Line Sizing Examples for Incompressible and

Compressible Fluids (Single and Two Phase)

(Hand Calculation)

Prepared by:
Sina Avaji

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1. Introduction
Line sizing is apparently an easy task but incorrect sizing leads to damages such as
corrosion, disinvestment, and etc. The main purpose of preparing this file is to solve
some examples of line sizing for compressible and incompressible fluids base on
their concept. It means hand calculation and step by step without relying on
computers. First, it is necessary to get acquainted with some important equations of
this topic.

2. Basic Equations
1. Darcy-Weisbach Equation
P1 P2

Flow

1 2
L
Assumption:
 Diameter of pipe is constant (𝑉1 = 𝑉2 )
 Incompressible Fluid
 Without Elevation Change (ℎ1 = ℎ2 )
𝑃1 > 𝑃2

Based on the Bernoulli’s Principle:

1 1
𝑃1 + 𝜌𝑉12 + 𝜌𝑔ℎ1 = 𝑃2 + 𝜌𝑉22 + 𝜌𝑔ℎ2 + ℎ𝑓 (1)
2 2

ℎ𝑓 = Head loss due to friction

Based on the assumptions and divide by 𝜌𝑔:
𝑃1 − 𝑃2
ℎ𝑓 = (2)
𝜌𝑔

Frictional Force at (1):

𝐹1
𝑃1 = → 𝐹1 = 𝑃1 × 𝐴
𝐴

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Frictional Force at (2):
𝐹2
𝑃2 = → 𝐹2 = 𝑃2 × 𝐴
𝐴
Total Frictional Force for (L):
𝐹
𝐹1 − 𝐹2 = 𝐹 → 𝑃1 − 𝑃2 = (3)
𝐴
Also, Frictional Force can be calculated by:

𝐶𝐷 × 𝜌 × 𝑉 2 × 𝐴𝑤𝑒𝑡𝑡𝑒𝑑 𝐶𝐷 × 𝜌 × 𝑉 2 × (𝜋𝐷𝐿)
𝐹= = (4)
2 2
𝐶𝐷 × 𝜌 × 𝑉 2 × (𝜋𝐷𝐿) (5)
𝐹 2
𝑃1 − 𝑃2 = → 𝑃1 − 𝑃2 = =
𝐴𝐶𝑟𝑜𝑠𝑠 𝐴

𝐶𝐷 × 𝜌 × 𝑉 2 × (𝜋𝐷𝐿)
2 2𝐶𝐷 𝜌𝑉 2 𝐿
=
𝜋𝑑2 𝐷
4

Note:
𝑓
(𝐶𝐷 = )
4
𝑓 = Friction Factor
Darcy’s Eq. Pressure drop along the L meter of the pipe can be calculated by
below equation:
𝑓𝐿𝜌𝑉 2
→ 𝑃1 − 𝑃2 = (6)
2𝑑

And:
𝑃1 − 𝑃2 = 𝜌𝑔ℎ𝑓

𝑓𝐿𝑉 2
→ ℎ𝑓 = (7)
2𝑔𝑑

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2. Reynolds Equation
𝜌𝑉𝐷
𝑅𝑒 = (8)
𝜇
Laminar flow: 𝑅𝑒 < 2100
Turbulent flow: 𝑅𝑒 > 4000
Transient Region: 2100 < 𝑅𝑒 < 4000

Example 1: Incompressible Fluid (Liquid)

Flow
Column

Fluid Liquid (Discharge of the pump)

Flow rate (Over Design Flow Rate, 1.1X 124061.9 kg/hr.
Normal Flow)
Density 1107 Kg/m3
Viscosity 1.9 cp
Pressure 4.12 bara
Temperature 135 °C
𝜀 0.0018 inch
Pressure Drop: 0.6- 0.9 bar/Km
Design Criteria for Pump Discharge Up to 3”: 0.6 m/s
Velocity:
>3” : 0.9 m/s

(a) First guess for diameter: 8”

8”=8×0.0254=0.2032 m

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 𝑚3 𝑚 𝐾𝑔 𝑚 3600 𝑠 𝐾𝑔
𝑄 ( ) = 𝑉 ( ) × 𝐴(𝑚2 ) → 𝑄 ( ) = 𝑉 ( ) × 𝐴(𝑚2 ) × × 𝜌( 3 )
𝑠 𝑠 ℎ 𝑠 ℎ 𝑚
𝑄 124061.9 𝑚 𝑚
→𝑉= = = 0.96 > 0.9 → Not Acceptable
3600𝜌𝐴 0.20322 𝑠 𝑠
3600 × 1107 × π × 4

