Line Size

Training Services
Line Sizing
and Hydraulics
2003 ENGINEERING DESIGN SEMINAR – LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential EDS 2003/LS-1
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training Services
Part I
Line Sizing
n General Guidelines
n Line ∆P Calculations for Liquid,
Vapor and Two-Phase
n Line Service Types and Guidelines
for ∆P and Velocity Limits
General Line Sizing Comments
n Guides and Approximations
n Reduce Time for Line Sizing
n Computer Not Required
n Good Judgment and Experience
Guidelines
n Use “normal” flow rates and “normal”

pressures from process design
n Consider effect of:

– Design flow rates
– Maximum flow rates
– Minimum flow rates
– Startup
– Shutdown
– Upset
Principle Pipe Design Criteria
n Pressure Drop in psi/100 Feet

(Cost in Utilities)
n Velocity in Feet Per Minute

(Noise, Erosion, Sonic Velocity)
Required Physical Properties
n Liquid Density (as Specific Gravity)

– Ratio of the density of the liquid at its flowing
temperature to the density of water at a base
temperature, usually 60°F (15.6°C) or 39.2°F
(4°C), its point of maximum density (1000
g/cm3)
n Vapor Density
– Pounds per cubic foot
n Vapor Specific Volume (inverse of density)
– Cubic feet per pound
Mechanical Considerations
n Minimum size rack piping 1“

(Some refiners set 1.5” or 2” minimum)
n Minimize purchasing, detailing and inventory

by avoiding 1¼", 2½", 3½", and 5" pipe
n For 2" and smaller pipe size, Schedule 80

minimum is recommended
Pipe Wall Thickness
n Pipe Outside Diameter (O.D.) is constant

n I.D. changes as wall thickness changes
n Wall thickness tolerance is +12.5% for
seamless pipe up to 24" O.D.
n Wall thickness tolerance is +0.01" if pipe is
fabricated from rolled plate
n Be careful of I.D. in high pressure or high
corrosion allowance systems
Revamp Considerations
n Economics and decision factors are different
n Line size can often be smaller than for new

plants
Pressure Drop for Liquid Flows
n The general equation for pressure drop of a

liquid in a pipe can be expressed as the Darcy-
Weisbach Equation (English units):
f ×ρ ×L ×V 2
∆P =
144 ×D ×2 ×g
(continued)
where:
∆P = Pressure Drop (psi)

ρ = Density (lb/ft3)
f = Darcy Friction Factor
= four times the Fanning Friction Factor
L = (Equivalent) Length of pipe (ft)
V = Velocity (ft/s)
D = Internal Diameter (ft)
d = Internal diameter (in)
g = Gravitational Constant (32.2 ft/s2)
Q = Flow (gpm)
(continued)
n By rearrangement of the equation, we can

obtain:
0.000216 x f x L x ρ x Q 2
∆P =
d5
(continued)
n Simplifications
– Assume L = 100 ft of equivalent length
– Define ∆P(100) = ∆P (when L = 100 ft)
– Substituting ρ = 62.4 lb/ft3 x SG
where SG = Specific Gravity of fluid
– By substitution and rearrangement yields
∆P100 1.348f × Q 2
=
SG 5
d
(continued)
∆P100
– Define ∆P0(100) =
SG
– By substitution:
1.348 f × Q 2
∆P0(100) =
5
d
n For small changes in flow, Q, assume Friction
Factor “f” remains constant. Thus we can
define a constant K as follows:
1.348f
= Constant, K
5
d
(continued)
n The equation then becomes:
∆P0(100) = K Q2
Which plots as a straight line on a Log-Log

Graph
Liquid Flow thru Commercial Steel Pipe
LS-R00-18
UOP Pressure Drop Chart
for Liquid Flow
LS-R00-17
Viscosity Correction
n Chart ∆P is based on a liquid with a kinematic

viscosity of 0.6 centistoke
n For materials with different viscosities, multiply
chart ∆P by correction factor:
0.2
v
 
0.6
v Kinematic viscosity in centistoke
µ Absolute viscosity in centipoise
ρ Density, specific gravity at same degF
µ
v=
ρ
Viscosity Correction
(continued)
n Example
– For υ = 20 Centistokes, Multiply ∆P read from
chart by the following factor:
0.2 0. 2
v  20
  =  = 2.016
0.6  .6 
(Correction is for turbulent flow, Reynolds

