CHE Design

Line Sizing Equipment datasheet

• Contains equipment operating condition and other
I. Introduction
equipment details
• Line Sizing is a crucial aspect of system design
• Line size optimization is necessary to achieve Plot Plan
competitive cost
• Shows the equipment location and overall plant area
• Acceptable line size purely depends on the line sizing
Process flow diagram
philosophy (ex: Velocity requirement)
• Contains process data and shows the process flow in a
• Important upstream activity for several deliverables
specific block
Piping and instrumentation diagram
• Contains piping, instrumentation and process flow
details

III. General Guidelines

• When determining line size, the maximum flow rate
expected during the life of the facility should be
considered rather than the initial flow rate.
Deliverables after line sizing and hydraulics calculation
• It is also usually advisable to add a surge factor of 20
• Line list to 50% to the anticipated normal flow rate, unless
• Update P&ID surge expectations have been more precisely
• Pump data sheet determined by pulse pressure measurements in
• Compressor Data sheet similar systems or by specific fluid hammer
• Equipment Data sheet (Nozzles) calculation.
• 2-D/3D piping layout • Also, the effects of the ff. should be considered:
• Design Flow Rates
II. Necessary Design Input • Normal Flow Rates
• Minimum Flow Rate
Documents
• Startup
Project Hydraulic Calculation Procedure • Shutdown
• Describes the design & review procedures for • Upset
hydraulic calculations based on company standards Principle Pipe Design Criteria
Basic Engineering and Design Data (Site Data)
• Pressure drop per length (bar/100m or
• Contains basic operating data and conditions about
psi/100ft)
the plant operation and site location
• For cost optimization in utilities for non-
static equipment
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Fluid Velocity
• To predict noise, erosion, sonic velocity
Mechanical Consideration
• Rack Piping Minimum Size
• 1 inch (Some refines set 1.5” or 2” minimum)
• Avoid using 1-1/4”, 2-1/2”, 3”, 3-1/2” and 5” pipes
• To minimize purchasing, detailing and inventory
• For 2” and smaller pipe size, schedule 80 minimum is recommended.

Pipe Wall Thickness

• The pipe wall thickness required for a particular piping service is primarily a function of internal operating
pressure and temperature.
• The standards under which pipe is manufactured permit a variation in wall thickness below nominal wall
thickness.
• It is usually desirable to include a minimum corrosion/mechanical strength allowance of 0.050 inches for carbon
steel piping.
• The pressure design thickness required for a particular application may be calculated by the following equation:

Pi Do
t=
2(SE + Pi Y)
where: E = Longitudinal Weld Joint Factor
t = Pressure Design Thickness (in) = 1.0 for seamless
Pi= Internal Design Pressure (psig) = 0.85 for ERW
Do = Pipe OD (in) Y = Temperature Factor (0.4 for ferrous materials at
S = Allowable Stress in accordance with ANSI B31.3 900°F or below t < D/6)
(psi)
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Pipe Roughness

IV. Pressure Drop Calculations

Friction Factor
Internal forces
Reynold’s Number – dimensionless quantity that is used to predict flow patterns in different fluid flow
Viscous forces
situations.

ρϑD
Re =
μ
Where: Notes:
ρ= fluid density Re < 2000 Laminar Flow
ϑ=Flow velocity 2000 < Re < 4000 Transition Flow
D = Pipe diameter Re > 4000 Turbulent Flow
μ= Fluid Viscosity Re > 10000 Fully Turbulent
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Friction Factor by Moody Chart

Friction Factor by Equation

Colebrook Equation: Darcy- Weisbach Equation:

Where:
Churchill Equation:

General Rule:
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Pressure Drop for Liquid flow

Equation derived from Darcy’s:

ΔP for Laminar Liquid Flow (Re < 2000):

Elevation ΔP:
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Pressure drop for vapor flow Empirical Pressure Drop Equation

Density Change
1. Weymouth Equation:
• If line AP ≤ 10% of upstream absolute pressure, use
either upstream or downstream gas density for line
AP calculation.
• If total line AP < 40% of upstream absolute pressure,
use average gas density. 2. Panhandle Equation:

• This is because energy losses due to acceleration and

density variations can be neglected up to this limit.
• If total line AP > 40% of upstream absolute pressure,
design the line in sections. • For compressed air flowing in pipes ranging from 0.8"
to 11.8". In this range, friction factor is independent
of Re. no. and dependent upon the relative roughness.
General Pressure drop Equation:
• In practice, Panhandle eq. is commonly used for large
diameter (d>10") long pippelines (in miles).
3. Spitzglass Equation:

