Line Sizing for Single Phase Liquid

Prepared by:
Hafif Aulia Nur Rahman
https://www.linkedin.com/in/hafifaulianurrahman/

January, 30th 2024

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Liquid Sizing for Single Phase Liquid

• Case Study
Perform calculations to ascertain the pipe diameter necessary for optimal liquid flow in accordance
with the process requirements at a Gathering Station, utilizing the provided data for sizing the
pipeline:
1. Pipe Material = Carbon Steel / Commercial Steel
2. Pipe Condition = New
3. Pipe Class = B3CS2F
4. Mass Flow Rate, (M) = 500,000 lb/hr
5. Mass Density, () = 60.57 lb/ft3
6. Viscosity, () = 0.37 cP
7. Length, (L) = 100 ft (assumption for this case study)
*Note : The fluid properties are generated from Process Simulation (HYSYS).

The following are the design criteria that must be considered when sizing the pipeline size:
1. Minimum Velocity = 3 ft/s, as per API RP 14E, 5th Ed.
2. Maximum Velocity = 15 ft/s, as per API RP 14E, 5th Ed.
3. Maximum Pressure Drop = 0.9 bar/100 m (3.96 psi/100 ft), as per NORSOK P-001
*Note : Those criteria are based on API standard and NORSOK P-001. However, you are allowed
to use other velocity and pressure drop criteria if your company follows different standards.

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• Solution
1. Determine the Pipe Roughness Value () for the pipe based on its specifications.
• Pipe Material = Carbon Steel / Commercial Steel
• Pipe Condition = New
• Pipe Roughness Value = 0.0018 in (0.045 mm)

*Note :
1. Source = Darby, Ron and Chhabra, Raj P., 2017, Chemical Engineering Fluid Mechanics
(3rd Ed.), CRC Press, New York.
2. You can use the VLOOKUP function to make it easier to determine the Pipe Roughness
Value.

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2. Take any Nominal Pipe Size (NPS) and Schedule Number as trial and error that will be used
in the next calculations.
Option 1 Option 2 Option 3
Nominal Pipe Size [in] 4 6 8
Schedule No. SCH40 SCH40 SCH40
Inside Diameter, (ID) [mm] 102.26 154.05 202.71
[in] 4.03 6.06 7.98

The pipe inside diameter for the chosen NPS and Schedule No. is determined using the table
provided below:
Inside Diameter (mm)

SCH10 SCH20 SCH30 SCH40 SCH60 SCH80 SCH100 SCH120 SCH140 SCH160 STD XS XXS SCH5S SCH10S SCH40S SCH80S
0.50 15.80 13.87 11.84 15.80 13.87 6.40 18.03 17.12 15.80 13.87
3/4 20.93 18.85 15.54 20.93 18.85 11.02 23.37 22.45 20.93 18.85
1 27.86 26.64 24.31 20.70 26.64 24.31 15.21 30.10 27.86 26.64 24.31
1.5 42.72 40.89 38.10 33.99 40.89 38.10 27.94 44.96 42.72 40.89 38.10
2 54.79 52.50 49.25 42.85 52.50 49.25 38.18 57.02 54.79 52.50 49.25
3 82.80 77.93 73.66 66.65 77.93 73.66 58.42 84.68 82.80 77.93 73.66
4 108.20 102.26 97.18 92.05 87.33 102.26 97.18 80.06 110.08 108.20 102.26 97.18
6 154.05 146.32 139.72 131.75 154.05 146.32 124.38 162.73 161.46 154.05 146.32
8 206.40 205.00 202.71 198.45 193.67 188.90 182.55 177.82 173.05 202.71 193.67 174.62 213.53 211.55 202.71 193.67
10 260.30 257.45 254.50 247.65 242.87 236.52 230.17 222.25 215.90 254.50 247.60 222.20 266.24 264.66 254.50 247.60
12 311.20 307.08 303.22 295.30 288.90 280.97 273.05 266.70 257.20 304.80 298.45 273.10 315.92 314.70 304.80 298.45
14 342.90 339.80 336.55 333.35 325.42 317.50 307.95 300.02 292.10 284.17 336.55 330.20 347.67 346.05
16 393.70 390.60 387.35 381.00 373.07 363.52 354.02 244.47 333.35 325.42 387.35 381.00 398.01 396.85
18 444.50 441.40 434.95 428.65 419.10 409.55 398.47 387.35 377.85 366.72 438.15 431.80 448.81 447.65
20 495.30 489.00 482.60 477.82 466.75 455.62 442.92 431.80 419.10 407.97 489.00 482.60 498.45 496.45
22 546.10 539.75 533.40 514.35 501.65 488.95 476.25 463.55 450.85 539.75 549.25 547.72
24 596.90 590.60 581.05 574.65 560.37 547.67 531.82 517.55 504.85 490.52 590.60 584.20 598.52
26 644.55 635.00 641.35 635.00
28 695.35 685.80 679.45 692.15 685.80
30 746.20 736.60 730.25 742.95 736.60 749.30
32 796.95 787.40 781.05 777.85 793.75 787.40
34 846.12 838.20 831.85 828.65 844.55 838.20
36 898.55 889.00 882.65 876.30 895.35 889.00
38 945.94 914.20
40 996.95
42 1047.74 1041.40
44 1098.55 1092.20
46 1149.34 1143.00
48 1200.15 1193.80

