Pipe Design Research Articles

Pipe Size Calculation for Steam Supply

Pipe designers and engineers often encounter complex mathematical equations to determine the diameter required for adequate steam discharge capacity at specific flow velocities. This article aims to simplify the calculation of steam pipe sizes. The formulas and factors derived herein can be utilized for determining pipe diameters in steam applications. Ultimately, the findings provide engineers and designers with practical tools to enhance the reliability and efficiency of steam system.

Pipe size calculation for compressed air supply

Pipe designers and engineers often encounter complex mathematical equations to determine the diameter required for adequate compressed air at specific flow velocities. This article aims to simplify the calculation of compressed air pipe sizes. The formulas and factors derived herein can be utilized for determining pipe diameters in compressed air applications. Ultimately, the findings provide engineers and designers with practical tools to enhance the reliability and efficiency of compressed air system.

Nonlinear vibrations and static bifurcation of a hyperelastic pipe conveying fluid

This study investigates the free and forced nonlinear vibrations, along with the static bifurcation behavior, of a fluid transmission hyperelastic pipe supported by clamped ends. Both geometrical and material nonlinearities are taken into account. The mathematical model is grounded in Euler–Bernoulli beam theory, incorporating von Kármán nonlinearity to capture the complexities of the system. For the hyperelastic materials, the strain energy function proposed by Yeoh is employed. Considering that the lowest critical velocity of the fluid flow is associated with the first mode, after deriving the governing equation using Hamilton’s principle, Galerkin discretization is applied to obtain the reduced order model in the first mode. Analysis of static bifurcation and stability is performed and critical velocity values of fluid flow are determined. The analysis of free and forced vibrations of the hyperelastic pipe is conducted using the method of multiple time scales, specifically focusing on the sub-critical velocity range of fluid flow, which corresponds to the unbuckled state of the pipe. This approach allows for a comprehensive examination of how fluid flow velocity influences the frequency characteristics of free vibrations, as well as the frequency response in the vicinity of the main resonance. The results obtained from this study can significantly enhance our understanding of the design and application of hyperelastic pipes in various fluid transfer scenarios. By elucidating the dynamic behavior and critical parameters associated with these pipes, the findings can inform engineering practices and contribute to the optimization of systems that utilize hyperelastic materials for fluid conveyance.

Design of high-temperature sodium heat pipe with composite wick based on non-dominated sorting genetic algorithm (NSGA)

As small modular reactors continue to advance, heat pipe reactors (HPRs) are being developed by multiple organizations. Designing heat pipes with optimal heat transfer capability is crucial for the effective performance of HPRs. Based on NSGA-III genetic algorithm, this paper presented the design method of a high-temperature heat pipe featuring a composite wick. The study examined the influence of heat pipe structure parameters on performance parameters and heat transfer limits. Based on the analysis, we built multi-objective modeling of heat pipe and obtained the optimal structural parameters by NSGA-III. Verification confirmed that the heat pipe met the Mach number and effective capillary radius requirements. This study provided valuable insights for improving heat pipe manufacturing techniques and reactor miniaturization.

Hybrid Radial‐Axial Flow for Enhanced Thermal Performance in Packed Bed Energy Storage

ABSTRACTIn this work, a hybrid radial‐axial (HRA) system is used to store thermal energy in a packed bed. The heat transfer fluid (HTF) is delivered via a perforated radial pipe placed at the center of the packed bed along the axial length. Hot fluid flows from the center toward the wall through the holes (like other radial systems), but then leaves via the traditional axial flow exit, creating the HRA flow configuration. A computational fluid dynamics (CFD) model is used to analyze the thermal performance of the packed bed during the charging process utilizing the new HRA system. Alumina beads of 6 mm were filler materials and air was HTF with inlet temperature of 75°C for proof of concept. The present paper focuses on two aims: (1) utilizing CFD models to analyze flow and temperature profiles in the packed bed; (2) comparing the model results to experimental results published in a previous HRA flow study and to traditional axial flow. Two HRA configurations were considered based on previous experimental designs, one with uniform holes in the central pipe (R1) and one with gradients in the hole sizes to promote even flow from the central pipe into the bed (R2). The numerical results agree with the experimental results in both cases. The HRA system performance depends on the flow profile created by the hole designs, and it can perform better than the axial flow depending on the design of the radial pipe. Design R2, which promotes even flow from the central pipe into the bed, has higher charging efficiency than standard axial flow methods. For HRA design R2 at 0.0048 m3/s (7 SCFM, standard cubic feet per minute), numerical results for charging efficiency were 75.5% versus 73.8% for traditional axial flow. For HRA design R2 at 0.0061 m3/s (9 SCFM), numerical charging efficiency was 80.5% versus 78.1% for traditional axial flow. These results are consistent with experimental data.

