Section 9 - Technical Reference

Calculating Pipe Sizes & Pressure Drops in Vacuum Systems

Piping design is an integral part of a well-designed central vacuum system. One critical element of piping design is pressure drop. Pressurized systems have an unlimited pressure range within which to operate, so pressure drops are not usually as critical. Vacuum systems, by definition, must operate between 0 and 29.92HgV, (a 14.7 psi maximum differential). So, for this reason alone, pressure drops must be considered carefully. There is a second important reason to limit pressure drops in a vacuum system. As vacuum level increases due to P, the volume of a given mass flow of a gas expands in proportion to the ratio of the pressures. High pressure drops, therefore, increase the flow in ACFM, requiring a larger vacuum system to do the job. This means higher power consumption and higher initial equipment cost. An example will illustrate the potential magnitude of the problem.
Example P1 = 20HgV (Vacuum requirement at farthest outlet) Anticipated pressure drop = 5Hg V1 = 200 ACFM (ACFM required at outlet, ignoring pressure drops) P2 = Vacuum requirement at system, factoring in P Solve for V2 1. 2. P1V1 = P2V2 Convert all pressures to absolute

P1 = 29.92HgV - 20HgV = 9.92HgAbs P2 = 9.92HgAbs - 5Hg P = 4.92HgAbs

3. Solve for V2 (Volume, after accounting for pressure drops)

V2 = (P1/P2) * V1 V2 = (9.92/4.92) * 200 V2 = (2.02) * 200 V2 = 404 ACFM In this example, system volume has doubled due to pressure drop of 5Hg. If the system pressure drop were limited to only 1Hg, the volume required at the vacuum system would have only been 222 ACFM, instead of the 404 ACFM required above. Every situation is different, due to system design vacuum level, and P through piping, valves and fittings. However, the ratio of pressures always governs the amount of expansion.

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Section 9 - Technical Reference

The goal of piping design is to reduce capital and installation costs, by using the smallest reasonable piping size for the application. This must be weighed against the increased cost and reduced operating efficiency of the vacuum system, as a result of higher pressure drops. A good rule of thumb is to limit the total pressure drop through all piping, valves and fittings to no more than 2 - 3 Hg. This is usually acceptable for systems operating between atmospheric pressure and approximately 22HgV. Pressure drop should be lower on higher vacuum systems, (aim for 10% of the design pressure as expressed in Absolute terms). It is always a good idea to go through the calculations, especially on higher vacuum systems. The ratio of pressures will show the impact on volume expansion and efficiency.
Selecting Piping and Fittings

The table below shows the estimated pressure drop per 100 feet of new pipe, based on an operating vacuum level of 20HgV, and flows from 50 2,000 ACFM. All pressure drops are shown in inches of mercury. Pressure drops through valves and fittings must be added to the anticipated pressure drop of the piping, to obtain total system P.
Example

What is the pressure drop through 400 feet of 4 pipe with a flow of 200 ACFM ? The chart below shows a pressure drop of 0.1Hg per 100 feet of 4 pipe, for a total pressure drop of 0.4Hg for 400 feet of piping. This would be a good selection, since valves and fittings will add additional pressure drops to the piping system (see next page). In most piping systems, there will also be smaller branch lines leading to the point of use, which will result in additional pressure drops. It is best to begin sizing with the longest pipe run first, working from the smallest pipe diameter to the largest. A diagram, with pressures and flows, makes the job easier.
PIPE SIZE
Inches 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.2 0.6 4.4 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.2 0.5 2.2

Estimated Pressure Drop per 100 Feet of New Pipe

(PRESSURE DROP IN INCHES OF MERCURY) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.2 0.4 1.1 4.5 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.3 0.7 1.9 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.6 1.4 4.0 0.0 0.0 0.0 0.0 0.0 0.1 0.2 1.0 2.3 0.0 0.0 0.0 0.0 0.1 0.1 0.4 1.4 3.4 0.0 0.0 0.0 0.0 0.1 0.2 0.5 2.0 4.7 0.0 0.0 0.0 0.0 0.1 0.3 0.8 3.3 0.0 0.0 0.0 0.0 0.2 0.4 1.2 5.0 0.0 0.0 0.0 0.1 0.2 0.6 1.7 0.0 0.0 0.0 0.1 0.3 0.8 2.3 0.0 0.0 0.0 0.1 0.4 1.0 2.9 0.0 0.0 0.0 0.1 0.5 1.2 3.6 0.0 0.0 0.1 0.2 0.6 1.5 4.3

PIPE SIZE
Inches

16 12 10 8 6 5 4 3 2.5 2 1.5 1 0.5 ACFM 50 100 150 200 FLOW @ 20.0 inHg (Gage)

300

400

500

600

16 12 10 8 6 5 4 3 2.5 2 1.5 1 0.5 800 1000 1200 1400 1600 1800 2000 ACFM

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Section 9 - Technical Reference

Accounting for Pressure Drops Through Valves and Fittings

Pressure drops through valves and fittings can often result in higher pressure drops than caused by the piping itself, due to increased turbulence and changes of direction. When sizing for pressure drops, calculate the equivalent length (in feet) of all fittings and valves in a piping run, then add that to the actual length of piping. The chart below provides approximate equivalent lengths for various fittings and fully open, full-ported gate valves.

PIPE SIZE
(Inches)

Pressure Drop Effect of Pipe Fittings

(Equivalent Feet added to Pipe Run)
Elbow Tee (Branch) Tee (Run) Gate Valve*

8 6 5 4 3 2.5 2 1.5 1 0.5

20 16 13 11 8 7 6 5 3 2

40 31 25 21 16 13 11 9 6 4

14 11 9 7 6 5 4 3 2 1

6 5 4 3 2 2 2 1 1 1

* Note: Valve equivalent lengths are estimates based on using a fully open, full-ported gate valve. Other valve types and designs can have dramatically higher pressure drops, and data should be verified with the manufacturer.

1. 2. 3. 4. 5. 6. 7. 8. 9.
Notes:

Sketch out the piping system, listing all valves and fittings in a specific run. Start at the point of use, and work back toward the vacuum system. Count all valves and fittings in a specific pipe run. Obtain equivalent length from table above. Add sum of equivalent lengths to actual length of piping. Use Chart on previous page to estimate P in that pipe run. Repeat this process with other branch lines. Add ACFM flows of all branch lines feeding into a header or main, and repeat the above process for the header. Repeat for each pipe run, until piping design is complete. Verify that pressure drops are within total acceptable limits.

Consider using the starting vacuum switch setting for the lead vacuum pump as your baseline vacuum level when calculating pressure drops and designing the piping system.

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