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7/31/2019 Process Design Training Pipe Sizing
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Process Design Training
Line Sizing
Based on GPSA
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Course goals
Understand fluid flow
Understand line sizing criteria
Understand requirements of special lines
Understand network sizing and special programs
Lines or pipes are the arteries of a plant
Cooling water and Fire water systems
Create your own sizing workbook in Excel
Automate the task, by linking simulation outputs
Understand piping engineering guidelines
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Overview:
All Chemical process plants are madeof pipes that transfer fluids from and todifferent equipment
Fluids are:
Liquid
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Process Engineers - are they glorified plumbers?
apour Two phase
Slurry
Fluids may flow under pressure orgravity
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Overview
Fluid Flow
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Meet the basics
2 Fluid physicalproperties affectingfluid flow are:
1. viscosity and2. density
Bernoullis Theorem:
Based on law of conservation of energy
Total energy of a fluid at any point abovea datum is the sum of the elevationhead, the pressure head, and thevelocity head
E2
Highly viscous fluids behave differently
Viscosity is a measure of a fluids internal resistance to deformation or shear. Itindicates resistance to flow when acted upon by an external force
Viscosity of most liquids decreases with temperature, whereas that of gasesincreases. Pressure has almost no effect on the viscosity of liquids or near perfectgases. Viscosity of saturated or slightly superheated vapour is changedappreciably by pressure changes
= = + +E1
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Reynolds Number
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 atthe pipe wall. Re < 2,100
Turbulent Flow: At higher velocities, fluid particles show a random motiontransverse to the direction of flow. There is always a boundary layer atthe pipe wall where flow is laminar. The velocity profile is nearly
Re = DV/
Turbulent flow is further categorized into partially or fully developed turbulence
Laminar or streamlined flow
Turbulent flow
. ,
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Reynolds Number
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 atthe pipe wall. Re < 2,100
Turbulent Flow: At higher velocities, fluid particles show a random motiontransverse to the direction of flow. There is always a boundary layer atthe pipe wall where flow is laminar. The velocity profile is nearly
Re = DV/
20% margin is taken on calculated P to take care of uncertainties in the empirical correlations
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. Forgases consider short line segments, such that density is essentially constant
. ,
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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
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1. Moody friction factor, 4 times higherthan Fanning friction factor. Moodysused largely by Civil engineers and their
hydraulics program
2. Fanning friction factor is used inProcess calculations
It does not mean P calculated by Civil Engineers is 4 times higher!
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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
Fittings take bulk of the pressure drop. Eye estimates in plant OK as long as all fittings are counted.
Equivalent Length of Valves and Fittings.P is usually accounted by equivalent lengths of the fitting. L/D or K factorcorrection for actual ID or NRe is usually ignored
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Overview
Line Sizing Criteria
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General Guidelines
Minimum andmaximum velocitylimits based onsediments deposit and
erosion; vibration andnoise
Sizing based on economics (fixed cost) Vs P (running cost)
Minimum 2 to avoid small bore pipe rupture.Smaller pipes need additional supports onsleepers/ pipe rack
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
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General GuidelinesThelinked imagecannotbed isplayed.The filemay havebeen moved,renamed,or deleted.Verify thatthelink pointsto thecorrect fileand location.
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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 sizedcondensate lines may lead to water hammer and pipe rupture
Optimum size Vs Special Requirements
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Liquid & Gas Lines
High velocity sonic flow maylead to pipe failure and fire
Liquid lines are usually sized on velocitycriteria
Special criteria based on fluid/ service such asNH3, C2=, NaOH, H2SO4, sea water etc
In saturated liquid, high velocity leads toflashing/ cavitation
In gas high P may lead to choked flow with
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Size high P gas lines in segments
1. Gas lines are sized to limit pressure drop (gas compressor being energyexpensive than liquid pumping!)
2. Where adequate pressure drop is available, then noise limits velocity incontinuous service and 50-70% sonic velocity limit in intermittent service
3. Use inlet or outlet density if P is
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Special Lines
Modulating steamtraps like float orthermostatic asopposed to bucket
discharge condensatecontinuously. Use aLCV with a boot asappropriate
Simplified formulae, such as Hazen andWilliams are available for water
Manning equation is used to size gravity flowlines
With recip pumps, design based on maximuminstantaneous or pulsating flow
Steam condensate lines may have high
All drain lines are gravity flow lines
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
.
But all traps do not open at the same time
If this pipe runs liquid full,vacuum d/s valve may
cause flashing, vibrationand pipe failure.
