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Webinar 18th July 2020
Contacts: jyotiswarup10@gmail.com, Mobile +91 98868 97021
About the speaker:
Mechanical, IIT Graduate, 45 years - Global Experience
Fluid Flow
And Piping
Employment: Nuclear Power Corporation (NPCIL) India; Engineers India Ltd,
India , L& T Valdel Engineering, Hyundai Offshore Korea, Technip Malaysia,
Comprimo Singapore, Sembawang Engineering Singapore; Nippon Steel
Construction Indonesia, Emirates National Oil Company (ENOC) Dubai;
Gryphon Energy Kuala Lumpur.
By: Jyoti Swarup
Expertise: Rotating Equipment, Piping systems, Vibration and Noise, Pressure
vessel, Heat Exchangers, and Tank-farms for Refineries, Oil terminals, Offshore
production facilities, FPSO/ FSO and Jetties.
18th Jul 2020
Codes: ASME Sec. VIII Div. 1 and Div. 2, API 610, API 613, API 614, API 617
etc. TEMA codes, API 620, API 650, API 575, API 653, ASME B31.1, B31.3 &
British Standards PD/BS 5500, etc.
4:00 PM to 6:00 PM
Google Meet
Previous Trainings Conducted: Sarawak Shell Berhad Malaysia, ExxonMobil
Singapore, Sembawang Engineering Singapore, Plant Engineering
Construction Singapore, ENOC Dubai, Tripatra Jakarta, Indonesia, HPCL India,
Quest Bangalore, Dubai Electricity & Water Authority (DEWA), Brunei Shell
Petroleum, Carthage Power Company Tunisia etc.
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Piping – Basics (1/2)
Piping – Basics (2/2)
Piping is seen in every day life – water supply from Water works
to your home, drain piping from home, irrigation pipes in farms,
cooling water to buildings.
Engineering is optimization – how to select most
optimum size and details of piping system from water
tank to your building or in a process plant?
The parameters are pipe materials, flow rate required,
desired velocities, pressure available at source and
pressure required at final outlet. These determine pipe
diameter and thickness.
After industrial revolution in 1700s, pipes were used to carry
pressurized, heating fluids, e.g. steam engines.
In a process plant, piping system account for a significant
portion of plant cost say 2020-25%.
The pipe and fittings
have pressure loss
while fluid is traveling
over its path from
source to destination.
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L.A. like ancient Rome - Aquaducts
Piping Engineering
Responsibilities of a Piping engineer:
Piping
Piping Engineering, design and layout
Pipe
Pipe flexibility analysis and support system design
Pipe
Pipe rupture restraints and jet shield design, if applicable
Piping
Piping around equipment
 Producing piping bill
of materials,
Isometrics etc. and
coordination of
piping fabrication
contract.
 Interface with other
disciplines
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Fluid Flow and Piping, by Jyoti Swarup
Lead pipe to supply water to the Great
Bath at Bath Roman Baths.
The pipe has a folded seam and is
thought to have carried water under
pressure.
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Webinar 18th July 2020
Pipe Sizes & Available lengths
Piping type, thicknesses commonly used ?
Standardized pipe dimensions, defined by OD and thicknesses defined by
schedules are available in the market to simply the interchangeability and the
work of piping engineers.
Pipes in various thicknesses available for each size. Three different
sources
ANSI Schedule numbers 10, 20, 30, 40, 60, 80, 100, 120, and 160. (Also Sch 5S,
10S, 20S, 40S, 80S for Stainless steels.)
ASME / ASTM Std, XS (extra strong) and XXS (Double extra strong)
API 5L specified thicknesses
Pipe Sizes available are ½”, ¾”, 1”, 1 ½”, 2”, 3”, 4”, 6”, 8”, 10”, 12”, and larger sizes.
(14”, 16”, 18”, 20”, 24”, 28”, 30”, 32”, 34”, 36”, 42”, 48”)
The pipe upto 12” size is nominal diameter and pipe OD is more than that in
inches.
Thin walled pipes of Stainless Steel are classified as Sch 5S and 10S.
The pipes are either “Seamless” made from piercing solid billets or
Welded type made from plate – either straight seam welded or spiral
welded.
Pipe 14” and above has same OD as pipe nominal diameter.
