DEPARTMENT OF CHEMICAL ENGINEERING

DIPLOMA IN CHEMICAL ENGINEERING

PRACTICAL PROGRAMME

REPORT TITLE: FLUID FLOW BENCH

SUBJECT : CHEMICAL ENGINEERING LABORATORY IIA

SUBJECT CODE : CEL260S

NAME : ORLY
SURNAME : MBWESE
STUDENT NUMBER : 217104983
DATE PERFORMED : 19 MARCH 2019
DUE DATE : 02 APRIL 2019

I swear that this assignment is my own work, is not copied from any person’s
work and does not involve plagiarism. I acknowledge and understand that
plagiarism is a punishable offense because it constitutes theft.

Signed………………………………Date………………………………

ORLY MBWESE 1
Contents

LIST SYMBOLS .............................................................................................................. 3

EXECUTIVE SUMMARY ................................................................................................. 4

AIM .................................................................................................................................. 4

INTRODUCTION ............................................................................................................. 5

LITTERATURE REVIEW AND THEORY ........................................................................ 6

EXPERIMENTAL PROCEDURE ................................................................................... 14

RESULTS...................................................................................................................... 16

Calculations..................................................................... Error! Bookmark not defined.

DISCUSSION ................................................................................................................ 16

CONCLUSION .............................................................................................................. 19

APPENDIX .................................................................................................................... 20

REFERENCES .............................................................................................................. 24

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LIST SYMBOLS

Roman Symbol Definition Units

d Pipe diameter m
f Friction factor Dimensionless
g Gravitational acceleration constant m.s-2
h Head m
k Minor loss coefficients for bends and fittings Dimensionless
L Pipe Length m
∆P Pressure drop KPa
µ Viscosity of water Pa .s
𝜌 Density of water Kg/m3
Subscripts
F Fanning

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EXECUTIVE SUMMARY

The design of a fluid flow bench was made in order to study the behavior of closed
flows. The aim of this experiment was to determine the experimental friction and shock
loss constants and compare it to the theoretical values. Theoretical and literature review
and the literature of the concept are explained; this experiment helps to understand how
properties such as density and viscosity influence the flow of fluids; it was performed
only on the results of laboratory practical conducted. This report also shows the
experimental procedure of the practical and the results obtained are discussed further in
the report. All fittings were identified on the fluid bench, pressure taps connected to
each of them, and the pressure drop recorded as well as the flow rate. The entire
process was repeated for differentes flow rates on each fitting and results obtained
showed an inconsistent trend between calculated friction factors and the theoretical
values; along with an inconsistent trend between the calculated k-values and the
theoretical ones provided. This experiment reached the objective, a clear conclusion
has been drawn from calculation and results obtained; this paper also provides an
appendix section with all side calculations for a better understanding of results.

ORLY MBWESE 4
INTRODUCTION

Fluid flow bench is a unit designed to study the behavior of closed flows by determining
the pressure drops in pipes as well as in different hydraulic accessories. The losses by
friction in straight pipes of different sizes can be determined on a certain range of the
Reynolds’ number. This classifies the types of flows as flow in laminar regime and flow
in turbulent regime (White, 1999).

The difference between laminar and turbulent flows in pipes was made by Osborne
Reynolds in his publication in 1883,the flow data in pipes was analyzed later on in the
beginning of the last century by Ludwig Prandtl , Thomas Stanton and Paul Blasius and
they then created the graph that is well known as the ‘’Stanton Diagram’’ . The work to
cover the case of rough pipes was extended by John Nikuradse, as the one supplied
with the fluid flow bench, which have different degrees of roughness in order to compare
the flows and pressures drops. It’s important to note that friction in pipes is one of the
classic laboratory experiments and it has always had a place in the practical teaching of
fluid mechanics. (Reynold, 1883).

In this experiment, the aim was to determine the experimental frictional and shock
losses in various fittings and length of pipe and compare the obtained friction and shock
loss constants to the theoretical values. The head loss through a smooth pipe will be
determined experimentally and compared with prediction made using moody diagram;
investigation on the effect of roughness on head loss and on the friction factor be
investigated in order to study the type of flow.

