1

FLUID FLOW

GAS LIQUID SOLIDS

FLUIDS

LIQUID MUST BE PUSHED TO OVERCOME FRICTION

IN ORDER TO HAVE FLOW, THERE MUST BE A PRESSURE DROP.

Downstream pressure must be less than

the upstream pressure for fluid to flow.
 2A
PIPE AND FITTINGS

WHEN PROCEDURES FOR MAKING STEEL PIPE WERE DEVELOPED MANY

YEARS AGO, EACH MANUFACTURER MADE PIPE TO HIS OWN PARTICU-
LAR SPECIFICATIONS, WHICH WERE OFTEN DIFFERENT FROM THOSE OF
OTHER MANUFACTURERS. ONE MANUFACTURER’S PIPE WOULD BE
SLIGHTLY LARGER AND HAVE DIFFERENT END FITTINGS (THREADS OR
FLANGES) THAN OTHERS, SO PIPE AND FITTINGS FROM DIFFERENT
MANUFACTURERS COULD NOT BE INTERCONNECTED.
THIS SITUATION LED TO THE FORMATION OF ENGINEERING SOCIETIES
IN THE U.S. THAT DEVELOPED STANDARDS FOR PIPING THAT ALL MANU-
FACTURES HAD TO COMPLY WITH. THE STANDARDS INCLUDED: PIPE
SIZES (1 IN., 2 IN., 3 IN., ETC.) OUTSIDE DIAMETER, WALL THICKNESS,
METAL QUALITY, PRESSURE RATINGS, THREAD AND FLANGE DIMEN-
SIONS, ETC.
THE PIPE SIZES THAT THE STANDARDIZING SOCIETIES SELECTED
RANGED FROM !/8 INCH TO 60 INCH.
PIPE SIZES 12 INCHES AND SMALLER ARE DESIGNATED BY THE INSIDE
DIAMETER OF STANDARD WEIGHT PIPE ROUNDED OFF TO THE NEAREST
INCH.
EXAMPLE
6 INCH STANDARD WEIGHT PIPE HAS AN INSIDE DIAMETER OF 6.0625
INCHES. ITS OUTSIDE DIAMETER IS 6 %/8 INCHES.
PIPE HAVING A DIAMETER OF 14 INCHES AND LARGER IS DESIGNATED
BY IS OUTSIDE DIAMETER. FOR EXAMPLE, 16 INCH PIPE HAS AN OUT-
SIDE DIAMETER OF 16.000 INCHES. THE INSIDE DIAMETER VARIES FROM
14.312 TO 15.5 INCHES, DEPENDING UPON ITS WALL THICKNESS.
THE STANDARDIZING SOCIETIES ALSO SELECTED DIFFERENT THICK-
NESSES FOR EACH PIPE SIZE.
THEY USED TWO NAMES FOR DESIGNATING PIPE THICKNESS:
1. SCHEDULE NUMBER: THE NUMBERS RANGE FROM 10, WHICH IS THE
THINNEST WALL, TO 160, WHICH IS THE THICKEST WALL. THE MOST
COMMON SCHEDULE NUMBERS ARE: 40, 80, AND 160.
2. WEIGHT: THE COMMON DESIGNATIONS ARE: LIGHT GAUGE (LG),
STANDARD(S), EXTRA HEAVY (X OR XH) AND DOUBLE EXTRA HEAVY
(XX OR XXH).
 2B
PIPE AND FITTINGS

THE STANDARDIZING SOCIETIES ALSO DEVELOPED PRESSURE RATINGS

FOR EACH DIFFERENT PIPE SIZE AND THICKNESS. THE PRESSURE RATING
FOR PIPE USED IN REFINERIES OR GASOLINE PLANTS IS ABOUT HALF THAT
FOR PIPE USED IN GAS PIPELINES. THE STANDARDS WERE ADOPTED, THEY
WERE USED BY EQUIPMENT MANUFACTURERS ALL OVER THE WORLD.

IN COUNTRIES THAT USE SI UNITS, PIPE SIZE IS DESIGNATED BY THE OUT-

SIDE DIAMETER IN MILLIMETERS, AND THE WALL THICKNESS IN MILLIME-
TERS.

