Process Design Training: Line Sizing

Process Design Training
Line Sizing
Based on GPSA
Course goals
Understand fluid flow
Understand line sizing criteria
Understand requirements of special lines
Understand network sizing and special programs
Cooling water and Fire water systems
Create your own sizing workbook in Excel
Automate the task, by linking simulation outputs
Understand piping engineering guidelines
Lines or pipes are the arteries of a plant
Overview:
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All Chemical process plants are made

of pipes that transfer fluids from and to
different equipment
Fluids are:
Liquid
Vapour
Two phase
Slurry
Fluids may flow under pressure or
gravity
Process Engineers - are they glorified plumbers?
Overview
Fluid Flow
Meet the basics

2 Fluid physical
properties affecting
fluid flow are:
Bernoullis Theorem:
Based on law of conservation of energy
Total energy of a fluid at any point above
a datum is the sum of the elevation
head, the pressure head, and the
velocity head
E1 = E2 = Z + P + VH
E1
E2
1. viscosity and
2. density
Viscosity is a measure of a fluids internal resistance to deformation or shear. It

indicates resistance to flow when acted upon by an external force
Viscosity of most liquids decreases with temperature, whereas that of gases
increases. Pressure has almost no effect on the viscosity of liquids or near perfect
gases. Viscosity of saturated or slightly superheated vapour is changed
appreciably by pressure changes
Highly viscous fluids behave differently
Reynolds Number
Re = DV/
Reynolds Number
Laminar Flow: At low velocities, fluid moves in a reasonably straight line.
Velocity of the fluid is maximum at the center of the pipe and zero at
the pipe wall. Re < 2,100
Turbulent Flow: At higher velocities, fluid particles show a random motion
transverse to the direction of flow. There is always a boundary layer at
the pipe wall where flow is laminar. The velocity profile is nearly
straight across the pipe. Re > 4,000
Laminar or streamlined flow

Turbulent flow
Turbulent flow is further categorized into partially or fully developed turbulence
Reynolds Number
Re = DV/
Reynolds Number
Laminar Flow: At low velocities, fluid moves in a reasonably straight line.
Velocity of the fluid is maximum at the center of the pipe and zero at
the pipe wall. Re < 2,100
Turbulent Flow: At higher velocities, fluid particles show a random motion
transverse to the direction of flow. There is always a boundary layer at
the pipe wall where flow is laminar. The velocity profile is nearly
straight across the pipe. Re > 4,000
Pressure Loss Due to Friction:

Flow results in friction and friction loss. Darcy-Weisbach equation is used to
determine frictional loss. [Also called, Poiseuilles law for laminar flow.]
It is valid for both laminar and turbulent flow of any liquid. Changes in elevation,
velocity, or density must be accounted for by applying Bernoullis theorem. For
gases consider short line segments, such that density is essentially constant
20% margin is taken on calculated P to take care of uncertainties in the empirical correlations
Friction Factor
Friction factor represents the fraction of velocity head lost due to flow
Pipe roughness has no effect on the friction factor in laminar flow, while it
increases loss in turbulent flow
Colebrook proposed a friction factor based on relative roughness, viz
/D, ratio of roughness of the pipe wall to diameter
1. Moody friction factor, 4 times higher

than Fanning friction factor. Moodys
used largely by Civil engineers and their
hydraulics program
2. Fanning friction factor is used in
Process calculations
It does not mean P calculated by Civil Engineers is 4 times higher!
Friction Factor
Friction factor represents the fraction of velocity head lost due to flow
Pipe roughness has no effect on the friction factor in laminar flow, while it
increases loss in turbulent flow
Colebrook proposed a friction factor based on relative roughness, viz
/D, ratio of roughness of the pipe wall to diameter
Equivalent Length of Valves and Fittings.