AIM

The objective of this study is to determine the experimental friction and shock losses in
various fittings and length of pipe and to compare the experimental friction factor and
shock loss constants to the theoretical ones.

ORLY MBWESE 5
LITTERATURE REVIEW AND THEORY

FLUID FLOW

Fluid flow is simply studying of liquids in motion. A fluid is any substance that can flow, liquids
and gases are fluids. In Chemical Engineering, the concept of fluid flow is an important factor to
analyze and its properties for things like the design of pipes since this branch of engineering
deals with various fluids such as oils, water and coolants.

For every engineering process involving pipping systems, pressure drop is affected by kinetic
energy loss and friction, this friction produces the pressure drop, which induces the flow of fluid.
(Nakayama, 1999)

Nature of the flow is defined in fluid kinetics using the Reynolds number which give
precision and name the flow based on the results such as from 2100 to 4000 the flow
is known as laminar and from the 4000 and up the flow is known as turbulent . The
Reynolds number is a dimensionless quantity which is used in fluids kinetics to determine
flow pattern and indicate the nature of a fluid, it is define as the ratio of momentum
forces to viscous forces and consequently quantifies the relative importance of two types
of forces for a given flow condition . It is the density of the fluid , the velocity of the
flow in motion and the diameter of the pipe driving the fluid subjected to resist to flow or
viscosity. (Cimbala, 2006)

A certain range of Reynolds’s number was used to study the losses by friction in straight pipes
of different sizes so that a flow might be found to be turbulent or laminar. It is important to note
that in this experiment rough pipes were supplied with the equipment, which has different
degrees of roughness in other to compare the flows and pressure drops.

The sum of all the friction losses and shock losses are the total head loss due to friction and
shock which are for instance sharp point entry, sharp point exit, sudden contractions and
sudden enlargements. The form friction refers to the friction produced by valves and fittings. In
laminar flow, the friction factor is only function of Reynold number. In turbulent flow, the friction
factor is function of Reynolds number and relative’s roughness.(Munson, 1998)

ORLY MBWESE 6
EQUATIONS USED IN FLUID FLOW

Different types of equations are useful in fluid flow. This includes the ideal gas equation, the
Reynold’s number, first law of thermodynamics, continuity equation and Bernoulli’s equation.
Fluids can flow steadily, or be turbulent. In steady flow, the fluid passing a given point maintains
a steady velocity. For turbulent flow, the speed and or the direction of the flow varies. In steady
flow, the motion can be represented with streamlines showing the direction the water flows in
different areas. The density of the streamlines increases as the velocity increases. Fluids can be
compressible or incompressible. This is the big difference between liquids and gases, because
liquids are generally incompressible, meaning that they do not change volume much in
response to a pressure change; gases are compressible, and change volume in response to a
change in pressure. (McDonough, 1999).

The following equations are used for the evaluation of fluid flow:

EQUATION 1

The Reynolds number is a dimensionless quantity which is used in fluids kinetics to

determine flow pattern and indicate the nature of a fluid, it is define as the ratio of
momentum forces to viscous forces (White, 1999)

𝜌. 𝑉. 𝑑
𝑅𝑒 =
𝑢

Having established the value of Reynolds' number for flow in the pipe, the value of may be
determined using a Moody diagram

 The viscosity (µ) of a fluid is a measure of its resistance to gradual deformation by shear
stress or tensile stress. For liquids, it corresponds to the informal concept of "thickness.
Both Equations can help us to calculate the viscosity (Munson, 1998)

µ = 𝑃. 𝑡

𝑚𝑎𝑠𝑠
µ=
𝑡. 𝐿

ORLY MBWESE 7
  The density (ρ) of a substance is its mass per unit volume (Cimbala, 2006)
and can be calculated by the following equation :
𝑚𝑎𝑠𝑠
𝜌=
𝑣𝑜𝑙𝑢𝑚𝑒

EQUATION 2

Fluid flow rate is the mass or volume of fluid that passes a given point per unit time. Flow rate Q
is defined to be the volume of fluid passing by some location through an area during a period of
time (White, 1999).

𝑉
𝑄=
𝑡

EQUATION 3

The equation of continuity states that for an incompressible fluid flowing in an enclosed tube, the
product of the velocity of flow and the cross-sectional area of the tube remains constant:
(B.R.Munson, 1998).

