Line Sizing For Single Phase Gashhhh

Line Sizing for Single Phase Gas
Prepared by:
Hafif Aulia Nur Rahman
https://www.linkedin.com/in/hafifaulianurrahman/
March, 25th 2024

linkedin.com/in/hafifaulianurrahman Line Sizing for Single Phase Gas
Line Sizing for Single Phase Gas
• Case Study
Perform calculations to ascertain the pipe diameter necessary for optimal gas flow in accordance
with the process requirements at a Gathering Station, utilizing the provided data for sizing the
pipeline:
1. Pipe Material = Carbon Steel / Commercial Steel
2. Pipe Condition = New
3. Pipe Class = B3CS2F
4. Operating Pressure, (P) = 3.50 psig
5. Operating Temperature, (T) = 165oF
6. Std. Gas Flow Rate, (Qg) = 1 MMSCFD
7. Molecular Weight, (MW) = 25.74
8. Mass Density, () = 0.07 lb/ft3
9. Viscosity, () = 0.0130 cP
10. Cp/Cv, (k) = 1.2250
11. Compressibility Factor, (Z) = 0.9960
12. Length, (L) = 100 ft (assumption for this case study)
*Note : The fluid properties are generated from Process Simulation (HYSYS).
The following are the design criteria that must be considered when sizing the pipeline size:
1. Maximum Velocity = 60 ft/s, as per API RP 14E, 5th Ed.
2. Maximum Mach Number = 0.5, as per API STD 521, 7th Ed.
3. Pressure Drop = 0.25 – 1.5 psi/100 ft, as per GPSA Section 17, 12th Ed.
In this case, 0.25 psi/100 ft is selected as the maximum
pressure drop for the worst case scenario.
*Note : Those criteria are based on API standard and GPSA Engineering Data Book. However,
you are allowed to use other criteria if your company follows different standards.
Page 2 of 14
• Solution
1. Determine the Pipe Roughness Value () for the pipe based on its specifications.
• Pipe Material = Carbon Steel / Commercial Steel
• Pipe Condition = New
• Pipe Roughness Value = 0.0018 in (0.045 mm)
*Note :
1. Source = Darby, Ron and Chhabra, Raj P., 2017, Chemical Engineering Fluid Mechanics
(3rd Ed.), CRC Press, New York.
2. You can use the VLOOKUP function to make it easier to determine the Pipe Roughness
Value.
Page 3 of 14
2. Take any Nominal Pipe Size (NPS) and Schedule Number as trial and error that will be used
in the next calculations.
Option 1 Option 2 Option 3
Nominal Pipe Size [in] 4 6 8
Schedule No. SCH40 SCH40 SCH20
Inside Diameter, (ID) [mm] 102.26 154.05 206.40
[in] 4.03 6.06 8.13
The pipe inside diameter for the chosen NPS and Schedule No. is determined using the table
provided below:
Inside Diameter (mm)
SCH10 SCH20 SCH30 SCH40 SCH60 SCH80 SCH100 SCH120 SCH140 SCH160 STD XS XXS SCH5S SCH10S SCH40S SCH80S
0.50 15.80 13.87 11.84 15.80 13.87 6.40 18.03 17.12 15.80 13.87
3/4 20.93 18.85 15.54 20.93 18.85 11.02 23.37 22.45 20.93 18.85
1 27.86 26.64 24.31 20.70 26.64 24.31 15.21 30.10 27.86 26.64 24.31
1.5 42.72 40.89 38.10 33.99 40.89 38.10 27.94 44.96 42.72 40.89 38.10
2 54.79 52.50 49.25 42.85 52.50 49.25 38.18 57.02 54.79 52.50 49.25
3 82.80 77.93 73.66 66.65 77.93 73.66 58.42 84.68 82.80 77.93 73.66
4 108.20 102.26 97.18 92.05 87.33 102.26 97.18 80.06 110.08 108.20 102.26 97.18
6 154.05 146.32 139.72 131.75 154.05 146.32 124.38 162.73 161.46 154.05 146.32
8 206.40 205.00 202.71 198.45 193.67 188.90 182.55 177.82 173.05 202.71 193.67 174.62 213.53 211.55 202.71 193.67
10 260.30 257.45 254.50 247.65 242.87 236.52 230.17 222.25 215.90 254.50 247.60 222.20 266.24 264.66 254.50 247.60
12 311.20 307.08 303.22 295.30 288.90 280.97 273.05 266.70 257.20 304.80 298.45 273.10 315.92 314.70 304.80 298.45
14 342.90 339.80 336.55 333.35 325.42 317.50 307.95 300.02 292.10 284.17 336.55 330.20 347.67 346.05
16 393.70 390.60 387.35 381.00 373.07 363.52 354.02 244.47 333.35 325.42 387.35 381.00 398.01 396.85
18 444.50 441.40 434.95 428.65 419.10 409.55 398.47 387.35 377.85 366.72 438.15 431.80 448.81 447.65
20 495.30 489.00 482.60 477.82 466.75 455.62 442.92 431.80 419.10 407.97 489.00 482.60 498.45 496.45
22 546.10 539.75 533.40 514.35 501.65 488.95 476.25 463.55 450.85 539.75 549.25 547.72
24 596.90 590.60 581.05 574.65 560.37 547.67 531.82 517.55 504.85 490.52 590.60 584.20 598.52
26 644.55 635.00 641.35 635.00
28 695.35 685.80 679.45 692.15 685.80
30 746.20 736.60 730.25 742.95 736.60 749.30
32 796.95 787.40 781.05 777.85 793.75 787.40
34 846.12 838.20 831.85 828.65 844.55 838.20
36 898.55 889.00 882.65 876.30 895.35 889.00
38 945.94 914.20
40 996.95
42 1047.74 1041.40
44 1098.55 1092.20
46 1149.34 1143.00
48 1200.15 1193.80
*Note : You can utilize the MATCH and INDEX functions in MS. Excel to simplify the search
for the Inside Diameter value according to the chosen NPS and Schedule No.
Page 4 of 14
3. Calculate the Design Volumetric Flow Rate (Q) using the following formula:
Qdesign = (1 + Margin) ∗ Qg
Where:
Qdesign = Design Volumetric Flow Rate (MMSCFD)
Margin = Additional Design Margin (10%)
Qg = Standard Gas Flow Rate (MMSCFD)
As the pipe being sized is new, add a design margin of 10% (based on common engineering
practice) to determine the Design Volumetric Flow Rate (Qdesign).
Qdesign = (1 + 10%) ∗ 1 MMSCFD = 𝟏. 𝟏 𝐌𝐌𝐒𝐂𝐅𝐃
4. Calculate the Specific Gravity (SG) using the following formula:

