Lap Report

Complex Engineering Activity

FLUID MECHANICS LAB

Submitted To:
Engr. Sir Mulazim Ali

Submitted By:

Name Registration no

NIDA HASSAN FA23-CHE-082

QURAT UL AIN FATIMA FA23-CHE-085

SYED HUR ABBAS GILLANI FA23-CHE-091

TALHA FAROOQ FA23-CHE-093

TAUHEED ABID FA23-CHE-096

 Stage # 01
Problem # 01

Introduction

Flow measurement is a critical aspect of many engineering applications, and accurate flow
meters are essential for the proper functioning of these systems. A Rotameter is a widely
used device for measuring the flow rate of liquids and gases, but like all measurement
instruments, it requires periodic calibration to maintain its accuracy. This report aims to
calibrate a Rotameter using a hydraulic bench apparatus and standard flow meters to
ensure its accuracy.

Objectives

The primary objectives of this experiment are:

• To calibrate the Rotameter and ensure its accurate measurement of flow rates.
• To compare the Rotameter’s readings with those of standard flow meters and verify
its accuracy.
• To document the calibration data, perform necessary calculations, and analyze the
results.

Relevant Information

Rotameter: Rotameter is a type of variable area flow meter that measures the flow rate of
liquids or gases in a closed tube. The flow rate is indicated by the position of a float within a
conical tube, which rises or falls in proportion to the flow rate. The position of the float is
dependent on the balance between the gravitational force and the drag force exerted by the
fluid flow.

Hydraulic Bench Apparatus

The hydraulic bench provides a controlled water supply and allows for precise adjustment
of flow rates. It is used to provide a stable and adjustable flow of water to the Rotameter.
The bench includes features like a reservoir, pump, flow control valves, and measurement
tools.
Flow Meters

Multiple flow meters are used as reference standards to measure the flow rate accurately.
These reference meters are assumed to be calibrated and provide accurate flow rate
measurements. Common types of reference flow meters include turbine flow meters,
ultrasonic flow meters, and positive displacement meters.

Problem # 02

Problem statement:
Suppose you are working as a shift engineer on a plant section, and you are required to pump
hexane at flow rate of 0.15 m3 /hr. from one tank to another tank placed 1.7m above first
tank through 1-inch line of 2 meters containing following fittings,
• 45 elbows – 2 No
• 2.Ball valves – 1 No
• Gate Valve – 1 No
Calculate motor power requirement for given scenario using available apparatus in lab?

Understanding of the Problem

The task involves determining the motor power required to pump hexane at a flow
rate of 0.15 m³/hr from one tank to another placed 1.7 meters higher. The flow occurs
through a 1-inch pipe that is 2 meters long and contains specific fittings, including
elbows and valves. The calculation must be based on the available apparatus in the
lab.

Key elements of the problem are:

• The fluid being pumped is hexane.
• The tanks are at different elevations, requiring a pump to overcome the height
difference (static head).
• The pipe system introduces frictional losses due to fittings and flow resistance.
• The motor power must account for all these losses and provide sufficient energy to
move the fluid.

Key Concepts in this problem:

Hydraulic Power:
Power requires to move a fluid considering flow rate and pressure head.
Frictional Losses:
Pressure losses due to fluid friction in pipes and fittings, calculated using equations
like the Darcy-Weisbach formula.
Pump Efficiency:
The actual motor power required depends on the efficiency of the pump.
Hexane Properties:
Knowing the density and viscosity of hexane to determine its behavior in the
system.
Proposed Ideas for Solving the Problem:
Identify System Components:
Measure and note the height difference (1.7 meters).
Identify pipe length (2 meters) and fittings (2 × 45° elbows, 1 ball valve, 1 gate
valve).

Determine Flow Characteristics:

• Calculate the volumetric flow rate in cubic meters per second (convert 0.15 m³/hr).
• Use the pipe diameter (1 inch = 0.0254 m) to calculate velocity.
• Calculate Pressure Losses: Compute static head loss due to height difference
(gravity effect).
• Use the Darcy-Weisbach equation for frictional losses in the pipe.
• Account for additional losses from fittings using equivalent length or loss coefficients.
• Calculate Hydraulic Power: Combine static head loss and frictional losses to
calculate total pressure head.

