Hydraulic System Calculator
Calculate TDH, pump sizing, turnover rates, and chemical dosing for your high-purity system commissioning projects
Why These Calculations Matter
Proper hydraulic system design is critical for successful cleaning, passivation, and commissioning operations
Total Dynamic Head
Determines pump size needed to overcome static elevation, friction losses, and system pressure requirements.
System Turnovers
Ensures complete chemical contact with all surfaces. ASTM requires minimum turnovers for each process step.
Chemical Concentration
Accurate dosing is essential for effective treatment. Too little yields poor results; too much wastes money.
Flow Velocity
Optimal velocity (3-6 ft/s) ensures turbulent flow for cleaning while preventing erosion damage.
Toggle above to switch between entering flow rate or target velocity. The other value calculates automatically based on pipe size.
Reference: 0 = pump level. Positive = above pump, Negative = below pump.
• Wear appropriate PPE (goggles, gloves, face shield)
• Ensure adequate ventilation
• Have neutralizing agents available
• Never mix acids with bleach/chlorine
• Monitor temperature during dissolution
Trusted by Industry Leaders
From pharmaceutical giants to aerospace pioneers, our calculations help ensure successful commissioning every time
📚 Reference Tables
Essential data for material properties, chemical characteristics, and industry standards
Pipe Material Friction (C Values)
| Material | C Value |
|---|---|
| PVC / CPVC / HDPE | 150 |
| Stainless Steel | 140 |
| Copper | 140 |
| Carbon Steel (new) | 130 |
| Lay Flat Hose | 120 |
| Reinforced Hose | 115 |
| Rubber Hose | 110 |
| Carbon Steel (10yr) | 100 |
Chemical Specific Gravities
| Chemical | Conc. | SG |
|---|---|---|
| Citric Acid | 50% | 1.24 |
| Nitric Acid | 67% | 1.41 |
| Nitric Acid | 52% | 1.33 |
| Phosphoric Acid | 85% | 1.69 |
| Sodium Hydroxide | 50% | 1.53 |
| Sodium Hydroxide | 25% | 1.27 |
| Sodium Hypochlorite | 12% | 1.17 |
| Hydrogen Peroxide | 35% | 1.13 |
Flow Velocity Guidelines
| Velocity | Class | Notes |
|---|---|---|
| < 2 ft/s | Too Low | Settling risk |
| 2 - 3 ft/s | Low | Acceptable |
| 3 - 6 ft/s | Optimal | Best cleaning |
| 6 - 8 ft/s | Elevated | Monitor noise |
| > 8 ft/s | Too High | Erosion risk |
Fitting Equivalent Lengths
| Fitting | L/D |
|---|---|
| Ball Valve (open) | 3 |
| Gate Valve (open) | 8 |
| Camlock | 8 |
| 45° Elbow | 16 |
| 90° LR Elbow | 20 |
| 90° Elbow | 30 |
| Y-Strainer | 40 |
| Check Valve | 50 |
ASTM Passivation Standards
| Method | Conc. | Temp |
|---|---|---|
| Citric (A967) | 4-10% | 120-150°F |
| Nitric (A380) | 20-50% | 70-120°F |
| Nitric + Dichromate | 20%+2% | 120-140°F |
Pipe Volume (gal/100 ft)
| Size | ID | Vol |
|---|---|---|
| 1/2" | 0.622" | 1.6 |
| 1" | 1.049" | 4.5 |
| 1-1/2" | 1.610" | 10.6 |
| 2" | 2.067" | 17.5 |
| 3" | 3.068" | 38.5 |
| 4" | 4.026" | 66.3 |
⚠️ Important Disclaimer
This calculator is provided for estimation and planning purposes only. Results should be verified by qualified engineers before implementation.
- Verify all calculations independently before use in actual projects
- Consult applicable codes and standards (ASTM, ASME, FDA)
- Engage qualified engineers for system design and equipment selection
- Follow manufacturer specifications for all chemicals and equipment
Clean X Passivation Solutions LLC is not responsible for any errors, omissions, or damages resulting from the use of this calculator.