Course Title: Line Sizing Fundamentals for Process Engineers

þ Course Objectives:
 Understand the principles of fluid flow in pipelines.
 Learn how to perform line sizing calculations for liquids, gases, and two-phase flows.
 Apply industry standards (like API, ASME, ISO) to line sizing decisions.
 Evaluate pressure drop, velocity limits, and safety considerations in pipeline design.
þ Course Structure:
Module 1: Introduction to Line Sizing
 What is line sizing?
 Importance in process design and safety.
 Overview of fluid types: Liquid, Gas, and Multiphase.

Module 2: Fluid Flow Fundamentals

 Bernoulli’s Equation and Continuity Equation.
 Laminar vs Turbulent flow.
 Reynolds number, friction factor.

Module 3: Line Sizing for Liquids

 Velocity and pressure drop criteria.
 Allowable velocities (per fluid type and pipe material).
 Hazen-Williams and Darcy-Weisbach equations.
 Example calculation: Sizing a water line.

Module 4: Line Sizing for Gases

 Compressibility and ideal gas law applications.
 Isothermal and adiabatic flow models.
 Choked flow and Mach number considerations.
 Pressure drop in long pipelines.
 Example calculation: Natural gas pipeline.

Module 5: Line Sizing for Two-Phase Flow

 Types of two-phase flow (slug, annular, stratified).
 Flow pattern maps (e.g., Baker's map).
 Homogeneous vs separated flow models.
 Empirical correlations (Lockhart-Martinelli, Dukler).
 Safety margins in two-phase systems.

Module 6: Industry Standards & Guidelines

 API 14E: Design and Installation of Offshore Production Platform Piping Systems.
 ASME B31.3: Process Piping.
 ISO standards related to fluid transport.
 Velocity and pressure drop limits per service.

Module 7: Software and Tools

 Use of simulation tools (e.g., AFT Fathom, PipeFlow Expert, Aspen HYSYS).
 Spreadsheets for line sizing.
 Reading P&IDs and understanding line numbers.

Module 8: Practical Case Studies

 Case Study 2: Natural Gas Distribution Network.
 Case Study 3: Cooling Water Line in Power Plant.
 Troubleshooting oversized and undersized lines.

Module 9: Assessment and Certification

 Mock exam and practical line sizing assignment.
 Certification quiz.
Module 1: Introduction to Line Sizing
1.1 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.

1.2 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.
The sizing is based on a balance of fluid dynamics, cost efficiency, and safety. A correctly sized line ensures:
 Sufficient flow rate.
 Acceptable pressure drop
 Prevents erosion, vibration, or cavitation.
 Maintains economic feasibility.

1.3 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.

1.4 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):
1. The reduction in pressure as fluid flows through a pipeline due to friction and fittings.
2. Excessive pressure drop increases pumping or compression costs.

1.5 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.

1.6 Importance in Process Design and Safety:

Correct line sizing is critical in engineering for both performance and safety reasons. Here's why:
Performance:
 Ensures that the process receives the required flowrate of the fluid.
 Helps maintain system pressure levels to avoid underperformance or inefficiencies.
 Avoids high velocities that may lead to noise, vibration, or erosion.

Cost Considerations:
 An oversized pipe increases capital cost (larger diameter, more material, higher support cost).
 An undersized pipe may require additional pumping power and can cause pressure drops or flow limitations.
Safety:
 Reduces risks of pipe rupture, flashing, or cavitation in liquid lines.
 Prevents choked flow and high-velocity gas erosion in gas lines.
 Ensures emergency shutdown systems function as intended (e.g., flare headers or relief systems).
Operational Efficiency:
 A properly sized line extends equipment life and reduces maintenance frequency.
 Maintains proper flow regime for instrument accuracy and control systems

1.7 Overview of Fluid Types

A. Liquids
 Incompressible (density doesn’t change much with pressure).
 Common fluids: water, oil, chemicals.
 Flow governed by pressure difference and pipe resistance.
 Key concern: pressure drop, pumping power, cavitation risk.

