How to calculate header pipe length

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Discussion Overview

The discussion revolves around calculating the losses in an equal length header pipe for a truck, specifically focusing on the impact of various bends (45, 60, 90, and 180 degrees) in 1.5 inch schedule 40 pipe. Participants explore the implications of header design on exhaust flow and pressure dynamics.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant seeks help in calculating losses through bends in the header pipe, emphasizing a desire to learn about the topic.
  • Another participant suggests that standard tables for loss calculations likely exist, indicating that engineers may commonly use such resources.
  • A link to a pipe flow resource is shared, though its applicability to the specific context of exhaust systems is questioned.
  • One participant argues that the equal length approach may prioritize equal volumes over equal losses, providing hypothetical data to illustrate their point about pressure drop in relation to exhaust flow.
  • Discussion includes the importance of pressure waves in header design, with references to established rules, testing, and computational fluid dynamics (CFD) as methods used in the field.
  • Several participants recommend automotive books on tuning, specifically mentioning works by Graham Bell as valuable resources.

Areas of Agreement / Disagreement

Participants express differing views on whether equal length headers are primarily about equal losses or equal volumes, indicating a lack of consensus on this aspect of header design.

Contextual Notes

Participants acknowledge the complexity of header design, including the potential limitations of steady-flow solutions in addressing the dynamics of exhaust systems.

Who May Find This Useful

This discussion may be of interest to automotive enthusiasts, engineers, and individuals involved in performance vehicle modifications, particularly those focused on exhaust system design.

SpencerC
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Hey guys n gals, Looking for a little help here. I am looking to build an equal length header for my truck and was wondering how to calculate the losses through the amount of 45, 60, 90 and 180deg bends for 1.5 sch.40 pipe. Now, for clarity, I do NOT mean equal centerline length, that's easy enough.

In the picture is an idea of what I am talking about. From right to left the first pipe would seem to have less friction loss than 3 or 4.

Explain it all, This curious mind likes to learn :) Thanks in advance.
 

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There have GOT to be standard tables for such losses...engineers must use that kind of stuff all the time...
 
I'm not so sure that the equal length approach is intended to give equal losses, it may be more important that the volumes be equal.

Just to make up a few numbers, a header pipe exhausting a one-liter cylinder running at 5000 rpm is going to pass about 80 cubic foot per minute (for a four stroke). If this pipe is about two feet long the pressure drop in the pipe is only a fraction of a psi (about 0.2). This is small relative to the pressure in the cylinder when the exhaust valve opens.

Header design is all about the pressure waves or pulses which take place due to the periodic stroking of the exhaust valve. There are a number of excellent textbooks out there that go into this in great detail. Commercial software such as that identified above is typically based on steady-flow solutions which are of no help in this instance. Headers are designed using (1) well established thumbrules,(2) extensive testing, and (3) maybe some sophisticated computational fluid dynamics (CFD). The price tag on those kinds of programs make the 700 GbPound price of the steady state piping program look cheeep.

Check Amazon dot com for automotive books with "tuning" in the title. A Graham Bell's books are classics, but there are many others.
 
gmax137 said:
Check Amazon dot com for automotive books with "tuning" in the title. A Graham Bell's books are classics...

seconded
 
Thanks a lot for the info guys. That really helped a lot.
 

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