Pipes are supplied as “Random lengths” (17 to 25 ft) or “double random”
lengths (38 to 48 ft)
“Nominal Pipe Size (NPS) is a dimensionless
designator of pipe sizes
The pipe ends are either plain ends, beveled ends or “threaded and
coupled”.
Diameter Nominal (DN) is a designator of
pipe sizes in metric units.
Joining methods include Butt Welded, Socket welded, screwed, Bolted
Flange, and Quick couplings.
For example: NPS 2” OD is 2.375”. DN 50 is
same as NPS 2.”
Pipe Wall thickness usually has a mill tolerance allowed
as per codes. For Carbon steel pipes, it is ±12.5%.
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Shell DEP :
Dimensions and
Properties
Pipe
dimensions
and weight
of pipes DN 6 to DN
750 (Sampleonly)
ANSI B 36.19
Ref: Van Leeuwen
Stainless
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Applicable ASME Codes and Standards
ASME B31.3 - 2018 - Process Piping
The increase of operating temperatures and pressures lead to development of B31 Codes in
60s and 70s; currently as below:
Power Piping
ASME B31.1
Fuel Gas Piping
ASME B31.2
Process Piping
ASME B31.3
Pipeline for Liquid
ASME B31.4
Refrigeration Piping
ASME B31.5
Design of chemical and petroleum plants and refineries
processing chemicals and hydrocarbons, water and steam.
This Code contains rules for piping typically found in petroleum
refineries; chemical, pharmaceutical, textile, and cryogenic
plants; and related processing plants and terminals.

Gas Pipeline systems ASME B31.8
System Integrity Gas
ASME B31.8S

Building Servics Piping ASME B31.9
Slurry Transpt Piping ASME B31.11
Hydrogen Pipeline
ASME B31.12
Corroded Pipelines
ASME B31G

Others are B31E Seismic Design, B31J SIF, B31P Heat
Treatment, B31Q Pers. Qualification, B31T Toughness.
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Fluid Flow and Piping, by Jyoti Swarup
It prescribes requirements for materials
and components, design, fabrication,
assembly, erection, examination,
inspection, and testing of piping.
This Code applies to piping for all fluids
including: (1) raw, intermediate, and
finished chemicals; (2) petroleum
products; (3) gas, steam, air and water;
and (4) cryogenic fluids.
Also included is piping which
interconnects pieces or stages within a
packaged equipment assembly.
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Webinar 18th July 2020
Material Selection
PIPE FITTINGS
Considerations for selecting piping materials:
Type
Type of service
Compatibility
Compatibility with other materials
Mechanical
Mechanical strength, ductility, elasticity and toughness
To be able to route a pipe across a plot
or through a building, one requires
elbows, reducers, tees, flanges, nipples
etc for usually drains, vents and
instrumentation.
Need
Need for special welding procedures or other joining
techniques
Need
Need for special inspections, tests or quality control
Possible
Possible misapplication in the field
Corrosion
Corrosion and erosion caused by internal fluids and/ or
marine environment
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Pipe Flanges
Welding Neck Type
Slip On
Blind
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Pipe data – on Mobile?
Lap Joint Flange
Standard Sizes
(dimensions) of Pipes and
Fittings are available on
Mobile apps. Some of
them may be
• Pipedata
• Pipe and Fittings
• Piping Toolbox: ASME,
Flange, Fitting
Engineering
• Piping Dimensions
• Etc.
Threaded
Socket Welded
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Example – Water Piping
Assuming a 25m high storage tank, the water pressure at ground
level shall be approx. 2.5 barg.
barg. (10.19 m Water Column is 1 bar.)
Assuming a Carbon steel piping of say 4” diameter, over a length
of 1,000m, with many elbows, valves, etc. will require a pressure
loss of ~1.1 bar for a flow rate of 30 m3/hr. Thus final pressure
available is (say) 1.4 bar at the ground level of the building.
The 4” pipe will have many outlets for various flats in an
apartment complex, say pipes of 1” and ½” size connections..
At 2nd floor, which is say 7m above ground level, the pressure
available in bath is < 0.7 bar.
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Jyoti Swarup
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Flange Ratings, ASME B16.5
Piping & Valves Codes
ASME B31.1 till B31.12
ASME B16.5 Pipe Flanges and Flanged
fittings (NPS
(NPS 1/2 through NPS 24
Metric/Inch Standard)
Ratings defines as nominal
150 lbs,
lbs, 300 lbs,
lbs, 600 lbs,
lbs, 900
lbs,
lbs, 1500 lbs and 2500 lbs.