B. Gases
 Compressible (volume and density vary with pressure/temperature).
 Common gases: air, natural gas, steam, nitrogen.
 Line sizing requires consideration of expansion, choked flow, and Mach number.
 Key concern: velocity control (to avoid erosion and noise), pressure loss due to compression.

C. Multiphase Fluids
 Mixture of two or more phases: liquid-liquid, gas-liquid, gas-solid, etc.
 Common in oil & gas: wet gas, gas-condensate, oil with water, etc.
 Complex flow regimes: slug, annular, bubble, stratified.
 Line sizing involves empirical models (e.g., Lockhart-Martinelli) and safety margins.

Example:
 If you are designing a pipeline for cooling water in a refinery:
 If the line is too small: high velocity causes erosion of elbows, pump needs to work harder.
 If the line is too big: unnecessary cost for pipe material and supports, slower flow may cause sedimentation.

Concept Key Points

What is line sizing? Determining optimal pipe diameter for safe, efficient fluid transport.
Why it's important Affects cost, performance, safety, energy use, and maintenance.

Fluid Types Liquids (incompressible), Gases (compressible), Multiphase (complex behavior)

Module 2: Fluid Flow Fundamentals
2.1. Continuity Equation
What it is:
The continuity equation is based on the conservation of mass. For incompressible flow (constant density), it states
that:
A1V1=A2V2A_1 V_1 = A_2 V_2A1V1=A2V2
Where :A = cross-sectional area of the pipe
V = fluid velocity
Key Takeaway:
As pipe diameter decreases, velocity increases (and vice versa).
Critical for understanding how flow rate behaves through varying pipe sizes.
2.2 Bernoulli’s Equation
🔍 What it is:
Bernoulli’s equation describes the conservation of mechanical energy in fluid flow:
Static pressure + Dynamic pressure = Total pressure

P +ρV^2 + ρgh ={constant}

Where: P = pressure
ρ = fluid density
V = fluid velocity
g = gravitational acceleration
h = elevation head

Use in Line Sizing:

1.Predict pressure loss or gain between two points.
2.Evaluate the impact of elevation, velocity, or fittings on pressure.
3.Simplified Bernoulli (no elevation): used in horizontal pipe runs.

2.3. Laminar vs Turbulent Flow

Flow Regimes:
A.Laminar Flow: Smooth, orderly fluid motion.
Occurs when Re<2,000
B.Turbulent Flow: Chaotic, mixed flow.
Occurs when Re>4,000
C.Transitional Flow: Between 2000 < Re < 4000

Importance in Line Sizing:

Turbulent flow is common in industrial applications.
Laminar flow results in lower friction but is rare in large pipelines.

2.4. Reynolds Number (Re) :It determines the flow regime.Helps select the appropriate friction factor for pressure
drop calculations.
Re=ρVD/μ
Where:
V = fluid velocity,D= pipe diameter,μ = dynamic viscosity,ν = kinematic viscosity

2.5. Friction Factor (f)

Definition:
The friction factor quantifies resistance to flow due to pipe surface roughness and flow regime.
Laminar Flow: f=64/Re
Turbulent Flow: Methods for finding the friction coefficient f include using a diagram such as the Moody chart, or
solving equations such as the Colebrook–White equation. Also, a variety of empirical equations valid only for
certain flow regimes such as the Hazen – Williams equation, which is significantly easier to use in calculations.
However, the generality of Darcy – Weisbach equation has made it the preferred one.Use the Moody chart or
Colebrook-White equation: for Re>4,000

1/√f=−2log10[(e/3.7D)+2.51/(Re√f)]
Where:ε= pipe roughness
D = pipe diameter
log10= Base-10 logarithm
Key Characteristics
Implicit: fff appears on both sides → can't solve analytically.
Numerical methods (like Newton-Raphson) are typically used.
Applies when Re>4000 (turbulent flow).
Role in Line Sizing:
Friction factor is used in Darcy-Weisbach equation for pressure drop:
hf = f (L/D) x (v 2 /2g)
Accurate pressure drop helps determine optimal pipe diameter.