EXAMPLE
6” SCH 40 PIPE HAS AN OUTSIDE DIAMETER OF 6 %/8 INCHES AND A WALL
THICKNESS OF 0.280 INCHES. ITS SI DESIGNATION IS: 168.275 MM DIAM-
ETER, 7.112 MM THICK.
 3A
PIPE SIZE AND REFINER PRESSURE RATING
SI UNITS - TABLE 1A
Pipe Size Wall Thickness Working Pressure in kPa
Outside Inside for Temperature from -29°C to
Diameter Diameter
mm Weight Schedule mm mm 204° 260° 316° 371°
S 40 3.378 26.645 14 503 13 710 12 544 11 965
33.401 X 80 4.547 24.308 23 917 22 600 20 689 14 731
[1 in.] XX - 9.093 15.215 65 751 62 138 56 875 54 248
S 40 3.912 52.502 10 131 9 572 8 758 8 358
60.325 X 80 5.537 49.251 17 158 16 214 14 841 14 158
[2 in.] - 160 8.712 42.850 31 841 30 089 27 544 26 268
XX - 11.074 38.176 43 338 40 958 37 489 35 758
S 40 5.486 77.927 11 310 10 689 9 786 9 331
88.9 X 80 7.620 73.660 17 600 16 634 15 220 14 517
[3 in.] - 160 11.125 66.650 28 427 26 862 24 593 23 455
XX - 15.240 58.420 41 993 39 682 36 324 34 648
S 40 6.020 102.260 9 924 9 372 8 579 8 186
114.3 X 80 8.560 97.180 15 689 14 827 13 572 12 945
[4 in.] - 160 13.487 87.235 27 434 25 931 23 731 22 634
XX - 17.120 80.061 35 600 34 586 31 655 30 193
S 40 7.112 154.051 8 310 7 855 7 186 6 855
168.275 X 80 10.973 146.329 14 220 13 434 12 296 11 731
[6 in.] - 160 18.237 131.749 25 924 24 496 22 420 21 386
XX - 21.949 124.384 32 131 30 365 27 793 26 510
S 40 8.178 202.717 7 572 7 151 6 552 6 248
219.075 X 80 12.700 193.675 12 855 12 144 11 117 10 600
[8 in.] XX - 22.225 174.625 24 510 23 165 21 200 20 220
- 160 23.012 173.050 25 510 24 110 22 068 21 048
S 40 9.271 254.508 7 048 6 662 6 096 5 814
273.05 X 60 12.700 247.650 10 234 9 675 8 855 8 441
[10 in.] XX - 25.400 222.250 22 662 21 414 19 600 18 690
- 160 28.575 215.900 25 765 24 352 22 289 21 255
S - 9.525 304.800 6 110 5 772 5 283 5 034
323.85 X - 12.700 298.450 8 586 8 117 7 427 7 082
[12 in.] XX 120 25.400 273.050 22 414 21 186 19 393 18 490
- 160 33.325 257.200 25 462 24 090 22 048 21 028
- 10 6.350 342.900 3 352 3 172 2 903 2 765
355.6 S 30 9.525 336.550 5 565 5 262 4 813 4 593
[14 in.] X - 12.700 330.200 7 807 7 372 6 751 6 441
- 80 19.050 317.500 12 207 11 538 10 558 10 069
- 10 6.350 393.700 2 931 2 772 2 538 2 420
406.4 S 30 9.525 387.350 4 862 4 593 4 200 4 006
[16 in.] X 40 12.700 381.000 6 807 6 434 5 889 5 620
- 80 21.438 353.520 12 152 11 490 10 517 10 034
- 10 6.350 444.500 2 600 2 462 2 248 2 149
457.2 S - 9.525 438.150 4 310 4 076 3 731 3 559
[18 in.] X - 12.700 431.800 6 041 5 676 5 221 4 979
- 80 23.825 409.550 12 096 11 366 10 455 9 972
- 10 6.350 495.300 2 338 2 213 2 021 1 931
508 S 20 9.525 488.950 3 876 3 662 3 352 3 200
[20 in.] X - 12.700 482.600 5 427 5 124 4 689 4 475
- 40 15.088 477.820 6 593 6 228 5 697 5 434
- 10 6.350 596.900 1 945 1 841 1 683 1 607
609.6 S 20 9.525 590.550 3 227 3 048 2 786 2 662
X - 172.700 584.200 4 551 4 262 3 896 3 717
[24 in.] - 40 17.475 574.650 6 448 6 090 5 666 5 310
 3B
PIPE SIZES AND REFINERY PRESSURE
RATINGENGLISH UNITS - TABLE 1 B
Working pressures in PSI
Nominal Outside Wall Thickness Inside for Temperature from -20°F to
Pipe Diameter Diameter
Size Inches Weight Schedule Inches Inches 400° 500° 600° 700°
1.315 S 40 0.133 1.049 2103 1988 1819 1735
1 in. X 80 0.179 0.957 3468 3277 3000 2861
XX - 0.348 0.599 9534 9010 8247 7866
2.375 S 40 0.154 2.067 1469 1388 1270 1212
2 in. X 80 0.218 1.939 2488 2531 2152 2053
- 160 0.343 1.687 4617 4363 3994 3809
XX - 0.436 1.503 6284 5939 5436 5185
S 40 0.216 3.068 1640 1550 1419 1353
3 in. 3.500 X 80 0.300 2.900 2552 2412 2207 2105
- 160 0.438 2.624 4122 3895 3566 3401
XX - 0.600 2.300 6089 5754 5267 5024
S 40 0.237 4.026 1439 1359 1244 1187
4 in. 4.500 X 80 0.337 3.826 2275 2150 1968 1877
- 160 0.531 3.438 3978 3760 3441 3282
XX - 0.674 3.152 5307 5015 4590 4378
S 40 0.280 6.065 1205 1139 1042 994
6 in. 6.625 X 80 0.432 5.761 2062 1948 1783 1701
- 160 0.718 5.187 3759 3552 3251 3101
XX - 0.864 4.987 4659 4403 4030 3844
S 40 0.322 7.981 1098 1037 950 906
8 in. 8.625 X 80 0.500 7.625 1864 1781 1612 1537
XX - 0.875 6.875 3554 3359 3074 2932
- 160 0.906 6.813 3699 3496 3200 3052
S 40 0.365 10.000 1022 966 884 843
10 in. 10.750 X 60 0.500 9.750 1484 1403 1284 1224
XX - 1.000 8.750 3286 3105 2842 2710
- 160 1.125 8.500 3736 3531 3232 3082
S - 0.375 12.000 886 837 766 730
12 in. 12.750 X - 0.500 11.750 1245 1177 1077 1027
XX 120 1.000 10.750 3250 3072 2812 2681
- 160 1.312 10.126 3692 3493 3197 3049
- 10 0.250 13.500 486 460 421 401
14 in. 14.00 S 30 0.375 13.250 807 763 698 666
X - 0.500 13.000 1132 1069 979 934
- 80 0.750 12.500 1770 1673 1531 1460
- 10 0.250 15.500 425 402 368 351
16 in. 16.000 S 30 0.375 15.250 705 666 609 581
X 40 0.500 15.000 987 933 854 815
- 80 0.844 14.312 1762 1666 1525 1455
- 10 0.250 17.500 377 357 326 311
18 in. 18.000 S - 0.375 17.250 625 591 541 516
X - 0.500 17.00 876 823 757 772
- 80 0.938 16.124 1754 1648 1516 1446
- 10 0.250 19.500 339 321 293 280
20 in. 20.000 S 20 0.375 19.250 562 531 486 464
X - 0.500 19.00 787 743 680 649
- 40 0.594 18.812 956 903 826 788
- 10 0.250 23.500 282 267 244 233
24 in. 24.000 S 20 0.375 23.250 467 442 404 386
X - 0.500 23.000 654 618 565 539
- 40 0.688 22.624 935 883 807 770
 4
FLANGES

SOCKET WELD
SLIP-ON FLANGE THREADED FLANGE
FLANGE

WELD NECK
WELD NECK FLANGE WITH RING JOINT
FLANGE
TYPES OF FLANGES

MOST OILFIELD PIPING WHICH IS 60.325 MM [2 IN] OR LARGER IS JOINED

WITH FLANGES RATHER THAN THREADED FITTINGS.

FLANGES ARE STRONGER AND LESS LIKELY TO LEAK THAN THREADED

FITTINGS. THEY ALSO ALLOW EASY DISMANTLING OF PIPING.

THE SAME ORGANIZATIONS THAT DEVELOPED PIPE STANDARDS ALSO

DEVELOPED FLANGE STANDARD FOR EACH SIZE OF PIPE AT DIFFERENT
PRESSURE RATINGS. THE STANDARDIZING ORGANIZATIONS ARBITRARILY
SELECTED SEVEN BASIC PRESSURE RATINGS OR CLASSES FOR EACH PIPE
SIZE.
 5
FLANGE PRESSURE RATINGS

TABLE 2A
ALLOWABLE WORKING PRESSURE IN kPa FOR VARIOUS STEEL FLANGE CLASSES

Operating Class Class Class Class Class Class Class

Temp, °C 1.034 MPa 2.069 MPa 2.759 MPa 4.138 MPa 6.207 MPa 10.345 MPa 17.241a MPa
-28 to 38 1966 5103 6927 10206 15310 25551 42551
93 1793 4655 6207 9310 13965 23275 38793
149 1586 4517 6034 9069 13586 22620 37724
204 1379 4379 5827 8758 13103 21862 36413
260 1172 4137 5517 8275 12379 20655 34413
316 9655 3793 5034 7552 11310 18862 31448
343 862 3689 4931 7413 11103 18517 30862
371 758 3689 4896 7345 11034 18379 30620
399 655 3483 4620 6965 10414 17379 28965
427 551 2827 3793 5689 8517 14206 23655
482 345 1172 1586 2379 3551 5931 9862
538 137 345 482 724 1069 1793 2966

TABLE 2B
ALLOWABLE WORKING PRESSURE IN PSIG FOR VARIOUS STEEL FLANGE CLASSES
Operating Class Class Class Class Class Class Class
Temp, °F 150 300 400 600 900 1500 2500
-20 to 100 285 740 990 1480 2220 3705 6170
200 260 675 900 1350 2025 3375 5625
300 230 655 875 1315 1970 3280 5470
400 200 635 845 1270 1900 3170 5280
500 170 600 800 1200 1795 2995 4990
600 140 550 740 1095 1640 2735 4560
650 125 535 715 1075 1610 2685 4475
700 110 535 710 1065 1600 2655 4440
750 95 505 670 1010 1510 2520 4200
800 80 410 550 825 1235 2060 3430
900 50 170 230 345 515 860 1430
 6
FLANGES

T C ODE TION
HEA ESIGNA
AL D
AT ERI
R L L S M
T URE A
W NES
FAC SIZE ASS K
MA N U IN A L C L THIC OF G
NOM S S URE T ION CHI
N
PR E N A AT
M PIPE
D ESIG
E
FAC

THE SIZE OF FLANGES WILL OBVIOUSLY DEPEND UPON THE SIZE OF

PIPING TO WHICH THEY ATTACH, AND ALSO UPON THE INSIDE PRES-
SURE THAT THE FLANGE MUST CONTAIN.