Covers Size ½” to 24”
All materials Classified as
groups 1.1, 1.2 etc.
Example 150# Flange for a
given (CS) material have a
design pressure at given
temperature. And hydrohydro-test
at 1.5 times design pressure.
Refer ASME B16.5 code for
flange dimensions, no. of bolt
holes, etc.
ASME B16.9 factory made Wrought
steel Butt welding fittings
ASME B16.34 Valves, Flanged, threaded
and welding ends.
ASME B16.47 Large diameter Steel
Flanges (NPS 26 through NPS 60)
API Spec 6D Pipeline and Piping Valves
BS Codes
MSS Codes
IS codes
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Flange Ratings, ASME B16.47
Temp.,°F
150
300
400
600
900
1500
2500
< 100
285
740
985
1,480
2,220
3,705
6,170
ASME B16.34 on Valves also has a Class 4500 but it
applies only to welding end valves
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Flanges MSS SPSP-4444-2019
MSS SPSP-44 “Steel Pipeline Flanges”
covers similar Class 150, 300, 400, 600,
and 900 flanges Size 12” to 60”, Class
150# to 900#
pressure--temperature ratings,
Covers pressure
materials, dimensions, tolerances and
testing Material Grades from F36, F42,
F46, F48, F50, F52, F56, F60, F65, F70,
F80, with yield strength from 36 ksi (F36)
to 80 ksi (F80).
Resulting in large inside pipe diameter
and thinner pipe wall.
Ratings defines as nominal 75#, , 150#,
300#, 600#, and 900#.
Covers Size 26” to 60”
This Standard provides two series of
flange dimensions.
Series A specifies flange dimensions for
general use flanges.
Series B specifies flange dimensions for
compact flanges that, have smaller bolt
circle diameter.
These two series of flanges are not
interchangeable.
ASME B16.47 Series A flanges, adopted MSS SP-44
dimensions but does not cover the SP-44 high
strength materials used in the pipeline industry to
match API line pipe of equivalent grades.
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Some Material Specifications (typ.)
MSS: Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.
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Common Pipe Materials Grades
Minimum Yield Strength and Tensile Strengths
Some Applicable ASME / ASTM Specifications
ASTM A53: Pipe Steel, Black and Hot dipped..
ASTM A106: Seamless Carbon steel pipes
ASTM A234: Wrought Steel Pipe Fittings
ASTM A312: Seamless and Welded Austenitic SS pipe
ASTM A333: Seamless and Welded Low Temp Steel Pipe
ASTM A420: Pipe Fittings Low temp CS
ASME B16.9: Wrought Steel Buttwelded Fittings
ASME B16.20: Metallic Gaskets
ASME B36.10: Welded and Seamless Wrought steel pipes
ASME B36.19: Stainless Steel pipes
API 5L: Spec for Line Pipes
ASME B31.3
Materials
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Fluid Flow and Piping, by Jyoti Swarup
Pressure in psig
Min. Yield
Strength
Min. Ultimate
Tensile
Strength
API 5L
Min. Yield
Grade
Strength
Min. Ultimate
Tensile
Strength
API 5L Grade A
30,000
48,000
•Grade A
30,000
48,000
API 5L Grade B
35,000
60,000
•Grade B
35,000
60,000
A 53
30,000
48,000
•X42
42,000
60,000
A 106 Gr B
30,000
48,000
•X46
46,000
63,000
A 283 Gr B
27,000
50,000
•X52
52,000
66,000
A 333
35,000
60,000
•X56
56,000
71,000
A 312, Tp 304L
25,000
70,000
•X60
60,000
75,000
A 376, TP 304
30,000
75,000
•X65
65,000
77,000
A 789, S 31803
65,000
90,000
•X70
70,000
82,000
A 789, S 32750
80,000
116,000
•X80
80,000
90,000
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Webinar 18th July 2020
Duplex stainless steel UNS S31803
(DIN Material no. 1.4462):
Stainless Steel - Properties
AISI 304 / 304L:
Most common CrCr-Ni 18/8 quality
Used widely in the food processing and pharmaceutical industries for
piping.
Used in chemical industry to manufacture equipment for processes
AISI 304L is used primarily in cases where the metal is deformed or
subjected to thermal loads over extended periods; where there is heating
to temps between 500 and 900°
900°C.