2.6 Conclusion for Module 2:

This module equips learners with the foundational physics of fluid flow. These concepts are essential for selecting
the right pipe size that ensures sufficient flow rate, minimal energy loss, and operational efficiency in process
systems.
 For laminar flow, f = 16 / Re
 For transitional flow, pipes' flow lies outside this region.
 For smooth turbulent (a limiting line of turbulent flow), all values of relative roughness (ks/d) tend toward this
line as R decreases. Blasius equation: f = 0.079 / R 0.25
 For transitional turbulent, it is the region where (f) varies with both (ks/d) & (Re). Most pipes lie in this region.
 For rough turbulent, (f) is constant for given (ks/d) and is independent of (Re).

Example 1:
Water flows in a steel pipe (d = 40 mm, k = 0.045x10-3 m, µ = 0.001 k/ms) with a rate of 1 lit/s. 53 Determine the
friction coefficient and the head loss due to friction per meter length of the pipe using:
1- Moody chart?
2- Smooth pipe formula?
Solution
v = Q / A = 0.001 / (π (0.04)2 /4) = 0.796 m/s Re = ρ v d / µ = (1000x0.796x0.04) / 0.001 = 31840 > 4000
Turbulent flow.
Moody chart: k/d = 0.045x10-3 / 0.04 = 0.0011 & Re = 31840 
from the chart, f = 0.0065
hf = 4 f LV^2/2 g d
= 4x0.0065x1x(0.796)2/ 2 x9.81x0.04
=0.0209 m / m of pipe

Module 3: Line Sizing for Liquids

3.1 Velocity and Pressure Drop Criteria
Objective:
To ensure that fluid velocity is within acceptable limits and that pressure losses are economically and operationally
feasible.
Typical Allowable Velocity Ranges:
Note: Excessive velocity can cause erosion, vibration, and noise, while very low velocity may lead to sedimentation
or poor flow assurance.

3.2 Pressure Drop Considerations:

 Acceptable pressure drop varies by system and fluid.
 Typical values:
○ 2 to 10 bar/km for general liquid systems
○ 1 psi/100 ft for cooling water or fire water
Fluid Type Recommended Velocity Range Notes

water 1 – 3 m/s To avoid erosion and reduce energy

loss
Oil 1 – 2 m/s Avoid emulsification and pressure loss
Condensate 0.5 – 1.5 m/s Minimize vapor formation
Acid < 1.0 m/s Avoid corrosion/erosion
Cooling Water (Closed Loop) 1.5 – 2.5 m/s Efficiency + minimize fouling
Slurry 2 – 3.5 m/s Avoid settling of solids
 Higher pressure drops increase pumping cost and energy consumption.
3.3 Key Equations
Darcy-Weisbach Equation (used for most liquid flow):
ΔP = f *L*ρ*V^2 / 2*D
Where:
ΔP : Pressure drop (Pa or N/m²)
f: Friction factor (Moody chart or Colebrook equation)
L: Length of pipe (m)
D: Pipe diameter (m)
ρ: Fluid density (kg/m³)
V: Flow velocity (m/s)

3.4 Example Calculation: Water Line Sizing

Problem Statement:
Design a pipeline for water flowing at 100 m³/h over a distance of 300 m, keeping velocity around 2 m/s and
pressure drop acceptable.
Step 1: Convert Flow Rate
Q=100*3600=0.0278 m3/s
Step 2: Estimate Pipe Diameter from Flow & Velocity
Q=A*V=π/4*D^2
D=π/4*0.0278
=0.133 m
=133 mm
Choose standard pipe size DN150 (6") with internal diameter ~154 mm.
Step 3: Use Darcy-Weisbach for Pressure Drop
Let’s assume:
● ρ=1000 kg/m3
● f=0.02 (turbulent water flow, estimated from Moody chart)
● L=300 m
● D=0.154 m
● V=2 m/s
ΔP=0.02*3000*0.154*1000*222
=0.02*1948.05*2000
=77,922 Pa
=0.78 bar

Conclusion:
● A 6" pipe (DN150) keeps the velocity near 2 m/s.
● Pressure drop is ~0.78 bar, acceptable for many pump systems.
Final design may consider pipe material, fittings, elevation changes.
Module 4: Line Sizing for Gases (Detailed View)
4.1. Compressibility and Ideal Gas Law Applications
Ideal Gas Law: PV=nRT
Where:
 P: Pressure (Pa or bar)
 V: Volume (m³)
 n: Moles of gas
 R: Universal gas constant (8.314 J/mol·K)
 T: Temperature (K)
 ρ: Gas density (kg/m³)

Compressibility Factor (Z):

Real gases deviate from ideal behavior at high pressure or low temperature.
The modified ideal gas law:
PV=ZnRTPV
 Z=1Z → Ideal gas
 Use charts or equations (e.g., Standing-Katz) to determine Z.

