Flow

Characteristics
D U C T I L E I R O N P I P E L I N E S Y S T E M S

Many formulae exist for the computation of

friction losses along a pipeline. Those most
commonly used are Hazen and Williams, Manning
and Colebrook-White.

Colebrook-White formula
The Colebrook-White formula is the most
recently developed and is regarded internationally
as the most accurate base for hydraulic design.
Pipe flow friction charts provide a convenient
graphical means of solving the Colebrook-White
formula and are sufficiently accurate for most
practical purposes.
The charts included in this text are based on the
Colebrook-White formula:
2.51
V = -2 2gDS log ( k
+
3.7D D2gDS )

Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water
where
V = velocity of flow. m/s
g = acceleration due to gravity. 9.81m/s2
D = actual internal diameter of pipe. m
S = hydraulic gradient. Head loss per unit length
k = linear measure of roughness. m
␯ = kinematic viscosity of water
0.11425 x 10-5m2/s at 15˚C

Recommended values of k
for raw and potable pressure mains
Type Approximate Fluid being
of pipe value of k. mm transported
Cement 0.03 Raw and
Mortar Lined Potable Water
Cement Mortar 0.01 Raw and
Lined Seal Coated Potable Water

Generally there is no significant deterioration

with time of the linear measure of effective
roughness k, where cement mortar lined pipes
are conveying treated potable waters. However,
conveying certain raw waters and sewage can
lead to a build up of slime in the bore of all pipes
and this will cause an increase in the value of k. The
formation of these slime deposits is not deleterious
to the linings and periodic cleaning
of this type of main will restore hydraulic
performance virtually to that of the pipeline
in its new condition.

2:13
 Pipe Flow Friction Charts are given for the values of k For boundary roughness factors k for velocities in
shown in the previous table for raw and potable water. excess of those given on the previous page, reference is
The charts are based on mean internal diameters for the made to ‘Tables for the Hydraulic Design of Pipes and
range of nominal size pipe. Reference can also be made Sewers’ published by Hydraulics Research Station Ltd,
to AS 2200 - Design charts for water supply and Wallingford, where the following values for sewer rising
sewerage. mains in normal condition, regardless of pipe material,
The values of k given are for straight pipelines with are recommended.
few fittings. Where the number of fittings is high in Mean velocity 1.0m/s k = 0.3mm
comparison with the pipe length (e.g. water treatment Mean velocity 1.5m/s k = 0.15mm
plant pipework) head losses can be calculated from the
Mean velocity 2.0m/s k = 0.06mm
table of minor pipeline losses.

Minor pipeline losses

Recommended values of k
for water pipelines
for sewage rising mains
Values of K L given in the minor pipeline losses table
A full description of the factors affecting sewage in are related to head loss by the equation
rising mains is contained in reference 20. Only those
KLV2
factors that affect pump design and the structural design Head loss (H) =
2g
of the rising main are treated here. The following extract
where
is taken from the New South Wales Department of
H = head loss. m head of water
Public Work’s manual.
V = velocity. m/s
A minimum velocity of 0.6m/s has generally been
accepted as necessary for satisfactory transport of g = acceleration due to gravity. 9.81 m/s2
solids through a rising main. However, if velocity is KL = minor losses coefficient
maintained constant throughout the range of pipe sizes, Most pipe materials are referred to in nominal sizes
it can be shown that as pipe size increases the shear for ease of notation. Actual internal diameters vary from
Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water

stress exerted on the wall decreases. At lower shear nominal pipe sizes for different pipe materials. If charts
stress levels slime growth on the wall may increase relating to exact pipe diameters are not available,
effectively causing high head losses in the system. internal diameters should be used in hydraulic
In order to achieve reasonable control of slime growths, calculations.
a velocity found by the following formula is considered
desirable under normal dry weather flow pumping rates. Entry losses
V = -0.3 log (0.1/D) Type of fitting KL
where
Sharp edged entrance 0.50
V = velocity. m/s
Re-entrant entrance 0.80
D = pipe internal diameter. mm
Providing this order of velocity is attained, the Slightly-rounded entrance 0.25
boundary roughness k may be taken as 0.3mm. Bellmouthed entrance 0.05
Such velocity (0.9m/s in DN 100 to 1.13m/s in
Footvalve and strainer 2.50
DN 600) achieves a shear stress of 0.3kg/m2 on the pipe
wall irrespective of pipe size.
Where such velocity leads to excessive head losses Exit losses
or discharge rates, the velocity may be reduced but the
slime growth may be expected to increase the effective Type of fitting KL
boundary roughness. It is expected that the effective Sudden enlargement 1.00
boundary roughness may increase to 1.5mm or more if
the shear stress is reduced to 0.15kg/m2. Such shear Bellmouthed outlet 0.20
stress is achieved at a velocity found by
V = -0.215 log (0.4/D)
Velocity here varies from 0.52m/s in DN 100 to
0.68m/s in DN 600 and solids transportation would be
considered barely adequate. For lesser velocities,
settled material may not be picked up on the resumption
of pumping thus allowing anaerobic fermentation and
the production of odorous gases to occur.

