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Line Sizing
and Hydraulics
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Training Services
Part I
Line Sizing
n General Guidelines
n Line ∆P Calculations for Liquid,
Vapor and Two-Phase
n Line Service Types and Guidelines
for ∆P and Velocity Limits
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General Line Sizing Comments
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Guidelines
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Principle Pipe Design Criteria
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Required Physical Properties
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Mechanical Considerations
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Pipe Wall Thickness
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Revamp Considerations
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Pressure Drop for Liquid Flows
f ×ρ ×L ×V 2
∆P =
144 ×D ×2 ×g
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Pressure Drop for Liquid Flows
(continued)
where:
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Pressure Drop for Liquid Flows
(continued)
0.000216 x f x L x ρ x Q 2
∆P =
d5
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Pressure Drop for Liquid Flows
(continued)
n Simplifications
– Assume L = 100 ft of equivalent length
– Define ∆P(100) = ∆P (when L = 100 ft)
– Substituting ρ = 62.4 lb/ft3 x SG
where SG = Specific Gravity of fluid
– By substitution and rearrangement yields
∆P100 1.348f × Q 2
=
SG 5
d
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Pressure Drop for Liquid Flows
(continued)
∆P100
– Define ∆P0(100) =
SG
– By substitution:
1.348 f × Q 2
∆P0(100) =
5
d
n For small changes in flow, Q, assume Friction
Factor “f” remains constant. Thus we can
define a constant K as follows:
1.348f
= Constant, K
5
d
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Pressure Drop for Liquid Flows
(continued)
∆P0(100) = K Q2
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Liquid Flow thru Commercial Steel Pipe
LS-R00-18
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UOP Pressure Drop Chart
for Liquid Flow
LS-R00-17
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Viscosity Correction
n Example
– For υ = 20 Centistokes, Multiply ∆P read from
chart by the following factor:
0.2 0. 2
v 20
= = 2.016
0.6 .6
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Liquid Flow Line Sizing/∆P Calculation
Exercise
n Flow Rate 500 gpm
Flowing Sp.Gr. 0.75
Viscosity 0.6 centistoke
a. Find ∆P/100' in 6" Sch 80 Pipe
b. Find ∆P/100' in 8" Sch 40 Pipe
c. Find velocity in 8" Sch 40 Pipe
d. Find corrected ∆P/100' in 6" Sch 80 Pipe if
υ = 50 centistoke
e. What size pipe would result in a ∆P/100' =
0.28 psi if flow is 4000 gpm, Sp.Gr. = 0.8
and υ = 0.6 centistoke? Solution
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Pressure Drop for Vapor Flows
3.36 ×10-6 ×f ×L ×W 2 ×V
∆P =
5
d
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Pressure Drop for Vapor Flows
(continued)
Where:
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Pressure Drop for Vapor Flows
(continued)
n Simplifications
– Assume L = 100 ft
– Define ∆P(100) = ∆P (when L = 100 ft)
∆P100
– Define ∆P0(100) =
V
– By substitution and re-arrangement, we
obtain:
2
336 f W
∆P0(100) = 5
d 1000
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Pressure Drop for Vapor Flows
(continued)
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Vapor Flow thru Commercial Steel Pipe
LS-R00-20
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Vapor Flow thru Commercial Steel Pipe
(See Previous Chart for Smaller Sizes)
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Vapor Flow thru Commercial Steel Pipe
LS-R00-22
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UOP Pressure Drop Chart
for Vapor Flow
