( ) = 0.431 m
D1 2g 0.30 2(9.8066)

▪ Considering the Discharge Pipe Line

Solving for the discharge velocity,

Q 4Q 4(0.23)
V2 = = 2 = = 4.539 m/s
A2 πD2 π(0.254)2

Solving for the Reynolds Number,

ρD2 V2 (1000)(4.539)(0.254)
R e2 = = = 1011321 ≈ 1.01 𝑥 106
µ 0.00114

Solving for the Relative Roughness,

ε 0.00025 m
e2 = = = 0.00098 ≈ 0.001
D2 0.254 m

Solving for the Friction Factor, using the Moody’s Chart

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Then, from the Moody’s Chart, fs = 0.02

Checking the value of f using Moody’s Equation,

1
ε 106 3
fd = 0.0055 + 0.0055 [20 000 ( ) + ]
D R e2

1
0.00025 106 3
fd = 0.0055 + 0.0055 [20 000 ( )+ 6
] = 0.021
0.254 1.01 x 10

Solving for the Equivalent Length of valves & fittings, Using the Crane Chart

From the Crane Chart,

Gate Valve: fully open 1.60 m
Check Valve 20.0 m
Standard Elbow (3 pcs x 8.3 m) 24.9 m
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Then, Leq2 = 1.60 + 20.0 + 24.9 = 46.5 m

Solving for the total length, Ld = L2 + Leq2 = 23 + 46.5 = 69.5 m

Solving for the head loss at the discharge line,

Ls V2 2 69.5 (4.539)2
hfd = fd = (0.02) ( )[ ] = 5.75 m
D2 2g 0.254 2(9.8066)

a) Solving for the Total Dynamic Head, TDH.

TDH = (zB + zA ) + HLAB = 16 + 0.431 + 5.75 = 𝟐𝟐. 𝟏𝟖 𝐦

b) For the pump efficiency:

WP ρgQ(TDH) 1000 (9.8066)(0.23)(22.18)

np = x 100 % = = = 𝟔𝟔. 𝟕𝟎 %
BP 1000BP 1000(75)

#2. What is the power of the pump required to draw 50 lps of water from reservoir A to
reservoir B, as shown below? Assume an over-all efficiency of the pump 70 % and an average
relative roughness for cast iron of 0.50 mm. The absolute viscosity of water is 0.001002 Pa-s.
Given: Pumping Installation Show

Suction Line Discharge Line

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Straight Pipe 18 m 50 m
Nominal Diameter 8 inches 6 inches
Schedule Number 80 40
Pipe Material Cast Iron Cast Iron
Absolute roughness 0.50 mm 0.50 mm
Water viscosity 0.001002 Pa-s 0.001002 Pa-s
Q = 50 lps
Pump efficiency = 70 %
Required:
The pump brake power if the pump efficiency is 70 %
Solution:
▪ Consider the Suction Pipe Line
o From Pipe Table (p114, MRII), inside diameter, D1 = 193.7 mm for 8’’ nominal
diameter of suction pipe.

Solving for the V1 ,

Q 4Q 4(0.050)
V1 = = 2 = = 1.70 m/s
A1 πD1 π(0.1937)2
Solving for the Reynolds Number,
ρD1 V1 (1000)(1.70)(0.1937)
Re = = = 328 632.73 ≈ 3.3 x 105
µ 0.001002
Solving for the Relative Roughness,
ε 0.0005
e1 = = = 0.00258 ≈ 0.003
D1 0.1937
For the friction factor using Moody’s Chart

Then, f1 = 0.026
Checking for the value of f using Moody equation,
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1
ε 106 3
fd = 0.0055 + 0.0055 [20 000 ( ) + ]
D2 R e2
1
0.0005 106 3
fd = 0.0055 + 0.0055 [20 000 ( )+ 6
] = 0.0264
0.254 3.3 x 10
Solving for the equivalent length of fittings and valve (Using the Crane Chart)

Elbow = (21 ft)(1 m/3.28 ft) 6.40 m

Gate valve (fully open) = (4.5 ft)(1 m/3.28 ft) 1.37 m
Then, Leq1 = 6.40 + 1.37 = 7.77 m
For the total length of the suction line, Ls = L1 + Leq1 = 18 + 7.77 = 25.77 m
Solving for the head loss, hf1
Ls V1 2 25.77 (1.70)2
hf1 = f1 = (0.026) ( )( ) = 0.51 m
D1 2g 0.1937 2(9.8066)
▪ Considering the Discharge Pipe Line
o From pipe table (p114, MRII), for 6’’ nominal diameter the inside diameter is D2 =
154.1 mm.

