BECHTEL CORPORATION

ENGINEERING DESIGN GUIDE

FOR

FLUID FLOW

IN

PIPING SYSTEMS

Prepared By: Shiv Verma

Reviewed By: GBU Mechanical Chiefs
Approved By: Lee Barrett

This document and the design it covers are the property of BECHTEL. They are merely loaned on the
borrower’s express agreement and they will not be reproduced, copied, loaned, exhibited, or used except
in the limited way and private use permitted and by any written consent given by the lender to the
borrower.

03 12/02 REVISED AND ISSUED AS CORPORATE

SV LTB
GUIDE
02 12/01 REVISED PER REVISION LIST – PAGES 2 & 3 HY JRP REP
REVISED PER REVISION LIST – PAGE 2
01 08/94 (REVISED DOC NO. FROM A-2 TO 3DG M11 HY SC RC
001)
REV. DATE REASON FOR REVISION BY CHECK APPR.
BECHTEL CORP.
DESIGN GUIDE NO. REV.
HORO
ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW 3DG-M11-00001 003
IN
PIPING SYSTEMS
Page 1

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3DG-M11-00001-003 PAGE 1 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW
IN
PIPING SYSTEMS

REVISION DESCRIPTION

Majority of sections and appendices have been revised to reflect the latest technological
developments with incorporation of computational and automation tools. Manual
methods have either been refined or deleted.

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Refer to the electronic documents in BecRef for current revisions.

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3DG-M11-00001-003 PAGE 2 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW IN PIPING SYSTEMS
INDEX

Section Description Page No.

1.0 PURPOSE AND SCOPE

Author: Han Yen/Sham Chadha
1.1 Lines ................................................................................................... 1
1.2 Fluid Systems ..................................................................................... 2
1.3 Overview............................................................................................. 2

2.0 PROCESS LIQUID LINES

Author: Han Yen/Sham Chadha
2.1 Process Lines ..................................................................................... 1
2.2 Water Lines......................................................................................... 2
2.3 Pump Suction Lines............................................................................ 2
2.4 Side Stream Draw-off ......................................................................... 3
2.5 Thermosyphon Feed........................................................................... 3
2.6 Lines from Condensers to Receivers.................................................. 3
2.7 Gravity Lines ....................................................................................... 3
2.8 Special Considerations ....................................................................... 4
2.9 Illustrative Problems............................................................................ 6
2.10 Slurry Pipelines ................................................................................... 9

3.0 WATER LINES

Author: Han Yen/Sham Chadha
3.1 Design Criteria .................................................................................... 1
3.2 Cooling Water Systems ...................................................................... 2
3.3 Cooling Water Network Analysis ........................................................ 5
3.4 Cooling Water Fouling in Heat Exchangers........................................ 5
3.5 Firewater System................................................................................ 5

4.0 UNSTEADY FLOW (LIQUIDS)

Author: John D. O’Sullivan
4.1 Scope and Definitions......................................................................... 1
4.2 Basic Equations .................................................................................. 2
4.3 Column Separation ........................................................................... 12
4.4 Causes of Transients........................................................................ 15
4.5 Method for Preventing/Controlling Transients................................... 23
4.6 Analytic Methods .............................................................................. 33
4.7 Manufacturer’s Data ......................................................................... 35
4.8 Field Testing ..................................................................................... 37
4.9 References ....................................................................................... 39
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3DG-M11-00001-003 PAGE 3 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW IN PIPING SYSTEMS
INDEX

Section Description Page No.