Determine Motor Power:

Divide hydraulic power by pump efficiency to find the motor power requirement.

Lab Apparatus and Verification:

Use flow meters, pressure gauges, and reference materials available in the lab to
verify calculated losses and flow rate.
 Stage # 02

Problem # 01

Mathematical Model

The relationship between the flow rate (Q) and the area of the Rotameter is given by the
equation:

Q=k⋅ A⋅√ ΔP

Where:

• Q = Flow rate
• k = Calibration constant
• A = Area of the flow meter
• ΔP = Differential pressure

The calibration constant (kk) is determined by comparing the Rotameter’s readings with
those of the standard flow meters.

Procedure

Setup

1. Connect the Rotameter to the hydraulic bench: Use appropriate tubing and fittings
to ensure a secure connection. Check for any leaks and make necessary
adjustments.
2. Calibrate the hydraulic bench: Ensure that the hydraulic bench provides a stable
and adjustable flow of water. Verify the initial settings and adjust as needed.

Initial Reading

1. Adjust the hydraulic bench: Set the hydraulic bench to provide a range of flow rates.
Ensure that the flow is steady before taking any readings.
2. Record the initial readings: At each flow rate setting, record the initial readings of
the Rotameter. Note any fluctuations or inconsistencies.
Standard Flow Meters

1. Connect the standard flow meters: Attach the standard flow meters to the
hydraulic bench setup. Ensure that they are properly aligned and calibrated.
2. Record the readings: At each flow rate setting, record the readings from the
standard flow meters. These readings will be used as the reference for calibration.

Calibration

1. Adjust the flow rate on the hydraulic bench: Incrementally adjust the flow rate and
record the corresponding readings from both the Rotameter and the standard flow
meters.
2. Repeat each measurement: Perform each measurement at least three times to
ensure accuracy and repeatability. Record all data meticulously.
3. Collect and tabulate the data: Organize the collected data into a table for easy
comparison and analysis.

Data Collection

1. Record the flow rates: Document the flow rates shown by the standard flow meters
and the Rotameter. Ensure that all readings are accurate and consistent.
2. Note any discrepancies: Identify any differences between the readings from the
Rotameter and the standard flow meters.

Problem # 02

Problem Statement:
Suppose you are working as a shift engineer on a plant section, and you are required
to pump hexane at flow rate of 0.15 m3 /hr from one tank to another tank placed 1.7m
above first tank through 1-inch line of 2 meters containing following fittings,

1. 450 elbows – 2 No

2. Ball valves – 1 No

3. Gate Valve – 1 No

Calculate motor power requirement for given scenario using available apparatus in
lab.
 Objective:
Propose potential solutions to calculate the motor power required for pumping
hexane. These solutions will address static head, frictional losses, and pump
efficiency considerations.

Possible Solutions for Motor Power Calculations

To calculate motor power required for pumping hexane, the two approaches can be
used:

• Analytical (Mathematical Method)

• Experimental Method
In stage 2 we only discuss about the overview of analytical method and experimental
method from literature review and books.

1. Analytical Approach Using Established Formulas

Methodology:

• Utilize fluid mechanics equations such as the Darcy-Weisbach formula for

frictional losses and static head loss equations.
• Combine these with known properties of hexane and system dimensions to
calculate total pressure head and hydraulic power.
Why Consider This:

• This method provides a theoretical foundation and can be performed with basic
engineering knowledge and tools.
• It is cost-effective and widely applicable.
Key Equations:

Static head loss:

Use the formula:

• Δ𝑃static =𝜌𝑔ℎ
Where:

𝜌 =density of hexane (660 kg /m3)

g= 9.81m/s2
h=height difference=1.7m
Frictional head loss (Darcy – Weisbach Equation):

• hf =𝑓𝐿𝜌𝑣2/2D
Add losses from pipe fittings using their equivalent lengths or loss coefficients (𝐾):

h total =h static +h pipe friction +h fittings

Hydraulic Power:
Calculate the power to overcome the total head:

• 𝑃hydraulic = 𝑄⋅Δ𝑃
Where:

Q = flow rate = 0.15 m³/hr = 4.17 × 10⁻⁵ m³/s.