When ΔP < 10%, we can assume that:

Where: hw
Therefore, = Pressure Drop (inches of water)

• This equation is used for near- atmospheric pressure

lines. It is derived by making the following
assumptions:
a) f = (1+3.6/d+0.03d)(1/100)
b) T = 520°R
c) P1 = 15 psi
d) Z = 1.0 for ideal gas
e) ΔP < 10% of P1
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Pressure Drop for Two – Phase Flow

Simplified Darcy Equation (From API 4E):

The density of the gas/liquid mixture may be calculated using:

Modified Lockhart-Martinelli Method:

1. Calculate the pressure drop ΔP*G, assuming that the fluid is flowing at full vapor.
2. Calculate the pressure drop ΔP*L, assuming that the fluid is flowing at full liquid.
3. Calculate the ratio ΔP*G/ΔP*L
4. Calculate the actual liquid volume fraction.

5. Determine the two-phase multiplier ΔPTP/ΔP*L, based on the chart.

6. Calculate two-phase pressure drop ΔPTP
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Pressure Drop for Fittings and Valves

Coefficient of Resistance (K):

Resistance Due to Pipe Entrance and Exit:

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Using Equivalent Length: 100% Opening Valves & Fittings in feet

Using Equivalent Length: Exact equivalent length is equal to the length between flange or wielding ends
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Using Equivalent Length: Equivalent length are in terms of smaller diameter. Values applicable to DN 600

• For simplification, the pressure drop induced by fittings can be easily assumed by introducing a design factor (e.g. 3x of the
pipe length) rather than by calculating it one-by-one which is a more tedious method.
• Also, the introduction of a design factor can be done for revamp considerations.
• For manual valves, usually pressure drop is assigned as per project design criteria (e.g. check valve ΔP = 5.0 kPa).

V. Criteria for line sizing

A. For Liquid Lines
• Maximum velocities for sizing Liquid Lines
Notes:

1. For SS and titanium, the maximum velocity is limited by system design (available pressure drop/reaction forces)
2. Minimum velocity shall be normally be 0.8 m/s
3. Minimum velocity for CuNi is 1.0 m/s
When the service is intermittent, the velocity can be increased to 10 m/s. For CuNi the the maximum velocity is 6-10 m/s depending
on duration and frequency of operation
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• Liquid with corrosion inhibitors velocity • Reciprocal Pump Suction and Discharge Line
With corrosion inhibited fluids in carbon steel piping, • The suction piping shall be sized based on NPSH
the velocity shall be limited by a wall shear stress of requirements
40 N/m2 to maintain the corrosion inhibiting film at
the pipe wall, with the corresponding maximum
velocity:

Notes:
1. The values in metric units are based on NORSOK
• Velocity Criteria for Liquid Transport Through standards
Control Valve (API RP 14E Standard) 2. The values in SI units are based on API RP 14E
Maximum flow velocity should not exceed 15 ft/s (4.6
m/s) at maximum flow rates to minimize flashing • Pump - Net Positive Suction Head (NPSH)
ahead of the control valve. • It is the absolute inlet total head (in m or ft liquid) above
Minimum flow velocity should not be practically less the head equivalent to the vapor pressure.
than 3 ft/s (0.9 m/s) to minimize deposition of sand • The requirement to achieve sufficient inlet head such
and other solids. that the pressure at suction is always above the vapor
pressure of the fluid to avoid cavitation.
• Centrifugal Pump Suction and Discharge Lines • Pump - Net Positive Suction Head Available (NPSHA)
• The suction piping shall be sized based on NPSH • It is the absolute pressure (in m or ft liquid) at pumping
requirements. Maximum velocity from the previous temperature available at the pump suction flange above
table and the following maximum pressure drops pressure.
shall in general be used:
MAXIMUM NPSHA = ±hs – hL+ hA- hv,
LIQUID TYPE PRESSURE DROP
(bar/100m) Where:
Subcooled Liquids 0.25 hs = Static suction head (+) or static suction lift (-), ft
Boiling Liquids 0.05 hL = Suction line losses (friction, entrance and fittings),
ft
The fluid temperature shall be at least 15°C below the fluid hA = Absolute pressure at the liquid's free surface, in ft
boiling point temperature to allow sizing based on the of liquid pumped
criterion for subcooled liquids. hv = Vapor pressure of liquid at pumping temperature,
converted to ft of liquid
The maximum velocity in the discharge piping is given in
the previous table. As a guideline, a pressure drop due to
friction up to 0.9 bar/100m may be assumed.
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• Pump - Net Positive Suction Head Required (NPSHR) • Vertical Gravity Lines
• NPSH that results to 3% loss of head determined • When the Froude number is larger than 0.30, the entrained
by vendor by performance testing with water. vapor will be swept down with the liquid.
• It usually determine through vendor's pump curve. • For a Froude number between 0.30 and 1.2, frictional
• Recommended NPSH Margin resistance will compete with the gravitational forces and
• In general, NPSHA should always be greater than the flow will not be stable.
NPSHR (NPSHA > NPSHR) to avoid cavitation. • Froude number exceeding 1.2 will not manifest a stable
• A good rule of thumb is to require a 10% margin or flow.
5 ft of difference between NPSHA and NPSHR, • As general practice, Froude number should be keep below
whichever is greater. 0.30.
• Centrifugal Pump NPSH Margins • Exception to this is the drain line from a condenser to a
reflux drum with some non-condensable gas.
APPLICATION NPSH MARGIN (%)
Water (Cold) 10-35 (1)(2) B. For Gas Lines:
Hydrocarbon 10 • Maximum Velocity
Boiler Feed (Small) (3)
50 • In lines where pressure drop does not have a cost penalty,
High Energy (4)
100 - 200 gas velocity shall not exceed limits which may create noise
Notes: or vibration problems.
1. Depends on size, higher margin for larger pumps. • For trouble-free operation, the maximum velocity should
2. Min. 3 ft be maintained below 1/2 of the critical velocity or 60 m/s,
3. Up to 2500 hp at 3600 rpm which ever is lower.
4. Velocity> 100ft/s • Critical velocity is given by:

• Vertical Gravity Lines

• Vertical gravity lines shall be designed such that
the Froude number < 0.3 to avoid air entrainment
• Fluid Induced Noise
and ensure undisturbed flow without pulsation.
• The allowable maximum flow velocities in cases where
the maximum sound pressure levels of the piping
The Froude number is a measurement of bulk flow and
noises must be kept 8 to 10 dB(A) under the sound
depth interaction at a given cross section. It measures
pressure level of the background noise, are as follows:
the ratio of inertial and gravitational forces of a given
flow regime.
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• Recommended Pressure Drops • Two-Phase Flow Pattern – Overview

• The sizing of gas pipes should be based on the • Phase distribution take on some commonly observed flow
guidelines in the table below. The pressure drop structures, which are defined as two-phase flow patterns
should be prorated between the operating pressures that have particular identifying characteristics.
given. • Analogous to predicting the transition from laminar to
turbulent flow in single phase flows, two-phase flow
pattern maps are used in predicting the transition from
one type of two-phase flow pattern to another.

C. For Two-Phase Flow Lines

• Erosional Velocity:
• Flow lines, production manifolds, process headers
and other lines transporting gas and liquid in two-
phase should be sized primarily on the basis of flow
velocity.
• The erosion velocity can be calculated using the
following formula:

• Two-Phase Flow Pattern (Vertical Pipes):

• General industry practice uses conservative value

of c = 100 for continuous service and c = 125 for
• Churn Flow
intermittent service.
• If corrosion is controlled by inhibition or employing The structure of the flow becomes unstable with the fluid
corrosion resistant alloys, the constant c may vary traveling up and down in an oscillatory fashion but with a net
from 150 to 200 and values up to 250 for upward flow.
intermittent services.
This flow pattern is an intermediate regime between the
• Froude Number for Downflow Vertical Pipe :
slug and annular flow regimes. The mass of the slugs in a
• Froude number should be keep below 0.31.
churn flow may have a destructive consequence on the
piping system
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• Plug Flow
• This flow regime has liquid plugs that are separated by
elongated bubbles.
• Annular-Dispersed Flow
• At even larger gas flow rates, the liquid forms a
continuous annular film around the perimeter of the pipe,
• Annular Flow similar to that in vertical flow but the liquid is thicker at
This flow regime is particularly stable and is the desired the bottom than the top.
flow pattern for two-phase pipe flows. The liquid is expelled • The flow maps are only applicable to very long pipes with
from the center of the tubes and flows as a thick film on equilibrium. two-phase flow
the wall while the gas flows as a continuous phase up the
center of the tube. • Two phase Flow Pattern Map (Horizontal)

