Process Design Training Pipe 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

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
2 Fluid physical properties affecting fluid flow are: 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
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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

Two phase lines are difficult to design and operate Flow regimes and terrain profile influence P, slug size and liquid hold-up
Baker, Gregory-Aziz-Mandhane , Taitel-Duckler maps

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
Pump Size
Line 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 When you write your program, its a good idea to provide the formulae and criteria for selection.
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
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 200 F 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
Check access to valves, instruments and sample points Check slope and no pocket requirements
1. Mark gravity flow lines, lines that should slope or should not have pockets, clearly. 2. Tap off from top
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
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 5. PSV where maintenance access is available. This may 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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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
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
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Slip-on
Raised Face
Pipe Fittings
RTJ
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
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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 -65 1 for 2-3; 2 for 4-8. C: Solidification 65-150 2 for 2; 3 for 4-8; 6 for 10-12; 8 for 14-18. C: 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
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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
Ball or Plug Ball valves widely used in upstream industry; gate in d/s Quick closing Limited to <250C .. Thermal contraction/ expansion Butterfly
Globe Good for throttling Install vertically Angle In high P service Diaphragm Made of elastomer Good for slurry, viscous and corrosive services
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
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.
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 Pipe Sizing

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Process Design Training

Fluids are: Liquid Vapour Two phase

Slurry Fluids may flow under pressure or gravity

Process Engineers - are they glorified plumbers?

Meet the basics

Laminar or streamlined flow

Turbulent flow is further categorized into partially or fully developed turbulence

It does not mean P calculated by Civil Engineers is 4 times higher!

Optimum size Vs Special Requirements

Optimum size Vs Special Requirements

Liquid & Gas Lines

Size high P gas lines in segments

Water Supply Network

Cooling Water Network

Cooling Tower & Pumps

Gas Transmission Lines

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

Correlations are usually developed for air-water system in pipes <1

Two Phase Lines

Dispersed bubble aerated turbulent slug flow annular mist

Two Phase Lines

Now you are an Expert in Plumbing

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

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

Thanks for helping to keep my reputation high!!

Excel for sizing

Be kind to your users: start with design basis

Make your workbook user friendly

Small bore piping safety engineers nightmare

Spec blinds should be in horizontal runs

What type of insulation? Insulation comes in preformed shapes, mattress or loose.

Insulation pays back in 3 months

Steam tracing requires steam supply and condensate collection headers

Electrical tracing is relatively simple

Valves help regulate or isolate fluid flow

Valves help regulate or isolate fluid flow

Check valves minimize back flow. All valves leak............!

Remote operated valves

ROVs can be automated to close on high level or pressure

With a proper blind, Bhopal disaster would not have happened

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