Use gutter or self-ventingsizing methods
10m
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Liquid Network
Instead of sizing a single line, attimes, you may have to size agroup of pipes forming anetwork
Example: From suction todischarge point of a pump, tocalculate the pump head, horseower and NPSH re uirements
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SourceDestinat
ion
Source
Destination
Town water and cooling water supply provide interesting network analysis
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Water Supply Network
Cooling Water Network
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Cooling Tower& Pumps
Coolers
Cooling water or hot water/ oil network are classical examples of network programs
Resistance in series R = R1 + R2
Resistance in parallel 1/R = 1/R1 + 1/R2Total R, then flow = Head/ R
Flow
He
ad
Head
Resistance
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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, providedifferent solutions to the transmission factor or ff . To adjustmeasured flow against calculated flow E is tweaked
Special equations are used to size pipelines
1. AGA Equations (a) partially and (b) fully turbulent flow with two differenttransmission factors
2. Weymouth Equation, takes ff as a function of the diameter. Good for shortpipelines 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
For low pressure lines, Oliphant or Spitzglass Formula may be used
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Comparison of Gas Transmission FactorsThelinked imagecannotbed isplayed.The filemay havebeen moved,renamed,or deleted.Verify thatthelink pointsto thecorrect fileand location.
Results differ widely. Go by what is an accepted practice in your plant
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Two Phase LinesThelinked imagecannotbedisplayed. Thefilemay havebeen moved,renamed,or deleted.Verify thatthelink pointsto thecorrectfileand location.
Baker, Gregory-Aziz-Mandhane ,Taitel-Duckler maps
Two phase lines are difficult todesign and operate
Flow regimes and terrain profileinfluence P, slug size andliquid hold-up
Correlations are usually developed for air-water system in pipes
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Two Phase LinesThelinked imagecannotbe displayed.The filemay havebeen moved,renamed,or deleted.Verify thatthelink pointsto thecorrect fileand location.
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Flow regimes - horizontal and vertical
Dispersed
bubble
aerated
turbulent
slug flow
annular
mist
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Two Phase Lines
Liquid Slugs 4 mechanisms
1. Wave formation at G/L interface in stratified flow. When liquid wavesgrow 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 gasflow. 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 causeslugs. As flow rate increases, liquid inventory in the pipeline
Several methods are available to predict random and pigging slugs
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
,
4. Pigging can cause large slugs as the liquid inventory of the line isswept ahead of the pig
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CONGRATULATIONS
Now you are an Expert in Plumbing
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Question 1
With head or supply pressure remaining the same, how muchthe 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
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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
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Question 3
A recip pump designed for 50 m/h and 10 bar head, willalways deliver it
1. True.
2. False.
Thanks for helping to keep my reputation high!!
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Sizing in Excel
Enter data
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Excel for sizing
You can use Excel toperform simple linesizing, pump sizingand distribution
network calculationsLine Size
Pump Size
Create your first line sizing workbook
Excel allows you to study different sizes, take output toa Line List, interact with project database.
You can link your simulation output to Excel andautomate the task.
The possibilities really are endless.
Network Analysis
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Be kind to your users: start with design basis
When you write yourprogram, its a goodidea to provide theformulae and criteria
for selection.
Let us look at a typical Excel sheet
Make your workbook user friendly
This way, anyone who shares your worksheet canunderstand what it all means (and you can understand ityourself, later on).
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Lesson 3
Process Piping
Engineering Guidelines
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Standard Pipes
Min pipe size = 2 toavoid broken pipes onimpact
Pipes come in standard diametersand wall thickness
Smaller diameter pipes can holdmore internal pressure.
Generally flanges limit theallowable pressure
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Small bore piping safety engineers nightmare
Allowable Working Pressures - ASTM A106, grade B seamless pipe - PetroleumRefinery Piping Code to ANSI B31.3-2002Corro allow = 0.05 at 200F
2 Standard Schedule 40 1,469 psig 150# Flange 260 psig8 1,09824 Sc 20 282
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Piping
Some clients opt for full rating,that is upping designconditions to suit, flange rating
Lines are hydrotested, exceptlarge low pressure lines thatare pneumatically tested.Molten K and Na lines are nothydrotested to avoid explosionon contact with water in
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
The task is not over with finding diameter.