Number > 2000)
Liquid Flow Line Sizing/∆P Calculation
Exercise
n Flow Rate 500 gpm
Flowing Sp.Gr. 0.75
Viscosity 0.6 centistoke
a. Find ∆P/100' in 6" Sch 80 Pipe
b. Find ∆P/100' in 8" Sch 40 Pipe
c. Find velocity in 8" Sch 40 Pipe
d. Find corrected ∆P/100' in 6" Sch 80 Pipe if
υ = 50 centistoke
e. What size pipe would result in a ∆P/100' =
0.28 psi if flow is 4000 gpm, Sp.Gr. = 0.8
and υ = 0.6 centistoke? Solution
Pressure Drop for Vapor Flows
n The general equation for pressure drop of a

vapor in a pipe can be expressed as the Darcy-
Weisbach Equation in the form:
3.36 ×10-6 ×f ×L ×W 2 ×V
∆P =
5
d
(continued)
Where:
∆P = Pressure Drop (psi)

ρ = Density (lb/ft3)
f = Darcy Friction Factor
L = Length of pipe (ft)
V = Specific Volume (ft3/lb)
d = Internal diameter (in)
W = Mass flow rate (lb/hr)
(continued)
n Simplifications
– Assume L = 100 ft
– Define ∆P(100) = ∆P (when L = 100 ft)
∆P100
– Define ∆P0(100) =
V
– By substitution and re-arrangement, we
obtain:
2
336 f  W 
∆P0(100) = 5  
d 1000 
(continued)
n For small changes in flow, W, assume the friction

factor “f” remains constant.
thus:
336 f
= Constant, K
5
d
2
W
∆P0 (100) = K  
1000
n This plots as a straight line on a Log-Log graph
Vapor Flow thru Commercial Steel Pipe
LS-R00-20
(See Previous Chart for Smaller Sizes)
LS-R00-21
LS-R00-22
UOP Pressure Drop Chart
for Vapor Flow
LS-R00-19
Vapor Flow Line Sizing/∆P Calculation
Exercise
n Flowing Quantity 40,000 lb/h

Specific Volume 0.9 ft3/lb
a. Find ∆P/100' in 6" Sch 80 Pipe
b. Find ∆P/100' in 8" Sch 40 Pipe
c. Find Velocity in 8" Sch 40 Pipe
d. What size pipe would result in a ∆P/100'
equal to or less than 0.4 psi, if the flow is
100,000 lb/h and density is 2 lb/ft3?
e. What is the velocity in the line?
Solution
Sonic Velocity of a Vapor
n A compressible fluid cannot move faster than

the speed of sound in that fluid
n Typical problem in vacuum heater transfer
lines, pressure relief piping, and high pressure
drop systems
n Usually occurs at end of a pipe or system (at a
change in cross-sectional area)
n If sonic velocity is disregarded the flow rate
calculated may be higher than you can achieve
Sonic Velocity of a Vapor
(continued)
n For a typical Cp/Cv of 1.1, the speed of sound

is equal to:
Temperature oR
Vs, ft/min = 14,000
Molecular Weight
n Sonic velocity is expressed in units of feet per
minute
n Sonic velocity is proportional to:
Cp Cv
Specific Volume Change
n If total line ∆P < 10% of upstream absolute

pressure, use either upstream or downstream
specific volume for line ∆P calculation
n If total line ∆P < 40% but > 10% of upstream
absolute pressure, use average specific volume
n If total line ∆P > 40% of upstream absolute
pressure, design the line in sections
Two-Phase Flow Pressure Drop
n Correlating Factors
– Liquid volume fraction
– Ratio of pseudo 100% gas ∆P and pseudo
100% liquid ∆P: ∆P*G/∆P*L
– Ratio of ∆P two phase and pseudo 100%
liquid ∆P: ∆PTP / ∆P*L
– See chart: Pressure Drop for two phase in

handout
(continued)
1. Calculate fictitious all vapor pressure drop,

∆P*G using total mass flow and flowing vapor
properties
2. Calculate fictitious all liquid pressure drop,

∆P*L by converting total mass flow to liquid
(gpm) and use the flowing properties of the
liquid phase
(continued)
3. Calculate the ratio ∆P*G/∆P*L
4. Calculate the actual liquid volume fraction
VL
Liquid Volume Fraction =
VL + VG
(continued)
5. Using these last two values and chart,

determine the two-phase multiplier:
∆PTP / ∆P*L
6. Calculate two-phase pressure drop, ∆PTP
∆PTP = (∆PTP / ∆P*L )x ∆P*L
LS-R00-23
LS-R00-25
Two-Phase Flow Line Sizing
∆P Calculation Exercise
n Find a Schedule 80 pipe size that will result in

approximately a pressure drop of 0.5 psi/100'
as a result of horizontal two-phase flow
having the following parameters:
– Liquid Flow
Rate 500 gpm
Sp.Gr. 0.75
– Vapor Flow
Rate 40,000 lb/h
Sp.Vol. 0.9 ft3/lb
Solution
Two-Phase Flow Patterns Example
Check for Slug Flow in 10” Schedule 80 Pipe
n Annular or mist flow is usually assured if the

average two-phase velocity in ft/sec is higher
than the velocity calculated here (Density ? as
lb/ft3):
60
υ minimum , ft / sec =
ρmp
total lbs hr 227650

