Head Loss - Am I missing something?

TeapotMaster

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Hello all,

New reefer here, with a recently post-cycled tank.

My first couple of weeks were spent trying to figure out equipment specs. One of the main ones I was trying to dial in was finding the right return pump that would fit in my pump and deliver the right turnover to my 48 gal tank. I went by the rules of thumb to calculate head loss -- to each foot of vertical height, add 1ft for 90 degree elbows, for every 10ft of pipe, so forth an so on. In my case, I have a bit over 3 ft of vertical rise, four 90 degree turns, for a total of approx. 8 ft of head. Based on this info, I purchased a Varios2 which, based on published info, delivers at max speed ~250 gph at 8ft of head pressure. A little over 5x turnover, should do the trick if cranked full.

Then, I decided to ask my handy dandy AI for some help, which suggested I only had about 3.4 feet of head, since rule of thumb of 1ft per 90 degree elbow is bunk. Based on this, it estimated that i should be able to hit 10x turnover at speed 3 on the pump. No way, I said. So, I chopped up my plumbing to fit a tee at the top of one of the return lines and ran a hose for a bucket test.

Lo and behold, at speed 3, I am cranking out ~470 gph. Tested it several times with consistent results.

So, although I am absolutely stoked about the pump I bought (I could not hear it operating inside a monastery while wearing a stethoscope) I clearly spent a bit extra on an overpowered pump, when a much smaller Sicce silent would have done the trick.

The question is, am I missing something? Based on the above, the "rule of thumb" estimated double the true head pressure for my system. That's nowhere close. And if I am not missing anything, why are we still citing a rule of thumb that is in no way an approximation of reality?
 

KStatefan

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The one foot per fitting “rule” would only be true at one fluid velocity. The friction loss in pipes / fittings depends on the velocity of the fluid
 

BeanAnimal

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Lo and behold, at speed 3, I am cranking out ~470 gph. Tested it several times with consistent results.

So, although I am absolutely stoked about the pump I bought (I could not hear it operating inside a monastery while wearing a stethoscope) I clearly spent a bit extra on an overpowered pump, when a much smaller Sicce silent would have done the trick.

The question is, am I missing something? Based on the above, the "rule of thumb" estimated double the true head pressure for my system. That's nowhere close. And if I am not missing anything, why are we still citing a rule of thumb that is in no way an approximation of reality?
A few things.

First, rules of thumb are just that. Velocity is one variable among many. Wall smoothness, pipe diameter, fittings, layout, and other factors all play into the fluid dynamics and total head loss. Rules of thumb get you in the ballpark in many situations, and they exist because the actual math has too many variables for the average, or even above average, reefer to apply for a better answer.

With DC speed controlled hobby pumps, you almost always want to buy oversized, often significantly oversized. The speed control circuits are built with marginally spec’d electronic components that will live a much longer life when run at lower power.

So, buy big and run at 75% or less and the pump will almost always outlive the same DC pump run at 100%.
 

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