NOMENCLATURE

Abbreviation Description Unit

P Pressure kpa
ρ Density of fluid Kg/m3
g Acceleration due to gravity m/s2
V Velocity of fluid m/s
Z Elevation m
hf Head loss due to friction -
Q Flow rate of fluid kg/s or m3/s
A Cross-sectional area of pipe m2
µ Viscosity of fluid Kg/m. s
L Length of line m
f Darcy friction factor -
ε Roughness in pipe mm
CC Coefficient of contraction -
A Area of pipe m2
a Area of obstruction m2
C Empirical constant -
D Diameter of pipe m
T Temperature 0
k
W Mass flow rate kg/s

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 Table of Contents
Nomenclature 1
Introduction 2
Standards for line sizing 2
Criteria for selection of line size 2
Steps for line sizing 4
Important equation and pressure drop calculations 4
Bernoulli’s Equation 4
Continuity Equation 4
Reynold’s number 4
Pressure Drop calculations 5
Line Sizing criteria for liquid and gases 9
Line sizing criteria for liquids 10
Line sizing criteria for gas 10
Erosion velocity 10
Vapor velocity 11
Sonic velocity and Mach number 11
References 17

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Title: Line Sizing Calculation.

Purpose of Line Sizing:

1. The purpose of line sizing is to fill in appropriate data on P&ID’s, datasheets and line list.
2. To determine pump head requirements.
3. To meet design process parameters such as flow, velocity & pressure.
1. Introduction:
Line sizing is one of the most important and critical activity for any Process
Engineer. In chemical and petrochemical plant fluids need to be transported from one unit
to another unit with desire process parameters (Temperature, Pressure and Flow rate). As
a result, pipe size should be appropriately calculated to meet the desired process
condition. It should not be less and more than requirement. Because material requirement
for manufacture of pipe will increase which directly going to increase the cost of project.
1.1. Standards that are followed for Line Sizing:
ASME B31.3, API RP 14E and GPSA Handbook.
1.2. Selection of pipe size depends upon the following things:
1.2.1. Factors:
i. Corrosion:
Pipeline corrosion is a natural deterioration and destruction of pipe material and essential
properties due to electrochemical and other ingredient reactions of pipeline materials with
their environment - on the inside as well as outside surfaces. Generally due to the
properties of flowing fluid corrosion is occurred in pipeline.
Carbon steel (CS) is generally used for non-corrosive fluid service and Stainless steel
(SS) is used for corrosive fluid service.
ii. Erosion:
Erosion is the abrasion of pipe inner material due to excess fluid velocity. Due to
the formation of very high stresses at the point where the fluid droplets/ bubbles
contact the pipe wall. In general practice flowing fluid velocity is kept below the
erosion velocity.
iii. Noise:

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 When the flow velocity exceeds the sonic velocity noisy operation takes place. In
plant the sound level is maintained below the 85 decibels. When noisy operation
takes place in pipe due to the high pressure drop and internal stresses the pipe
material gets erode which directly going to affect the economy of pipe.
iv. Economy:
Economy of pipe is depending upon the size and thickness of material. Larger the
size and thickness of pipe larger the cost of pipe. To get the minimum cost
requirement the pipe size is kept small considering velocity and pressure drop
criteria.
1.2.2. Pipe Friction:
The major loss in energy in pipe occurs due to the friction in pipe it’s considered
as the major loss and minor losses are due to the pipe fittings and sudden changes
in the direction of flow in the pipe. While sizing the pipeline fitting losses are
converted into the equivalent length if pipe.
Table 1: Difference between frictional losses and fitting losses.

Frictional losses Fitting losses

1. This loss occurs due to the 1. This loss occurs due the different
roughness of pipe material and the types of fittings like valves, elbows
fluid properties. and due to sudden change in direction
of flow.
2. In this case resistance to flow is 2. In this case resistance to flow is
offered by the inner surface of offered by the fittings itself.
pipe.
3. It’s calculated by Darcy equation. 3. It’s calculated by the equivalent
length method or K-factor method.
4. This offers major resistance. 4. This offers less resistance
compared to the frictional losses.