MWgas
SG =
MWair
Where:
SG = Gas Specific Gravity (dimensionless)
MWgas = Molecular Weight of the Gas
MWair = Molecular Weight of the Air (28.97)
25.74
SG = = 𝟎. 𝟖𝟖𝟖𝟓
28.97
The Specific Gravity (SG) will later be used in calculating the pressure drop.
5. Calculate the Mass Flow Rate (W) at standard conditions using the formula derived from ideal
gas law, as follow:
W∗R∗T∗Z Qdesign ∗ 144 ∗ P
Qdesign = ≡ W=
144 ∗ P R∗T∗Z
Where:
Qdesign = Design Volumetric Flow Rate (SCFH)
W = Mass Flow Rate (lb/hr)
R = Universal Gas Constant (1,545.348 ft.lbf/(lbmol.oR) divided by the Gas MW)
T = Temperature at Standard Condition (oR or [60oF + 459.67])
Z = Compressibility Factor (dimensionless)
P = Pressure at Standard Condition (14.7 psia)
Page 5 of 14
1 hr
(1.1 MMSCFD ∗ 106 ∗ ) ∗ 144 ∗ 14.7 psia
24 day
W= = 𝟑, 𝟏𝟐𝟐 𝐥𝐛⁄𝐡𝐫
ft. lbf
1,545.348
lbmol. °R ∗ (60℉ + 459.67)°R ∗ 0.9960
25.74
The Mass Flow Rate (W) will later be used in calculating the pressure drop.
6. Calculate the Sound of Speed (c) of the gas using the following formula:
k ∗ T 0.5
c = 223 ∗ ( )
MW
Where:
c = Speed of Sound (ft/s)
k = Specific Heat Ratio or Cp/Cv of the gas (dimensionless)
T = Operating Temperature (oR or [oF + 459.67])
MW = Gas Molecular Weight
Reference: Eq. 59 page 140, API STD 521 (2020), 7 th Ed.
0.5
1.2250 ∗ (165℉ + 459.67)°R
c = 223 ∗ ( ) = 𝟏, 𝟐𝟏𝟔 𝐟𝐭⁄𝐬
25.74
The Speed of Sound (c) of the gas will later be used in calculating the Mach Number.
7. Calculate the Fluid Velocity (v) using the following formula:

60 ∗ Z ∗ Qdesign ∗ T
v=
ID2 ∗ P
Where:
v = Gas Velocity (ft/s)
Qdesign = Design Volumetric Flow Rate (MMSCFD), at Std. Conditions, 14.7 psia and 60oF
ID = Pipe Inside Diameter (inch)
P = Operating Pressure (psia or [psig + 14.7])
Reference: Eq. 2.13 page 140, API STD 521 (2020), 7th Ed.
Page 6 of 14
For example, for Option 1 where the NPS = 4 inch, Schedule No. = SCH40, and ID = 4.03 in,
the following result is obtained:
60 ∗ 0.9960 ∗ 1.1 MMSCFD ∗ (165℉ + 459.67)°R
v= = 𝟏𝟑𝟗. 𝟐𝟎 𝐟𝐭⁄𝐬
(4.03 inch)2 ∗ (3.50 psig + 14.7)psia
By using the same formula, Fluid Velocity is obtained for Option 2 and Option 3.
[in] 4.03 6.06 8.13
Speed of Sound, (c) [ft/s] 1,216
Fluid Velocity, (v) [ft/s] 139.20 61.34 34.17
8. Calculate the Mach Number (Ma) using the following formula:

v
Ma =
c
Where:
Ma = Mach Number (dimensionless)
v = Gas Velocity (ft/s)
c = Speed of Sound (ft/s)
Reference: Eq. C.7 page 175, API STD 521 (2020), 7 th Ed.
For Option 1, the following result is obtained:

139.20 ft⁄s
Ma = = 𝟎. 𝟏𝟏
1,216 ft⁄s
[in] 4.03 6.06 8.13
Mach Number, (Ma) 0.11 0.05 0.03
Page 7 of 14
9. Calculate the Reynolds Number (Re) using the following formula:

ρ ∗ ID ∗ v
Re =
μ
Where:
Re = Reynolds Number (dimensionless)
 = Mass Density (lb/ft3)
ID = Pipe Inside Diameter (ft)
v = Fluid Velocity (ft/s)
 = Viscosity (lb/ft.s), or
= cP divided by 1,488, or
= cSt times SG and then divided by 1,488
Reference: Eq. 2.3 page 15, API RP 14E (R2013), 5th Ed.
For example, for Option 1, the following result is obtained:
lb 4.03 in ft
0.07 3 ∗( in ) ∗ 139.20
ft s
12
Re = ft = 𝟑𝟕𝟒, 𝟏𝟖𝟓
0.0130 cP
1,488
[in] 4.03 6.06 8.13
Mach Number, (Ma) 0.11 0.05 0.03
Reynolds Number, (Re) 374,185 248,388 185,389
Page 8 of 14
10. Calculate the Friction Factor (f)

