TRAINING

SUBJECT  LINE SIZING

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 TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 OVERVIEW OF LINE SIZING CALCULATIONS

3.0 DESIGN BASIS FOR LINE SIZING

4.0 PRESSURE DROP IN SINGLE PHASE FLUID FLOW IN PIPELINES

5.0 TWO PHASE FLUID FLOW IN PIPELINES

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1. INTRODUCTION

Flow of fluids at the desired rate and within the design parameters is very important for proper
operation of any process plant. Plant designer has to ensure that the prime movers installed
such as pumps, blowers and compressors should be able to move the fluids at the desired
flow rate. In today’s industry pipelines are used for flow of almost every type of fluid or their
mixtures. Hence it has become essential for any engineer to understand the principles of fluid
flow and pressure drop in pipelines.

Size of pipeline for transport of a fluid is ideally based on economic calculations. The capital
investment (fixed cost) for installation of a pipeline system increases as the size of the pipe is
increased. At the same time, the pressure drop in the system reduces as the size of pipe is
increased. This results in decreased power or variable cost for bigger pipe sizes. Thus the
optimum pipe size can be calculated for which the total cost of operation would be minimum.

Pipe having smaller than required diameter may not be able to transport the fluid at the
desired flow rate. An “oversized” pipe may be suitable for the desired fluid flow – however this
may not be economic. Hence ideally sizing of pipelines should be done by economic
calculations. However in practice, most companies have developed standards or economic
criteria for sizing of pipe lines. These standards are developed using a given set of cost
information and calculations done. Yet these standards can be used for optimum sizing of
pipelines without much error.

Piping is an important element which can be optimized during execution of a project. For a
given process technology, the sizes of equipment and instrumentation depend largely on the
plant capacity. Thus the cost of these elements is “fixed” by the plant capacity. However the
length of piping required to interconnect these equipments can be minimized by deciding an
appropriate equipment layout. Lower length of piping leads to lower pressure drops and
allows selection of lower diameter of piping. Thus while carrying out engineering design of a
plant, the designer is able to minimize the cost of piping. This explains the importance of
piping systems in the total project cost. In most process plants, cost of piping is about 15% of
the total project cost. This is why the equipment layout is developed by piping group during
project execution. The process group provides only the conceptual layout for the process
equipment.

2. OVERVIEW OF LINE SIZING CALCULATIONS

Process engineers need to specify line sizes during basic engineering phase of the project.
However at this stage, all the inputs required to calculate pressure drops and to specify the
line sizes are not available at. Therefore using the conceptual equipment layout, the line
lengths and number of fittings are estimated. Based on these inputs, line sizing calculations
are done during BEP phase. Appropriate over design margins need to be considered so that
major changes are not required at a later stage.

During detailed engineering, the final equipment layouts and piping drawings such as
isometrics / general arrangement drawings are available. At this stage the line sizes specified
in the BEP are verified using the inputs such as actual line lengths and number of fittings
installed.

Following inputs are required for line sizing calculations:

 Fluid Conditions / Properties
 Temperature, Pressure
 State of Fluid (Liq / Vap / 2 phase)
 Properties @ T&P – Density, Viscosity, MW, Surface Tension

 Properties of Pipes

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  MOC – Roughness Factor
 Std. Pipe Sizes – Pipe ID

 Plant Operations Data

 Design Flowrate
 Normal / Min Flowrate

3. DESIGN BASIS FOR LINE SIZING

For deciding size of a pipeline for flow of fluids, allowable pressure drop per 100 m of piping is
used as the design basis or criteria.
When preparing process flow sheets, process engineer allocates suitable pressure drop
allowances for piping. Ideally these should be “economic”. But a full fledged economic
evaluation is generally impracticable. Therefore the method of allowable ∆P/100 m followed
for line sizing is a reasonable approximation to a generalised economic basis. In addition,
certain overriding factors such as velocity limitations, total pressure drop available, design
pressure of the system need to be considered.

3.1. Design basis for deciding size of most common piping systems is summarized below:

Pump Suction Lines

  Pipe Diam <= 8" Pipe Diam >= 10"

Max Vel Max. ΔP Max. Vel Max. ΔP
(m/sec) (bar/100m) (m/sec) (bar/100m)
Nonboiling Liquid 1.5 0.11 3.5 0.13
Boiling Liquid 1.2 0.07 2.7 0.11
(Pump NPSHA >9 m)
Boiling Liquid 0.9 0.05 0.9 0.07
(Pump NPSHA <9 m)

Pump Discharge Lines

Max. Vel Max. ΔP

Pipe Diameter
(m/sec) (bar/100m)
£ 4" 1.8 0.33
6 to 12" 3.0 0.33
³ 14" 3.6 0.33

Hydrocarbon Vapour Lines

Max. ΔP DROP TOTAL
COLUMN OVHD
(bar/100m) (bar)
Vacuum Towers 0.002 0.0007
Atm to 1.7 barg 0.02 0.07
>1.7 barg 0.04 0.14

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 Reboiler Lines

REBOILER LINES Max. ΔP Max. Vel.