Duplex SS is made up of a 22-phase structure of ferrite and
austenite. The ferrite gives it excellent mechanical properties,
while austenite provides good notch toughness at low
temperatures.
Duplex SS is used in oil and gas production, the chemical and
petrochemical industries and elsewhere. The major alloying
elements are chromium, nickel, molybdenum and nitrogen.
AISI 316/ 316L:
The addition of molybdenum makes this alloy oxygen resistant, even in
the welding zone.
This alloy is found in the chemical industry, where it is used in reactor
vessels, piping and equipment for the production of all sorts of salts and
organic and inorganic acids.
AISI 316L is used primarily in places ‘where the material is exposed to
prolonged thermal loads, particularly at temp. between 500 and 900°
900°C’.
AISI: The American Iron and Steel Institute
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Flange Pressure temperature ratings
Glass Reinforced Plastics (GRP) Piping System
ASMEB16.34aB16.34a-2017,Table22-1.1AStandardClass(MaterialGroup1.1)
Low to medium pressures (typ. 0 – 40 bar) GRP piping system with
nominal diameters 25mm to 1200mm may be used on offshore
installations in nonnon-hydrocarbon service.
Typical applications are
Service (or process) water; Potable water
Cooling medium
Grey water (non hazardous waste)
Chemicals; Non hazardous drains/ vents
Fire water ring main/ wet deluge/ dry deluge
Produced water
Ballast water
The components of GRP piping system are Pipe, bends, reducers,
tees, supports, flanges and joints.
lay--up, or
Manufacturing methods may be filament winding, hand lay
centrifugal casting
Ref: UKOOA Specification and Recommended Practice for the use of GRP Piping Offshore.
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Internal Pressure - Refinery Straight Piping
t
=
Working Pressures by Classes, psig
Temp °F
150#
300#
600#
900#
1500#
2500#
-20 to 100
285
740
1480
2220
3705
6170
4500#
11110
200
260
675
1350
2025
3375
5625
10120
300
230
655
1315
1970
3280
5470
9845
400
200
635
1270
1900
3170
5280
9505
500
170
600
1200
1795
2995
4990
8980
600
140
550
1095
1640
2735
4560
8210
650
125
535
1075
1610
2685
4475
8055
700
110
535
1065
1600
2665
4440
7990
750
95
505
1010
1510
2520
4200
7560
800
80
410
825
1235
2060
3430
6170
850
65
270
535
805
1340
2230
4010
900
50
170
345
515
860
1430
2570
950
35
105
205
310
515
860
1545
1000
20
50
105
155
260
430
770
ASME B16.5-2017 has all these values converted into metric units, temp in °C and pressure in bar
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Representative Allowable Stresses in tension for Materials
(Developed from ASME B31.3, Table AA-1, AA-1B
ASME B31.3, para. 304.1.2
Design Thickness for t < D/6
tm = t + c
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Pi d o
2 (S E W + P Y )
tm = Minimum required thickness, satisfying requirements for pressure, mechanical
corrosion, and erosion allowances.
The minimum thickness T of the pipe selected considering manufacturer’s minus tolerance
shall not be less than tm
t = Pressure design thickness as calculated
c = sum of the mechanical allowances, (thread depth and groove depth) corrosion and
erosion allowances
Pi = Internal design gage pressure
Do = Outside diameter of pipe
S = Allowable Stresses, from Table AA-1 or A1M
E = Longitudinal weld joint factor, Seamless 1.00, ERW, 0.85, Table AA-1B
W = Weld joint strength reduction factor (applicable for T > 510 °C) Para 302.3.5 (e)
Y = Coefficient; for Ferritic steels = 0.4 < 900 °F, 0.5 for 950 °F and 0.7 for 1000 °F and
above.