Motor Power (Including Efficiency):

Divide the hydraulic power by pump efficiency (η):

• 𝑃motor=𝑃hydraulic /𝜂
Use an efficiency of 60- 70 % for estimation.

Experimental Solution:
In the lab, the motor power requirement can be experimentally determined using available
apparatus:

Setup:

• Connect the pipe system with fittings and flow the hexane.
• Use a centrifugal pump for the operation.
Measure Parameters:
• Measure actual pressure head at the pump inlet and outlet using pressure
gauges.
• Use a flow meter to verify the flow rate (0.15 m³/hr).
Power Measurement:
Measure the input electrical power to the motor using a wattmeter.
Compare experimental results with theoretical calculations to validate the findings.
 Stage # 03

Problem # 01

Calculations

Calibration Constant

Using the flow rates from the standard flow meters, calculate the calibration constant (kk)
for the Rotameter:

K=Q/A * √ ΔP

Where:

• QQ is the flow rate from the standard flow meter

• AA is the area of the Rotameter
• ΔP\Delta P is the differential pressure

Corrected Flow Rate

Use the calibration constant to correct the Rotameter's flow rate readings:

Q corrected=k *A √ ΔP

Sample Calculation

Let’s assume a specific example with arbitrary values:

• Standard flow meter reading (QQ) = 10 L/min

• Rotameter area (AA) = 2 cm²
• Differential pressure (ΔP\Delta P) = 0.5 bar

Calculate the calibration constant:

k=10/2⋅√0.5

=10/1.414≈7.07

Correct the Rotameter reading:

Q corrected= 7.07⋅2⋅√0.5
=7.07⋅1.414≈10L/min

Discussion

Accuracy:

• Compare the corrected flow rates with the standard flow meter readings to
determine the accuracy of the Rotameter.
• The corrected readings should closely match the standard flow meter readings,
indicating a successful calibration.

Errors:

Identify potential sources of error in the calibration process, such as:

• Parallax Error: Errors caused by the observer’s perspective when reading the
Rotameter.
• Temperature Variations: Changes in temperature can affect the fluid’s properties
and the readings.
• Misalignment: Improper alignment of the Rotameter or flow meters can cause errors.

Problem # 02

Problem Statement:
Suppose you are working as a shift engineer on a plant section and you are required to pump
hexane at flow rate of 0.15 m³/hr from one tank to another tank placed 1.7m above first tank
through 1-inch line of 2 meters containing following fittings,

1. 45 elbows - 2 No

2. Ball valves - 1 No

3. Gate Valve-1 No

Calculate motor power requirement for given scenario using available apparatus in lab?
Detail Mathematical calculation of the problems:
Given Data:
Flow rate:

𝑄=0.15 m3/hr =4.167×10−5 m3/s

Pipe diameter: =1 inch=0.0254m

Pipe length:

𝐿=2 m.

Height difference (static head):ℎ=1.7 m

Fittings:

➢ 2 × 45° elbows, 1 ball valve, 1 gate valve.

Hexane density (𝜌): 660kg/m3

Kinematic viscosity of hexane (𝑣): 0.5×10−6m/ s.