ρmp = = = 5.7 lbs cu.ft.
total cu.ft. hr 40017
60
υ minimum = = 25 ft sec
5.7
10” Schedule 80 pipe cross area = 0.4989 sq.ft.
40017
υ 10" = = 22.3 < 25 ft sec
3600 x 0.4989
Check further by use of flow regime map PD 901
Approximate Two-Phase Flow Patterns
(Vertical Upflow)
500
100
50
Bubble Slug Annular Mist
Flow Flow Flow Flow
10
5
1
X=
(WL 0.9
WG (ρρ (
G
L
0.5 µL 0.1
µG
W = lb/sec
ρ = lb/ft3 (
µ = centipoise 1
0.1 0.5 1.0 5 10 50 100
X LS-R02-24
n Calculate Chart Coordinates
0.9
 
W W  = (187650 40,000) = 4.0
0.9
 L G
0.5
ρ ρ 
 = (1.1 46.8) = 0.15
0.5

 G L
0.1
µ µ  = (0.6 x 0.75 0.015)0.1 = 1.40
 
 L G
(continued)
227,650
Mass velocity = = 127 lb sec - ft 2
3600 x 0.4989
1 1
x= = = 1.2
(WL WG ) (ρG ρL ) (µL µG ) 4.0 x 0.15 x 1.40
0.9 0.5 0.1
Annular flow is indicated
Line Sizing Design Criteria
n Tables give pressure drop and velocity for various

flows and pipe sizes - BUT -
n Engineer needs to be familiar with the reasonable

and desirable piping design pressure drop and
velocity for a given service - HENCE -
n Line sizing design criteria, which are based upon

years of experience and studies, should always be
treated as a guide
Line Sizing Criteria
(continued)
n Assumptions for Economic Pipe Sizing

– Flow in pipe is turbulent
– Motive power is supplied by pump or compressor
– Pump NPSH requirement must be met
– Slurry lines to have velocity high enough to avoid
settling, but low enough to avoid excessive erosion
Line Sizing Design Criteria
Line Type Allowable Velocity or Pressure Drop Restraint
?P/100'
Vacuum Service Vapor Lines 4% of Absolute P

Compressor Suction (Reciprocating) 0.043 P0.5 Velocity, ft/min = 2000(28.8/Mol wt)1/2 and
(last suction vessel to compressor) ? P/100' =1.0
Compressor Suction (Centrifugal) 0.043 P0.5 Velocity, ft/min = 3540/?v1/4 and ? P/100' = 1.0
(last suction vessel to compressor)
Compressor Discharge (Reciprocating) 0.043 P0.5 Velocity, ft/min =3000(28.8/Mol wt)1/2
discharge to liquid feed mix point, etc.) and ? P/100' = 1.0
Compressor Discharge (Centrifugal) 0.043 P0.5 Velocity, ft/min = 6000/?v1/2 and ? P/100' =1.0
(discharge to liquid feed mix point, etc.)
Reactor Circuits - first approximation 2.0 Velocity, ft/min = 6000/?o1/2 and ? P/100' = 2.0
(confirm with PDC for Process)
Pump Suction - Bubble Point Liquid 0.15
Pump Discharge 1.5 Velocity, ft/min < 700
Non-Pumped Liquid to Control 2.6 S.G. Velocity, ft/min < 700
(Gravity Flow of a Bubble Point Liquid)
Available ?P,150 < ? P Control Valve 2.0 Max Velocity Criteria, ft/min shown below
Available ?P, 50 < ? P Valve <150 2.0 Applies to Available DP and Frac. Feed services
Available ?P, 25 < ? P Control Valve < 50 1.0
Fractionator Feed; 50 <? P Control Valve 2.0 (Liquid Velocity, ft/min < 700)
Fractionator Feed; 25 = ?PCtrl Valve = 50 1.5 (2-phase Velocity, ft/min < 6000/?o1/2
Fractionator Feed; ?P Control Valve <25 0.5 Vapor Velocity, ft/min < 6000/?v1/2
Feed to FCC Fractionator/Main Column 0.10 Velocity, ft/sec < 110