If laminar flow occurs in the pipe (Re < 2,000), utilize the following formula:
64
f=
Re
Where:
f = Friction Factor (dimensionless)
Reference: Page 1-6, Crane (1986)
However, if turbulent flow occurs (Re > 4,000), utilize the Swamee-Jain equation to obtain the
Friction Factor (f).
0.25
f= 2
ε⁄ID 5.74
[log10 ( 3.7 + 0.9 )]
Re
Where:
 = Pipe Roughness Value (in)
ID = Pipe Inside Diameter (in)
Let’s calculate the Friction Factor (f) for Option 1. The calculated Reynolds Number is greater
than 4,000. So, use the Swamee-Jain equation:
0.25
f= 2 = 𝟎. 𝟎𝟏𝟕𝟕𝟒
0.0018 in⁄4.03 in 5.74
[log10 ( + )]
3.7 (374,185)0.9
By using the same formula, Friction Factor is obtained for Option 2 and Option 3.
[in] 4.03 6.06 8.13
Mach Number, (Ma) 0.11 0.05 0.03
Friction Factor, (f) 0.01774 0.01736 0.01745
Page 9 of 14
11. Calculate the Pressure Drop (∆P)

There are two (2) methods that can be used to calculate the pressure drop of gas flow in the
pipeline. The first method is based on Equation 2.17 on page 23 of API RP 14E (R2013), 5th
Edition, as follow:
0.000336 ∗ f ∗ W 2
∆P =
(ID)5 ∗ ρ
Where:
∆P = Pressure Drop (psi/100 ft)
W = Mass Flow Rate (lb/hr)
 = Gas Mass Density (lb/ft3)
For example, for Option 1 the following result is obtained:

lb 2
0.000336 ∗ 0.01774 ∗ (3,122 )
∆P = hr = 𝟎. 𝟕𝟖𝟒𝟖 𝐩𝐬𝐢⁄𝟏𝟎𝟎 𝐟𝐭
lb
(4.03 in)5 ∗ 0.07 3
ft
Meanwhile, the second method to calculate the pressure drop is based on Equation 2.9 on page
21 of API RP 14E (R2013), 5th Edition, as follow:
2
SG ∗ (Qdesign ) ∗ Z ∗ T ∗ L
∆P = 12.6 ∗
P ∗ (ID)5
Where:
∆P = Pressure Drop (psi/100 ft)
SG = Gas Specific Gravity (dimensionless)
Qdesign = Design Volumetric Flow Rate (MMSCFD), at Std. Conditions, 14.7 psia and 60oF
L = Length (100 ft)
P = Operating Pressure (psia or [psig + 14.7])
Page 10 of 14
For example, for Option 1 the following result is obtained:

0.8885 ∗ (1.1 MMSCFD)2 ∗ 0.9960 ∗ (165℉ + 459.67)°R ∗ 100 ft
∆P = 12.6 ∗ = 𝟎. 𝟕𝟕𝟔𝟕 𝐩𝐬𝐢⁄𝟏𝟎𝟎 𝐟𝐭
(3.50 psig + 14.7)psia ∗ (4.03 in)5
After calculating the pressure drop using two methods, the largest pressure drop value was
chosen as the worst case scenario. For Option 1, pressure drop of 0.7848 psi/100 ft was chosen.
If the length of the pipeline (L) is 100 ft, then the pressure drop is:
psi psi
∆P = ∆P ( ) ∗ L (ft) = 0.7848 ∗ 100 ft = 𝟕𝟖. 𝟒𝟖 𝐩𝐬𝐢
100 ft 100 ft
The following is the calculated pressure drop for Option 2 and Option 3:
Inside Diameter, (ID) [in] 4.03 6.06 8.13
Mach Number, (Ma) 0.11 0.05 0.03
Pressure Drop, (∆P)
First Method [psi/100 ft] 0.7848 0.0990 0.0230
Second Method [psi/100 ft] 0.7767 0.0979 0.0228
Selected [psi/100 ft] 0.7848 0.0990 0.0230
[psi] 78.48 9.90 2.30
Page 11 of 14
• Conclusion
Based on the results of the calculations carried out in the previous section, it can be concluded
that:
1. Option 1, featuring NPS = 4 inch and SCH40, indicates a calculated velocity exceeding
the threshold (60 ft/s), suggesting a potential for noise problems in the pipeline. Moreover,
the calculated pressure drop significantly surpasses the acceptable limit (0.25 psi/100 ft).
Thus, NPS 4 inch is deemed unsuitable and unsafe for selection.
2. Option 2, featuring NPS = 6 inch and SCH40, results in a calculated velocity that exceeds
the criteria (60 ft/s), similar to Option 1. However, the calculated pressure drop in this
option remains below the maximum pressure drop (0.25 psi/100 ft). Therefore, NPS 6 inch
is not suitable for selection as a pipe size for the required operating conditions. However,
it is necessary to assess the noise generated in the pipeline. Exceeding criteria for
velocity can be considered acceptable when pipe routing, valve selection, and placement
are done to minimize or isolate noise.
3. Option 3, featuring NPS = 8 inch and SCH20, maintains a calculated velocity below the
maximum criteria (60 ft/s), effectively preventing noise problems in the pipeline.
Furthermore, NPS 8 inch maintain pressure drops below the stipulated criteria (0.25
psi/100 ft), making it a suitable choices to meet process requirements.
4. In terms of Mach number, the three options produce a Mach number that remains
below the maximum criterion of 0.5. This indicates that the gas flow in the piping for the
three options is subsonic, which is generally more predictable and easier to manage
compared to supersonic flow. Furthermore, subsonic flow reduces the likelihood of
encountering problems such as fluctuations, gas compression, formation of shock waves,
high noise, and vibration
Page 12 of 14
Table – Summary of Line Sizing Results for Single Phase Gas