SERVICE (bar/100m) (m/sec)
Reboiler Inlet 0.05 1.2
Reboiler Vapor Return 0.07 14
Thermosiphon Reboiler 0.07
Return

Steam Lines

NOMINAL Max. ΔP
PRESSURE (bar/100m)
> 25 Barg
Short Lines 0.33
Long Lines 0.22
3.5 – 7 Barg
Short Lines 0.22
Long Lines 0.11
<1 Barg
Short Lines 0.06
Long Lines 0.022

Long Distance OSBL Lines

Long distance OSBL lines such as utility interconnection headers and process lines moving
fluid from one unit to another unit fall under this category. Most often the total pressure drop
available is limited by the source pressure. Hence these lines are sized to keep total ∆P
within allowable limit.
The ∆P/ 100 m criteria used for long distance utility and water headers is 0.05 bar/100m.

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3.2. Velocity Limitations
A check on velocity is desirable in all cases to ensure that various undesirable effects are
avoided.
3.2.1. Excessive Erosion
Erosion of pipeline can be caused if very high velocities are encountered. In addition
corrosive liquids can pose a problem as protective corrosion layer formed on the metal
surface can be scoured off.
Recommended maximum velocities for liquid service are given in the tables in section 3.1
above.

For droplet and grit free gases and vapours the following limits are recommended:

Specific Volume <0.062 0.062 to 0.31 0.31 – >0.93

M3/kg 0.93
Max. Velocity 30 37 55 61
m/s

Erosion is most severe in two phase flow services. This is caused by flow of liquid droplets
having higher density at high velocities caused by high gas velocity. Special precautions are
needed while sizing and deciding routing two phase lines.

3.2.2. Excessive Noise

If the above limitations are employed, noise generated by flow in the full pipe cross section
will not be a problem. Two phase line sizes need to be checked for excessive noise.

3.2.3. Static Electricity Generation

This occurs when products of low conductivity are handled. The following operations are
particularly probe to high electrification:
 When beginning to fill a tank
 When adding a low density product to a tank containing a high density product
 When handling a product containing a second phase
 When changing the grade of product during pumping when contamination with water can
occur
These operations are dangerous when the liquid is discharged into a space containing an
explosive gas mixture. In these circumstances it is necessary to limit the velocity to
approximately 1 m/s.

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3.2.4. Sedimentation
A critical factor in the design of slurry piping is the minimum velocity required to keep the
material in suspension. In systems having very low solid concentration, eg. cooling water, a
minimum velocity of 1 m/s is recommended. In case of high solid concentrations and
heterogeneous slurries a detailed calculation of the critical velocity is necessary.

3.3. Other Constraints

3.3.1. Total available pressure drop

Process units are typically designed with a predetermined pressure of product streams at
battery limit. Hence total pressure drop available is a constraint frequently faced while sizing
long distance OSBL lines.

3.3.2. Design pressure

Constraint of system design pressure is faced frequently while sizing headers for utility
systems, such as cooling water. In most instances a new utility system is to be integrated
with an existing system. Hence the design pressures of the existing utility system must not be
exceeded while sizing the new headers / interconnections. Accordingly, the allowable
pressure drop in new utility headers has to be decided.

4. PRESSURE DROP IN SINGLE PHASE FLUID FLOW IN PIPELINES

4.1. Pipe sizes

Pipe inside diameter is required as an input for calculation of pressure drop in pipelines.
Thicknesses of Standard Pipe sizes are designated by Schedule Number such as

 Sch.5,10, 20, 30
 Std. 40, 60, Extra strong
 80,100,120,160, Double extra strong

For all schedule designated pipes, thickness increases with size for a particular schedule.
Irrespective of the Schedule, for a given size, pipe OD is fixed.
Up to 12” pipe, OD is > Nominal size
Beyond 12” pipe OD matches with Nominal size
Non standard sizes such as 5”, 14”, 22” are not used expect for special cases (slurry/velocity
requirements)

