RUMAILA PROJECT

PROCESS LINE SIZING CRITERIA

DOCUMENT NUMBER

0000RE-C-G0-G000-PR-CRT-0001
01 September 2018

Rev Description Originator Review Project Date

Approval

B01 Issued for Use T.Bushell J.Jarvis T.Bushell 01 Sep 2018

Digitally signed Thomas Digitally signed by
Thomas Bushell

J.Jarvis by J.Jarvis
Date: 2018.10.03 Bushell
Date: 2018.10.03
09:49:26 +04'00'
09:44:54 +04'00'

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

REVISION DESCRIPTION SHEET

Rev. Para. Reason for Revision

B01 First Revision. Issued for Use.

Hold No. Para. Description of Hold

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

CONTENTS

1 PURPOSE .......................................................................................................................... 4

2 BASIC PHILOSOPHY......................................................................................................... 4

3 GENERAL ........................................................................................................................... 5

3.1 Permissible Pipe Sizes ...................................................................................................... 5

3.2 Pipe Roughness................................................................................................................. 5

3.3 Design Margins .................................................................................................................. 5

3.4 Viscosity ............................................................................................................................. 5

4 SIZING OF LIQUID LINES ................................................................................................. 6

4.1 Unit Lines ........................................................................................................................... 6

4.2 Centrifugal Pump Suction and Discharge Lines ................................................................ 6

4.3 Reciprocating Pump Suction and Discharge Lines ........................................................... 7

4.4 Control Valve Inlet Lines .................................................................................................... 7

4.5 Liquid Flowing by Gravity................................................................................................... 7

4.6 Fire Water Lines................................................................................................................. 8

4.7 Oily Water Systems ........................................................................................................... 8

5 SIZING OF GAS LINES ...................................................................................................... 8

5.1 Maximum Velocity .............................................................................................................. 8

5.2 Recommended Pressure Drops ........................................................................................ 8

6 SIZING OF GAS/LIQUID TWO-PHASE/MULTIPHASE LINES.......................................... 9

6.1 Flow Patterns ..................................................................................................................... 9

6.2 Maximum Velocity .............................................................................................................. 9

7 SIZING OF FLARE AND VENT LINES .............................................................................. 9

7.1 General .............................................................................................................................. 9

7.2 Flare Headers and Sub-Headers ..................................................................................... 10

7.3 Pressure Safety Valve Lines............................................................................................ 10

7.4 Controlled Flaring Lines ................................................................................................... 10

7.5 Depressurisation Lines .................................................................................................... 10

7.6 Relief Lines with Slug/Plug Flow...................................................................................... 10

7.7 Vent Lines ........................................................................................................................ 10

8 APPENDIX 1: MAINPAY & MISHRIF OIL VISCOSITY DATA ......................................... 11

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 3 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

1 PURPOSE

This document defines the maximum velocity and pressure drop /100 m criteria that shall be
used by CONTRACTOR for sizing process and utility pipework for Rumaila Projects. It is based
on NORSOK Std P-002 section 7.

When sizing lines, the following constraints shall be addressed:

1. Required capacity /available pressure drop

2. Flow induced forces (piping stress)
3. Noise/vibration
4. Pressure surges
5. Material degradation – erosion, corrosion, cavitation
6. Liquid accumulation/slug flow
7. Sand accumulation

2 BASIC PHILOSOPHY

The flowrate used to calculate the line size shall be the maximum process design flow rate at the
minimum operating pressure drop available. Consideration of the full range of possible operating
conditions, other than nominal design rates, shall also be considered.

Lines for liquids, gases and multiphase fluids for different piping materials and flow situations
shall be sized using the following method:

 Liquids

1. Determine the line size based on the maximum velocity criteria given in §4.1.
2. Check if the calculated pressure drop is compatible with the process, adjusting the line
size if required.
3. Check if specific requirements are applicable (see §4.2 - 4.7) and if required, adjust the
line size to meet the governing criteria.
4. Check if line is classified as “medium or “high” using Table T1-1 of EI Guidelines for the
Avoidance of Vibration Induced Fatigue Failure in Process Pipework, and if classed as
medium/high, confirm the piping design is acceptable.

 Gases

1. Determine the line size based on the maximum velocity criteria given in §5.1.
2. If pressure drop is considered “critical”, adjust the line size to satisfy the criteria given in
§5.2.
3. If pressure drop is not considered “critical”, check if the calculated pressure drop is
compatible with the process, adjusting the line size if required.
4. Check if line is classified as “medium or “high” using Table T1-1 of EI Guidelines for the
Avoidance of Vibration Induced Fatigue Failure in Process Pipework, and if classed as
medium/high, confirm the piping design is acceptable.

