Section V-A4 - page 1 PRODEM

FLUID FLOW D. LARREY

PLANT LINE SIZING November 1996
TEP/DC/ED/ETP

FLUID FLOW

PLANT LINE SIZING

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CONTENT

PLANT LINE SIZING 4

1. A PPLICABILITY 4
2. L IQUID LINES SIZING PROCESS CRITERIA 5
3. VAPOR AND STEAM LINES SIZING PROCESS CRITERIA 5
4. T WO PHASE FLOW LINE SIZING PROCESS CRITERIA 5
5. CORROSION / EROSION CRITERIA 6
5.1. Corrosion 6
5.2. Erosion 6
6. PLANT LINE PRESSURE DROP CALCULATIONS 10
6.1. Monophasis fluid (gas or liquid) 10
6.1.1. AFTP charts could be used to determine the friction pressure
drop with the correction of the line diameter such as indicated on
these charts. 10
6.1.2. Method using MOODY Or "regular" Fanning friction factors 10
6.2. Two phase fluid 10
6.2.1. "AFTP" Chart for gas could be used with the correction of the line
diameter ; taking the liquid viscosity as the fluid viscosity. 10
6.2.2. Method using MOODY or "regular" Fanning friction factors. 11
6.3. Correction for valves and line fittings 11
6.4. Pressure differential due to gravity 11
7. PIPING CLASS 11
7.1. Class numbering principles (from SP-TCS-112 "Piping material
classes") 11
7.1.1. Generation of number 11
7.1.2. Letters representing the flanges rating of the class 12
7.1.3. Numbers representing the main material of the class 12

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7.2. Pipe wall thickness calculation principle (From SP-TCS-112 "Piping

Material Classes") 12
7.2.1. Corrosion allowance 12
7.2.2. Mill tolerance 13
7.2.3. Retirement thickness 13

LIST OF TABLES

Table V-A4.1 - Liquid lines sizing - Process criteria

Table V-A4.2 - Vapor and steam lines sizing - Process criteria

APPENDIX

Table V-A4.3 - Piping material class typical for class D03

Figure V-A4.1 - AFTP chart - gas lines typical for a 20" diameter tube

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PLANT LINE SIZING

1. APPLICABILITY

The purpose of this paragraph is to provide guidelines for the sizing of process and utility lines within
the battery limit of a plant.

• For a feasibility study a quick estimate of the size of some main lines may be required.

• For a pre-project study a better estimate of the line size will be required.

• For both the feasibility and pre-project studies the AFTP ("Abaques de Lefevre") charts
can be used :
- "Pour le calcul des pertes de charges des liquides dans les conduites"
- "Pour le calcul des pertes de charges des gaz dans les conduites" (see typical
example of the AFTP chart for a 20" gas line on Figure V-A4.1).

Flare lines are excluded from this chapter. For the design of flare lines, refer to PRODEM Section
XXXII SAFETY EQUIPMENT - Chapter C Flares.

Notes :
• The AFTP charts are applicable for commercial seamless steel tubes, corresponding to
0.046 mm absolute roughness wall surface
• Multiplying correction factors must be applied to the pressure drops and velocities indicated
on the AFTP charts when used for internal diameters different from the referenced ones :

Pressure drop correction factor

FG
D internal AFTP IJ 4

Laminar flow regime =

H
D internal actual K
Pressure drop correction factor
FG D internal AFTP IJ 5

Turbulent flow regime =

H D internal actual K
FG D internal AFTP IJ 2

Velocity correction factor =

H D internal actual K

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• The line sizing depends on the service :

- Flare lines, pipeline and riser sizing are not included in this section.

• For nominal diameter standards and wall thickness determination, refer to Chapter V-A1.

2. L IQUID LINES SIZING PROCESS CRITERIA

See Table V-A4.1

3. VAPOR AND STEAM LINES SIZING PROCESS CRITERIA

See Table V-A4.2.

The ρV²criteria of Table V-A4.1 are governed by consideration of vibration and forces on piping
supports. The ρV3 criteria are governed by consideration of noise levels. When exceeding those
criteria, the energy of the fluid can be detrimental to the material (piping, fatigue of supports...) and
to the personnel (noise).
Table V-A4.2 does not cover the sizing criteria of flare lines.