P is usually accounted by equivalent lengths of the fitting. L/D or K factor
correction for actual ID or NRe is usually ignored
Fittings take bulk of the pressure drop. Eye estimates in plant OK as long as all fittings are counted.
Overview
Line Sizing Criteria
General Guidelines
Sizing based on economics
(fixed cost) Vs P (running cost)
Minimum 2 to avoid small bore pipe rupture.
Smaller pipes need additional supports on
sleepers/ pipe rack
Minimum and
maximum velocity
limits based on
sediments deposit and
erosion; vibration and
noise
1. In lines injected with corrosion inhibitors, maintain recommended velocity

2. Low velocity and pressure drop in pump suction and PSV inlet piping
3. To avoid vortex in vessel liquid outlet lines h > 2 VH or V < gh
Optimum size Vs Special Requirements
General Guidelines
1. Avoid bends close to control valve / pump outlet/ steam injection points.
Usually leads to high erosion, rupture and plant fire
2. Liquid lines with check valve or quick closing valve OR poorly sized
condensate lines may lead to water hammer and pipe rupture
Optimum size Vs Special Requirements
Liquid & Gas Lines

Liquid lines are usually sized on velocity
criteria
Special criteria based on fluid/ service such as
NH3, C2=, NaOH, H2SO4, sea water etc
In saturated liquid, high velocity leads to
flashing/ cavitation
In gas high P may lead to choked flow with
sonic velocity
High velocity sonic flow may

lead to pipe failure and fire
1. Gas lines are sized to limit pressure drop (gas compressor being energy
expensive than liquid pumping!)
2. Where adequate pressure drop is available, then noise limits velocity in
continuous service and 50-70% sonic velocity limit in intermittent service
3. Use inlet or outlet density if P is <10%; average density if P is 10-40%
Size high P gas lines in segments
Special Lines
Simplified formulae, such as Hazen and
Williams are available for water
Manning equation is used to size gravity flow
lines
With recip pumps, design based on maximum
instantaneous or pulsating flow
Steam condensate lines may have high
instantaneous rate when they discharge.
But all traps do not open at the same time
Modulating steam
traps like float or
thermostatic as
opposed to bucket
discharge condensate
continuously. Use a
LCV with a boot as
appropriate
10m
Rules of Thumb
Pump suction line 1 or 2 sizes bigger than inlet nozzle.
Should be sized to start standby pump viz n+1 pumps
Tank outflow line 1 or 2 sizes bigger than inlet line
All drain lines are gravity flow lines
If this pipe runs liquid full,

vacuum d/s valve may
cause flashing, vibration
and pipe failure.
Use gutter or self-venting
sizing methods
Liquid Network
Instead of sizing a single line, at
times, you may have to size a
group of pipes forming a
network
Example: From suction to
discharge point of a pump, to
calculate the pump head, horse
power and NPSH requirements
Source
Destinat
ion
Destination
Source
Town water and cooling water supply provide interesting network analysis
Water Supply Network

Cooling Water Network
Coolers
Cooling Tower
& Pumps
Resistance in series R = R1 + R2
Resistance in parallel 1/R = 1/R1 + 1/R2
Total R, then flow = Head/ R
Head
Head
Resistance
Flow
Cooling water or hot water/ oil network are classical examples of network programs
Gas Transmission Lines

Steady-state, isothermal gas flow:
Q = 38.77 (Ts/Ps) E ff [(P1^2P2^2)/S Lm TavZav]^0.5 d^2.5
Different equations proposed, all based on empirical data, provide
different solutions to the transmission factor or ff . To adjust
measured flow against calculated flow E is tweaked
For low pressure lines, Oliphant or Spitzglass Formula may be used
1. AGA Equations (a) partially and (b) fully turbulent flow with two different
transmission factors
2. Weymouth Equation, takes ff as a function of the diameter. Good for short
pipelines as in gathering systems. Good results when compressibility is taken.
Not valid in partially developed turbulence
3. Panhandle A for partially developed and Panhandle B for fully turbulent flows
Special equations are used to size pipelines
Comparison of Gas Transmission Factors

Results differ widely. Go by what is an accepted practice in your plant
Two Phase Lines
Baker, Gregory-Aziz-Mandhane ,
Taitel-Duckler maps
Two phase lines are difficult to

design and operate
Flow regimes and terrain profile
influence P, slug size and
liquid hold-up
Flow regime boundaries are affected by pipe inclination.