Thermosyphon Reboiler Return to 0.15 Velocity, ft/sec = 5.0 [(?l-? v)/ ? v]1/2
Column
Liquid to Non-Pumped Reboiler 0.2 P = Absolute Pressure in psi unless otherwise indicated.
Line Sizing Design Criteria (Continued)
Allowable
Line Type ? P/100' Velocity or Pressure Drop Restraint
Column Overhead Vapor = 300 P 1.25 .
150 =P < 300 psia 0.75
14.7 = P < 150 0.3
3.75 = P < 14.7 0.15
P < 3.75 4% of Absolute P
FCC Main Column Overhead Vapor 0.10
Condenser Rundown 0.25
(Equalizing line is 1/3-1/4 of rundown line size)
Gravity Feed 0.15
All Other Two-Phase Lines 315 = P 2.0 Velocity, ft/min < 6000/?o1/2
165 = P < 315 psia 1.0
14.7 = P < 165 0.5
3.75 = P < 14.7 0.15
P < 3.75 4% of P
Forced Circulation Reboiler Return 0.7 Velocity, ft/min < 6000/?o1/2
Cooling Water
0-700 gpm (up to 347,520 lb/hr 1.3 --
701-2800 gpm (up to 1,390,060 lb/hr) 500 ft/min
2801-7000 gpm (up to 3,475,150 lb/hr) 600 ft/min
7001+ gpm (3,475,150+ lb/hr) 700 ft/min
Steam - Saturated 1.1 6,000 ft/min
Steam - Superheated (at least 20ºF) 1.1 15,000 ft/min
FCC Slurry (Main Column Bottoms)
Pump Discharge ---- 420 ft/min maximum
Pump Suction ** 0.15 180 ft/min minimum
Pump Suction – Subcooled 0.35
(liquid subcooled at least 50ºF or vapor
pressure at least 25 psi below system
pressure)
P = Absolute Pressure in psi unless otherwise indicated.
Training Services
Part II
Hydraulics
n Piping Equivalent Length
n Equipment Elevations: Column, Receiver
n Pumps NPSH Calculations
n Thermosyphon Reboiler Hydraulic
n Typical Equipment Pressure Drops: Heaters,
Exchangers, Control Valves
n Hydraulic Circuit: Fractionator Column
Hydraulic Procedure and Sample Problem
Piping Equivalent Length
n ∆P charts give pressure drop for 100 feet of

piping
n Piping circuits consist of straight piping and
fittings
– Elbows
– Tees
– Valve
n Task is to convert fitting ∆P to equivalent
straight pipe length
Equivalent Length
Description of Product in Pipe Diameters
(L/D) Representative
Globe
Stem Perpendicular
to Run
With no obstruction in flat, bevel, or plug type seat
With wing or pin guided disc
(No obstruction in, bevel, or plug type seat
Fully open
Fully open
340
450 Equivalent
Valves
Y-Pattern - With stem 60 degrees from run of pipe line
- With stem 45 degrees from run of pipe line
Fully open
Fully open
175
145
Length in Pipe
Angle Valves With no obstruction in flat, bevel, or plug type seat
With wing or pin guided disc
Fully open
Fully open
145
200
Diameters (L/D)
Wedge, Disc,
Double Disc,
Fully open
Three-quarters open
One-half open
13
35
160
of Various Valves
Gate
Valves
or Plug Disc One-quarter open
Fully open
900
17
and Fittings
Three-quarters open 50
Pulp Stock One-half open 200
One-quarter open 1200
Conduit Pipe Line Gate, Ball, and Plug Valves Fully open 3**
Conventional Swing 0.5’...Fully open 135
Check Clearway Swing 0.5’...Fully open 50
Valves Globe Lift or Stop; Stem Perpendicular to Run or Y-Pattern 2.0’...Fully open Same as Globe
Angle Lift or Stop 2.0’...Fully open Same as Angel
In-Line Ball 2.5 vertical and 0.25 horizontal...Fully open 150
0.3’...Fully open 420
Foot Valves with Strainer
0.4’...Fully open 75
Butterfly Valves (8-inch and larger) Fully open 40
Straight-Through Rectangular plug port area to 100% of pipe area Fully open 18
Cocks Rectangular plug port area equal to 80% Flow straight through 44
Three-Way
of pipe area (fully open) Flow through branch 140
90 Degree Standard Elbow 30
45 Degree Standard Elbow 16
90 Degree Long Radius Elbow 20
90 Degree Street Elbow 50
Fittings 45 Degree Street Elbow 26
Square Corner Elbow 57
With flow through run 20
Standard Tee 60
With flow through branch
Close Pattern Return Bend 50
90 Degree Pipe Bends See Page A-27
Pipe Miter Bends See Page A-27
Sudden Enlargements and Contractions See Page A-26
Entrance and Exit Losses See Page A-26
** Exact equivqlent length is 1 Minimum calculated pressure
eaual to the length between drop (psi) across valve to provide
flange faces or welding ends. sufficient flow to lift disc fully.
Crane Co. “Flow of Fluids through Valves, Fittings and Pipe,”