Design temperature shall consider site black body temperature as a minimum.Steam traced lines shall consider steam condensing temperature. Designminimum 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
p ng w a es con ons
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Piping
1. Mark gravity flow lines, linesthat should slope or shouldnot have pockets, clearly.
2. Tap off from top
3. Min length for meter runs
and vessel inlet
4. 2 pressure equalisationvalves are given acrossvalves >4 to avoid opening
Check access to valves, instruments and samplepoints
Check slope and no pocket requirements
In liquid lines with slurry, sand or polymer solution,
ensure LR bends, flushing points and cleaningaccess
Symmetrical piping where equal flow required
Piping will locate valves such as control valve andPSV where maintenance access is available. This mayvoid desired slope or inlet pressure drop requirements.
Check piping 3D drawings of all PSV, thermosyphonand pump inlet lines
Spec blinds should be in horizontal runs
valves against high P, that
could result in high velocityand seat cutting/ damage
5. Check high point vents andlow point drains.
6. Eccentric reducers flat ontop in pump suction but atbottom u/s of control valves
,
valves and flow orifices/ turbine meters
The task is not over with finding diameter.
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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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Pipe Fittings
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 requireservicing e.g relief valve, control valve
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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
S ecs for askets, bolts etc
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Slip-on
Construction requirement like, stress relieving, radiography, dyepenetration, hardness test for welding etc
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Raised Face RTJ
Pipe Fittings
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Insulation
Heat or cold loss to conserve energy
Personnel protection to avoid injury on accidentalcontact
Noise or vibration reduction, in high velocity/compressor piping
Insulated pipes are covered with vapor barriers andmetal casing as required
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Insulation pays back in 3 months
What type ofinsulation?
Insulation comes inpreformed shapes,mattress or loose.
Foot traffic usually damages yard piping insulationThelinked imagecannotbe displayed.The filemay havebeen moved,renamed,or deleted.Verify thatthelink pointsto thecorrect fileand location.
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Heat tracing
Steam or electrical resistance orself-limiting electrical tracing
1. To maintain temperature toavoid congealing or wax
deposition2. In intermittent operation lines
3. To avoid cooling and
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Steam tracing requires steam supply and condensate collection headers
and gas to glycol dehydrationSteam Tracing Number of tracers:
General: 1 for 2-4; 2 for 6-20. Solidification 25-65C: 1 for 2-3; 2 for 4-8.Solidification 65-150C: 2 for 2; 3 for 4-8; 6 for 10-12; 8 for 14-18.
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
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Heat tracingThelinked imagecannotbed isplayed.The filemay havebeen moved,renamed,or deleted.Verify thatthelink pointsto thecorrect fileand location.
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Steam tracing requires steam supply and condensate collection headers
H i
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Heat tracing
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Electrical resistance heaters canheat fluids during start-up
Self-regulating tapes requiredtemperature during shutdown/
normal operation
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Electrical tracing is relatively simple
V l
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Valves
Service decides type ofvalve
Shut-off: Ball, Gate, Plug,Butterfly and diaphragm
Throttling: Angle, globe,needle
Check: Swing, lift, pistonand foot
Gate:
Rising stem in non-corrosive;non rising steam in waterservice
Solid Vs split wedge. Split cantake care of thermalcontraction on cooling
Valves help regulate or isolate fluid flow
u por
open Not quick acting
Takes more space
Not good in slurry service
Install vertically to avoid gatefalling in closed position
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V l
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Valves
Globe Good for throttling
Install vertically
Angle
In high P serviceDiaphragm
Made of elastomer
Good for slurr
Ball or Plug
Ball valves widely used in upstreamindustry; gate in d/s
Quick closing
Limited to
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Check valves
Swing checkFull unrestricted flow. No good in pulsatingflow
Wafer check - similar to butterfly. Good for
pulsating flow. No chatteringLift or piston check - similar to globe. Good for
high velocity (gas) flow
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,
lead to backflow, rupture and fatal incidents
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Check valves minimize back flow. All valves leak............!
Remote operated valves
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Remote operated valves
Remote operated valves can beused to isolate an equipment orsection of a plant remotely.
They are usually operated by a
motor (MOV) or electricalsolenoid (SOV) or air / hydraulicactuators
ROVs help quick isolation, shutdown and blowdown bringing the plant to a safe state
For quick opening and closing; Battery limit
Emergency shutdown.
For large valves - 10 (150~300#), 6 (600~1500#)
ROVs can be automated to close on high level or pressureThelinked imagecannotbed isplayed.The filemay havebeen moved,renamed,or deleted.Verify thatthelink pointsto thecorrect fileand location.
Spectacle blinds
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Spectacle blinds
Note: All valves,including check valvesleak in service.
To provide positive isolation, usually for entryinto confined spaces and in hazardousservices
Spades are used in small bore pipes (
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Thank you
Trust you found it interesting andof value .