Hydronic Pipe Sizer

Darcy-Weisbach pipe sizing for hydronic systems
Inputs

Sizing Method
Results
Recommended Size
in. nominal
Velocity
Head / 100 ft
Total Head
Pressure Drop
Adjust Size
in.
⚠ Velocity exceeds 8 ft/s — erosion risk. Consider upsizing.
⚠ Laminar flow (Re < 2300) — head loss may be underestimated.
Fluid Properties at Temperature
Density
Viscosity
Reynolds No.

All Sizes —
Nom. (in.) ID (in.) Vel. (ft/s) HL / 100ft OK?
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About This Calculator

This hydronic pipe sizer selects a nominal pipe size for chilled water, hot water, and glycol systems by computing velocity and friction head loss for every size in the chosen material schedule. Enter the flow in GPM, fluid temperature, and equivalent length; the tool returns the smallest size that meets your sizing target, along with velocity, head loss per 100 ft, total head, and pressure drop.

Two sizing methods are supported. Equal Friction picks the first size at or below a target friction rate (ft per 100 ft); Velocity picks the first size at or below a target velocity. Fluid density and viscosity are interpolated from temperature, and 30% ethylene or propylene glycol corrections are applied so antifreeze systems size correctly.

Formula & Method
VelocityV (ft/s) = Q (GPM) × 0.002228 ÷ A   A = π · (d ÷ 24)²
ReynoldsRe = V · D · ρ ÷ μ
Head losshL = f · (L ÷ D) · V² ÷ (2 · g)
Friction fColebrook–White (turbulent); f = 64 ÷ Re (laminar)

Sizing uses the Darcy–Weisbach equation with the Colebrook–White friction factor, solved iteratively, the standard basis for hydronic pipe sizing in ASHRAE Fundamentals. The constant 0.002228 converts GPM to cubic feet per second (1 GPM ≈ 0.002228 ft³/s); g = 32.174 ft/s². For Reynolds numbers below 2,300 the flow is laminar and f = 64 ÷ Re. Pipe roughness ε is set per material (steel ≈ 0.00015 ft, copper and plastic much smoother).

Frequently Asked Questions
What head loss should I target when sizing hydronic pipe?
For most chilled and hot water mains, a friction rate of about 1–4 feet of head per 100 feet of pipe is common practice, with 2.5 ft/100 ft a frequent default. Lower rates save pump energy but increase pipe cost; higher rates reduce pipe size but raise pumping power and noise. This tool defaults to 2.5 ft/100 ft and lets you adjust the target.
Why does the calculator cap velocity near 8 ft/s?
Above roughly 8 ft/s, water velocity in steel pipe causes noise and accelerates erosion-corrosion at fittings and elbows. A practical minimum near 2 ft/s helps carry entrained air and dirt toward separators. The tool flags a velocity warning above 8 ft/s so you can consider upsizing.
How does glycol change the pipe size?
Glycol antifreeze raises both density and viscosity relative to water. The higher viscosity increases friction loss for the same flow, so a glycol line often needs to be one size larger than a water line. This tool applies approximate 30% ethylene and propylene glycol corrections to density and viscosity before computing the Reynolds number and friction.
What is Reynolds number used for here?
The Reynolds number determines whether flow is laminar or turbulent and which friction equation applies. Below about 2,300 the flow is laminar and friction factor equals 64 divided by Reynolds number; above that the tool solves the Colebrook-White equation iteratively. A laminar-flow warning appears if Reynolds number drops below 2,300, where head loss can be underestimated.
Related Tools
Pipe Head Loss Pipe Velocity & Friction Pump Selector Glycol Correction GPM / Tons / ΔT Pipe Insulation Heat Loss Control Valve Cv Balancing Valve Cv
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Results are design estimates for preliminary sizing. Verify final designs against applicable codes and standards — engineering judgment and a licensed professional engineer’s review are required.