Chapter II

Pipeline Sizing
Learning Objectives
Reading this chapter would enable you to understand:
l Pipeline size taking into account characteristic of fluid, optimum
pressure drop at economic velocities.
Contents
2.1 Introduction
2.2 Classification of Pipeline
2.2.1 Pipeline Sizing
2.3 Economic Velocity for Different Piping System
2.3.1 Liquid Flow under Gravity
2.3.2 Hot Liquid Flow
2.3.3 Bypass Line for Equipment/Instrument
2.3.4 Sample Line
2.3.5 Cooling Water Circulation
2.3.6 Tank Overflow
2.3.7 Slurry Flow
2.4 Numericals for Line Size
Self-assessment
2.1 Introduction
The chemical process industry is involved in many operations, for different
types of fluids, with different applications. Though in principle, various
guidelines and formulae are available for pipeline sizing for different services.
Hence it becomes critical at times conceptualisation is necessary before
deciding design parameters.
When fluids are to be carried from one place to another in household piping to
cross country pipeline, piping and fitting constitutes a high cost. The size of
piping plays an important role in the pumping cost. Hence the selection of the
line size becomes important. Though in principle, various formulae are available
for sizing for different services, conceptualisation is necessary before deciding
parameters.
2.2 Classification of Pipelines
2.2.1 Pipeline Sizing
In any chemical process industry, various types of fluids are being used in
different forms like liquid, gaseous, slurry, etc. Raw material, intermediate
product or finished product produced through various unit operations require
connectivity of all the units with pipelines and fittings due to the following
reasons:
l Ease of operation
l Safe handling of materials
l Avoiding loss of material
l Hygienic conditions of the plant
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For example, liquid feed is transported from its bulk storage area to day-storage
using pump connecting bulk storage tank, pump and day storage tank with the
necessary pipelines. It is very difficult to imagine a chemical process industry
complex without any pipeline work. Rather one can see huge piping network
within the complex. The design of any piping network involves various activities
like the selection of piping material, specification with respect to thickness, pipe
size, its routing, etc. This chapter deals with conceptual basis of pipeline sizing.
Though various formulae and thumb rules are available in literature and can be
used directly for sizing of pipelines, criticality with respect to experience in the
fluid handling of related chemical process industry cannot be avoided. Over or
under sizing of pipelines may even become a bottleneck for plant operations. For
slurry applications, a larger size pipeline not only increases the plant cost but
also creates operational problems. Likewise, the smaller pipe size may consume
more energy for fluid movement. One should bear in mind that the larger
pipeline size than necessary increases plant cost due to pipelines along with the
connected valves, fittings, supporting structures, etc.
Many factors should be kept in mind before sizing any pipeline. The basic
principle of pipeline size is based on the available pressure drop between its two
ends. Normally to maintain certain fluid velocity (may be from the available
thumb rules), e.g. considering 1.5 metre / second for clear water at pump
discharge for the maximum possible fluid flow rate through that pipeline, cross-
sectional area (or diameter) of pipeline is calculated. Based on this, the nearest
commercially available pipeline size (of inside diameter closely matching with
the calculated value) is selected for application. With these preliminary
calculations of pipeline sizing and pipe routing, pressure drop between start and
end point, incorporating all fittings, is calculated. Decision of the selection of
higher or lower pipeline size is made according to the available pressure drop
versus calculated pressure drop.
Normally pipelines are sized after optimising between the costs of material
versus operating cost (incurred due to line pressure drop). Higher the pipeline
diameter (i.e., higher initial investment), lower will be the pressure drop (thus
less operating cost) and vice versa. Velocity norms are fixed for different
applications, based on the optimum design conditions and pipeline sizes are
only calculated using these norms. In some typical applications discussed here,
these guidelines are not valid and one needs to understand the typical
application and size the pipelines accordingly.
2.3 Economic Velocity for Dif ferent Piping Systems
Here typical applications are discussed for conceptualising pipeline sizing.
2.3.1 Liquid Flow under Gravity
Liquid flows under gravity due to the elevation difference between the start
point (always at higher elevation) and the end point (at lower elevation), i.e.
difference in potential energy. The elevation difference mainly governs the
pipeline sizing. Additional effects of pressure conditions for start/end point
matter in pipeline sizing. If the available elevation difference is higher, a high
liquid velocity (i.e. with high allowable pressure drop) can be considered for
pipeline sizing. Thus, a lower pipeline size can be selected for such a condition.
Fluid Handling
In case, the end point is connected to a pressurised system, e.g. distillation
column, the equivalent pressure shall be deducted from the available elevation
difference and the effective available differential pressure is reduced. Thus