Application:
 Used to calculate density and mass flow rate, especially at high pressures in pipelines.

4.2. Isothermal and Adiabatic Flow Models

Isothermal Flow (Temperature remains constant):
Used for long gas pipelines where heat exchange with the environment
occurs. ΔP=f*L*ρv2/2D
Or more detailed for ideal gases:
P12−P22=2fLRTD⋅G2P1P2P_1^2 - P_2^2
Where:
f: Darcy friction factor (from Moody chart)
L: Length of pipe
D: Pipe diameter
G: Mass flux
Adiabatic Flow (No heat exchange):
Important when flow is fast or insulated (e.g., gas turbines, compressors).

4.3 Choked Flow and Mach Number Considerations

Mach Number (Ma):
Ma=vc
● V: Flow velocity
● C: Speed of sound in gas

Choked Flow:
Occurs when gas velocity reaches the speed of sound (Ma = 1). At this point, increasing downstream pressure will
not increase flow rate.
Critical Pressure Ratio:
(P2P1)critical=(2k+1)kk−1
Where:
k: Heat capacity ratio Cp/Cv
Choked flow is critical in valve sizing and control orifices.
4.4 Pressure Drop in Long Pipelines
Weymouth Equation (for high-pressure gas pipelines, turbulent flow):
Q=433.5*D*2.667*(P12−P22)fL*T*Z*MW)
Panhandle A / B Equations:
Empirical equations used for natural gas. These consider:
 Pipe diameter
 Length
 Inlet and outlet pressure
 Temperature
 Specific gravity or molecular weight

Velocity Limit Guidelines:

 For compressible flow: Mach < 0.3 is preferred to avoid compressibility effects.
 API 14E recommends velocity limits between 60–100 ft/s (18–30 m/s) depending on service.

4.5. Example Calculation: Natural Gas Pipeline

Problem Statement:
A natural gas pipeline transports gas at 60 bar from a compressor station to a plant 10 km away. The gas
temperature is 35°C, and the pipe ID is 300 mm. Find the flow rate if the outlet pressure is 50 bar. Use the
Weymouth Equation.
Assume:
 Z=0.9
 Molecular weight = 17 g/mol
 Friction factor f=0.015
 Temperature T=308 K

Step 1: Convert Pressure

 P1=60 bar=6,000 kPa
 P2=50 bar=5,000 kPa
Step 2: Pipe Diameter
 D=300 mm=0.3 m

Step 3: Use Weymouth Equation (metric form):

 Q=0.849⋅D2.667⋅P12−P22L⋅Z⋅T⋅M
 D=0.3D
 P12−P22=(602−502)=1100 bar
 L=10 kmL
 T=308 K
 MW=17M
 Z=0.9
Estimate flow rate Q(you can also solve it in Excel or simulation tools).

4.6 Key Takeaways

 Gases require compressibility corrections (use Z-factor).
 Use isothermal models for long-distance piping.
 Choked flow is a limiting condition for design.
 Empirical formulas (like Weymouth, Panhandle) are widely used in gas transmission systems
Module 5: Line Sizing for Two-Phase Flow
Two-phase flow refers to the simultaneous flow of two distinct phases—typically liquid and vapor (e.g.,
steam/water, gas/condensate, oil/gas)—through a pipeline.
 Correct line sizing ensures:
 Safe transport of both phases.
 Avoidance of flow regime transitions that cause vibration, erosion, or slugging.
 Efficient pressure drop control.