The flow rate (Q) can be determined by equation:

𝑄 = 𝐴𝑣 , Area( A)   .r 2

EQUATION 4

Using the velocity, the viscosity of the fluid, the density of the fluid, the length of the pipe and the
diameter of the pipe the pressure drop across a pipe can be determined using Bernoulli’s
equation. (J.M.Cimbala, 2006)

1 1
𝑃1 + 𝜌𝑣12 + 𝜌𝑔𝑦1 = 𝑃2 + 𝜌𝑣22 + 𝜌𝑔𝑦2
2 2

Bernoulli’s Equation of Pressure Head:

ORLY MBWESE 8
 𝑃1 𝑉1 2 𝑃2 𝑉2 2
+ + 𝑍1 + 𝐻𝐷 = + + 𝑍2 + 𝐻𝐿
𝜌𝑔 2𝑔 𝜌𝑔 2𝑔

Assume V1=V2 (they will cancel each other)

Z1 = Z2 = 0 and HD = 0

The equation will be:

𝑃1 − 𝑃2
= 𝐻𝐿
𝜌𝑔

Therefore, friction losses in a pipe system can be determined by the following equation:

4𝑓𝐿𝑉 2
𝛥ℎ𝑓 =
𝑑 2𝑔

Where L is the length of the pipe between tapings, d is the internal diameter of the pipe, u is the
mean velocity of water through the pipe in m/s, g is the acceleration due to gravity in m/s2
and 𝑓 is pipe friction coefficient.

Shock losses

As mentioned earlier, shock losses occur in fittings. The type of fitting used determines the
magnitude of the pressure loss. (White, 1999).

This magnitude is characterized by a constant, the K-factor calculated by:

𝑘𝑣 2
𝛥ℎ =
2𝑔

ORLY MBWESE 9
The pressure drop in terms of pressure head can be calculated by the following
equation:

∆P 𝑘𝑉 2
=
𝜌𝑔 2𝑔

The total head loss due to friction and shock are the sum of all the friction losses and
shock losses in the different fittings and pipes in the system.

Having established the value of Reynolds' number for flow in the pipe, the fanning
friction factor 𝑓, is determined from the Moody Chart, Figure 1 as shown below:

F IGURE 1: MOODY DIAGRAM

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 F IGURE 2: FLUID FRICTION IN PIPES 1

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F IGURE 2 LOSS COEFFICIENTS FOR PIPES COMPONENTS

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 F IGURE 3 FLUID FRICTION IN PIPES.

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EXPERIMENTAL PROCEDURE

APPARATUS
The units consist of:

Types of pipes:

1. Rough pipe (PVC covered in sand) with an external diameter of 25 mm and an

internal diameter of 17mm.
2. Rough pipe (PVC covered in sand) with an external diameter of 32 mm and an
internal diameter of 23 mm.
3. Smooth pipe (methacrylate) with an external diameter of 10 mm and an internal
diameter of 6.5 mm.
4. Smooth pipe (PVC) with an external diameter of 20 mm and an internal diameter
of 16.5 mm.
5. Smooth pipe (PVC) with an external diameter of 32 mm and an internal diameter
of 26.5 mm.

Types of Valves

1. Angle-seat valve with inner diameter of 20 mm.

2. Gate valve with inner diameter of 20 mm.
3. Diaphragm valve with inner diameter of 20 mm.
4. Ball valve with inner diameter of 20 mm.

Types of Couplings

1. In-line strainer. Inner diameter of 20mm.

2. Elbow of 90°. Inner diameter of 20 mm.
3. Double elbow of 90°. Inner diameter of 20 mm.
4. Elbow of 45°. Inner diameter of 20 mm.
5. T of 45°.Inner diameter of 20 mm.
6. Inclined T. Inner diameter of 20 mm.
7. Symmetrical Y branch. Inner diameter of each pipe is 20 mm.
8. Gradual narrowing. Its section changes from 40 mm to 25 mm.

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 9. Gradual widening. Its section changes from 25 mm to 40 mm.