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Vapor Flow Line Sizing/∆P Calculation
Exercise
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Sonic Velocity of a Vapor
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Sonic Velocity of a Vapor
(continued)
Temperature oR
Vs, ft/min = 14,000
Molecular Weight
n Sonic velocity is expressed in units of feet per
minute
n Sonic velocity is proportional to:
Cp Cv
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Specific Volume Change
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Two-Phase Flow Pressure Drop
n Correlating Factors
– Liquid volume fraction
– Ratio of pseudo 100% gas ∆P and pseudo
100% liquid ∆P: ∆P*G/∆P*L
– Ratio of ∆P two phase and pseudo 100%
liquid ∆P: ∆PTP / ∆P*L
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Two-Phase Flow Pressure Drop
(continued)
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Two-Phase Flow Pressure Drop
(continued)
VL
Liquid Volume Fraction =
VL + VG
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Two-Phase Flow Pressure Drop
(continued)
∆PTP / ∆P*L
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LS-R00-23
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LS-R00-25
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Two-Phase Flow Line Sizing
∆P Calculation Exercise
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Two-Phase Flow Patterns Example
40017
υ 10" = = 22.3 < 25 ft sec
3600 x 0.4989
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Approximate Two-Phase Flow Patterns
(Vertical Upflow)
500
100
50
Bubble Slug Annular Mist
Flow Flow Flow Flow
10
5
1
X=
(WL 0.9
WG (ρρ (
G
L
0.5 µL 0.1
µG
W = lb/sec
ρ = lb/ft3 (
µ = centipoise 1
0.1 0.5 1.0 5 10 50 100
X LS-R02-24
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Two-Phase Flow Patterns Example
0.9
W W = (187650 40,000) = 4.0
0.9
L G
0.5
ρ ρ
= (1.1 46.8) = 0.15
0.5
G L
0.1
µ µ = (0.6 x 0.75 0.015)0.1 = 1.40
L G
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Two-Phase Flow Patterns Example
(continued)
227,650
Mass velocity = = 127 lb sec - ft 2
3600 x 0.4989
1 1
x= = = 1.2
(WL WG ) (ρG ρL ) (µL µG ) 4.0 x 0.15 x 1.40
0.9 0.5 0.1
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Line Sizing Design Criteria
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Line Sizing Criteria
(continued)
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Line Sizing Design Criteria
Line Type Allowable Velocity or Pressure Drop Restraint
?P/100'
Fractionator Feed; 50 <? P Control Valve 2.0 (Liquid Velocity, ft/min < 700)
Fractionator Feed; 25 = ?PCtrl Valve = 50 1.5 (2-phase Velocity, ft/min < 6000/?o1/2
Fractionator Feed; ?P Control Valve <25 0.5 Vapor Velocity, ft/min < 6000/?v1/2
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Line Sizing Design Criteria (Continued)
Allowable
Line Type ? P/100' Velocity or Pressure Drop Restraint
Column Overhead Vapor = 300 P 1.25 .
150 =P < 300 psia 0.75
14.7 = P < 150 0.3
3.75 = P < 14.7 0.15
P < 3.75 4% of Absolute P
FCC Main Column Overhead Vapor 0.10
Condenser Rundown 0.25
(Equalizing line is 1/3-1/4 of rundown line size)
Gravity Feed 0.15
All Other Two-Phase Lines 315 = P 2.0 Velocity, ft/min < 6000/?o1/2
165 = P < 315 psia 1.0
14.7 = P < 165 0.5
3.75 = P < 14.7 0.15
P < 3.75 4% of P
Forced Circulation Reboiler Return 0.7 Velocity, ft/min < 6000/?o1/2
Cooling Water
0-700 gpm (up to 347,520 lb/hr 1.3 --
701-2800 gpm (up to 1,390,060 lb/hr) 500 ft/min
2801-7000 gpm (up to 3,475,150 lb/hr) 600 ft/min
7001+ gpm (3,475,150+ lb/hr) 700 ft/min
Steam - Saturated 1.1 6,000 ft/min
Steam - Superheated (at least 20ºF) 1.1 15,000 ft/min
FCC Slurry (Main Column Bottoms)
Pump Discharge ---- 420 ft/min maximum
Pump Suction ** 0.15 180 ft/min minimum
Pump Suction – Subcooled 0.35
(liquid subcooled at least 50ºF or vapor
pressure at least 25 psi below system
pressure)
P = Absolute Pressure in psi unless otherwise indicated.