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Piping Flexibility Analysis
Butane
Condenser
Butane
Accumulator
2nd
Stg
SCR
A
Butane
Separator
PFD
Formal analysis not required if (1) system duplicates a successful
service (2) is adequate by comparison (3) is of uniform size, with ≤ 2
fixed points, no intermediate restraints, and falls within following
limitations
1st
Stg
SCR
A
Butane Tank 180’
dia x 80’ high
Comp. A
D y
≤ K
(L − U )2
K = 2 . 08 Χ 10
2nd
Stg
SCR
B
1st
Stg
SCR
B
1
5
,
SA
( mm / m ) 2
Ea
D = Outside diameter of pipe, mm
Ea = Reference modulus of elasticity at 21 °C, MPa
L = Developed length of piping between anchors, m
SA = Allowable Displacement stress range, MPa
U = Anchor distance, straight line
y = resultant of total displacement strain, mm to be absorbed by
piping system
Comp. B
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Thermal Expansion loops
Piping Flexibility Analysis - Example
Pipe material:Carbon Steel, C ≤ 0.3%
h
Size:
8" Sch 40
SA = f (1.25 Sc + 0.25 Sh), f = 1
Temperature range:
30°C to 400°C
Ea at 21 °C (70 °F)
Range F
86 °F to 752 °F
From Table A-1
Find: h where L = U + 2 h, Length U 100m
Sh = 13000 psi
The expansion stresses and end
reactions shall be calculated using
largest differential temperature
compared with ambient temp.,
including short term/ upset
conditions.
The expansion stresses can be
mitigated by using flexible
connections/ bellows, change in
piping direction or thermal
expansion loops.
The expansion loops in long piping
may be horizontal 2D; or 3D to save
space, specially say for steam line
on pipe racks.
Some guidelines for expansion loop
design are as shown in sketch.
2.95 E07
Sc = 20000 psi
Pipe OD 219.1mm, U = 100m, ΔT = 400 – 30 = 370 °C (666 °F),
Assume h = 5m, L = 110m
Thermal Expansion Coefficient α at 400°C (752 °F) = 7.54 E-06 mm/mm / °F,
Total Displacement strain ε = α ΔT = 7.54E-6 x 666,
y = ε x 100 E3 = 502 mm for 100m span.
SA = 1 x (1.25 x 20000 + 0.25 x 13000) = 28,250 psi, SA / EA = 9.576E-4,
K = 2.08 x E5 x 9.576 E-4 = 199.2 (mm/m)2
D y/ (L-U)2 =(219.1 x 502)/ (110 – 100)2 = 1100 > K, hence 5m loop not acceptable.
Assume h = 12m, L = 100 + 2 x 12 = 124m, L – U = 24m, D y/ (L-U)2 = 191 < K.
Hence, we may need say two loops of 6m each in the run.
(Ref. Exxonmobil GP 0303-7777-06)
ANCHOR
POINT
h
GUIDES
1 ft - 0 in.
(30.48 cm)
MIN. TYP.
PS
a/2
L
a
PS
GUIDES
PS
ANCHOR
POINT
NOTES:
(1) L/a = 20 to 40.
(2) L/h = 10 to 20.
(3) h/a = 2.
(4) Pipe stress and flexibility shall be verified per GP 03-77-06 and GP 03-77-07.
(5) Anchors and guides shall be per GP 04-77-01.
(6) PS = Pipe support.
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Types of Gaskets
Piping Class
Nonmetallic – composite sheet materials for FF flanges, low
pressure applications
Piping Class Ratings 150, 300, 600, 900, 1500, 2500
corresponding to flange ratings.
Piping Class designations A, B, C etc. as in ONGC or 1xx, 3xx,
6xx, 9xx etc. as in Shell specifications.
Providing applicable codes and material selections for pipes,
fittings, flanges, valves, bolts, gaskets and accessories.
Providing design limits in terms of pressure, temperature
ratings, hydrotest pressure, and pipe wall thicknesses for a
given corrosion allowance for all pipe sizes as applicable.
Applicability and any
special requirements.
Material codifications, if any.
Semi Metallic – composite of metal and non metals
Spiral Wound Gaskets for raised face flanges – most commonly used, in all
pressure classes 150# to 2500#
Camprofile Gaskets – solid serrated metal core faced on each side with soft
non metallic material
Jacketed Gaskets – non metallic gasket material in metallic sheath
Metallic Gaskets – high temp. and pressure applications
RingRing-Joint type gaskets: Style R (oval or octgonal),
octgonal), RX (pressure energised R)
and BX (very high pressures). Manufactured to codes API 6A and B16.20.
Lens Ring, Spherical surface, special purpose
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ONGC Piping Class F1 (1500#) 2/2
ONGC Piping Class F1 (1500#) 1/2
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Fluid Flow
Few Problems in fluid flow may be solved with acceptable
accuracy using idealized equations.