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 Standard pipe thicknesses as per ASME B.36.10 or ANSI / ASME B.36.19 for different pipe
schedules and nominal diameters are shown in table below:

Seamless and Welded Steel Pipe

Nominal
Pipe Sched. Sched. Sched. Sched. Stand- Sched. Sched. Extra Sched. Sched. Sched. Sched. Sched. XX
Size 5 10 20 30 dard* 40 60 Strong 80 100 120 140 160 Strong

1/8" 0.049 0.057 0.068 0.068 0.095 0.095 0.124 0.190

1/4" 0.065 0.073 0.088 0.088 0.119 0.119 0.145 0.238
3/8" 0.065 0.073 0.091 0.091 0.126 0.126 0.158 0.252
1/2" 0.065 0.083 0.095 0.109 0.109 0.147 0.147 0.188 0.294
3/4" 0.065 0.083 0.095 0.113 0.113 0.154 0.154 0.219 0.308
1" 0.065 0.109 0.114 0.133 0.133 0.179 0.179 0.250 0.358
11/4 “ 0.065 0.109 0.117 0.140 0.140 0.191 0.191 0.250 0.382
11/2” 0.065 0.109 0.125 0.145 0.145 0.200 0.200 0.281 0.400
2" 0.065 0.109 0.125 0.154 0.154 0.218 0.218 0.344 0.436
21/2" 0.083 0.120 0.188 0.203 0.203 0.276 0.276 0.375 0.552
3" 0.083 0.120 0.188 0.216 0.216 0.300 0.300 0.600
31/2" 0.083 0.120 0.188 0.226 0.226 0.318 0.318 0.438 0.636
4" 0.083 0.120 0.188 0.237 0.237 0.337 0.337 0.438 0.531 0.674
5" 0.109 0.134 0.258 0.258 0.375 0.375 0.500 0.625 0.750
6" 0.109 0.134 0.250 0.277 0.280 0.280 0.406 0.432 0.432 0.594 0.562 0.812 0.719 0.864
8" 0.109 0.148 0.322 0.322 0.500 0.500 0.719 0.906 0.875
10" 0.134 0.165 0.250 0.307 0.365 0.365 0.500 0.500 0.594 0.719 0.844 1.000 1.125 1.000
12" 0.156 0.180 0.250 0.330 0.375 0.406 0.562 0.500 0.688 0.844 1.000 1.125 1.312 1.000
14" 0.156 A 0.312 0.375 0.375 0.438 0.594 0.500 0.750 0.938 1.094 1.250 1.406
16" 0.165 0.250 0.312 0.375 0.375 0.500 0.656 0.500 0.844 1.031 1.219 1.438 1.594
18" 0.165 A 0.312 0.438 0.375 0.562 0.750 0.500 0.938 1.156 1.375 1.562 1.781
20" 0.188 0.250 0.375 0.500 0.375 0.594 0.812 0.500 1.031 1.281 1.500 1.750 1.969
22" 0.188 A
A 0.375 0.500 0.375 0.688 0.875 0.500 1.125 1.375 1.625 1.875 2.125
24" 0.218 0.250
0.250 0.375 0.562 0.375 0.969 0.500 1.219 1.531 1.812 2.062 2.344
26" 0.250 0.250
0.312 0.500 0.625 0.375 0.500
30" 0.312 0.500 0.375 0.500
34" 0.312 0.500 0.625 0.375 0.688 0.500
36" 0.312 0.500 0.625 0.375 0.750 0.500
42" 0.375 0.500
48" 0.375 0.500
All dimensions are given in inches and are in accordance with ASME B36.10 * For nominal sizes through 10", Standard Weight
or ANSI/ASME B36.19 as applicable. thicknesses are identical to Schedule 40 thicknesses.
The decimal thickness listed for the pipe sizes represent their nominal or
average wall dimensions. fFor nominal sizes through 8", Extra Strong thicknesses
are identical to Schedule 80 thicknesses.
#These do not conform to ANSI/ASME B36.19.