4. TWO PHASE FLOW LINE SIZING PROCESS CRITERIA

The ρV²and ρV3 criteria as stated for vapor lines can be followed in two-phase line, using the fluid
apparent density ρm expressed as :

W
ρ = ρm = in kg/m3
Wl Wv
+
ρl ρv

W = Wl + Wv = total flow rate in kg/h ρl = liquid density in kg/m3

Wl = liquid flow rate in kg/h ρv = vapor density in kg/m3
Wv = vapor flow rate in kg/h
and the apparent fluid velocity V m :

W
Vm = m s
D²
ρm π 3600
4

D = internal diameter of the line in m.

In addition, the flow regime may have to be checked ; using flow pattern can be considered for small
diameter lines and low operating pressures (ex : reboiler lines).

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For high pressure large diameter lines (ex : production headers) one shall preferably use computer
programs :

• For horizontal lines slug and plug flow regimes should be avoided.
• For vertical lines slug flow regimes should be avoided.

Refer to Chapter V-A.3 TWO-PHASE FLOW for details on flow regimes.

5. CORROSION / EROSION CRITERIA

5.1. Corrosion

For corrosion resistant material (Duplex, SS321, Special alloys), no limitation of flowing velocity up
to 100 m/s and no requirement for corrosion allowance.
For Carbon Steel, piping in corrosive fluid service, corrosion inhibitor injection is required. The
flowing velocity is limited by the inhibitor film integrity (Based on experimental results collected on
test loop, shear stress to be maintained below 45 N/m²) ; the corrosion allowance, calculated by
DPS/TEC (program LIPUCOR) for a design service life, is added to the calculated pipewall
thickness.

5.2. Erosion

For Duplex, Stainless Steel or alloy material, the flowing velocity must be limited to :
• 100 m/s in single phase vapour lines and multiphase lines in stratified flow regimes (65 m/s
for 13% Cr material),
• 20 m/s in single phase liquid lines and multiphase lines in annular, bubble or hydrodynamic
slug flow regime,
• 70 m/s in multiphase lines in mist flow regimes.

For Carbon Steel material :

• In case of continuous injection of corrosion inhibition, the inhibitor film ensures a lubricating
effect which drifts the erosion velocity limit. The corrosion inhibitor film erosion velocity limit
is calculated by TOTAL proprietary program LIPUCOR taking into account the inhibitor film
wall shear stress.
• In case of uninhibited fluid, in absence of updated experimental results, the API RP 14E
recommendation should still apply : the flowing velocity must be maintained below the
erosional limit :

Ve = C / ρ
m

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With Ve erosional velocity limit in ft/s

ρm gas /liquid mixture density at flowing conditions in lb/ft 3
C empirical constant equal to 150 to 170. C value up to 200 can be considered
on peak flowrate only.

The above velocity limitations only apply in absence of abrasive (solid) particles such as
sand.

"Where solid and/or corrosive contaminants are present or when "C" values higher than 100 for
continuous service are used, periodic surveys to access pipe wall thickness should be considered"
(API RP 14E - Edition 1991).

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Table V-A4.1

Liquid lines sizing - Process criteria

∆P bar/km MAXIMUM VELOCITY m/s (2)

LIQUID LINE TYPE NORMAL MAXI Ø ≤ 2" 3" ≤ Ø ≤6" 8"≤ Ø ≤ 18" Ø ≥ 20"

Pumps suction :
. Liquid at bubble point or
with dissolved gas 0.6 0.9 0.6 0.9 1.2 1.5
. Non boiling liquid 2.3 3.5 0.9 1.2 1.5 1.8

Unit lines :
. Liquid at bubble point or
with dissolved gas 0.6 1.0 0.6 1.0 1.4 1.8
. Non boiling liquid 2.3 3.5 0.9 1.2 1.8 2.4

Pump discharge :
. Discharge pressure ≤ 50 barg 3.5 4.5 Velocity 1.5 to 4.5 m/s 6.0
. Discharge pressure > 50 barg 7.0 9.0 Velocity 1.5 to 4.5 m/s 6.0
(1)
Column outlet 0.6 0.9 0.6 0.9 0.9 0.9

Gravity flow 0.25 0.45 0.6 (normal velocity)

Water (carbon steel) lines :

