JTB-SF-P-CAL-900-00003 - 0 Calculation - Lines Sizing (Replace)

GAS DEVELOPMENT PROJECT
FOR THE UNITIZATION OF

THE JAMBARAN-TIUNG BIRU FIELD
CALCULATION – LINE SIZING
DOCUMENT NUMBER: JTB-SF-P-CAL-900-00003
CONTRACTOR COMPANY
REV DESCRIPTION DATE
PREPARED CHECKED APPROVED REVIEWED APPROVED
A Issued for Internal Review 03-Nov-14 ANR SAN PG
B Issued for Review 28-Nov-14 ANR SAN PG
C Issued for Approval 19-Jan-15 ANR ARY/SAN PG
0 Issued for Design 13-Mar-15 ANR ARY/SAN PG
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REVISION HISTORICAL SHEET
Page/Section Date Description
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Table of Contents
1 INTRODUCTION......................................................................................5
1.1 Scope............................................................................................................................... 5
2 DEFINITIONS AND ABBREVIATIONS..........................................................5
3 REFERENCES..........................................................................................5
4 DESIGN BASIS..........................................................................................7
4.1 Fluid Condition and Properties Data.................................................................................7
4.2 Sizing Basis..................................................................................................................... 7
4.3 Line Sizing Margin............................................................................................................ 7
4.4 Sizing Criteria for Single Phase Liquid Lines....................................................................7
4.5 Pumped Liquid for Salt and Produced Water...................................................................9
4.6 Liquids Flowing by Pressure..........................................................................................10
4.7 Gravity Flow Lines..........................................................................................................10
4.8 Liquids from Drain Boxes...............................................................................................10
4.9 Static Accumulation........................................................................................................11
4.10 Firewater........................................................................................................................ 11
4.11 Other Corrosive Liquids..................................................................................................11
4.12 Drains............................................................................................................................. 11
4.13 Tank Overflows............................................................................................................... 12
4.14 Single Phase Gas Line...................................................................................................12
4.15 Line Sizing Criteria for Two Phase Flow.........................................................................13
4.15.1 Flow Pattern.....................................................................................................13
4.15.2 Erosion.............................................................................................................14
4.15.3 Line Sizing Criteria for Two Phases..................................................................15
4.16 Sizing Criteria for Relief and Depressuring Lines...........................................................15
4.16.1 Relief Valve Inlet Lines.....................................................................................16
4.16.2 Relief Valve Outlet Lines...................................................................................16
4.16.3 Flare Headers and Sub Headers......................................................................17
4.16.4 Flare Stack.......................................................................................................17
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4.16.5 Blowdown Inlet Lines........................................................................................17

4.16.6 Blowdown Outlet Lines.....................................................................................17
4.16.7 Atmospheric Tank Vents...................................................................................17
4.16.8 Calculation Methods.........................................................................................17
4.16.9 Liquid Nozzle Sizing.........................................................................................18
5 CALCULATION METHOD.........................................................................18
5.1 Single Phase Gas Line Calculation................................................................................18
5.1.1 Velocity.............................................................................................................18
5.1.2 Pressure Drop..................................................................................................18
5.1.3 Friction Factor...................................................................................................19
5.2 Single Phase Liquid Line Calculation.............................................................................20
5.2.1 Velocity.............................................................................................................20
5.2.2 Pressure Drop..................................................................................................20
5.2.3 Friction Factor...................................................................................................21
5.3 Two Phase Line Calculation...........................................................................................21
5.3.1 Erosional velocity..............................................................................................21
5.3.2 Minimum diameter............................................................................................21
6 METHODOLOGY......................................................................................22
7 RESULT.................................................................................................22
APPENDICES..............................................................................................23
APPENDIX A – LINE SIZING CALCULATION (PROCESS)....................................23
APPENDIX B – LINE SIZING CALCULATION (UTILITIES)...................................24
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1 INTRODUCTION
Gas Development Project for the Jambaran– Tiung Biru Field is located onshore on the
island of Java, between the cities of Cepu and Bojonegoro. The Processing Facility is
needed to gather gas from various wells, remove or reduce undesirable H2S and CO2
components to acceptable limits, meet sales specifications and safety, transport the gas at
the required pressure, temperature, quantity and quality to the sales point.
1.1 Scope
This document is intended to present the line sizing calculation for Gas Development
Project of Jambaran-Tiung Biru Field in all process and utility unit.
2 DEFINITIONS AND ABBREVIATIONS

