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Contents
◾ 1 Piping design
◾ 2 Bernoulli equation
◾ 3 Reynolds number and Moody friction factor
◾ 4 Pressure drop for liquid flow
◾ 4.1 General equation
◾ 4.2 Hazen Williams equation
◾ 5 Pressure drop for gas flow
◾ 5.1 General equation
◾ 5.2 Simplified equation
◾ 5.2.1 Weymouth equation
◾ 5.2.2 Panhandle equation
◾ 5.2.3 Spitzglass equation
◾ 5.3 Application of the formulas
◾ 5.3.1 Simplified gas formula
◾ 5.3.2 Weymouth equation
◾ 5.3.3 Panhandle equation
◾ 5.3.4 Spitzglass equation
◾ 6 Multiphase flow
◾ 6.1 Flow regimes
◾ 6.1.1 Bubble
◾ 6.1.2 Slug flow
◾ 6.1.3 Transition flow
◾ 6.1.4 Annular mist flow
◾ 6.2 Two phase pressure drop
◾ 6.3 Simplified friction pressure drop approximation for two phase flow
◾ 6.4 Pressure Drop Because of Changes in Elevation
◾ 7 Pressure drop caused by valves and fittings
◾ 7.1 Resistance coefficients
◾ 7.2 Flow coefficients
◾ 7.3 Equivalent lengths
◾ 8 Nomenclature
◾ 9 References
◾ 10 Noteworthy papers in OnePetro
◾ 11 External links
◾ 12 See also
Piping design
The minimum basic parameters that are required to design the piping system include, but are not limited to, the
following.
These basic parameters are needed to design a piping system. Assuming steady-state flow, there are a number of
equations, which are based upon the general energy equation, that can be employed to design the piping system.
The variables associated with the fluid (i.e., liquid, gas, or multiphase) affect the flow. This leads to the derivation
and development of equations that are applicable to a particular fluid. Although piping systems and pipeline design
can get complex, the vast majority of the design problems encountered by the engineer can be solved by the
standard flow equations.
Bernoulli equation
The basic equation developed to represent steady-state fluid flow is the Bernoulli equation which assumes that total
mechanical energy is conserved for steady, incompressible, inviscid, isothermal flow with no heat transfer or work
done. These restrictive conditions can actually be representative of many physical systems.
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The equation is stated as
(/File%3AVol3_page_319_eq_001.PNG) (Eq. 1)
where
(/File%3AVol3_Page_320_Image_0001.png)
and
(/File%3AVol3_page_319_eq_003.PNG) (Eq. 3)
where
HL = head loss, ft,
f = Moody friction factor, dimensionless,
L = pipe length, ft,
D = pipe diameter, ft,
V = velocity, ft/sec,
g = gravitational constant ft/sec2,
ΔP = pressure drop, psi,
ρ = density, lbm/ft3,
and
d = pipe inside diameter, in.
ρ = density, lbm/ft3,
D = pipe internal diameter, ft,
V = flow velocity, ft/sec,
and
μ = viscosity, lbm/ft-sec.
where
μ = viscosity, cp,
d = pipe inside diameter, in.,
SG = specific gravity of liquid relative to water (water = 1),
Ql = liquid-flow rate, B/D,
and
V = velocity, ft/sec.
where
μ = viscosity, cp,
d = pipe inside diameter, in.,
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S = specific gravity of gas at standard conditions relative to air (molecular weight divided by 29),
and
Qg = gas-flow rate, MMscf/D.
The Moody friction factor, f, expressed in the previous equations, is a function of the Reynolds number and the
roughness of the internal surface of the pipe and is given by Fig. 3. The Moody friction factor is impacted by the
characteristic of the flow in the pipe. For laminar flow, where Re is < 2,000, there is little mixing of the flowing
fluid, and the flow velocity is parabolic; the Moody friction factor is expressed as f = 64/Re. For turbulent flow,
where Re > 4,000, there is complete mixing of the flow, and the flow velocity has a uniform profile; f depends on
Re and the relative roughness (Є/D). The relative roughness is the ratio of absolute roughness, Є, a measure of
surface imperfections to the pipe internal diameter, D. Table 9.1 lists the absolute roughness for several types of
pipe materials.