EXPERIMENTAL PROCEDURE

1. The tubes between the hydraulic bench and the fluid flow bench were put in
order. The tube from the fluid flow bench drained onto the tank of hydraulic
bench.
2. The wiring of the unit was connected and turned on.
3. The pump switched on.
4. The V2 valve opened until all the air from the pipe was expelled.
5. A rough pipe identified to be used in the experiment and the inner diameter was
17 mm.
6. The pressure taps of the corresponding manometer to the inlet and outlet of the
pipe was connected. The manometer tubes were chosen when the difference
water column was lower than 800 mm.
7. The flow rate and pressure drop across the pipe taken.
8. It was repeated 6 to 7 for three flow rates.
9. It was repeated 5 to 8 for several pipes.
10. The gate valve was identified and the pressure taps of the corresponding
manometer to the inlet and the outlet of the gate valve was connected. The
manometer tubes were chosen when differences of water column were lower
than 800 mm. 6 and 7.
11. The flow rate and the pressure drop across the gate valve for three different flow
rates were recorded.
12. It was repeated 10 and 11 for the diaphragm valve and ball valve.
13. Results were calculated and recorded.

ORLY MBWESE 15
 RESULTS

TABLE 1 1
Fitting Diam flow Volum Tim Flow Veloci ΔP EXP ΔP Reynold Friction F
eter e e rate ty Theo Number factor theor
(m3 ) (s) (m3/s) (m/s) Mm kpa (kpa) ( no unit) experiment etical
2
inner al.

(m)
Smoot 0.025 High 0.008 8.43 0.00099 2.033 11 0.10 7.28 50840 4.88 × 10−8 0.022
h pipe 4 64 5 78

low 0.008 12.4 0.00067 1.373 8.0 0.07 3.47 34330 7.78 × 10−8 0.023
4 8 3 84
Smoot 0.020 high 0.008 8.34 0.001 4.679 10.5 0.10 45.98 77203 1.81 × 10−7 0.021
h pipe 4 3
low 0.008 10.9 0.00076 3.58 13.5 0.13 28.19 59070 3.04 × 10−7 0.022
4 8 2
Smoot 0.015 high 0.008 9.27 0.00090 5.145 61 0.59 74.11 77175 1.68 × 10−7 0.021
h pipe 4 5 5
low 0.008 11.9 0.0007 3.977 36.0 0.35 46.39 59655 1.67 × 10−7 0.022
4 9

TABLE 1.2
Fitting Diameter flow Volume Time Flowrate Velocity ∆P Experimental ∆P k
Q Theoretical Experime
ntal
(m) (m3) (s) (m3/s) (m/s) (mmH2O) (kPa) (kPa) -
Gate 0.020 high 0.0084 12.04 0.00069 2.248 139 1.363 0.376 0.000534
valve low 15.37 0.00054 1.761 96.5 0.946 0.263 0.0006
Globe 0.020 high 0.0084 11.79 0.00071 2.29 80 0.784 26.22 0.000299
valve low 18.22 0.00046 1.483 36.5 0.358 10.19 0.000325

ORLY MBWESE 16
DISCUSSION

The experiment was done using a pipe with a known diameter, and water was pumped
in from a tank. Throughout the process, measurements of the quantity of water and time
were taken as well as the hydraulic gradient. With these different parameters, the flow
rate, Reynolds number and friction factor could be calculated for each test as show
above smooth pipe( 25, 20 and 15 mm) as well as globe valve and gate valve. The main
purpose of the process was to analyze and identify the regions of laminar flow, and
turbulent flow, since all the points on moody graph are greater than 2300. We can
conclude that all the flows in this experiment were turbulent.

these values enable the calculation of the fanning friction factor for the pipes and the
shock loss constant for the fittings (gate valve and globe valve) for specific flow rates,
time and pressure.

Knowing that friction losses are a complex function of the system geometry, fluid
properties and the flow rate in the system; by observation, the head loss is directly
proportional to the square of the flow rate, but the resistance of the material in which the
equipment where the fluid is flowing is made mostly influences it (McDonough, 1999).

For this experiment, we calculated only smooth types of pipes. It was found that the
frictional factor experimentally of all the three pipes mention above was very small than
the theoretical one found on the moody chart as shown in table 1.1.