* Cooling water and service water
. Large feeders between pumps 1.5 Velocity 1.5 to 3.0 m/s
and units
. Unit lines 1.5 long lines 1.5 2.5 3.0 3.0
2.5 to 3.5 short lines
* Boiler feed :
. Pressure ≤ 50 barg 3.5 4.5 Velocity 1.5 to 4.5 m/s 6.0
. Pressure > 50 barg 7.0 9.0 Velocity 1.5 to 4.5 m/s 6.0

* Sea water lines Velocity 2.5 to 3.5 m/s (2 m/s mini)

Steam condensate return Velocity 1 to 1.5 m/s

Notes (1) : 3.0 m/s maxi (2 m/s average) at storage tank inlet or in loading
(2) : Vendor requirements could supersede maximum velocity values, upon Company agreement

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Table V-A4.2

Vapor and steam lines sizing - Process criteria

MAXIMUM ρV2 MAXIMUM ∆P bar/km

VAPOR AND STEAM LINES ρ = gas density kg/m3 VELOCITY
(FLARE LINES EXCLUDED) V = gas velocity m/s m/s NORMAL MAXI

VAPOR LINES
- Continuous operation :
. P ≤ 20 bar g 6 000 ) ∆ P must be considered and be
. 20 < P ≤ 50 bar g 7 500 )
. 50 < P ≤ 80 bar g 10 000 (1) ) compatible with the
. 80 < P ≤ 120 bar g 15 000 )
. P > 120 bar g 20 000 ) corresponding service
)
- Discontinuous operations e.g.: compressor )
anti-surge : . P ≤ 50 bar g 10 000 (1) )
. 50 < P ≤ 80 bar g 15 000 )
. P > 80 bar g 25 000 )

- Compressor suction ) To be compatible 0.2 0.7

- Compressor discharge ) with above 0.45 1.15

STEAM LINES

- P ≤ 10 bar g . Short line L ≤ 200 m 0.5 1.0

. Long line L > 200 m 0.15 0.25

- 10 < P ≤ 30 barg . Short line L ≤ 200 m 42 1.2 2.3

. Long line L > 200 m 42 0.25 1.0

- P > 30 bar g . Short line L ≤ 200 m 30 1.2 2.3

. Long time L > 200 m 30 0.35 1.0

Notes (1) : Value for design. Could be increased but not exceeding 15 000, in case of debottlenecking.
(2) : Noise limit : ρV3 = 100 000 to 200 000 kg/s 3 max, or velocity limit as per API RP 14 E : V ≤ 60 ft/s.

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6. PLANT LINE PRESSURE DROP CALCULATIONS

6.1. Monophasis fluid (gas or liquid)

6.1.1. AFTP charts could be used to determine the friction pressure drop
with the correction of the line diameter such as indicated on these
charts.

6.1.2. Method using MOODY Or "regular" Fanning friction factors

Step 1 : Calculate Reynolds number. Re is a dimensionless number

D ρ Vm
Re =
µ

D = line internal diameter in mm µ = fluid dynamic viscosity in cP

ρ = fluid density in kg/m3
Vm = velocity in m/s

ε
Step 2 : Determine the relative roughness : See Figure V-A1.1 à =
D

Step 3 : Determine f D = friction factor : See Figure V-A2.1 à f D =

V²
Step 4 : ∆P = f D ρ (bar / 100m)
2D

6.2. Two phase fluid

Different methods exist to calculate the pressure drop for two phase flow. Those based on empirical
correlations have limited range of applicability depending on vertical or horizontal line, gas and liquid
superficial velocities, pressure and temperature conditions. The mechanistic models are more
deterministic, with a wider applicability, they should preferably be used for accurate calculation.
Quick methods for rough estimation are as follows :

6.2.1. "AFTP" Chart for gas could be used with the correction of the line
diameter ; taking the liquid viscosity as the fluid viscosity.

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6.2.2. Method using MOODY or "regular" Fanning friction factors.

It is the same method as described in paragraph 6.1.2 with ρ = ρm and

V = Vm as defined in paragraph 4 of this Chapter V-A4 and the fluid viscosity taken as the liquid
viscosity.

6.3. Correction for valves and line fittings

Add equivalent lengths or Resistance Coefficients to account for pressure drop in valves and
fittings, as explained in paragraph V-A2.3.
For two phase fluid the Resistance Coefficients can be used with ρ = ρm and V = Vm as defined in
paragraph 4 of this Chapter.
This correction will most of the time be necessary for plant line sizing valves bends and fittings
participate to the overall pressure drop, not negligibly compared to friction pressure drop along
straight piping sections.

