Line Sizing

Line Sizing

CONTENTS

Nomenclature

1. Introduction
2. Purpose of Line sizing
3. Factors affecting line sizing decisions
4. Pipe standards and wall thickness
5. Line sizing (Single phase Liquid line)
6. Line sizing (Single phase Gas line)
7. Pressure drop in Valves and Pipe fittings
8. Line sizing procedure
9. Recommended velocities & max P
10. Line Sizing (Two phase)
11. Solved Examples

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Appendix -1: Pipe roughness table

Appendix -1: ANSI Pipe schedules
Appendix -1: Table of Pipe schedules (DEP Standard)
Appendix -1: Table of Pipe wall thickness

Nomenclature

Q = flow rate of gas, m3/day at base conditions

Ts = base absolute temperature, K : Ts = 288.9 K
Ps = base absolute pressure, kPa (abs) = 101.56 kPa (abs)
E = pipeline efficiency factor (fraction)
P1 = inlet pressure, kPa (abs)
P2 = outlet pressure, kPa (abs)
= relative density of flowing gas (air = 1.0)
Lm = length of line, m
Tavg = average temperature, K [Tavg = 1/2 (Tin + Tout)]
Zavg = average compressibility factor

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1. Purpose of line sizing

1. The purpose of line sizing (for common, water-like liquids, gases, and applications) is to
fill in appropriate data on P&IDs, data sheets, and line lists
2. To determine pump head requirements
3. To meet design process parameters such as flow, velocity & pressure.

2. Factors affecting Line sizing decisions

Line sizing decisions are affected by:

A. Economics
1. Line sizing decisions have economic impacts, including:
a. cost of pipe
b. cost of pipe supports
c. operating pressure/power requirements
2. Liquid lines that are sized smaller will require a larger system supply pressure (due to
higher friction losses), and possibly a larger pump and pump motor, increasing equipment
capital cost and operating cost. Another factor to consider is the cost of the piping
(including valves). The difference of capital cost of to piping is negligible, however
the cost of 3 to 2 piping is significant.
3. Therefore, line sizing involves multiple economic factors, as well as other impacts.

B. Velocity/Turbulence
1. In compressible fluids (air steam, nitrogen, etc.), the only design concern is to avoid
sonic velocity (typically above 100 ft/sec). Usually, pressure drop guidelines result in pipe
size selections that avoid sonic velocity.
2. In non-sanitary liquid applications, velocity and turbulence are typically not a concern,
unless slurry flow is present.
3. For sanitary, non-compressible applications (our most frequent designs), velocity and
turbulence are concerns. It is necessary to maintain fully turbulent flow to avoid stagnant
areas in the piping system that can promote bacterial growth. Guidelines for velocity and
turbulence are found in each application section below.

C. Pressure Drop Effects

1. The effect of pressure drop within a system is closely correlated to the economics of the
system. Smaller pipe sizes result in larger pressure drop requirements; economic
considerations require a balance between pipe size and pumping/power requirements to
overcome pressure losses through the system.
2. Pressure drop guidelines have been developed for all major piping applications, and
reference is made to the appropriate guideline in all sections below.

D. Line Holdup
1. In the biopharm industry, certain product liquids may have exceedingly high value, and
the holdup in piping systems may be a primary concern. In addition to minimizing the
length of piping systems and the recovery capabilities (air blows, sloped piping, etc.) of
the piping systems, a smaller line size may be chosen to further minimize the loss
potential of the liquid held up in the line. This becomes the governing criterion for sizing
even though pressure drop exceeds the recommended range.

E. Space
1. Typically, space requirements are not a significant concern in the biopharm industry,
since most pipe sizes are less than 6 inches in diameter. Space may be a concern when
existing pipe racks are used, where areas are tightly piped, or with gravity drainage

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systems. Interaction with the piping designer will identify critical areas where space is a
consideration.

F. Expansion
1. Header system sizing should consider the possibility of plant expansion. The
incremental cost of a larger pipe size will avoid many headaches down the road if
expansion is a distinct possibility.
2. Sizing of sanitary water loops must critically consider expansion possibilities, since
oversizing the supply loop may reduce the velocity below the acceptable values to
maintain full turbulence. Often, the supply pump needs to be oversized as well as the
header to account for expansion. This oversizing should only be done if expansion is a
distinct probability.