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 Standard pipe Inside diameters as per ASME B.36.10 or ANSI / ASME B.36.19 for different
pipe schedules and nominal diameters are given in table below:

BORE CHART (I.D.OF PIPE)

Seamless and Welded Steel Pipe

P ipe O.D. Sched. Sch ed . Sched. Sch ed . Sched. Sch ed . Sched. Sch ed . Sched. Sched. Sched. Std. XS XXS
Size 5 10 20 30 40 60 80 100 120 140 160
1/8" 0.40 5 0.307 0.291 0.269 0.215 0.157 0.269 0.215 0.025
1/4" 0.54 0 0.410 0.394 0.364 0.302 0.250 0.364 0.302 0.064
3/8" 0.675 0.545 0.529 0.493 0.42 3 0.359 0.493 0.423 0.171
1/2" 0.84 0 0.710 0.674 0.650 0.622 0.546 0.464 0.622 0.546 0.252
3/4" 1.05 0 0.920 0.884 0.860 0.824 0.742 0.612 0.824 0.742 0.434
1" 1.315 1.185 1.097 1.087 1.049 0.95 7 0.815 1.049 0.957 0.59 9
1/4" 1.66 0 1.530 1.442 1.426 1.380 1.278 1.160 1.380 1.278 0.896
1 /" 1.90 0 1.770 1.682 1.650 1.610 1.500 1.338 1.610 1.500 1.100
2" 2.375 2.245 2.157 2.125 2.067 1.93 9 1.687 2.067 1.939 1.50 3
2 /" 2.87 5 2.709 2.635 2.499 2.469 2.323 2.125 2.469 2.323 1.771
3" 3.50 0 3.334 3.260 3.124 3.068 2.900 2.624 3.068 2.900 2.300
3 /" 4.000 3.834 3.760 3.624 3.548 3.36 4 3.548 3.364 2.72 8
4" 4.50 0 4.334 4.260 4.124 4.026 3.826 3.624 3.438 4.026 3.826 3.152
5" 5.56 3 5.345 5.295 5.047 4.813 4.563 4.313 5.047 4.813 4.063
6" 6.625 6.407 6.357 6.065 5.76 1 5.501 5.187 6.065 5.761 4.89 7
8" 8.62 5 8.407 8.329 8.125 8.071 7.981 7.813 7.625 7.437 7.187 7 .001 6.813 7.981 7.625 6.875
1 0" 10.750 1 0.482 10.420 1 0.250 10.136 1 0.020 9.750 9.562 9.312 9.062 8 .750 8.500 1 0.020 9.750 8.750
1 2" 12.750 1 2.438 12.390 1 2.250 12.090 11.938 11.626 11.374 11.0 62 10.750 10.500 10.126 12.000 11.750 10.750
1 4" 14.000 1 3.688 13.500 1 3.376 13.250 1 3.124 12.812 12.500 12.124 11.812 11.500 11.188 1 3.250 13.000
1 6" 16.000 1 5.670 15.500 1 5.376 15.250 1 5.000 14.688 14.312 13.938 13.562 13.124 12.812 1 5.250 15.000
1 8" 18.000 1 7.670 17.500 1 7.376 17.124 16.876 16.500 16.124 15.6 88 15.250 14.876 14.438 17.250 17.000
20" 20.000 1 9.624 19.500 1 9.250 19.000 1 8.812 18.376 17.938 17.438 17.000 16.500 16.062 1 9.250 19.000
24" 24.000 2 3.564 23.500 2 3.250 22.876 22.624 22.062 21.562 20.9 38 20.376 19.876 19.312 2 3.250 23.000
30" 30.000 2 9.500 29.376 2 9.000 28.750 29.250 29.000

All dimensions are given in inches and are in accordance with ASME B36.10 or ANSI/ASME B36.19 as applicable.
The decimal thickness listed for the pipe sizes represent their nominal or average wall dimensions.
*For nominal sizes through 10", Standard Weight thicknesses are identical to Schedule 40 thicknesses.
For nominal sizes through 8", Extra Strong thicknesses are identical to Schedule 80 thicknesses.

4.2. Pipe fittings

Various pipe fittings constitutes major pressure drop in a piping system. Hence it is necessary
to correctly consider the number of pipe fittings in a piping system while calculating pressure
drop. Equivalent lengths or k values are documented for a large number of standard pipe
fittings. Some examples of pipe fittings are given below:
 45° Elbow – Short and Long Radius
 90° Elbow - Short and Long Radius
 TEE – Used as Elbow
 Flow Through TEE
 Expander
 Reducer
 Entrance Loss / Exit Loss
 Valves –
 On/OFF (Isolation) – Gate/Ball/Plug
 Controlling – Globe, Diaphragm

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4.3. Nomenclature
Table below summarizes the nomenclature and units used in the design guidance for
pressure drop calculations

Symbol Description Units

D pipeline internal diameter m
V velocity m/s
ρ density kg/m3
μ dynamic viscosity Ns/m2
Re Reynold’s number -
P pressure barA
∆P pressure drop bar
dP pressure drop per unit pipe length bar/m
f Fanning friction factor -
L length m
ε pipe roughness factor m
σ surface tension N/m
g acceleration due to gravity m/s2
W mass flowrate kg/s
k equivalent velocity heads -

4.4. Pressure drop in single phase incompressible fluid flow

Fanning Friction Factor Equation is used for Pressure drop calculation.