5.1 Types of Two-Phase Flow Regimes

The behavior of the phases in the pipe determines the flow pattern or flow regime, influenced by:
 Phase velocities
 Densities
 Pipe diameter
 Inclination (horizontal/vertical)

5.1.1 Major Flow Regimes:

● Stratified Flow: Liquid flows at the bottom and gas on top (in horizontal pipes).
● Slug Flow: Alternating segments of liquid and gas form "slugs"—causing pressure surges.
● Annular Flow: Gas flows in the center, with a liquid film along the pipe wall.
● Bubble Flow: Gas bubbles dispersed in liquid.
● Mist Flow: Fine droplets of liquid entrained in the gas phase.
● Plug Flow: Large bullet-shaped gas pockets push through a continuous liquid stream.

Why it matters: Slug flow can damage equipment due to surges. Mist flow risks poor heat transfer.

5.2 Flow Pattern Maps

Flow pattern maps help determine the regime based on flow conditions.

5.2.1 Common Maps:

● Baker's Map: Based on superficial gas and liquid velocities; widely used in horizontal flow analysis.
● Taitel-Dukler Map: Incorporates pipe inclination.
● Mandhane Map: Used for air-water systems; gives visual classification.

5.2.2 Usage Steps:

1. Calculate superficial velocities:
○ vsg=QgAv
○ vsl=QlAv
2. Locate on map to predict flow regime.

5.2.3. Homogeneous vs. Separated Flow Models

Homogeneous Model:

● Assumes uniform mixture of gas and liquid.

● Single set of properties (density, viscosity) used.
● Simpler but less accurate at high phase slip conditions.

5.2.4. Separated Flow Model:

● Treats phases as separate entities with different velocities.
● More realistic, especially in annular or slug flow.
● Needs flow pattern-dependent correlations.
5.2.5 Empirical Correlations :
Two-phase flow involves complex interactions; so we rely on empirical correlations.
Lockhart-Martinelli Correlation:

● Used for pressure drop in horizontal flow.

● Based on dimensionless Martinelli parameter (X):
● X=(ΔPlΔPg)0.5X = \left( \frac{\Delta P_l}{\Delta P_g} \right)^{0.5}X=(ΔPgΔPl)0.5
● Total pressure drop = ϕ2×ΔPl\phi^2 \times \Delta P_lϕ2×ΔPl

Dukler’s Correlation:

● Accounts for phase interaction and slip.

● Good for stratified and annular flow.
● Often used with flow pattern maps.
Many correlations are flow-regime specific, requiring selection based on pattern maps.

5. 2.6 Safety Margins in Two-Phase Line Sizing

Due to flow complexity, sizing must be conservative to avoid risks like:

● Slugging in downstream vessels.
● Erosion due to high velocities.
● Water hammer in transient operations.

5.2.7 Design Guidelines:

● Use maximum allowable velocities (e.g., API 14E recommends 60 ft/s for gas).
● Maintain liquid holdup and prevent full entrainment of liquid in gas.
● Provide surge volumes for liquid slugs.
● Size separators and receivers to handle phase separation safety.

5.2.8 Summary Table

Concept Description Application

Flow Regime Type of phase distribution Influences pressure drop and equipment wear

Flow Map Visual guide for regime prediction Input: superficial velocities

Homogeneous Model Simple, assumes mixed flow Rough estimates

Separated Model More realistic, uses slip Detailed designs

Lockhart-Martinelli Empirical pressure drop method Horizontal flow

Safety Margin Velocity/slug control Prevents surge, erosion, cavitation

Module 6: Industry Standards & Guidelines
6.1 API 14E – Recommended Practice for Design and Installation of Offshore
Production Platform Piping Systems
6.1.1 Purpose:
API 14E provides guidance specifically for the design of piping systems used in offshore oil and gas
production. It emphasizes reliability and safety in harsh marine environments.