THE NUMBER OF BOLT HOLES IN A FLANGE WILL VARY FROM 4 TO 20

OR MORE, DEPENDING UPON THE SIZE AND PRESSURE RATING. WITH
FEW EXCEPTIONS, THE BOLT HOLES IN FLANGES OF DIFFERENT
PRESSURE RATINGS WILL NOT MATCH, SO A LOW PRESSURE FLANGE
CANNOT BE MADE UP WITH ONE OF A HIGHER PRESSURE.
 7
PIPE AND FLANGES

EXAMPLES

SI UNITS ENGLISH UNITS

PIPE SIZE IS 168.275 MM 6 IN
OPERATING PRESSURE 13500 KPA 1960 PSI
OPERATING TEMPERATURE 90°C 195°F
PIPE THICKNESS 10.973 MM 0.432 IN
FLANGE SIZE 168.275 MM 6 IN
FLANGE CLASS 6.207 MPA 900
FLANCE BORED FOR WALL THICKNESS 10.973 MM 0.432 IN

PROBLEMS

1. PIPE SIZE IS 114.3 MM 4 IN

PIPE THICKNESS IS 13.487 MM 0.531 M
OPERATING TEMPERATURE 138°C 280°F
MAX. WORKING PRESSURE IS 27434 KPA 2978 PSI
FLANGE SIZE ______ MM ______ IN
FLANGE CLASS ______ MPA ______
FLANGE BORED FOR WALL THICKNESS ______ MM ______ IN

2. FLANGE SIZE IS 219.075 MM 8 IN

FLANGE CLASS IS 6.207 MPA 900
FLANGE IS BORED FOR THICKNESS 12.70 MM 0.50 IN
OPERATING TEMPERATURE 176°C 350°F
MAX. OPERATING PRES. OF FLANGE ______ KPA ______ PSI
MAX. OPERATING PRES. OF PIPE ______ KPA ______ PSI
 8
PRINCIPLES OF LIQUID FLOW

PRESSURE DROP IS THE PRIMARY CONSIDERATION IN SELECTING PIPE

SIZES IN PROCESS FACILITIES. THE PRESSURE DROP DEPENDS UPON:

1. VELOCITY OR FLOW RATE OF THE FLUID.

2. VISCOSITY OF THE FLUID.
3. ROUGHNESS OF THE PIPE.
4. THE RELATIVE DENSITY OF FLUID.

AN INCREASE IN EACH WILL RESULT IN AN INCREASE IN PRESSURE DROP,

WHICH MUST BE MADE UP WITH A PUMP OR COMPRESSOR.

FLOW RATE IS THE MOST SIGNIFICANT FACTOR.

THE EQUATION FOR DETERMINING THE PRESSURE DROP DUE TO CHANGE

IN FLOW IS;

2
FF
∆PF = ∆PI X (F )
I

WHERE…

∆PI = INITIAL PRESSURE DROP

FI = INITIAL FLOW RATE

∆PF = FINAL PRESSURE DROP

FF = FINAL FLOW RATE

PRESSURE DROP WILL CHANGE PROPORTIONALLY WITH CHANGE IN

RELATIVE DENSITY OF LIQUID.

IF RELATIVE DENSITY CHANGE IS 10%, PRESSURE DROP WILL CHANGE

10%.
 9A
EFFECT OF FLOW RATE AND
RELATIVE DENSITY ON PRESSURE DROP - SI UNITS

∆P = 20 KPA = ∆P1

WATER FLOW = 750 L/M = V

∆P2 = ( )
V2
V1
2
( )
1500
(∆P1)= 750
2
X (20) = 80 kPa

WATER FLOW = 1500 L/M = V2

( ) X (20) = 5 kPa
375
∆P2 = 750
2

WATER FLOW = 375 L/M = V2

∆P = 80 X 0.5 = 40 KPA

PROPANE FLOW = 1500 L/M

REL DENS PROPANE = 0.5
 9B
EFFECT OF FLOW RATE AND RELATIVE DENSITY ON
PRESSURE DROP - ENGLISH UNITS

∆P = 3 PSI = ∆P1

WATER FLOW = 200 GPM = V1

2
400
( ) (3) = 12 PSI = ∆P
∆P2 =
200 2

WATER FLOW = 400 GPM = V2

2
100
∆P2 =( )
200
X 3 = 0.75 PSI

WATER FLOW = 100 GPM = V2

∆P = 12 X 0.5 = 6 PSI

PROPANE FLOW = 400 GPM

REL DENS PROPANE = 0.5
 10A
PRESSURE DROP IN WATER PIPING - SI UNITS
2 3 4 5 6 7 8 10 20 30 40 60 100 200 400 600 800
1000 1000

800 800
700

e
700

Pip
600 in] 600

e
500 500

Pip
[1
m

in]
400 400
1m

[2
m
. 40

300 300

5m
33

e
.32
PRESSURE DROP IN WATER PIPING, KPA PER 100 METERS OF PIPE

Pip
200
60
200

in]

e
[3

Pip
mm

in]
.9

[4
88
100

mm
100

e
Pip
80

4.3
80
70 70

11

in]
60 60

[6
50 50

m
5m

e
Pip
40 40

7
8.2

in]
16

[8
30 30

mm

e
75

Pip
20 20
9. 0

e
in]
21

Pip
[10

in]
mm

e
[12
Pip
10 10
.05

m
9 9

in]
5m
3

8 8
27

[14

pe
3.8

7 7

i
]P
mm
32

6 6
n

e
i
Pip
5.6

5
[16
5
35

n]
m

4 4
i
m

[18

e
6.4

Pip
mm

3 3
40

in]
.2
[ 20
7
45

2 2
m
8m
50

1 1
2 3 4 5 6 7 8 10 20 30 40 60 100 200 400 600 800

WATER FLOW RATE, M3/HOUR

FIGURE 1A
PRESSURE DROP IN WATER PIPING - SI UNITS
EXAMPLE: WATER FLOWING AT 50 M3/HR IN A 114.3 MM PIPE WILL HAVE A
PRESSURE DROP OF 54 KPA PER 100 M OF PIPE.
 10B
PRESSURE DROP IN WATER PIPING - ENGLISH UNITS
PRESSURE DROP IN WATER PIPING, PSI PER 100 FT OF PIPE

WATER FLOW RATE, GPM

FIGURE 1B
PRESSURE DROP IN WATER PIPING - ENGLISH UNITS
EXAMPLE: WATER FLOWING AT A RATE OF 250 GPM IN A 4 IN. PIPE WILL
HAVE A PRESSURE DROP OF 3 PSI PER 100 FT OF PIPE.
 11
PRESSURE DROP IN WATER PIPING
EXAMPLE
AT WHAT RATE WILL WATER FLOW OUT THE 114.3 MM [4 IN] PIPE FROM THE
TOWER BELOW?

10 cm [4 in] pipe

100 M
[330 ft]
100 m

[100 FT]

240 m3/h
[1050 gpm]

THE PRESSURE DROP IN THE PIPING BETWEEN THE TANK AND THE
GROUND WILL BE THE LIQUID HEAD PRESSURE.

SI UNITS ’ ENGLISH UNITS ’

LIQUID HEAD PRES = (HT) (REL DENS) (9.8) = (HT) (REL DENS) (0.43)
= (100) (1.0) (9.8) = (100) (1) (0.43)
= 980 KPA PER 100 M 43 PSI PER 100 FT

AT THE PRESSURE DROP CALCULATED ABOVE, THE FLOW OF WATER

THROUGH A 114.3 MM PIPE IS = 240 M 3/HR [4 IN. PIPE IS 1050 GPM].