G. Equipment Nozzle Connections

Equipment nozzle connections for piping tie-ins are typically undersized when compared to
the recommended pipe size. Be sure to perform the sizing calculation, select the
appropriate pipe size, and, if required use reducers to connect the pipe to the equipment
nozzle.

3. Pipe standards & wall thickness

Refer Appendix 1 (ANSI Pipe Schedules)

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4. Line sizing (Single phase Liquid line)

The objective of fluid distribution system is to supply the fluid at correct pressure to the
point of use. It follows; therefore, that pressure drop through the distribution system is an
important feature.

DArcy pointed out that for fluid flow to occur there must be more energy at point 1 than
point 2 (See figure below). The difference in energy is used to overcome frictional
resistance between the pipe and flowing fluid.
Fig - 1

All these variables are brought together in the DArcy Weisbach equation (often referred
as the DArcy equation)

Eq - 1

The Moody friction factor, fm, is used in the equations above. Some equations are shown
in terms of the Fanning friction factor, ff, which is one fourth of fm (fm = 4.0
ff). A graph of both Fanning and Moody friction factors as a function of Reynolds number
appears in above figure

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Fig - 2

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The Darcy-Weisbach equation is valid for both laminar and turbulent flow of any
liquid, and may also be used for gases with certain restrictions. When using this equation,
changes in elevation, velocity, or density must be accounted for by applying Bernoullis
theorem. The Darcy-Weisbach equation must be applied to line segments sufficiently short
such that fluid density is essentially constant over that segment. The overall pressure drop
is the sum of the D Pf values calculated for the individual segments. For gas applications
the segmental length may be relatively short, as compared to liquid applications, since
many gas applications involve compressible gases where gas densities vary with pressure.

Friction Factor and Effect of Pipe Roughness

When the fluid flow is laminar (Re<2000), the friction factor has a direct
relationship to the Reynolds number, such that:

fm = 64 Eq - 2
Re
Pipe roughness has no effect on the friction factor in laminar flow.

When the flow is turbulent, the friction factor depends on the Reynolds number and
the relative roughness of the pipe, /D, which is the roughness of the pipe, , over the
pipe diameter, D

For turbulent flow in smooth tubes, the Blasius equation gives the friction factor
accurately for a wide range of Reynolds numbers.

ff = 0.079 Eq - 3
4000 < Re < 105
Re0.25
An equation by Churchill for both smooth and rough tubes offers the advantage of
being explicit in f:

1 0.27 Eq - 4
4LOG
7 Re 0.9 Re > 4000
ff D

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Chart for relative roughness of Pipe

Fig - 3

5. Line sizing (Single phase Gas line)

Isothermal Flow: The steady-state, isothermal flow behaviour of gas in pipelines is

defined by a general energy equation of the form:

Eq - 5

Where,
Eq - 6

Eq - 7

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This equation is completely general for steady-state flow, and adequately accounts for
variations in compressibility factor, kinetic energy, pressure, and temperature for any
typical line section. However, the equation as derived involves an unspecified value of the
transmission factor, 1 ff

The AGA Equation for fully turbulent flow accounts for the relative pipe roughness, /D,
based on the rough-pipe law.

Eq - 8

The partially turbulent flow equation is based on the smooth-pipe law and is modified to
account for drag-inducing elements.

Eq - 9

The Weymouth Equation, published in 1912, evaluated the coefficient of friction as a

function of the diameter.

Eq - 10

The Weymouth formula for short pipelines and gathering systems agrees more closely with
metered rates than those calculated by most other formulae.

Low Pressure Gas Flow:

Gas gathering often involves operating pressures below 690 kPa. Some systems flow
under vacuum conditions. For these low pressure conditions, equations have been
developed that give a better fit than the Weymouth or Panhandle equations.
Two such formulas are:
The Oliphant Formula9 for gas flow between vacuum and 690 kPa:

Eq - 11
The Spitzglass Formula for gas flow below 7 kPa (ga) at 15C:

Eq - 12

Plant Piping Gas Flow

For estimating pressure drop in short runs of gas piping, such as within plant or battery
limits, a simplified formula for compressible fluids is accurate for fully turbulent flow,
assuming the pressure drop through the line is not a significant fraction of the total
pressure (i.e. no more than 10%).