Baker Chart
• Two-Phase Flow Pattern (Horizontal Pipes):
• Dispersed Bubble
Flow
• The gas bubbles
are dispersed in
the liquid with a
high
concentration
of bubbles in
the half of the
tube due to their buoyancy. This flow regime typically
occurs only at high mass flow rates. • Two phase Flow Pattern Map (Vertical)
• Stratified Flow
• At low liquid and gas velocities, complete separation of
the two phases occurs
• Stratified-Wavy Flow
• Increasing the gas velocity in a stratified flow, waves are
formed on the interface and travel in the direction of flow.
• Slug Flow
• At higher gas velocities, the diameters of elongated
bubbles become similar in size to the channel height. The
liquid slugs separating such elongated bubbles can also be
described as large amplitude waves.
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D. Additional Checkpoints: VII. Pipe Routing Consideration

• Pump Suction Line vs. Discharge Line A. Basic of Pipe Routing
• Pump suction line should be larger than the discharge line. • Pipe lines are placed in sub-pipe racks,
• Control Valve Inlet vs. Outlet Line structures/platforms and main pipe rack or
• Outlet line should be at least equal or greater than the underground.
inlet line. • Access roads should not be used in laying down pipe lines
• Pressure Relief Valve Inlet vs. Outlet Line and must be cleared of any permanent structures.
• Outlet line should be at least one size larger than the inlet • Underground piping shall be assumed 1.0m below the
line. ground level, unless otherwise specified.
• As much as possible, avoid liquid and vapor pockets

VI. Line sizing assumptions

• Control Valve Pressure Drop (For Liquid System Only)
• Pressure drop of control valve, which is installed at the
discharge of pump, should be a minimum of 30% of the
system dynamic pressure loss at normal flow rate or 1.0
bar, whichever is greater. • When necessary, expansion loops are to be considered
• Normally, 10% of the total friction loss or 0.50 bar, for lines which could be subjected to thermal stress.
whichever is larger, is a guideline for standard system. • Branching should be at the bottom of the main line for
• Equipment Elevation liquid and at the top of the main line for the vapor.
• When skirt height is not fixed, 7m is used.
• Packaged Equipment Pressure Drop
• Common practice ranges from 0.50 to 1.0 bar, depending
on the service.

• Always consider operability and ergonomics when finding

Assumptions if data in unavailable:
the proper location for control valves, instruments and
• Pump Shut-off Ratio
instrumentations.
• When shut-off pressure ratio is not given, 1.25 is a safe
• Control valve should be placed where it is easily
assumption but should be noted in the hydraulic report.
accessible for the plant operator and near the
• Liquid Level
equipment where the control is required.
• For pump suction vessel, 50% of the TL-TL may be used
• Flowmeters should be placed at approximately 10D from
for a practical assumption but should be noted in the
hydraulic report or confirm with the client. the location where high velocity profile is expected.
• Control valve elevation should be at least 0.50m above
• Pipe Schedule Number
grade level (GL).
• If there is no available material service class table, STD
may be used as the pipe schedule number but should • Downstream
be line length of control valve used for throttling service
should be minimized as much as possible and without any pockets.
noted in the hydraulic report.
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• For compressors, piping shall have minimum change in • Elevated Equipment

direction with due consideration given to flexibility. TOB = Top of Beam
• Piping should not run directly over the equipment. XS = Structure
• Pump center line elevation should be at least 1.0m above GL = Ground Level
grade level (GL). FL = Floor

B. Pipe Rack Elevation & Piping Arrangement

• Ground Equipment

C. Plot plan & Its Elements

• Wind Rose
• A graphic tool used to give a view of
Steps to Consider:
how wind speed and direction are
typically distributed at a particular • Define the system.
location. • Divide the system into segments at points where the
flowrate and fluid properties change.
• Prevailing Wind • Underground piping shall be assumed 1.0m below the
• The trends in speed and ground level, unless otherwise specified.
direction of wind over a • In a plot plan, measure the pipe length from point to point
particular point on the (as divided in the previous step), considering also the
earth's surface. changes in elevation.
• Create the model in an organized and systematic way.
• Input the process data and equipment data needed.
• Assume initial pipe size.
• Assign fixed pressure points, free pressure points and
calculated pressure points.
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• Calculate.
• Check the result versus the criteria given in the project.
• Adjust the pipe size. (Do not forget to change the schedule
number when service class table is available.)
• Recalculate until all the criteria are satisfied.