PIPE SIZE FOR WATER FLOW RATE OF 240 M 3/HR [1050 GPM] WITH
PRESSURE DROP OF 23 KPA PER 100 M [1 PSI PER 100 FT] IS
_______________.
 12
PRESSURE DROP IN PIPING
EXAMPLE
SYSTEM OPPOSITE HAS AVERAGE
FLOW RATE OF 20 M3/H [90 GPM]
Level controller
AND A PRESSURE DROP OF 100 KPA opens and closes
[15 PSI]. HOWEVER, THE LEVEL control valve
CONTROLLER IS SET SO THAT THE
PUMPING RATE IS 50% OR 10 M3/H 20 m3/h [90 gpm]
[45 GPM] FOR HALF OF THE TIME, Average flow rate
AND 150% OR 30 M3/H [135 GPM]
FOR THE OTHER HALF. HOW MUCH
ENERGY IS BEING WASTED? PUMP

SI UNITS ENGLISH UNITS

AVERAGE FLOW RATE 20 M3/H 90 GPM
PRES DROP AT AVERAGE
FLOW RATE 100 KPA 15 PSI
2
FF
∆P EQUATION ∆PF = ∆PI X ( )
FI

= 100 X ( 20)
2 2
SUBSTITUTE ACTUAL FLOW 30 135
AT 150% = 15 X 90 ( )
= 225 KPA = 33.8 PSI

FLOW HALF THE TIME = 10 M3/H = 45 GPM

2 2
∆P AT FLOW OF 50% = 100 X
10
( )
20
= 15 X ( )
45
90
= 25 KPA = 3.8 PSI
AVERAGE ∆P = 225 + 25 = 125 KPA = 33.8 + 3.8 = 18.8 PSI
2 2
IF THE LEVEL CONTROLLER WERE SET TO HOLD ABOUT 20 M3/H [90 GPM],
THE PRESSURE DROP WOULD BE 100 KPA [15 PSI]. IT IS ACTUALLY 125 KPA
[18.8 PSI], WHICH IS 25% MORE THAN DESIGN, OR 25% OF THE PUMPING
ENERGY IS BEING WASTED.
 13A
HYDROCARBON LIQUID PIPE SIZING CHART - SI UNITS

LIQUID FLOW RATE PIPE SIZE FOR PRESSURE DROP OF 23 KPA

M3/DAY L/MIN PER 100 M OF PIPE
62 700 43 530
457.2 MM
[18 IN]
45 250 31 420
406.4 MM
[16 IN]
23 470 16 300
323.85 MM
[12 IN]
14 270 10 200
273.05 MM
[10 IN]
7 630 5 300
219.075 MM
[8 IN]
3 890 2 700
168.275MM
[6 IN]
1 370 950
114.3 MM
[4 IN]
600 416
88.9 MM
[3 IN]
217 151
60.325 MM
[2 IN]
115 80
48.26 MM
[1 !/2 IN]
29 20 EXAMPLE: AT A FLOW
RATE OF 400 LITERS
33.401 MM
[1 IN] PER MINUTE, USE 88.9
0 0 MM [3 IN] PIPE.

FIGURE 2A
HYDROCARBON LIQUID PIPE SIZING CHART - SI UNITS
 13B
HYDROCARBON LIQUID PIPE SIZING CHART
ENGLISH UNITS
LIQUID FLOW RATE PIPE SIZE FOR PRESSURE DROP OF 1 PSI
1000 BPD GPM PER 100 FEET OF PIPE
394 11 500
18 IN

285 8 300
16 IN

147 4 300

12 IN
93 2 700
10 IN
48 1 400
8 IN
24.7 720
6 IN
8.6 250
4 IN

3.8 110
3 IN
1.4 40
2 IN
0.8 22
1 !/2 IN
0.2 5 EXAMPLE: AT A FLOW
RATE OF 100 GPM, USE
1 IN 3 IN PIPE.
0 0

FIGURE 2A
HYDROCARBON LIQUID PIPE SIZING CHART - ENGLISH UNITS
 14
LIQUID PIPE SIZING
PIPING IN PROCESS FACILITIES IS SIZED FOR PRESSURE DROP OF 23 KPA
PER 100 M OF PIPE [1 PSI PER 100 FT OF PIPE].

THIS RESULTS IN VELOCITY OF LIQUID FLOWING INSIDE PIPE OF 2 TO 5 M/

SEC [6 - 15 FT/SEC].

HIGHER VELOCITY MAY ERODE PIPE.

PROBLEMS

SI UNITS ENGLISH UNITS

1. CRUDE OIL FLOW RATE 1 000 M3/D 6 300 B/D

PIPE SIZE ______ MM ______ IN

MAX FLOW IN THIS PIPE ______ M3/D ______B/D

2. CONDENSATE FLOW RATE 1 130 L/M 3 000 GPM

PIPE SIZE ________ ________

3. PIPE SIZE GLYCOL FLOWS IN 60.325 MM 2 IN

MAX GLYCOL FLOW RATE ______ L/M ______ GPM

 15A
EFFECT OF PRESSURE ON GAS VOLUME
SI UNITS
PRESSURE DROP IN GAS PIPING IS AFFECTED BY SAME FACTORS AS
LIQUID PIPING. FLOW RATE IS MAIN FACTOR.

GAS FLOW RATE SHOWN ON METER IS A THEORETICAL VOLUME THE

GAS WOULD OCCUPY IF ITS PRESSURE WAS 101 KPA (A) AND ITS TEM-
PERATURE WAS 15°C.
0 kPa
15°C
1m
1m

1m
1 Standard Cubic Meter of Gas
GAS FLOW IS ALMOST ALWAYS AT A PRESSURE ABOVE ATMOSPHERIC. THE
ACTUAL VOLUME IS MUCH LESS THAN THE FLOW METER VOLUME.

0 101 kPa 909 kPa

Gas Volume 1 m3 0.5 m 3 0.1 m 3

Gauge Pressure 0 kPa 101 kPa 909 kPa
Atmos. Pressure 101 kPa 101 kPa 101 kPa
Absolute Pres. 101 kPa 202 kPa 1010 kPa

GAS VOLUME VARIES INVERSELY WITH CHANGE

IN ABSOLUTE PRESSURE
 15B
EFFECT OF PRESSURE ON GAS VOLUME
ENGLISH UNITS
PRESSURE DROP IN GAS PIPING IS AFFECTED BY SAME FACTORS AS
LIQUID PIPING. FLOW RATE IS MAIN FACTOR.

GAS FLOW RATE SHOWN ON METER IS A THEORETICAL VOLUME THE

GAS WOULD OCCUPY IF ITS PRESSURE WAS 14.7 PSIA AND ITS TEM-
PERATURE WAS 60°F.
0 psi
ft 60°F
10
10 ft

10 ft
1 Standard Mcf of Gas
GAS FLOW IS ALMOST ALWAYS AT A PRESSURE ABOVE ATMOSPHERIC. THE
ACTUAL VOLUME IS MUCH LESS THAN THE FLOW METER VOLUME.

0 14.7 psi 132.3 psi

Gas Volume 1 Mcf 0.5 Mcf 0.1 Mcf

Gauge Pressure 0 psi 14.7 psi 132.3 psi
Atmos. Pressure 14.7 psi 14.7 psi 14.7 psi
Absolute Pres. 14.7 psi 29.4 psi 147.0 psi
Relative Abs. Pres 1 2 10
Relative Volume 1 1/2 1/10th

GAS VOLUME VARIES INVERSELY WITH CHANGE

IN ABSOLUTE PRESSURE
 16A
EFFECT OF TEMPERATURE ON ACTUAL GAS VOLUME
SI UNITS

0 0

15°C 303°C

3
Volume 1 m3 2m
Temperature 15°C X2= 303°C
Abs Zero 273°C 273°C
Abs Temp 288°C 576°C
Relative Volume 1 2
Relative Abs Temp 1 2

GAS VOLUME VARIES PROPORTIONALLY

WITH CHANGE IN ABSOLUTE TEMPERATURE

PRESSURE DROP IN PIPING DEPENDS ON THE M3 ACTUALLY FLOWING IN

THE LINE, AND NOT THE THEORETICAL FLOW RATE SHOWN ON THE FLOW
METER.

THE EQUATION FOR CALCULATING THE ACTUAL VOLUME FLOWING IS:

0.35 (STD VOL) (273 + T)

ACTUAL GAS VOLUME, VA =
P + 100

WHERE:
STD VOL = FLOW METER VOLUME, M3
T = FLOWING TEMPERATURE, °C
P = FLOWING GAUGE PRESSURE, KPA
 16B
EFFECT OF TEMPERATURE ON ACTUAL GAS VOLUME
ENGLISH UNITS

0 0

60°F 580°F

Volume 1 Mcf 2 Mcf

Temperature 60°F X2= 580°F
Abs Zero 460°F 460°F
Abs Temp 520°F 1040°F
Relative Volume 1 2
Relative Abs Temp 1 2

GAS VOLUME VARIES PROPORTIONALLY

WITH CHANGE IN ABSOLUTE TEMPERATURE

PRESSURE DROP IN PIPING DEPENDS ON THE MCF ACTUALLY FLOWING IN

THE LINE, AND NOT THE THEORETICAL FLOW RATE SHOWN ON THE FLOW
METER.