Mach Number, (Ma) 0.11 0.05 0.03
Selected [psi/100 ft] 0.7848 0.0990 0.0230
[psi] 78.48 9.90 2.30
CRITERIA
Minimum Velocity [ft/s] 0
Maximum Velocity [ft/s] 60
Maximum Mach Number 0.5
Maximum Pressure Drop [psi/100 ft] 0.25
CONCLUSION
Velocity Check OV! OV! OK
Mach Number Check OK OK OK
Pressure Drop Check OPD! OK OK
Remark NOT OK NOT OK OK
Selected Size [in] 8
*Note : The step-by-step calculation results may have slight differences because the
data/numbers listed in this document are rounded off from those in MS. Excel. Please see the
Attachment for the details.
Page 13 of 14
ATTACHMENT
LINE SIZING CALCULATION
Page 14 of 14
Prepared by: Hafif Aulia Nur Rahman htps://www.linkedin.com/in/hafifaulianurrahman/
LINE SIZING
CALCULATION SHEET
Project Title : FEED Chemical EOR Project No. : ---

Client : World Govt. Oil and Gas Company Phase/CTR : ---
Document No. : --- Page : 1 of 1
Activity : Line Sizing for Single Phase Gas
DATE REVISION BY CHECKED APPROVED
25-Mar-24 0A HR --- ---
LINE SIZING - SINGLE PHASE GAS

British Unit
LINE DETAILS
P&ID No. : ---
Line No. : ---
From : Gas Boot (V-01) Gas Outlet
To : 8" Flare Header
PIPE DETAILS
Pipe Material Commercial Steel
Condition New
Pipe Roughness Value, (e) [in] 0.00180
Pipe Class B3CS2F
INPUT
Additional Design Margin [%] 10
Operating Pressure, (P) [psig] 3.50
Operating Temperature, (T) [oF] 165.00
Std. Gas Flow Rate, (Qg) [MMSCFD] 1.0000
Molecular Weight, (MW) 25.74
Mass Density, (r) [lb/ft3] 0.0700
Viscosity, (m) [cP] 0.0130
Cp/Cv, (k) 1.2250
Compressibility Factor, (Z) 0.9960
Length, (L) [ft] 100
OUTPUT
Design Vol. Flow Rate, (Qdesign) [MMSCFD] 1.1000
Specific Gravity, (SG) 0.8885
Mass Flow Rate, (W) [lb/hr] 3,122
Mach Number, (Ma) 0.11 0.05 0.03
Relative Roughness, (e/ID) 0.00045 0.00030 0.00022