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Training Services
Part II
Hydraulics
n Piping Equivalent Length
n Equipment Elevations: Column, Receiver
n Pumps NPSH Calculations
n Thermosyphon Reboiler Hydraulic
n Typical Equipment Pressure Drops: Heaters,
Exchangers, Control Valves
n Hydraulic Circuit: Fractionator Column
Hydraulic Procedure and Sample Problem
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Piping Equivalent Length
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Equivalent Length
Description of Product in Pipe Diameters
(L/D) Representative
Globe
Stem Perpendicular
to Run
With no obstruction in flat, bevel, or plug type seat
With wing or pin guided disc
(No obstruction in, bevel, or plug type seat
Fully open
Fully open
340
450 Equivalent
Valves
Y-Pattern - With stem 60 degrees from run of pipe line
- With stem 45 degrees from run of pipe line
Fully open
Fully open
175
145
Length in Pipe
Angle Valves With no obstruction in flat, bevel, or plug type seat
With wing or pin guided disc
Fully open
Fully open
145
200
Diameters (L/D)
Wedge, Disc,
Double Disc,
Fully open
Three-quarters open
One-half open
13
35
160
of Various Valves
Gate
Valves
or Plug Disc One-quarter open
Fully open
900
17
and Fittings
Three-quarters open 50
Pulp Stock One-half open 200
One-quarter open 1200
Conduit Pipe Line Gate, Ball, and Plug Valves Fully open 3**
Conventional Swing 0.5’...Fully open 135
Check Clearway Swing 0.5’...Fully open 50
Valves Globe Lift or Stop; Stem Perpendicular to Run or Y-Pattern 2.0’...Fully open Same as Globe
Angle Lift or Stop 2.0’...Fully open Same as Angel
In-Line Ball 2.5 vertical and 0.25 horizontal...Fully open 150
0.3’...Fully open 420
Foot Valves with Strainer
0.4’...Fully open 75
Butterfly Valves (8-inch and larger) Fully open 40
Straight-Through Rectangular plug port area to 100% of pipe area Fully open 18
Cocks Rectangular plug port area equal to 80% Flow straight through 44
Three-Way
of pipe area (fully open) Flow through branch 140
90 Degree Standard Elbow 30
45 Degree Standard Elbow 16
90 Degree Long Radius Elbow 20
90 Degree Street Elbow 50
Fittings 45 Degree Street Elbow 26
Square Corner Elbow 57
With flow through run 20
Standard Tee 60
With flow through branch
Close Pattern Return Bend 50
90 Degree Pipe Bends See Page A-27
Pipe Miter Bends See Page A-27
Sudden Enlargements and Contractions See Page A-26
Entrance and Exit Losses See Page A-26
** Exact equivqlent length is 1 Minimum calculated pressure
eaual to the length between drop (psi) across valve to provide
flange faces or welding ends. sufficient flow to lift disc fully.
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Tray
1
Fractionator Piping
Details
Equivalent Length
Problem
(See Handout)
Straight run Tee
Gate Valve
Branch Tee
Swing Check Valve
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Equivalent Length Problem
Problem Tasks
n There are 3 line segments:
n 1) Line from globe control valve to
tray 1 – all data has been filled in.
n 2) Line of storage split to globe valve
- fill in column of Equivalent feet.
n 3) Pump Discharge line to storage
split - fill in all columns.