Exploring Biomimetic Heat Pipes for Space Radiator Enhancement

This study investigates biomimetic heat pipes for space radiator applications, utilizing nature-inspired structures to potentially enhance heat transfer efficiency. The research addresses the imperative for improved heat dissipation mechanisms in nuclear space systems, crucial for effective thermal management. Heat pipes are passive heat transfer devices widely adopted for thermal control. The study aims to evaluate the effectiveness of a biomimetic heat pipe design in comparison to a traditional design while also validating the fabrication process through industry-made heat pipe comparisons. Innovative hot oil bath testing methods are employed to fabricate and test both heat pipe types, utilizing comprehensive thermal analysis, physical experiments, and validation techniques to assess heat transfer capabilities. Tests span varying temperature levels to analyze heat pipe behavior and performance. Findings suggest the potential for enhanced heat dissipation along the length of the biomimetic heat pipe, hinting at the biomimetic structure’s role in improving heat transfer. This study underscores the promise of biomimetic design principles and their potential for advancing heat pipe technology. Recommendations for further exploration include alternative materials, optimized testing procedures, and refined fabrication processes.

The effect of carbon black on degradation of pipe grade black polyethylene in high concentration chlorine dioxide solutions

In this research, the impact of carbon black on the accelerated degradation of pipe grade polyethylene (PE100) exposed to high levels of chlorine dioxide (150 ppm) is examined. Tensile testing reveals a faster degradation rate in black samples compared to neat samples, indicating a detrimental effect of carbon black aggregates on the polymer's aging process. Rheological analysis shows changes in molecular weight and structure due to chemical degradation and chain scission and can be a reliable method for detecting slight changes in molecular structure. Isothermal crystallization shows a slowdown in crystallization kinetics at first, explained by gel-formation due to crosslinking which hinder the crystallization, and then an increase in the kinetics as apparently the chain scission gets dominant again. Neat samples exhibit a higher density of tie molecules, indirectly revealed by much more fibrils in crack wall observed in FESEM images, suggesting better resistance to chemical degradation while the black sample shows a much less fibrillar crack wake and becomes almost completely devoid of any fibrils at later stages of aging. The fibrils, which essentially offer a load-bearing role against the widening and growth of the crack play a key role in resistance to slow crack growth (SCG). Therefore, the higher SCG resistance is expected for neat grade compared to black samples. The study proposes a dual-layer pipe design with a UV-resistant black outer layer and an oxidation-resistant neat inner layer to prolong the lifespan of PE100 pipes by protecting against UV radiation and chemical reactions. This solution offers increased durability, lower maintenance costs, and environmental sustainability benefits.

Research on Temperature Control of Mass Concrete for Multi-Tower Cable-Stayed Bridge Cap during Construction

In the construction process of mass concrete structures, the large temperature gradient due to exothermic hydration makes the mass concrete highly susceptible to cracking. This paper carried out research on temperature control methods of mass concrete for the purpose of ensuring construction quality based on the construction of Fengyi cable-stayed bridge caps. Firstly, the temperature and stress change rule in the concrete pouring process of the caps was analyzed though the finite element method (FEM). Then, targeted-oriented comprehensive temperature control schemes were formulated according to the structural characteristics and construction environment of the cap, including the optimization of the material ratio, the arrangement of crack-resistant reinforcing steel, the design of a water pipe cooling scheme and reasonable maintenance. Finally, the whole bridge cap construction process using the optimized water pipe cooling solution was monitored, and the temperature gap between inside and outside the concrete satisfied the specification requirements rigorously. In the concrete demolding session, the concrete surface was smooth and no cracks were found, which indicates the temperature control scheme is reasonable and effective. The research results have reference significance for the pouring and temperature control of mass concrete for bridge caps.

Investigation of the effect of elbow pipes of Ti6Al4V, 304 stainless steel, AZ91 materials on erosion corrosion by finite element analysis

