Table of Contents

Section 1 Introduction
Section 2 Hydrocarbon Properties
Section 3 Process Data Development
Section 4 Engineering Flow Diagrams
Section 5 Equipment Selection, Sizing & Design
Section 6 Mechanical & Safety Aspects
Section 7 Cost Estimating
Section 8 Process Design Specifications Packages
Equipment Selection,
Sizing & Design
• Process Equipment Categories
• Fluid Flow and Piping
• Pumps and Pumping Systems
• Compressors & Gas Compression
• Heat Exchangers
• Air Coolers
• Fired Heaters
• Process Vessels
• Fractionators
• Reactors
• Ancillary Equipment
 Process Equipment
Categories
• Standardized: Equipment designed and fabricated
to pre-defined sizes, capacities and types. Selection
involves matching required process operating
conditions to standard available designs.
• Customized: Equipment designed and fabricated to
meet specific process conditions and operating
requirements
• Proprietary: Equipment designed and fabricated in
accordance with proprietary know-how and licensed
to meet specific process performance.
 Fluid Flow & Piping

• Fluid Flow Principles

• Pressure Loss Categories
• Pipe Properties
• Sizing Calculation
• Two-Phase Flow
Fluid Flow Principles

• Fluid Flow Regimes

• Laminar (Re < 2000)
• Turbulent (Re > 4000)

• Basic Flow Relations

• Reynolds Number
• Friction Factor
• Darcy Equation
 Fluid Flow Relations

• General Relation:

• Reynolds Number:

• Darcy Equation:

• Friction Factor:
Fluid Flow Relations
 Fluid Flow
Recommended Velocities

Velocity

Fluid Type of flow ft/s m/s

Thin Liquid Gravity flow 0.5 – 1 0.15 – 0.3

Pump inlet 1–3 0.3 – 0.9
Pump discharge 4 – 10 1.2 – 3
Process line 4–8 1.2 – 2.4

Viscous Liquid Pump inlet 0.2 – 0.5 0.06 – 0.15

Pump discharge 0.5 – 2 0.15 – 0.6

Steam 30 – 50 9 – 15
(Saturated)
30 – 100 9 - 30
Air or Gas
Fluid Flow:- Line Sizing
Recommended Velocities
 Fluid Flow:- Line Sizing
Recommended Velocities

Typical Design Velocities for Process System Applications

Service Velocity
ft/s m/s
Average liquid process 4 - 6.5 1.2 - 2
Pump suction (except boiling) 1-5 0.3 - 1.5
Pump suction (boiling) 0.5 - 3 0.15 - 1
Boiler feed water (disch., pressure) 4-8 1.2 - 2.5
Drain lines 1.5 - 4 0.5 - 1.2
Liquid to reboiler (no pump) 2-7 0.6 - 2.1
Vapour-liquid mixture out reboiler 15 - 30 4.5 - 9
Vapour to condenser 15 - 80 4.5 - 25
Gravity separator flows 0.5 - 1.5 0.15 - 0.5
Fluid Flow:- Line Sizing
Recommended Velocities
Fluid Flow:- Line Sizing
Recommended Velocities
Fluid Flow:- Line Sizing
Recommended Velocities
Fluid Flow:- Line Sizing
 Fluid Flow:- Line Sizing

• Define fluid flow rate, properties and conditions

• Select pipe size/schedule and calculate velocity1
• Establish total equivalent pipe length2
• Calculate Re and establish flow regime
• Determine Roughness and Friction Factor
• Calculate ΔP/100m (or ΔP/100ft) and compare
criteria/limits3
• Calculate total ΔP for final pipe size/configuration

1. Or select velocity and calculate pipe size

2. Including estimate of valves and fittings
3. Using Darcy equation. Recalculate size to meet criteria
 Fluid Flow:- Line Sizing
A handy relationship for turbulent flow in commercial
steal pipe:

Holds for a Re number range 4100 to 106. For smooth tubes (heat
exchanger tubeside ΔP, use constant = 23000
 Fluid Flow:- Line Sizing
A handy relationship for turbulent flow in commercial
steal pipe:

Holds for a Re number range 2100 to 106. For smooth tubes (heat
exchanger tubeside ΔP, use constant = 7 x 108
 Fluid Flow:- Line Sizing
Example 1:

You need to install a new line to transfer process condensate from a

knock-out drum (KOD) to the cooling water tower (CWT). The distance
from the KOD to the CWT is 600 m. The pressure in the KOD is
atmospheric and the temperature is 45 ºC. The normal flow rate of the
process condensate is 30 m3/h. At maximum plant load the flow rate is 35
m3/h.

