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line sizing calculation

Line sizing is the process of determining the appropriate pipe diameter for fluid pipelines to ensure safety and efficiency while balancing costs. It involves understanding fluid types, key parameters like flowrate and pressure drop, and adhering to industry standards. Proper line sizing is critical in various applications, including oil and gas, chemical industries, and water treatment, to prevent issues such as excessive pressure drops and erosion.

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Santosh Jayasaval
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14 views

line sizing calculation

Line sizing is the process of determining the appropriate pipe diameter for fluid pipelines to ensure safety and efficiency while balancing costs. It involves understanding fluid types, key parameters like flowrate and pressure drop, and adhering to industry standards. Proper line sizing is critical in various applications, including oil and gas, chemical industries, and water treatment, to prevent issues such as excessive pressure drops and erosion.

Uploaded by

Santosh Jayasaval
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Line sizing calculation

1.​ What is Line Sizing?

●​ Definition:
Line sizing refers to the process of determining the appropriate pipe diameter for a
fluid-carrying pipeline. It ensures the system operates safely and efficiently, balancing capital
cost and operating cost.

●​ Role in Process Plant Design:


Proper line sizing avoids issues like:
●​ Excessive pressure drops leading to energy losses.
●​ High velocities causing erosion and noise.
●​ Oversized pipelines increasing capital costs.

2.​ Types of Fluids:

●​ Liquids:
Incompressible fluids (like water, oil) maintain constant density. Pressure drop primarily
depends on viscosity and velocity.

●​ Gases:
Compressible fluids (like air, natural gas) change density with pressure and temperature.
Requires specific calculations to account for compressibility.

●​ Two-Phase Flows:
A combination of gas and liquid phases flowing simultaneously (e.g., steam-water or
gas-condensate). More complex due to varying flow regimes like bubbly, slug, or annular flow.

3.​ Key Parameters for Line Sizing:

●​ Flowrate (Q):
The volume or mass of fluid passing through a pipeline per unit time, typically measured in
m³/s or kg/s.

●​ Velocity (v):
Speed at which the fluid flows inside the pipe, expressed in m/s. Optimal velocities minimize
erosion and noise while ensuring sufficient flow.

●​ Pressure Drop (ΔP):


The reduction in pressure as fluid flows through a pipeline due to friction and fittings.
Excessive pressure drop increases pumping or compression costs.

●​ Fluid Properties:
○​ Density (ρ): Mass per unit volume of a fluid (kg/m³).
○​ Viscosity (μ): Resistance of a fluid to flow (Pa·s or cP).
○​ Compressibility: How much a gas's density changes with pressure.
4.​ Line Sizing Standards and Guidelines:

●​ Industry Standards:
Guidelines from organizations like:

●​ API (American Petroleum Institute): For oil and gas pipelines.


●​ ASME (American Society of Mechanical Engineers): For process piping (e.g.,
B31.3 standard).
●​ ISO: International standards for industrial piping.

●​ Recommended Velocities:
Typical velocity ranges to avoid issues:
●​ Liquids: 1-3 m/s (avoids turbulence and erosion).
●​ Gases: 10-20 m/s (prevents excessive pressure drop).
●​ Steam: 15-40 m/s (ensures heat transfer efficiency).

5.​ Equations and Calculations

5.1. Liquid Flow Sizing

1.​ Basic Parameters


○​ Fluid Properties: Density (ρ), viscosity (μ), compressibility (Z), molecular weight, etc.
○​ Flow Rate: Volumetric (Q) or mass flow rate (m ).
○​ Pressure and Temperature: Operating conditions.
○​ Pipe Material: Surface roughness (ϵ).

2.​ Volumetric and Mass Flow Relationships

Where:
●​ Q: Volumetric flow rate (m^3/s or ft^3/s)
●​ 𝑚 : Mass flow rate (kg/s or lb/s)
●​ ρ: Fluid density (kg/m^3 or lb/ft^3)

3. Velocity of Fluid
The velocity (V) is given by:

Where:

●​ 𝐴 : Cross-sectional area of the pipe (m^2 or ft^2)


●​ D : Internal diameter of the pipe (m or ft)
5.2. Gas Flow Sizing
●​ Compressible Flow Adjustments:
Consider changes in pressure and temperature along the pipe. Common methods include:

●​ Isothermal Flow: Assumes constant temperature.


●​ Adiabatic Flow: Assumes no heat transfer.

●​ Pressure Drop for Gases:


Uses extended versions of Darcy-Weisbach to include compressibility.

5.3. Two-Phase Flow Sizing


●​ Flow Regimes:

●​ Bubbly: Small gas bubbles in liquid.


●​ Annular: Gas flows as a central core, liquid forms a film on pipe walls.
●​ Slug: Alternating gas and liquid slugs.

●​ Lockhart-Martinelli Parameter:
Helps estimate pressure drops for two-phase flow by relating liquid and gas flow rates.

6. Tools and Software

●​ Aspen HYSYS: Industry-standard software for process simulation and equipment sizing.
●​ PipeFlow Expert: Dedicated tool for pipe network design and pressure drop analysis.
●​ MATLAB/Python: For custom calculations and modeling using engineering equations.

7. Best Practices
●​ Minimize Pressure Drop:
Optimize pipe length, diameter, and avoid excessive fittings.
●​ Erosion and Noise:
Avoid high velocities to protect pipe materials.
●​ Allowance for Fouling:
Design slightly larger diameters for fluids prone to deposit buildup (e.g., slurries).