Several empirical formulas have been developed to fit particular
circumstances in predicting flow capacity and pressure drops.
Beranoulli Theorem based on conservation of energy as total of
elevation, pressure head and velocity at points 1 and 2,
considering friction loss hL may be defined as
Ze1 + P1 / ρ1 + V12/2g = Ze2 + P2 / ρ2 + V22/2g + hL
Modifications to above equation have been proposed by many
investigators to account for this friction losses.
Jyoti Swarup
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Fluid Physical Properties
VISCOSITY: readiness by which a fluid flows when acted upon by
an external force and is temperature dependent
Absolute viscosity is a measure of fluids resistance to deformation
Kinematic Viscosity is ratio of absolute viscosity to mass density.
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Reynolds Number
At low velocities, the velocity of fluid at the centre of the pipe
is maximum and zero at pipe wall. (laminar flow)
At higher velocities, the fluid particles begin to show a random
motion transverse to the direction of flow (turbulent flow)
Specific Volume is inverse of density.
Relative density of a gas is the ratio as
Reynolds number defined as Re = D V ρ /μ defines this
transition. Re < 2,000 flow is laminar, Re . 4,000 is turbulent. In
between Re 2,000 to 4,000 it is undefined.
γ = M (gas)/ M (air)
Non circular conduits, equivalent diameter D may be
approximated as 4 x Hydraulic radius as
Hydraulic radius = Area of Flowing fluid/ Wetted perimeter
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Reynolds number
Flow velocity limits
Velocity in single phase liquid lines should not normally exceed 5 m/sec
at maximum flow rates to minimize flashing ahead of control valves.
Velocity should not be less than 1m/sec to minimize deposition of
sands and other solids.
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Reynolds number (CGS units)
Reynolds number (FPS units)
 Dimensionless number Re = D V ρ / μ where
ρ = liquid density, lb/ft
μ = liquid viscosity, cP
lb/ft3
D = Pipe ID, ft
V = fluid velocity, ft/sec
 Example 4” Sch 40 pipe, OD = 4.5”, Thk = .216”, Pipe ID =
4.068” = 0.339 ft
 Assumed Flow rate 30 m3/hr = 1059.4 ft3/hr = 0.2943 ft3/sec
 Flow velocity = Flow / area = 0.2943/(π
0.2943/(π ID2/4) = 0.2943 /3.1415
/ 0.3392 x 4 = 3.26 ft/sec
Water Density 62.4 lb/ft
lb/ft3,
Viscosity 1 cP = 0.000672
lbm/ft
lbm/ft sec,
Reynolds number Re =
0.339 x 3.26 x 62.4 /
0.000672 = 102,620
Dimensionless number Re = D V ρ / μ where
ρ = liquid density, kg/m3
μ = liquid viscosity, Pa.s
D = Pipe ID, m
V = fluid velocity, m/sec
Example 4” Sch 40 pipe, OD = 0.1143m, Thk = 5.486mm, ID =
103.33mm = 0.10333 m
Flow rate 30 m3/hr = 0.0083 m3/sec
Flow velocity = Flow
/ area = 0.0083/(π
0.0083/(π ID2/4) = 0.0083
/3.1415 / 0.103332 x 4 = 0.994 m/sec
Water Density 1000 kg/m3, Viscosity 1 cP,
cP, Reynolds number
Re = 0.10333 x 0.994 x 1000 / 1 x 1000 = 102,710
Kinematic Viscosity ν = μ / ρ
1 cSt (centiStokes) = 10-6 m2/s
Dynamic Viscosity 1 cP
= 0.001 Pascal second
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Typical Roughness of pipe materials
Pipe Friction
The resistance to the incompressible flow of any fluid in
any pipe is from the equation
hf = f (L/D) (V2/2g)
hf frictional resistance in ft (m) of fluid
L Total design length of pipe in ft (m)
V average velocity in pipe ft/sec (m/sec)
g acceleration due to gravity ft/sec2 (m/sec2)
f friction factor, which can be computed from Colebrook
equation (or Moody charts)
1 / √f = 2 log10 [ε / (3.7D) + (2.51/Re √f )]
ε = surface roughness parameter, which may be as
typically below
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Fluid Flow and Piping, by Jyoti Swarup