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Equivalent Length Worksheet – (Partially filled in solution)
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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Straight Pipe
Column Elevation Set By
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Receiver Elevation Set By
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Pump Net Positive Suction Head
(NPSH)
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Pump Net Positive Suction Head
(NPSH)
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NPSH Calculation
n Contractor Calculation
versus
n Basic Engineering Calculation
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NPSH Calculation Procedure
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Single Stage Centrifugal Pumps
Minimum Required NPSH Back
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NPSH(R) for Single Centrifugal Pumps
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Typical Column Bottoms Pump
Min. Level
6”
TL TL
Pump PI
C
L 8”
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NPSH Example Calculations
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NPSH Example Calculation
3. Friction Loss
For 8" line ∆P100 = 0.11 psi
500 equivalent feet = .55 psi x 2.31 ft H2O/.65sg 2.0 ft
Suction Valve (Assume gate valve - one line size smaller)
Equivalent length = 13 D
∆P = (0.11 psi)(8"/6")5(13)(6"/12")(1/100)(2.31/0.65) 0.1 ft
6” Suction Strainer (0.11 psi) x (8”/6”)5 = 0.46 psi/100’
Equivalent length = 300 ft
(0.46 psi)(300 ft/100 ft)(2.31 ft H2O /0.65sg) 4.9 ft
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NPSH Example Calculation
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NPSH Example Problem Summary
1. NPSH(R) 6.2 ft
2. Pump Centerline Elevation 2.5 ft
3. Friction Loss = (2.0 + 0.1 + 4.9) 7.0 ft
4. System Pressure-Vapor Pressure -0.0 ft
5. Minimum Level (credit) -0.5 ft
6. Contingency 2.0 ft
TOTAL 17.2 ft
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Thermosyphon Reboiler Hydraulics
Entrance Loss into Column
CL Exchanger
Centerline
Exit Loss
Out of Column Exchanger Friction Loss
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Thermosyphon Reboiler Systems
Determine Required Driving Head, H
0.5 V 2 S.G.
n Exit Loss at Column Outlet = ×
2g 2.31
n Line Loss to Exchanger
n Exchanger Loss:Entrance Loss, Bundle Loss, Exit Loss
n Line Loss to Column
n Static Loss to Column
1.0 V S.G. 2
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Thermosyphon Reboiler Systems
Trial Line Size for Maximum 30% Vaporization
n Outlet Piping
– 24 < d2/Q < 30
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Minimum Column Elevation
T.L.
3" Minimum
Minimum
Skirt 1 1/2 x Dia. of Pipe
Height 1/2 Dia. of Pipe
2" Insulation
6" Clearance
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Typical Heater Pressure Drops
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Typical Heater Pressure Drops
(continued)
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Typical Heat Exchanger
Pressure Drops
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Typical Heat Exchanger
Pressure Drops
(continued)
n Exceptions
– Cooling Water Side 10 psi
– Combined Feed Exchangers 2-5 psi/side
– Condensers 1-5 psi
– Reboilers - Kettle and 0.2-0.5 psi
Thermosyphon
– Reboilers - Forced Circulation 5-10 psi
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Control Valve Pressure Drops
