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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...............................................................................

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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

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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

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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)