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Material
ε ft
μm
Plastic Piping
0.000005
2
Steel or wrought iron
0.000150
46
Asphalt-dipped CI
0.000400
122
Galvanized iron
0.000500
152
Cast Iron
0.000850
259
Concrete
0.003000
914
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Webinar 18th July 2020
Moody friction factors as a function of Reynolds numbers
Relative
Roughness of
Pipe
materials
and friction
factors for
complete
turbulence
(Ref GPSA)
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Pressure Drop calculations - Example
GPSA:
Equivalent
lengths for
valves and
fittings
Example
Darcy-Weisbach formula
Pipe length m
Flow rate m3/Hr
Flow rate m3/sec
Diameter mm
Roughness e mm
Kin. Viscosity 20 °C m2/sec
Velocity V m/sec
Ratio e/D
Reynolds Number VD/ν
Moody Friction factor f
Friction loss m H2O
Water Flow
Asphalt Pipe Comerc. Stl
1000
1000
180
1440
0.05
0.4
200
500
0.12
0.045
1.01E-06
1.01E-06
1.59
2.04
0.0006
0.00009
3.15E+05 1.01E+06
0.018
0.013
11.62
5.50
GPSA: Gas Processors
Supplier Association
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Head Loss
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Pipe Span Calculations
Pressure drop in a piping can be
calculated using the flow parameters
as above by adding the equivalent
length of various fittings into the pipe
length.
For a 4” Sch 40 pipe, 600 GPM Water
flow rate, Surface Roughness
0.048mm, Re = 471,000, and a
pressure drop of 1.81 bar for a eq.
pipe length of 100m. The flow velocity
is 4.61 m/sec.
A simple web based online calculator
as shown may be used. There are
many such calculators available on the
net.
This calculator has calculation options
for bends, Tees, Valves, Strainers etc.
 Maximum allowable spans between supports for
horizontal piping are limited by three factors
Bending
Bending Stress
Vertical
Vertical deflection
Natural
Natural Frequency
Natural frequency is related to
maximum deflection as f = 1/2π
√( g/ Δ ) = 3.12/Δ, where g = 386
in/sec2, Δ deflection in inches.
Thus for a 1” sag, natural
frequency is 3.12 cps.
http://www.pressure-drop.com/Online-Calculator/
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Webinar 18th July 2020
Deflection and Stress is based on end conditions
Pipe Deflections
If both ends Simply supported, and no concentrated loads
(e.g. valves)
L = √ (8 Z Sh / w) limited by Stress
L = 4√ (384 Δ E I / 5 w) limited by deflection
If end condition assumed between simply supported and fixed
at both ends, we may use
L = √ (12 Z Sh / w) limited by Stress
L = 4√ (384 Δ E I / 3 w) limited by deflection
L allowable pipe span in
Z modulus of section of pipe, in3
Sh allowable tensile stress at design temp. Refer Table AA-1,
B31.3 x Factor (Typically 1500 to 3000 psi)
w total weight of pipe (Metal + Contents + Insulation) lb/in
lb/in
Δ allowable deflection sag, in
C--6, B31.3
E modulus of elasticity at design temp, psi , Table C
Example : 10” Std WT, 400 °F, A106 Gr B
Filled with Liquid, Sp. Gr. 1.2,
Insulation 2” Calcium Silicate, 11 lb/ft
lb/ft3
Assume maximum deflection allowed 5/8”
Self weight = PI/4 (10.752-10.022)(0.283)(12) = 40.44 lb/ft
lb/ft
Contents weight = PI/4 (10.022)(62.4/123)(12)(1.2) = 41.0 lb/ft
lb/ft
Insulation weight = PI/4 (14.752-10.752)(11/123)(12) = 6.12 lb/ft
lb/ft
Total weight of pipe 40.44 + 41.0 + 6.12 = 87.56 lb/ft
lb/ft = 7.30 lb/in
lb/in
Allowable Stress at design temperature (assumed) 20,000 psi x .25
Section Modulus Z = 29.9 in3
Young’s Modulus 27.2 x 106 psi, Moment of Inertia I = 160.7 in4
Limited by stress L = √ (8 Z Sh / w) = √8 29.9 20000 0.25 / 7.30 = 33.7 ft (10.28m)
Limited by deflection L = 4√ (384 Δ E I / 5w) = 4√384 5/8 27.2E6 160.7 / 5 7.30 =
34.3 ft (10.5m)
Select lower of the two i.e. 33.7 ft as maximum span allowed.