6.4. Pressure differential due to gravity

The overall pressure differential between two locations of a piping system must account for the
change in elevation, or hydrostatic head.
This term is of major importance for liquid lines and two phase lines.

In two phase flow lines, the hydrostatic head depends on the liquid hold-up, i.e. the distribution of the
vapour and liquid phases in the line cross section.
As for pressure drop, different methods exist to determine the liquid hold-up. The mechanistic
models will be used preferably to the empirical correlations, for accurate calculations.
Refer to Chapter V-A3 on TWO-PHASE FLOW.

7. PIPING CLASS

The purpose of this paragraph is to determine the piping class used as shown on PID line when the
piping material class document does not exist. This is generally the case for feasibility and pre-
project studies.

7.1. Class numbering principles (from SP-TCS-112 "Piping material

classes")

7.1.1. Generation of number

The class number consists of a capital letter representing the ANSI series and a two-digit number
representing the main material entering into the composition of the material used for the valves
bodies, tubes, fittings and flanges of the material class question.

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Example :
B 01
. .
. .
. .
150 Lbs Rating.............. .................Carbon steel material

The tables below give the letters and numbers to be used for numbering piping classes.

7.1.2. Letters representing the flanges rating of the class

Rating (Lbs) 125 150 250 300 400 600 900 1500 2500 Tracing
Letter A (1) B C (1) D E (1) F G H J Y

Note (1) : these rating are not normally used.

7.1.3. Numbers representing the main material of the class

01 to 20 : Carbon steels (ordinary, galvanised, normalized, etc.)

(digits 01 to 06 also indicate the corrosion allowance)
21 to 45 : Alloys steels
46 to 70 : Stainless steels
71 to 85 : Special alloys (Monel, Inconel, Hastelloy, GRP, etc.)
86 to 99 : Other materials (cost-iron, copper, copper alloy, GRP, etc...)

7.2. Pipe wall thickness calculation principle (From SP-TCS-112 "Piping

Material Classes")

The calculation of pipe wall thickness are in accordance with the ANSI B31.3 design code (refer to
Chapter V-A.1, paragraph 4.3.3), and shall include a corrosion allowance as well as mill tolerances
as applicable. The weld efficiency coefficient of welded pipes shall be equal to 1 (i.e. full
radiography).

An example of a typical Piping Material Class (D03), from SP-TCS-112 is given in Table V-A4.3.
These classes are regularly updated. The process engineer shall check that he/she uses the latest
issue, applicable to the specific project he/she is working for.

7.2.1. Corrosion allowance

All carbon steel and low alloy steel materials shall incorporate a minimum corrosion allowance of
1.27 mm. Stainless steels, copper nickels, galvanised carbon steels, glass reinforced materials, and
other corrosion resistant material shall be used without extra-thickness for corrosion allowance.

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7.2.2. Mill tolerance

The mill tolerance on wall thicknesses shall be as follows :

• minus 10% for API 5 LB for diameters larger than 24"
• minus 8 % for API 5 LX grades in diameters 20" and above
• minus 12.5% for all other materials or diameters
(These rules take into account the fabrication tolerances applicable to fittings, with a particular
reference to the TOTAL specification n°SP-TCS-144).

7.2.3. Retirement thickness

The minimum wall thickness after reduction by :

a) Corrosion allowance
b) Mill tolerance
c) Threading allowance, where applicable, in accordance with ANSI B1.20.1 (NPT)

shall not be less than the following :

Nominal Pipe Size Minimum corroded thickness

(retirement thickness)

1/2" to 3/4" 1.0 mm

1" to 8" 1.5 mm
10" 2.3 mm
12" to 14" 2.8 mm
16" to 24" 3.1 mm
26" to 36" 3.8 mm
38" to 46" 4.6 mm
48" 5.3 mm
Above 48" 6.4 mm

Additionally, schedules "5 S" shall not be used for stainless steels, and schedule 80 shall be
selected as a minimum for pipes 1 1/2" in diameter and below for offshore applications.

If the wall thickness required to contain the pressure is less than the "Minimum Corroded
Thickness", the "Minimum Corroded Thickness" shall be used for pipe wall thickness selection
purpose.

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