(b) Second guess for diameter: 10”

𝑊 124061.9 𝑚 𝑚
𝑉= = = 0.613 < 0.9 → Acceptable Velocity
3600𝜌𝐴 0.2542 𝑠 𝑠
3600 × 1107 × π × 4
𝐾𝑔 𝑚
𝜌( ) × 𝑢( ) × 𝐷(𝑚) 1107 × 0.613 × 0.254
𝑅𝑒 = 𝑚3 𝑠
= = 90716.9
𝐾𝑔 1.9 × 10−3
𝜇 (𝑐𝑝) × 10−3 (
𝑚. 𝑠)

Based on the calculated Re number and the Moody diagram, friction factor is about
0.02. (See the below diagram)
𝜀 0.0018"
= = 0.00018
𝐷 10"

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Note: Below equation is an accurate equation and it can be used for (f) calculation.
For laminar flow regime: Re < 2100 or 2300 (based on some references)
64
𝑓= (9)
Re
𝜀
Where 5000 <Re< 108 and 10-6 < < 10-2 (For turbulent flow):
𝐷

1.325
𝑓=
𝜀 5.74 (10)
[ln(𝐷 + 0.9 )]2
𝑅𝑒

1.325
𝑓= = 0.02
0.0018 5.74 2
[ln( 10 + )]
90716.90.9
Now pressure drop along the line can be calculated per each 100 m.

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 𝑓𝐿𝜌𝑉 2 0.02 × 100 × 1107 × 0.6132 𝑏𝑎𝑟 𝑏𝑎𝑟
∆𝑃 = = = 1637.7 𝑃𝑎 = 0.0164 → 0.16 ()
2𝐷 2 × 0.254 100𝑚 1𝐾𝑚
Selected Diameter= 10”

3. Compressible Fluid
ENERGY BALANCE OF A FLOWING FLUID
1. Elevation potential (z,)
2. Kinetic energy, u2/2g,
3. Internal energy, U,
4. Work done in crossing the boundary, PV,
5. Work transfer across the boundary, Ws,
6. Heat transfer across the boundary, Q.
With single inlet and outlet streams of a uniform region, the change in internal
energy within the boundary is:

𝑑(𝑚𝑢) = 𝑚𝑑𝑢 + 𝑢𝑑𝑚 = 𝑚𝑑𝑢 + 𝑢(𝑑𝑚1 − 𝑑𝑚2 )

𝑢12 𝑢22 (11)
= 𝑑𝑄 − 𝑑𝑊𝑠 + [𝐻1 + + 𝑔𝑍1 ] 𝑑𝑚1 − [𝐻2 + + 𝑔𝑍2 ] 𝑑𝑚2
2 2

For steady state conditions d(mu)=0, and dm1=dm2=dm.

∆𝑢2 𝑄 − 𝑊𝑠 ∆𝑢2 𝑄 − 𝑊𝑠
∆𝐻 + + 𝑔∆𝑧 = => ∆𝑈 + ∆(𝑃𝑉) + + 𝑔∆𝑧 = (12)
2 𝑚 2 𝑚

Now, we can apply this equation for a differential length:

dL
𝑑𝐻 + 𝑢𝑑𝑢 + 𝑔𝑑𝑍
Flow

dQ dWs

Friction is introduced into the energy balance by noting that it is a mechanical

process, dWf, whose effect is the same as that of an equivalent amount of heat
transfer dQf Moreover, the total effective heat transfer results in a change in entropy
of the flowing liquid given by:
𝑇𝑑𝑆 = 𝑑𝑄 + 𝑑𝑤𝑓

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Based on the thermodynamic:

𝑑𝐻 = 𝑉𝑑𝑃 + 𝑇𝑑𝑆 => 𝑑𝐻 = 𝑉𝑑𝑃 + 𝑑𝑄 + 𝑑𝑤𝑓 (13)

By substituting Eq.13 into the Eq.12, mechanical energy balance equation can be
obtained.