2:14
Intermediate losses
Type of fitting KL Type of fitting KL

Elbows Sudden contractions*

R/D = 0.5 approx 221⁄2˚ 0.20 Inlet dia Outlet dia
45˚ 0.40 5 4 0.15
90˚ 1.00 4 3 0.20
3 2 0.30
Close radius bends
2 1 0.35
R/D = 1 approx 221⁄2˚ 0.15
3 1 0.45
45˚ 0.30
5 1 and over 0.50
90˚ 0.75
Tapers*
Long radius bends
Flow to small end neg.
R/D = 2 to 7 221⁄2˚ 0.10
Flow to large end
45˚ 0.20
Inlet dia Outlet dia
90˚ 0.40
4 5 0.03
Sweeps 3 4 0.04
R/D = 8 to 50 22 ⁄2˚
1
0.05 1 2 0.12
45˚ 0.10

Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water
Valves
90˚ 0.20
Gate valve fully open 0.12
Tees 25% closed 1.00
Flow in line 0.35 50% closed 6.00
Line to branch or branch to line 75% closed 24.00
sharp-edged 1.20 Globe valve 10.00
radiused 0.80 Right angle valve 5.00
Angle branches Reflux valve 1.00
flow in line 0.35 *Figures for enlargements, contractions and AS/NZS 2280
tapers apply to smaller diameter.
Line to branch or branch to line
Note. The 'Mean Internal Diameter' values shown in this manual
30˚ angle 0.40 are based on mean external diameters and nominal wall thicknesses.
The wall thicknesses may be greater than the nominal shown in local
45˚ angle 0.60
areas due to minor process variation. As per AS/NZS 2280 there are no
90˚ angle 0.80 upper tolerances on wall thickness. If pipe bore is critical to hydraulic
performance, additional process controls can be applied. Please consult
your Tyco Water Regional Marketing Office.
Sudden enlargements*
Inlet dia Outlet dia
4 5 0.15
3 4 0.20
2 3 0.35
1 2 0.60
1 3 0.80
1 5 and over 1.00

2:15
 Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water

1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000 TYTON 2100 SERIES

2:16
100 100
TYTONXCEL 20
Cement Lined (XL20C)
Ductile Iron Pipelines
50 50
40
Ve
lo
cit
4.0 y – m
40 Colebrook-White coefficient
(k) = 0.03mm.
1
etr
30 es 30
pe Values based on
r se
co mean internal diameters.
20 3.0 nd 20

Notes.
1. Flow chart accuracy is limited by plotting
accuracy and graphical representation. For
10 2.0 10 greatest accuracy direct use of the Colebrook-
White Formula is recommended.
2. The 'Mean Internal Diameter' values shown
in this manual are based on mean external
1.5 diameters and nominal wall thicknesses. The
5.0 5.0
wall thicknesses may be greater than the
4.0 4.0 nominal shown in local areas due to minor
process variation. As per AS/NZS 2280 there
3.0 3.0 are no upper tolerances on wall thickness. If
1.0 pipe bore is critical to hydraulic performance,
additional process controls can be applied.
2.0 2.0 Please consult your Tyco Water Regional
0.7 Marketing Office.
5

1.0 1.0

0.5

5
22
0
25
0.5 0.5

DN
0

DN
0.4 0.4

30

Head Loss – metres of water per 1000 metres of pipeline

5

DN
37
0.3 0.3

DN
45
0
50
0.2

DN
0.2 5 0.2
0

DN
60
0

DN
75
DN

0.1 0.1
1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000
Flow – litres per second
 1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000 TYTON 2100 SERIES
100 100
TYTONXCEL 20
Cement Lined
Seal Coated (XL20CSC)
50 50
40
Ve
loc
ity
40
Ductile Iron Pipelines
2
4.0 –m Colebrook-White coefficient
30 etr 30
es (k) = 0.01mm.
per
se Values based on mean internal
co
20 nd 20
3.0 diameters.