Technical Paper 410
Tray
1
Fractionator Piping
Details
Equivalent Length
Problem
(See Handout)
Straight run Tee
Gate Valve
Globe Control Valve
Branch Tee
Swing Check Valve
Equivalent Length Problem
Problem Tasks
n There are 3 line segments:
n 1) Line from globe control valve to
tray 1 – all data has been filled in.
n 2) Line of storage split to globe valve
- fill in column of Equivalent feet.
n 3) Pump Discharge line to storage
split - fill in all columns.
Equivalent Length Worksheet – (Partially filled in solution)
Pipe: Control V alve to Size = 3 inch (D=0.25)

Tray 1
Quantity Type of Fitting Equiv. Length (each) Equiv. Length

in Pipe Diameters feet
6 90 deg Ells 20D 30

1 Tee St 20D 5
1 Gate Valve 13D 3
Total Fitting Equiv. 38
Equivalent Straight Pipe

Total Equiv. Length
163
201
Length Pipe: Split To storage to

Control Valve
Size = 3 inch (D=0.25)
Problem Quantity Type of Fitting Equiv. Length (each)

in Pipe Diameters
Equiv. Length
feet
4 90 deg Ells 20D

1 Tee St 20D
1 Gate Valve 13D
Total Fitting Equiv.
Straight Pipe
Total Equiv. Length
Pipe: Pump Discharge to Size = 3 inch (D=0.25)

split to storage
Quantity Type of Fitting Equiv. Length (each) Equiv. Length

in Pipe Diameters feet
Solution
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or Total Fitting Equiv.
Straight Pipe
Column Elevation Set By
n Bottoms Pump Suction Head Requirement
n Thermosyphon Reboiler Head Requirement
n Mechanical Clearance Requirements
Receiver Elevation Set By
n Overhead Pump Head Requirement

- Lower density requires higher elevation
n Mechanical Clearance Requirements
– Water Boot
Pump Net Positive Suction Head
(NPSH)
n NPSH Required:NPSH(R) is a characteristic

of the pump
– Experimentally determined by the pump
manufacturer
n Pressure requirement in excess of the fluid
vapor pressure at the suction flange of a pump
– This additional pressure prevents vaporization
of liquid at the pump inlet, thus insuring
proper operation of the pump
Pump Net Positive Suction Head
(NPSH)
n NPSH Available: NPSH(A) is set by the

design engineer
– This is the NPSH designed into the system for
the pump mentioned above
– This value must be greater than the NPSH(R)
for proper operation of the pump
n Expressed in feet of fluid being pumped
NPSH Calculation
n Contractor Calculation
versus
n Basic Engineering Calculation
n Difference depends on how much layout

detail is known
NPSH Calculation Procedure
n Basic Engineering Calculation Procedure to

Set a Vessel Elevation:
– Estimate minimum NPSH required
– Estimate pump centerline above base line
– Estimate suction piping friction loss
– Investigate system absolute pressure (Bubble
point or sub-cooled)
– Determine minimum controlled liquid level in
the vessel
– Evaluate need for contingency
Single Stage Centrifugal Pumps
Minimum Required NPSH Back
LS-R00-01
NPSH(R) for Single Centrifugal Pumps
LS-R00-02
Typical Column Bottoms Pump
Min. Level
6”
TL TL
Pump PI
C
L 8”
Vessel Elevation From Chart

Baseline
LS-R00-03
NPSH Example Calculations
n Design a system(see sketch previous slide)

that provides sufficient NPSH for the
following column bottoms pump
Single Stage Pump

Capacity 500 gpm
Specific Gravity 0.65
Line Frequency 50 Hz
Pump RPM 1450 (Half Speed)
Assume Vapor Pressure = System Pressure
NPSH Example Calculation
1. NPSH(R) from Chart or Manufacturer Chart 6.2 ft
2. Pump Centerline Above Base Line 2.5 ft
3. Friction Loss
For 8" line ∆P100 = 0.11 psi
500 equivalent feet = .55 psi x 2.31 ft H2O/.65sg 2.0 ft
Suction Valve (Assume gate valve - one line size smaller)
Equivalent length = 13 D
∆P = (0.11 psi)(8"/6")5(13)(6"/12")(1/100)(2.31/0.65) 0.1 ft
6” Suction Strainer (0.11 psi) x (8”/6”)5 = 0.46 psi/100’
Equivalent length = 300 ft
(0.46 psi)(300 ft/100 ft)(2.31 ft H2O /0.65sg) 4.9 ft
NPSH Example Calculation
4. System Pressure - Vapor Pressure = 0 0.0 ft
5. Minimum Level in Vessel (NPSH credit) -0.5 ft
6. Contingency – highest of: 2.0 ft