1.2.3. Hydrostatic law:

The law states that the rate of increment of pressure is equal to the specific weight of

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 the fluid at any point in a static fluid system. It’s given as

P=hρg…………………………………………………………………………. (1)

Thumb Rule in EPC’s:

Pressure
( cmkg )= Head(m)
2
10
× Specific gravity

2. Basic steps for line sizing:

1) Assume velocity and calculate diameter of pipe using the continuity equation.
2) Calculate the Reynold’s number and decide the type of flow.
3) Check the roughness factor for given pipe material.
4) Calculate the fanning friction factor (ff).
5) Calculate the pressure drop due to the friction and fittings in pipe.
6) Depending upon the velocity and pressure drop criteria decide the pipe size.
3. Important equations and Pressure drop calculations:
1) Bernoulli’s equation:
It states that the total energy of a fluid at any point above a datum line is the sum of
pressure energy, kinetic energy and potential energy. It is represented mathematically
as below:
P 1 V 12 P 2 V 22
+ + Z 1= + + Z 2+ hf ……………………………………………… (2)
ρg 2 g ρg 2 g
2) Continuity equation:
It states that the product of cross-sectional area of pipe and the fluid velocity at any
point along the pipe is constant.
Q= VA= Constant……………………………………………………………….... (3)

3) Reynold’s number:
It’s the ratio of inertia force to the viscous force. It’s used to predict the type of flow.
It’s written mathematically as below:
DVρ
Re = …………………………………………………………………………. (4)
μ

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 If the Reynolds number is less than 2000, flow may be considered laminar. If it is
above 4000, the flow is turbulent. If Reynolds number is in between 2000-4000 then
flow is transition flow.
4) Pressure drops calculations:
I. Frictional losses:
For incompressible fluid:
Darcy- Weisbach equation relates head loss due to friction along a given
length if pipe to the average velocity of fluid for an incompressible fluid.
2
fL V
∆ P= …………………………………………………………………. (5)
2 gD
f is the Darcy friction factor changes according to the flow.
For laminar flow: Friction factor is independent of roughness.

64
f¿ ……………………………………………………………………. (8)
Re

For turbulent flow: Friction factor is strongly depending upon the roughness.

1
√f
=−2 log ⁡
ε
( +
2.51
3.7 D ℜ √ f )
………………………………………………. (9)

Roughness is different materials and it’s dependent of pipe diameter.

Roughness values for some materials are given below in Table 2.

Table 2: Roughness values for different materials.

Material Condition Ɛ (mm)

Steel Sheet metal, new 0.05
Stainless, new 0.002
Commercial, new 0.046
Riveted 3.0
Rusted 2.0
Iron Cast, new 0.26
Wrought, new 0.046
Galvanized, new 0.15
Asphalted cast 0.12
Brass Drawn, new 0.002
Drawn tubing 0.0015
Glass - Smooth

6
 Concrete Smoothed 0.04
Rough 2.0
Rubber Smoothed 0.01
Wood Stave 0.5

The moody chart (ref. Fig.1) is graph used to calculate pressure drop in the pipe. The
moody chart relates the Darcy friction factor, Reynolds number and surface roughness for
a given flow in pipe.

For smooth pipe and turbulent flow friction factor can be calculated using formula below

−1
f =( 100 × R e ) 4 …………………………………………………………………. (10)

For large Reynold number the friction factor is independent of Reynolds number because
thickness of laminar sublayer decreases as we increased the Reynolds number.

Fig.2.Moody Diagram.

For compressible fluid:

The pressure drop in the vapor/gas lines are calculated by modified Darcy equation given
below:

7
 2
∆ P 5200 f f W T
= ……………………………………………………………………….
100 D5 P(M .W )
(11)

Where,

ff = Fanning friction factor.

W = Mass flow rate, (kg/s)

T= Temperature, (0k)

D = Pipe diameter, (mm)

P = Source pressure (kg/cm2a)
Moody friction factor for gases is calculated as follow depending upon the flow region:
1. For laminar flow:
64
f m= …………………………………………………………………………… (12)
Re
2. For turbulent flow:
354 W
f m= ………………………………………………………………………..….
μD
(13)

II. Minor loss is due to fittings:

In general calculations pressure drop across fittings is converted as a length of
pipe.
There are different methods for calculation of pressure drop due to fittings:
1. Equivalent length method:
Pressure drop due to fittings is converted in terms of equivalent length
of straight pipe. The equation is given below:
2
fL V
∆ P= ……………………………………………………………. (14)
2 gD

Typical values for the equivalent length of various fittings are shown in table
below:

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 Table 3: Equivalent length for various fittings. [1]