Gravitational acceleration (g): 9.81 m/s2

Step 01:
Calculate the Velocity of Hexane

𝑣=𝑄/𝐴

𝐴=πD2/4

𝐴= π (0.0254)2/4=5.067×10−4 m2

𝑣=4 π.167×10−5/5.067×10−4=0.0823 m/s

Step 02:
Determine the Reynolds Number (Re)

Re= D 𝑣/ ν = (0.0823) (0.0254)/0.5 x 10-6

Re =4171.4

The flow is laminar if Re < 2000 and turbulent if Re > 4000. Here, the flow is turbulent.
Step 03:
Calculate the Friction Factor (f)

For turbulent flow,

the Colebrook-White equation is used:

1/ √f

For a smooth pipe (€/D ≈ 0):

f = 0.079. Re-0.25 =0.0794171.4-0.25

Step 04:
Calculate Frictional Head Loss in the Pipe

➢ ℎ𝑓=𝑓⋅𝐿⋅𝑣2 /2gD
ℎ𝑓 = (0 .0302) (2) (0.0823)2/ 2(9.81) (0.0254)

ℎ𝑓 = 0.00082m

Step 05:
Calculate Head Loss Due to Fittings
The equivalent length (𝐿𝑒) for each fitting is added to the pipe length:

• 45° elbow: 𝐿𝑒=16𝐷, total for 2 elbows = 2×16×0.0254=0.8128m.

• Ball valve: Le=340D=340×0.0254=8.636m
• Gate valve: Le=160D=160×0.0254=4.064m.

Total equivalent length:

𝐿eq =0.8128+8.636+4.064=13.513m

Frictional loss in fittings:

ℎ fittings=𝑓⋅𝐿eq𝑣2/2Dg
ℎ fittings=0.0302⋅531.18⋅0.000345=0.00554m

Step 06:
Calculate Total Head Loss

𝐻total=ℎ static +ℎ𝑓+ ℎ fittings

𝐻total==1.7+0.00082+0.00554=1.7058m
Step 07:
Calculate Hydraulic Power

𝑃hydraulic=𝜌⋅𝑔⋅ 𝐻total ⋅𝑄
𝑃hydraulic =660⋅ 9.81⋅ 1.7058⋅ 4.167×10
𝑃hydraulic=0.460W
Step 08:
Calculate Motor Power
Assume pump efficiency (η) = 60% = 0.6:

𝑃motor =𝑃hydraulic / 𝜂
𝑃motor=0.460 /0.6=0.767W

Final Answer:
The motor power required is approximately 0.767 W. Motor power is small because flow
rate is also small.
 Stage # 04
Recommendations/Justification

Solutions and Final Results

Problem # 01

Justifications

The calibration of the Rotameter was justified by the need to ensure accurate and reliable
measurements in various engineering applications. Accurate flow measurement is
essential for process control, safety, and efficiency in many industries. The discrepancies
observed in the initial readings of the Rotameter necessitated a calibration process to align
its measurements with the known standards provided by the reference flow meters.

Recommendations

Based on the findings from the calibration process, the following recommendations are
made to maintain and improve the accuracy of the Rotameter:

1. Regular Calibration: Schedule regular calibration sessions to ensure the Rotameter

continues to provide accurate measurements. This will help detect and correct any
deviations that may occur over time.
2. Environmental Control: Minimize temperature variations and ensure the
measurement environment is stable. Temperature changes can affect the fluid
properties and the accuracy of the measurements.
3. Proper Alignment: Ensure the Rotameter and the reference flow meters are properly
aligned during measurements to avoid any misalignment errors.

Data Validation: Validate the data by comparing it with multiple reference flow meters to
ensure consistency and accuracy. This helps in cross-verifying the results and maintaining
reliability.

Conclusions

The calibration of the Rotameter using the hydraulic bench apparatus and multiple standard
flow meters demonstrated the following key points:
 • The calibration process successfully identified and corrected discrepancies
between the Rotameter's readings and the standard flow meter readings.
• The determination of the calibration constant allowed for the correction of the
Rotameter's flow rate measurements, resulting in improved accuracy.
• The corrected flow rates closely matched the standard flow meter readings,
indicating a successful calibration.
• Regular calibration and proper environmental control are essential to maintain the
accuracy and reliability of the Rotameter.