15% of NPSH(R)
2.0 ft Minimum
NPSH Example Problem Summary
1. NPSH(R) 6.2 ft
2. Pump Centerline Elevation 2.5 ft
3. Friction Loss = (2.0 + 0.1 + 4.9) 7.0 ft
4. System Pressure-Vapor Pressure -0.0 ft
5. Minimum Level (credit) -0.5 ft
6. Contingency 2.0 ft
TOTAL 17.2 ft
(From Baseline to Bottom of Vessel)
Thermosyphon Reboiler Hydraulics
Entrance Loss into Column
Two Phase Friction Loss
Two Phase Static

Pressure Loss
CL Exchanger
Centerline
Exit Loss
Out of Column Exchanger Friction Loss
Liquid Friction Loss

LS-R00-05
Simple Horizontal Thermosyphon
Reboiler Flow Schemes
Thermosyphon Reboiler Systems
Determine Required Driving Head, H
0.5 V 2 S.G.
n Exit Loss at Column Outlet = ×
2g 2.31
n Line Loss to Exchanger
n Exchanger Loss:Entrance Loss, Bundle Loss, Exit Loss
n Line Loss to Column
n Static Loss to Column
1.0 V S.G.  2
n Entrance Loss at Column inlet =  x 

 2g 2.31 
n Contingency
n Note: S.G. in reboiler return calculations is for 2-Phase
Thermosyphon Reboiler Systems
Trial Line Size for Maximum 30% Vaporization
n For d=inches, Q= Reboiler duty in million Btu/hr,

the following could be used as a first guess on line
sizes.
n Inlet Piping
– 12 < d2/Q < 15
n Outlet Piping
– 24 < d2/Q < 30
– Note: Final line sizes should follow the design

criteria summarized in the Line Sizing tools
Minimum Reboiler Elevation
LS-R00-10
Minimum Column Elevation
For Mechanical Clearance
T.L.
1/4 Dia. of Vessel (For 2:1 Heads)
3" Minimum
Minimum
Skirt 1 1/2 x Dia. of Pipe
Height 1/2 Dia. of Pipe
2" Insulation
6" Clearance
8" - 1'-0" Based on Vessel Size
LS-R00-09
Typical Heater Pressure Drops
n Crude Heaters 125 psi

n Vacuum Heaters 75 psi
n Hydrotreating Heaters 20-60 psi
n Platforming (per Heater) 3-20 psi
n Thermal Crackers 200 psi
Typical Heater Pressure Drops
(continued)
n Coker Heaters 300 psi

n Visbreakers 250 psi
n Hot Oil Heaters 20-40 psi
n Fired Reboilers 50 psi
n Fractionator Charge 40 psi
Preliminary Pressure Drops - Must be confirmed

or corrected based on final heater design
Typical Heat Exchanger
Pressure Drops
n For normal fluid shell and tube heat exchangers,

allow at least 5 psi pressure drop for each shell
Typical Heat Exchanger
Pressure Drops
(continued)
n Exceptions
– Cooling Water Side 10 psi
– Combined Feed Exchangers 2-5 psi/side
– Condensers 1-5 psi
– Reboilers - Kettle and 0.2-0.5 psi
Thermosyphon
– Reboilers - Forced Circulation 5-10 psi
– Vacuum Condensers 10-25 mm mercury
Control Valve Pressure Drops
n Control valves in pump discharge circuits -

allow greatest of:
– 25 psi
– 50% of system friction pressure drop
– 7-10% of pump differential
Control Valve Pressure Drops
(continued)
n For other control valves, allow pressure drop

in accordance with available pressure
n Control valve rangeability consideration is

from turndown to 110% capacity
n Control valve compensates for changes in

operations and system aging
System Hydraulic Curves
Atmospheric Fixed Point Pressure
LS-R00-06
Identical Pumps Handling Liquids
of Different Specific
100 ft. 100 ft. 100 ft.
32.5 psi 43 psi 52 psi
Gasoline, S.G. = 0.75 Water, S.G. = 1.0 Brine, S.G. = 1.2
Disch. 100’ x 0.75 Disch. 100’ x 1.0 Disch. 100’ x 1.2