6.1.2 Key Concepts:

● Erosional Velocity Equation:
The most cited formula in API 14E:
V=C2ΔPρV = C \sqrt{\frac{2 \Delta P}{\rho}}V=Cρ2ΔP More commonly,
it's simplified and given as:
V=CρV = C \sqrt{\rho}V=Cρ
where:
V = maximum allowable velocity (ft/s or m/s)
C = empirical constant
ρ = fluid density (lb/ft³ or kg/m³)
● C values:
○ 100 for continuous service of solids-free fluids
○ 60–80 for fluids with sand or solids
○ 40 for severe erosion risk or corrosive fluids
● Line sizing should avoid exceeding erosional velocities to prevent pipe wall thinning due to sand,
corrosion, etc.
● Material compatibility and corrosion allowances are addressed for carbon steel piping in
offshore applications.

6.2 ASME B31.3 – Process Piping

6.2.1 Purpose:
This is the most widely applied code for the design of process piping systems in refineries, chemical plants, and oil
& gas facilities onshore.

6.2.2 Key Concepts:

● Design Pressure and Temperature: Used to determine wall thickness and flange ratings.
● Allowable Stress: Based on material strength and operating conditions.
● Corrosion Allowance: Added to wall thickness depending on expected corrosion rate.
● Wall Thickness Equation (simplified for straight pipe):
t=P⋅D2(S⋅E+P⋅Y)t = \frac{P \cdot D}{2(S \cdot E + P \cdot Y)}t=2(S⋅E+P⋅Y)P⋅D where:
t = required wall thickness
P = design pressure
D = outside diameter
S = allowable stress
E = weld efficiency
Y = temperature-dependent coefficient
● Flexibility and Stress Analysis: Required for piping systems subject to thermal
expansion.
● Hydrostatic Testing: Piping must be tested at 1.5 times design pressure unless
exempted
 6.3 ISO Standards Related to Fluid Transport
6.3.1 Key Standards:
● ISO 15649: Petroleum and natural gas industries — Piping
● ISO 3183: Line pipe for pipeline transportation systems
● ISO 5167: Flow measurement — Orifice plates, nozzles, Venturi tubes

6.3.2 Key Concepts:

● Defines quality assurance, material traceability, and testing methods.
● Emphasis on dimensional tolerances, pressure ratings, and marking.
● Standardizes line sizing across international projects.
● ISO emphasizes risk-based inspection and lifecycle design philosophy.

Service Typical Velocity Notes

Limits

Water (cooling/service) 1.0 – 3.0 m/s To avoid erosion and water hammer

Steam (low pressure) 20 – 30 m/s High velocities acceptable if pipe supports strong

Air (compressed) 10 – 20 m/s Prevents noise, vibration

Natural Gas 10 – 40 m/s Ensure subsonic flow; consider noise/erosion

Crude Oil / Hydrocarbons 1.5 – 3.0 m/s Avoid emulsification and high-pressure drop

Slurry / Multiphase Flow < 1.5 m/s Avoids settling and erosion

6.4 General Guidelines:

● Pressure drop per 100 m is often limited:
○ Liquids: 0.1 – 1 bar/100m
○ Gases: up to 0.3 bar/100m depending on service
● Sudden changes in direction (elbows, tees) increase pressure loss; accounted for in
equivalent length method.

End-of-Module Exercise Ideas:

● Calculate maximum velocity using API 14E for a given gas stream.
● Size a cooling water line using ASME B31.3 wall thickness formula.
● Compare ISO 15649 vs ASME B31.3 design assumptions
Module 7: Software and Tools for Line Sizing
7.1 Use of Simulation Tools
AFT Fathom
● Purpose: Models incompressible fluid systems (liquids).
● Features:
○ Simulates pressure drops, flow distribution.
○ Automatically sizes pipes based on velocity or pressure drop criteria.
○ Visual schematic builder with drag-and-drop interface.
● Application in Line Sizing:
○ Design cooling water systems, chemical process lines, etc.
○ Optimize pump selection and piping diameter.
● Hands-on Exercise: Simulate a cooling water network for a heat exchanger loop.

PipeFlow Expert
● Purpose: Simple interface for liquid flow modeling and pipe network analysis.
● Features:
○ Calculates friction losses using Darcy-Weisbach.
○ Automatic pipe sizing with built-in database of pipe types.
● Application:
○ Small-scale industrial systems, HVAC, water supply.
● Hands-on Exercise: Size a domestic water supply system with 5 branches.