Notes.
10 10 1. Flow chart accuracy is limited by plotting
2.0 accuracy and graphical representation. For
greatest accuracy direct use of the Colebrook-
White Formula is recommended.

1.5 2. The 'Mean Internal Diameter' values shown

5.0 5.0 in this manual are based on mean external
4.0 4.0 diameters and nominal wall thicknesses. The
wall thicknesses may be greater than the
3.0 3.0 nominal shown in local areas due to minor
process variation. As per AS/NZS 2280 there
1.0
are no upper tolerances on wall thickness. If
2.0 2.0 pipe bore is critical to hydraulic performance,
additional process controls can be applied.
0.7 Please consult your Tyco Water Regional
5 Marketing Office.

1.0 1.0

0.5

5
22
0
0.5 0.5

25

DN
0

DN
0.4 0.4

30

Head Loss – metres of water per 1000 metres of pipeline

5

DN
0.3 0.3

37
0

DN
45
0
50
0.2 0.2 0.2
DN
5
0

DN
60
0

DN
75
DN

0.1 0.1
1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000

2:17
Flow – litres per second

Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water
 Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water

1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000 TYTON 2100 SERIES

2:18
100 100
TYTONXCEL 35
Ve
loc
i
Cement Lined (XL35C)
4.0 ty –
me
tre
Ductile Iron Pipelines
50 50
40
3.0
sp
er
sec
on
d
40 Colebrook-White coefficient
(k) = 0.03mm.
3
30 30
Values based on mean internal
diameters.
20 20
2.0
Notes.
1. Flow chart accuracy is limited by plotting
accuracy and graphical representation. For
10 1.5 10 greatest accuracy direct use of the Colebrook-
White Formula is recommended.
2. The 'Mean Internal Diameter' values shown
in this manual are based on mean external
5.0 5.0 diameters and nominal wall thicknesses. The
1.0 wall thicknesses may be greater than the
4.0 4.0 nominal shown in local areas due to minor
process variation. As per AS/NZS 2280 there
3.0 0.7 3.0 are no upper tolerances on wall thickness. If
5 pipe bore is critical to hydraulic performance,
additional process controls can be applied.
2.0 2.0 Please consult your Tyco Water Regional

0
Marketing Office.

10
DN
0.5

0
1.0 1.0

15
DN
0
20
5
22
0

DN
25
0.5 0.5

DN
0

DN
30
0.4 0.4

Head Loss – metres of water per 1000 metres of pipeline

0.2
5

DN
37
0.3 0.3

DN
45
0
50

DN
0.2 0.2
0

DN
60
0

DN
75
DN

0.1 0.1
1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000
Flow – litres per second
 1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000 TYTON 2100 SERIES
100 100
TYTONXCEL 35
Ve
loc
Cement Lined
i Seal Coated (XL35CSC)
4.0 ty –
me
50 50
40
3.0
tr e
s pe
r se
co
nd
40
Ductile Iron Pipelines
Colebrook-White coefficient
4
30 30
(k) = 0.01mm.
Values based on mean internal
20 20
diameters.
2.0

Notes.
10 10 1. Flow chart accuracy is limited by plotting
1.5 accuracy and graphical representation. For
greatest accuracy direct use of the Colebrook-
White Formula is recommended.
2. The 'Mean Internal Diameter' values shown
5.0 5.0 in this manual are based on mean external
1.0
4.0 4.0 diameters and nominal wall thicknesses. The
wall thicknesses may be greater than the
3.0 3.0 nominal shown in local areas due to minor
0.7 process variation. As per AS/NZS 2280 there
5
are no upper tolerances on wall thickness. If
2.0 2.0 pipe bore is critical to hydraulic performance,

0
additional process controls can be applied.

10
Please consult your Tyco Water Regional

DN
0.5 Marketing Office.

