Jordan University of Science and Technology

Faculty of Engineering
Department of Chemical Engineering

Project
Course: Equipment design

CHE 471

Semester: Fall 2020

Instructor: Dr. Mohammad Al-Azzam

Students names and ID:

Mohammad-Ameen Al-Bdour (126843)

Walid Khaled Al-Lala (135017)

Date of Submission: 20/12/2020

1
Table of content:
Abstract: .......................................................................................................................................... 3
Introduction: .................................................................................................................................... 4
Path Selection: ................................................................................................................................ 4
Material of construction: ................................................................................................................. 5
Crude oil properties: ....................................................................................................................... 5
Design: ............................................................................................................................................ 6
Piping design:.............................................................................................................................. 7
Friction calculations: ................................................................................................................... 9
Pipe friction:............................................................................................................................ 9
Fittings friction: ...................................................................................................................... 9
Work Calculations .................................................................................................................... 10
Number of Pumps ................................................................................................................. 11
Pump Station: ........................................................................................................................ 12
Cost ............................................................................................................................................... 13
Pipe cost: ................................................................................................................................... 13
Pump Cost: ............................................................................................................................ 13
Valve Cost ................................................................................................................................. 13
Fittings Cost .............................................................................................................................. 14
Stand by Cost ............................................................................................................................ 14
Cost of Operating: ..................................................................................................................... 15
Total Cost .................................................................................................................................. 16
References: .................................................................................................................................... 17

List of Table
Table 1: Distance and elevations for the selected path. .................................................................. 6
Table 2 Frictions Calculations ........................................................................................................ 7
Table 3 Work and Power Calculations ......................................................................................... 10
Table 4 Pump Stations Calculations ............................................................................................. 12
List of Figures
Figure 1: the selected path using Google Maps .............................................................................. 5
Figure 2 Stand By Line ................................................................................................................. 15

2
Abstract:

This project is concerned in designing a pipeline system to transport

crude oil from Kirkuk’s to Haifa.
The path was selected according to the least price of Electricity and to avoid destruction and
construction.
Temperature was selected in 20o C according to the average temperature in these regions.
The pumps are Centrifugal pump with 80% efficiency and the pipes from welted carbon steel.

Total cost for this project was calculated and it equal Capital cost = $101,442,225.
In another hand, Cost of Operating = $24,541,600.57 for one year.

3
Introduction:
It is desired to pump 150000 bbl/day of light crude oil from Kirkuk, Iraq to Haifa Palestine,
while using suitable material of construction, select closest way and considering physical laws,
safety regulations, standards and codes, and economical value. Furthermore, assumptions will be
taken a place in calculations.

Path Selection:
The path was between Iraq (Kirkuk) and Palestine (Haifa). It was chosen to be near cities,
highways, and internal streets. However, it took several changes in direction to stay as much as
possible near them and this was to decrease the generators and electrical power required
subsequently decreasing the total cost. In addition, to avoid smashing streets or building.
Also, it was chosen to avoid rivers and watercourses, and this was taken a place to decreasing the
energy required and cost for it.
The distance between the two cities was 1102 km, and it passes through 3 countries which are
Iraq, Jordan, and Palestine. And the path was chosen to be the closest way, while taking the
mentioned factors in consider.
The following figure shows the path and the elevation differences starting from Kirkuk (344m)
above the sea level and ending with Haifa (0 m).

4
Figure 1: the selected path using Google Maps

Material of construction:
Choosing a suitable material of construction is the most important step in the design, and the
decision taken is based on two factors, one is the corrosion rate of the material with both the
environmental factors and the fluid it interacts with, and the other is cost per meter length of the
pipe. Carbon steel meets the latter factors so it will be the material of construction for the
pipeline designed in the project including pipes, valves and fittings

Crude oil properties:

While the properties of the crude oil vary with the temperature across the distance, density and
viscosity are changing. So, to avoid the problem that will be caused by the variation, the
reference temperature is assumed at 20 0C. So, it will keep the safety to the selected diameter for

5
the pipes and valves from taking high load pressure. However, density at 20 0C is 933.1(kg/m3)
and viscosity is (9.095 cp).

Design:
The following calculations were tabled to show the Nominal Pipe Size (NPS), the friction loss in
the system, the required power for the pumps, the efficiency for the pump and the number of
pumps required in the system, these calculations will help us to select a suitable pump and pipe
size.
At first, the distance was measured by using Google Earth [1], the elevations differences along the
selected path, and the horizontal distance for each elevation change. Then, all of this is tabled in
(table1).

Table 1: Distance and elevations for the selected path.