THE EQUATION FOR CALCULATING THE ACTUAL VOLUME FLOWING IS:

0.028 (STD VOL) (460 + T)

ACTUAL GAS VOLUME, VA = P + 15

WHERE:
STD VOL = FLOW METER VOLUME, MCF/D OR MMCF/D
T = FLOWING TEMPERATURE, °F
P = FLOWING GAUGE PRESSURE, PSI
 17A
ACTUAL GAS VOLUME - SI UNITS

5500 KPA 2800 KPA

32°C 27°C
7 MILLION 3 M/D

320 KM
GAS PIPELINE

ACT. GAS VOL EQUATION, VA = 0.35 (STD VOL) (273 + T)

P + 100

ACT. VOL START OF PIPELINE = 0.35 (7) (273 + 32)

55 + 100

= 0.133 MILLION M3/D

or
133 000 M3/D

ACT. VOL AT END OF PIPELINE (0.35) (7) (273 + 27)

2800 + 100

= 0.253 MILLION M3/D

or
253 000 M3/D

ACTUAL FLOWING VOLUME AT THE END OF THE PIPELINE IS ABOUT TWICE

THAT AT THE START. PRESSURE DROP WILL BE ALMOST 4 TIMES AS MUCH
IF PIPELINE SIZE IS CONSTANT.

PRESSURE DROP IN LONG GAS LINES MUST BE CALCULATED IN SECTIONS

BECAUSE ACTUAL VOLUME INCREASES AS GAS FLOWS DOWN THE LINE.
 17B
ACTUAL GAS VOLUME - ENGLISH UNITS

800 PSI 400 PSI

90°F 80°F
260 MMCF/D

200 MI

GAS PIPELINE

ACT. GAS VOL EQUATION, VA = 0.028 (STD VOL) (460 + T)

P + 100

ACT. VOL START OF PIPELINE = 0.028 (260) (460 + 90)

P + 15

= 4.9 MMCF/D

ACT. VOL AT END OF PIPELINE (0.028) (260) (460 + 80)

400 + 15

= 9.47 MMCF/D

ACTUAL FLOWING VOLUME AT THE END OF THE PIPELINE IS ABOUT TWICE

THAT AT THE START. PRESSURE DROP WILL BE ALMOST 4 TIMES AS MUCH
IF PIPELINE SIZE IS CONSTANT.

PRESSURE DROP IN LONG GAS LINES MUST BE CALCULATED IN SECTIONS

BECAUSE ACTUAL VOLUME INCREASES AS GAS FLOWS DOWN THE LINE.
 18A
GAS PIPE SIZING GRAPH - SI UNITS
GAS FLOW RATE, MILLION m3/D

GAS PRESSURE, MPA (GAUGE)

Figure 3A
GAS PIPE SIZING GRAPH FOR PRESSURE DROP
OF 23 KPA PER 100 METERS - SI UNITS
 18B
GAS PIPE SIZING GRAPH - ENGLISH UNITS
500 500

400 400
ipe
i nP
18 e
300
in Pip 300
16
e
in Pip
200 14 200
e
n Pip
150 12 i 150

Pipe
100 10 i n 100
90 90
80 80
GAS FLOW RATE, MMCF/D

70 ipe 70
8 in P
60 60

50 50

40 40
ipe
6 in P
30 30

20 20

15 15
e
4 in Pip

10 10
9 9
8 8
7 7
ipe
6 3 in P 6
5 5

4 4

3 3

2 2
0 100 200 300 400 500 600 700 800 900 1000 1100 1200

GAS PRESSURE, PSIG

Figure 3B
GAS PIPE SIZING GRAPH FOR PRESSURE DROP
OF 1 PSI PER 100 FEET - ENGLISH UNITS
 19
GAS PIPING
700 000 m3/d
[25 MMcf/d]
2000 kPa
[290 psi] 4°C
[40°F]

4400 kPa
COMPRESSOR [640 psi]
77°C
[200°F]

ACTUAL VOLUME EQUATION ( )( )( )

( )

ACTUAL SUCTION VOLUME ( )( )( )

( )

= _______________

SUCTION PIPE SIZE ___________

ACTUAL DISCHARGE VOLUME ( )( )( )

( )

= _______________

DISCHARGE PIPE SIZE ______________

PIPE SIZE FROM GRAPH USEDS STANDARD GAS VOLUME AND NOT
ACTUAL VOLUME.
 20A
LIQUID FLOW SYSTEMS - SI UNITS

DETERMINE SIZE OF PIPE AND PUMP FOR THE FOLLOWING

1000 kPa
1700 kPa

12 m
LC

REL. DEN. = 0.67

380 ltr/min
SEPARATOR

FRACTIONATOR

CONTROL
PUMP VALVE
∆P = 70 kPa
THE TOTAL PRESSURE THAT THE PUMP HAS TO OVERCOME:
1. PRESSURE DROP ACROSS THE CONTROL VALVE.
2. PRESSURE DROP IN THE PIPING.
3. LIQUID HEAD PRESSURE BETWEEN SEPARATOR AND FRACTION-
ATOR.
4. DIFFERENCE IN PRESSURE BETWEEN THE SEPARATOR AND
FRACTIONATOR.
PIPE SIZE AT DESIGN FLOW = _________________________
EQUIVALENT LENGTH OF 88.9 MM PIPE:
FITTING QUANTITY PER FITTING TOTAL
LONG RADIUS ELL 6 2M 12 M
BALL VALVE 3 1M 3M
CHECK VALVE 1 8M 8M
TOTAL EQUIVALENT LENGTH OF PIPE 23 M
LENGTH OF STRAIGHT PIPE 50 M
TOTAL EQUIVALENT PIPE 73 M
ALLOWABLE PRES. DROP IN PIPING 23 KPA/100 M
73
PRESSURE DROP IN 73 M OF PIPING =23 X 100
= 16.8 KPA
 20B
LIQUID FLOW SYSTEMS - ENGLISH UNITS

DETERMINE SIZE OF PIPE AND PUMP FOR THE FOLLOWING

145 psi
250 psi

40 ft
LC

REL. DENS. = 0.67

1000 gpm
SEPARATOR

FRACTIONATOR

CONTROL
PUMP VALVE
∆P = 10 psi

THE TOTAL PRESSURE THAT THE PUMP HAS TO OVERCOME:

1. PRESSURE DROP ACROSS THE CONTROL VALVE.
2. PRESSURE DROP IN THE PIPING.
3. LIQUID HEAD PRESSURE BETWEEN SEPARATOR AND FRAC-
TIONATOR.
4. DIFFERENCE IN PRESSURE BETWEEN THE SEPARATOR AND
FRACTIONATOR.
PIPE SIZE AT DESIGN FLOW = _________________________
EQUIVALENT LENGTH OF 3 IN. PIPE:
FITTING QUANTITY PER FITTING TOTAL
LONG RADIUS ELL 6 6 FT 36 FT
BALL VALVE 3 2 FT 6 FT
CHECK VALVE 1 25 FT 25 FT
TOTAL EQUIVALENT LENGTH OF PIPE 67 FT
LENGTH OF STRAIGHT PIPE 165 FT
TOTAL EQUIVALENT PIPE 232 FT
ALLOWABLE PRES. DROP IN PIPING I PSI/100 FT
232
PRESSURE DROP IN 232 FT OF PIPING = 1 X 100
= 2.32 PSI
 21A
LIQUID FLOW SYSTEM - SI

1000 kPa

12 m
1700 kPa

LC

REL. DENS. = 0.67

380 ltr/min
SEPARATOR

FRACTIONATOR

CONTROL
PUMP VALVE
∆P = 70 kPa

LIQUID HEAD PRESSURE = (HT, M) X (REL DENS) X (9.8)