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The following method is a simplification of the Darcy formula, which eliminates calculation
of fm, the Moody friction factor. This simplification was checked over a wide range of flows
and densities for pressure drops of 6 to 35 kPa/100 m.
Density was varied over a range of 100 to 1; flows varied over a range of 75 to 1.
Pressure variation was from atmospheric to 7000 kPa (abs). The error from using the
simplified approach as compared to the actual friction factor calculated in the Darcy
formula was from zero to 5%, with the simplified approach giving consistently lower
calculated pressure drop for a given flow.

The Darcy formula can be written in the simple form:

Eq - 13

Eq - 14

Eq - 15

Refer Figure 4

Eq - 16

Refer Figure - 5

Fig - 4

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Fig - 5

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6. Pressure drop in Valves and Pipe Fittings

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In many piping situations, including those in most production facilities where space
is limited, the pressure drop through valves, pipe fittings, and enlargements and
contractions is a significant portion of the overall pressure drop in the pipe segment. A
pipe flow restriction that changes velocity or direction of the flow stream causes pressure
drops greater than that which would normally occur in a straight piece of pipe of the same
length. The three most common ways of calculating these pressure drops are by using
resistance coefficients for fittings, flow coefficients for valves and equivalent lengths for
both valves and fittings.

6.1. Resistance Coefficients for Fittings

The Darcy-Weisbach equation can be rewritten as:

V2
H f Kr
2g

where :
K r resistance coefficient, dimensionless
H f head loss in fitting, m ft
V average velocity, m / sec ft / sec

g acceleration of gravity, 9.81m / sec 2 32.2ft / sec 2
For a straight pipe:

fL
Kr
D

Approximate values of Kr are given in below table for various pipe fittings.

Resistance Coefficients for Pipe Fittings

Kr
Globe Valve, wide open 10.0
Angle Valve, wide open 5.0
Gate Valve, wide open 0.2
Gate Valve, half open 5.6
Return Bend 2.2
Tee 1.8
90 Elbow 0.9
45Elbow 0.4

Figure - Resistance Coefficients for Different Types of Pipe Entrances and Exits
(Courtesy of Paragon Engineering Services, Inc.)

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Figure - Resistance Coefficients for Sudden Enlargements and Contractions

(Courtesy of Paragon Engineering Services, Inc.)

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6.2. Flow coefficient for valves

The valve industry generally expresses valve pressure drop characteristics in terms
of a flow coefficient, Cv. The flow coefficient is measured experimentally for each valve
and is defined as the flow of water at 60F, in gpm, at a pressure drop of 1 psi across the
valve. It can be shown from Darcy's equation that Cv can be expressed as follows:

Metric :
0.0105 d 2 0.0105 d 2
Cv 1
1
fl / D 2 Kr 2
Metric :
Customary
0.0105 :d 2 0.0105 d 2
Cv 2
29.9 d1 29.9 d 2 1
C v fl / D 21 K1r 2
fl / D 2 K r 2
Customary :
where29.9 : d 2 29.9 d 2
Cv
C v flow 1coefficien1 t, m 3 / hr gpm
fl / D 2 K r 2
D fitting ID, m ft
d fitting ID, mm in
where :
L fitting length, m ft
For any fitting with C flow coefficient, m 3 / hr a gpm known Cv :
f Moody friction factor, dimensionless
v

D fitting ID, m ft
K r resistance coefficient, dimensionless
d fitting ID, mm in
Metric :
L fitting length, 2 m ft
Ql
fP 6.89 friction
Moody SG
factor, dimensionless
C v
K r resistance coefficient, dimensionless
Metric :
Customary : 2
Ql
P 6.89 SG 2
C v - 4 Q l

P 8.5 10 SG
Cv
Customary :
where : 2
-4 Q l
PQ 8.5 10
l liquid flow
SG
rate, m 3 / hr BPD
Cv
P pressure drop, kPa psi
6.3. Equivalent Length
SG
where : specific gravity of liquid relative to water
v flow coefficient,3m / hr gpm
It is 3 often simpler to treat
QC l liquid flow rate, m / hr BPD
valves and fittings in terms of their equivalent
length of pipe. P pressure drop, kPa psi The equivalent length of a valve or
fitting is the SG specific gravity of liquid relative to water length of an equivalent
section of pipe of the same diameter
C v flow coefficient, m 3 / hr gpm
that gives the same pressure drop as the valve or
fitting. Total pressure drop can then be determined by adding all equivalent lengths to the
pipe length. The equivalent length, Le, can be determined from Kr and Cv as follows:

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KrD
Le
f

Metric :
1.108 10 -7 d 5
Le
fC 2v
Metric :
Customary
1.108 10 -7 d: 5
Le 2 5
74.5d
fC
Le v 2
fC v
Customary :
where5 :
74.5d
Le
e v equivalent length, m ft
LfC 2

K r resistance coefficient, dimensionless

whereD: fitting ID, m ft
d fitting ID,
L e equivalent mmm
length, in ft
For valves and fittings, Le is given in the table below
f Moodycoefficien
K r resistance friction factor
t, dimensionless diameter):
(in which D = nominal pipe
C v flow
D fitting ft
ID, mcoefficien t, m 3 / hr gpm
d fitting ID, mm in
f Moody friction factor
C v flow coefficient, m 3 / hr gpm

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7. Line sizing procedures

Step 1 Assume line size

Step 2 Calculate velocity by

V = Q / (Flow Area) Eq - 17

Step 3 Calculate pressure drop by method described earlier.

Step 4 Check whether calculated velocity & pressure drop falls within
recommended ranges.
- If YES then select the line size
- If NO then select new line size and repeat step 2 to 4.

8. Recommended velocities & max P

Table 1 Liquid Lines in Process & Equipment service

Sr. Types of Service Velocity (m/sec) Maximum P

No Kg /cm2/100m
1 General Recommendation 1.5 4.6 0.92
2 Pump Suction
- Boiling Liquid 0.6 1.8 0.115
- Non Boiling Liquid 1.2 2.4 0.23
3 Pump Discharge
- 0 57 m3 / hr 1.8 2.4 1.38
- 57 159 m3 / hr 2.4 3.0 0.92
- >159 m3 / hr 3.0 4.6 0.46
4 Bottom Outlet 1.2 1.8 0.14
5 Reboiler Trapout 0.3 1.2 0.035
6 Liquid from Condenser 0.9 1.8 0.11
7 Liquid to chillers 1.2 1.8
8 Refrigerant Lines 0.6 1.2 0.09
9 Gravity Lines 0.2 0.5 0.04
10 Drain Lines 0.5 1.2
11 Boiler feed 2.4 4.6
12 Liquid with suspended solids 0.9

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Table 2 Vapour Lines in Process & Equipment service

Sr. Types of Service Velocity (m/sec) Maximum P

No Kg /cm2/100m
1 General Recommendation for pressure level
(Kg /cm2)
P > 35.1 0.46
14.1 < P < 35.1 0.35
10.5 < P < 14.1 0.14
3.5 < P < 10.5 0.069
0 < P < 3.5 0.034
Subatmospheric 0.023
2 Compressor piping Suction 0.12
3 Compressor piping discharge 0.23
4 Refrigerant suction lines 4.6 11
5 Refrigerant discharge lines 11 18
6 Tower Discharge
Pressure (P > 50 psia) 12 18 0.046 0.12
Atmospheric 18 30
Vacuum (P < 10 psia) 38 61 0.012 0.023
7 Saturated steam 60
8 Superheated Steam 75
9 Steam Pressure
P > 3.5 0.06
3.5 < P < 10.5 0.115
10.5 < P < 21 0.25
P > 21 0.35

Gas Line Sizing (Incompressible) criteria as per PDO standards

Table 3 Pressure Drop Criteria

Pressure Friction Loss for Lines

Friction Loss for Lines between
Less
than 50m (kPa/100m) 50m and 150m (kPa/100m)
50mm Hg 1.5 1.2
100mm Hg 2.0 1.5
400mm Hg 2.5 2
760mm Hg to 2.0 bar 3.0 2.5
a
2.0 to 5.0 bar a 10 5
5.0 to 8.0 bar a 12 7
8 to 12 bar a 14 9
12 to 15 bar a 16 10
15 to 35 bar a 19 12
Over 35 bar a 25 14

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Table 4 Velocity Criteria

Wet Dry
Gas Gas
For PDO Projects Minimum 3 m/s N/A
(ref ERD-10-01) Maximum 20 m/s 20 m/s

For non PDO

Projects Maximum 75 m/s 75 m/s

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9. Line sizing (Two phase)

Two-phase flow presents several design and operational difficulties not present in
single phase liquid or vapour flow. Frictional pressure drops are much harder to calculate.
For cross-country pipelines, a terrain profile is needed to calculate elevation pressure
drops. At the downstream end of a pipeline, it is frequently necessary to separate the
liquid and vapour phases in a separator. The presence of liquid slugs complicates this
process, and a slug catcher may be required.

