Single-phase fluid flow

GUIDELINE TO PIPE SIZING FOR SINGLE-PHASE FLOW

AUTHOR: VIKRAM SHARMA

DATE: 7th MARCH 2017
Table of Contents
Introduction
Bernoullis Equation
Friction factor graph
Pressure Drop in Pipe and Fittings
Recommended fluid velocities
Calculation Methodology
References
Introduction
Pipeis a common sight in chemical plant
Pipework & fittings:
20-30% of the total design cost;
10-20% of the total plant investment; and
Other added cost due to maintenance req. & energy
usage in the form of P in the fluids being pumped
Thesize of a pipe (diameter) is expressed in
two ways that are:
Nominal Pipe Size (NPS); and
Diametre Nominal (DN)
NPS is measured in inches, DN is measured in
mm
DN is generally equiv. to NPS multiplied by 25
Introduction (contd)
DNis generally equiv. to NPS multiplied by 25
except:
NPS is DN15
NPS 3 is DN80
Pipe size are designated by two numbers that
are (i) pipe diameter and (ii) thickness
Pipe diameter is generally associated with inside
dia.
Outside dia. is the same for a given size
maintain certain interchangeability of pipe
fittings
NPS 14 and beyond, it is equal to the outside dia.
(OD) in inch.
Introduction (contd)
NPS 14 and beyond, it is equal to the outside
dia. (OD) in inch. (contd)
Pipe wall thickness is referred to pipe
schedule (Sch)
Standardize from 5 to 160 determined by
the service req. like Pressure, Temp., Flow
and corrosion
Pipe wall thickness Pipe Schedule
Bernoullis Equation
P or head loss in a piping system is caused by:
Elevation;
Friction;
Shaft work; and
Turbulence due to sudden change in direction or cross
sectional area
Mechanical Energy Balance (MEB) eq. conservation
of sum of pressure, kinetic and potential energies,
net heat transfer (q), work done by the system (w)
and frictional energy (ef).
efis usually +ve & represents the rate of irreversible
conversion of mech. energy into thermal energy
Sometimes called head loss, friction loss or frictional
pressure drop.
Bernoullis Equation
(contd)
Bernoullis Equation
(contd)
The first 3 terms (pressure, velocity &
elevation) are point functions depend
only on conditions at the inlet & outlet of the
system
w and ef are path functions depend on
what is happening to the system between
the inlet and outlet points
ef loss due to friction and includes losses due
to flow through lengths of pipe, fittings such
as elbows, valves, orifices and pipe
entrances and exits
Bernoullis Equation
(contd)

Kf is the excess head loss due to pipe or pipe

fittings, v is the fluid velocity
Fluids flowing through pipes;

P is the same due to flow is the same

whether the pipe is horizontal, vertical or
inclined
Friction factor

Friction factor is expressed as Moody friction

factor (fM) or Fanning friction factor (fF).
fM = 4fF
Friction factor (contd)
Laminar region (or viscous): Re < 2,000
Critical zone is the transition frm. laminar
to turbulent: 2,000 < Re < 4,000.
Turbulent flow: Re > 4,000
Friction factor is laminar region is not affected
by the relative roughness (/D) but it is
influenced by the fluid viscosity
Friction factor at transition region strongly
depends on both the Re and /D
Friction factor at turbulent region is
independent of Re and is a function of
relative roughness (/D).
Friction factor (contd)
Friction

factor can be computed using two

equations based on the fluid flow regime.
Laminar flow (Re < 2,000) :
Turbulent flow (Re > 4,000):
Reynolds Number:
fD = Darcy friction factor
= Absolute pipe roughness (m):
Carbon Steel = 0.02-0.05 mm
Stainless steel = 0.03 mm
D = Pipe inner diameter (m)
= Fluid density (kg/m3)
= Dynamic viscosity (Ns/m2)
Friction factor (contd)
Colebrooks equation require iteration to
determine the friction factor.
Author propose Churchill (1977) equation
that allows engineers to determine the
friction factor for both laminar and turbulent
flows.
Pressure Drop in Pipe and
Fittings
P

for straight pipe run:

Pressure drop for fittings can be computed
using resistance coefficient method (K).
This could be done via Darby 3-K method for
fittings

Why Darby 3-K method is preferred?

Accounts directly for the effect of both Re & fitting
size on the loss coefficient.
Pressure Drop in Pipe and
Fittings (contd)
Other option: The Equivalent Length Method (Leq/D)
The Leq/D method assumes that:
Size of fittings of a given type can be scaled corresponding to a given dia.
Reynolds number on the friction loss is the same as the pipe loss
The above assumptions are incorrect. Why?
The laminar or turbulent flow within a valve or a
fitting is generally quite different from that of
straight pipe.
With this, there is an uncertainty when determining
the effect of Re on the loss coefficients.
Leq/D method does not account for the lack of exact
scaling for valves and fittings
Pressure Drop in Pipe and
Fittings (contd)
For Darby 3-K constants, refer to:
https://neutrium.net/fluid_flow/pressure-loss-from-f
ittings-3k-method/
For
other fittings such as sudden pipe
contractions, square reduction, tapered
reduction, sharp orifice, square expansion,
tapered expansion, thick orifice and pipe
reduce, refer to Coker (2007)
Recommended fluid velocities
Typical velocities and pressure drop:
Liquid (pumped, not viscous): 1-3 m/s, 0.5 kPa/m
Liquid (gravity flow): - m/s , 0.05 kPa/m
Gases & vapours: 15-30 m/s, 0.02 % of the line
pressure
HP steam (> 8 bar): 30-60 m/s, - kPa/m
Typical
velocities at pump suction and
discharge lines:
Recommended fluid velocities
(contd)
Typicalvelocities and pressure drop for
single-phase gas process lines:
Calculation Methodology
Obtain the piping layout from PFD, P&IDs or Piping
Isometrics
Obtain data at fluid inlet of the pipe corresponding to
inlet temperature and pressure. Info req. are mass
flow, , , T & P.
Select a pipe size and material (Refer to Slide #5)
Calc. the fluid velocity. Ensure it comply with the fluid
req. (Refer to Slide #17)
Calc. Re Laminar or Turbulent (Refer to Slide #12)
Calc. the fD Churchills (1977) eq. (Refer to Slide
#13)
Calc. the Pbar/100m of the straight pipe. Include
elevation (Refer to Slide #14).
Calc. Pbar by multiplying with pipe straight length
Calculation Methodology (contd)
Calc. P of fittings. Use Darby 3-K method and
Coker (2007) (Refer to Slide #16 and Slide
#14)
Calc. P of other items such as process
equipment etc.
Calc. the total pressure drop of the system (P)
PT = Pfriction + Pfittings + Pother items
Check if downstream pressure P2 is as per
specifications.
P2 = P1 - PT
Ifnot, repeat the above calc. by selecting a
different pipe size
References
Bahadori, A. (2014). Process pipe sizing for plants
location. In Natural Gas Processing: Technology and
Engineering Design (p. 83). Oxford: Gulf Professional
Publishing.
Murty, K. K. (2010). Sizes, Schedules, And Standards.
In All-in-One Manual of Industrial Piping Practice and
Maintenance On-The-Job Solutions, Tips and Insights
(p. 52). New York: Industrial Press.
Native Dynamics. (2012, May 19). Neutrium. Retrieved
March 7, 2017, from Absolute Roughness of Pipe
Material: https://neutrium.net/fluid_flow/absolute-
roughness/
Sinnot, R. K. (2005). Piping and Instrumentation. In
Chemical Engineering Design (Vol. 6, p. 218). Oxford:
Elsevier.