= 12 X 0.67 X 9.8
= 78.8 KPA
PRES DIFF BETWEEN 1700 - 1000
SEPR. AND FRACT. = 700 KPA
TOTAL PRESSURE PUMP DELIVERS:
CONTROL VALVE ∆P 70.0 KPA
PIPING PRES. DROP 16.8 KPA
LIQUID HEAD PRES. 78.8 KPA
PRES. DIFF. 700.0 KPA
TOTAL 865.6 KPA
CALL IT 866 KPA
 21B
LIQUID FLOW SYSTEM - ENGLISH

145 psi

250 psi

40 ft
LC

REL. DENS. = 0.67

1000 gpm
SEPARATOR

FRACTIONATOR

CONTROL
PUMP VALVE
∆P = 10 psi

LIQUID HEAD PRESSURE = (HT, FT) X (REL DENS) X (0.43)

= 40 FT X 0.67 X 0.43
11.5 PSI
PRES DIFF BETWEEN 250 - 145
SEPR. AND FRACT. = 105 PSI
TOTAL PRESSURE PUMP DELIVERS:
CONTROL VALVE ∆P 10.00 PSI
PIPING PRES. DROP 2.32 PSI
LIQUID HEAD PRES. 11.50 PSI
PRES. DIFF. 105.00 PSI
TOTAL 128.82 PSI
CALL IT 130 PSI
 22A
LIQUID FLOW SYSTEM - SI UNITS

1000 kPa

12 m
1700 kPa

LC

REL. DENS. = 0.67

380 ltr/min
SEPARATOR

FRACTIONATOR

CONTROL
PUMP VALVE
∆P = 70 kPa

PUMP POWER = 0.0017 X (∆P, KPA) X (FLOW, L/M)

EFFICIENCY, %
∆P IS THE DIFFERENTIAL PRESSURE PUT UP BY THE PUMP. IT EQUALS THE
DISCHARGE PRESSURE MINUS THE SUCTION PRESSURE.
A PUMP WILL BE BOUGHT FOR A HIGHER FLOW AND DIFFERENTIAL PRES-
SURE THAN DESIGN.
DESIGN PUMP FLOW RATE 415 LTR/MIN
DESIGN PUMP ∆P 1000 KPA
EFFICIENCY 75%
SUBSTITUTE IN 0.0017 (1000) X (415)
POWER EQUATION 75
= 9.4 KW
STANDARD SIZE MOTOR = 11 KW
PIPING PRES DROP WAS 16.8 KPA
PUMP POWER TO OVERCOME (0.0017) (16.8) (415)
PIPE PRES DROP 75
= 0.16 KW
 22B
LIQUID FLOW SYSTEM - ENGLISH UNITS

145 psi

250 psi

40 ft
LC

REL. DENS. = 0.67

1000 gpm
SEPARATOR

FRACTIONATOR

CONTROL
PUMP VALVE
∆P = 10 psi

PUMP POWER = 0.058 (∆P, PSI) X (FLOW, GPM)

EFFICIENCY, %
∆P IS THE DIFFERENTIAL PRESSURE PUT UP BY THE PUMP. IT EQUALS THE
DISCHARGE PRESSURE MINUS THE SUCTION PRESSURE.
A PUMP WILL BE BOUGHT FOR A HIGHER FLOW AND DIFFERENTIAL PRES-
SURE THAN DESIGN.
DESIGN PUMP FLOW RATE 110 GPM
DESIGN PUMP ∆P 145 PSI
EFFICIENCY 75%
SUBSTITUTE IN 0.058 (145) X (110)
POWER EQUATION 75
12.3 HP
STANDARD SIZE MOTOR 15 HP
PIPING PRES DROP WAS 2.3 PSI
PUMP POWER TO OVERCOME 0.058 (2.3) (110)
PIPE PRES DROP 75
= 0.2 HP
 23
LIQUID FLOW SYSTEM
1200 kPa
[174 psi]

Flow = 900 ltr/min [240 gpm]

Relative Density of Propane = 0.5
PROPANE
STORAGE
1400 kPa
TANK

[33 ft]
10 m
[203 psi]
PUMP

50m
[165 ft]

THE PRESSURE THAT THE PUMP MUST OVERCOME EQUALS:

1. THE PRESSURE DROP IN PIPING.

2. THE LIQUID HEAD PRESSURE, WHICH IS NEGATIVE BECAUSE LIQUID IS
FLOWING DOWNHILL.
3. THE DIFFERENCE IN PRESSURE BETWEEN TANK AND TRUCK.

PIPE SIZE _____________

EQUIVALENT LENGTH OF FITTINGS:

FITTING QUANTITY PER FITTING TOTAL

LR ELL 8 __________ _____
TEE 1 __________ _____
BALL VALVE 4 __________ _____
CHECK VALVE 1 __________ _____
STRAIGHT PIPE _____
TOTAL EQUIVALENT PIPE _____

PRESSURE DROP IN PIPE ( )X( ) = ______

( )
 24
LIQUID FLOW SYSTEM
1200 kPa
[174 psi]

Flow = 900 ltr/min [240 gpm]

Relative Density of Propane = 0.5
PROPANE
STORAGE
1400 kPa
TANK

[33 ft]
10 m
[203 psi]
PUMP

50m
[165 ft]

CALCULATE LIQUID HEAD PRESSURE

LIQ. HEAD PRESSURE EQUATION: ( )( )( )
SUBSTITUTE IN EQUATION: ( )( )( )
= ____________
DIFFERENCE IN OPERATING PRESSURE
OF TRUCK AND TANK _______ - _______ = _______
TOTAL PRESSURE PUMP MUST DELIVER:
PIPING PRESSURE DROP _________
LIQUID HEAD PRESSURE - _________
DIFF. IN OPER. PRESSURES _________
TOTAL _________
PUMP WITH SAFETY FACTOR WILL HAVE CAPACITY OF ______ AND PRES-
SURE RISE OF ______
PUMP POWER EQUATION ( )( )( )
( )
SUBSTITUTE IN EQUATION ( )( )( )
( )
 25
LIQUID FLOW SYSTEM

1200 kPa
[174 psi]

Flow = 900 ltr/min [240 gpm]

Relative Density of Propane = 0.5
PROPANE
STORAGE
1400 kPa
TANK

[33 ft]
10 m
[203 psi]
PUMP

50m
[165 ft]

LIQUID HEAD PRESSURE IS ________

PIPING PRESSURE DROP IS ________
DIFFERENCE ________

SINCE TRUCK IS LOWER THAN THE TANK, LIQUID WILL FLOW AT DESIGN
RATE IF THE DIFFERENCE IN TRUCK PRESSURE AND TANK PRESSURE IS
LESS THAN ___________.
 26
LIQUID FLOW SYSTEM

15 kPa 200 kPa

[2 psi] [29 psi]
To
Oil
Pressure Pipeline
Crude Oil Flow
Oil Pump Meter Regulator
Storage Tank
Rel Dens = 0.80 Eff = 75% 160 m3/hr
[24 000 b/d]
∆P = 7 kPa [1 psi]

PUMP DISCHARGE PRESSURE WILL EQUAL 200 KPA [29 PSI] PLUS PRES-
SURE DROP IN DISCHARGE PIPING AND PRESSURE DROP ACROSS FLOW
METER.

PIPE SIZE ____________

EQUIVALENT LENGTH OF DISCHARGE PIPING.