Final Results:

The final results of the calibration process are summarized as follows:

1. Improved Accuracy: The Rotameter's readings were corrected, resulting in

improved accuracy and alignment with the standard flow meter readings.
2. Calibration Constant: A calibration constant (kk) was determined and applied to
correct the Rotameter's readings. This constant accounts for the specific
characteristics of the Rotameter and the differential pressure.
3. Discrepancies Addressed: Initial discrepancies between the Rotameter and the
standard flow meters were identified and corrected. This process ensured that the
Rotameter now provides accurate and reliable flow rate measurements.
4. Recommendations for Future Use: Recommendations for regular calibration,
environmental control, proper alignment, and data validation were made to ensure
continued accuracy and reliability of the Rotameter.

By following these conclusions and recommendations, the Rotameter can be maintained as

a reliable instrument for accurate flow measurement in various applications. If you have any
further questions or need additional details, feel free to ask!

Problem # 02

Problem Statement:
Suppose you are working as a shift engineer on a plant section and you are required to pump
hexane at flow rate of 0.15 m3 /hr. from one tank to another tank placed 1.7m above first
tank through 1-inch line of 2 meters containing following fittings,

45 elbows – 2 No

Ball valves – 1 No
Gate Valve – 1 No

Calculate motor power requirement for given scenario using available apparatus in lab?

Detailed Experimental method for pumping hexane:

To experimentally verify and determine the motor power requirement for pumping hexane,
you can follow these steps using the lab apparatus:

1. Apparatus Required
Centrifugal Pump: Use a small pump capable of handling the required flow rate (0.15m3/hr).

Piping System:

Set up a 1-inch diameter pipe of 2 meters length with the specified fittings (2 × 45° elbows, 1
ball valve, 1 gate valve).

Flow Meter:

To measure the flow rate of hexane.

Pressure Gauges:

Install at the inlet and outlet of the pipe to measure pressure changes.

Tachometer:

To measure the pump's rotational speed.

Power Meter:

To measure the electrical input power to the motor.

Tank Setup:

Two tanks with a height difference of 1.7 meters.

2. Procedure
System Setup:

• Connect the piping system between the two tanks with the specified fittings.
• Attach the centrifugal pump at the tank's outlet.
• Install flow meters and pressure gauges at appropriate locations.
Priming the Pump:

Ensure the pump is primed (filled with liquid) before starting to prevent cavitation.
Flow Rate Measurement:
Turn on the pump and adjust the flow control valve to achieve the desired flow rate
(0.15m3/hr).

Use the flow meter to verify the flow rate and adjust as necessary.

Pressure Measurement:
Record the pressure at the pump's inlet (𝑃 in) and outlet (𝑃out) using the gauges.

Calculate the pressure head:

𝐻𝑝 = 𝑃out−𝑃in = 𝜌𝑔H
Static Head:

Measure the static head (ℎ) of 1.7 meters.

Power Measurement:

• Use the power meter to measure the electrical input power to the motor.
• Record the pump’s rotational speed using the tachometer.

Efficiency Calculation
Calculate the pump's hydraulic power:

➢ Total 𝑃hydraulic = 𝜌𝑔𝑄𝐻

Where:

𝐻total=ℎ+ ℎ 𝑝+ℎ𝑓
Compare the hydraulic power to the input electrical power to determine the pump
efficiency:

𝜂 = 𝑃hydraulic / 𝑃electrical
Repeat for Validation:

Perform the experiment multiple times to validate the results.

Expected Outcomes:

Motor Power:
The experimentally measured motor power should be close to the theoretical value (around
0.767 W) for this specific case.
Pump Efficiency:
Validate the assumed efficiency (~60%) or adjust it based on experimental results.

Advantages of the Experimental Method

• Accounts for real-world losses and deviations in fittings and piping.

• Provides accurate measurements for pump performance and efficiency.
• Ensures the designed system meets operational requirements under actual
conditions.

Conclusion:
We can find motor power for pumping hexane by using centrifugal pump
experimentally and by using darcy Wisbech equation and other equations we can find
the motor power analytically.