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ASME B 31.131.1-2018 Table Pipe support Spans (1/2)
Shell DEP 31.38.01.11
Appendix 11
(a) Suggested max. spacing between supports
for horizontal straight runs of standard and
heavier pipe at max. op. temp. of 750°
750°F
(400°
(400°C).
(b) Does not apply where span calculations
are made or where there are concentrated
loads between supports, such as flanges,
valves, specialties, etc.
(c) The spacing is based on a fixed beam
support with a bending stress < 2,300 psi
(15.86 MPa) and insulated pipe filled with
water or the equivalent weight of steel pipe.
A sag of 0.1 in. (2.5 mm) between supports is
permissible.
(d) See Table 121.5121.5-1 attached in next slide
Pipe Spans for
CS & Heavy
Wall SS pipes
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ASME B31.1 Table 121.5-1
Suggested Steel Pipe Support Spacing
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Equipment Layout (1/2)
Equipment layout shall be
developed based on the
following data:
P&IDs
P&IDs
Overall
Overall Plot Plan
Wind
Wind direction
Equipment
Equipment Data Sheets
Indicative
Indicative Equipment
Layout from Process
Licensor
Process
Process package
These values are identical to support spacing in MSS-SP-58
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Webinar 18th July 2020
SELECTION OF VALVES
Equipment Layout (2/2)
The skills required for plant layout designer of a project as well as
person vetting those layouts include:
Common
Common sense and creativity
Knowledge
Knowledge of what a particular plant is designed to do.
A
A general understanding of how process equipment is
maintained and operated.
The
The ability to generate a safe, comprehensive layout within a
specified time and with consideration toward constructability
and costcost-effectiveness.
Knowledge
Knowledge and the ability to use input from other disciplines.
Willingness
Willingness to compromise in the best interest of the project.
* Designed to control flow Throttle or On-Off
* Operated Manually, Remotely or Automatically
* Variety of Materials
LIFE CYCLE COST
VALVE SELECTION
INITIAL EXPENSES
REPLACEMENT VALVE
LABOR FOR REPLACEMENT
DOWNTIME AND LOSS OF
PRODUCTION
 INTERNAL LEAKAGE
 ENVIRONMENTAL
CONCERNS
 DECIDE TYPE OF FLOW
CONTROL
 TYPE OF VALVE
 MATERIAL OF
CONSTRUCTION
 MANUFACTURER




The
The ability to generate clear and concise documents, and to
defend designs when challenged.
VALVE VARIETIES
 GATE
 GLOBE
 QUARTER TURN (Plug, Ball,
Butterfly)
 CHECK
ASME B16.34-2017▹Valves - Flanged, Threaded
and Welding End covers Valves upto 60” size
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Thank You
3D Plant Design and Management System
Contacts: jyotiswarup10@gmail.com, Mobile +91 98868 97021
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Exercise
1.
For an 10” 600# flange, 400°
400°F operating, CS material, what is design
pressure in bar and psi in ASME B16.5? Also, design pressure at ambient
temp. (Hint Refer ASME B16.5 Table IIII-2-1.1 Pressure–
Pressure–Temperature Ratings for Group 1.1 Materials.)
2.
What is above size Flange OD in inch and mm from ASME B16.5 (or Mobile
apps)? WNRF flange weight & Nuts/ Bolts weight?
3.
What is Seamless CS (A(A-106 Gr B) 10” pipe OD? Welded 10” Pipe OD?
4.
Please calculate pipe thickness for above 600# flange design pressure at
ambient temperature? CA=1.5 mm. (Hint: See ASME B31.3 Table AA-1 Basic Allowable
Stresses in Tension for Metals for S.)
5.
What pipe schedule can be used for above design if mill tolerance on pipe
thk.
12.5%.
thk. is ±12.5%.
6.
What is Pressure drop in above pipe (10” Sch xxx) 150m long, flowing liquid
300 m3/Hr, Sp. Gr. 0.8, Pipe roughness to be assumed 0.045 mm and Fluid
kinematic Viscosity 0.3E0.3E-6 m2/sec (0.3 cSt).
cSt).
7.
Above Pipe support span (in m and ft) from table in the ppt. (Assume
insulated pipe as it is high temperature.). Also, to verify this with pipe
support span calculations.
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