Fitting Types (L/D) eq

90 Elbow Curved,
0 Standard Radius (R/D = 1) 30
Threaded Long Radius (R/D = 1.5) 16
Standard Radius (R/D = 1)  
Long Radius (R/D = 1)
20
900 Elbow Curved,
Flanged/Welded Long Radius (R/D = 2) 17
Long Radius (R/D = 4) 14
Long Radius (R/D = 6) 12
1 Weld (900) 60
900 Elbow Mitered 2 Weld (450) 15
3 Weld (30 )0
8
Standard Radius (R/D = 1)
45 Elbow Curved.
0
16
Threaded
Long Radius (R/D = 1.5)  
1 Weld 450
450 Elbow Curved. 15
Mitered
2 Welds 22.50 6
Threaded, Close- Return (R/D =
50
1)
180 Bend
0
Flanged (R/D = 1)  
All types (R/D = 1.5)  
Threaded (r/D = 1) 60
Tee Through-branch as an Threaded (r/D = 1.5)  
Elbow Flanged (r/D = 1) 20
Stub-in branch  
Threaded (r/D = 1) 20
Tee Run-through Flanged (r/D = 1)  
Stub-in branch  
450, Full line size, β = 1 55
Angle Valve
900, Full line size, β = 1 150
Globe Valve Standard, β = 1 340
Ball valve Standard, β = 1 3
Branch flow 90
Straight through 18
Plug valve
Three-way (Flow through)
30

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 Gate valve Standard, β = 1 8
Diaphragm Dam type  
Swing Check Valve Vmin = 35 [ρ (lbm/ft3)]-0.5 100
Lift Check Valve Vmin = 35 [ρ (lbm/ft3)]-0.5 600
Hose Coupling Simple, Full Bore 5

III. Minor loss due to sudden change in direction of flow: [2]

Minor loss of energy occurs due to change of velocity of fluid in magnitude and
direction.
i. Loss of head due to sudden enlargement:
In this case loss of head takes place due to formation of eddies. Which is calculated
by equation given below:
2
( V 1−V 2 ) ……………………………………………………………………...
h e=
2g
(15)
ii. Loss of head due to sudden contraction:
In this case loss of head takes place due to sudden enlargement from vena-contracta
to smaller pipe. It is calculated by following formula:
2
V2
h c =0.5 ……………………………………………………………………… (16)
2g
iii. Loss of head at the entrance of a pipe:
This is the loss pf energy which occurs when a liquid enters a pipe which is connected
to large reservoir. It is expressed as follows:
2
V
hi =0.5 ……………………………………………………………….………. (17)
2g
iv. Loss of head at the exit of a pipe:
This is the loss of energy due the velocity of outlet of the pipe which is dissipated
either in the form of free jet. It’s calculated as below:
2
V
h o= ………………………………………………………………………….. (18)
2g
v. Loss of head due to an obstruction in the pipe:
It’s given by following equation

10
 ( )
2 2
V A
= −1 ……………………………………………………………...…
2 g C c ( A−a)
(19)
vi. Loss of head due to bend and various pipe fittings in a pipe:
When there is bend or fitting in pipe the velocity changes due to the separation of the
flow from the boundary layer and formation of eddies also takes place due to which
energy loss are occurred in pipe. Which is calculated by
2
kV
h b= ………………………………………………...………………………… (20)
2g
Where k is the coefficient of fitting or bend.

4. Line sizing criteria for liquid and gases:

1. Liquid line sizing criteria:
The maximum design consideration depending upon the velocity and pressure drop
per 100 m of length of pipe is given below in table:
Table 4: Liquid (Incompressible fluid) line sizing criteria

  Velocity (m/s) ΔP/100m (kg/cm2)

Pump suction line 0.5-1 0.035-0.085
Pump discharge line 1.5-2 0.15-0.6
Cooling water network 1<V<VErosion 0.3
Gravity lines 1-2 0.3

2. Gas/ vapor line sizing criteria:

The maximum design consideration depending upon the velocity and pressure drop
per 100 m of length is given below in table:
Table 5: Gas (compressible fluid) line sizing criteria

  Velocity (m/s) ΔP/100m (kg/cm2)

Saturated steam 15-30
Superheated 0.2
30-60
steam
Plan
air/instrument 10-20 0.2-0.3
air/Nitrogen lines

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 Vapor (P<3.5   V
0.04
kg/cm2g)
Vapor (3.5< P<10
0.06 W
kg/cm2g)
Vapor (10< P<14
0.13
kg/cm2g)
Compressor
0.025-0.06
suction
Compressor
0.1-0.2
discharge
Gas line 0.11

5. Erosion velocity (Ve):

The velocity at which the abrasion of inside material of pipe starts called as erosion
velocity. It’s represented by the following equation:
C
V= ………………………………………………………………………………. (21)
√ρ
Typical values of C are given below in table:

Table 6: Values of ‘C’ and it’s applicability.

