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LINE SIZING CRITERIA

Prepared : morteza asgari

TABLE OF CONTENT
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1.1. GENERAL...........................................................................................2

1.1.1 LINE SIZE.............................................................................................................................................2

1.2. LIQUID LINE SIZING CRITERIA............................................................3

1.2.1 PUMP LINES..................................................................................................................................3

1.2.1.1 PUMP SUCTION LINES.................................................................................................3
1.2.1.2.CORROSION / EROSION CRITERIA.........................................................................4

1.2.2 PUMP DISCHARGE LINES........................................................................................................5

1.2.3 GRAVITY TRANSFER LINES....................................................................................................5
1.2.4LINE SIZING CRITERIA FOR OFFSITE LINE.......................................................................6
1.2.5CLOSED & OPEN DRAINS. DRAINAGE AND SEWAGE SYSTEM....................................6

1.3. GAS AND STEAM LINES SIZING CRITERIA..............................................7

1.3.1. MAXIMUM ALLOWABLE PRESSURE DROP......................................................................8

1.3.2ALLOWABLE VELOCITIES.......................................................................................................8
1.3.3. CENTRIFUGAL COMPRESSOR SUCTIONS.........................................................................9
1.3.4.PSV INLET.....................................................................................................................................9
1.3.5.PSE INLET / OUTLET..................................................................................................................9
1.3.6.ATMOSPHERIC VENT SYSTEM LINE SIZING CRITERIA..............................................10

1.4. UTILITY LINE SIZING METHOD AND CRITERIA......................................11

1.4.1.PRODUCED WATER SYSTEM................................................................................................11

1.4.2.SEAWATER SYSTEM................................................................................................................11
1.4.3.POTABLE WATER SYSTEM...................................................................................................11
1.4.4.FUEL GAS SYSTEM...................................................................................................................11
1.4.5.DIESEL SYSTEM........................................................................................................................11
1.4.6.CHEMICAL INJECTION FACILITY SYSTEM....................................................................11
1.4.7.METHANOL SYSTEM...............................................................................................................12

1.5. TWO-PHASE PROCESS LINES (VAPOUR/LIQUID MIXTURES)...........................12

1.1. GENERAL
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The fluid quantities to be used in determining line sizes shall be those called for by the maximum
process design flowrates and in any case shall not be less than 110% of the unit design throughput.
However, line sizes shall be in compliance with the equipment (pumps, exchangers, etc.) design
capacity

1.1.1 LINE SIZE

The nominal pipe size (NPS) will be designated DN (Diameter Nominal), although in
calculations the diameter is normally expressed in millimeters (mm).

DN (mm) NPS (inches) DN (mm) NPS (inches)

15 1/2 350 14

20 3/4 400 16

25 1 450 18

40 1 1/2 500 20

50 2 600 24

80 3 650 26

100 4 700 28

150 6 750 30

200 8 800 32

250 10 900 36

300 12 1000 40

1.2. LIQUID LINE SIZING CRITERIA

1.2.1 PUMP LINES

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Maximum normal flows shall be used for calculations. For viscous liquids, the velocity
criteria could lead to excessive pressure drops; in those cases, pressure drop criteria
shall govern.
Gas blanketed liquids shall be considered boiling liquids for line sizing, pump
calculations, specifications, etc.

1. The limiting factor in line sizing is either the upper limit of the friction loss range or
maximum velocity (upper limit of the velocity range).

2. When available pressure drop in the system calls for a lower friction loss/velocity as
compared to the above ranges, then such lower friction loss/ velocity shall apply.

3. Reciprocating pumps line sizing criteria shall be based on the maximum flow rate of pulse
flow. Suction and discharge line for simplex and proportioning pumps should be sized for
1.6 and 3.14 of the maximum pumping rate respectively.

1.2.1.1 Pump Suction Lines

SUBCOOLED BOILING
m/s m/s
Pump suction: up to 2” 0.3 ~ 0.6 max. 0.5
(1) & (2) from 3” to 6” 0.6 ~ 1.0 max. 0.9
from 8” to 10” 0.8 ~ 1.5 max. 1.2
over 12” 0.9 ~ 3.0 max. 2.0

1. Saturated liquid pump suction lines call for larger suction nozzles to prevent vortexing,
when no enough liquid depth on vessel is provided.