API American Petroleum Standard
BFW Boiler Feed Water
EG Ethylene Glycol
GPSA Gas Processor Supplier Association
HP High Pressure
LP Low Pressure
NPS Nominal Pipe Size
TEG Tri Ethylene Glycol
3 REFERENCES
Document No. Document Title

JTB-SF-P-PHI-900-00004 Equipment Design Criteria, latest revision
JTB-SF-P-PFD-221-00003 Heat and Material Balance Inlet Separation, Design
Case 2
JTB-SF-P-PFD-222-00003 Heat and Material Balance Produced Water Storage,
Design Case 2
JTB-SF-P-PFD-223-00003 Heat and Material Balance Condensate Storage,
Design Case 2
JTB-SF-P-PFD-224-00003 Heat and Material Balance Vapor Recovery Unit,
Design Case 2
JTB-SF-P-PFD-231-00003 Heat and Material Balance Dew Point Control, Design
Case 2
JTB-SF-P-PFD-232-00003 Heat and Material Balance Condensate Stabilization,
Design Case 2
JTB-SF-P-PFD-233-00004 Heat and Material Balance EG Regeneration, Design
Case 2
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JTB-SF-P-PFD-234-00003 Heat and Material Balance Refrigeration Unit, Design

Case 2
JTB-SF-P-PFD-240A-00009 & Heat and Material Balance Refrigeration Unit, Design
JTB-SF-P-PFD-240A-00010 Case 2
JTB-SF-P-PFD-250-00003 Heat and Material Balance Sales Gas Dehydration Unit,
Design Case 2
JTB-SF-P-PFD-260-00003 Heat and Material Balance Sales Gas Compression
Unit, Design Case 2
JTB-SF-P-PFD-280A-00009 ~ Heat and Material Balance Acid Gas Enrichment Unit,
JTB-SF-P-PFD-280A-00012 Design Case 2
JTB-SF-P-PFD-290-00007 ~ Heat and Material Balance Acid Sulphur Recovery Unit,
JTB-SF-P-PFD-290-00009 Design Case 2
JTB-SF-P-PFD-310-00003 Heat and Material Balance Tail Gas Unit, Design Case 2
JTB-SF-P-PFD-460-00005 Heat and Material Balance Thermal Oxidizer Unit,
Design Case 2
JTB-SF-P-HMB-410- Heat and Material Balance BFW, Steam, and
00007~00018 Condensate System; Design Case 2
JTB-SF-P-UFD-440-00003 Heat and Material Balance Air System
JTB-SF-P-UFD-440-00004 Heat and Material Balance Nitrogen System
JTB-SF-P-UFD-450-00003 Heat and Material Balance Water Treating
JTB-SF-P-CAL-900-00018 Fuel Gas Consumption Calculation
JTB-SF-P-CAL-900-00026 Equipment Sizing – Utility Vessel Sizing
JTB-SF-P-CAL-900-00004 Equipment Sizing – Tank Sizing
JTB-SF-L-SPE-900-00005 Specification for Piping Material Class
JTB-SF-P-RPT-900-00001 Flow Assurance Study
JTB-SF-P-CAL-900-00007 Equipment Sizing – Emergency Depressurization
API STD RP 14E Recommended Practice for Design and Installation of
Offshore Production Platform Piping Systems, fifth
edition, October 1, 1991
GPSA 12th edition, section 17 Fluid Flow and Piping
4 DESIGN BASIS
4.1 Fluid Condition and Properties Data

Fluid condition and properties used in Line Sizing Calculation are taken from Heat and
Material Balance Case-2 for process & utility lines, and Case-4 for liquid & mixed phase in
Inlet Separation Unit (221).
4.2 Sizing Basis

Sizing piping shall consider for the controlling operating case determined by analysis of
flowrates, mechanical and process limitation, expected life time of piping, CO 2/H2S content,
etc. When sizing of the piping, following constraints shall be considered such as: required
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capacity/available driving pressure, flow induced forces, noise/vibration, pressure surges,

erosion, corrosion, cavitation, liquid accumulation/slug flow, stability of two phase flow, and
sand accumulation.
For gas and two phase lines, particular attention shall be given to the effects of changes in
operating pressures, temperatures and gas composition with time.
No provision for future increased capacity shall be made unless stated otherwise.
Pressure drop in either liquid, gas or two-phase line is assumed to be linear with pipe
length. Pressure drop due to piping components are to be accounted for in terms of
equivalent length.
Piping not protected by a pressure relieving device, or that can be isolated from a pressure
relieving device, shall be designed for at least the highest pressure that can be developed.
All piping shall be sized / designed to eliminate / minimize the impact of pressure surge due
to transient operating condition and events.
Minimum size of process lines is ¾ inch. Minimum pipe size on pipe rack is 2 inch.
4.3 Line Sizing Margin