Horizontal flow regime maps must not be used for vertical
flow, and vice versa. 0.1-1.0inclination can affect. Fluid
pressure, pipe diameter and surface tension also affect
Empirical methods: Lockhart-Martinelli, Duckler for P.

Flanigan for elevation correction. Eaton for liquid hold-up
Correlations are usually developed for air-water system in pipes <1
Two Phase Lines

Dispersed
bubble
aerated
turbulent
slug flow
annular
mist
Flow regimes - horizontal and vertical
Two Phase Lines

Liquid Slugs 4 mechanisms
1. Wave formation at G/L interface in stratified flow. When liquid waves
grow large and fill the pipe cross section, a slug flow is formed
2. Slugs form due to terrain. Liquid collects at low points and blocks gas
flow. Gas pressure rises and blows the accumulated liquid as a slug
3. Changes in inlet flow rate, as during start-up or ramp-up can cause
slugs. As flow rate increases, liquid inventory in the pipeline
decreases, and the excess liquid forms a slug or series of slugs
4. Pigging can cause large slugs as the liquid inventory of the line is
swept ahead of the pig
1. Greskovich - Shrier and Brill methods for calculating wave induced slugs
2. Schmidt for terrain generated slugs
3. Cunliffe for inlet flow rate generated slugs and
4. McDonald and Baker method for analyzing pigging dynamics
Several methods are available to predict random and pigging slugs
CONGRATULATIONS
Now you are an Expert in Plumbing
Question 1
With head or supply pressure remaining the same, how much
the flow will increase when you double the pipe size
1. Will remain the same

2. Will double
3. Will quadruple
Let us check it out if Expert1 is really good in training as he claims
Question 2
A centrifugal pump designed for 500 m/h and 10 bar head,
will always deliver it
1. True.
2. False.
Looks like, Expert1 is really good in training as he claims
Question 3
A recip pump designed for 50 m/h and 10 bar head, will
always deliver it
1. True.
2. False.
Thanks for helping to keep my reputation high!!
Sizing in Excel
Enter data
Excel for sizing

You can use Excel to
perform simple line
sizing, pump sizing
and distribution
network calculations
Line Size
Pump Size
Network Analysis
Excel allows you to study different sizes, take output to

a Line List, interact with project database.
You can link your simulation output to Excel and
automate the task.
The possibilities really are endless.
Create your first line sizing workbook
Be kind to your users: start with design basis

Let us look at a typical Excel sheet
This way, anyone who shares your worksheet can

understand what it all means (and you can understand it
yourself, later on).
Make your workbook user friendly
When you write your

program, its a good
idea to provide the
formulae and criteria
for selection.
Lesson 3
Process Piping
Engineering Guidelines
Standard Pipes
Pipes come in standard diameters
and wall thickness
Smaller diameter pipes can hold
more internal pressure.
Generally flanges limit the
allowable pressure
Min pipe size = 2 to

avoid broken pipes on
impact
Allowable Working Pressures - ASTM A106, grade B seamless pipe - Petroleum

Refinery Piping Code to ANSI B31.3-2002Corro allow = 0.05 at 200F
2 Standard Schedule 40 1,469 psig
8
1,098
24 Sc 20
282
150# Flange 260 psig
Small bore piping safety engineers nightmare
Piping
Size pipes
Based on operating pressure and temperature,
decide design pressure and temperature
Based on selected material, then decide ANSI
flange rating 150 ~ 1500# and ID
Decide on steam/ electrical tracing and hot /
cold/ noise insulation requirements
Piping will add Test conditions
Some clients opt for full rating,

that is upping design
conditions to suit, flange rating
Lines are hydrotested, except
large low pressure lines that
are pneumatically tested.
Molten K and Na lines are not
hydrotested to avoid explosion
on contact with water in
isolated pockets
Design temperature shall consider site black body temperature as a minimum.