The line must run 6 ~ 8 times nozzle diameter vertically before reducing the size of the line.

2. Pump suction lines to be primarily sized by NPSH requirement.

3. In general for corrosive or erosive fluids velocity limits should be halved. Lines in
corrosive and erosive services shall be investigated individually and in case of requirement
of lower velocity then such lower velocity shall be based upon for the design of such line.

1.2.1.2 CORROSION / EROSION CRITERIA

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Corrosion

For corrosion resistant material (SS, Special alloys,... ), no limitation of flowing

velocity up to 100 m/s and no requirement for corrosion allowance. For non corrosion
resistant material, in corrosive fluid service, corrosion allowance for a designservice life and
corrosion inhibitor injection is required. The flowing velocity is limited by the inhibitor film
integrity.

Erosion
For Duplex, SS or alloy material, the flowing velocity must be limited to:

 100 m/s in single phase vapor lines and multiphase lines in stratified
flow regimes (65 m/s For 13% Cr material),
For Carbon Steel material:

 In case of continuous injection of corrosion inhibitor, the inhibitor

films ensure a lubricating effect which drifts the erosion velocity limit. The corrosion
inhibitor erosion velocity limit will be calculated taking into account the inhibitor
film wall shear stress.

 In case of uninhibited fluid, the API RP 14 E recommendation should

apply : the flowing velocity must be maintained below the erosional limit :

Ve = C / (ρ m )0.5
With: Ve erosional velocity in ft/s
ρ gas / liquid mixture density at flowing conditions in lb/ft3
C empirical constant equal to 150 to 170. C value up to 200 can be considered on peak
flow rate only in case of absence of abrasive (solid)
Particles such as sand. When solid and/or corrosive contaminants are present C value
shall not be higher than 100.

 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.

1.2.2 PUMP DISCHARGE LINES

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Velocity limits depend on line diameter:

SUBCOOLED BOILING
m/s m/s
Pump discharge up to 2” 0.6 ~ 1.2 max. 1
(1) & (2) from 3” to 6” 1.0 ~ 2.4 max. 2
from 8” to 10” 1.5 ~ 2.8 max. 2.4
over 12” 2.4 ~ 3.6 max. 3.2

1. Cooling water header and branches sizing shall be based on velocity range within a max.
limit of 3 m/s. for branches and 2.44 m/s for main header.

2. For cement lined pipe, maximum velocity limit is 3 m/s.

 Snuffing steam piping shall be sized according to the maximum pressure available at injection
point at steam flow rate corresponding to firebox fill up in 2 minutes. Snuffing steam for
fire box, header boxes and convection section shall be three separate laterals.

 Above friction loss/velocity ranges can be slightly exceeded for short branch lines, when
pressure-drop is not limiting or in intermittent services.

 Above criteria shall apply unless more stringent requirement is mandatory by the process
Licensor.

1.2.3 GRAVITY TRANSFER LINES

Gravity transfer lines shall have a pressure drop within the range of 0.023 to 0.079 Bar/100
m, depending upon available head.
In cases where no controller is provided for liquid level in the liquid draw-off tray, flow
velocity in the first 3 m of the vertical line shall be less than 0.762 m/s.
Where a boiling liquid enters a control valve, line sizes shall be based on the following.
With consideration given to static head and length of the line from liquid level to control
valve, no vaporization shall occur at the inlet of the control valve. In this case, the following
should be satisfied:

4.91 x 10-5 ρ.H > P (flow meter) + P (line friction) (Eq. 3.3-1)
Where,
ρ: density, kg/m3
H: static head, m
P (flow meter): pressure drop in flow meter, Bar
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P (line friction): pressure drop in line, Bar

1.2.4 LINE SIZING CRITERIA FOR OFFSITE LINE

The following criteria are typical and may have to be supported by economical appraisal.

P (bar / km) Max. velocity (m/s)

LINE TYPE
Normal Maxi
Long Carbon steel water line 0.58 1.16 -
Bonna line - - 2.5 to 3
Steam condensate (mixture) 0.2 to 0.3 - 10 to 20

1.2.5 CLOSED & OPEN DRAINS. DRAINAGE AND SEWAGE SYSTEM

Pump discharge is sized according to pump discharge criterion (P<50 or P>50, depending on
discharge pressure), limiting the pressure drop to 4.50 or 9.00bar/km.