The design margin applied to the equipment shall also apply to the lines entering and
exiting the equipment. For all other lines in general (e.g. utilities, etc) a design margin of
10% shall be applied to design flowrates. No margin should be added to the calculated
pressure drop in this case. Where the addition of 10% increases the line size, engineering
judgment will be applied to determine if the line size increase is in fact warranted based on
system hydraulics and fluid velocities.
4.4 Sizing Criteria for Single Phase Liquid Lines

The sizing of single phase liquid lines shall be based on considerations of both pressure
drop and velocity in accordance with the guidelines given below. In determining maximum
allowable velocities, consideration shall also be given to noise and erosion/corrosion
aspects.
In systems where sand may be present, a minimum velocity of 1 m/s shall be maintained
for all pipe sizes to minimize sand depositions in the lines. This may be relaxed for the
liquid pipeline where pigging and other corrosion control methods are available.
Table 4.1 – Line Sizing Criteria for Single Phase

Max Pressure Drop (psi/100ft)
Line Size
No Service Velocity
(in) Normal Max
(ft/s)
2
≤ 2” 0.3 0.4
3
Pump Suction, 3” – 10” 0.3 0.4
4
1 buble point (1) 12” - 18” 0.3 0.4
5
≥ 20” 0.3 0.4
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Line Size Max Pressure Drop (psi/100ft)

No Service
(in) Velocity Normal Max
(ft/s)
≤ 2” 3 1.0 1.6
Pump Suction, 3” – 6” 4 1.0 1.6
2
subcooled 8” – 18” 5 1.0 1.6
≥ 20” 6 1.0 1.6
Pump discharge :
up to 20” 5 – 20 1.6 2.0
3 P ≤ 725 psig
5 – 20 3.0 4.0
P > 725 psig
4 Gravity flow - 2 0.1 0.2

Side stream ≤ 2” 2 0.3 0.4
5
draw-off(2) ≥ 3” 3 0.3 0.4
6 Cooling Water 10 1.0 1.6
7 BFW Up to 20” 20 1.6 2.0
≤ 2” 2 0.3 0.4
8 Column Outlet
≥ 3” 3 0.3 0.4
Notes:
1. Applicable to liquid to Thermosyphon Reboiler and liquid containing dissolved gas.
2. Provide a vertical run of 10 ft minimum from nozzle (at nozzle size) before reducing the size of
the line.
3. For non gravity flow lines, not pumped, use pump discharge criteria.
4. 4” lines of carbon steel is carrying only liquid amine solution, a velocity of 2 m/s (6½ ft/s) shall
not be exceeded in order to avoid erosion corrosion.
Friction factor should be calculated using pipe roughness as specified in the Table 4.2
below.
Table 4.2 – Roughness value
Roughness
Material / Application
in mm
Carbon Steel non-corroded 0.0018 0.046
Carbon Steel for Flare/Vent Headers (Heavily

0.0181 0.46
Corroded)
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Roughness
Material / Application
in mm
Stainless Steel for Flare Headers (Hot Rolled,
0.0018 0.046
Longitudinally Welded)
Duplex/Stainless Steel (New Seamless, Cold Drawn) 0.0016 0.041
Galvanised Carbon Steel 0.0059 0.15
Epoxy Lined Pipe 0.0059 0.15
Glass Reinforced Epoxy (GRE) 0.0002 0.005
Flexible line (rough bore) ID/2 (Note 1) ID/20 (Note 1)

Note 1: ID is in inch. This formula is an approximate and shall be used for preliminary
calculation only. Vendor to be clarified.
4.5 Pumped Liquid for Salt and Produced Water

The sizing of single phase liquid lines shall be based on considerations of pressure drop
and velocity. In determining maximum allowable velocities, consideration shall also be given
to erosion, water hammer pressure surges, noise, vibration and reaction forces aspects.
The following are the criteria for pumped (liquid flowing by maximum velocity) line sizing for
salt and produced water:
Table 4.3 – Pumped Liquid Line Sizing Criteria
No Pipe NPS mm (Inch) Max. Velocity, ft/s (m/s)