On the gate valve the shock losses found were not uniform and were very different from
each other and from the accepted value, there was no reasonable relation between the
change in flowrate and the frictional factor for the gate valve; the shock loss was
increasing with an increase in the flow rate.

For other flow rates, the value was very different, meaning that the shock loss is
efficient only in a certain range of flowrate. the values were largely different from the
exact value.

Valve: when flow rate increases: the pressure drop and the shock loss k decreases for
all the flow (low, high). The shock loss experimental is higher than the theoretical. “k”

ORLY MBWESE 17
increases for low to medium but decreases for low to high and medium to high flow
rates and is higher than the theoretical for all the flow .

For Smooth pipe it was found that when the flow rate increases, the pressure drop and
the friction factor decreases for low to medium and low to high flow rate but increases
for medium to high. The friction factor f experimental is less than the theoretical.

From the results of the experiment, the experiment that has greater Reynolds number
has the lower friction factor as shown in table 1.1.

ORLY MBWESE 18
CONCLUSION
The aim of this experiment was to determine the experimental friction and shock losses
in various fittings and length of pipes, and compare the experimental friction factor and
shock loss constants to the theoretical ones. the friction was found from pressure drops
base on time and the law of conservation such as energy balance (Bernoulli’s equation).

To demonstrate that fluid flow is influenced by density, viscosity by using 3 pipes of

different diameter, pressure gauge, stopwatch, Pressure drop calculations have to be
done for a quantitative analysis of the type of fluid. Reynolds number was applied
successfully in this experiment. It was useful to prove how related it is to other factors
that influence the flow of fluids in a pipe. In this experiment, it was important especially
on the calculation of flow rate, time and volume. Pressure drop, time, flow rate and
velocity were analyzed, distinguished and obtained.

The results are not consistent with the theory. It was noticed that the experimental
values obtained differed from the theoretical. This was believed to be due to the time
and pressure for the low and high flow recorded separately which affect the difference in
flow rate and velocity.

ORLY MBWESE 19
APPENDIX

CALCULATIONS

 Smooth pipe 25 mm = 0.025 m

𝜌 = 1000𝑘𝑔/𝑚3

𝑑2 (0.025𝑚)2
𝐴=𝜋 =𝜋× = 0.00049𝑚2
4 4

1𝑚3
Ṽ = 8.4 𝑙 × = 0.0084 𝑚3
1000 𝑙

Ṽ 0.0084𝑚3
𝑄= = = 0.0009964 𝑚3 /𝑠
𝑡 8.43 𝑠

𝑄 0.0009964
𝑉= = = 2.0335 𝑚/𝑠
𝐴 0.00049

Pressure drop calculations:

1𝑚𝑚 𝐻2 0 = 9.80665 𝑃𝑎

(256 − 245) 𝑚𝑚 𝐻2 0 = 11 × 9.80665 𝑃𝑎 = 107.87 𝑃𝑎

1𝑃𝑎 = 10−3 𝑘𝑃𝑎

∆P Experimental = (256 − 245) × 9.80665 × 10−3 = 0.1078 𝑘𝑃𝑎

Bernoulli’s Equation of Pressure Head:

𝑃1 𝑉1 2 𝑃2 𝑉2 2
+ + 𝑍1 + 𝐻𝐷 = + + 𝑍2 + 𝐻𝐿
𝜌𝑔 2𝑔 𝜌𝑔 2𝑔

Assuming: V1=V2 (they will cancel each other)

ORLY MBWESE 20
 Z1 = Z2 = 0 and HD = 0

The equation will be:

𝑃1 − 𝑃2
= 𝐻𝐿
𝜌𝑔

∆P 4𝑓𝐿𝑉 2
=
𝜌𝑔 2𝑔𝑑

L = 1 m, u=0.001 Pa.s

1mm = 10-3m , d= 25 × 10−3 m

∆P × d 0.1078 × 25 × 10−3
𝑓𝐸𝑥𝑝 = = = 3.259 × 10−7
2𝜌 × 𝐿 × 𝑉 2 2 × 1000 × 1 × (2.0335)2

 Calculation of Reynolds’s number,

𝜌 × 𝑉 × 𝑑 1000 × 2.0335 × 25 × 10−3

𝑅𝑒 = = = 5.084 × 104
𝑢 0.001

(The flow is turbulent)