5.0 PROCESS VAPOR LINES

Author: Han Yen/Sham Chadha
5.1 Compressible and Incompressible Fluids ........................................... 1
5.2 Limitations of the Pressure Drop Formulae ........................................ 2
5.3 Low Pressure and Vacuum Systems.................................................. 2
5.4 Limiting Velocities ............................................................................... 2
5.5 Acoustic Velocity................................................................................. 4
5.6 Tower Overheads ............................................................................... 4
5.7 Illustrative Problems............................................................................ 4

6.0 STEAM/CONDENSATE LINES

Author: Han Yen/Sham Chadha
6.1 Steam Lines........................................................................................ 1
6.2 Illustrative Problems............................................................................ 1
6.3 Steam Network Analysis..................................................................... 4
6.4 Steam Condensate Lines ................................................................... 4

7.0 TWO-PHASE FLOW

Author: Han Yen/Sham Chadha
7.1 Introduction ......................................................................................... 1
7.2 Two-Phase Calculations ..................................................................... 1
7.3 Horizontal Flow ................................................................................. 11
7.4 Vertical Flow ..................................................................................... 12
7.5 Limitation of In-House Programs ...................................................... 12
7.6 Recommended Velocity Range ........................................................ 13
7.7 Reboiler Return Lines ....................................................................... 14
7.8 Isenthalpic Two-Phase Flow............................................................. 14
7.9 Inclined Flow..................................................................................... 14

8.0 NON-PROCESS GAS LINES

Author: Han Yen/Sham Chadha

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3DG-M11-00001-003 PAGE 4 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW IN PIPING SYSTEMS
INDEX

Section Description Page No.

9.0 PNEUMATIC CONVEYING

Author: Andy Bhalerao
9.1 Introduction ......................................................................................... 1
9.2 Dilute Phase Systems......................................................................... 1
9.3 Calculation Methods ........................................................................... 2
9.4 Illustrative Problems............................................................................ 2

10.0 PUMP DESIGN AND PUMP SYSTEM DESIGN

Author: Han Yen/Sham Chadha
10.1 Criteria for Pump Design..................................................................... 4
10.2 Sample Pump Calculations............................................................... 11

11.0 COMPRESSORS, BLOWERS AND FANS

Author: David Hesse/Tim Hattenbach
11.1 Thermodynamics of Compression...................................................... 3
11.2 Centrifugal Compressors .................................................................. 18
11.3 Positive Displacement Compressors ................................................ 21
11.4 Pressure Profiles............................................................................... 22
11.5 Fans.................................................................................................. 22
11.6 Compressor Design and Compressor System Design ..................... 25
11.7 Criteria for Compressor Design ........................................................ 27

12.0 COMPUTER PROGRAMS FOR LINE SIZING

Author: David Richardson
12.1 Pressure Profile Suite (PPS)............................................................... 1

13.0 LINE DESIGNATION TABLES

Author: Jose Flores

14.0 SELECTION OF ECONOMIC PIPE SIZE

Author: David Haim
14.1 Pumped Liquids .................................................................................. 1
14.2 Gas Lines............................................................................................ 2

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3DG-M11-00001-003 PAGE 5 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW IN PIPING SYSTEMS
INDEX

APPENDIX A – BASIC DATA

A 1.0 Preface - Appendix A ...........................................................................A-2

A 2.0 Density of Gas ......................................................................................A-2

Chart A 2.1 Specific Gravity and Weights per Unit Volume....................................A-3
Chart A 2.2 Approximate Specific Gravity vs. Temperature for
Petroleum Liquids.................................................................................A-4

Chart A 3.1 Density of Steam ..................................................................................A-5

Chart A 3.2 Density of Air ........................................................................................A-6

Chart A 4.1 Viscosity Conversion Factors...............................................................A-7

Chart A 4.2 Viscosity Conversion Scales ................................................................A-8
Chart A 4.3 Kinematic/Absolute Viscosity Conversion for Liquids –
Low Range............................................................................................A-9
Chart A 4.4 Kinematic/Absolute Viscosity Conversion for Liquids –
High Range .........................................................................................A-10

Chart A 5.1 Viscosity of Steam and Water ............................................................A-11

Chart A 5.2 Kinematic Viscosity of Steam as a Function of Temperature ..........A-12
Chart A 5.3 Viscosity of Gases at Low Pressures ................................................A-13
Chart A 5.4 Kinematic Viscosity of Air as a Function of Temperature .................A-14
Chart A 5.5 Percent Flash for Various Initial Steam Pressures and
Flash Tank Pressures ........................................................................A-15

APPENDIX B – PRESSURE DROP FORMULAS

B 1.0 Preface - Appendix B............................................................................B-2