= 32.5 psi = 43 psi = 52psi
Pres. 2.31 Pres. 2.31 Pres. 2.31
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or PD-R00-05
Elevated Fixed Point Pressure
Differential, psi
Design SG 1
Alternate SG2
LS-R00-07
Fixed Available Pressure Source
LS-R00-08
Control Valve ∆P Selection
System 1 2 3 4
Fixed End Pressure 0 0 250 500
Frictional Losses 25 100 100 100
Total Required Press. 25 100 350 600
∆P Options
25 Min. 25 25 25 25
50% Friction 12.5 50 50 50
7-10% Diff 2.5 10 35 60
Pump Discharge 50 150 400 660
Hydraulics of a Fractionating Column –
Problem Exercise
Objective
n Determine operating pressure profiles for

normal, design, and turndown operations
n Design = 110% of normal flow
n Turndown = 60% of normal flow
Hydraulics General Procedure
Procedure - Normal HWB flow

n Obtain pertinent heat and weight balance
information for the system
n Establish a working Hydraulic Flow Diagram
n Determine fixed pressure locations
n Define hydraulic circuits between fixed
pressure locations
n Establish line sizes, line pressure drops, and
equivalent lengths for each piping segment
(continued)
Procedure - Normal HWB flow (continued)
n Set Equipment Elevations

n Establish fixed pressure drops (static heads) due
to elevation changes
n Establish equipment allowable pressure drops
n Establish pump differential and control valve
pressure drop for the normal flow case
(continued)
Procedure - Alternate flow rates
n Alternate flow rates: Design and Turndown

n Prorate equipment pressure drops for alternate
flow cases and determine the alternate flow case
pump differential from actual or generic pump
curves
n Calculate the control valve pressure drop for the
alternate flow cases to complete the hydraulic
tabulation
Debutanizer Hydraulic Flow Diagram
DEBUTANIZER DEBUTANIZER
Debutanizer Hydraulics Problem RECEIVER
Debutanizer Off
182
250 psig
163 Gas To Refinery
PRC Fuel Gas
4# 40 ft
164
170 FR
1
166
8# At Grade
165
Cooling Water
TRC
OD=6.6 ft
8
LIC
1.92 ft
21 ft
167
16 2.5 ft
168
FRC
183 171 151 150

169
FRC
30
175
LIC
32.15 ft
172
FRC
Net Overhead Liquid
152
To Refinery LPG
176 173 TRC B.L. Pressure = 300 psig
Debutanizer Feed From

143 160
Recontact Drum
177
Pressure = 425 psig FRC

190
Debutanizer Bottoms To HYDRAULIC FLOW DIAGRAM

Reformate Splitter DEBUTANIZER SECTION
CUSTOMER'S OIL COMPANY, LTD.
NEW REFINERY PROJECT
DES PLAINES, ILLINOIS
LS-R00-11
Line Sizes and Equivalent Lengths
Debutanizer Overhead Pipe Segments
Line No. Line Size Equiv. Length DP/100 ft Line DP

inches feet psi psi
150 6 47.1 0.14 0.06

151 3 30 0.18 0.05
152 3 22222 0.18 40
157 10 5 0.14 0.01
163 10 372.8 0.14 0.53
164 8 277.1 0.11 0.29
165 8 264.7 0.09 0.23
167 8 390.8 0.03 0.13
168 6 310.4 0.14 0.43
169 6 192.7 0.1 0.19
170 6 324.3 0.1 0.33
183 3 525 0.18 0.95
Characteristic Pump Head Curves
Figure 1: Characteristic Centrifugal Pump Differential Head versus Capacity Curves
1.3
Normal flow when rated is 125% of normal

All Other

1.25

Percent of Rated Differential Head
1.2
1450, 1750 RPM single & multi-stage > 1000 gpm & Q/H > 5
1.15
Sundyne
1.1
2950, 3550 RPM single & two stage < 125 gpm & Q/H < 0.1
1.05
1
0 10 20 30 40 50 60 70 80 90 100
Percent of Rated Capacity
UOP
Heat and Weight Balance
P9.8 - THERMODYNAMIC OPERATIONS UOP
MATERIAL BALANCE REPORT
UOP NOTE - THE INFORMATION IN THIS DOCUMENT IS PAGE

DES PLAINES, IL CONFIDENTIAL AND THE PROPERTY OF UOP LLC, AND DATE 2002
PLATFORMING PROCESS UNIT MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED IN PROJ 9999-99
Case 2 ANY MANNER OR USED FOR ANY PURPOSE WHATSOEVER BY Engineer
WITHOUT ITS WRITTEN PERMISSION. DFID
DEBUTANIZER
FLWG TEMP PRESS MM FLWG MOLS LBS BTU MMBTU