Aspen HYSYS / Aspen Plus

● Purpose: Comprehensive process simulation tool.
● Features:
○ Simulates both steady-state and dynamic processes.
○ Integrates with pipe segment models and pressure drop calculations.
○ Handles complex systems like two-phase and compressible gas flow.
● Application:
○ High-fidelity simulation of oil and gas pipelines, flare systems.
Hands-on Exercise: Use pipe segment in HYSYS to size a natural gas line.

7.2 Spreadsheet Tools for Line Sizing

Custom Excel Tools
● Build custom tools for:
○ Liquid line sizing (velocity or pressure drop basis).
○ Gas line sizing using AGA, Weymouth, Panhandle equations.
○ Two-phase sizing (simplified Lockhart-Martinelli model).
● Include:
○ Pipe roughness, Reynolds number, friction factor calculators.
○ Automatic unit conversion.
● Benefits:
○ Transparent calculations.
○ Quick checks without simulation tools.
● Hands-on Exercise: Develop an Excel sheet to size a water line using the Darcy-
Weisbach equation.
7.3 Reading P&IDs and Understanding Line Numbers
Understanding P&IDs (Piping and Instrumentation Diagrams)
● Elements:
○ Process lines, instruments, control valves, pumps, tanks.
○ Line types: solid for process, dashed for signal, dotted for pneumatic.
● Symbols:
○ ANSI/ISA standard symbols for valves, instruments.
○ Line tags indicating size, material, insulation, service.
Line Numbering System
● Format: e.g., 6"-1001-PW-SS-001
○ 6" – Nominal pipe size
○ 1001 – Line sequence number
○ PW – Service (e.g., Potable Water)
○ SS – Material (e.g., Stainless Steel)
○ 001 – Circuit or loop number
● Helps in identifying pipe specifications quickly.
● Important for traceability during maintenance and shutdown planning.
Hands-on Activity:
● Analyze a sample P&ID and extract:
○ Pipe size and length
○ Line material
○ Service and operating conditions
● Match the extracted data with a spreadsheet or simulation setup.

Learning Outcome for Module 7

● By the end of this module, learners will be able to:
● Use at least one simulation tool (AFT, PipeFlow, or HYSYS) to size a pipeline.
● Build their own spreadsheet tools to validate hand calculations.
● Read and interpret P&IDs and line numbers
● for practical use in design and maintenance

Module 8: Practical Case Studies

This module focuses on applying line sizing principles to real-world systems. Each case study includes process
description, line sizing methodology, calculations, and lessons learned, followed by a troubleshooting guide.

Case Study 1: Crude Oil Line in a Refinery

Scenario:
● Transporting crude oil from a storage tank to a distillation column.
● Distance: 250 meters
● Flow rate: 120 m³/h
● Viscosity: 25 cP
● Density: 850 kg/m³

Objectives:
● Determine optimal pipe diameter.
● Maintain velocity below erosion limit (~2 m/s for crude oil).
● Limit pressure drop to < 0.5 bar.

Approach:
1. Flow regime check using Reynolds number.
 2. Use Darcy-Weisbach equation for pressure drop.
3. Select standard schedule steel pipe (e.g., Schedule 40 carbon steel).
Calculation Snapshot:
● Trial pipe: 4-inch diameter
● Velocity ≈ 1.6 m/s → ✔
● Pressure drop ≈ 0.35 bar → ✔
Outcome:
● Selected 4-inch pipe.
● Added corrosion allowance as per API 14E.
● Included insulation for thermal stability.
●
Case Study 2: Natural Gas Distribution Network
Scenario:
● Distributing natural gas from a compressor to plant utility users.
● Flow rate: 1000 Nm³/h
● Pressure: 8 bar(g) at source, minimum 6 bar(g) at destination
● Temperature: 30°C
● Pipe length: 500 meters

Objectives:
● Avoid choked flow.
● Maintain minimum delivery pressure.
● Control pressure drop within 2 bar.

Approach:
1. Use Ideal Gas Law for gas density at operating conditions.
2. Apply Weymouth or Panhandle equation for high-pressure gas flow.
3. Consider compressibility factor (Z) at 8 bar.