Examples of two-phase flow situations include:

1. Fluid coming out of the well bore prior to liquid separation
2. Gas and oil that have been metered and then recombined for flow in a common line to
a central facility

Horizontal pipe flow Regimes

When a gas-liquid mixture enters a horizontal pipeline, the two phases tend to separate
with the heavier liquid settling to the bottom. The type of flow pattern depends primarily
on the gas and liquid flow rates. Following figure shows typical flow patterns in horizontal
two-phase pipe flow.

Fig - 6 Two phase flow pattern in horizontal flow

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Horizontal flow regimes can be described as follows:

Horizontal flow regimes can be described as follows:
a) Bubble
Very low gas-liquid ratios. Gas bubbles rise to the top.
b) Elongated Bubble
With increasing gas-liquid ratios, bubbles become larger and form gas plugs.
c) Stratified
Further increases in gas-liquid ratios make the plugs become longer until the gas and
liquid are in separate layers.
d) Wavy
As the gas rate increases, the flowing gas causes waves in the flowing liquid.
e) Slug
At even higher gas rates, the waves touch the top of the pipe, trapping gas slugs
between wave crests. The length of these slugs can be several hundred feet long in
some cases.
f) Annular Mist
At extremely high gas-liquid ratios, the liquid is dispersed into the flowing gas stream.

Vertical pipe flow Regimes

Two-phase flow patterns in vertical flow are somewhat different than those occurring in
horizontal flow. Different flow regimes may occur at different segments of pipe, such as
flow in well tubing where pressure loss causes gas to come out of solution as the fluid
moves up the well. Following figure shows typical flow regimes in vertical two-phase flow.

Fig - 7 Figure Two phase flow pattern in vertical flow

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Vertical flow regimes can be described as follows:

a) Bubble
Small gas-liquid ratio with gas present in small, randomly distributed bubbles. The
liquid moves up at a uniform velocity. Gas phase has little effect on pressure gradient.
b) Slug Flow
The gas phase is more pronounced. Although the liquid phase is still continuous, the
gas bubbles coalesce into stable bubbles of the same size and shape, which are nearly
the diameter of the pipe. These bubbles are separated by slugs of liquid. Both phases
have a significant effect on the pressure gradient.
c) Transition Flow or Churn Flow
The change from a continuous liquid phase to a continuous gas phase occurs in this
region. The gas phase is predominant and the liquid becomes entrained in the gas.
The effects of the liquid are still significant.
d) Annular-Mist Flow
The gas phase is continuous and the bulk of the liquid is entrained in and carried by
the gas. A film of liquid wets the pipe wall and its effects are secondary. The gas
phase is the controlling factor.

Flow Regime Determination

Several empirical flow regime maps have been presented that determine vapour-liquid
flow patterns as a function of fluid properties and flow rates. Map commonly used was
developed by Gregory, Aziz, and Mandhane for horizontal flow.

The coordinates of the map are:

VsL = superficial liquid velocity = QL/A Eq - 18

Vsg = superficial gas velocity = Qg/A Eq - 19

Mandhane proposed a fluid property correction to the superficial velocities, but concluded
that the fluid property effects are insignificant compared to the errors in the empirical
map. The map reports the flow regimes: stratified, wavy, annular mist, bubble, slug, and
dispersed. Care should be taken in the interpretation
of these flow maps as the regime boundaries are strongly affected by pipe inclination. In
particular, horizontal flow regime maps must not be used for vertical flow, and vertical flow
regime maps must not be used for horizontal flow. The Mandhane map was developed for
horizontal lines flowing air and water at near atmospheric pressure. Inclinations in the
range of 0.1-1.0 degrees can cause substantial regime boundary movement.