For pump suction line, pump suction for liquid at bubble point criterion (APB) is used. The
maximum allowable velocity is 0.90m/s and maximum allowable pressure drop is 0.90bar/km.
Piping line sizes of the following services are not calculated and were selected based on
operating experience as follows:

• 2" minimum diameter for closed drain lines from individual process equipment.
• 4" minimum diameter for closed drain headers.
• 4" minimum diameter for open drain lines (2" from equipment skid drip pans)
• 4" minimum diameters for sewage drain headers.

1.3.GAS AND STEAM LINES SIZING CRITERIA

Friction loss Velocity
Ranges range
Service (Bar/100 m) ( m/s (2) )
Gas and vapors
Less than 1 bar (a) ( vac.) 0.01 ~ 0.02 20 ~ 30
Up to 7 bar (g) 0.02 ~ 0.1 20 ~ 30
From 7 to 69 bar (g) 0.1 ~ 0.4 20 ~ 35
Over 69 bar (g) 0.7 % of the op. press. 20 ~ 40

Steam (saturated)
Less than 3.5 bar (g) 3.3 % of the op. press. 5.2 (d)0.5 (3)
From 3.5 to 17 .2 bar (g) 0.1 ~ 0.3 12.0 (d)0.5 (3)
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From 17.2 to 69 bar(g) 0.3 ~ 0.7 9.0 (d)0.5 (3)

Steam (super heated)

Less than 17.2.bar (g) same as gas and vapor
Above 17.2.bar (g) 2.3 % of the op. Press. 15.2 (d)0.5 (3)

1. The limiting factor in line sizing is either the upper limit of the friction loss range or
maximum velocity (upper limit of the velocity range).

2. When available pressure drop in the system calls for a lower friction loss / velocity as
compared to the above ranges, then such lower friction loss / velocity shall be
applied.

3. Absolute maximum velocities limits, where technically applicable, are as follows:

- gas and vapors and superheated steam
less than 17.2 bar (g) : 50% sonic (*)

- saturated steam and superheated steam

above 17.2 bar (g) : 30.5 (d)0.5

subject to the following absolute limitations

• saturated steam : 50 m/s ;

• superheated steam : 75 m/s

(*) sonic or acoustic velocity:

- sonic velocity : 91.2 { (T / M . W) }0.5.

Where:

T = fluid temperature, deg. K

M.W. = fluid molecular weight
d = Nominal pipe Diameter (inches)

3. For corrosive or erosive fluids velocity limits should be halved.

 Above friction loss / velocity limits can be slightly exceeded for short branch lines,
when pressure drop is not limiting or in intermittent services.
 Operating pressure refers to in absolute pressure.
 Above criteria shall apply unless more stringent requirement is indicated by the process
licensor.

1.3.1. MAXIMUM ALLOWABLE PRESSURE DROP

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For lines not exceeding 100 meters in length, the following shall apply:

Pressure Level Pressure Drop, Bar/100 m

0 to 3.5 Bar(g) 0.056 to 0.113*

3.5 to 10.5 Bar(g) 0.113 to 0.339*

10.5 to 35 Bar(g) 0.339 to 0.678*

Over 35 kPa(g) (0.5% of pressure level)

 Interpolate linearly for intermediate pressure levels.

1.3.2 ALLOWABLE VELOCITIES

Maximum for gas = 122/SQRT (v) m/s, where v is the gas density in kg/m3.

1.3.3 Centrifugal Compressor Suctions

Recommended velocity and pressure drop for compressor suction lines are as follows:

Velocity m/s Pressure Drop

Operating Range Maximum Limit

0.12 Bar for reciprocating

6 to 15 v = 122/SQRT(v) 0.7% inlet Bara for
centrifugal

1.3.4. PSV INLET

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I outlet

1. PSV inlet lines are sized based on maximum pressure drop of 3% PSV set pressure
as per API 520.

2. PSV outlet lines are sized based on rated relieving rate for tail pipes and required
relieving rate for headers as per API 521.

3. PSV outlet lines back pressure shall not exceed 10% PSV set pressure as per API 520 (for
conventional valves). The wellhead PSV outlet lines are excluded from this
criterion as they are balanced type valves.