Steam traced lines shall consider steam condensing temperature. Design
minimum temperature shall consider low temperature reached on blowdown.
Design pressure shall consider vapor pressure of LPG at max site temperature,
pipe shut-off head, upstream PSV set point and full/ half vacuum as applicable.
Pipes numbered with Sequence No - ANSI Rating - Material code - Insulation
The task is not over with finding diameter.
Piping
1. Mark gravity flow lines, lines
that should slope or should
not have pockets, clearly.
Check access to valves, instruments and sample

points
Check slope and no pocket requirements
In liquid lines with slurry, sand or polymer solution, 3. Min length for meter runs
ensure LR bends, flushing points and cleaning
and vessel inlet
access
4. 2 pressure equalisation
Symmetrical piping where equal flow required
Flow direction to be maintained in globe, check

valves and flow orifices/ turbine meters
2. Tap off from top
valves are given across

valves >4 to avoid opening
valves against high P, that
could result in high velocity
and seat cutting/ damage
Piping will locate valves such as control valve and

PSV where maintenance access is available. This may5. Check high point vents and
low point drains.
void desired slope or inlet pressure drop requirements.
6. Eccentric reducers flat on

Check piping 3D drawings of all PSV, thermosyphon
top in pump suction but at
bottom u/s of control valves
and pump inlet lines
Spec blinds should be in horizontal runs

The task is not over with finding diameter.
Piping
Usually piping class decides:
Material of construction
Piping type - seamless, ERW, forged or cast
Pipe schedule (wall thickness) / ANSI Rating
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and location.
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location.
Plant piping is usually welded to minimize leaks.

Bends and reducers are usually welded
Flanged (bolted) connections are used to take out a component that may require
servicing e.g relief valve, control valve
Pipe Fittings
Piping
Slip-on
Piping class also decides:

Flange - slip on, weld neck
Facing - Flat FF, Raised Face RF, Ring Type Joint RTJ
Pipe schedule (wall thickness) / ANSI Rating
Corrosion allowance
Type of valves ball, gate, globe
Specs for gaskets, bolts etc
Weld Neck
Construction requirement like, stress relieving, radiography, dye
penetration, hardness test for welding etc
location.
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location.
RTJ
Raised Face
Pipe Fittings
Insulation
Heat or cold loss to conserve energy
Personnel protection to avoid injury on accidental
contact
Noise or vibration reduction, in high velocity/

compressor piping
Insulated pipes are covered with vapor barriers and
metal casing as required
Foot traffic usually damages yard piping insulation
What type of
insulation?
Insulation comes in
preformed shapes,
mattress or loose.
Insulation pays back in 3 months
Heat tracing
Steam or electrical resistance or

self-limiting electrical tracing
1. To maintain temperature to
avoid congealing or wax
deposition
2. In intermittent operation lines
3. To avoid cooling and
condensation as in fuel gas
and gas to glycol dehydration
Steam Tracing Number of tracers:
General: 1 for 2-4; 2 for 6-20. Solidification 25-65C: 1 for 2-3; 2 for 4-8.
Solidification 65-150C: 2 for 2; 3 for 4-8; 6 for 10-12; 8 for 14-18.
Max run length is 50m for . 1 steam header for 3-5 tracers; 2 for 16-30.
Condensate header is of same size.
Steam Vs Electrical: Capex: 0.3-0.6 : 1; Opex: 2-20 : 1
Steam tracing requires steam supply and condensate collection headers
Heat tracing
Steam tracing requires steam supply and condensate collection headers
Heat tracing
Electrical resistance heaters can
heat fluids during start-up
Self-regulating tapes required
temperature during shutdown/
normal operation
Electrical tracing is relatively simple
Valves
Gate:
Rising stem in non-corrosive;
non rising steam in water
service
Solid Vs split wedge. Split can
take care of thermal
contraction on cooling
Low pressure drop when full
open
Not quick acting
Takes more space
Not good in slurry service
Install vertically to avoid gate
falling in closed position
Service decides type of

valve
Shut-off: Ball, Gate, Plug,
Butterfly and diaphragm
Throttling: Angle, globe,
needle
Check: Swing, lift, piston
and foot
Multiport
Valves help regulate or isolate fluid flow
Valves
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Ball or Plug
Ball valves widely used in upstream
industry; gate in d/s
Quick closing
Limited to <250C .. Thermal
contraction/ expansion
location.
Globe
Good for throttling
Install vertically
Angle
In high P service
Diaphragm
Made of elastomer
Good for slurry,
viscous and corrosive
services
Butterfly
Less weight and less space