Corrosion is the degradation of metals caused by chemical or electrochemical reactions with their environment. As a result of these reactions, undesirable conditions occur in the physical, chemical, mechanical and electrical properties of metals. These conditions cause parts made of metallic materials to become unusable. Erosion corrosion is one of the most common types of corrosion in fluid transfer. There are several methods for preventing erosion corrosion. First of all, some precautions should be taken to prevent wear. Intervention is very important in terms of cost, especially at the design stage. Measures such as wide angle bends, wall thickness of wear-resistant material and corrosion allowance can be taken, especially in applications where the flow direction needs to be changed. The aim of this study was to determine the effect of liquid fluid on erosion corrosion in Ti6Al4V, 304 stainless steel and MgAz91 elbow pipes by using the computer aided and finite element based AnsysWorkbench Explicit Dynamics module. For the design of the elbow pipe, SolidWorks was used for 3D studies. In the analysis of the pipe, the suitability of the pipe for the 3D model was examined. The effect of fluid rotation on the pipe walls and the effect of the pipe material on the flow along the pipe were determined. The standard k-e model based on the velocity-pressure relationship in continuous and steady flow was used for the flow calculations. The flow simulation showed that for all models the flow accumulation after rotation was more concentrated on the opposite walls of the pipe, as expected. The results obtained showed that the deformation in MgAZ91 material had the highest value at 9.14 × 10−8 mm. This situation has been interpreted to mean that it may vary depending on the flow rate automation. Designs on the old designs in the erosion structure of the liquid that occurs in the pipes with a new product design in the analysis design.

Experimental investigation of material properties of GFRP pipe for numerical simulation of novel nuclear power plant cooling water intake system

The cooling systems of nuclear power plants are typically made of reinforced concrete water intake structures and special steel pipes, making them large, important structures that necessitate very expensive special productions. In the scope of this research, an innovative design for 4-meter diameter GFRP composite pipes used in nuclear power plant cooling systems was developed using the circular wrapping method. The composite GFRP pipe used in the study has a substantial embedment depth. For this reason, an innovative design was created using unique stiffening rings, and the impact of these rings on the overall behavior was investigated. The nonlinear numerical analysis model of the nuclear power station cooling system, which consists of three pipes with a diameter of 4 m, was then created with ANSYS finite element software using the determined material models, and the results were interpreted. As a result of the study, a composite GFRP pipe design that can be used as a cooling system in significant structures like nuclear power plants has been developed.

A simplified analytical solution of pipeline response under normal faulting

Buried pipelines are one of the critical lifeline structures, and the evaluation of pipeline performance under seismic faulting is essential for protection of pipeline networks. This paper explores an analytical solution incorporating implementation of Winkler models around a beam-type structure using the finite difference method to evaluate the pipeline response under normal faulting. The effectiveness of the analytical solution is assessed by comparing the calculated pipe strains with centrifuge and full-scale laboratory testing measurements. Subsequently, the effect of pipe size, faulting condition, and burial condition on pipe response are investigated. It can be found that a pipeline with a smaller pipe wall thickness or larger pipe diameter is generally more prone to failure. Larger pipe wall thickness or lower D/t ratio should be used for pipe design crossing an active fault. In geotechnically problematic areas, shallow burial depth and less stiff soil with lower modulus are recommended to reduce the probability of exceedance of allowable limit states due to normal faulting. In the end, empirical functions relating to critical D/t ratio are proposed to evaluate the critical states of fault displacement, burial depth, and spread of fault rupture with different diameter-to-thickness ratio considering the controlled limit of failure modes.

Vibration control of FG-pipe conveying fluid using a nonlinear absorber with nonlinear damping in longitudinal direction

This study investigates the use of a nonlinear absorber with nonlinear damping to mitigate the transverse vibrations of a fluid-conveying pipe made of functionally graded materials (FGM). The nonlinear effects arising from the pipe’s curvature and inertia are precisely accounted for in the equation of motion. The governing equations of the FGM pipe-nonlinear absorber system are derived using extended Hamilton’s principle and solved using the method of multiple scales. 1:1 internal resonance condition between the first natural frequency of the pipe and absorber is explored for transferring energy from the pipe to the absorber based on the modal interaction. The frequency-amplitude curves reveal that as the power-law index (n) increases, the nonlinear hardening behavior of the pipe decreases, while that of the absorber increases. Incorporating nonlinear damping in the absorber is found to further improve vibration suppression, leading to a strongly modulated response that reduces the pipe vibrations by over 84.57% and the absorber vibrations by over 94.57%. The impact of the absorber’s nonlinear stiffness on the strongly modulated response is also investigated, indicating that excessively high stiffness can cause the disappearance of this beneficial behavior. The findings of this study provide valuable insights into the optimal design of FGM pipes conveying fluid and the integration of nonlinear absorbers with nonlinear damping for enhanced vibration mitigation.