 Multiphase

1. Determine the line size based on the maximum velocity criteria given in §6.2.
2. Check the flow regime and check if the calculated pressure drop is compatible with the
process, adjusting the line size if required.
3. Check if line is classified as “medium or “high” using Table T1-1 of EI Guidelines for the
Avoidance of Vibration Induced Fatigue Failure in Process Pipework, and if classed as
medium/high, confirm the piping design is acceptable.

Piping with gas at the dew point and/or with some droplets shall be designed as per gas lines.

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 4 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

3 GENER AL

3.1 Permi ssible Pi pe Sizes

A minimum size of DN50 (2”) should in general be used for all process piping to ensure adequate
mechanical integrity. Smaller piping can be used on utility systems, where protection and/or
support is provided to withstand human activity and vibrations, and where small volume flows
make the use of small piping a requirement.

Minimum size for sewage and open/closed drain headers shall be DN100 (4”) and DN80 (3”) for
sub-headers. Overflows from atmospheric tanks shall as a minimum be equal to the largest inlet
pipe.

Tubing may be used for air, hydraulic oil and other fluids (e.g. chemicals) for line sizes below 1”.

3.2 Pipe Roughness

For all calculations of pressure drop, the pipe roughness values in Table 1 shall be used:

Table 1 – Pipe roughness values

Material Roughness(mm)
Carbon Steel (CS) non-corroded 0.050
Carbon Steel (CS) corroded (for flare lines): 0.500
Stainless Steel (SS) (hot rolled, longitudinally welded): 0.050
Stainless Steel (SS), Duplex Steel (new, seamless, cold drawn): 0.0305
Galvanized Carbon Steel: 0.150
Epoxy Lined Pipe: 0.150
Titanium and Cu-Ni: 0.050
Glass fiber Reinforced Pipe (GRP): 0.02
Polyethylene, PVC: 0.005
Smooth Bore Flexible 0.005

3.3 Design Mar gins

Design margins should not be doubled up, causing line sizes to be over-conservative. E.g. for
pump circuit calculations, design margins should not be added to both the pressure drop and the
pump sizing calculations.

For all pressure drop calculations, it is suggested that a 10% margin should be added to the
calculated pressure drop at design stage to cater for line routing/layout changes prior to
isometrics being produced.

3.4 Viscosity

Crude oil viscosity at line (fluid) operating temperature should be derived from measured data
wherever possible. Viscosities taken from process simulation packages (HYSIS/PIPESIM) should
be treated with caution and should not generally be used.

The viscosity at fluid operating temperature can be derived from the following Riedel equations,
depending on the number of measured viscosity data points available:

𝜈 = 𝑒𝑥𝑝 𝐴 + for 2 measured viscosity data points

𝜈 = 𝑒𝑥𝑝 𝐴 + + 𝐶. ln(𝑇) for 3 measured viscosity data points

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 5 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

where;
ν’ = kinematic viscosity of (dry) crude oil (cSt)
T = temperature (K)
A,B,C = Riedel coefficients to be determined by least squares method

Appendix 1 provides the oil viscosities that shall be used for Rumaila Main Pay and Mishrif fluids.

Where emulsions are likely to be formed, the emulsion viscosity must be considered when sizing
lines. The emulsion viscosity is potentially much higher than the viscosity of the water or oil
phase alone. For estimating this emulsion viscosity, the following equation (Vand’s correlation)
should be used:

𝜇 2.5∅
= 𝑒𝑥𝑝
𝜇 1 − 0.609∅

where;
µe = viscosity of the emulsion (cP).
µc = viscosity of the continuous phase (e.g. oil for water-in-oil emulsions) (cP)
ϕ = dispersed phase volume fraction. I.e. (volume of dispersed phase) / (total liquid volume)

4 SIZING OF LIQUID LINES

4.1 Uni t Li nes

Table 2 provides the recommended maximum velocities for sizing of liquid lines.

Table 2 – Recommended maximum velocities for sizing of liquid lines

Fluid Maximum Velocities (m/s) (note 1)

Carbon Steel SS /Titanium CuNi GRP
Liquids 6 7 3 6
Liquids with sand 5 7 NA 6
Liquids with large
4 4 NA NA
quantities of mud or silt
Untreated seawater 3 7 3 6
Deoygenated seawater 6 7 3 6

Note 1: when the service is intermittent, the velocity can be increased to 10 m/s, except for CuNi,
which shall be limited to 6 m/s.

In lines carrying liquids with solids, the minimum velocity shall be 0.8 m/s to avoid solid
deposition at the bottom of the pipe.

