Factors Affecting Line Sizing of Piping or Pipeline

Systems
Written by Anup Kumar Deyin Pipeline,Piping Design Basics,Piping Interface,Process

Line sizing by the Process department is one of the most important and critical activities
for any project. Line size is determined with proper sizing calculations considering various
parameters.

Purpose of Line Sizing

The main purpose of line sizing are:
The purpose of line sizing (for common, water-like liquids, gases, and applications) is to fill in
appropriate data on P&ID’s, datasheets, and line lists
To determine pump head requirements
To meet design process parameters such as flow, velocity & pressure.

This article will highlight a few of the factors which must have to be considered during line
sizing.

Factors affecting Line sizing decisions

Line sizing decisions are affected by:
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1. Economics :
Line sizing decisions have economic impacts, including:
cost of pipe
cost of pipe supports
operating pressure/power requirements

Liquid lines that are sized smaller will require a larger system supply pressure (due to higher
friction losses), and possibly a larger pump and pump motor, increasing equipment capital cost
and operating cost. Another factor to consider is the cost of the piping (including valves). The
difference of the capital cost of ½” to ¾” piping is negligible, however, the cost of 3” to 2” piping
is significant.

Therefore, line sizing involves multiple economic factors, as well as other impacts.
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2. Effect of Velocity/Turbulence in Pipeline Sizing:
Incompressible fluids (air steam, nitrogen, etc.), the only design concern is to avoid sonic
velocity (typically above 100 ft/sec). Usually, pressure drop guidelines result in pipe size
selections that avoid sonic velocity.
 In non-sanitary liquid applications, velocity and turbulence are typically not a concern, unless
slurry flow is present.
For sanitary, non-compressible applications (our most frequent designs), velocity and
turbulence are concerns. It is necessary to maintain a fully turbulent flow to avoid stagnant
areas in the piping system that can promote bacterial growth.

3. Pressure Drop Effects for Line Sizing:

The effect of pressure drop within a system is closely correlated to the economics of the
system. Smaller pipe sizes result in larger pressure drop requirements; economic
considerations require a balance between pipe size and pumping/power requirements to
overcome pressure losses through the system.

4. Impact of Line Holdup in Pipe Sizing:

In the biopharma industry, certain product liquids may have exceedingly high value, and the
holdup in piping systems may be a primary concern. In addition to minimizing the length of
piping systems and the recovery capabilities (air blows, sloped piping, etc.) of the piping
systems, a smaller line size may be chosen to further minimize the loss potential of the liquid
held up in the line. This becomes the governing criterion for sizing even though pressure drop
exceeds the recommended range.

5. Space requirements for Line Sizing:

Typically, space requirements are not a significant concern in the biopharma industry, since
most pipe sizes are less than 6 inches in diameter. Space may be a concern when existing
pipe racks are used, where areas are tightly piped, or with gravity drainage systems.
Interaction with the piping designer will identify critical areas where space is a consideration.

6. Effect of Expansion Effects in Line Sizing:

Header system sizing should consider the possibility of plant expansion. The incremental
cost of a larger pipe size will avoid many headaches down the road if expansion is a distinct
possibility.
Sizing of sanitary water loops must critically consider expansion possibilities, since
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oversizing the supply loop may reduce the velocity below the acceptable values Telegram
full turbulence. Often, the supply pump needs to be oversized as well as the header to
account for expansion. This oversizing should only be done if expansion is a distinct
probability.
7. Line Sizing based on Equipment Nozzle Connections:
Equipment nozzle connections for piping tie-ins are typically undersized when compared to the
recommended pipe size. Be sure to perform the sizing calculation, select the appropriate pipe
size, and, if required use reducers to connect the pipe to the equipment nozzle.

Steps in Line sizing procedures

Step 1 – Assume line size

Step 2 – Calculate velocity by

V = Q / (Flow Area)

Step 3 – Calculate the pressure drop by the proper method.

Step 4 – Check whether calculated velocity & pressure drop falls within recommended ranges.
If YES then select the line size
If NO then selects a new line size and repeat steps 2 to 4.