Fig - 8

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Horizontal flow regime map (Mandhane map)

For vertical flow, the stratified flow regime cannot exist as there is no preferred direction
for the liquid to settle. An empirical flow regime map developed by Aziz for vertical upward
flow is shown in Fig. below. The coordinates for this flow map are the same as for the
Mandhane map except that fluid property corrections are used. The coordinates used in
the Aziz vertical map are:

Nx = Vsg XA Eq - 20

Ny = VsL YA Eq - 21

Eq - 22

Eq - 23

Fig - 9 Vertical up flow regime map (Mandhane map)

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Pressure Drop Calculation

Calculation of pressure drop in two-phase flow lends itself better to computer calculation
than to hand calculation. Several two-phase pressure drop correlations are available for
both horizontal and vertical flows. Due to the complexity of two-phase flow, uncertainties
associated with pressure drop calculations are much greater than uncertainties in single
phase pressure drop calculations. As a result, errors in calculated two-phase pressure
drops in the order of plus or minus twenty percent may normally be anticipated, especially
in circumstances where fluid velocities are unusually high or low, where terrain is rugged,
or where fluid properties are inadequately known. In addition, different two-phase flow
correlations
may give significantly different pressure drops. In order to evaluate these differences,
several correlations should be used. A method suggested by the American Gas Association
can serve as a basis for hand calculation generated by Dukler and an elevation pressure
drop correlation by Flanigan.

Frictional Component Using the Dukler frictional pressure drop calculation method,
the frictional pressure drop is given by the equation:

Eq - 24

Eq - 25

Eq - 26

The single phase friction factor, fn, can be obtained from the correlation:

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Eq - 27

The mixture Reynolds number, Rey, is calculated according to the equation:

Eq - 28

Calculation of this Reynolds number requires

determination of mixture velocity, Vm, and mixture viscosity, mn. These quantities can be
determined according to:

Eq - 29
Eq - 30

The two-phase friction factor ratio, ftpr, representing a two phase frictional efficiency can
be determined by reference to Fig. 10 or by the equation:

Eq - 31

Where y =

Fig - 10

The remaining quantity to be calculated in the Dukler scheme is an estimate of the liquid
holdup, HLd. This holdup can be estimated using Fig. 11. This figure gives liquid holdup as
a function of and Rey. Since Rey is itself a function of liquid holdup, the calculation is, in
general, iterative. For most calculations, however, the Rey line can be used for a first
estimate.

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Elevation Component The elevation component of pressure drop can be found using
the Flanigan method. In this method, the elevation component is calculated using the
equation:

Eq - 32

Fig - 11

Where HLf is determined from Fig. 12 or calculated according to the formula:

Eq - 33

Fig - 12

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The term Ze is the vertical elevation rise of a hill. The rises are summed. No elevation
drops are considered. This is tantamount to ignoring any possible hydrostatic pressure
recoveries in downhill sections of pipeline and may lead to a
considerable error in the pressure drop analysis.

Once the frictional component or pressure drop is found using the Dukler method, and the
elevation component is found using the Flanigan method, the overall two-phase pressure
drop is found by summing the friction and elevation components.
Eq - 34

Since fluid properties and liquid holdups can change rapidly in a two-phase line, accuracy
is improved if this AGA calculation procedure is performed segmentally. The need for
segmental calculations is one of the reasons why two-phase calculations are best suited
for computer calculation.

Liquid Hold-up The liquid hold-up correlation given in Fig. 11 is intended only for use
in the Dukler friction pressure drop calculation. A correlation by Eaton et al. is better
suited for liquid hold-up determination in liquid inventory calculations. The Eaton hold-up
correlation is shown in Fig. 13. In this figure, the hold-up fraction, HLe, is plotted directly
as a function of the dimensionless group, NE. This dimensionless group is of the form:

Eq - 35

Eq - 36

Eq - 37

Eq - 38

Eq - 39

Fig - 13

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The Eaton correlation has been found reasonably accurate by several investigators,
particularly for low hold-up flows.
The liquid hold-up fraction, HLe, is the fraction of the flow area of the pipe occupied by
liquid. To calculate the liquid inventory in the pipe, IL, the pipe internal volume is
multiplied by this hold-up fraction.

Eq - 40

Since hold-up fractions may change along the length of the pipe, a segmental calculation
is more accurate.

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10. Solved Examples

10.1. Liquid line sizing

Given:

Flow Rate: = 170.8 m3/h

Liquid density: = 1100 Kg/m3

Viscosity = 1.5 cP

Length = 10 m

Inlet Pressure = 200 KPa

Fluid Water

Line location Pump suction

Pipe material CS

Problem:

Find out line size & pressure drop

Solution:

Recommended velocity = 0.6 to 1.8 m / sec

Recommended pressure drop = 0.115 kg/cm2/100m or 12 KPa / 100m

Step 1: Assume line size

Preliminary 8 line size assume

Step 2: Calculate velocity

V = Q / (flow Area)
V = (170.8/60) / ( * (8 * 0.0254)2/ 4)
V = 0.89 m/s

Step -3: Calculate pressure drop

Check the Reynolds no.