𝑉𝑑𝑃 + 𝑢𝑑𝑢 + 𝑔𝑑𝑍 = −(𝑑𝑊𝑠 + 𝑑𝑊𝑓 ) (14)

𝑓𝑢2
According to the friction work (𝑑𝑊𝑓 = 𝑑𝐿) :
2𝐷

𝑓𝑢2
𝑉𝑑𝑃 + 𝑢𝑑𝑢 + 𝑔𝑑𝑍 + 𝑑𝐿 = −𝑑𝑊𝑠 (15)
2𝐷

Three cases of particular importance are of isentropic or isothermal or adiabatic

flows. Equations will be developed for them for ideal gases, and the procedure for
non-ideal gases also will be indicated.
Ideal gas (Isentropic Flow)
In short lines., nozzles, and orifices, friction and heat transfer may be neglected,
which makes the flow essentially isentropic. Work transfer also is negligible in such
equipment. (Assumptions: Q= 0, dz= 0 (without elevation change), Ws= 0):
1
𝑑𝐻 + 𝑢𝑑𝑢 = 0 → 𝐻2 − 𝐻1 + (𝑢12 − 𝑢22 ) = 0 (16)
2
𝑢𝐴 𝑚 2 2
𝜈2 2 𝐴2 × 𝜈1 2
𝑚= = 𝜌𝑢𝐴 → 𝑢 = → 𝑢1 − 𝑢2 = (𝑚 ) [1 − ( ) ] (17)
𝜈 𝜌𝐴 𝐴2 𝐴1 × 𝜈2

For ideal gas we can use:

𝐻2 − 𝐻1 = 𝐶𝑃 (𝑇2 − 𝑇1 ) (18)

And:
𝑇2 𝑃2 𝐾−1 𝑉1
= ( ) 𝐾 = ( )𝐾 (19)
𝑇1 𝑃1 𝑉2

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 2𝑃1 0.5 𝐾 𝑃2 2/𝐾 𝑃
𝑚 ( 𝑉1 ) [𝐾 − 1 ((𝑃1 ) − (𝑃2 )𝐾+1/𝐾 )]0.5
1
→ =
𝐴2 𝐴2 2 𝑃2 2/𝐾 0.5
[1 − (𝐴 ) (𝑃 ) ]
1 1

as the pressure falls, the cross section at first narrows, reaches a minimum at which
the velocity becomes sonic; then the cross section increases and the velocity
becomes supersonic. In a duct of constant cross section, the velocity remains sonic
at and below a critical pressure ratio given by:

𝑃𝑆 2 𝑘/(𝑘−1)
= (20)
𝑃1 𝐾 + 1

𝑢𝑠 = √𝐾𝑅𝑇/𝑀𝑤 (21)

𝐾𝐽
𝑅 = 8.314 , T shall be absolute temperature.
𝐾𝑚𝑜𝑙.𝐾

𝐾𝑔. 𝑚
𝐽 𝑁. 𝑚 2 .𝑚
×𝐾 ×𝐾 √ 𝑠 ×𝐾 𝑚
𝑢𝑠 = √ 𝑚𝑜𝑙. 𝐾 = √ 𝑚𝑜𝑙. 𝐾 = 𝑚𝑜𝑙. 𝐾 =
𝐾𝑔 𝐾𝑔 𝐾𝑔 𝑠
𝑚𝑜𝑙 𝑚𝑜𝑙 𝑚𝑜𝑙

Mach Number:
𝑢 𝑢
𝑀= = (22)
𝑢𝑠 √𝐾𝑅𝑇/𝑀𝑤

Ideal gas (Isothermal flow)

When elevation head and work transfer are neglected, the mechanical energy balance
equation with the friction term become:
𝑓𝑢2
𝑉𝑑𝑃 + 𝑢𝑑𝑢 + 𝑑𝐿 = 0 (23)
2𝐷

We can substitute the u by below equation:

𝑢 𝑃1 𝑉1 𝑑𝑉 𝑑𝑃
𝐺 = 𝜌𝑢 = &𝑉 = → =−
𝑉 𝑃 𝑉 𝑃

𝑃𝑑𝑃 2
𝑃1 𝑓𝐺 2 𝐿
→ + 𝐺 ln ( ) + =0 (24)
2𝑃1 𝑉1 𝑃 2𝐷

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Applying the inlet and outlet conditions:
(𝑃22 − 𝑃12 ) 𝑃1 𝑓𝐺 2 𝐿 𝑓𝐿 𝑃1
2
+ 𝐺 ln ( ) + =0 , 𝑃22 = 𝑃12 − 2𝑃1 𝑉1 𝐺 2 [ + ln ( )] (25)
2𝑃1 𝑉1 𝑃2 2𝐷 2𝐷 𝑃2

For convenience, logarithmic term can be neglected by a good approximation. So,

𝑓𝐿
𝑃22 = 𝑃12 − 2𝑃1 𝑉1 𝐺 2 (26)
2𝐷

Ideal gas (Adiabatic flow)

In this condition we can start with below equation.

