ENERGY LOSSES IN HYDRAULIC PIPING SYSTEM

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BY:

• Mustafa Mahmoud Fattalla
• Kareem Magdy Ahmed Fouad
• Begad Ahmed Zaki Farouk
• Ibrahim Mohamed El-Maghraby
• Abdelrahman Reda Abdeen

Supervisors

Prof. Hassan El-Gamal

Dr. Mina Atta

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INTRODUCTION

• The main idea of the project is to measure energy loss in hydraulic piping system. By knowing the pressure difference along PVC piping system.
• Using water and nanofluid
• Collecting experimental data from multiple measurements at various pump speeds for both fluids

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WHAT IS NANOFLUID�

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• A nanofluid containing nanometer sized particles called nanoparticle these fluids are engineered colloidal suspensions of nanoparticle in a base fluid.
• A nanoparticle used in nanofluid are made of metals, oxides, carbides or carbon nanotubes.
• Common base fluid include water, ethylene glycol and oil.

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NANOPARTICLES INTO A BASE FLUID

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Colloidal dispersion of nanoparticles in a base fluid (Nanofluids)

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NANOFLUID APPLICATION

• Electronics Cooling:

Nanofluids are utilized for efficient thermal management in electronic devices, such as computer chips, LEDs, and power electronics, where heat dissipation is critical for performance and reliability.

• Heat Exchangers

Nanofluids are employed in heat exchangers across industries like automotive, aerospace, and HVAC (heating, ventilation, and air conditioning) systems to improve heat transfer efficiency and reduce energy consumption.

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NANOFLUID APPLICATION

• Solar Thermal Systems

Nanofluids are used in solar thermal collectors to enhance heat absorption and transfer, thereby increasing the overall efficiency of solar energy conversion systems .

• Biomedical Applications

Nanofluids find applications in biomedical fields for hyperthermia cancer treatment, drug delivery systems, and bio-imaging, leveraging their unique optical and thermal properties.

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NANOFLUID APPLICATION

• Coolant in Nuclear Reactors

Nanofluids are explored as coolants in nuclear reactors to enhance heat transfer efficiency and safety margins.

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COMPONENTS

• Pump
• Dimmer
• Tank
• Pipes
• Ball valve
• Flange
• Orifice plate
• Pressure gauge
• Support stand

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PUMP

• principle of a pump is that it uses energy to move fluids from one point to another.
• The moving component (impeller, vane, and piston)
• decreasing the pressure and creating a partial vacuum.
• Using 1 hp variable speed (dimmer controller) centrifugal pump

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DIMMER

• principle of a dimmer switch is to control the amount of current flowing through a circuit
• It controls the current by using a small motor to turn an internal resistance up and down quickly
• Using a 7 gradual speeds dimmer.

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TANK

• tank is a large capacity container designed to store water and industrial manufacturing use.

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• Using Plastic tank 20 liter volume

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PIPES

• The PVC pipes are used in both commercial and residential sectors.
• The application of the PVC pipes includes their use in plumbing, drainage systems, drinking water distribution, irrigation systems, exhaust and ventilation ducts.
• Advantages of plastic piping include excellent resistance to different types of water and fluids, good flow characteristics, and lower friction-loss levels than metals.

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BALL VALVE

• A ball valve is a flow control device which uses a hollow, perforated, and pivoting ball to control fluid flowing through it.
• One of the easiest mechanism for a valve and has a lot of applications
• Using 12 ball valves ¾” with adapters to fit the pipe line at different diameter.

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FLANGE

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• Flanges are used to connect pipes with each other to valves and to fittings.
• Flanges are joined by bolting, and sealing.
• Using 4 Steel blind flange 2” .
• Inside them the orifices .

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�ORIFICE PLATE�

• A metal disk with a concentric hole in it, which is inserted into the pipe carrying the flowing fluid.
• Orifices are used as fixed throttles that generate head loss. The head loss caused by an orifice can be used to determine the volume or mass rate of flow during flow metering.
• Using 4 orifice plate (1- ¾ - ½ - ¼) inch.
• Made from steel in a work shop by Turing machine.

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PRESSURE GAUGE�

• The term pressure gauge usually refers to a self-contained indicator that converts the detected process pressure into the mechanical motion of a pointer.
• The pressure gauges used are a liquid filled pressure gauge.
• Using Pressure gauges scale 2.5 bar and 6 bar.
• The pressure gauges are used to calculate the pressure value along the system.

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SUPPORT STAND�

• Steel stand structure designed and manufactured from cast iron (4*4) to support the system supported by 6 wheels with friction brakes.
• Calculating the dimensions and then choosing the material and designing the system on solid edge so it can be implemented on the real design.

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MINOR LOSSES IN PIPES

• Minor losses differ from major losses, which are caused by friction between the fluid and the pipe walls along the entire length of the pipe.
• Minor losses refer to the energy losses that occur in piping systems due to the presence of fittings, expansions, contractions, and geometry of system components.
• These losses result from sudden changes in the flow direction, flow area, or flow velocity and can cause a drop in system pressure.