even with the higher available elevation difference, for the end point of the
pipeline connected to the pressurised system, the pipeline size will be of a lower
size. Similarly if the start point of the pipeline is under vacuum, i.e. in barometric
condensers, pipelines of high diameters are selected to reduce pipeline friction
losses and thus increase the available differential pressure.
Such applications are work-based on the available pressure drop. These cannot
be sized only as per the economic pipeline size guidelines only, i.e. optimising
material cost versus operating cost.
2.3.2 Hot Liquid Flow
Various problems are commonly observed in the process plants handling hot
boiling liquids. These are mainly due to vaporisation of flowing hot liquid, i.e. the
phase change of liquid to vapour, inside the pipeline or equipment. This
phenomenon is also called the flashing of liquid. A typical example is centrifugal
pump cavitation, which is due to low available NPSH (Net Positive Suction
Head).
The higher pipeline size is preferred to lower down pressure drop and thus to
achieve higher available NPSH at pump suction port. Similarly in other
pipelines, the pressure drop due to sudden change in the flow direction or the
reduction of the line size, hot liquid vaporisation takes place which generates
vapour bubbles inside the pipeline. Due to this more space is occupied by the
mixture of generated vapours and flowing liquid and subsequently fluid flow is
obstructed. Similar type of phenomena are observed in case of liquids carrying
dissolved gases, which expand at higher temperatures. For these types of
applications normally higher pipeline sizes are recommended.
2.3.3 Bypass Line for Equipment/Instrument
Equipment/instruments especially which create a high-pressure drop and are
provided with a bypass line (to have the facility for maintaining process
continuity even during maintenance work). i.e. plate heat exchangers, control
valves, etc. are provided with a bypass arrangement, which normally has two
isolation valves in line of the unit and a flow regulation valve in parallel to this
unit.
In normal operations, as fluid passes through the main units either the plate heat
exchanger or control valve, it exerts an additional pressure drop. Accordingly
the supply pressure for the fluid stream is estimated, which the connecting unit
like the centrifugal pump creates. The centrifugal pump is selected based on
this created pressure drop by the unit. During bypassing of the connected unit,
this additional pressure is eliminated, while running pump discharges the high
flow rate as per the typical pump characteristics. To avoid this situation, it is
always recommended to use a lower size bypass line with a regulation valve to
create pressure equivalent to the main connecting unit.
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2.3.4 Sample Line
Normally a small fluid quantity is collected for analysis to determine its
composition. It is applicable for any stage of processing like for raw material,
intermediate product, finished product or it may be even utility or effluent. Even
for small quantity of sample collection, line size mainly depends upon the type of
fluid being handled and the location of the sample point in the process.
For example, for gases under pressurised conditions, small lines with valves
(e.g. 6 mm) are sufficient for withdrawing the representative sample quantity.
Providing a high sample line size will not only be difficult to control but higher
wastage of gases during sample collection cannot be avoided. On the other
hand, small sample line will create trouble for slurries where solid particles may
choke the sample line quite frequently. Thus, irrespective of material losses and
the cost of the pipeline and valve, the sample line size is dependent upon the
solid particle size and the characteristics of the slurry. Similar are the
experiences for viscous liquids.
Even for clear liquids, the sample line size depends upon its location like at the
atmospheric tank, pump suction/or discharge, etc. Though it is very difficult to
define proper guidelines for sample line sizing, the following points should be
kept in mind while sizing:
Characteristics of sample fluid
Less fluid losses
Safety during sample withdrawal
Ease of operation
Location of sample point, etc.
2.3.5 Cooling Water Circulation
Higher velocities are preferred for cooling water circulation pipelines. This is
mainly due to the following two reasons:
Cooling water, in the cooling tower, is exposed to sunlight that helps in the
development of algae formation. This generated algae material goes to the
circulating cooling water. At a lower liquid velocity in the pipelines, algae starts
growing within the pipeline and after some time, they start blocking cooling
water circulation or it passes to the connected heat exchanger unit. Thus, a
higher liquid velocity (e.g. 1.8 - 2.5 metre/second) for circulation line is
recommended to avoid algae development within the pipeline.
Normally higher cooling water circulation flow rates are encountered in the
chemical process industries that require large size pipelines with longer lengths
to cover various heat exchanging units. Thus, to reduce the cost of pipe material
even with high power consumption (due to increased pressure drop) will be an
appropriate choice.
2.3.6 Tank Overflow
Overflow lines in the tanks are provided for the following reasons:
To avoid liquid losses (overflowed liquid is recovered in another
tank)
To avoid unwanted spillage of liquid around plant building
To maintain liquid levels in the overhead tanks