Chart B 2.1 Rational Flow Formulas........................................................................B-4

Chart B 2.2 Rational Flow Formulas for Ducts & Stacks ........................................B-5
Chart B 2.3 Rational Flow Formulas - Non Circular Conduits ................................B-6
Chart B 2.4 Head and Pressure Losses for Laminar or Viscous Flow...................B-7

Chart B 3.1 Reynolds Number for Liquids...............................................................B-8

Chart B 3.2 Reynolds Number for Gases................................................................B-9
Chart B 3.3 Reynolds Number for Any Fluid .........................................................B-10

Chart B 4.1 Reynolds Number vs. Friction Factor ..................................................B-11

Chart B 4.2 Friction Factor Correction for Roughness..........................................B-12
Chart B 4.3 Roughness Factors in Inches.............................................................B-13
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3DG-M11-00001-003 PAGE 6 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW IN PIPING SYSTEMS
INDEX

APPENDIX C – PRESSURE DROP CHARTS

C 1. 0 Preface - Appendix C .......................................................................... C-2

Chart C 2.01 Liquid Pressure Drop in 1/2" Schedule 80 Pipe ................................... C-5
Chart C 2.02 Liquid Pressure Drop in 3/4" Schedule 80 Pipe ................................... C-6
Chart C 2.03 Liquid Pressure Drop in 1" Schedule 40 Pipe ...................................... C-7
Chart C 2.04 Liquid Pressure Drop in 1" Schedule 80 Pipe ...................................... C-8
Chart C 2.05 Liquid Pressure Drop in 1 1/2" Schedule 40 Pipe ................................ C-9
Chart C 2.06 Liquid Pressure Drop in 1 1/2" Schedule 80 Pipe .............................. C-10
Chart C 2.07 Liquid Pressure Drop in 2" Schedule 40 Pipe .................................... C-11
Chart C 2.08 Liquid Pressure Drop in 3" Schedule 40 Pipe .................................... C-12
Chart C 2.09 Liquid Pressure Drop in 4" Schedule 40 Pipe .................................... C-13
Chart C 2.10 Liquid Pressure Drop in 6" Schedule 40 Pipe .................................... C-14
Chart C 2.11 Liquid Pressure Drop in 8" Schedule 40 Pipe .................................... C-15
Chart C 2.12 Liquid Pressure Drop in 10" Schedule 40 Pipe .................................. C-16
Chart C 2.13 Liquid Pressure Drop in 12" Schedule 40 Pipe .................................. C-17
Chart C 2.14 Liquid Pressure Drop in 14" Schedule 10 Pipe .................................. C-18
Chart C 2.15 Liquid Pressure Drop in 16" Schedule 10 Pipe .................................. C-19
Chart C 2.16 Liquid Pressure Drop in 18" Schedule 10 Pipe .................................. C-20

Chart C 3.1 Pressure Drop Chart for Turbulent Flow Conditions .......................... C-21

Chart C 4.1 Loss in Head, Water Flowing in Smooth Steel Pipe........................... C-22
Chart C 4.2 Loss in Head, Water Flowing in Steel Pipe with
Centrifugal Cement Lining.................................................................. C-23
Chart C 4.3 Loss in Head, Water Flowing in Cement Pipe with
Steel Shell, Centrifugally Lined........................................................... C-24
Chart C 5.1 Condensate Line Sizing Chart where Pressure at Traps
is Above 60 psi ................................................................................... C-25

APPENDIX D – VELOCITY CHARTS

D 1.0 Preface - Appendix D .......................................................................... D-2

Chart D 2.1 Fluid Velocity vs. GPM ......................................................................... D-3

Chart D 2.2 Fluid Velocity vs. Cubic Feet per Minute .............................................. D-4

Chart D 3.1 Steam Lines - Velocity vs. Flow Rate................................................... D-5

Chart D 4.1 Critical Flow of Gases........................................................................... D-6

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3DG-M11-00001-003 PAGE 7 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW IN PIPING SYSTEMS
INDEX

APPENDIX E – PIPE EQUIVALENTS OF VALVES AND FITTINGS

E 1.0 Preface - Appendix E............................................................................E-2
E.1.1 Preface ..................................................................................................E-8