𝐺 2
𝑢 (
2
𝜌) 𝐺 2 𝜈𝑑𝜈
𝑑𝐻 = −𝑢𝑑𝑢 = −𝑑 ( ) = −𝑑 ( ) = −𝑑 ( ) (27)
2𝑔 2𝑔 2𝑔

(28)
𝑅𝑘 𝑘
𝑑𝐻 = 𝐶𝑝 . 𝑑𝑇 = 𝑑𝑇 = 𝑑(𝑃𝜈)
𝑘−1 𝑘−1

𝑘−1 2 𝑘 − 1 𝐺2 (29)
→ 𝑑(𝑃𝜈) = ( ) 𝐺 𝜈𝑑𝜈 => 𝑃𝜈 = 𝑃1 𝜈1 − ( ) (𝜈 − 𝜈12 )
𝑘 𝑘 2

Rearranging Eq.29 for P2:

𝑃2 𝑉2 𝑇2 𝑘−1 2 𝑉2
= =1+( 𝑀 )(1 − ( )2 ) (30)
𝑃1 𝑉1 𝑇1 2𝑘 𝑉1

Also we know that:

𝑑𝑉
𝑉𝑑𝑝 = 𝑑(𝑝𝑉) − (𝑃𝑉) (31)
𝑉

𝑓𝑢2 𝑓(𝐺𝑉)2 (32)

𝑉𝑑𝑃 + 𝑢𝑑𝑢 + 𝑑𝐿 = 0 → 𝑉𝑑𝑃 + 𝐺 2 𝑉𝑑𝑉 + 𝑑𝐿 = 0
2𝐷 2𝐷

By substituting the 𝑉𝑑𝑃 we have:

𝑑𝑉 2
𝑓(𝐺𝑉)2
𝑑(𝑃𝑉) − 𝑃𝑉 + 𝐺 𝑉𝑑𝑉 + 𝑑𝐿 = 0 (33)
𝑉 2𝐷

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And finally substituting the Eq.29 into Eq.30 and multiplying through by
2𝑘/𝐺 2 𝑉 2 :

𝑑𝑉 2𝑘𝑃1 𝑉1 2
𝑑𝑉 𝑑𝑉 𝑘𝑓
2 −[ + (𝑘 − 1)𝑉1 ] + (𝑘 − 1) + 𝑑𝐿 = 0 (34)
𝑉 𝐺2 𝑉3 𝑉 𝐷
Integrating from V1 to V2 and L= 0 to L:
𝑉2 1 2𝑘𝑃1 𝑉1 1 𝑘𝑓𝐿
(𝑘 + 1)𝑙𝑛 + [ 2
+ (𝑘 − 1)𝑉12 ] ( 2 2 )+ =0
𝑉1 2 𝐺 𝑉2 − 𝑉1 𝐷

𝑓𝐿 1 2𝑘𝑃1 𝑉1 𝑉1 2 𝑘 + 1 𝑉1
= [ + (𝑘 − 1)] [1 − ( ) ] + ln( ) (35)
𝐷 2𝑘 𝐺2 𝑉2 2𝑘 𝑉2

In terms of the Mach number:

𝑓𝐿 1 2 𝑉1 2 𝑘 + 1 𝑉1 2
= [(𝑘 − 1) + 2 ] [1 − ( ) ] + ln( ) (36)
𝐷 2𝑘 𝑀 𝑉2 2𝑘 𝑉2

Example 2: Steam at the rate of 7000 kg/h with an inlet pressure of 23.2
bara and temperature of 220 ℃ flows in a line that is 77.7mm diameter
and 305 m long. Viscosity is 28.5×10-6 N.s/m2 and specific heat ratio is k
= 1.31. For the pipe, 𝜀/D = 0.0006. The pressure drop will be found in:
(a) isothermal flow;
(b) adiabatic flow. Also,
(c) the line diameter for sonic flow will be found.
According to steam table: ρ = 11.6 Kg/m3
𝜌 × 𝑢 × 𝐷 𝐺𝐷
𝑅𝑒 = =
𝜇 𝜇
𝑚 7000 𝐾𝑔
𝐺 = 𝜌𝑢 = →𝐺= 2 = 410 2
𝐴 0.0777 𝑚 .𝑠
3600 × 𝜋 × 4
410 × 0.0777
→ 𝑅𝑒 = = 1.12 × 106
28.5 × 10−6
Based on the Moody diagram and 𝜀/D = 0.0006, friction factor is about 0.019.