NRe = D*V* /
= 0.203*0.89*1100/0.0015
= 132491.33 flow is turbulent

From figure 3 relative roughness factor = 0.00025

Calculate friction factor

By churchills eqn

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1 0.27
4LOG
7 Re 0.9
ff D

1
ff

4 log 0.27 x 0.00025 7 / 132491.3
0.9

ff = 0.00461

From figure 2 ,
ff 0.0045

Calculate pressure drop

4Ff L v 2
hL
2 gD

2
4 x 0.00461x10x0.89
hL
2 x9.81x 0.0203

hL = 0.0366 m

= 0.0366 x 1100 x 9.81 x 10-3

= 0.39 KPa for 10 m pipe

= 3.9 KPa for 100 m pipe

Summary

Permissible Limit Calculated Remarks

Velocity 0.6 to 1.8 m / sec 0.89 m / sec Calculated pressure

drop and velocity are
Pressure drop 12 KPa / 100m 3.9 KPa / 100m within recommended
limit so assumed pipe
size is suitable

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10.2. Two phase pressure drop

Example A pipeline segment with a 6-inch inside diameter (150 mm), 1200 m long,
transports a mixture of gas and oil. The pipeline has a gradual upward slope and rises 30
m over the 1200 m length. The inlet pressure of the pipeline is 2800 kPa (abs), liquid
viscosity is 0.02 Pa s, the vapor viscosity is 0.000015 Pa s, and the interfacial surface
tension is 1.5 x 10-6 N/m. The liquid flow rate is 17 m3/h and the vapour flow rate is 425
m3/h. The density of the liquid phase is 880 kg/m3, and the density of the gas phase is
20.8 kg/m3 at operating conditions. What is the pressure at the downstream end of the
line segment, and what is the liquid inventory of the
line?

Solution Steps
Calculate the flowing liquid volume fraction using Eq - 26.

Calculate the mixture viscosity, n using Eq - 30.

For a first guess, assume HLd = l and estimate k using Eq - 25.

Calculate the superficial velocities and the mixture velocity.

Calculate an estimate of the mixture Reynolds number, Rey, using Eq - 28

From Fig. 11, determine a better estimate for the hold-up fraction HLd using
= 0.038, Rey = 70 839

Using this improved HLd, recalculate k using Eq - 25

Using this improved k recalculate Rey using Eq - 28

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From Fig. 11 with = 0.038 and Rey = 43 024, HLd = 0.16.

Another iteration using HLd = 0.16 indicates Rey = 40 900 and HLd = 0.16.

Calculate the single phase friction factor with Rey = 40 900 using Eq - 27

Determine the two-phase friction factor, ftpr, from Fig. 10

Using

using Eq - 25.

Calculate the frictional component of pressure drop Pf using Eq - 24

Find HLf from Fig. 12 using Vsg = 6.472 m/s

Determine the elevation component of pressure drop, Pe, using Eq - 32

Find the total pressure drop, Pt, using Eq - 34

Find the segment discharge pressure

The pipeline segment has a discharge pressure of 2450.4 kPa.

To calculate the liquid inventory, the liquid hold-up fraction from Eatons correlation must
be found. First determine the non-dimensional parameters:

Using Eq - 36

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Determine Eatons non-dimensional abscissa, NE, using Eq - 35

From Fig. 13, read the hold-up fraction, HLe

Note that this estimate is close to the HLf predicted in Fig. 12 for elevation pressure drop
determination. It also coincides closely with the value of 0.16 from Fig. 11.

Calculate the pipeline segment liquid inventory from Eq - 40

The pipeline segment contains 3.064 cubic m of liquid at any instant.