The minimum velocity for CuNi piping materials is 1.0 m/s.

4.2 Centrifugal Pump Suction and Discharge Lines

The suction piping shall be based on NPSH requirements.

The maximum velocity in the suction piping shall be as per Table 2 and the pressure drop /100 m
shall be limited to:
 0.25 bar/100 m for subcooled liquids
 0.05 bar/100 m for boiling liquids

The fluid temperature shall be at least 15°C below the fluid boiling point temperature to allow
sizing based on the criterion for sub-cooled liquids.

The maximum velocity in the discharge piping shall be as per Table 2 and as a guideline, a
pressure drop of up to 0.9 bar/100 m should be used.
0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 6 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

4.3 Reciprocating Pump Suction and Di scharge Lines

For reciprocating pumps, the recommended maximum velocities in Table 3 shall be used.
(Consistent with ISO 13703).

Table 3 – Recommended maximum velocities for reciprocating pump suction and

discharge lines

Speed (RPM) Maximum Velocity (m/s)

Suction Discharge
< 250 0.6 1.8
250 - 330 0.45 1.4
> 330 0.3 1.0

The limits are for a single plunger pump and the velocity is the average during several strokes.
The discharge velocities can be increased if the number of plungers are increased, and/or if
dampers are installed.

4.4 Control Valve Inlet Li nes

Control valve inlet lines shall be sized such that single phase is maintained upstream of the
valve.

4.5 Liquid Flow ing by Gravity

Lines flowing by gravity includes drains (sanitary, closed and open drains) and any other lines
where the liquid flows due to gravity forces instead of pressure difference.

Pipes that are running full, and do not require a minimum downward slope to avoid particle
deposition, shall be sized according to the total available static pressure head, and the maximum
allowable velocities for liquid unit lines (ref. Table 2).

Near horizontal pipes not running full shall be sized based on the maximum flow given in Table 4.

Table 4 – Flow capacity – near horizontal pipes

Diameter Liquid Flow Capacity (based on water density) (m3/h)

mm (inch)
Slope 1:50 Slope 1:100
50 (2) 3.7 2.6
80 (3) 9.9 6.9
100 (4) 24 17
150 (6) 70 49
200 (8) 150 106
250 (10) 271 192
300 (12) 441 312
350 (14) 665 471
400 (16) 950 672

The liquid in the entrance part of a near horizontal pipe normally needs some acceleration
distance to reach fully established velocity. To reduce the entrance pressure loss, the inlet
section should have increased diameter compared to Table 4. For the first ten pipe diameter
length, the next larger pipe diameter in Table 4 shall be selected ending with an eccentric
reducer.

Vertical, self-venting lines shall be designed such that the Froude number is less than 0.3. This is
to avoid air entrainment and ensure undisturbed flow without pulsations

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 7 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

𝑉
𝐹𝑟𝑜𝑢𝑑𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 =
𝐷. 𝑔

where;
V = velocity assuming full pipe (m/s)
D = pipe inner diameter (m)
g = gravity constant (m/s2)

4.6 Fire Water Lines

The sizing of fire water lines shall be based on available system pressure and maximum
allowable flow velocities in Table 2.

The pressure drop through large deluge systems shall be calculated on basis of the most
unfavourable pipe routing to those systems.

4.7 Oily Water S ystems

Where retaining the size of oil droplets in the water is crucial, this can be achieved by providing
low flow velocities. Typically, the velocity should not exceed 3 m/s. This should also be
considered in selection of fittings and instruments in these lines to avoid shearing of oil droplets.

5 SIZING OF G AS LINES

5.1 Maximum V eloci ty

The gas velocity shall not exceed limits which may create noise or vibration problems.

The velocity shall be limited to:

.
1
𝑉 = 175
𝜌

where;
V = maximum velocity of gas to avoid noise (m/s)
p = density of gas (kg/m3)

… or 60 m/s, whichever is lowest.

If solid particles exist, special attention shall be given to particle erosion.

5.2 Recommended Pressure Drops

In gas lines where the pressure drop is considered “critical”, the guidelines in Table 5 shall be
used. The pressure drop should be pro-rated between the operating pressures given.

The pressure drop is considered critical when:

 The cost increase due to additional power requirement is larger than the potential cost
savings due to reduced pipe diameter.
 It results in unacceptable liquid drop out in suction lines between scrubber and compressor
suction, inlet lines to turbo expanders and contactors etc.

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 8 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

Table 5 – Recommended pressure drop for single phase gas process lines

Operating Pressure (barg) Pressure Drop (bar/100 m)

0 – 35 0.001 - 0.11
35 – 138 0.11 - 0.27
> 138 P/500 (note 1)

Note 1: P = operating pressure (bara).