C Applicability
122 Solid free fluids (Continuous Service)
152 Solid free fluids (Intermittent Service)
100 Solid present fluid

6. Vapor velocity:
Recommended velocity for vapor lines is calculated from the formula given below:
C
V= 0.3333 …………………………………………………………………………… (22)
ρ
Where, C= 10 to 24.

7. Sonic velocity and Mach number:

Sonic velocity is the measure of speed of sound. It’s generally 342m/s.
In pipeline noise is define by the Mach number.
Fluid velocity
Mach number=
Sonic velocity

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 Sound/sonic flow pattern depending upon the Mach number:

Flow pattern Mach number

Subsonic <1
Sonic 1
Supersonic >1
In normal conditions the flow should be in subsonic pattern and Mach number <1.
5. Liquid line sizing calculation:

5m

2m

Fig.2. Liquid line sizing problem

Given:
Q = 50m3/hr
Elbows in suction line = 1
Density of fluid = 1000 kg/m3
Viscosity = 10 Cp
Roughness factor = 0.046
Solution:
For suction:
Assuming velocity 1 m/s in pump suction line.
Q=V × A

d=
√ 4Q
3.14 ×V

¿
√ 4 ×50
3.14 × 1× 3600
¿ 0.133 m

13
 ¿ 5.236
Selecting d = 6” (0.1524m)
Estimating velocity
Q=VA
Q
V=
A
50
V=
0.018 ×3600

= 0.763 m/s
Equivalent length for 900 elbows = 0.1524 × 17
¿ 2.5908 m
Total length of pipe ¿ 5+2+2.5908
= 9.59m
Pressure drop calculation
DVρ
N ℜ=
μ
0.1524 ×0.763 ×1000
¿
0.01
¿ 11628.12
As fluid flow is in turbulent region, friction factor is calculated by following equation
1
√f
=−2 log
( ε
+
2.51
3.7 D ℜ √ f )
=−2 log ⁡(
3.7 × 0.1524 11628.12 × √ f )
1 0.046 2.51
+
√f
f =0.0402
2
fL V
∆ P=
2 gD
0.0402 × 9.59× 0.7632
∆ P=
2× 9.81× 0.1524
¿ 0.07506

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As it’s below the criteria the line size is correct.
6. Gas line sizing calculation:
Given:
Flowing fluid: CO2 gas
P = 11.2 bar g
T = 3.40c
Q = 11500 Nm3/hr
Solution:
P = 11.2 bar g = 11.2 + 1.0132
= 12.213 bar
12.213× 101.325
¿
1.0132
= 1221.60 kpa
T = 3.40c
= 3.4 + 273.15
= 276.55k
MW = 44 kg/kmol
PM
ρ=
RT
1221.60 × 44
¿
8.314 ×276.55
= 23.37 kg/m3
Q = 11500 Nm3/hr
11500× 44
¿
22.41
= 22575 kg/hr
22575
¿
ρ
22575
¿
23.37
= 965.70 m3/hr

15
Maximum vapor velocity:
C
V= 3
√ρ
24
¿
√23.37
3

= 8.3944 m/s
Q=V × A

d=
√ 4Q
3.14 ×V

¿
√ 4 ×965.70
3.14 × 8.3944 ×3600
¿ 0.2017 m
¿ 6.9
Considering 8 pipe diameter (0.2032 m)
Q=VA
Q
V=
A
965.70
V=
0.0314 × 3600
= 8.19 m/s
Pressure drop calculation

( 0.000336 )
2
W fm
∆ P100 =
ρ 5
d

Where d is in inch, W is in lb/hr and Density in lb/ft3

0.008
ff=
√3 d
0.008
¿
√7.9409
3

−3
f f =4 × 10
f m=4 × f f
−3
¿ 4 ×4 ×10

16
 ¿ 0.016

∆ P100 =
1.4587 (
49768.4852 0.000336 ×0.016
7.9404 5 )
= 0.2891 psi
= 0.02032 kg/cm2
As it’s below the criteria the line size is correct.

Bibliography

[1] R. Darby, "Chemical Engineering Fluid Mechanics,2nd edition," 2001, pp. 206-209.

[2] D. R. K. Bansal, A textbook of fluid mechanics and hydraulic machines, Laxmi publication, 2005.

[3] A. K. Coker, "Ludwig's Applied Process Design for Chemical and Petrochemical Plants, Fourth
Edition," 2007.

[4] "GPSA Engineering Data Book, 12th edition," GSAP, 2004.

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