Numerical Analysis of Low-Enthalpy Deep Geothermal Energy Extraction Using a Novel Gravity Heat Pipe Design

Geothermal energy, derived from the Earth’s internal heat, can be harnessed due to the geothermal gradient between the Earth’s interior and its surface. This heat, sustained by radiogenic decay, varies across regions, and is highest near volcanic areas. In 2020, 108 countries utilised geothermal energy, with an installed capacity of 15,950 MWe for electricity and 107,727 MWt for direct use in 2019. Low-enthalpy sources require binary systems for power production. Open-loop systems face issues like scaling, difficult water treatment, and potential seismicity, while closed-loop systems, using abandoned petroleum or gas wells, reduce costs and environmental impacts greatly. The novel geothermal gravity heat pipe (GGHP) design eliminates parasitic power consumption by using hydrostatic pressure for fluid circulation. Implemented in an abandoned well in north-east (NE) Slovenia, the GGHP uses a numerical finite difference method to model heat flow. The system vaporises the working fluid in the borehole, condenses it at the surface, and uses gravitational flow for circulation, maintaining efficient heat extraction. The model predicts that continuous maximum capacity extraction depletes usable heat rapidly. Future work will explore sustainable heat extraction and potential discontinuous operation for improved efficiency.

Study on interfacial mechanical properties of bonded pipe joint under dynamic load

This study analyses the interfacial mechanical behaviour of adhesive-bonded pipe joints under dynamic loading conditions. First, a mechanical model of the bonding interface of a pipe joint was established. Next, computational formula for the interfacial slip and shear stress in the pipe joints were obtained using variable separation, eigenfunction expansion, and Laplace transform methodologies. Further, the effects of various parameters, including the loading duration, bond length, adhesive layer thickness, stress rate, adhesive shear modulus, elastic moduli of the main pipe and coupler pipe, and adhesive-layer thickness, on the mechanical response of the pipe joints were assessed. The goal is to study the impact of these parameters on the maximum shear stress, interfacial slip, and normal stress in the main and coupler pipes, their effects on the pipe joint strength can be determined, thereby providing a theoretical basis for the design of practical pipe–joint configurations. The innovation of this study is as follows: it considers high-stress-rate dynamic loads for formulating complete mathematical equations. Further, it employs theoretical methods to calculate the relative slip and shear stress in pipe joints, through which theoretical formulas for engineering applications of adhesive-bonded pipe joints were derived. Additionally, the study analyses the impact of various parameters on the dynamic mechanical behaviour of the adhesive layer at the pipe joint interface, leading to a deeper understanding of the interface mechanical behaviour characteristics and key parameters to be considered while receiving dynamic loads in pipe joints.

Automated pipe design in 3D using a multi-objective toolchain for efficient decision-making

Abstract Pipe design in 3D is typically characterized by competing objectives, since the different design objectives, such as the reduction of length, weight, number of bends, manufacturing cost, and overall angle sum, are examples for such competing design goals, where one goal is often at the expense of the other. The origin of these competing design goals lies in the highly coupled problems of finding a permissible and collision-free pipe path in a complex 3D geometry and the physical properties of the path found. Because of the complex physics and geometry, these couplings are highly non-linear and mostly accessible via simulation only. The underlying pipe design optimization problem can thus not be solved explicitly and is tackled instead with a multi-disciplinary search procedure. Since the trade-offs between different competing evaluation objectives are often not known in advance, an automated design space exploration can be performed to generate different pipe designs, leading to well-informed design decisions by human experts. Such a design space exploration is shown and discussed using the pipework in a mounting rack in an Airbus A320 main landing gear bay. A total of 144 valid designs are generated, out of which the best in each criteria and the pareto-optimal solutions are automatically selected. Compared to the manually created Airbus A320 series solution, up to $10.4\%$ of the pipe length or up to $16.9\%$ of the bends can be saved using the same fixings and connection points, demonstrating both the feasibility and the industrial applicability of the automated toolchain.

Preliminary neutronics design and analysis of lithium heat pipe cooled space reactor with low-enriched uranium

The space nuclear reactor cooled by heat pipes has become the preferred choice for future space missions and deep space exploration missions. The use of low-enriched uranium (LEU) is promoted to achieve the goal of nuclear non-proliferation worldwide. In this study, a lithium heat pipe cooled space reactor with LEU (HP-LEU) was proposed based on Heat Pipes-Segmented Thermoelectric Module Converters (HP-STMCs), with the addition of moderators. The HP-LEU employs yttrium hydride (YH2) as the moderator and 19.9 % enriched uranium nitride (UN) as the fuel. The neutronics analysis has been performed on the HP-LEU reactor and the results have showed that the HP-LEU has a lifetime of more than 12 years. Two control systems have been applied in the reactor and have demonstrated the capacity to independently regulate and shut down the reactor. The total temperature reactivity coefficients are consistently negative, indicating that the HP-LEU reactor is inherently safe during operation. During normal operation, the temperatures of the materials are all acceptable. This study can serve as a reference for lithium heat pipe cooled space reactors with LEU.