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Control Valve Pressure Drops
(continued)
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System Hydraulic Curves
Atmospheric Fixed Point Pressure
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Identical Pumps Handling Liquids
of Different Specific
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System Hydraulic Curves
Elevated Fixed Point Pressure
Differential, psi
Design SG 1
Alternate SG2
LS-R00-07
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System Hydraulic Curves
Fixed Available Pressure Source
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Control Valve ∆P Selection
System 1 2 3 4
Fixed End Pressure 0 0 250 500
Frictional Losses 25 100 100 100
Total Required Press. 25 100 350 600
∆P Options
25 Min. 25 25 25 25
50% Friction 12.5 50 50 50
7-10% Diff 2.5 10 35 60
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Hydraulics of a Fractionating Column –
Problem Exercise
Objective
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Hydraulics General Procedure
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Hydraulics General Procedure
(continued)
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Hydraulics General Procedure
(continued)
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Debutanizer Hydraulic Flow Diagram
DEBUTANIZER DEBUTANIZER
Debutanizer Hydraulics Problem RECEIVER
Debutanizer Off
182
250 psig
163 Gas To Refinery
PRC Fuel Gas
4# 40 ft
164
170 FR
1
166
8# At Grade
165
Cooling Water
TRC
OD=6.6 ft
8
LIC
1.92 ft
21 ft
167
16 2.5 ft
168
FRC
175
LIC
32.15 ft
172
FRC
Net Overhead Liquid
152
To Refinery LPG
176 173 TRC B.L. Pressure = 300 psig
LS-R00-11
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Line Sizes and Equivalent Lengths
Debutanizer Overhead Pipe Segments
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Characteristic Pump Head Curves
Figure 1: Characteristic Centrifugal Pump Differential Head versus Capacity Curves
1.3
1.2
1450, 1750 RPM single & multi-stage > 1000 gpm & Q/H > 5
1.15
Sundyne
1.1
2950, 3550 RPM single & two stage < 125 gpm & Q/H < 0.1
1.05
1
0 10 20 30 40 50 60 70 80 90 100
Percent of Rated Capacity
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UOP
Heat and Weight Balance
P9.8 - THERMODYNAMIC OPERATIONS UOP
MATERIAL BALANCE REPORT
DEBUTANIZER
160 DEC4 FD TO F/B EXCH 98.4 100 298 5697.4 560449 17 9.45
TOTAL VAPOR 5.0 0.261* 100 298 0.22* 0* 24.3 122 154 0.019
HYDROGEN 100 298 22.2 45
HYDROCARBON 100 298 2.1 77
TOTAL LIQUID 41.3 10.9 98.8 0.800 100 298 46895 1399 5673.1 560327 17 9.43
EQUIPMENT DUTY 75.54
161 DEC4 FD FR F/B EXCH 98.4 360 283 5697.4 560449 152 84.99
TOTAL VAPOR 41.6 1.488* 360 283 0.71* 1* 78.3 3257 297 0.97
HYDROGEN 360 283 31.5 63
HYDROCARBON 360 283 46.8 3193
TOTAL LIQUID 41.0 10.8 99.2 0.659 360 283 46566 1690 5619.1 557192 151 84.03
162 DEC4 FD TO COLUMN 98.4 360 263 5697.4 560449 152 84.99
TOTAL VAPOR 43.7 1.462* 360 263 0.91* 1* 99.4 4339 295 1.28
HYDROGEN 360 263 37.1 75
HYDROCARBON 360 263 62.3 4265
TOTAL LIQUID 40.9 10.8 99.3 0.660 360 263 46450 1685 5598.0 556109 151 83.71
163 GAS TO DEC4 CONDR 47.8 2.510* 177 261 16.93* 10* 1858.8 88785 190 16.85
HYDROGEN 177 261 83.2 168
HYDROCARBON 177 261 1775.6 88617
EQUIPMENT DUTY 12.31
164 MTL TO DEC4 TRIM CONDR 47.8 118 257 1858.8 88785 51 4.55
TOTAL VAPOR 32.2 1.589* 118 257 2.53* 2* 277.7 8931 169 1.51
HYDROGEN 118 257 74.1 149