Z1 (m) Z2 (m) L (m) Dis (Km) ΔZ

344 154 64000 64 -190
154 154 19000 83 0
154 74 197000 280 -80
74 606 235000 515 532
606 583 9000 524 -23
583 809 109000 633 226
809 665 138000 771 -144
665 958 47000 818 293
958 691 36000 854 -267
691 861 52000 906 170
861 658 37000 943 -203
658 712 20000 963 54
712 506 25000 988 -206
506 571 7000 995 65
571 -270 38000 1033 -841
-270 55 33000 1066 325
55 0 36000 1102 -55

6
Then, after studying the properties of the crude oil, the condition that it will go through, and
choosing the suitable material of construction, it was assumed turbulent flow using equation [3] to
calculate the optimum diameter at the specific conditions, and it was found to be (0.4947 m) but
it was neglected because it does not give the desired flowrate. So, to find the optimum diameter
the calculation was repeated to find new velocity value then check whether it was suitable or not.
Finally, the value which was estimated for inner diameter at the given conditions was (23.25 in)
with nominal pipe size 24 and schedule number is 20.
After finding the optimum values, calculations were tabled in (table2):

Table 2 Frictions Calculations

V (m/s) D (m) f F along Pipes F fittings Total F g*ΔZ

1.0076 0.59055 0.02067 4548.519805 4548.519805 -1863.9
1.0076 0.59055 0.02067 1350.341817 1350.341817 0
1.0076 0.59055 0.02067 14000.91253 0.525798303 14001.43832 -784.8
1.0076 0.59055 0.02067 16701.59616 16701.59616 5218.92
1.0076 0.59055 0.02067 639.6355976 639.6355976 -225.63
1.0076 0.59055 0.02067 7746.697794 0.175266101 7746.87306 2217.06
-
1.0076 0.59055 0.02067 9807.74583 9807.74583 1412.64
1.0076 0.59055 0.02067 3340.319232 3340.319232 2874.33
-
1.0076 0.59055 0.02067 2558.542391 2558.542391 2619.27
1.0076 0.59055 0.02067 3695.672342 0.175266101 3695.847608 1667.7
-
1.0076 0.59055 0.02067 2629.613013 2629.613013 1991.43
1.0076 0.59055 0.02067 1421.412439 0.175266101 1421.587705 529.74
-
1.0076 0.59055 0.02067 1776.765549 0.175266101 1776.940815 2020.86
1.0076 0.59055 0.02067 497.4943537 0.175266101 497.6696198 637.65
-
1.0076 0.59055 0.02067 2700.683634 1.57739491 2702.261029 8250.21
1.0076 0.59055 0.02067 2345.330525 0.350532202 2345.681057 3188.25
1.0076 0.59055 0.02067 2558.542391 0.350532202 2558.892923 -539.55

The equations that have been used to fill the table and find the calculated values:
As it was mentioned before, it was assumed to have turbulent flow, so to ensure that the
assumption was correct, Reynolds number must be checked:

Piping design:

𝐷𝑖,𝑜𝑝 = 0.363 ṁ0.45

𝑣 𝜌0.13

𝐷𝑖,𝑜𝑝 = 0.363 ∗ 0.2760.45 ∗ 933.10.13 = 0.4947𝑚

7
After finding the diameter the velocity must be calculated:
𝑄 0.276 𝑚
𝑣=𝐴=𝜋 = 1.4359
∗0.49472 𝑠
4

Then check Reynolds:

𝑘𝑔 𝑚
𝜌𝐷𝑣 933.1 3 ∗1.4359 ∗0.4547 𝑚
𝑚 𝑠
𝑅𝑒 = = = 66883.75
𝜇 0.009905 𝑝𝑎.𝑠

When Reynolds value calculated is higher than 2100, therefore the assumption is correct. Since
the assumption is correct, the value of nominal pipe size must be found:

Now, from table (D-13) [4], at 𝐷 = 0.4947 𝑚 = 19.476 𝑖𝑛𝑐ℎ ,then the value of nominal pipe size
is 20in, and schedule number is 20. So, optimum diameter = 20 in.
Now checking whether the optimum diameter can give the required flowrate:

𝐷𝑖,𝑜𝑝 = 0.363 ṁ0.45

𝑣 𝜌0.13

𝐷𝑖,𝑜𝑝 = 19.25 𝑖𝑛 = 0.48895 𝑚

0.48895 = 0.363 ∗ ṁ0.45

𝑣 ∗ 933.10.13

𝑚3 𝑚3
ṁ𝑣 = 0.2688 , which is less than the required flowrate ṁ𝑣𝑟𝑒𝑞 = 0.276 .
𝑠 𝑠

So that, for safety the (NPS) that must be taken from table (D-13) [4], is 24 with Sch# 20, with an
𝐷𝑖,𝑜𝑝 = 23.25 𝑖𝑛 = 0.59005 𝑚.