1 25 (1”) 4.0 (1.2)
2 50 (2”) 6.0 (1.8)
3 75 (3”) 8.0 (2.4)
4 >100 (4”) 10.0 (3.0)
4.6 Liquids Flowing by Pressure

In general, these lines sizing shall refer to Table 7.3 above. Lines where flashing may occur
upstream of control valves and flow meters shall be sized according to the pump suction
criteria for pressure drop The line should be sized to prevent vapor flash ahead of the
valve. Where the available pressure drop is low, the line should be sized such that the
actual pipe frictional pressure drop does not exceed 50% of the available pressure drop.
4.7 Gravity Flow Lines

Gravity flow lines shall be sized using a maximum pressure drop of (0.15 psi/100ft)
equivalent length (based on 1:100 slopes). This may be exceeded for sub-cooled liquids
with large available heads. Caution should be taken to prevent flashing in barometric legs.
Pipes with a diameter below 200 mm (8 inches) shall be designed for 50% full of liquid,
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while pipes with a diameter of 200 mm (8 inches) and greater shall be designed for 75% full
of liquid.
4.8 Liquids from Drain Boxes

In addition to the sizing criteria given for gravity flow lines, the Froude Number for
this service shall be less than 0.3 to avoid air entrainment (self-venting downflow).
For fully flooded vertical downflow, the Froude number shall be greater than 0.6.
FR = V / (gu D)1/2
Where
FR = Froude Number
V = Velocity (ft/s)
gu =
[ ρl−ρ g ]
g
ρl = density of liquid (lb/ft3)
ρg = density of gas or vapor (lb/ft3)
g = 32.2 ft/s
D = internal pipe diameter (ft)
Gravity flowlines shall be sized to avoid the formation of siphons and to avoid pulsation and
vibration. One of the following methods can be adopted dependent on the individual
engineering circumstances:
 Size the line as self venting as above.
 Install a siphon breaker at the system high point.
 Size the line for all expected flow rates such that frictional forces offset gravitational
forces thus avoiding sub-atmospheric pressures at the top of the pipe.
 Install a back-pressure control near the base of the line.
4.9 Static Accumulation

The maximum velocity in lines entering/leaving tanks containing hydrocarbons, and not
installed with a gas blanket shall be limited to 0.9 m/s (3 ft/s) in the first 9 m (30 ft) of line
to/from the tank in order to reduce the accumulation of static charge. This criterion applies
to tanks containing flammable fluids such as diesel, jet fuel etc. Refer also to API RP 2003
– Protection against Ignitions Arising out of Static, Lightning and Stray Currents.
4.10 Firewater
The design of the firewater piping systems shall be conformed to “Specification for Piping
Material Class”, Doc. No. JTB-SF-L-SPE-900-00005. Pipe flow velocities shall not exceed 6
m/s (20 ft/sec) in any area of the distribution system piping, or any lower velocitiy required
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due to the properties of the pipe material. Pressure drop in firewater distribution systems
shall be evaluated using PIPENET.
4.11 Other Corrosive Liquids

To minimize corrosion, pipes containing corrosive liquids shall be sized for the maximum
velocities and pressure drops. Table 7.4 is guidelines for Lines Containing Corrosive iquids
as follow.
Table 4.4 – Guidelines for Lines Containing Corrosive Liquids
Max. ∆P Maximum Velocity ft (m/s)
Service Psi/100ft
NB 4” (100mm) & NB 6” (150mm) &
(kPa/100m)
smaller larger
Pump Suction 0.5-1.0 (11.3-22.6) 3-3.6 (0.9-1.1) 5 (1.5)
Pump Discharge 2 (45.2) 5 (1.5) 5 (1.5)
4.12 Drains
To avoid deposits of solid particles, sewage, closed and open drains shall be designed for
the minimum fluid velocities given in Table 7.5 below.
Table 4.5 – Guidelines for Sizing Drain Piping
Max.Velocity
No Service
ft/s (m/s)
1 Sanitary drains 2.6 (0.8)
2 Oily water drains (Open drains) 3.0 (0.9)
3 Other drains 3.6 (1.1)
However, a minimum size of NPS 4” (100) shall be used for the headers and NPS 3” (75
mm) for sub headers.
4.13 Tank Overflows