(/File%
(/File%3AVol3_Page_321_Image_0001.png)
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If the viscosity of the liquid is unknown, Fig. 4 can be used for the viscosity of crude oil, Fig. 5 for effective
viscosity of crude-oil/water mixtures, and Fig. 6 for the viscosity of natural gas. In using some of these figures, the
relationship between viscosity in centistokes and viscosity in centipoise must be used
(/File%3AVol3_page_321_eq_002.PNG) (Eq. 7)
where
γ = kinematic viscosity, centistokes,
ϕ = absolute viscosity, cp,
and
SG = specific gravity.
(/File% (/File%
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Fig. 4—Standard viscosity/temperature charts for Fig. 5—Effective viscosity of an oil/water mixture
liquid petroleum products (courtesy of ASTM). (courtesy of AMEC Paragon).
(/File%3AVol3_Page_327_Image_0001.png)
Eq. 3 can be expressed in terms of pipe inside diameter (ID) as stated next.
(/File%3AVol3_page_323_eq_001.PNG) (Eq. 8)
where
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ΔP = pressure drop, psi (total pressure drop).
The Hazen-Williams equation, which is applicable only for water in turbulent flow at 60°F, expresses head loss as
(/File%3AVol3_page_323_eq_002.PNG) (Eq. 9)
where
(/File%3AVol3_Page_327_Image_0001.png)
Table 2
where
Assumptions: no work performed, steady-state flow, and f = constant as a function of the length.
Simplified equation
where
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(/File%
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Three simplified derivative equations can be used to calculate gas flow in pipelines:
All three are effective, but the accuracy and applicability of each equation falls within certain ranges of flow and
pipe diameter. The equations are stated next.
Weymouth equation
This equation is used for high-Reynolds-number flows where the Moody friction factor is merely a function of
relative roughness.
where
Panhandle equation
This equation is used for moderate-Reynolds-number flows where the Moody friction factor is independent of
relative roughness and is a function of Reynolds number to a negative power.
where
E = efficiency factor (new pipe: 1.0; good operating conditions: 0.95; average operating conditions: 0.85),
Qg = gas-flow rate, MMscf/D,
d = pipe ID, in.,
P1 = upstream pressure, psia,
P2 = downstream pressure, psia,
Lm = length, miles,
T1 = temperature of gas at inlet, °R,
S = specific gravity of gas,
and
Z = compressibility factor for gas, dimensionless.
Spitzglass equation
where
Assumptions:
As previously discussed, there are certain conditions under which the various formulas are more applicable. A
general guideline for application of the formulas is given next.
Weymouth equation
The Weymouth equation is recommended for smaller-diameter pipe (generally, 12 in. and less). It is also
recommended for shorter lengths of segments ( < 20 miles) within production batteries and for branch gathering
lines, medium- to high-pressure (+/–100 psig to > 1,000 psig) applications, and a high Reynolds number.
Panhandle equation
This equation is recommended for larger-diameter pipe (12-in. diameter and greater). It is also recommended for
long runs of pipe ( > 20 miles) such as cross-country transmission pipelines and for moderate Reynolds numbers.
Spitzglass equation
The Spitzglass equation is recommended for low-pressure vent lines < 12 in. in diameter (ΔP < 10% of P1).
The petroleum engineer will find that the general gas equation and the Weymouth equation are very useful. The
Weymouth equation is ideal for designing branch laterals and trunk lines in field gas-gathering systems.
Multiphase flow
Flow regimes
Fluid from the wellbore to the first piece of production equipment (separator) is generally two-phase liquid/gas
flow.
The characteristics of horizontal, multiphase flow regimes are shown in Fig. 8. They can be described as follows:
◾ Bubble: Occurs at very low gas/liquid ratios where the gas forms bubbles that rise to the top of the pipe.
◾ Plug: Occurs at higher gas/liquid ratios where the gas bubbles form moderate-sized plugs.
◾ Stratified: As the gas/liquid ratios increase, plugs become longer until the gas and liquid flow in separate
layers.
◾ Wavy: As the gas/liquid ratios increase further, the energy of the flowing gas stream causes waves in the
flowing liquid.