Then, by repeating the calculation to check whether it will give the required flowrate or not:

𝐷𝑖,𝑜𝑝 = 0.363 ṁ0.45

𝑣 𝜌0.13

0.59055 = 0.363 ∗ ṁ0.45

𝑣 ∗ 933.10.13

𝑚3 𝑚3
ṁ𝑣 = 0.409 𝑠 , which is higher than the required flowrate ṁ𝑣𝑟𝑒𝑞 = 0.276 , and this must be
𝑠
suitable.
Then, velocity and Reynolds number must be calculated:
𝑄 0.276 𝑚
𝑣=𝐴=𝜋 2
= 1.0076 𝑠
∗0.59055
4

Then check Reynolds:

8
 𝑘𝑔 𝑚
𝜌𝐷𝑣 933.1 3 ∗1.0076 ∗0.59055 𝑚
𝑚 𝑠
𝑅𝑒 = = = 56027.25 >> 2100, then the turbulent assumption is
𝜇 0.009905 𝑝𝑎.𝑠
correct.
Friction calculations:

Pipe friction:

Since it is used Carbon-Steel welded pipe, the relative roughness 𝜀 = 0.046 𝑚𝑚, so
𝜀 0.046∗10−3
= = 7.8 ∗ 10−5 , 𝑅𝑒 = 56027 , by using Moody chart [4]:
𝐷 0.59055

𝑓 = 0.02067

2.𝑓.𝑣 2 2∗0.02067∗1.00762 𝑚.𝑁

𝐹𝑝𝑖𝑝𝑒 = = = 0.071 …. Friction for 1 m pipe
𝐷 0.59055 𝑘𝑔
𝑚.𝑁 𝑁.𝑚2
𝐹𝑎𝑙𝑜𝑛𝑔 𝑝𝑖𝑝𝑒𝑠 = 0.071 ∗ 1102 ∗ 103 𝑚 = 78319.8
𝑘𝑔 𝑘𝑔

Fittings friction:
When calculating the fittings friction, it must be mentioned what fittings will be used along the
path, which are:

a- 14 (450) elbows.
b- 3 (900) elbows.
c- 100 Gate Valve

𝐾𝑓 .𝑣 2
𝐹𝑒𝑙𝑏𝑜𝑤 = 2

F 45 elbows=14* (0.35*1.00762/ 2) =2.487

F 90 elbows =3*(0.7*1.00762/2) =1.066
F valves = 100*(0.15*1.00762/2) = 7.6144

9
Table 3 Work and Power Calculations
W (N.m/Kg) Power eff 80% (W) # Pumpes Actual Pump eff 80% #Pump
2684.619805 864231.4655 1.325406741 1.656758426 2
1350.341817 434701.3626 0.666668756 0.833335946 1
13216.63832 4254693.601 6.525103291 8.156379114 9
21920.51616 7056641.602 10.82224002 13.52780002 14
414.0055976 133276.475 0.204396097 0.255495121 1
9963.93306 3207584.349 4.919230655 6.149038319 7
8395.10583 2702548.271 4.144694841 5.180868552 6
6214.649232 2000616.773 3.068195343 3.835244179 4
-60.72760944 -19549.40167 No need No need No Need
5363.547608 1726630.564 2.648003319 3.310004149 4
638.1830125 205443.5563 0.315073317 0.393841646 1
1951.327705 628170.4392 0.963377715 1.204222144 2
-243.9191849 -78522.34204 No need No need No Need
1135.31962 365481.5244 0.560511501 0.700639376 1
-5547.948971 -1785992.959 No need No need No Need
5533.931057 1781480.319 2.732122259 3.415152824 4
2019.342923 650065.864 0.99695708 1.24619635 2

80801.46175 26011566.17 39.89198093 49.86497617 50

Work Calculations

𝒘 = 𝒈(𝒛𝟏 − 𝒛𝟐) + ∆𝑽2/𝟐𝜶 + 𝒗∆𝑷 + ∑𝑭

ASSUME:

ΔV²/2α term = 0
Because V1 = V2 in the pipe and V1 = V2 =0 in the start and end of the path so ΔV = 0

P1=P2 = atmospheric pressure so ΔP = 0 we will neglect the change of the atmospheric pressure
with elevation change because it a low values compares with other terms

𝒘 = 𝒈(𝒛𝟏 − 𝒛𝟐) + ∑𝑭

𝑭 = F long pipe+ F fittings

10
F long pipe = (2fV²L)/D

To calculate f :

𝜖 = 0.046 mm
D = 590.55 mm
𝜖/𝐷 = 7.7893*10-5
Re=56027.253
f from moody diagram
f= 0.02067

After calculate for each zone :

The total work = 80801.46175 (N.m/Kg)

Power = Wtot * Q * 𝜌
P = 80801.46175*0.276*933.1
= 20809254.32 W

Using an 80% Efficiency :

Power = 26011566.17 W

Number of Pumps

# 𝒐𝒇 𝒑𝒖𝒎𝒑𝒔 = (𝑾𝒕𝒐𝒕 ∗ 𝝆)/𝑷𝒔

To calculate Ps :

Schedule Number =1000 Ps/Ss

Schedule Number =20

From table 12-10 :

Ss=94500 Kpa

Ps= 1890000 Pa

#Of pumps = (26011566.17 * 933.1)/ 1890000= 49.86 so it’s almost 50 pumps.