Good in low P service; as control valve in large size
Equal change in flow for equal change in valve
position
Valves help regulate or isolate fluid flow
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Check valves
Swing check
Full unrestricted flow. No good in pulsating
flow
Wafer check - similar to butterfly. Good for
pulsating flow. No chattering
Lift or piston check - similar to globe. Good for
high velocity (gas) flow
Without check valves, utility connections may
lead to backflow, rupture and fatal incidents
Check valves minimize back flow. All valves leak............!
Remote operated valves

Remote operated valves can be
used to isolate an equipment or
section of a plant remotely.
They are usually operated by a
motor (MOV) or electrical
solenoid (SOV) or air / hydraulic
actuators
ROVs can be automated to close on high level or pressure

For quick opening and closing; Battery limit

Emergency shutdown.
For large valves - 10 (150~300#), 6 (600~1500#)
ROVs help quick isolation, shutdown and blowdown bringing the plant to a safe state
Spectacle blinds
To provide positive isolation, usually for entry
into confined spaces and in hazardous
services
Spades are used in small bore pipes (<2) that
can be pushed apart and a spade inserted
Fig 8 or spectacle blinds are used bigger pipes
A ring spacer or drop-out spool pieces are used
for large pipes, that would be blind flanged
Note: All valves,

including check valves
leak in service.
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file and location.
Ham(m)er blinds allow swinging a spectacle blind with

minimum effort
Blinds are life savers. All valves leak and the leak can
injure with the energy associated with it or kill if
hazardous.
With a proper blind, Bhopal disaster would not have happened
Thank you
Trust you found it interesting and
of value .

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Process Design Training

All Chemical process plants are made

Process Engineers - are they glorified plumbers?

Meet the basics

Viscosity is a measure of a fluids internal resistance to deformation or shear. It

Laminar or streamlined flow

Turbulent flow is further categorized into partially or fully developed turbulence

Pressure Loss Due to Friction:

1. Moody friction factor, 4 times higher

Equivalent Length of Valves and Fittings.

1. In lines injected with corrosion inhibitors, maintain recommended velocity

Optimum size Vs Special Requirements

Optimum size Vs Special Requirements

Liquid & Gas Lines

High velocity sonic flow may

Size high P gas lines in segments

If this pipe runs liquid full,

Water Supply Network

Cooling Water Network

Gas Transmission Lines

Comparison of Gas Transmission Factors

Results differ widely. Go by what is an accepted practice in your plant

Two Phase Lines

Two phase lines are difficult to

Flow regime boundaries are affected by pipe inclination.

Empirical methods: Lockhart-Martinelli, Duckler for P.

Two Phase Lines

Two Phase Lines

Now you are an Expert in Plumbing

1. Will remain the same

Let us check it out if Expert1 is really good in training as he claims

Looks like, Expert1 is really good in training as he claims

Thanks for helping to keep my reputation high!!

Excel for sizing

Excel allows you to study different sizes, take output to

Be kind to your users: start with design basis

This way, anyone who shares your worksheet can

Make your workbook user friendly

When you write your

Min pipe size = 2 to

Allowable Working Pressures - ASTM A106, grade B seamless pipe - Petroleum

150# Flange 260 psig

Small bore piping safety engineers nightmare

Some clients opt for full rating,

Design temperature shall consider site black body temperature as a minimum.

Check access to valves, instruments and sample

Check slope and no pocket requirements

Symmetrical piping where equal flow required

Flow direction to be maintained in globe, check

2. Tap off from top

valves are given across

Piping will locate valves such as control valve and

6. Eccentric reducers flat on

Spec blinds should be in horizontal runs

Plant piping is usually welded to minimize leaks.

Piping class also decides:

Noise or vibration reduction, in high velocity/

Insulation pays back in 3 months

Steam or electrical resistance or

Steam tracing requires steam supply and condensate collection headers

Electrical tracing is relatively simple

Service decides type of

Valves help regulate or isolate fluid flow