Shane,
Who said I used a program?
Actually I used a spreadsheet that Sanjay is working on for an article he is doing on plumbing. It's not ready for distribution or anything and I'm not entirely sure what his plans are for it (an attachment to article or what). I think he is going to try to get it published in advanced aquarist in the July or August issue.
The problem with most calculations are that the whole thing is a circular argument. You don't calculate the head loss at 3,000 gph because the flow isn't going to be 3,000 gph because there is going to be head loss. You have to guess what the flow rate will be and calculate the head loss based on that and keep doing it over and over again until the flow rate you used to calculate the friction losses actually matches the performance curve of the pump you are using. If you use the same facts and circumstances as you ran on the RC calculator at 2,000 gph you get the following:
Using the following input parameters:
Friction Factor = .0155
Vertical Length = 7
Horizontal Length = 12
Pipe Diameter = 1.5
Flow Rate = 2000
90° Elbows = 1
45° Elbows = 0
Head losses are calculated as
Frictional head loss is 2.42 foot head or 1.05 psi.
Elevation head loss is 7 foot head or 3.02 psi.
Total head loss is 9.42 foot head or 4.07 psi.
When you look at the ampmaster performance curve they show 1,800 gph at 11' head and 2,520 gph at 8' head so if you split the difference to get to 9.5 you would get 2,160 gph. So my friction loss calculated at 2,000 gph would actually be to low and I would need to guess again and do the whole calculation over. Say maybe using 2,075 gph. You can see it is a circular argument and it actually takes multiple calculaitons. Sanjays spreadsheet includes a solver to tackle the circular calculation.
I actually used 3 - 90 degree elbows in my calculation with the spreadsheet and thats why I got a little lower number.
FWIW, Nathan