(233d) Pipe-Flow Challenge: An Open-Ended, Experiential Engineering Module Based on Fluid Dynamics

As engineering educators, we are always wanting for lab modules that are some combination of interesting, challenging and feasible. As chemical engineering educators specifically, we also need more laboratory exercises that require students to build.

The pipe-flow challenge is a fluids-based, open-ended laboratory where students practice the application of science and math for building a fluid network that achieves a design objective within certain constraints. As important, the components for this lab are easily and cheaply acquired from any local hardware store.

The pipe-flow challenge requires components including valves, quick connects, and straight tubing typically found in every day domestic plumbing. Our lab makes use of the PEX line of tubing, fittings and gauges, and a Barracuda ½ horsepower model pump. When connected with a regular sink faucet, this system is ready to evaluate pressure / flow relationships in order to understand fluid dynamic calculations.

Students apply science by testing and measuring system pressures relative to flow rates in order to characterize, e.g., pump curves, pipe roughness and friction factors, and K-values for fittings and valves. Students apply math using best-fit regression between measured and calculated pressure drops based on appropriate fluid dynamic friction equations. Finally, students are required to build a fluid network to deliver a certain number of gallons of water within pre-defined constraints. Constraints may include a designated pump running time, a minimum or maximum number and type of fittings and pipe / diameter combinations, and distance and elevation change requirements.

The pipe-flow challenge has many potential extensions. For instance, packed beds can be made with glass beads of varying size and shape, with pressure/flow data to estimate best fit parameters for the Ergun equation. With a plug-in power meter to measure pump voltage and current, parameters including pump power and efficiency can be included in either the objectives or the constraints. The pipe-flow challenge also spans multiple disciplines and is practical for both civil and mechanical engineering students.

The pipe-flow challenge was first incorporated into the Unit Operations lab at Trine University in 2021. This talk will present on the materials, methods, and design objectives developed over the past three iterations of implementation. By attending, audience members will appreciate the materials and methods as well as learning objectives and outcomes associated with applying the pipe flow challenge on their own campuses.