Calculate the line sizes and pressure drop.

Calculate the delivery pressure for a pump to transfer the process
condensate to the CWT.
 Fluid Flow:- Line Sizing
Example 1: Drawing

First prepare a simple PFD of the system:

Cooling Water
KOD FI Tower
LIC
35m3/h max
T = 45ºC

600m
 Fluid Flow:- Line Sizing
Example 1: Line Sizing

Typical Design Velocities for Process System Applications

Service Velocity
ft/s m/s
Average liquid process 4 - 6.5 1.2 - 2
Pump suction (except boiling) 1-5 0.3 - 1.5
Pump suction (boiling) 0.5 - 3 0.15 - 1
Boiler feed water (disch., pressure) 4-8 1.2 - 2.5
Drain lines 1.5 - 4 0.5 - 1.2
Liquid to reboiler (no pump) 2-7 0.6 - 2.1
Vapour-liquid mixture out reboiler 15 - 30 4.5 - 9
Vapour to condenser 15 - 80 4.5 - 25
Gravity separator flows 0.5 - 1.5 0.15 - 0.5

For pump suction, choose flow = 1m/s

For transfer line, choose flow = 2m/s
 Fluid Flow:- Line Sizing
Example 1: Line Sizing cont.

For pump suction, choose flow = 1m/s

For transfer line, choose flow = 2m/s

Sizing of pump suction line:

u = V/A
u = flow velocity = 1 m/s
V = volumetric flow rate = 35/3600 m3/s

1 = (35/3600)/(πd2/4)
d = 0.11m = 4.4”
 use 6” line for suction. u = (35/3600)/(π 0.1542/4) = 0.52 m/s

Similar for discharge line:

2 = (35/3600)/(πd2/4)
d = 0.079m = 3.1”
 use 3” line for discharge. u = (35/3600)/(π 0.0782/4) = 2.03 m/s
 Fluid Flow:- Line Sizing
Example 1: Pressure drop

Discharge Line:
Calculate Reynolds number:

Re = ud/μ
 = density = 1000kg/m3
u = 2.03 m/s
d = 0.078 m
μ = 651 x 10-6 Pa.s
 Re = 1000 x 2.03 x 0.078 / 0.00065 = 2.4 x 10 5
 Turbulent flow

use

W = 35000 kg/h
μ = 0.65 cP
 Fluid Flow:- Line Sizing
Example 1: Pressure drop cont.

ΔP = (35000)1.8 x 0.650.2 / (6 x 108 x 0.0784.8 x 1000)

= 48.1 kPa/100m

Equivalent pipe length = 600m + pipe fittings

Pipe fittings: Estimate from planned routing = about 10 elbows.

Gate valves = 2, fully open
Check valves = 1
Fluid Flow Example 1: Pressure drop cont.

Elbow = 10 x 10ft
= 100 ft
= 30.5 m
Gate valve = 2 x 2.5ft
= 5 ft
= 1.5 m
Check valve = 30 ft
= 9.1 m
Enlagement = 10 ft
= 3.0 m

Fittings = 30.5 + 1.5

+ 9.1 + 3
= 44.1 m
 Fluid Flow:- Line Sizing
Example 1: Pressure drop cont.

ΔP = 52.3 kPa/100m

Equivalent pipe length = 600m + pipe fittings

= 644.1m

Total pressure drop = 48.1 x 644.1/100

= 310 kPa (excluding control valve)
A good rule of thumb is to let the control valve take 50% - 60% of
the system flowing head loss for short lines and 30%-50% for longer
lines:

For this case we can use ⅓ as the line is long and control will be
simple. A 100 kPa pressure drop allowed for the control valve should
be adequate.

For pump sizing, add 20% to the calculated pressure drop

 Delivery pressure of pump = (310 x 1.2) + 100 = 472 kPa
 Fluid Flow:- Line Sizing
Example 1: Pressure drop cont.

Let us check our answer with the Darcy Equation:

Re = 2.4 x 105

For commercial steel, Surface Roughness: ε = 0.0018 in = 0.04572 mm

 ε/d = 0.04572/78 = 0.00059

Read friction factor from chart:

 Fluid Flow:- Line Sizing
Example 1: Pressure drop cont.