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 1.31 × 8.314 × 1000 × (220 + 273.15) 𝑚
𝑢𝑠 = √ = 546.25
18 𝑠

𝑢 𝐺/𝜌 410/11.6
𝑀= = = = 0.065
𝑢𝑠 𝑢𝑠 546.25

If we assume a constant density for gas and consider it as an incompressible fluid:

410 2
𝑓𝐿𝜌𝑉 2 0.019 × 305 × 11.6 × (11.6)
∆𝑃 = = = 5.4 𝑏𝑎𝑟𝑎
2𝐷 2 × 0.0777
𝑃2 = 23.2 − 5.4 = 17.8 𝑏𝑎𝑟𝑎
∆𝑃 = 23.2 − 17.8 = 5.4 𝑏𝑎𝑟

a) Isothermal flow
𝑓𝐿
𝑃22 = 𝑃12 − 2𝑃1 𝑉1 𝐺 2
2𝐷
1
2𝑃1 𝑉1 𝐺 2 = 2 × 23.2 × 105 × × 4102 = 6.724 × 1010
11.6
𝑓𝐿 0.5 0.019 ∗ 305 0.5
𝑃2 = (𝑃12 − 2𝑃1 𝑉1 𝐺 2
) = [(23.2 × 105 )2 10
− 6.724 × 10 × ]
2𝐷 2 × 0.0777

5 2
0.019 ∗ 305 0.5
𝑃2 = 10 × [23.2 − 6.724 × ] = 1700000 𝑝𝑎 = 17 𝑏𝑎𝑟
2 × 0.0777
∆𝑃 = 23.2 − 17 = 6.2 𝑏𝑎𝑟

b) Adiabatic flow
𝑓𝐿 1 2 𝑉1 2 𝑘 + 1 𝑉1 2
= [(𝑘 − 1) + 2 ] [1 − ( ) ] + ln( )
𝐷 2𝑘 𝑀 𝑉2 2𝑘 𝑉2

0.019 × 305 1 2 𝑉1 2 1.31 + 1 𝑉1 2

= [(1.31 − 1) + 2
] [1 − ( ) ]+ ln( )
0.0777 2 × 1.31 0.065 𝑉2 2 × 1.31 𝑉2

𝑉1 2 𝑉1 𝑉1
→ 74.6 = 180.8 × [1 − ( ) ] + 0.88 × ln( )2 → = 0.766
𝑉2 𝑉2 𝑉2
Regarding to the Eq.30, P2 can be calculated:

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𝑃2 𝑉2 𝑇2 𝑘−1 2 𝑉2
= =1+( 𝑀 )(1 − ( )2 )
𝑃1 𝑉1 𝑇1 2𝑘 𝑉1
𝑃2 𝑉2 1.31 − 1
=1+( × 0.0652 ) (1 − (1.305)2 ) = 0.999
𝑃1 𝑉1 2 × 1.31
𝑉1
→ 𝑃2 = 𝑃1 × × 0.999 = 23.2 × 0.766 × 0.999 = 17.75 𝑏𝑎𝑟
𝑉2
∆𝑃 = 23.2 − 17.75 = 5.45 𝑏𝑎𝑟

C) Diameter of Line for Sonic Flow

Critical pressure drop can be calculated based on the Eq.20.
𝑃2 2 𝑘/(𝑘−1) 2 1.31/(1.31−1)
= = = 0.544
𝑃1 𝐾 + 1 1.31 + 1
By using from Eq.30:

𝑉2 𝑃1 𝑘−1 2 𝑉2 2 𝑘−1 2 𝑉2 2
= [1 + ( 𝑀 ) (1 − ( ) )] = 1.8382 × [1 + ( 𝑀 ) (1 − ( ) )]
𝑉1 𝑃2 2𝑘 𝑉1 2𝑘 𝑉1

Mach number:
𝑤
𝐷2 7000 × 4
𝑢 3600𝜌 × 𝜋 −4
𝑀= = 4 = 3600 × 11.6 × 3.14 × 𝐷2 = 3.94 × 10
𝑢𝑠 546.25 546.25 𝐷2

For define the diameter of the line related to the sonic flow, we should solve three
below equations simultaneously.
3.94 × 10−4
1) 𝑀 =
𝐷2
𝑉2 𝑘−1 2 𝑉2 2
2) = 1.8382 × [1 + ( 𝑀 ) (1 − ( ) )]
𝑉1 2𝑘 𝑉1