◾ Slug: As the gas/liquid ratios continue to increase, the wave heights of the liquid increase until the crests
contact the top of the pipe, creating liquid slugs.
◾ Spray: At extremely high gas/liquid ratios, the liquid is dispersed into the flowing-gas stream.
(/File%3AVol3_Page_331_Image_0001.png)
Fig. 9[1] shows the various flow regimes that could be expected in horizontal flow as a function of the superficial
velocities of gas and liquid flow. Superficial velocity is the velocity that would exist if the other phase was not
present.
(/File%
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The multiphase flow in vertical and inclined pipe behaves somewhat differently from multiphase flow in horizontal
pipe. The characteristics of the vertical flow regimes are shown in Fig. 10 and are described next.
(/File%
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Bubble
Where the gas/liquid ratios are small, the gas is present in the liquid in small, variable-diameter, randomly
distributed bubbles. The liquid moves at a fairly uniform velocity while the bubbles move up through the liquid at
differing velocities, which are dictated by the size of the bubbles. Except for the total composite-fluid density, the
bubbles have little effect on the pressure gradient.
Slug flow
As the gas/liquid ratios continue to increase, the wave heights of the liquid increase until the crests contact the top
of the pipe, creating liquid slugs.
Transition flow
The fluid changes from a continuous liquid phase to a continuous gas phase. The liquid slugs virtually disappear
and are entrained in the gas phase. The effects of the liquid are still significant, but the effects of the gas phase are
predominant.
The gas phase is continuous, and the bulk of the liquid is entrained within the gas. The liquid wets the pipe wall, but
the effects of the liquid are minimal as the gas phase becomes the controlling factor. Fig. 11[2] shows the various
flow regimes that could be expected in vertical flow as a function of the superficial velocities of gas and liquid flow.
(/File%
3AVol3_Page_334_Image_0001.png)
The calculation of pressure drop in two-phase flow is very complex and is based on empirical relationships to take
into account the phase changes that occur because of pressure and temperature changes along the flow, the relative
velocities of the phases, and complex effects of elevation changes. Table 3 lists several commercial programs that
are available to model pressure drop. Because all are based to some extent on empirical relations, they are limited in
accuracy to the data sets from which the relations were designed. It is not unusual for measured pressure drops in
the field to differ by ± 20% from those calculated by any of these models.
(/File%3AVol3_Page_335_Image_0001.png)
Table 3
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Eq. 16 provides an approximate solution for friction pressure drop in two-phase-flow problems that meet the
assumptions stated.
where
where
There are several notable characteristics associated with pressure drop because of elevation changes in two-phase
flow. The flow characteristics associated with the elevation changes include:
◾ In downhill lines, flow becomes stratified as liquid flows faster than gas.
◾ The depth of the liquid layer adjusts to the static pressure head and is equal to the friction pressure drop.
◾ There is no pressure recovery in the downhill line.
◾ In low gas/liquid flow, the flow in uphill segments can be liquid "full" at low flow rates. Thus, at low flow
rates, the total pressure drop is the sum of the pressure drops for all of the uphill runs.
◾ With increased gas flow, the total pressure drop may decrease as liquid is removed from uphill segments.
The pressure drop at low flow rates associated with an uphill elevation change may be approximated with Eq. 19.
(/File%3AVol3_page_335_eq_001.PNG) (Eq. 19)
where
The total pressure drop can then be approximated by the sum of the pressure drops for each uphill segment.
Resistance coefficients
The head loss in valves and fittings can be calculated with resistance coefficients as
where
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HL = head loss, ft,
Kr = resistance coefficient, dimensionless,
D = pipe ID, ft,
and
V = velocity, ft/sec.
The resistance coefficients Kr for individual valves and fittings are found in tabular form in a number of industry
publications. Most manufacturers publish tabular data for all sizes and configurations of their products. One of the
best sources of data is the Crane Flow of Fluids, technical paper No. 410. [3] The Natural Gas Processors Suppliers
Assn. (NGPSA) Engineering Data Book[4] and Ingersoll-Rand’s Cameron Hydraulic Data Book[5] are also good
sources of references for the information. Some examples of resistance coefficients are listed in Tables 4 and 5.