0
1.0 1.0

15
DN
0
20
5
22
0

DN
25
0.5 0.5

DN
0

DN
0.4 0.4

30

Head Loss – metres of water per 1000 metres of pipeline

0.2
5

DN
37
0.3 0.3

DN
45
0
50

DN
0.2 0.2
0

DN
60
0

DN
75
DN

0.1 0.1
1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000

2:19
Flow – litres per second

Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water
 Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water

1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000 TYTON 2100 SERIES
100 100

2:20
Ve
FLANGE CLASS
loc
it
4.0 y – m
Cement Lined (FLCLC)
etr
es
Ductile Iron Pipelines
50 pe 50
40 3.0
r se
co
nd 40 Colebrook-White coefficient
(k) = 0.03mm.
5
30 30
Values based on mean internal
diameters.
20 20
2.0
Notes.
1. Flow chart accuracy is limited by plotting
accuracy and graphical representation. For
10 1.5 10 greatest accuracy direct use of the Colebrook-
White Formula is recommended.
2. The 'Mean Internal Diameter' values shown
in this manual are based on mean external
5.0 1.0 5.0 diameters and nominal wall thicknesses. The
wall thicknesses may be greater than the
4.0 4.0 nominal shown in local areas due to minor
process variation. As per AS/NZS 2280 there
3.0 0.7 3.0 are no upper tolerances on wall thickness. If
5
pipe bore is critical to hydraulic performance,
additional process controls can be applied.
2.0 2.0

0
Please consult your Tyco Water Regional

10
Marketing Office.

DN
0.5

0
15
1.0 1.0

DN
0
20
5
22
0

DN
25

DN
0.5 0.5

DN
30
0.4 0.4

Head Loss – metres of water per 1000 metres of pipeline

0.2
5

DN
37
0.3 0.3

DN
0

45
50

DN
0

0.2 0.2

DN
60
0

DN
75
DN

0.1 0.1
1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000
Flow – litres per second
 1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000 TYTON 2100 SERIES
100 100
FLANGE CLASS
Ve Cement Lined
loc
it
4.0 y – m Seal Coated (FLCLCSC)
50 etr 50
40
3.0
es
pe
r se
co
nd
40
Ductile Iron Pipelines
6
Colebrook-White coefficient
30 30
(k) = 0.01mm.
Values based on mean internal
20 20
diameters.
2.0

Notes.
10 10 1. Flow chart accuracy is limited by plotting
1.5
accuracy and graphical representation. For
greatest accuracy direct use of the Colebrook-
White Formula is recommended.
2. The 'Mean Internal Diameter' values shown
5.0 5.0 in this manual are based on mean external
1.0
4.0 4.0 diameters and nominal wall thicknesses. The
wall thicknesses may be greater than the
3.0 3.0 nominal shown in local areas due to minor
0.7
5 process variation. As per AS/NZS 2280 there
are no upper tolerances on wall thickness. If
2.0 2.0 pipe bore is critical to hydraulic performance,

0
additional process controls can be applied.

10
Please consult your Tyco Water Regional

DN
0.5 Marketing Office.

0
1.0 1.0

15
DN
0
20
5
22
0

DN
25
0.5 0.5

DN
0

DN
30
0.4 0.4

Head Loss – metres of water per 1000 metres of pipeline

0.2
5

DN
37
0.3 0.3

DN
0

45
50

DN
0.2 0.2
00

DN
6
0

DN
75
DN

0.1 0.1
1 2 3 4 5 10 20 30 40 50 100 200 300 400 500 1000 2000

2:21
Flow – litres per second

Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water
 Application of table and charts
Top
water
Applications of Pipe Flow Friction Charts and the level
Minor Pipeline Losses Table are shown in the
following examples. 60m
difference
100 in level
Example 1 0 0m
Du
Cla ctil
ss e Ir Water
A PN20 ductile iron pipe, cement lined PN on
20 Pip level
Cem e
raw water rising main is required to deliver ent
Lin
approximately 200l/s from a river source at a velocity ed
of 1.0m/s. The main is 5000m long and rises 30m.
Determine the size of pipe required
and the total pumping head.
Assume that the losses in fittings would be Example 2
insignificant compared to pipe losses.
A water discharge of approximately 70l/s is
Cement lining will provide sufficient internal
required for a 10,000m long gravity main. The difference
protection except for extremely aggressive water,
between the top water level at the intake end and
therefore use k = 0.03.
the level at the discharge end is 60m. Determine
the nominal size of ductile iron PN 20 cement
Top water level in tank Discharge lined pipe required, the velocity of flow and the
exact discharge.
30m difference in level ipe
ronP The available hydraulic gradient is 60m head
Bottom tileI ine
d
c L loss per 10,000m = 6m per 1,000m.
water level Du ent
m em
00 C
50 20 Using Pipe Flow Chart 1 for PN 20 ductile iron
s PN pipe, cement lined with k = 0.03.
C las
Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water