HYDROCARBON 118 257 203.6 8782
TOTAL LIQUID 4.519 14.2 50.5 0.496 118 257 10098 322 1581.1 79854 38 3.04
EQUIPMENT DUTY 1.44
165 MTL TO DEC4 RCVR 47.8 100 250 1858.8 88785 35 3.10
TOTAL VAPOR 27.5 1.320* 100 250 1.80* 1* 197.6 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5284
TOTAL LIQUID 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
166 OVHD GAS FR DEC4 RCVR 27.5 1.320* 100 250 1.80* 1* 197.5 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5283
182 DEC4 OVHD GAS TO FUEL 27.5 0.263* 83 40 1.80* 6* 197.5 5427 162 0.88
HYDROGEN 83 40 71.1 143
HYDROCARBON 83 40 126.5 5283
167 LIQ FR DEC4 RCVR 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
168 LIQ FR DECR OVHD PUMP 4.507 14.2 50.2 0.511 100 310 10568 326 1661.3 83358 27 2.23
171 NET DEC4 OVHD LIQ TO CV 4.507 14.2 50.2 0.511 100 310 1528 47 240.2 12052 27 0.32
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UOP
Heat and Weight Balance (continued)
P9.8 - THERMODYNAMIC OPERATIONS UOP
MATERIAL BALANCE REPORT
DEBUTANIZER
160 DEC4 FD TO F/B EXCH 98.4 100 298 5697.4 560449 17 9.45
TOTAL VAPOR 5.0 0.261* 100 298 0.22* 0* 24.3 122 154 0.019
HYDROGEN 100 298 22.2 45
HYDROCARBON 100 298 2.1 77
TOTAL LIQUID 41.3 10.9 98.8 0.800 100 298 46895 1399 5673.1 560327 17 9.43
EQUIPMENT DUTY 75.54
161 DEC4 FD FR F/B EXCH 98.4 360 283 5697.4 560449 152 84.99
TOTAL VAPOR 41.6 1.488* 360 283 0.71* 1* 78.3 3257 297 0.97
HYDROGEN 360 283 31.5 63
HYDROCARBON 360 283 46.8 3193
TOTAL LIQUID 41.0 10.8 99.2 0.659 360 283 46566 1690 5619.1 557192 151 84.03
162 DEC4 FD TO COLUMN 98.4 360 263 5697.4 560449 152 84.99
TOTAL VAPOR 43.7 1.462* 360 263 0.91* 1* 99.4 4339 295 1.28
HYDROGEN 360 263 37.1 75
HYDROCARBON 360 263 62.3 4265
TOTAL LIQUID 40.9 10.8 99.3 0.660 360 263 46450 1685 5598.0 556109 151 83.71
163 GAS TO DEC4 CONDR 47.8 2.510* 177 261 16.93* 10* 1858.8 88785 190 16.85
HYDROGEN 177 261 83.2 168
HYDROCARBON 177 261 1775.6 88617
EQUIPMENT DUTY 12.31
164 MTL TO DEC4 TRIM CONDR 47.8 118 257 1858.8 88785 51 4.55
TOTAL VAPOR 32.2 1.589* 118 257 2.53* 2* 277.7 8931 169 1.51
HYDROGEN 118 257 74.1 149
HYDROCARBON 118 257 203.6 8782
TOTAL LIQUID 4.519 14.2 50.5 0.496 118 257 10098 322 1581.1 79854 38 3.04
EQUIPMENT DUTY 1.44
165 MTL TO DEC4 RCVR 47.8 100 250 1858.8 88785 35 3.10
TOTAL VAPOR 27.5 1.320* 100 250 1.80* 1* 197.6 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5284
TOTAL LIQUID 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
166 OVHD GAS FR DEC4 RCVR 27.5 1.320* 100 250 1.80* 1* 197.5 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5283
182 DEC4 OVHD GAS TO FUEL 27.5 0.263* 83 40 1.80* 6* 197.5 5427 162 0.88
HYDROGEN 83 40 71.1 143
HYDROCARBON 83 40 126.5 5283
167 LIQ FR DEC4 RCVR 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
168 LIQ FR DECR OVHD PUMP 4.507 14.2 50.2 0.511 100 310 10568 326 1661.3 83358 27 2.23
171 NET DEC4 OVHD LIQ TO CV 4.507 14.2 50.2 0.511 100 310 1528 47 240.2 12052 27 0.32
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Pro-Rate Pressure Drop Formula
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Hydraulic Tabulation - Start Solution
H y d ra ulic Circuit De s c rip tion: D e b u ta nize r N e t Ov e rhe a d Liquid to LP G S to ra g e
Solution
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Hydraulics - Final Thoughts
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Questions?
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