Different equations are required for determination of friction factor f, for different flow regions.
Reynolds number provides an indication of the flow region.

For Laminar Flow, Re<2100; Hagen-Poiseuille equation is used.

For Turbulent Flow, Re>4000, Churchill equation provides a reasonably accurate direct
calculation method.

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 In case of Transition Region, 2100 < Re < 4000, a conservative choice should be made for
design approach.
Graphical method is available to determine Fanning friction factor. Graph of Fanning friction
factor as a function of Reynold’s number is given below:

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4.5. Losses in fittings
It is recommended that the frictional head loss attributable to bends and fittings be expressed
in terms of the equivalent number of velocity heads, k.

∆Hf = k V2/2g

where ∆Hf = head loss due to fittings and

V = velocity.

Table below gives k values for some of the pipe fittings. These values are considered to be
most applicable for industrial piping systems:

Pipe fitting k
Swing check valve – open 2.3
Gate valve – 100% open 0.21
Angle valve - open 4.5
Globe valve – open 9.4
45º Elbow R/d = 1.0 (short radius) 0.29
45º Elbow R/d = 1.5 (standard) 0.21
90º Elbow R/d = 1.0 (short radius) 0.45
90º Elbow R/d = 1.5 (standard) 0.31
90º Elbow R/d = 3.0 (long radius) 0.23
Sudden change in pipe diameter (enlanging) 1.0
Expander d/d1 = 0.25 0.9
Expander d/d1 = 0.50 0.56
Sudden change in pipe diameter (reducing) 0.5
Reducer d/d1 = 0.25 0.43
Reducer d/d1 = 0.50 0.33

4.6. Pressure drop in single phase compressible fluid flow

Fluid flow is typically considered compressible when the density varies due to change in
pressure by more than 5 – 10%. In practice it is normally limited to gases, supercritical fluids
and multiphase flows containing gases. For pressure drop calculation in case of compressible
fluid flow, the line segment is divided into smaller segments such that the variation of
pressure (which is an indicator of density) is less than 5 – 10% of the inlet pressure of the
segment. Pressure drop in each such segment can then be calculated using average density
and applying the same equations as for incompressible fluids.

4.7. Pressure drop due to flow of Slurry

Pressure drop due slurry flow in vertical pipes is observed to be about 10% higher than the
pressure drop for a liquid under similar conditions. In case of horizontal pipes this figure
becomes 15%.

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4.8. Pressure drop due to flow of Non Newtonian Fluid
In case of non Newtonian Fluids viscosity changes with change in flow parameters. Graph
below shows variation of viscosity with shear stress and various types of Newtonian Fluids.

Non Newtonian fluids offer high resistance to flow initially. However once flow is established, the flow
parameters become steady. Due to high viscosity, flow of non Newtonian fluids remains mostly within
the laminar flow region.
For calculation of pressure drop due to flow of non Newtonian fluids, the fluid’s viscosity is determined
at the average velocity. Then using this viscosity, pressure drop is calculated using method same as
for Newtonian fluids.

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5. TWO PHASE FLUID FLOW IN PIPELINES
While choosing pipe size for two phase flow needs to ensure the following:
 the pipe size gives an acceptable pressure drop
 plant stability is maintained over all operating conditions by avoiding slug flow and mist
flow
 erosion is avoided by not having excessive velocities.

Various flow patterns are observed in two phase flow.

Graph below shows two phase flow regimes in vertical pipes:

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 Graph below shows two phase flow regimes in horizontal pipe:

For pressure drop calculation and to determine the flow region, various methods are available.
Lockhart Martinelli method is described below:
 Calculate pressure drop per unit length (dP G, dPL), that would result if the two phases were
flowing separately in two lines of the same size as the specified line size.
 Calculate X using equation
X = (dPL / dPG)1/2

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  Using graph determine value of YL and YG

 Two phase ∆P is calculated from either of the two equations

dPTP = YG2 . dPG used if X < 1.0

dPTP = YL2 . dPL used if X >= 1.0

Common design guidelines for sizing two phase flow lines are given below:
For short lines within a unit
 Vm : 10 to 25 m/s
 ρm Vm2 : 5000 to 10,000 kg.m/s2
 Avoid slug flow and mist flow regimes

The subscript m refers to mixed phase.

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