FITTING QUANTITY PER FITTING TOTAL

L.R. ELL 3 ______ ______
BALL VALVE 1 ______ ______
CHECK VALVE 1 ______ ______
STRAIGHT PIPE 6 M [20 FT] ______
TOTAL ______
PRESSURE DROP IN PIPING ( )( )= ______
( )

PRESSURE DROP ACROSS FLOW METER ______

PRESSURE DOWNSTREAM OF FLOW METER ______
PUMP DISCHARGE PRESSURE ______
PUMP SUCTION PRESSURE ______
PRESSURE PUMP DEVELOPS ______
 27
LIQUID FLOW SYSTEM

15 kPa 200 kPa

[2 psi] [29 psi]
To
Oil
Pressure Pipeline
Crude Oil Flow
Oil Pump Meter Regulator
Storage Tank
Rel Dens = 0.80 Eff = 75% 160 m3/hr
[24 000 b/d]
∆P = 7 kPa [1 psi]

PUMP POWER = ( )( )( )
( )

SUBSTITUTE IN EQUATION = ( )( )( ) = ________

( )

FITTING QUANTITY PER FITTING TOTAL

L.R. ELL 4 ______
BALL VALVE 2 ______
STRAIGHT PIPE 6 M [20 FT] ______
TOTAL ______
PRESSURE DROP IN PIPING ( )( )= ______
( )

PRESSURE SUCTION PRESSURE ______

LIQUID HEAD PRESSURE ______
LIQUID HEAD PRESSURE EQUATION: PRES. = ( )( )( )
SUBS. IN EQUATION: _________ = ( )( )( )
REARRANGE EQUATION; HEIGHT = ( ) ‘
( )( )
= _______________
 27A
GAS FLOW SYSTEM - SI
COMPRESSOR SUCTION PRESSURE CALCULATION
60 m

4 million m3/d

2000 kPa

COMPRESSOR

60 m 5520 kPa
GAS COOLER

SEPARATOR
PIPELINE
∆P = 50 kPa

SUCTION PRESSURE = SEPARATOR PRESSURE - PRESSURE DROP IN PIPING.

PIPE DIAMETER AT 2000 KPA & 4 MILLION M3/D = 355.6 MM

EQUIVALENT LENGTH OF 355.6 MM PIPE.

FITTING QUANTITY PER FITTING TOTAL

LONG RADIUS ELL 5 5M 25 M
TEE 2 19 M 38 M
PLUG VALVE 1 24 M 24 M
87 M

LENGTH OF STRAIGHT PIPE 60 M

TOTAL EQUIVALENT LENGTH OF PIPE 147 M
PRESSURE DROP IN PIPING @ 23 KPA/100 M 147
= 23 X 100 = 34 KPA

PRESSURE IN SUCTION SCRUBBER 2000 KPA

LESS PRESSURE DROP IN PIPING 34 KPA
SUCTION PRESSURE AT COMPRESSOR 1966 KPA
 27B
GAS FLOW SYSTEM - ENGLISH
COMPRESSOR SUCTION PRESSURE CALCULATION
150 ft

148 MMcf/d

290 psi

COMPRESSOR
200 ft 800 psi
GAS COOLER

SEPARATOR
PIPELINE
∆P = 7 psi
SUCTION PRESSURE = SEPARATOR PRESSURE - PRESSURE DROP IN PIPING.

PIPE SIZE @ 290 PSI AND 148 MMCF/D = 14 INCH

EQUIVALENT LENGTH OF 14 IN PIPE.

FITTING QUANTITY PER FITTING TOTAL

LONG RADIUS ELL 5 16 FT 80 FT
TEE 2 62 FT 124 FT
PLUG VALVE 1 80 FT 80 FT
284 FT

LENGTH OF STRAIGHT PIPE 150 + 125 = 275 FT

TOTAL EQUIVALENT LENGTH OF PIPE 559 FT
PRESSURE DROP IN PIPING @ 1 PSI/100 FT 559
= 5.59 PSI
100
PRESSURE IN SUCTION SCRUBBER 290 PSI
LESS PRESSURE DROP IN PIPING 5.59 PSI
SUCTION PRESSURE AT COMPRESSOR 284.4 PSI
 28A
GAS FLOW SYSTEM - SI
COMPRESSOR DISCHARGE PRESSURE CLACULATION
60 m

4 million m3/d

2000 kPa

COMPRESSOR

60 m 5520 kPa
GAS COOLER

SEPARATOR
PIPELINE
∆P = 50 kPa
DISCHARGE PRES = PIPELINE PRES + PRES DROP IN PIPING AND COOLER.
PIPE SIZE @ 5520 KPA & 4 MILLION M3/D = 323.85 MM

EQUIVALENT LENGTH OF FITTING

FITTING QUANTITY PER FITTING TOTAL
LONG RADIUS ELL 6 4M 24 M
TEE 2 17 M 34 M
PLUG VALVE 1 52 M 24 M
TOTAL 110M
LENGTH OF STRAIGHT PIPE 60 M
TOTAL EQUIVALENT LENGTH OF PIPE 170 M
PRESSURE DROP IN PIPING @ 23 KPA/100 M 170
= 23 X = 39 KPA
100
PRESSURE DROP IN COOLER 50 KPA
PRESSURE DROP IN DISCHARGE LINE 39KPA
PRESSURE DROP IN DISCH. PIPING 89 KPA
PRESSURE IN PIPELINE 5520 KPA
PRES. AT DISCHARGE OF COMPRESSOR 5609 KPA
 28B
GAS FLOW SYSTEM - ENGLISH
COMPRESSOR DISCHARGE PRESSURE CALCULATION
150 ft

148 MMcf/d

290 psi

COMPRESSOR
200 ft 800 psi
GAS COOLER

SEPARATOR
PIPELINE
∆P = 7 psi

DISCHARGE PRES = PIPELINE PRES + PRES DROP IN PIPING AND COOLER.

PIPE SIZE @ 800 PSI AND 148 MMCF/D = 12 INCH

EQUIVALENT LENGTH OF FITTING

FITTING QUANTITY PER FITTING TOTAL
LONG RADIUS ELL 6 14 FT 84 FT
TEE 2 55 FT 110 FT
PLUG VALVE 1 170 FT 170 FT
TOTAL 364 FT

LENGTH OF STRAIGHT PIPE 200 FT

TOTAL EQUIVALENT LENGTH OF PIPE 564 FT
PRESSURE DROP IN PIPING @ 1 PSI/100 FT 564
100 = 5.6 PSI
PRESSURE DROP IN COOLER 7.0 PSI
PRESSURE DROP IN DISCHARGE LINE 12.6 PSI
PRESSURE IN PIPELINE 800 PSI
PRES. AT DISCHARGE OF COMPRESSOR 812.6 PSI
 29A
GAS FLOW SYSTEM - SI
COMPRESSOR POWER
60 m

4 million m3/d

2000 kPa

COMPRESSOR

60 m 5520 kPa
GAS COOLER

SEPARATOR
PIPELINE
∆P = 50 kPa

COMPRESSOR POWER = 550 (DISCH PRES + 100) (MILLION M3/D

SUCTION PRESSURE + 100
SUBSTITUTE PRESSURES 550 (5609 + 100) (4)
AND FLOW RATE: 1966 + 100
= 6079 KW
CALCULATE POWER IF THERE WERE NO PRESSURE DROP IN PIPING
SUCTION PRESSURE 2000 KPA
DISCHARGE PRESSURE 5520 + 50
= 5570 KPA
SUBST IN POWER EQUATION (550) (5570 + 100) (4)
2000 + 100
= 5940 KW

POWER USED TO OVERCOME PIPING ∆P = 6079 - 5940 = 139

ANNUAL UNIT FUEL COST $250 PER KW
TOTAL ANNUAL COST 250 X 128
= $34 750/YR
 29B
GAS FLOW SYSTEM - ENGLISH
150 ft

148 MMcf/d

290 psi

COMPRESSOR
200 ft 800 psi
GAS COOLER

SEPARATOR
PIPELINE
∆P = 7 psi

COMPRESSOR POER EQUATION: 21 (DISCH. PRES + 15) (MMCF/D)

SUCTION PRES + 15

SUBSTITUTE PRESSURES 21 (812.6 + 15) (148)

AND FLOW RATE: 284.4 + 15
= 8591 HP
CALCULATE POWER IF THERE WERE NO PRESSURE DROP IN PIPING
SUCTION PRESSURE 290 PSI
DISCHARGE PRESSURE 800 + 7
= 807 PSI
SUBST IN POWER EQUATION (21) (807 + 15) (148)
290 + 15
= 8376 HP