Chart E 2.1 Representative Equivalent Length in Pipe Diameters (L/D) of

Valves and Fittings ..............................................................................E-11
Chart E 2.2 Head Loss Coefficients and Equivalent Lengths.................................E-12
Chart E 2.3 Equivalent Length "L", "L/D" and Coefficient "K" .................................E-14

Chart E 3.1 Length of Straight Pipe Equivalent to 90° Welded Elbows..................E-15

Chart E 3.2 Head Losses in Pipe Fittings - Coefficients of Resistance in
Equal Tees - Separation or Diverging Flow.........................................E-16
Chart E 3.3 Head Losses in Pipe Fittings - Coefficients of Resistance in
Equal Tees - Confluence or Converging Flow.....................................E-17
Chart E 3.4 Equivalent Lengths of Miter Bends - "K" Coefficients for
Sudden Contraction and Enlargement ................................................E-18
Chart E 3.5 Pressure Loss Characteristics of Swages and Gate Valves ...............E-19
Chart E 3.6 Pressure Loss Characteristics of Diverging Swage ............................E-20
Chart E 3.7 Dimensions and Included Angles for Concentric Swages...................E-21
Chart E 3.8 Equivalent Length of Valves and Fittings ............................................E-22
Chart E 3.9 Equivalent Length of Fittings in Feet of Pipe.......................................E-23
Chart E 3.10 Equivalent Length of Reducer/Enlarger ..............................................E-24

APPENDIX F – DATA FOR PIPES AND PIPING MATERIALS

Chart F 1.1 Commercial Wrought Steel Pipe Data...................................................F-2
Chart F 1.2 Commercial Wrought Steel Pipe Data (Continued)...............................F-3
Chart F 1.3 Commercial Wrought Steel Pipe Data (Continued)...............................F-4

Chart F 2.1 List of Material Specifications ................................................................F-5

Chart F 2.2 Pressure – Temperature Ratings for Groups 1.1 through 3.16
Materials................................................................................................F-6
Chart F 2.3 Deleted ..................................................................................................F-7
Chart F 2.4 Deleted ..................................................................................................F-7
Chart F 2.5 Deleted ..................................................................................................F-7
Chart F 2.6 Deleted ..................................................................................................F-7
Chart F 2.7 Deleted ..................................................................................................F-7

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3DG-M11-00001-003 PAGE 8 OF 9
 ENGINEERING DESIGN GUIDE
FOR
FLUID FLOW IN PIPING SYSTEMS
INDEX

APPENDIX G – CENTRIFUGAL PUMP SELECTION

Chart G 1.1 Centrifugal Pump Selection, Single Stage ........................................... G-2

APPENDIX H – FORMS
Form H-1 PPS Line Designation Table (Blank Form)........................................... H-2
Form H-2 PPS Pump Calculation (Blank Form) ................................................... H-3
Form H-3 PPS Centrifugal Compressor Calculation (Blank Form)....................... H-4
Form H-4 PPS Reciprocating Compressor Calculation (Blank Form).................. H-5
Form H-5 PPS Control Valve Datasheet (Blank Form) ........................................ H-6

APPENDIX I – COMPUTER PROGRAMS

(DELETED)

APPENDIX J – DESIGN PRESSURES AND TEMPERATURES

(DELETED)

APPENDIX K – PETROLEUM TRANSPORTATION BY PIPELINE AND COMPUTER

PROGRAMS FOR PIPELINE DESIGN
(DELETED)

APPENDIX L – PULP STOCK LINES

L 1.0 Pulp Stock Lines ...................................................................................L-2
L.1.1 Friction Loss Estimation Procedure.......................................................L-3
L.1.2 Density of Stock ....................................................................................L-5
L.1.3 Equivalent Length of Valves and Fittings ..............................................L-5

Table I Data for Use with Equation 1 or Equation 1M ....................................... L-6

Table II Data for Use with Equation 2 or Equation 2M ....................................... L-7

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3DG-M11-00001-003 PAGE 9 OF 9