6 SIZING OF G AS/LIQUID TWO-PHASE/MULTIPHASE LINES

6.1 Flow Patterns

Attention must be given to the flow regime when sizing lines for multiphase flow. The operation of
lines in unstable flow regimes may result in unexpectedly high pressure drops and hydraulic and
vibration problems.

6.2 Maximum V eloci ty

For solids-free fluids, where corrosion is not anticipated or when corrosion is controlled by
inhibition or by employing corrosion resistant alloys the maximum allowable fluid velocity shall be
kept below:

183
𝑉=
𝜌

where;
V = maximum allowable fluid velocity limit (m/s)
ρm = gas/liquid mixture density at flowing pressure and temperature (kg/m3)

For solids-free fluids, where corrosion is anticipated and is not controlled by inhibition, the fluid
velocity shall be limited to 10 m/s to limit erosion of the protective layer of corrosion products.

If the pipe is internally coated with liquid epoxy lining, the fluid velocity shall not exceed 15 m/s.

If solids are present, the maximum allowable velocity shall be calculated based on sand
concentration, piping geometry (bend radius, restrictions), pipe size and added erosion
allowance. For calculation of maximum velocity and life time, specialized software is available
and shall be used.

Rumaila field does not experience sand production and so for design purposes, all well stream
fluids shall be assumed to be solids free.

7 SIZING OF FL ARE AND VENT LINES

7.1 Gener al

In general, all flare lines shall be designed to keep the ρv2 < 200 000 kg/ms2 (ρ is the fluid
density or mixed density for two phase conditions in kg/m3 and v is the velocity in m/s).

If the ρv2 criteria cannot be met, additional calculations will be required to document that the
selected pipe size is still acceptable. This involves evaluating piping stress levels, supporting,
noise etc.

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 9 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

Further, the selection of piping specification must consider the effect of acoustic fatigue, which
are affected by factors such as:
 Relative differential pressure in upstream restriction device
 Temperature in the flowing gas
 Molecular weight of flowing gas
 Pipe diameter and wall thickness
 Mass flow rate

7.2 Flare Header s and Sub-Headers

Piping for flare and sub-headers shall be primarily sized to meet back pressure requirements on
relieving devices.

Piping for flare headers shall be designed for a maximum velocity of 0.5 Mach and piping for flare
sub-headers shall be designed for a maximum velocity of 0.7 Mach.

7.3 Pressure Safety Valve Lines

The upstream and downstream line shall be sized according to the requirements of API Std
520/521.

Maximum flowing velocity in the lines downstream of the PSVs to the first sub-header, should in
general be less than 0.7 Mach. For PSVs where the outlet velocity is higher, a reducer should be
installed as close as possible (preferably flange-to-flange) to the PSV to increase line size and
hence limit the velocity to maximum 0.7 Mach downstream of the reducer. Nevertheless, the
actual back pressure at the PSV outlet and in the block valve shall be checked to be consistent
with back pressure limitations.

7.4 Controll ed Flaring Lines

Flaring lines downstream of control valves shall be designed for a maximum velocity of 0.5 Mach.

7.5 Depr essurisation Lines

The maximum flowing velocity in the lines downstream of a reducer shall be 0.7 Mach.

The pressure loss shall not impose any restrictions on the depressurisation objectives.

7.6 Reli ef Lines w ith Slug/Plug Flow

For potential slug/plug flow, line sizing shall be based on slug velocity and slug density. These
slug characteristics shall form the basis for stress calculations and design of piping supports.

7.7 Vent Lines

Maximum backpressure shall be 0.07 barg.

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 10 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
PROCESS LINE SIZING CRITERIA

8 AP PENDIX 1: M AI NP AY & MISHRIF OIL VISCOSITY DATA

Temperature Main Pay Crude Viscosities Mishrif Crude Viscosities

°C cSt cP (note 1) cSt cP (note 2)
10 16.6 14.4 31.5 28.6
20 12.1 10.4 25.1 22.6
30 9.4 7.9 20.4 18.4
40 7.4 6.2 17.4 15.5
50 6.2 5.2 15.1 13.3
60 5.3 4.4 13.3 11.6
70 4.7 3.9 12.0 10.4
80 4.3 3.5 11.0 9.5

Note 1: Main Pay crude = 32.9 °API @ 60 °F (average)

Note 2: Mishrif crude = 25.0 °API @ 60 °F (average)

0000RE-C-G0-G000-PR-CRT-0001 Rev B01 (01 September 2018) Page 11 of 11

This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company