POWER USED FOR PIPING 8591 - 8376

PRESSURE DROP = 215 HP
ANNUAL UNIT FUEL COST $200 PER HP
TOTAL ANNUAL COST 200 X 215
= $43,000/YR
 30A
SI UNITS
1800 KPA

REFRIGERATION CONDENSER
100 KPA
COMPRESSOR

3
280 000 M /D
SURGE TANK

CHILLER

550 (DISCH PRES + 100) M3/D X 106

POWER EQUA. KW =
(SUCT PRES + 100)
SUCTION PRESSURE 100 KPA
DISCHARGE PRESSURE 1800 KPA
FLOW RATE 0.28 X 106 M3/D
550 (1800 + 100) 0.28
SUBST. IN EQUATION 100 + 100
= 1463 KW
SUPPOSE, PRESSURE DROP IN SUCTION LINE IS 7 KPA. THE SUCTION PRES-
SURE WILL BE 93 KPA.
550 (1800 + 100) 0.28 = 1516 KW
POWER = 93 + 100
POWER DIFFERENCE 1516 - 1463 = 53 KW

IN THIS OPERATION, SUCTION PIPE PRESSURE DROP TAKES 10 TIMES AS

MUCH POWER AS DISCHARGE PIPE PRESSURE DROP.
 30B
ENGLISH UNITS

261 PSI

REFRIGERATION CONDENSER
14.5 PSI
COMPRESSOR

10 MMCF/D

SURGE TANK

CHILLER

21 (DISCH PRES + 15) X (MMCF/D)

POWER EQUA. HP = (SUCT PRES + 15)
SUCTION PRESSURE 14.5 PSI
DISCHARGE PRESSURE 261 PSI
FLOW RATE 10 MMCF/D
21 (261 + 15) (10)
SUBST. IN EQUATION 14.5 + 15
= 1965 HP
SUPPOSE, PRESSURE DROP IN SUCTION LINE IS 1 PSI. THE SUCTION PRES-
SURE WILL BE 13.5 PSI.
21 (261 + 15) (10) = 2034 HP
POWER = 13.5 + 15
POWER DIFFERENCE 2034 - 1965 = 69 HP

IN THIS OPERATION, SUCTION PIPE PRESSURE DROP TAKES 10 TIMES AS

MUCH POWER AS DISCHARGE PIPE PRESSURE DROP.
 31

DIFFERENTIAL
PRESSURE GAUGE

COMPRESSOR
SEPARATOR

PRESSURE DROP MEASUREMENT IN PIPING

SUMMARY

1. SIZE OF PIPING MAY LIMIT FLOW IN A PLANT.

2. MAXIMUM VELOCITY OF FLUID FLOWING IN PIPE IS SONIC VELOCITY
— 340 M/S [1115 FT/SEC].
3. OPERATING AT FLOWS ABOVE DESIGN WILL INCREASE LOADS ON
PUMPS AND COMPRESSORS.
 32A
EQUIVALENT LENGTH OF VALVES
AND FITTING IN METERS

NOMINAL PIPE SIZE, OUTSIDE DIAMETER MM

60.325 88.9 114.3 168.275 219.075 273.05 323.85 355.6
FITTING 2 3 4 6 8 10 12 14

GLOBE VALVE 21 30 40 60 80 100 120 137

ANGLE VALVE 10 15 20 30 38 49 58 64

SWING CK VALVE 5 8 10 15 20 24 29 32

PLUG VALVE 4 5 9 21 37 52 52 24

GATE OR BALL
VALVE 1 1 1 2 2 2 3 3

45° WELD ELL 1 1 1 2 2 2 3 3

SHORT RAD.
WELD ELL 1 2 2 3 4 5 6 8

LONG RAD.
WELD ELL 1 1 2 2 3 4 4 5

WELD TEE,
SIDE ENTRY 3 4 6 9 11 14 17 19

EXAMPLE

A PLUG VALVE IN 168.275 MM PIPE HAS A PRESSURE DROP EQUIVALENT

TO 21 M OF STRAIGHT PIPE.
 32B
EQUIVALENT LENGTH OF VALVES
AND FITTING IN FEET

NOMINAL PIPE SIZE, INCHES

FITTING 2 3 4 6 9 10 12 14 16 18

GLOBE VALVE 70 100 130 200 260 330 400 450 500 550

ANGLE VALVE 33 50 65 100 125 160 190 210 240 280

SWING CK VALVE 17 25 32 48 64 80 95 105 120 140

PLUG VALVE 14 17 30 70 120 170 170 80 145 160

GATE OR BALL
VALVE 2 2 3 4 6 7 9 10 11 12

45° WELD ELL 2 2 3 4 6 7 9 10 11 12

SHORT RAD.
WELD ELL 4 6 7 11 15 18 22 26 29 33

LONG RAD.
WELD ELL 3 4 5 8 9 12 14 16 18 20

WELD TEE,
SIDE ENTRY 10 14 19 28 37 47 55 62 72 82

EXAMPLE

A PLUG VALVE IN 6 IN. PIPE HAS A PRESSURE DROP EQUIVALENT TO 70 FT

OF STRAIGHT 6 IN. PIPE.
 FLUID FLOW VALIDATION
2nd Edition Answers
Trainee __________________
SI UNITS
Scoring A propane refrigeration system is shown below.
10 1. What is the actual volume of gas at the intake of the compressor?
0.35 x (170 000) x (273 -18) = 56 194 m3/d
—————————————
____________________________________________
170 + 100
10 2. 14 518 m3/d
What is the actual gas volume at the discharge? ___________________________
1500 = 5.55. Power = 5.55 x 550 x 0.17 = 519 kW
G.R. = ———
15 3. What is the compressor power?_________________________________________
270
10 4. 6” - 168.275 mm, 7.112 mm thick
What size and thickness suction line should be used? _______________________
10 5. 4” - 114.3 mm, 6.020 mm thick
What size and thickness discharge line should be used? _____________________
10 6. What size and thickness liquid line should be used for a pressure drop of
4” - 114.3 mm, 6.020 mm thick
23 kPa/100 m? _____________________________________
7. The level of propane in the surge tank is 3 m above the level in chiller. There is 30 m of
piping between the surge tank and chiller. Valves and fittings are equivalent to 20 m of
piping.
10 a. What is the pressure drop in the piping between the surge tank and the expansion
(30
————+ 20) x 23 = 11.5 kPa
valve? ___________________________________________________
100
10 b. What is liquid head pressure of propane (Relative Density = 0.5)?
3 x 0.5 x 9.8 = 14.7 kPa
_________________________________________
10 c. What will the pressure gauge at the expansion valve read?
Total 95 1350 + 14.7 - 11.5 = 1353.2 kPa
_________________________________________

PROPANE REFRIGERATION SYSTEM

 FLUID FLOW VALIDATION
2nd Edition Answers
Trainee __________________
ENGLISH UNITS
Scoring A propane refrigeration system is shown below.
10 1. What is the actual volume of gas at the intake of the compressor?
0.028 x 6.0 x (460 + 0) = 1.84 MMcf/d
____________________________________________
27 + 15
0.028 x 6.0 x (460 + 200) = 0.516 MMcf/d
10 2. 200 + 15
What is the actual gas volume at the discharge? ___________________________
9 3. 6 in, sch 40, class 150
What size and thickness suction line should be used? _______________________
9 4. 4 in, sch 40, class 150
What size and thickness discharge line should be used? _____________________
5. What size and thickness liquid line should be used for a pressure drop of
9 4 in, sch 40 class 150
1 psi/100 ft? _____________________________________
6. The level of propane in the surge tank is 10 ft above the level in chiller. There is 100 ft of
piping between the surge tank and chiller. Valves and fittings are equivalent to 60 ft of
piping.
5 a. What is the pressure drop in the piping between the surge tank and the expansion
valve? (100 + 60) x 1 ÷ 100 = 1.6 psi
___________________________________________________
10 b. What is liquid head pressure of propane (Relative Density = 0.5)?
10 x 0.5 x 0.43 = 2.15 psi
_________________________________________
5 c. What will the pressure gauge at the expansion valve read?
Total 67 192 + 2.15 - 1.6 = 192.55 psi
_________________________________________

PROPANE REFRIGERATION SYSTEM