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Table 4 Table 5
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Table 5 (Cont'd)
Flow coefficients
The flow coefficient for liquids, CV, is determined experimentally for each valve or fitting as the flow of water, in
gal/min at 60°F for a pressure drop of 1 psi through the fitting. The relationship between flow and resistance
coefficients can be expressed as
In any fitting or valve with a known CV, the pressure drop can be calculated for different conditions of flow and
liquid properties with Eq. 22.
where
Again, the CV is published for most valves and fittings and can be found in Crane Flow of Fluids,[3] Engineering
Data Book,[4] Cameron Hydraulic Data Book,[5] as well as the manufacturer’s technical data.
Equivalent lengths
The head loss associated with valves and fittings can also be calculated by considering equivalent "lengths" of pipe
segments for each valve and fitting. In other words, the calculated head loss caused by fluid passing through a gate
valve is expressed as an additional length of pipe that is added to the actual length of pipe in calculating pressure
drop.
All of the equivalent lengths caused by the valves and fittings within a pipe segment would be added together to
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compute the pressure drop for the pipe segment. The equivalent length, Le, can be determined from the resistance
coefficient, Kr, and the flow coefficient, CV, using the formulas given next.
and
where
Table 6 shows equivalent lengths of pipe for a variety of valves and fittings for a number of standard pipe sizes.
(/File%
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Table 6
Nomenclature
Z = elevation head, ft,
P = pressure, psi,
ρ = density, lbm/ft3,
V = velocity, ft/sec,
g = gravitational constant, ft/sec2,
HL = head loss, ft.
f = Moody friction factor, dimensionless,
L = pipe length, ft,
D = pipe diameter, ft,
ΔP = pressure drop, psi,
μ = viscosity, lbm/ft-sec.
SG = specific gravity of liquid relative to water (water = 1),
Ql = liquid-flow rate, B/D,
S = specific gravity of gas at standard conditions relative to air (molecular weight divided by 29),
Qg = gas-flow rate, MMscf/D.
γ = kinematic viscosity, centistokes,
ϕ = absolute viscosity, cp
Ql = liquid flow rate, B/D,
w = rate of flow, lbm/sec
P1 = upstream pressure, psia
P2 = downstream pressure, psia.
ΔhW = pressure loss, inches of water,
W = rate of flow of mixture, lbm/hr,
ρM = density of the mixture, lbm/ft3
P = operating pressure, psia,
R = gas/liquid ratio, ft3/bbl,
T = operating temperature, °R,
ΔPZ = pressure drop because of elevation increase in the segment, psi,
ΔZ = increase in elevation for segment, ft.
HL = head loss, ft,
Kr = resistance coefficient, dimensionless
CV = flow coefficient for liquids, dimensionless.
Kr = resistance coefficient, dimensionless,
References
1. ↑ 1.0 1.1 Griffith, P. 1984. Multiphase Flow in Pipes. J Pet Technol 36 (3): 361-367. SPE-12895-PA.
http://dx.doi.org/10.2118/12895-PA (http://dx.doi.org/10.2118/12895-PA).
2. ↑ 2.0 2.1 Taitel, Y., Bornea, D., and Dukler, A.E. 1980. Modelling flow pattern transitions for steady upward
gas-liquid flow in vertical tubes. AIChE J. 26 (3): 345-354. http://dx.doi.org/10.1002/aic.690260304
(http://dx.doi.org/10.1002/aic.690260304).
3. ↑ 3.0 3.1 Crane Flow of Fluids, Technical Paper No. 410. 1976. New York City: Crane Manufacturing Co.
4. ↑ 4.0 4.1 Engineering Data Book, ninth edition. 1972. Tulsa, Oklahoma: Natural Gas Processors Suppliers
Assn.
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5. ↑ 5.0 5.1 Westway, C.R. and Loomis,A.W. ed. 1979. Cameron Hydraulic Data Book, sixteenth edition.
Woodcliff Lake, New Jersey: Ingersoll-Rand.
External links
Use this section to provide links to relevant material on websites other than PetroWiki and OnePetro
See also
Piping and pipeline systems (/Piping_and_pipeline_systems)
Pipelines (/Pipelines)
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