Overflows are sized for the maximum net inflow to the tank taking full advantage of
the available head above the overflow. For overflows through vertical internal pipes, use the
Francis formula:
Q = K.D.H.1.5
Q = flowrate (ft3/min)
D = pipe internal diameter (inch)
H = liquid height above top of overflow pipe (inch)
K = constant = 1.26 (for above units)
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4.14 Single Phase Gas Line

Sizing Criteria for Single Phase Vapor Lines, Steam and Condensate (Steam) Lines for
gases, final line sizing shall be based on the pressure drop calculations. For tentative line
sizing, the following criteria can be used.
Table 4.6 – Guidelines for Single Phase Gas Lines
Max Velocity Max RhoP square
Service Pressure (psig)
(ft/s) (lb/ft-s2)
Gases; P < 290 200 10,000
General (1) 290 < P ≤ 725 160 10,000
725<P < 1160 130 10,000
P>1160 100 10,000
Compressors:
Suction (2) (4)
Discharge -
(3) (4)
Column
Overhead - - 10,000
Stripper
Vapour (5) -
-
Return
Kettle Vapour
Return -
(5) -
Notes:
1) The above indicated line sizing criteria are valid for continuous operation. The pressure
drop in psi/100ft shall be less than 5% of the absolute static pressure for long headers and 10%
for short headers. For intermittent operation, these limits may be exceeded on a case by case
basis.
2) Allowable pressure drop between 0.1 and 0.3 psi/100ft.
3) Allowable pressure drop between 0.2 and 0.5 psi/100ft. In addition to these criteria, the noises
from excessive flowing velocity have also to be considered.
4) Maximum ρ V2 to be comparable with values above.
5) Allowable pressure drop between 0.1 and 0.2 psi/100 ft.
4.15 Line Sizing Criteria for Two Phase Flow
4.15.1 Flow Pattern

Two phase flow in pipes can be classified by flow patterns which describe the type of flow
exhibited, with different flow patterns identified for horizontal and vertical flow. The flow
patterns are determined from standard flow pattern maps for horizontal and vertical flow.
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Figure 4.1 – Mandhane et al. Horizontal Flow Pattern Map

Figure 4.1 is the horizontal flow pattern map developed by Mandhane et al. taken from
GPSA Fig. 17-15.
Figure 4.2 – Aziz et al. Vertical Up-Flow Pattern Map

Figure 4.2 is the vertical flow pattern map developed by Aziz et al. taken from GPSA Fig.
17-16.
4.15.2 Erosion
High velocities in two-phase lines can cause rapid wear by erosion. The velocity at which
erosion may occur is calculated by the formula given in API RP 14E:
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C
Ve ¿
√ ρm
Ve = erosional velocity, ft/s

Empirical constant used are: (refer to API RP 14 E)
C = constant, ft/s
= 100 for carbon steel lines in continuous services
= 122 for carbon steel lines in intermittent services
= 200 for duplex and stainless steel lines in non-erosional (continous)services and
for flexible line.
= 330 - 370 for carbon steel lines in intermittent services
ρm= mixture density, lb/ft3, at operating pressure and temperature.
The density of the gas/liquid mixture, ρm, can be estimated by the following:
ρm= ρg ( 1−l ) +l ρl
Where,
l = liquid volume fraction.
ρg = gas densityliquid (lb/ft3).
ρl = liquid density (lb/ft3).
Alternatively the mixture density can be determined from the HYSYS simulation program.
4.15.3 Line Sizing Criteria for Two Phases

Flow assurance issues include line sizes, slugging (multiphase flow instabilities), scale,
hydrates, wax, asphaltenes, sand, emulsion, foaming, corrosion and erosion. Consideration
shall be given to the operability of the system during normal operation and during start-up
and shutdown of flow. Long pipelines are excluded from this procedure and shall be
sized using proprietary software e.g. PIPESIM and OLGA Dynamic software latest
edition.
The following criteria can be used to size two phase lines.
a. Calculate the erosional velocity and determine the minimum pipe size required to avoid
fluid erosion.
b. Check the flow pattern to ensure that slug flow is avoided. Annular mist flow is preferred
as shown in the figure 2 and figuere 3. However, if slug flow cannot be avoided due to
erosional velocity constraints, then the line size will be accepted.
c. Calculate the pressure drop as noted in this document.
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Wellhead flowlines, production manifolds and other lines transporting gas and liquid in two
phase flow where significant pressure drop is available, are generally sized on the basis of
velocity.
Calculation of static head resistance in two phase systems should consider the fluid to be
all liquid since this is likely to occur at some stage of operation. Static gain should be
treated with caution since flashed vapour present may not necessarily recondense in the
downcomer pipe.
Slug flow with resultant pressure pulsation and vibration is to be avoided. Problems are
most likely in lines from exchangers where partial vaporization or condensation has
occurred. In comparison, equilibrium fluids that are continuously flashing with vapour
expansion are usually relatively stable. Where slug flow is expected to be a problem,
consideration should be given to equipment layout, e.g. locate exchanger near terminus so
that the liquid vapour line is as short as possible. In all cases however, it is good
engineering practice to layout piping so that it is self venting to the terminus (i.e. no
pockets).
4.16 Sizing Criteria for Relief and Depressuring Lines