11
So we need 50 Station pump

Pump Station:

Table 4 Pump Stations Calculations

Z1 Z2 L (m) #Pump Pump Station Distance (Km)

344 154 64000 2 32
154 154 19000 1 19
154 74 197000 9 21.88888889
74 606 235000 14 16.78571429
606 583 9000 1 9
583 809 109000 7 15.57142857
809 665 138000 6 23
665 958 47000 4 11.75
958 691 36000 No Need No need
691 861 52000 4 13
861 658 37000 1 37
658 712 20000 2 10
712 506 25000 No Need No need
506 571 7000 1 7
571 -270 38000 No Need No need
-270 55 33000 4 8.25
55 0 36000 2 18
In zone 1 we need to calculate what is the distance between the Pumps so

Dis = L/ #Pumps

Dis = 64000/2 = 32000 m = 32 Km between the two pumps.

12
Cost

Pipe cost:

Pipe Cost
• Material of construction: the carbon steel welded pipe
• Inner diameter = 23.25 in = 0.59055m
• Sch #20

From Figure 12-4 :

Cost of the carbon steel welded pipe = $60/m
Cost of pipeline = $60/m * 1102000m = $ 66,120,000

Pump Cost:
Centrifugal pump was chosen; simple and inexpensive and has a low maintenance cost with
high efficiency.

Pump Capacity = 0.276 *3600 = 993.6 m³/hr

From figure 12-17
Pump efficiency is 80%

The capacity factor = 0.276 m³/s * 101.3 = 27.9588

From figure 12-20 in book

So the price of one pump = $10000 (almost)

So the total cost of the pump = 10000*50 = $500,000

Valve Cost

For each Pump stage we need 2 Gate valves, for safety and maintenance so 50*2 =100 Gate
valves.

From Figure 12-8

13
Cost of gate valve at 2070 Kpa = $10000

Total Valve Cost =100* $10000 = $1000,000

Fittings Cost

Cost 90 elbows = 3*150= $450

Cost 45 elbows = 14*550 =$7700

Stand by Cost

If we need to be always in safe the Stand by line is a perfect to ensure no stop

flowrate .

To have a Stand by we need a pump for each pump and a tee and 2 vavles.

50 Control valve, 50 pump , 50 Tee

The addition Pipes around 500 m

Cost of Valves = 50*17000 =$850,000

Cost of Pumps= 50*10000=$500,000

Cost of Tee= 50*6260=$313,000

Cost of Pipe =500*60 =$30,000

Total cost of Stand by line = $1,693,000The Control valve is Air to open .

14
Figure 2 Stand By Line

Cost of Operating:

Assuming the system need 2 weeks for maintenance over 1 year, so the number of working is
351 day/ year

As calculated previously that the power required is 26,011,566.17 W

In 351 day = 26011.5662 KW*351*24 h/day = 219,121,433.7 KWh for one year

The electricity cost in Haifa is $0.112/KWh

Operating Cost = .112*219121433.7= $24,541,600.57 for one year

15
Total Cost

Capital cost = Cost Pipes +Cost fittings + Cost Pumps + Cost valves + Installation Cost

= 66120000+500000+1000000+450+7700=$ 67,628,150 + Installation Cost

Installation Cost = 67628150 *0.5 = $33,814,075

Capital cost = 33,814,075 + 67,628,150 = $101,442,225

16
References:

1. Eduardo D. Glandt, M. T. K. F. E., 2003. Plant Design and Economics for chemical
engineers 5th eddition. New York: University of Colorado.

2. Google earth.

3. www.propertiesofmatter.si.edu/Changing_Temp.html.

4. www.petro-online.com/article/analytical-instrumentation/11/anton-paar/the-facts-
andnbspfigures-of-digitalnbspdensity-measurement-nbsp/1304

5. http://belgo.6te.net/doc/Iraqi%20Kirkuk%20Light%20Crude%20Oil.pdf?fbclid=IwAR1pYd0zgtq3l
_wExs6NTPBlYy79YEOBM6USXc4pRsAAprvGuVLbKoBTW1U

6. http://blog.dwyer-inst.com/2018/08/29/common-valves-used-in-theoil-gas-
industry/#sthash.34DPgnpU.dpbs

7. https://www.globalpetrolprices.com/Iraq/electricity_prices/

8. Viscosity of Crude Oil – viscosity table and viscosity chart :: Anton Paar Wiki (anton-
paar.com)

17