Draw a vertical line at a discharge

corresponding to 70l/s. Draw a horizontal line
Pumping station corresponding to a head loss of 6m per 1,000m
and read off nearest larger nominal size of pipe
Using Pipe Flow Chart 1, draw a vertical line at a flow which is DN 250.
corresponding to 200l/s intersecting velocity For 6m per 1,000m head loss and DN 250, PN 20
= 1.0m/s line. pipe actual flow is 79l/s.
Establish the nearest larger nominal pipe size line to By interpolation velocity is approximately 1.4m/s.
that point (DN 500) and locate the intersection point
between that line and the 1.0m/s velocity line.
Draw a line from that point, read the head loss of
1.33m per 1000m from the chart by drawing a horizontal
line from the intersection point of the DN 500 size line
and 1.0m/s velocity line.
Friction head loss = 5 x 1.33 = 6.6m
Static head = 30.0m
Total pumping head = 36.6m
Therefore use a DN 500, PN 20 ductile iron pipe
cement lined which gives a total pumping head of
36.6m.

2:22
 Example 3 Example 4
Initial head
The top water level in tank A is 10.35m. Tank B is A reservoir is 30.0m in Ho – 10m
connected to tank A by DN 250, FC flanged ductile iron diameter, with a top water
pipe, cement lined. The maximum potable water flow level 10.0m above the outlet.
from tank A to B is 100l/s. Determine the water level in The capacity of the reservoir
tank B under these conditions. based on these dimensions
Using Pipe Flow Chart 5 with k = 0.03 is approximately 7.07 ML. The
Note. Flanged pipe is Flange Class Cement Lined (FLCLC). DN 300 outlet has a
bellmouth entry in the
For a flow of 100l/s and DN 250 cement lined pipe
reservoir and a resilient
approximate velocity from chart is 2.0m/s. The friction
seated gate valve
head loss from chart per 1000m of pipe = 12.1m.
immediately where the outlet
exits the
Top water level Water reservoir. The KL
RL 10.35m 4.0m level value for the
90˚
Flanged bellmouth is
Flow
Bellmouth Bends 0.05. The valve
entry
when fully open,
has a KL value of
2.0m

Tank A
0.12. Under
DN 250 flanged Sudden these initial End
Ductile Iron Pipe enlargement conditions, how point
Class K12 exit head
Cement Lined 4.0m long will it take H
to drain the
reservoir?
Tank B
The time to
drain a tank or

Flow Characteristics – Design Guidelines – Ductile Iron Pipeline Systems – Tyco Water
 Fitting Losses: Using minor pipeline losses table reservoir from Ho to H is
on page 2:14. given by the equation:
2A1 0.5
Type of fitting KL t = K (Ho0.5 - H0.5)
A2
Bellmouth entry 0.05 where
Two 90˚ elbow bends 2.00 A1 = cross sectional (circular) plan area of the tank
A2 = cross sectional area of the outlet
Sudden enlargement exit 1.00
K = (loss coefficients) + 1;
(KL = 1 for E of outlet jet)
As pipework is a constant size the velocity will be
Ho = initial head over the outlet
approximately constant throughout.
H = end point head over the outlet
Therefore total fittings losses
A1 = 707m2
V2
= (0.05 + 2.00 + 1.00) = 0.585m A2 = 0.071m2
2g
K = 0.05 + 0.12 + 1.00
 Pipe Losses:
= 1.17
Length of pipe = 4.0 + 2.0 + 4.0 = 10.0m
Ho = 10.0m
10 x 12.1
Friction head loss = = 0.121m H = 0.00m
1000 t = 68,411s
 Total Losses: t = 19.0h
Pipe plus fitting losses = 0.121 + 0.585 Qav = 103L/s
= 0.706m
vav = 1.46m/s
say 0.71m
Therefore water level in tank B
= 10.35 - 0.71
= 9.64m

2:23