Solving for the velocity,

Q 4Q 4(0.050)
V2 = = 2 = = 2.68 m/s
A2 πD2 π(0.1541)2
Solving for the Reynolds Number,
ρD2 V2 (1000)(2.68)(0.1541)
R e2 = = = 412 163.67 ≈ 4.1 x 105
µ 0.001002
Solving for the Relative Roughness,
ε 0.0005
e2 = = = 0.00324
D2 0.1541
For the value of Friction factor using Moody’s Chart
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Then, fd = 0.027
Checking for the value of f using Moody Equation,
1
ε 106 3
fd = 0.0055 + 0.0055 [20 000 ( ) + ]
D2 R e2
1
0.0005 106 3
fd = 0.0055 + 0.0055 [20 000 ( )+ ] = 0.0279
0.1541 4.1 x 105
Solving for the Equivalent length of Fittings and Valves
Using equivalent length table (p112, MRII), for 6 inches nominal diameter
Elbows (2 x 4.88) 9.76 m
Gate valve (full open) 1.07 m
Check valve 10.67 m
Then, Leq2 = 9.76 + 1.07 + 10.67 = 21.5 m
Solving for the total length of the discharge line, Ld = L2 + Leq2 = 50 + 21.5 = 71.5 m
Solving for the head loss at the discharge line,
Ld V2 2 71.5 (2.68)2
hf2 = fd = (0.027) ( )( ) = 4.59 m
D2 2g 0.1541 2(9.8066)
Solving for the Total Dynamic Head, TDH:
TDH = (zB + zA ) + HLAB = (zB + zA ) + (hf1 + hf2 )
TDH = (20 + 4.5) + (0.51 + 4.59) = 29.6 m
Solving for the pump Brake Power, BP
ρgQ(TDH) 1000(9.8066)(0.05)(29.6)
BP = = = 20.73 kW
1000ƞ 1000(0.70)
Therefore, use a 25-kW motor, if the pump is directly coupled to the motor.
PIPE SIZE SPECIFICATIONS
• If the requirement is to specify the pipe sizes, take following example.

SAMPLE PROBLEM:
#1. A pump is to draw water from reservoir A to reservoir B, as shown in the figure below.
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Recommend the pipe sizes and the size of motor to be used for the following specifications:
Suction Pipe Line
Length of straight pipe: 100 m Pipe Material: Cast
Iron
Absolute roughness: 0.50 mm Schedule Number: Sch. 80
Discharge Pipe Line
Length of straight pipe: 400 m Pipe Material: Cast Iron
Absolute roughness: 0.50 mm Schedule Number: Sch. 40
Other Data:
Pump Capacity: 40 lps Pump efficiency: 78 %
Water viscosity: 0.001002 Pa-s Allowable velocity: 1.0 to
2.50 m/s
Pipe sizes D1 > D2
Specify the pipe size.
Figure:

Solution:
• Considering the Suction Pipe Line
Solving for the Pipe Inside Diameter, Try say,

4Q 4(0.040)
Vs1 = 1.25 m/s ∶ Ds1 = √ =√ = 0.2019 m = 201.9 mm
πVs1 π(1.25)

o Then, referring to the pipe table (p114, MRII), the nearest ID = 0.2027 m, with
nominal diameter of 8 inches for Sch. 80.

Checking the actual velocity for 8’’ nominal diameter, D1 = 0.2027 m

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4Q 4(0.040)
V1 = 2 = = 1.24 m/s
πD1 π(0.2027)2

o Since, 1.0 m/s < 1.24 m/s < 2.50 m/s, the assumption is correct. Therefore, use
the following pipe specification for the suction line:
8” Nominal Diameter
Sch. 80 Cast Iron Pipe
(ID = 0.2027 m)

o If the computed velocity, V, is outside the given velocity range, try another value of
velocity, then refer to the table and check the actual velocity.

• Considering the Discharge Pipe Line

Solving for the discharge pipe inside diameter,

m 4Q 4(0.040)
try, Vs2 = 2.0 : Ds2 = √ = √ = 0.1596 m = 159.6 mm
s πVs2 π(2.0)

o Then, referring to pipe table (p114, MRII), the nearest Id = 0.1541 m with nominal
diameter of 6” for Sch. 40 pipe.