*Note : You can utilize the MATCH and INDEX functions in MS. Excel to simplify the search
for the Inside Diameter value according to the chosen NPS and Schedule No.

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3. Calculate the Volumetric Flow Rate (Q) using the following formula:
M
Qactual =
ρ
Where:
M = Mass Flow Rate (lb/hr)
 = Mass Density (lb/ft3)
lb
500,000
Qactual = hr = 8,254.78 ft 3 ⁄hr
lb
60.57 3
ft

Convert the calculation result into BPD (Barrel per Day) unit using the CONVERT function
or multiplying it manually by the conversion constant, 4.2746.
ft3 hr
Qactual = CONVERT ((8,254.78 hr ) , "ft^3", "barrel") ∗ 24 day = 35,286 BPD, or

ft 3 barrel hr
Qactual = 8,254.78 ∗ 4.2746 ∙ = 35,286 BPD
hr ft 3 day

As the pipe being sized is new, add a design margin of 10% (based on common engineering
practice) to determine the Design Volumetric Flow Rate (Qdesign).
Qdesign = 35,286 BPD ∗ (1 + 10%) = 𝟑𝟖, 𝟖𝟏𝟒 𝐁𝐏𝐃

4. Calculate the Specific Gravity (SG) using the following formula:

ρ
SG =
lb
62.366 3
ft
lb
60.57 3
SG = ft = 𝟎. 𝟗𝟕𝟏
lb
62.366 3
ft
The Specific Gravity parameter will later be used in calculating the pressure drop.

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5. Calculate the Fluid Velocity (v) using the following formula:

0.012 ∗ Qdesign
v=
ID2
Where:
v = Fluid Velocity (ft/s)
Qdesign = Design Volumetric Flow Rate (BPD)
ID = Pipe Inside Diameter (in)
Reference: Eq. 2.1 page 15, API RP 14E (R2013), 5th Ed.

For example, for Option 1 where the NPS = 4 in, Schedule No. = SCH40, and ID = 4.03 in,
the following result is obtained:
0.012 ∗ 38,814 BPD
v= = 𝟐𝟖. 𝟕𝟒 𝐟𝐭 𝟑 ⁄𝐬
(4.03 in)2

By using the same formula, Fluid Velocity is obtained for Option 2 and Option 3.
Option 1 Option 2 Option 3
Nominal Pipe Size [in] 4 6 8
Schedule No. SCH40 SCH40 SCH40
Inside Diameter, (ID) [mm] 102.26 154.05 202.71
[in] 4.03 6.06 7.98
Fluid Velocity, (v) [ft/s] 28.74 12.66 7.31

6. Calculate the Reynolds Number (Re) using the following formula:

ρ ∗ ID ∗ v
Re =
μ
Where:
Re = Reynolds Number (dimensionless)
 = Mass Density (lb/ft3)
ID = Pipe Inside Diameter (ft)
v = Fluid Velocity (ft/s)
 = Viscosity (lb/ft.s), or
= cP divided by 1,488, or
= cSt times SG and then divided by 1,488
Reference: Eq. 2.3 page 15, API RP 14E (R2013), 5th Ed.