A novel coaxial heat pipe with an inner vapor tube for cooling high power electronic devices

Improving heat transfer limit of heat pipe is important for their application in high-power equipment system. Shear stress at the liquid–vapor interface affects the heat transfer capacity of heat pipe. In this study, a novel coaxial heat pipe is designed to eliminate vapor entrainment from interfacial shear stress for the first time. An inner thin-walled tube is sintered with the powder wick in the adiabatic section by one-step sintering process. The effects of filling ratio and powder size of sintered wick on the thermal performance of coaxial heat pipe are investigated experimentally. The results indicate that the optimal powder size range for the sintered wick of coaxial heat pipe is 106–125 μm, while the optimal filling ratio is about 125 %. It means that the sintered wick with 106–125 μm powder can achieve better trade-off between capillary performance and permeability. The coaxial heat pipe can operate at heat loads of 70 ∼ 140 W with the total thermal resistance less than 0.06 °C /W. Moreover, compared with the normal heat pipe, the heat transfer capacity of coaxial heat pipe is increased by 57 %, while the evaporation temperature is decreased by 9.6 ∼ 19.1 °C and the total thermal resistance is decreased by 41 %∼320 %. The inner tube can improve the replenishment efficiency of working liquid by eliminating interfacial shear stress, resulting in the significant heat transfer improvement. The design of coaxial heat pipe is an effective and low-cost solution to improve the thermal performance of heat pipe.

Novel computational model for the failure analysis of composite pipes under bending

This study presents a novel computational model to investigate the bending behaviour of thin- and thick-walled composite pipes made from fully bonded fibre-reinforced thermoplastic composite materials. The primary objective is to analyse the stress state and predict potential failure modes of these pipes, which have gained significant interest in the oil and gas industry due to their advantageous properties. The developed model is validated through comparisons with finite element analysis and published results, demonstrating its accuracy and adaptability. Utilising the validated computational model, safety zones for composite pipes with various stacking sequences are established, providing valuable insights into the optimal design of composite pipes under bending loads. Furthermore, the method is employed to determine the maximum bending moment and critical bendable radius of the pipe, revealing the direct correlation between maximum bending moment and bending stiffness, independent of the bending radius. The findings of this study offer practical guidance for the design and optimisation of composite pipes in the oil and gas industry, promoting their adoption as a viable alternative to traditional metal pipes. The developed computational model serves as an efficient and reliable tool for engineers to make informed decisions in the design and selection of advanced composite materials for pipe applications, enabling the optimisation of pipe performance under various bending load scenarios.

Chezy's resistance coefficient in vaulted rectangular conduit

ABSTRACT Calculating resistance coefficients for flows in pipes and channels, such as the Darcy–Weisbach coefficient of friction and the Chezy or Manning coefficients, is a complex process aimed at accurately reflecting flow under load or a free surface. Generally, these coefficients are given as constants, although they can be challenging to ascertain due to implicit models expressing these coefficients. Therefore, the design of pipes and channels necessitates an explicit and comprehensible expression of the resistance coefficient, incorporating numerous flow parameters, including aspect ratio, kinematic viscosity, pipe slope, and roughness of internal walls. To achieve this outcome, we suggest employing the rough model method (RMM) giving the volume flowrate to identify the Chezy's resistance coefficient C in uniform and free surface flow for the vaulted rectangular conduit. This applies in both cases where the diameter of the geometric profile of the conduit is known or unknown.

Transport Behavior of Pure and Mixed Gas through Thermoplastic-Lined Pipes Materials

Abstract To determine the permeability properties of lining materials for the design of nonmetallic pipes in oil and gas fields, we conducted a study on the transport behavior of pure and mixed gases (carbon dioxide [CO2] / methane [CH4]) through commonly used thermoplastic-lined pipe materials. The material tested were high-density polyethylene (HDPE), polyamide (PA), and polyvinylidene fluoride (PVDF). It was observed that the permeability coefficient of the pure gas through HDPE, PA12, and PVDF increased with increasing temperature. The permeation of mixed gas with different volume fractions was also tested at different temperatures, in which the deviation between the test and the ideal state was founded. For HDPE and PVDF, the permeability coefficient of the mixed gas is higher than that of pure gas because of the plasticization effect of CO2. However, for PA12, the permeability coefficient of mixed gas is lower than that of the pure gas. This is because of the tight interaction between the chains and the competition between CO2 and CH4 for a limited number of active sites.