Vapor flow in relief and depressuring lines is treated as adiabatic compressible flow. The
size of flare headers, subheaders and individual relief valves may be estimated by
the method of Lapple or by more rigorous proven computer methods. For
preliminary engineering the guidelines given below should be followed.
A preliminary network analysis will also be undertaken for all principal
relieving/depressuring cases in order to ensure that the maximum allowable back pressure
at each individual relieving device is not exceeded. Network analysis will be
performed using the Flarenet software package or equivalent. Vapour flow in relief and
depressurizing lines is treated as adiabatic compressible flow. Calculations will be
performed in accordance with API Std 520, ANSI/API standar 521 and ISO 23251 and
ANSI/API RP 2000.
4.16.1 Relief Valve Inlet Lines

The inlet line pressure drop is to be less than 3% of set pressure calculated at set pressure
conditions assuming flow based on installed relief valve area for conventional and
balanced valves. (Note - not for pilots) However pressure drop in the inlet line for a pilot
valve should be calculated and considered when determining the relief valve capacity. The
inlet line shall not be smaller than the inlet flange of the relief valve. Pilot operated relief
valves shall be used on inlet piping greater than 3.0 m (10.0 ft), except for liquid thermal
relief valves.
4.16.2 Relief Valve Outlet Lines

The discharge line shall not be smaller than the outlet flange of the relief valve. The
computation of the allowable back pressure using the required relief capacity is as follows:
 Conventional Valve
Size the discharge line from conventional valves to limit the built-up back pressure to
less than 10% of the set pressure (gauge).
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 Balanced - Bellows Valve

Higher pressure drops may be used to affect considerable cost savings. Limit the total
back pressure to no more than 30% of the set pressure (gauge) and to no more than
the rating of the internal bellows.
A balance pressure relief valve should be used where the built-up back pressure is too
high for conventional pressure relief valves or where the superimposed back pressure
varies widely compared to the set pressure.
 Pilot-Operated Valve
For a pilot-operated pressure relief valve, neither the set pressure nor the capacity is
typically affected by back pressure, for compressible fluids at critical flow conditions. Tail
pipe and flare header sizing are typically based on other considerations. However, for
the design purpose, size the discharge line of pilot valves to limit the total back pressure
to 50% of the set pressure (gauge).
Where there are a number of valves discharging into the same manifold, caution will be
exercised to ensure that the back pressure in the manifold allows all relief valves to
discharge properly.
The maximum Mach number is 0.5 - 0.75 calculated at rated flow rate and downstream end
of line conditions. Back pressure based on installed critical area shall be checked to
confirm it is below the system design pressure. Accoustic Induced Vibration (AIV) shall
checked as per the relief, flare, and vent Specification.
Note that Mach number for vapor lines is calculated from the following equation:
V s= √ γRT
Where,
Vs = sonic velocity (m/s)
γ = ratio of specific heats for the gas (Cp/cv)
R = individual gas constant = 8314/M (J/kg K), where M = gas molecular weight
T = absolute temperature (K)
4.16.3 Flare Headers and Sub Headers

The maximum Mach number range is 0.5 - 0.7 calculated at rated flow rate at the
downstream end of line conditions. Normal practice is that 0.5 Mach Number is applied for
new flare facilities to anticipate next expansion/addition. The Mach Number 0.7 is used for
rating existing header (brownfield).
4.16.4 Flare Stack
The diameter of the flare stack is generally sized on a velocity basis although pressure drop
should be checked. For stable flare burning in pipe flares, API Std 521 recommends a
Mach number of 0.5 for a peak short term infrequent flow, with Mach number of 0.2 for the
more normal and possible more frequent conditions. Requirement for pipe flares, maximum
Mach number for stable flare burning and other proprietary designs should be discussed
with the vendor.
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4.16.5 Blowdown Inlet Lines