Fluid Handling
In all the above-mentioned cases, overflow line is sized for the maximum
possible input liquid flow rate to the tank irrespective of the outlet liquid flow
rate. Other design guidelines are similar to the pipeline sizing for gravity liquid
flow, i.e. as per the availability of vertical available height between the highest
and end points (where it comes in contact with the atmosphere) of the overflow
pipeline.
Here the highest point which is also the start point of the liquid flow line is
located almost at the top of the tank (overflow nozzle of the tank), while the
endpoint may be somewhere near the drain gutter (close to ground). This may
not always be true, as the overflow line may also be terminated at the higher
elevation floor. In that case the available differential head will be lower. Hence as
per the pipeline location, the overflow line shall be sized, based on the gravity
flow principle.
2.3.7 Slurry Flow
Slurries, mixtures of suspended solids in liquids, are kept in agitated conditions
to maintain homogeneity, other wise, depending upon the solid's
characteristics, lighter or heavier than liquid, particles float or settle down
respectively. Agitated conditions are maintained in equipment, like tanks by the
use of agitators or gases sparing. While in the pipelines it is achieved by
maintaining turbulent fluid flow conditions.
At a lower fluid velocity in the pipeline, solids have a tendency to separate out
from the liquid phase. Thus sufficiently high fluid velocity shall be maintained in
the pipelines, irrespective of encountering a high-pressure drop in the pipelines
for slurries (beyond the guidelines for optimum pipeline sizing for clear liquids).
On the other hand, for very small pipeline size for slurries, its choking is quite
frequently observed in plants. Thus, a small pipeline size is also not
recommended for these applications. Apart from this, some slurry containing
abrasive solid particles may cause pipeline erosion at very high fluid velocities.
Hence, high fluid velocities are not recommended. Various slurries behave in
different fashions at different fluid velocities, hence pipeline size is more critical.
Along with the basic design guidelines, past experience to understand slurry
behaviour shall also be used during pipeline sizing.
Apart from above discussion, many other applications can be seen in any
chemical process industry. i.e. very low fluid velocities are considered for
designing pipelines carrying highly viscous liquids, storage tank vent lines
(depending upon the tank design pressure), tank drain lines (related with the
vent line size as well as the time required for the draining out tank), etc.
2.4 Numericals for Line Size
Example 1
Select pipe size for the following design parameters:
3
Liquid flow rate, Q = 300 m/hr
3
Liquid density, = 1000 kg/m
Liquid viscosity, = 1.0 CP or 0.001 kg/m-sec
Pipe Roughness, = 0.4 mm

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Pipe Schedule = 40
Pipe Straight Length = 100m
Solution
Let liquid velocity = 2.5 m/sec
Calculated Pipe Diameter =
= 206.01mm
Selected Pipe Internal Diameter, D = 202.7 mm
sel
2
Internal pipe cross section area = 0.032269 m
Liquid velocity in selection pipe, V = 300 / (0.032269 x 3600)
cal
= 2.582 m/sec
Reynolds Number, N =
Re

=
= 523371.4
= 0.4 / 202.7
= 0.00197
From Moody Friction Factor Chart, for NRe and ;

Friction factor, f = 0.024
Pressure drop,
=

2
= 0.4027 kg /cm
Thus for the selected pipeline 200 NB schedule 40 of 100 metres pipe length
2
pressure drop is 0.4027 kg/cm. If the available pressure drop is more than
2
0.4027 kg/cm, liquid flow is possible.
1000
5 . 2 3600
300 4
2 / 1

cal sel
V D
001 . 0
1000 582 . 2 ) 1000 / 7 . 202 (
sel
D /
sel
D /

g
V
D
L f
p
cal
sel
2 10000
2

8 . 9 2
582 . 2
10000 2027 . 0
1000 100 024 . 0
2

Fluid Handling

Self- assessment
a. Fill in the blanks
1) Recommended economic velocity for pump suction is --------------
2) Overflow shall be sized based on the ----------- principle
3) NPSH stands for ---------------
4) Erosion may cause in pipeline due to ---------------
b. State whether true or false
1) Cooling water circulation pipeline sizes is done on the basis of lower
velocity.
2) Overflow line shall be sized based on the quality flow principle.
3) For liquid flow under gravity elevation difference mainly governs the
line sizing.
4) Every line sizing for different application guidelines are not valid.
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