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Appendix - 1
Pipe Roughness table

Absolute Roughness ()

Type of Pipe
(New, clean condition) (mm) (ft) (in)
Unlined Concrete 0.30 0.001-0.01 0.012-0.12
Cast Iron - Uncoated 0.26 0.00085 0.0102
Galvanized Iron 0.15 0.0005 0.006
Carbon Steel 0.046 0.00015 0.0018
Fiberglass Epoxy 0.0076 0.000025 0.0003
Drawn Tubing 0.0015 0.000005 0.00006

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Appendix - 2
ANSI Pipe Schedules

Nominal O. D. Wall Weight/Ft Schedule

Pipe Size Thickness
3
/4 in 1.050 .113 1.131 40
.154 1.474 80
.218 1.937 160
.308 2.441
1 in 1.315 .133 1.679 40
.179 2.172 80
.250 2.844 160
.358 3.659
1 1/2 in 1.900 .145 2.718 40
.200 3.631 80
.281 4.859 160
.400 6.408
2 in 2.375 .154 3.653 40
.218 5.022 80
.343 7.444 160
.436 9.029
3 in 3.500 .216 7.576 40
.300 10.25 80
.437 14.32 160
.600 18.58
4 in 4.50 .237 10.79 40
.281 12.66 60
.337 14.98 80
.437 19.01 120
.531 22.51 160
.674 27.54
6 in 6.625 .280 18.97 40
.432 28.57 80
.562 36.39 120
.718 45.30 160
.864 53.16
8 in 8.625 .250 22.36 20

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 Line Sizing

Nominal O. D. Wall Weight/Ft Schedule

Pipe Size Thickness

.277 24.70 30
.322 28.55 40
.406 35.64 60
.500 43.39 80
.593 50.87 100
.718 60.63 120
.812 67.76 140
.906 74.69 160
.875 72.42
10 in 10.75 .250 28.04 20
.307 34.24 30
.365 40.48 40
.500 54.74 60
.593 64.33 80
.718 76.93 100
.843 89.20 120
1.000 104.1 140
1.125 115.7 160
12 in 12.75 .250 33.38 20
.330 43.77 30
.375 49.56
.406 53.53 40
.500 65.42
.562 73.16 60
.687 88.51 80
.843 107.2 100
1.000 125.5 120
1.125 139.7 140
1.312 160.3 160
14 in 14.0 .250 36.71 10
.312 45.68 20
.375 54.57 30
.437 63.37 40
.500 72.09
.593 84.91 60

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Nominal O. D. Wall Weight/Ft Schedule

Pipe Size Thickness

.750 106.1 80
.937 130.7 100
1.093 150.7 120
1.250 170.2 140
1.406 189.1 160
16 in 16.0 .250 42.05 10
.312 52.36 20
.375 62.58 30
.500 82.77 40
.656 107.5 60
.843 136.5 80
1.031 164.8 100
1218 192.3 120
1.437 223.5 140
1.593 245.1 160

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Appendix - 3
Table of Pipe Schedules (DEP Standard)

Nominal Nominal Pipe Spec Spec Spec Spec Spec Spec Spec Spec Spec Spec Spec Spec
size size OD 11410 11420 11430 11440 31410 31420 31430 31440 61410 61420 61430 61440
inch mm mm
2 50 60.33 40 40 80 80 40 40 80 80 40 40 160 160
3 80 88.90 40 40 80 80 40 40 80 80 40 40 80 80
4 100 114.30 40 40 80 80 40 40 80 80 40 40 80 80
6 150 168.28 40 40 80 80 40 40 80 80 80 80 80 80
8 200 219.08 20 20 40 40 30 30 40 40 80 80 80 80
10 250 273.05 20 20 40 40 30 30 40 40 80 80 80 80
12 300 323.85 20 20 40 40 30 30 40 40 80 80 80 80
14 350 355.60 20 20 40 40 30 30 40 40 80 80 80 80
16 400 406.40 20 20 40 40 30 30 40 40 80 80 80 80
18 450 457.20 20 20 30 30 30 30 40 40 80 80 80 80
20 500 508.00 20 20 30 30 30 30 40 40 80 80 80 80
24 600 609.60 20 20 30 30 30 30 40 40 80 80 80 80

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Appendix - 4
Table of Pipe Wall Thickness

Nominal Schedule Schedule Schedule Schedule Schedule

size 20 30 40 80 160
inch mm mm mm mm mm
2 - - 3.91 5.54 8.71
3 - - 5.49 7.62 -
4 - - 6.02 8.56 -
6 - - 7.11 10.97 -
8 6.35 7.04 8.18 12.70 -
10 6.35 7.80 9.27 15.06 -
12 6.35 8.38 10.31 17.45 -
14 7.92 9.53 11.10 19.05 -
16 7.92 9.53 12.70 21.41 -
18 7.92 11.10 14.27 23.80 -
20 9.53 12.70 15.06 26.19 -
24 9.53 14.27 17.45 30.94 -

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