Process Manufacturing worked example

Pressure Drop with process flow rate of 210 gal / min: a worked example in process manufacturing

Push process flow rate up to 210 gal / min and the picture changes. This example computes every intermediate figure at that operating point. screening whether a transfer path may create excess pressure drop or low flow

The inputs for this scenario

  • process flow rate: 210 gal / min (raised for this scenario; the documented default is 85)
  • line resistance factor: 0.08 psi per gpm (unchanged)
  • viscosity or density correction: 1.3 x (unchanged)
  • fittings, filter, and elevation factor: 1.2 x (unchanged)

Working through the calculation

  • Applying the documented formula (Pressure drop = flow rate × line resistance factor × fluid correction × fittings factor) to the inputs above produces each figure below.
  • At this operating point the engine returns 26.21 psi for estimated pressure drop, the number this scenario is built around.
  • At this operating point the engine returns 21.84 value for clean-line pressure drop.
  • At this operating point the engine returns 1.2 x for fittings and filter factor.
  • At this operating point the engine returns 16.8 value for flow resistance product.

How this compares with the baseline

  • Against the tool's baseline example, where process flow rate sits at 85 gal / min and the headline result is 10.61 psi, this scenario comes in 147% above the baseline at 26.21 psi.
  • It multiplies process flow rate by a line resistance factor, then applies a fluid (viscosity/density) correction and a combined fittings/filter/elevation factor to estimate total system pressure drop in psi. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • estimated pressure drop: 26.21 psi (headline result)
  • clean-line pressure drop: 21.84 value
  • fittings and filter factor: 1.2 x
  • flow resistance product: 16.8 value

Run it with your numbers

  • Every input above is editable in the live Pressure Drop calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.