Calculation Snapshot:
● Trial pipe: 3-inch carbon steel pipe
● Pressure drop ≈ 1.6 bar → ✔
● Flow velocity < 30 m/s → ✔

Outcome:
● 3-inch Sch. 40 pipe selected.
● Pressure regulator added at user inlet.
● Future expansion buffer designed.
Case Study 3: Cooling Water Line in a Power Plant
Scenario:
● Circulating cooling water to a heat exchanger.
● Flow rate: 500 m³/h
● Pipe length: 120 meters
● Head loss to be < 1.5 bar
Objectives:
● Maintain velocity between 1.5–3 m/s (to prevent biofouling and erosion).
● Ensure sufficient pressure to overcome heat exchanger losses.
Approach:
1. Use Hazen-Williams equation for water.
2. Determine pipe size and head loss.
3. Include friction losses from elbows and valves.

Calculation Snapshot:
4. 10-inch PVC/steel pipe
5. Velocity ≈ 2.3 m/s → ✔
6. Total head loss ≈ 1.3 bar → ✔
Outcome:
● 10-inch pipe selected with epoxy lining.
● Supports added to minimize vibration.
● Maintenance schedule implemented for strainer cleaning.

Troubleshooting: Oversized vs Undersized Lines

Issue Oversized Line Undersized Line

Symptoms Low velocity, solids settling, high capital cost Excessive pressure drop, high velocity noise,
erosion

Problems Water hammer, slugging in multiphase Risk of pipe failure, flow restriction

Fix Use reducers, flow conditioning, or rerouting Increase pipe size, add booster pump

Tools Flow simulations, ultrasonic flow meters Pressure surveys, vibration monitoring

Module 9: Assessment and Certification

Objectives:

● Reinforce learning through problem-solving.

● Validate practical and theoretical knowledge.
● Prepare learners for real-world line sizing challenges.
● Issue certification based on performance.
Section 9.1: Mock Exam
Format:
● Total Questions: 20–25
● Duration: 60 minutes
● Passing Score: 70%
Types of Questions:
○ Multiple-choice (conceptual & formula-based)
○ Calculation-based (requires working out velocity, pressure drop, etc.)
○ Scenario-based decision-making (choose pipe size from options)
Topics Covered:
1. Fluid Flow Basics
○ Identify flow regime.
○ Apply Reynolds number concepts.
2. Liquid Line Sizing
○ Use of Darcy-Weisbach and Hazen-Williams equations.
○ Select appropriate diameter for given flow rate and pressure drop limits.
3. Gas Line Sizing
○ Calculate velocity and pressure loss for air/natural gas flow.
○ Understand choked flow conditions.
4. Two-Phase Flow
○ Basic interpretation of flow pattern maps.
○ Lockhart-Martinelli correlation questions.
5. Standards and Velocity Limits
API/ASME limits on velocity for various fluids (e.g., 1.5 m/s for water, 15–60 m/s for gases).
6. Engineering Judgement
○ Choose pipe material and size considering erosion, noise, and vibration.

Section 9.2: Practical Line Sizing Assignment

Deliverable:
● A design task with process conditions.
● You will be asked to:
○ Analyze flow data (flow rate, density, viscosity, temperature, pressure).
○ Determine the appropriate pipe size.
○ Justify your selection with calculations.
○ Include pressure drop and velocity checks.
○ Make references to API 14E or ASME B31.3 limits.
Example Assignment Scenario:
“You are tasked with designing a 100-meter carbon steel pipeline to transport 60°C water at 150
m³/hr. The allowable pressure drop is 1 bar, and maximum velocity should not exceed 2 m/s.
Suggest a suitable nominal pipe size and calculate pressure loss using Darcy-Weisbach equation.”
Deliverables must be submitted in:
● Excel or PDF format.
● Include all assumptions, steps, and conclusions.

Section 9.3: Certification Quiz

Quiz Structure:
● Short quiz (10 questions)
● Must score at least 80% to qualify for certification.
● Questions focus on:
○ Safety margins.
○ Standard references (e.g., API 14E limits).
○ Troubleshooting line sizing issues.