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For example, for Option 1, the following result is obtained:

lb 4.03 in ft
60.57 ∗( in ) ∗ 28.74 s
ft 3 12
Re = ft = 𝟐, 𝟑𝟐𝟑, 𝟑𝟓𝟓
0.37
1,488

By using the same formula, Fluid Velocity is obtained for Option 2 and Option 3.
Option 1 Option 2 Option 3
Nominal Pipe Size [in] 4 6 8
Schedule No. SCH40 SCH40 SCH40
Inside Diameter, (ID) [mm] 102.26 154.05 202.71
[in] 4.03 6.06 7.98
Fluid Velocity, (v) [ft/s] 28.74 12.66 7.31
Reynolds Number, (Re) 2,323,355 1,542,268 1,172,050

7. Calculate the Friction Factor (f)

If laminar flow occurs in the pipe (Re < 2,000), utilize the following formula:
64
f=
Re
Where:
f = Friction Factor (dimensionless)
Re = Reynolds Number (dimensionless)
Reference: Page 1-6, Crane (1986)

However, if turbulent flow occurs (Re > 4,000), utilize the Swamee-Jain equation to obtain the
Friction Factor (f).
0.25
f= 2
ε⁄ID 5.74
[log10 ( 3.7 + 0.9 )]
Re
Where:
f = Friction Factor (dimensionless)
 = Pipe Roughness Value (in)
ID = Pipe Inside Diameter (in)
Re = Reynolds Number (dimensionless)

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Let’s calculate the Friction Factor (f) for Option 1. The calculated Reynolds Number is greater
than 4,000. So, use the Swamee-Jain equation:
0.25
f= 2 = 𝟎. 𝟎𝟏𝟔𝟔𝟎
0.0018 in⁄4.03 in 5.74
[log10 ( + )]
3.7 (2,323,355)0.9

By using the same formula, Friction Factor is obtained for Option 2 and Option 3.
Option 1 Option 2 Option 3
Nominal Pipe Size [in] 4 6 8
Schedule No. SCH40 SCH40 SCH40
Inside Diameter, (ID) [mm] 102.26 154.05 202.71
[in] 4.03 6.06 7.98
Fluid Velocity, (v) [ft/s] 28.74 12.66 7.31
Reynolds Number, (Re) 2,323,355 1,542,268 1,172,050
Friction Factor, (f) 0.01660 0.01548 0.01492

8. Calculate the Pressure Drop (∆P)

0.00115 ∗ f ∗ Q2design ∗ SG
∆P =
ID5
Where:
∆P = Pressure Drop (psi/100 ft)
f = Friction Factor (dimensionless)
Qdesign = Design Volumetric Flow Rate (BPD)
SG = Specific Gravity (dimensionless)
ID = Pipe Inside Diameter (ft)
Reference: Eq. 2.2 page 15, API RP 14E (R2013), 5th Ed.

For example, for Option 1 the following result is obtained:

0.00115 ∗ 0.01660 ∗ (38,814 BPD)2 ∗ 0.971
∆P = = 𝟐𝟔. 𝟒𝟏 𝐩𝐬𝐢⁄𝟏𝟎𝟎 𝐟𝐭
(4.03 in)5

If the length of the pipeline (L) is 100 ft, then the pressure drop is:
psi psi
∆P = ∆P ( ) ∗ L (ft) = 26.41 ∗ 100 ft = 𝟐, 𝟔𝟒𝟎 𝐩𝐬𝐢
100 ft 100 ft

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The following is the calculated pressure drop for Option 2 and Option 3:
Option 1 Option 2 Option 3
Nominal Pipe Size [in] 4 6 8
Schedule No. SCH40 SCH40 SCH40
Inside Diameter, (ID) [in] 4.03 6.06 7.98
Fluid Velocity, (v) [ft/s] 28.74 12.66 7.31
Pressure Drop, (∆P) [psi/100 ft] 26.41 3.17 77.57
[psi] 2,641 317 78