4. PSV outlet line is sized based on maximum Mach no. of approximately 0.70. However,
basic design sizes that are above Mach 0.70 are maintained as long as all other criteria
are met e.g. pipe stress, AlV and back pressure

1.3.5. PSE INLET / OUTLET

1) PSE inlet lines are sized based on maximum 'C' factor erosional velocity of approximately
125 (assuming values for CS intermittent service as per API 14E for conservatism).
However, as a minimum, the line sizes shall not be smaller than the bursting disc size.

2) PSE outlet line back pressure shall not exceed 30% PSE rupture pressure (3.3barg)
(as per BS&B vendor requirement). However, as a minimum, the line sizes shall not be
smaller than the bursting disc size.

During an emergency relief to flare, discharge line and header velocities shall not exceed 70% of
sonic velocity
Where,

Sonic velocity: 91.215 (k*T/M)0.5

T: °K,
M: mol. wt.,
k: Cp/Cv.
Flare headers shall be self-draining toward the flare knockout drum, which shall be located
near the flare. Flare piping slopes shall be provided as follows:

 Main Header 1:1200

 Unit Header 1:500

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 Unit Laterals 1:250

Discharge lines from relief and depressuring valves shall preferably enter the headers at the
top but shall, in any case, free the drain into the headers.

1.3.6. ATMOSPHERIC VENT SYSTEM LINE SIZING CRITERIA

There are no specific criteria for PCV and PSV inlet line sizing. However, pressure drop is
kept to a minimum not exceeding 6 mbarg.
PSV outlet line sizing is based on maximum back pressure of 6mbarg. Minimum header size is 4".

1.4. UTILITY LINE SIZING METHOD AND CRITERIA

1.4.1. PRODUCED WATER SYSTEM

The water criterion (BONNA) is applied for produced water system lines. The
maximum allowable velocity is 3m/s

1.4.2. SEAWATER SYSTEM

The seawater criterion (EMER) is applied for seawater system lines.

The maximum allowable velocity 3.5 m/s for continuous service and for 6 m/s for
intermittent service. Seawater Lift Pump discharge is sized according to pump
discharge criterion (P<50), limiting the pressure drop to 4.50bar/km.

1.4.3. POTABLE WATER SYSTEM

The water criterion (BONNA) is applied for potable water lines. The maximum
allowablevelocity is 3m/s. Pump discharge is sized according to pump discharge
criterion (P<50), limiting the pressure drop to 4.50bar/km.
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1.4.4. FUEL GAS SYSTEM

The gas criterion (GAZ) is applied for fuel gas system lines.

1.4.5. DIESEL SYSTEM

For diesel loading lines, a maximum flow velocity of 4.6 m/s is applied (SANS). For
pump suction lines, pump suction for sub cooled liquid critenon (APSR) is
used. The maximum allowable velocity is 1.2m/s and maximum allowable
pressure drop is 3.50bar/km. Pump discharge is sized according to pump
discharge criterion (P<50), limiting the pressure drop to 4.50bar/km.

1.4.6. CHEMICAL INJECTION FACILITY SYSTEM

No calculation was performed for chemical injection line as flow rates are minimal. A
1 ½” line size is used for all chemical injection lines for mechanical integrity
reason.

1.4.7. METHANOL SYSTEM

There is no specific line sizing criteria for methanol system. A maximum flow velocity
of 4.6 m/s is applied (SANS) as per API 14E (I). Pump discharge is sized
according to pump discharge criterion (P>50), limiting the pressure drop to
9.00bar/km.

1.5. TWO-PHASE PROCESS LINES (VAPOUR/LIQUID MIXTURES)

The primary concern in designing a pipe for two-phase flow is that various flow patterns can
occur. Particular attention shall be paid to the flow regime to avoid slug flow, where
possible. For preliminary sizing, line velocities shall be limited by the following:

Maximum mixture velocity for two-phase flow =122 / SQRT (mix), m/s
Minimum mixture velocity for two-phase flow = 3.0, m/s
Where (mix) is the density of the mixture, kg/m3.

Velocity may be less than 3.0, m/s at the vessel inlet or for horizontal runs where
separation of the two phases is desirable.
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For critical two-phase process lines, detailed calculations shall be made for pressure drop
and flow regime.