𝑓𝐿 1 2 𝑉1 2 𝑘 + 1 𝑉1 2
3) = [(𝑘 − 1) + 2 ] [1 − ( ) ] + ln( )
𝐷 2𝑘 𝑀 𝑉2 2𝑘 𝑉2

First guess for D: 2.5” = 0.06 m

𝑀 = 0.1094
𝑉2 𝑉1
= 1.832 → = 0.544
𝑉1 𝑉2

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𝑓𝐿 0.019 × 305
= 45.3 → = 45.3 → 𝐷 = 0.128 𝑚
𝐷 𝐷
It can be seen that two values of diameter (calculated and guess) are not equal. So
we change our guess to the 0.07 m.
Second guess for D: 3” = 0.07 m
𝑀 = 0.080
𝑉2 𝑉1
= 1.835 → = 0.545
𝑉1 𝑉2
𝑓𝐿 0.019 × 305
= 84.25 → = 84.25 → 𝐷 = 0.069 𝑚 ≅ 0.07 𝑚
𝐷 𝐷
So, 0.07 m or 3” is diameter that sonic flow occurs.

Example 3: Define the appropriate line size for below stream.

Natural Gas (35758 Kg/h)

Components
Nitrogen 0.0109
Methane 0.9685
CO2 0.00242
Ethane 0.0123
Propane 0.00216 Design Criteria T=40°C, P=17 bara, Mw=16.4 kg/kmol
i-Butane 0.00054 Parameter Allowable Range ν=0.012 cP, ρ=11.16 kg/m3
n-Butane 0.00085 ΔP 0.11-0.45 bara/100m
i-Pentane 0.00041 ρV2 15000 Kg/m.s2
3
n-Pentane 0.00042 ρV 200000 Kg/s3
n-Hexane 0.0015 V 46 m/s (max.)

By using Hysys simulation it can be calculated: 𝑘 = 1.33 & 𝑍 = 0.97

A) At the first we assume that density of the gas is constant along the pathway.
First guess: 12” = 0.305 m
𝑊 35758
𝑉= = = 12.18 𝑚/𝑠
3600𝜌𝐴 0.3052
3600 × 11.16 × π × 4

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 𝐾𝑔
𝜌𝑉 2 = 11.16 × 12.182 = 1655.6 (Vibration)
𝑚.𝑠2
𝐾𝑔
𝜌𝑉 3 = 11.16 × 12.183 = 20165 𝑠3 (Noise)
𝜌 × 𝑢 × 𝐷 11.16 × 12.18 × 0.305
𝑅𝑒 = = = 3454857 ≅ 3.5 × 106
𝜇 × 10−3 0.012 × 10−3
1.325
→𝑓= = 0.018
0.0018 5.74 2
[ln( 10 + )]
34548570.9
2
𝑓𝐿𝜌𝑉 0.018 × 100 × 11.16 × 12.182
∆𝑃 = = = 4885.4 𝑃𝑎 = 0.05 𝑏𝑎𝑟
2𝐷 2 × 0.305

Check for: 10” = 0.254 m

𝑊 35758
𝑉= = = 17.6 𝑚/𝑠
3600𝜌𝐴 0.2542
3600 × 11.16 × π × 4
𝐾𝑔
𝜌𝑉 2 = 11.16 × 17.62 = 3456
𝑚. 𝑠 2
𝐾𝑔
𝜌𝑉 3 = 11.16 × 17.63 = 60842
𝑠3
𝜌 × 𝑢 × 𝐷 11.16 × 17.6 × 0.254
𝑅𝑒 = = = 4157472 ≅ 4 × 106
𝜇 × 10−3 0.012 × 10−3
𝜀
= 0.00018
𝐷
From moody diagram: 𝑓 = 0.018
𝑓𝐿𝜌𝑉 2 0.018 × 100 × 11.16 × 17.62
∆𝑃 = = = 12248.93 𝑃𝑎 = 0.12 𝑏𝑎𝑟
2𝐷 2 × 0.254
This size is correct and acceptable due to it is affordable. We can also do the
calculations for 8” diameter.
Check for: 8” = 0.203 m
𝑊 35758
𝑉= = = 27.5 𝑚/𝑠
3600𝜌𝐴 0.2032
3600 × 11.16 × π ×
4
𝐾𝑔
𝜌𝑉 2 = 11.16 × 17.62 = 8439.75
𝑚. 𝑠 2
𝐾𝑔
𝜌𝑉 3 = 11.16 × 17.63 = 232093.125 3
𝑠