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• Conclusion
Based on the results of the calculations carried out in the previous section, it can be concluded
that:
1. Option 1, featuring NPS = 4 in and SCH40, indicates a calculated velocity exceeding the
threshold (15 ft/s), suggesting a potential for flashing before the control valve. Moreover,
the computed pressure drop significantly surpasses the acceptable limit (3.96 psi/100 ft).
Thus, NPS 4 in is deemed unsuitable and unsafe for selection.
2. Option 2 (NPS = 6 in and SCH40) and Option 3 (NPS = 8 in and SCH40) maintain
calculated velocities within the acceptable range (3 - 15 ft/s), effectively preventing sand
and solid deposition by ensuring fluid velocity remains above 3 ft/s. Additionally, the risk
of flashing before the control valve is minimized as fluid velocity remains below 15 ft/s.
Furthermore, both Option 2 and Option 3 maintain pressure drops below the stipulated
criteria (3.96 psi/100 ft), making them suitable choices to meet process requirements.
3. For economic reasons, given that both Option 2 and Option 3 meet the design criteria,
Option 2 (NPS 6 in and SCH40) is selected as the appropriate pipe size for the process
needs at the Gathering Station.
Option 1 Option 2 Option 3
Nominal Pipe Size [in] 4 6 8
Schedule No. SCH40 SCH40 SCH40
Inside Diameter, (ID) [in] 4.03 6.06 7.98
Fluid Velocity, (v) [ft/s] 28.74 12.66 7.31
Pressure Drop, (∆P) [psi/100 ft] 26.41 3.17 77.57
[psi] 2,641 317 78
CRITERIA
Minimum Velocity [ft/s] 3
Maximum Velocity [ft/s] 15
Maximum Pressure Drop [psi/100 ft] 3.96
CONCLUSION
Velocity Check OV! OK OK
Pressure Drop Check OPD! OK OK
Remark NOT OK OK OK
Selected Size [in] 6

*Note : The step-by-step calculation results may have slight differences because the
data/numbers listed in this document are rounded off from those in MS. Excel.

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ATTACHMENT
LINE SIZING CALCULATION

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Prepared by: Hafif Aulia Nur Rahman htps://www.linkedin.com/in/hafifaulianurrahman/

LINE SIZING
CALCULATION SHEET

Project Title : FEED Chemical EOR Project No. : ---

Client : World Govt. Oil and Gas Company Phase/CTR : ---
Document No. : --- Page : 1 of 1
Activity : Line Sizing for Single Phase Liquid
DATE REVISION BY CHECKED APPROVED

29-Jan-24 0A HR --- ---

LINE SIZING - SINGLE PHASE LIQUID

British Unit

LINE DETAILS
P&ID No. : ---

Line No. : ---

From : Discharge of Water Injection Pump (P-1001)

To : Discharge Header of Water Injection Pumps (P-1001/02/03)

PIPE DETAILS
Pipe Material Commercial Steel

Condition New

Pipe Roughness Value, (e) [in] 0.00180

Pipe Class B3CS2F

INPUT
Option 1 Option 2 Option 3

Nominal Pipe Size [in] 4 6 8

Schedule No. SCH40 SCH40 SCH40

Inside Diameter, (ID) [in] 4.03 6.06 7.98

Additional Design Margin [%] 10

Mass Flow Rate, (M) [lb/hr] 500,000

Mass Density (r) [lb/ft3] 60.57

Viscosity, (m) [cP] 0.37

Length, (L) [ft] 100

OUTPUT
Actual Volumetric Flow Rate, (Qactual) [BPD] 35,286

Design Volumetric Flow Rate, (Qdesign) [BPD] 38,814

Specific Gravity, (SG) 0.971

Option 1 Option 2 Option 3

Fluid Velocity, (v) [ft/s] 28.74 12.66 7.31

Reynolds Number, (Re) 2,323,355 1,542,268 1,172,050

Relative Roughness, (e/ID) 0.00045 0.00030 0.00023

Friction Factor, (f) 0.01660 0.01548 0.01492

Pressure Drop, (∆P) [psi/100 ft] 26.41 3.17 0.78

[psi] 2,640.59 317.34 77.57

CRITERIA
Minimum Velocity [ft/s] 3

Maximum Velocity [ft/s] 15

Maximum Pressure Drop [psi/100 ft] 3.96

CONCLUSION
Option 1 Option 2 Option 3

Velocity Check OV! OK OK

Pressure Drop Check OPD! OK OK

Remark NOT OK OK OK

Selected Size [in] 6

NOTES
➢ This spreadsheet was generated using several references:
1. -----, 2013, API RP 14E (R2013) : Recommended Practice for Design and Installation of Offshore Production Platform Piping Systems (5th Ed.),

American Petroleum Institute (API), Washington D. C.

2. Crane, 1982, Flow of Fluids Through Valves, Fittings and Pipe, Crane Co., New York.

3. -----, 2006, NORSOK Standard P-001 : Process design (5th Ed.), Standards Norway, Norway.

4. Darby, Ron and Chhabra, Raj P., 2017, Chemical Engineering Fluid Mechanics (3rd Ed.), CRC Press, New York.

➢ The fluid properties are generated from Process Simulation (HYSYS), Doc. No. ---.

Confidential 1/29/2024 Page 1 of 1