Selected [psi/100 ft] 0.7848 0.0990 0.0230
[psi] 78.48 9.90 2.30
CRITERIA
Minimum Velocity [ft/s] 0
Maximum Velocity [ft/s] 60
Maximum Mach Number 0.5
Maximum Pressure Drop [psi/100 ft] 0.25
CONCLUSION
Velocity Check OV! OV! OK
Mach Number Check OK OK OK
Pressure Drop Check OPD! OK OK
Remark NOT OK NOT OK OK
Selected Size [in] 8
NOTES
➢ This spreadsheet was generated using several references:
1. -----, 2013, API RP 14E (R2013) : Recommended Practice for Design and Installation of Offshore Production Platform Piping Systems (5th Ed.),
American Petroleum Institute (API), Washington D. C.
2. Crane, 1982, Flow of Fluids Through Valves, Fittings and Pipe, Crane Co., New York.
3. -----, 2004, Engineering Data Book (12th Ed.), The Gas Processors Suppliers Association, Oklahoma.
4. Darby, Ron and Chhabra, Raj P., 2017, Chemical Engineering Fluid Mechanics (3rd Ed.), CRC Press, New York.
➢ The fluid properties are generated from Process Simulation (HYSYS), Doc. No. ---.
Confidential 3/24/2024 Page 1 of 1

Line Sizing For Single Phase Gashhhh

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Line Sizing for Single Phase Gas

March, 25th 2024

Line Sizing for Single Phase Gas

4. Calculate the Specific Gravity (SG) using the following formula:

7. Calculate the Fluid Velocity (v) using the following formula:

8. Calculate the Mach Number (Ma) using the following formula:

For Option 1, the following result is obtained:

9. Calculate the Reynolds Number (Re) using the following formula:

For example, for Option 1, the following result is obtained:

10. Calculate the Friction Factor (f)

11. Calculate the Pressure Drop (∆P)

For example, for Option 1 the following result is obtained:

For example, for Option 1 the following result is obtained:

Table – Summary of Line Sizing Results for Single Phase Gas

Project Title : FEED Chemical EOR Project No. : ---

LINE SIZING - SINGLE PHASE GAS

Pipe Roughness Value, (e) [in] 0.00180

Pipe Class B3CS2F

Nominal Pipe Size [in] 4 6 8

Schedule No. SCH40 SCH40 SCH20

Inside Diameter, (ID) [in] 4.03 6.06 8.13

Additional Design Margin [%] 10

Operating Pressure, (P) [psig] 3.50

Operating Temperature, (T) [oF] 165.00

Std. Gas Flow Rate, (Qg) [MMSCFD] 1.0000

Molecular Weight, (MW) 25.74

Mass Density, (r) [lb/ft3] 0.0700

Viscosity, (m) [cP] 0.0130

Cp/Cv, (k) 1.2250

Compressibility Factor, (Z) 0.9960

Length, (L) [ft] 100

Specific Gravity, (SG) 0.8885

Mass Flow Rate, (W) [lb/hr] 3,122

Speed of Sound, (c) [ft/s] 1,216

Option 1 Option 2 Option 3

Fluid Velocity, (v) [ft/s] 139.20 61.34 34.17

Mach Number, (Ma) 0.11 0.05 0.03

Reynolds Number, (Re) 374,185 248,388 185,389

Relative Roughness, (e/ID) 0.00045 0.00030 0.00022

Friction Factor, (f) 0.01774 0.01736 0.01745

Pressure Drop, (∆P)

Second Method [psi/100 ft] 0.7767 0.0979 0.0228

Selected [psi/100 ft] 0.7848 0.0990 0.0230

[psi] 78.48 9.90 2.30

Maximum Velocity [ft/s] 60

Maximum Mach Number 0.5

Maximum Pressure Drop [psi/100 ft] 0.25

Velocity Check OV! OV! OK

Mach Number Check OK OK OK

Pressure Drop Check OPD! OK OK

Remark NOT OK NOT OK OK

Selected Size [in] 8

Confidential 3/24/2024 Page 1 of 1

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