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Noise value is not in range, so 8” is not suitable.
B) Ideal Gas (isothermal flow)
Line 10”:
𝑓𝐿
𝑃22 = 𝑃12 − 2𝑃1 𝑉1 𝐺 2
2𝐷
1
𝑃22 = (17 × 105 )2 − 2 × (17 × 105 ) × × (11.16 × 17.16)2
11.16
0.018 × 100
×
2 × 0.254
=> 𝑃2 = 1687706.6 𝑃𝑎 = 16.8 𝑏𝑎𝑟
∆𝑃 = 17 − 16.87 = 0.13 𝑏𝑎𝑟
C) Ideal Gas (Adiabatic flow)

𝑢𝑠 = √𝐾𝑅𝑇/𝑀𝑤

1.33 × 8.314 × 1000 × (40 + 273.15) 𝑚

𝑢𝑠 = √ = 459.5
16.4 𝑠
𝑢 17.16
𝑀= = = 0.04
𝑢𝑠 459.5
𝑓𝐿 1 2 𝑉1 2 𝑘 + 1 𝑉1 2
= [(𝑘 − 1) + 2 ] [1 − ( ) ] + ln( )
𝐷 2𝑘 𝑀 𝑉2 2𝑘 𝑉2
0.018 × 100 1 2 𝑉1 2 1.33 + 1 𝑉1 2
= [(1.33 − 1) + ] [1 − ( ) ] + ln( )
0.254 2 × 1.33 0.042 𝑉2 2 × 1.33 𝑉2
𝑉1
→ = 0.992
𝑉2
Regarding to the Eq.30, P2 can be calculated:
𝑃2 𝑉2 𝑇2 𝑘−1 2 𝑉2
= =1+( 𝑀 )(1 − ( )2 )
𝑃1 𝑉1 𝑇1 2𝑘 𝑉1
𝑃2 𝑉2 1.33 − 1
=1+( × 0.042 ) (1 − (1.008)2 ) = 1
𝑃1 𝑉1 2 × 1.33

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 𝑉1
→ 𝑃2 = 𝑃1 × × 1 = 17 × 0.992 × 1 = 16.864 𝑏𝑎𝑟
𝑉2
∆𝑃 = 17 − 16.864 = 0.14 𝑏𝑎𝑟

4. Pressure Drop due to Fitting and Valve

Friction due to fittings, valves and other disturbances of flow in pipe lines is
accounted for by the concepts of equivalent lengths of pipe. This is an important
issue and shall be considered in process calculations.
𝑢2
∆𝑃 = 𝑓(𝐿 + ∑ 𝐿𝑖 ) × 𝜌
2𝐷
Below table illustrates the equivalent length for diverse fitting and valves.

Medium Long Gate Globe Swing

Pipe size Standard 45°
Radius Radius Tee valve Valve Check,
(in.) Ell. Ell.
Ell. Ell. (Open) (Open) (Open)

1 2.7 2.3 1.7 1.3 5.8 0.6 27 6.7

2 5.5 4.6 3.5 2.5 11 1.2 57 13
3 8.1 6.8 5.1 3.8 17 1.7 85 20
4 11 9.1 7 5 22 2.3 110 27
5 14 12 8.9 6.1 27 2.9 140 33
6 16 14 11 7.7 33 3.5 160 40
8 21 18 14 10 43 4.5 220 53
10 26 22 17 13 56 5.7 290 67
12 32 26 20 15 66 6.7 340 80
14 36 31 23 17 76 8 390 93
16 42 35 27 19 87 9 430 107
18 46 40 30 21 100 10.2 500 120
20 52 43 34 23 110 12 560 134
24 63 53 40 28 140 14 680 160
36 94 79 60 43 200 20 1000 240

Example 3: Equivalent length calculation for below piping system for a pipe with
𝑚
12” in diameter and 1000 m in length. Assuming fittings: (𝑉 = 0.613 & 𝑓 =
𝑠
0.02 & ρ = 1107)

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 Diameter 12” Eq. Length Overall
Long Radius Elbow 7 17 7×17=119
Tee 2 56 2×56=112
Gate Valve 2 5.7 2×5.7=11.4
Globe Valve 1 290 1×290=290

Total Length = 1000+119+112+11.4+290 = 1532.4 m

𝑓𝐿𝜌𝑉 2 0.02 × 1000 × 1107 × 0.6132

∆𝑃𝑤𝑖ℎ𝑜𝑢𝑡 𝐸𝑞. 𝐿 = = = 16377.01 𝑘𝑃𝑎 = 0.164 𝑏𝑎𝑟
2𝐷 2 × 0.254

𝑓𝐿𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝜌𝑉 2 0.02 × 1532.4 × 1107 × 0.6132