8. Challenges in Line Sizing Design:

1.​ Pressure Drop vs. Capital Cost Trade-offs:


○​ Small Diameter Pipes: Lower capital cost but higher pressure drop, requiring more
energy for pumps or compressors.
○​ Large Diameter Pipes: Higher capital cost but reduced energy costs and lower
pressure drop.
2.​ Erosion and Noise:
○​ High fluid velocities can lead to pipe erosion, noise, and vibration.
○​ Erosion is more common in pipelines carrying slurries or fluids with abrasive particles.
3.​ Flow Regime Uncertainty:
○​ In two-phase flows, the unpredictable nature of flow regimes can make calculations
challenging.
○​ Design must consider the worst-case scenario to ensure safe operation.
4.​ Thermal Expansion:
○​ Temperature changes in fluids can cause pipe expansion and contraction.
○​ Proper stress analysis and expansion loops are critical to prevent failures.
5.​ Future Scalability:
○​ Sizing pipelines for current requirements may overlook future plant expansions.
○​ Adding spare capacity can balance current costs with future flexibility.

9. Best Practices and Design Tips:

To ensure efficient and reliable line sizing, follow these best practices:

Hydraulic Design Considerations:


●​ Use recommended velocity ranges for the fluid type (liquid, gas, or two-phase flow).
●​ Minimize sudden changes in direction or pipe diameter to reduce turbulence and pressure
loss.
●​ Include safety margins in design for abnormal operating conditions (e.g.,
higher-than-expected flowrates).

Economic Optimization:
●​ Perform a cost-benefit analysis to select pipe diameter. Consider operational costs (energy
consumption) vs. installation costs.

Standards and Regulations:


●​ Follow the appropriate industry codes and standards for specific applications:
○​ API 14E: Recommended practice for offshore production facilities.
○​ ASME B31.3: Process piping guidelines.

Material Selection:
●​ Choose pipe material compatible with the fluid (e.g., stainless steel for corrosive fluids, carbon
steel for non-corrosive fluids).
11. Tools and Software

Excel Templates for Manual Calculations:


●​ Pre-built Excel sheets can automate key calculations like velocity, pressure drop, and
Reynolds number.

Specialized Software:
●​ PipeFlow Expert: Easy-to-use tool for pressure drop and flowrate analysis in pipe networks.
●​ Aspen HYSYS: Industry-standard simulation software for process optimization, including line
sizing.

Python for Custom Solutions:


●​ Develop Python scripts to calculate line sizes using equations for specific needs.
12. Advanced Topics in Line Sizing

12.1. Reynolds Number and Flow Regimes

12.2. Pressure Drop Components


12.3. Surge and Water Hammer Effects:

12.4 . Heat Transfer Effects on Line Sizing:

In thermal systems (e.g., steam or condensate lines), heat loss affects fluid properties:

●​ Steam Lines:
●​ Sizing must account for condensation losses.
●​ Insulation minimizes heat loss.

●​ Cryogenic Lines:
●​ Super-insulated pipelines are required for liquids like LNG or liquid nitrogen to reduce
heat ingress.

13. Real-World Applications

Oil and Gas Industry

●​ Crude Oil Pipelines:


○​ Design for high flowrates with attention to viscosity changes due to temperature.
●​ Natural Gas Pipelines:
○​ Compressible flow analysis is critical, especially for long-distance transport.

Chemical Industry
●​ Reactant Lines:
○​ Precise sizing ensures reactants are delivered at the correct flowrate and pressure to
reactors.
●​ Slurry Pipelines:
○​ Requires design to prevent settling of solid particles in the slurry.

Water Treatment Plants


●​ Water Distribution Lines:
○​ Hydraulic modeling ensures efficient delivery while maintaining pressure at
end-users.
14. Example: Complete Line Sizing Calculation
Problem Statement:
Design a pipeline to transport 200 m³/h of water over a distance of 500 m with the following data:
Fluid density (ρ) = 1,000 kg/m³.
Fluid viscosity (μ) = 1 cP.
Maximum allowable pressure drop = 1.5 bar.

Solution:

1.​ Flowrate Conversion:


Q = 200/3600 = 0.0556m^3/s

2.​ Initial Velocity Estimate:


Assume v=2m/s (within recommended range for liquids).

3.​ Pipe Diameter Calculation:


Using
Q=v⋅A
A = Q/v = 0.0556/2 = 0.0278 m^2

D = √((4A)/π) = √((4×0.0278)/3.14 ≈0.188m (or 188 mm)

4.​ Check Reynolds Number:


Re = (ρvD)/μ
Re = (1000×2×0.188) / (0.001) = 376,000(Turbulent Flow)

5.​ Calculate Friction Factor (f):


Using Moody diagram or Colebrook equation, estimate f ≈ 0.02.

6.​ Pressure Drop:


∆P = =f⋅ (L/D)⋅(ρv^2 / 2)
∆P = 0.02 × (500/0.188)× (100.2^2)/2 = 1.06 bar

7.​ Result:
The calculated pressure drop (1.06 bar) is within the allowable limit (1.5 bar). Pipe size of 188
mm (standardized to 200 mm) is acceptable.

15. Conclusion
●​ Line sizing is a critical design step that directly impacts the efficiency, cost, and safety of
process systems.
●​ Engineers must balance fluid properties, pressure drop, and velocity considerations while
adhering to industry standards.
●​ Continuous learning and the use of modern software tools can simplify complex line sizing
tasks.

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