Recommended velocities & max ΔP for Line Sizing:

Sr. No Types of Service Velocity (m/sec) Maximum ΔP
 
Kg /cm2/100m
1 General Recommendation 1.5 – 4.6 0.92
2 Pump Suction
– Boiling Liquid 0.6 – 1.8 0.115
– Non – Boiling Liquid 1.2 – 2.4 0.23
3 Pump Discharge
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– 0 – 57 m3 / hr 1.8 – 2.4 1.38
– 57 – 159 m3 / hr 2.4 – 3.0 0.92
– >159  m3 / hr 3.0 – 4.6 0.46
4 Bottom Outlet 1.2 – 1.8 0.14
5 Reboiler Trapout 0.3 – 1.2 0.035
6 Liquid from Condenser 0.9 – 1.8 0.11
7 Liquid to chillers 1.2 – 1.8
8 Refrigerant Lines 0.6 – 1.2 0.09
9 Gravity Lines 0.2 – 0.5 0.04
10 Drain Lines 0.5 – 1.2
11 Boiler feed 2.4 – 4.6
12 Liquid with suspended solids 0.9

Table – 1     Sizing of Liquid Lines in Process & Equipment service

Sr. Velocity Maximum ΔP

 
Kg
Types of Service
No (m/sec) /cm2/100m
General Recommendation for pressure
1
level (Kg /cm2)
                   P > 35.1 0.46
       14.1 < P < 35.1 0.35
       10.5 < P < 14.1 0.14
         3.5 < P < 10.5 0.069
            0 < P < 3.5 0.034 Join us on Telegram
        Subatmospheric 0.023
2 Compressor piping Suction 0.12
3 Compressor piping discharge 0.23
4 Refrigerant suction lines 4.6 – 11
5 Refrigerant discharge lines 11 – 18
6 Tower Discharge
Pressure (P > 50 psia) 12 – 18 0.046 – 0.12
Atmospheric 18 – 30
Vacuum (P < 10 psia) 38 – 61 0.012 – 0.023
7 Saturated steam 60
8 Superheated Steam 75
9 Steam Pressure
                   P > 3.5 0.06
        3.5 < P < 10.5 0.115
      10.5 < P < 21 0.25
                 P  >  21 0.35

Table – 2     Size of Vapour Lines in Process & Equipment service

Friction Loss for Lines Less Friction Loss for Lines between 50 m
Pressure
than 50 m (kPa/100m) and 150 m (kPa/100m)

50mm Hg
 
  1.5 1.2
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100mm Hg
 
  2.0 1.5
400mm Hg
 
  2.5 2
760mm Hg 3.0 2.5
to 2.0 bar a
2.0 to 5.0 bar
10 5
a
5.0 to 8.0 bar
12 7
a
8 to 12 bar a
 
  14 9
12 to 15 bar a
 
16 10

15 to 35 bar a
19 12

Over 35 bar a
25 14

Table – 3   Pressure Drop Criteria for Line Sizing

Few more Resources for you…

Offshore Pipeline Design

Hydraulic calculation in piping networks
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 Anup Kumar Dey
I am a Mechanical Engineer turned into a Piping Engineer. Currently, I work in a reputed MNC as
a Senior Piping Stress Engineer. I am very much passionate about blogging and always tried to
do unique things. This website is my first venture into the world of blogging with the aim of
connecting with other piping engineers around the world.

5 thoughts on “Factors Affecting Line Sizing of Piping or

Pipeline Systems”
Zahid says:
July 7, 2020 at 6:33 pm
Dear Anup, That’s very useful article you have have written. could you please give reference
to the recommended velocities and pressure drops?
Best Regards
Zahid.
Reply

NISHANT says:
August 21, 2020 at 4:19 pm
Dear sir,
All information provided by you is very useful.
For more study purpose could you provide some data for natural gas pipeline line size
calculation if discharge flow is known. Join us on Telegram
Reply

K L PAI says:
August 21, 2020 at 4:21 pm
 Applied process equipment design by E E ludwig, volume 1, chapter 4 is n
Best reference for piping. I can send a copy if email ID is sent to me. klpai49@gmail.com
Reply

philip delfino says:

October 29, 2020 at 1:16 pm
can i have a material for putting formulars for line sizing in spreedsheet?
Reply

Aqib says:
December 20, 2020 at 10:01 am
Could anyone please send me the reference for above article.
Reply

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