The friction factor was determined by using the Moody Diagram

𝑒
𝑓𝑇ℎ ( , 𝑅𝑒)
𝑑

Relative roughness for smooth pipes =0 (Cimbala, 2006)

𝑒
=0
𝑑

𝑓𝑇ℎ (5.084 × 104 ) = 0.022

∆P Theoretical 4𝑓𝐿𝑉 2
=
𝜌𝑔 2𝑔𝑑

ORLY MBWESE 21
 2𝜌𝑓𝐿𝑉 2 2 × 1000 × 0.022 × 1 × (2.0335)2
∆P Theoretical = = = 7277.8𝑃𝑎 = 7.278 𝑘𝑝𝑎
𝑑 25 × 10−3

4𝑓𝐿𝑉 2 4×0.022×1×(2.0335)2
𝛥ℎ𝑓 = = = 0.742 𝑚
𝑑 2𝑔 2×9.81×0.025

The calculations for low flow rate were performed the same way as above.

Gate Valve Open: d=20 mm = 0.020 m, k theoretical = 0.15

𝜌 = 1000𝑘𝑔/𝑚3

𝑑2 (20 × 10−3 )
𝐴=𝜋 =𝜋× = 0.00031𝑚2
4 4

1𝑚3
Ṽ = 8.4 𝑙 × = 0.0084 𝑚3
1000 𝑙

Ṽ 0.0084𝑚3
𝑄= = = 0.000697 𝑚3 /𝑠
𝑡 12.04 𝑠

𝑄 0.000697
𝑉= = = 2.248 𝑚/𝑠
𝐴 0.00031

1𝑚𝑚 𝐻2 0 = 9.80665 𝑃𝑎

1𝑃𝑎 = 10−3 𝑘𝑃𝑎

∆P Experimental = (319 − 180) × 9.80665 × 10−3 = 1.36 𝑘𝑃𝑎

ORLY MBWESE 22
 Bernoulli’s Equation of Pressure Head:

𝑃1 𝑉1 2 𝑃2 𝑉2 2
+ + 𝑍1 + 𝐻𝐷 = + + 𝑍2 + 𝐻𝐿
𝜌𝑔 2𝑔 𝜌𝑔 2𝑔

Assume V1=V2 (they will cancel each other)

Z1 = Z2 = 0 and HL = 0

The equation will be:

𝑃1 − 𝑃2
= 𝐻𝐷
𝜌𝑔

∆P 𝑘𝑉 2
=
𝜌𝑔 2𝑔

L = 1 m & u=0.001 Pa.s

1mm = 10-3m & d= 20 × 10−3 m

∆P × 2 1.363 × 2
𝑘𝐸𝑥𝑝 = = = 0.000539
𝜌 × 𝑉 2 1000 × (2.248)2

∆P Theoretical 𝑘𝑉 2
=
𝜌𝑔 2𝑔

𝜌𝑘𝑉 2 1000×0.15×(2.248)2
∆P Theoretical = = = 376.32 𝑃𝑎 = 0.376𝑘𝑝𝑎.
2 2

𝑘𝑣 2 0.15 × (2.248)2
𝛥ℎ = = = 0.0386 𝑚
2𝑔 2 × 9.81

ORLY MBWESE 23
REFERENCES

Cengel, Y. A. and Cimbala J. M. 2006. Fluid Mechanics: Fundamentals and Applications.2nd

Ed. McGraw Hill.

McDonough, J. M. 2004. Lectures in Elementary Fluid Dynamics: Physics, Mathematics and

Applications, University of Kentucky, Lexington.

Munson, B. R. Young D. F. and T. H. Okiisshi. 1998. Fundamentals of Fluid Mechanics, John

Wiley and Sons, Inc.

Nakayama Y. and Boucher, R.F.1999. Introduction to Fluid Mechanics, Butterworth Heinemann.

Reynolds. 1883b. An experimental investigation of the circumstances, which determine whether

the motion of water shall be direct or sinuous, and the law of resistances in parallel channels.
Phil. Trans. R. Soc.(London) 174(1), 84-99.

White, F. M. 1999. Fluid Mechanics, McGraw-Hill.

ORLY MBWESE 24