The maximum velocity is 60 m/s (200 ft/s).
4.16.6 Blowdown Outlet Lines
The maximum Mach number is 0.7, calculated at rated flow rate and downstream end of
line conditions. Back pressure based on installed critical area shall be checked to confirm it
is below the system design pressure.
4.16.7 Atmospheric Tank Vents

Non-refrigerated atmospheric tank vents are sized on the basis of maintaining an operating
pressure that the tank can safely withstand. Flowrates are determined by consideration of
thermal inbreathing and outbreathing, maximum fluid inflow or outflow, and vapor
production resulting from fire exposure.
4.16.8 Calculation Methods

For the purposes of calculating line sizes and pressure drops the following
calculation methods shall be used:
 Single Phase Lines - In-house validated spreadsheets
 Two Phase Lines - In-house validated spreadsheets
 PIPESIM or equivalent where applicable
 Firewater Systems - PIPENET or equivalent
 Flare Networks - FLARENET or equivalent
4.16.9 Liquid Nozzle Sizing

Minimum liquid outlet nozzles will be sized as per COMPANY Standard practices. Please
note that size will not be smaller than outlet line size.
5 CALCULATION METHOD
5.1 Single Phase Gas Line Calculation
5.1.1 Velocity
The velocity for single gas phase line is calculated based on equation 2.13 API RP 14E:
60 ZQgT
Vg= 2
d P
Therefore, the minimum diameter can be determined as follows:
d=
√ 60 ZQgT
VgP
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Where,
Vg = Gas velocity, ft/s
Qg = Volumetric flow rate, MMSCFD

T = Temperature (R)
Z = Gas compressibility factor
P = Pressure, psia
d = Internal diameter of pipe, in
Note:
For minimum diameter calculation, used maximal gas velocity for Vg, based on Table 4.7 –
Guidelines for Single Phase Gas Lines above.
5.1.2 Pressure Drop

Pressure drop on the single gas line is determined using equation 2.9 API 14E, as follows:
SQgZT 1 fL
∆ P=12.6
P 1 d5
Where:
ΔP = Pressure drop, psi
QG = Volumetric flow rate, MMSCFD
T = Temperature, °R
Z = Gas compressibility factor
f = Moody friction factor
d = Internal diameter of pipe, in
L = Pipe length, ft
S = Specific gravity
5.1.3 Friction Factor

Friction factor is determined based on the Colebrook equation [GPSA Section 17 Eq. 17-
11], as follows:
1 2.51
√f m
=−2 log 10
( 3.7ϵ D +
ℜ√ f m )
Where:
Re = Reynolds number, dimensionless
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ε = Absolute roughness, ft
D = internal diameter of pipe, ft
fm = Moody friction factor, dimensionless
Reynolds number equation:

ρ Dv
Re=
μ
Where:
ρ = Mass density, lb/ft3
D = Inner diameter of pipe, ft
v = Fluid velocity, ft/s
µ = Fluid viscosity, cP
5.2 Single Phase Liquid Line Calculation
5.2.1 Velocity
The velocity for single liquid phase line is calculated based on equation 2.1 API RP 14E:
0.012Q1
V 1=
di
2
Therefore, the minimum diameter can be determined as follows:
Note:
d=
√ 0.012Q1
V1
For minimum diameter calculation, used maximal gas velocity for Vg, based on liquid phase line
sizing basis in section 4 above.
Where:
V1 = Average liquid flow velocity, ft/s
Q1 = Liquid flow rate, barrel/day
di = Pipe inside diameter, in
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5.2.2 Pressure Drop

Pressure drop on the single gas line is determined using equation 2.2 API 14E, as follows:
0 . 00115 f Ql S l
2
∆ P=
di5
Where:
∆P = Pressure drop, psi/100ft
f = Moody friction factor, dimensionless
di = Pipe inside diameter, in
Q1 = Liquid flow rate, barrel/day
S1 = Liquid specific gravity (water = 1)
5.2.3 Friction Factor

Friction factor is determined based on the Colebrook equation [GPSA Section 17 Eq. 17-
11], as follows:
1 2.51
√f m
=−2 log 10
( ϵ
3.7 D
+
ℜ√ f m )
Where:
ε = Absolute roughness, ft
D = internal diameter of pipe, ft
fm = Moody friction factor, dimensionless
Reynolds number equation:
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ρl d i V l
ℜ=
µl
Where:
ρl = Liquid density, lb/ft3
di = internal diameter of pipe, ft
µl = Liquid viscosity, lb/ft-sec, or centipoises divided by 1488
Vl = Liquid flow velocity, ft/sec
5.3 Two Phase Line Calculation
5.3.1 Erosional velocity