0.019
 Fluid Flow:- Line Sizing
Example 1: Pressure drop cont.

Read friction factor from chart:

fs = 0.019

Darcy equation: ΔP = fslu2/2d

= 0.019 x 100 x 1000 x 2.032 / (2 x 0.078)
= 50 190 Pa/100m
= 50.2 kPa/100m

This compares good with our previous calculated 48.1 kPa/100m !

 Fluid Flow:- Line Sizing
Example 2: Pressure drop

Size reactor outlet piping for 5.7m 3/h liquid of sp.gr 0.93 and viscosity
0.91cP flowing at 138ºC and 17.2 barg. Piping configuration as shown:
Piping length 80m, 10 elbows, 8 T’s, 4 gate valves, 1 orifice and 1, control
valve.
Maximum allowable velocity = 1.5 m/s. Allow 70 kPa for orifice friction
press drop. Control valve to be sized to take the balance of pressure
drop. Control valve
Gate valve Gate valve
Orifice place

Gate valve
Gate valve
Globe valve
Dip pipe Crude product
storage tank at
atmospheric
Reactor at 24 barg pressure
 Fluid Flow:- Line Sizing
Example 2: Pressure drop: Calculation

Max Velocity = 1.5 m/s

u = V/A
1.5 = (5.7/3600)/((π/4)d2)
d = 0.0037m
= 1.4”
 choose 1.5” line size (ID = 1.61” = 0.041m

recalculate line velocity: = (5.7/3600)/((π/4)0.0412)

= 1.2 m/s

Calculate Reynolds number:

Re = ud/μ
= (930 x 1.2 x 0.041)/(0.93 x 10-3)
= 49 200  Turbulent flow
Fluid Flow Example 2: Pressure drop, cont’d

Elbow = 10 x 4.5ft
= 45 ft
= 14 m

T’s = 8 x 3ft
= 24ft
= 7.3m

Gate valve = 4 x 1ft

= 4 ft
= 1.2 m
= 3.0 m

Fittings = 14 + 7.3 + 3
= 24 m
 Fluid Flow:- Line Sizing
Example 2: Pressure drop: Calculation, cont’d

Equivalent line length = 80 + 24 = 104 m

For commercial steel, Surface Roughness: ε = 0.0018 in

ε/d = 0.0018/1.61 = 0.0011
Fluid Flow:- Line Sizing
Example 2: Pressure drop: Calculation, cont’d
 Fluid Flow:- Line Sizing
Example 2: Pressure drop: Calculation, cont,d

Read friction factor from chart:

fs = 0.020

Darcy equation: ΔP = fslu2/2d

= 0.02 x 104 x 930 x 1.22 / (2 x 0.041)
= 33970 Pa
= 34 kPa

Summary: Pipe/Valves and fittings 34 kPa

Orifice 70 kPa
Control Valve 1616 kPa
Total 1720 kPa
 Fluid Flow:- Two Phase Flow

Two phase flow (liquid/vapour) is quite complicated

and even the long winded methods do not have high
accuracy.

You cannot even have complete certainty as to which

flow regime exists for a given situation!

Rough estimates can be achieved with the Lockhart

and Martinelli correlation (see Perry)
 Fluid Flow:- Two Phase Flow

• Flow Regime Types

• Dispersed
• Annular
• Wave
• Stratified
• Slug and Plug
• Bubble or Froth

• ΔP Calculation Methods
• Industry Calculations
• Short-Cuts
Fluid Flow:- Two Phase Flow
Fluid Flow:- Two Phase Flow
 Fluid Flow:- Two Phase Flow
Rough estimate using Lockhart and Martinelli

• Pressure drop of each phase is calculated as though it alone was

in the line

• Then calculate the following parameter: X = (ΔPL/ΔPG)0.5

where: ΔPL and ΔPG are the phase pressure drops

• The X factor is then related to either YL of YG. Whichever one

is used is multiplied by its companion pressure drop to obtain
the total pressure drop

• For both phases in turbulent flow, the following equations are

from the YL of YG curves in Perry:

YL = 4.6X-1.78 + 12.5X-0.68 + 0.65

2
Two Phase Flow: Sizing Flashing Steam Condensate
 Two Phase Flow: Sizing Flashing Steam Condensate

Example:

If 1000 lb/hr of saturated 600 psig condensate is

flashed to 200 psig, what size line will give a pressure
drop of 1.0 psi/100ft or less?
Two Phase Flow: Sizing Flashing Steam Condensate

Velocity = 16.5 ft/s

Velocity correction factor = 0.41

Corrected velocity = 0.41 x 16.5 = 6.8 ft/s