Checking the velocity for 6” nominal diameter, D2 = 0.1541 m

4Q 4(0.040)
V2 = 2 = π(0.1541)2 = 2.14 m/s
πD2
o Since 1.0 m/s < 2.14 m/s < 2.50 m/s, the trial is correct. Therefore, use the following
discharge pipe specifications:
6” nominal diameter
Sch. 40 Cast Iron Pipe
(ID = 0.1541 m)

o If the computed value of velocity, V, is outside the given velocity range, try another
value then refer to the pipe table and check for the actual velocity.
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Determination of the BP of the Pump

• Consider the suction line

ρV1 D1 1000(1.24)(0.2027) ε 0.0005

R s1 = = ≈ 2.51 x 105 e1 = = = 0.0025
µ 0.001002 D1 0.2027
1
ε 106 3
f1 = 0.0055 + 0.0055 [20 000 ( ) + ]
D1 R s1
1
0.0005 106 3
f1 = 0.0055 + 0.0055 [20 000 ( )+ 5
] = 0.0262
0.2027 2.51 x 10

Equivalent Length, using Crane Chart,

Standard Elbow 6.40 m

Gate Valve (fully open) 1.37 m

Then, Leq1 = 7.77 m Ls = 100 + 7.77 = 107.77 m

Ls V1 2 107.77 (1.24)2
hf1 = f1 = (0.0262) ( )[ ] = 1.09 m
D1 2g 0.2027 2(9.8066)

• Consider the discharge line

ρV2 D2 1000(1.145)(0.1541)
R e2 = = ≈ 3.3 x 105
µ 0.001002

1
ε 106 3
f2 = 0.0055 + 0.0055 [20 000 ( ) + ]
D2 R e2
1
0.0005 106 3
fd = 0.0055 + 0.0055 [20 000 ( )+ ] = 0.0279
0.1541 3.3 x 105

Equivalent length, using table for the equivalent length

Standard Elbow = 3(4.88) 14.64 m

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Gate Valve (full open) 1.07 m

Check valve 10.67 m

Then, Leq2 = 26.38 m

Ld = 400 + 26.38 = 426.38 m

Ld V2 2 426.38 (1.145)2
hf2 = f2 = (0.0279) ( )[ ] = 18.11 m
D2 2g 0.1541 2(9.8066)
• Solving for the total dynamic head (TDH)

TDH = z2 + z1 + HLAB = 12 + 3.5 + 1.09 = 18.11 = 34.7 m

• Pump brake power

ρgQ(TDH) 1000(9.8066)(0.04)(34.7)
BP = = = 17.45 kW
1000ƞp 1000(0.78)

Use a 20-kW motor drive.

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LECTURE WORKSHEET 4
Answer the following problems correctly. Present the solution
completely with figures. Send it in pdf format to our gclassroom.
#1. A pump is required to draw 50 lps of water (SG = 0.988) from reservoir A, with
static suction lift of 4.5 m, to reservoir B, with static discharge head of 15 m. the pipe
in the suction line is a 6” nominal diameter, sch. 40, and 80 m long. The pipe in the
discharge side is a 4” nominal diameter, schedule 40, and 150 m long. The fittings and
valves installed in the suction line are one-foot valve, one standard elbow, and one
gate valve: and in the discharge line are one check valve, one gate valve, and two
standard elbows. Assuming an absolute roughness of 0.24 mm for a cast iron pipe, and
an absolute viscosity of water of 0.01002 Poise. Neglecting the head losses in the foot
valve and at the exit in the discharge reservoir. Determine the pump brake power if
the pump efficiency is 82 %.

#2. Specify the sizes of pipes (cast Iron, schedule 40) and the size of the motor to be
used for a pump to lift water at 40 lps, from reservoir A to reservoir B.
Consider the following data:

Total static head 50

Fittings and valves;
Suction line (1 foot valve, 1 standard elbow & 1 gate valve)
Discharge line (1 check valve, 1 gate valve, 1 long sweep elbow, & 2
standard elbows)
Length of straight pipes:
Suction line 300 m
Discharge line 80 m
Absolute viscosity of water 0.001002 Pa-s
Absolute roughness of Cast Iron 0.00026 m
Darcy-Weisbach friction factor 0.025
Water velocity 1.0 m/s to 2.75 m/s

Neglect the head losses in the foot valve an at the pipe exit in the discharge reservoir,
and do not use equal sizes of the suction and discharge pipes.