Erosional velocity is calculated based on equation in section 4.15.2.
5.3.2 Minimum diameter
(√ QcVc ) x ( phi4 )
Where:
Qc = Volumetric flow rate, ft/s
Vc = Erosional velocity, ft/s
6 METHODOLOGY
The Line Sizing Calculation using spreadsheet with input data are taken from Heat and
Material Balance Case-2 for process & utility lines, and Case-4 for liquid & mixed phase in
Inlet Separation Unit (221).
7 RESULT
The Sales Gas pipeline from GPF to Pertagas tie-in shall be 20” diameter as recommended
by Flow Assurance Study.
Result of line sizing in process and utility can be shown detail in Appendix A and Appendix
B.
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APPENDICES
APPENDIX A – LINE SIZING CALCULATION (PROCESS)
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APPENDIX B – LINE SIZING CALCULATION (UTILITIES)
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GAS DEVELOPMENT PROJECT

FOR THE UNITIZATION OF

CALCULATION – LINE SIZING

DOCUMENT NUMBER: JTB-SF-P-CAL-900-00003

REVISION HISTORICAL SHEET

Page/Section Date Description

4.16.5 Blowdown Inlet Lines........................................................................................17

2 DEFINITIONS AND ABBREVIATIONS

Document No. Document Title

JTB-SF-P-PFD-234-00003 Heat and Material Balance Refrigeration Unit, Design

4.1 Fluid Condition and Properties Data

4.2 Sizing Basis

capacity/available driving pressure, flow induced forces, noise/vibration, pressure surges,

4.3 Line Sizing Margin

4.4 Sizing Criteria for Single Phase Liquid Lines

Table 4.1 – Line Sizing Criteria for Single Phase

Line Size Max Pressure Drop (psi/100ft)

4 Gravity flow - 2 0.1 0.2

Carbon Steel for Flare/Vent Headers (Heavily

Duplex/Stainless Steel (New Seamless, Cold Drawn) 0.0016 0.041

Galvanised Carbon Steel 0.0059 0.15

Epoxy Lined Pipe 0.0059 0.15

Glass Reinforced Epoxy (GRE) 0.0002 0.005

Flexible line (rough bore) ID/2 (Note 1) ID/20 (Note 1)

4.5 Pumped Liquid for Salt and Produced Water

No Pipe NPS mm (Inch) Max. Velocity, ft/s (m/s)

4.6 Liquids Flowing by Pressure

4.7 Gravity Flow Lines

4.8 Liquids from Drain Boxes

4.9 Static Accumulation

4.11 Other Corrosive Liquids

Pump Suction 0.5-1.0 (11.3-22.6) 3-3.6 (0.9-1.1) 5 (1.5)

Pump Discharge 2 (45.2) 5 (1.5) 5 (1.5)

4.13 Tank Overflows

4.14 Single Phase Gas Line

4.15 Line Sizing Criteria for Two Phase Flow

4.15.1 Flow Pattern

Figure 4.1 – Mandhane et al. Horizontal Flow Pattern Map

Figure 4.2 – Aziz et al. Vertical Up-Flow Pattern Map

Ve = erosional velocity, ft/s

4.15.3 Line Sizing Criteria for Two Phases

4.16 Sizing Criteria for Relief and Depressuring Lines

4.16.1 Relief Valve Inlet Lines

4.16.2 Relief Valve Outlet Lines

 Balanced - Bellows Valve

4.16.3 Flare Headers and Sub Headers

4.16.5 Blowdown Inlet Lines

4.16.7 Atmospheric Tank Vents

4.16.8 Calculation Methods

4.16.9 Liquid Nozzle Sizing

5.1 Single Phase Gas Line Calculation

Therefore, the minimum diameter can be determined as follows:

Vg = Gas velocity, ft/s

Qg = Volumetric flow rate, MMSCFD

5.1.2 Pressure Drop

5.1.3 Friction Factor

Reynolds number equation:

5.2 Single Phase Liquid Line Calculation

Therefore, the minimum diameter can be determined as follows:

5.2.2 Pressure Drop

5.2.3 Friction Factor

Reynolds number equation:

5.3 Two Phase Line Calculation