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TYPES OF MINOR LOSSES IN PIPES

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Minor losses in pipes

Orifice

FLOW EXPANSION

• Expansions in piping systems happen when the fluid moves from a smaller diameter pipe to a bigger diameter pipe leading to the decrease of fluid velocity.
• The expansion occurs when the fluid moves from ¾ inch pipe to 2 inch leading to a decrease in velocity.

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FLOW CONTRACTION AT ORIFICE PLATE

• Contractions happen when the flow moves from the bigger diameter pipe to the smaller diameter pipe leading to an increase in flow velocity and decrease in pressure.
• The flow is throttled through the orifice plate with each diameter (1/4”, ½” , ¾” , 1”) increasing velocity and decreasing the pressure.

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EXPANSION THEN CONTRACTION

• After the flow is throttled at the orifice plate, it is expanded through the 2” pipe then finally contracts again to the ¾” pipe to continue flowing through the system to the tank.

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VALVE LOSSES

• Valves can cause almost no head loss at all to almost a complete loss of head. This depends on how the valve is positioned and the type of valve.
• 12 Ball Valves are used in the system.

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BENDS AND BRANCHES LOSSES

• Losses from bends are not all the same. The loss coefficient is influenced by factors such as the radius of curvature, angle of bend, or branch and the relative pipe diameters.
• 90 degree Elbows and Tees are used in the system.

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PREPARATION OF NANOFLUID

• It is required to prepare water base Al₂O₃ nano fluids and that needs pure nanoparticles of alumina.
• WBA nanofluids were synthesized using the two-step preparation method because the two-step method is more suitable to synthesize nanofluids containing oxide nanoparticles.

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PREPARATION OF NANO FLUID (CONT.)

• Two step method :

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PREPARATION OF NANO FLUID (CONT.)

• Two step method :

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Concentration 🡪 0.05%

Amount of grams 🡪 8*3.6125= 28.9 g

PREPARATION OF NANO FLUID (CONT.)

• Two step method :
• Ethylene glycol & water

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2/3 water + 1/3 EG

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14 L of mix of water & E.G / 8 = 1.75 L of the mix

For water = 9.8 L

For E.G = 4.2 L

Where 8 is the number of mixing processes

PREPARATION OF NANO FLUID (CONT.)

• Two step method :

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PREPARATION OF NANO FLUID (CONT.):

• Two step method :

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Ultrasonic agitation helps to homogenate between particles and base fluid.

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PREPARATION OF NANO FLUID (CONT.)

• Two step method :
• Surfactant added 🡪 sodium dodecyl sulphate (SDS)

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Nano particles always tend to aggregate so the surfactant was added to low the surface tension and improve the stability of nanofluid by uniform the dispersion of particles

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PREPARATION OF NANO FLUID (CONT.)

• Two step method :

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EQUATIONS USED IN CALCULATION K FACTOR IN PIPELINE

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The Eddy Losses Equation

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Equations used in calculation K factor in pipeline in the project (CONT.)

First, we have used pressure gauges to take readings for p1, p2 and the we took an difference between them

Where�p1 = pressure before orifice (bar)�p2= pressure after orifice (bar)�p diff= difference in pressures (bar)

Second, we used to calculate the time taken by the system to fill a volume of 2 liters in many trials and took average for them.

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Equations used in calculation K factor in pipeline in the project (CONT.)

Third, we divided the volume given by the average time taken to get the flow rate V/T=Q�Where�T = average time taken to fill two liters (sec)�Q = flow rate (gpm)�v = fluid volume(m^3)

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Fourth, by using the pipe diameter 2” we get the velocity for the system by equation V1=Q/A

Where�A = area inside pipe diameter (inches)�Q = flow rate (gpm)�V1 = fluid velocity (m/sec)

Equations used in calculation K factor in pipeline in the project (CONT.)

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Equations used in calculation K factor in pipeline in the project (CONT.)

Fifth, calculate H loss which is H loss= P diff /9800

H loss = head loss (m)�P diff = differential pressure (Pascal)

The last step is to calculate the K factor by Equation K= (H loss *2*9.81)/(v1^2)

Then many readings at each speed of the pump are taken.

we have 7 speeds and then an average between them is taken to calculate the final value of K.

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CALCULATION OF K FACTOR USING WATER AT DIFFERENT SPEEDS AND ORIFICES: �

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Fitting orifice 1 inch

Fitting orifice 3/4 inch

CALCULATION OF K FACTOR USING WATER AT DIFFERENT SPEEDS AND ORIFICES (CONT.): �

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Fitting orifice 1/2 inch

Fitting orifice 1/4 inch

COMPARISON BETWEEN LOSSES IN WATER AND NANO FLUID:

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CONCLUSION

• From the present study, it can be concluded that:
• The factor of eddy losses coefficient has a direct relation with the head loss.
• The readings showed that the tighter the orifice diameter, the higher the eddy losses in the system.
• Comparison between the two fluids in the system (water, AL₂O₃-water Nano fluid 0.05%) showed that the Nano fluid has slightly higher eddy losses than the water due to different properties (density).

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