∆𝑃𝑊𝑖𝑡ℎ 𝐸𝑞. 𝐿 = = = 25096 𝑘𝑃𝑎 = 0.25 𝑏𝑎𝑟
2𝐷 2 × 0.254

5. Two Phase Flow

a) Determine the flow regime
 Horizontal Pipe
1/3
𝑊𝐿 (𝜌𝐿 × 𝜌𝑔 )1/2 𝜇𝐿
𝐵𝑥 = 210.3( ) × ×( ) (37)
𝑊𝑔 𝜌𝐿 2/3 𝜎𝐿

7.087𝑊𝑔
𝐵𝑦 = 1 (38)
𝐴 × (𝜌𝐿 × 𝜌𝑔 )2

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Flow regime will be calculated using Baker map.

 Vertical Up-ward Pipe

𝑁𝑥 = 𝑉𝑔 𝑋𝐴
𝑁𝑥 = 𝑉𝑔 𝑋𝐴
𝜌𝑔 1/3
𝑋𝐴 = ( ) × 𝑌𝐴
𝜌𝐿
𝜌𝐿 𝜎𝑤
𝑌𝐴 = ( )1/4 ( )1/4
𝜌𝑊 𝜎𝐿
Flow regime will be calculated using Aziz, Gavier & Fogarasi map.

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Bellow figure illustrates different flow regime in horizontal pipe:

Bubble Flow Slug Flow

Plug Flow Annular Flow

Stratified Flow Dispersed Flow

Wavy Flow

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Bellow figure illustrates different flow regime in vertical pipe:

Bubble Flow Slug Flow Churn/Froth Flow Annular Flow

Example 5: Calculation of pressure drop for gas-liquid pipe line

(Lockhart-Martinelli Correlation)
Consider the below data:
Flow (lb/hr) Density (lb/cuft) Viscosity (lbf.sec/sqft)
Liquid 140000 51.85 0.15
Gas 800 0.142 2.5×10-7
𝜖
3 inch. (0.2557 ft) pipe with = 0.00059
𝐷

140000
4𝑚 4×( )
3600
𝑅𝑒𝐿 = = = 40.09 (Turbulent)
𝜋𝐷𝑔𝑐 𝜇 𝜋×0.2557×32.2×0.15
800
4𝑚 4×( )
3600
𝑅𝑒𝑔 = = = 137458 (Turbulent)
𝜋𝐷𝑔𝑐 𝜇 𝜋×0.2557×32.2×2.5×10−7

1.6434 0.0272 𝑓𝑜𝑟 𝑙𝑖𝑞𝑢𝑖𝑑

𝑓= →𝑓={
𝜀 6.5 0.0204 𝑓𝑜𝑟 𝑔𝑎𝑠
[ln(0.135 𝐷 + Re )]2

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 140000 2
∆𝑃 8𝑓𝑚 8 × 0.0272 × ( )
( )𝐿 = 2 = 3600 = 18.3 𝑝𝑠𝑓/𝑓𝑡
𝐿 𝜋 𝑔𝑐 𝜌𝐷5 𝜋 2 × 32.2 × 51.85 × 0.25575
800 2
∆𝑃 8𝑓𝑚 8 × 0.0204 × ( )
( )𝑔 = 2 = 3600 = 0.1663 𝑝𝑠𝑓/𝑓𝑡
𝐿 𝜋 𝑔𝑐 𝜌𝐷5 𝜋 2 × 32.2 × 0.142 × 0.25575
∆𝑃
( )𝐿
𝑋2 = 𝐿 = 111.8 (39)
∆𝑃
( )𝑔
𝐿

𝐶 1
𝜑𝐿2 = 1 + + 2 (40)
𝑋 𝑋

C coefficient can be specified by below table: (presented by Lockhart-Martinell)

Liquid Gas Subscript C
Turbulent Turbulent tt 20
Viscous Turbulent vt 12
Turbulent Viscous tv 10
Viscous Viscous vv 5
C=20, and:
20 1
𝜑𝐿2 = 1 + + = 2.9
10.6 10.62
∆𝑃 ∆𝑃 psf 𝑝𝑠𝑖
( )𝑡𝑤𝑜−𝑝ℎ𝑎𝑠𝑒 = 𝜑𝐿2 ( )𝐿 = 2.9 × 18.3 = 53 (36.8 )
𝐿 𝐿 100ft 100𝑓𝑡

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