API OR UOP MOL LB/CF* DEG. PSIG SCFD* CFS* PER PER PER PER
STREAM LB/GAL K WT S.G. F MMHG* BPSD GPM HOUR HOUR LB HOUR
160 DEC4 FD TO F/B EXCH 98.4 100 298 5697.4 560449 17 9.45
TOTAL VAPOR 5.0 0.261* 100 298 0.22* 0* 24.3 122 154 0.019
HYDROGEN 100 298 22.2 45
HYDROCARBON 100 298 2.1 77
TOTAL LIQUID 41.3 10.9 98.8 0.800 100 298 46895 1399 5673.1 560327 17 9.43
EQUIPMENT DUTY 75.54
161 DEC4 FD FR F/B EXCH 98.4 360 283 5697.4 560449 152 84.99
TOTAL VAPOR 41.6 1.488* 360 283 0.71* 1* 78.3 3257 297 0.97
HYDROGEN 360 283 31.5 63
HYDROCARBON 360 283 46.8 3193
TOTAL LIQUID 41.0 10.8 99.2 0.659 360 283 46566 1690 5619.1 557192 151 84.03
162 DEC4 FD TO COLUMN 98.4 360 263 5697.4 560449 152 84.99
TOTAL VAPOR 43.7 1.462* 360 263 0.91* 1* 99.4 4339 295 1.28
HYDROGEN 360 263 37.1 75
HYDROCARBON 360 263 62.3 4265
TOTAL LIQUID 40.9 10.8 99.3 0.660 360 263 46450 1685 5598.0 556109 151 83.71
163 GAS TO DEC4 CONDR 47.8 2.510* 177 261 16.93* 10* 1858.8 88785 190 16.85
HYDROGEN 177 261 83.2 168
HYDROCARBON 177 261 1775.6 88617
164 MTL TO DEC4 TRIM CONDR 47.8 118 257 1858.8 88785 51 4.55
TOTAL VAPOR 32.2 1.589* 118 257 2.53* 2* 277.7 8931 169 1.51
HYDROGEN 118 257 74.1 149
HYDROCARBON 118 257 203.6 8782
TOTAL LIQUID 4.519 14.2 50.5 0.496 118 257 10098 322 1581.1 79854 38 3.04
EQUIPMENT DUTY 1.44
165 MTL TO DEC4 RCVR 47.8 100 250 1858.8 88785 35 3.10
TOTAL VAPOR 27.5 1.320* 100 250 1.80* 1* 197.6 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5284
TOTAL LIQUID 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
166 OVHD GAS FR DEC4 RCVR 27.5 1.320* 100 250 1.80* 1* 197.5 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5283
182 DEC4 OVHD GAS TO FUEL 27.5 0.263* 83 40 1.80* 6* 197.5 5427 162 0.88
HYDROGEN 83 40 71.1 143
HYDROCARBON 83 40 126.5 5283
167 LIQ FR DEC4 RCVR 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
168 LIQ FR DECR OVHD PUMP 4.507 14.2 50.2 0.511 100 310 10568 326 1661.3 83358 27 2.23
171 NET DEC4 OVHD LIQ TO CV 4.507 14.2 50.2 0.511 100 310 1528 47 240.2 12052 27 0.32
LS-R00-36
UOP
Heat and Weight Balance (continued)
P9.8 - THERMODYNAMIC OPERATIONS UOP
MATERIAL BALANCE REPORT
UOP NOTE - THE INFORMATION IN THIS DOCUMENT IS PAGE

DES PLAINES, IL CONFIDENTIAL AND THE PROPERTY OF UOP LLC, AND DATE 2002
PLATFORMING PROCESS UNIT MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED IN PROJ 9999-99
Case 2 ANY MANNER OR USED FOR ANY PURPOSE WHATSOEVER BY Engineer
WITHOUT ITS WRITTEN PERMISSION. DFID
DEBUTANIZER
FLWG TEMP PRESS MM FLWG MOLS LBS BTU MMBTU

API OR UOP MOL LB/CF* DEG. PSIG SCFD* CFS* PER PER PER PER
STREAM LB/GAL K WT S.G. F MMHG* BPSD GPM HOUR HOUR LB HOUR
160 DEC4 FD TO F/B EXCH 98.4 100 298 5697.4 560449 17 9.45
TOTAL VAPOR 5.0 0.261* 100 298 0.22* 0* 24.3 122 154 0.019
HYDROGEN 100 298 22.2 45
HYDROCARBON 100 298 2.1 77
TOTAL LIQUID 41.3 10.9 98.8 0.800 100 298 46895 1399 5673.1 560327 17 9.43
161 DEC4 FD FR F/B EXCH 98.4 360 283 5697.4 560449 152 84.99
TOTAL VAPOR 41.6 1.488* 360 283 0.71* 1* 78.3 3257 297 0.97
HYDROGEN 360 283 31.5 63
HYDROCARBON 360 283 46.8 3193
TOTAL LIQUID 41.0 10.8 99.2 0.659 360 283 46566 1690 5619.1 557192 151 84.03
162 DEC4 FD TO COLUMN 98.4 360 263 5697.4 560449 152 84.99
TOTAL VAPOR 43.7 1.462* 360 263 0.91* 1* 99.4 4339 295 1.28
HYDROGEN 360 263 37.1 75
HYDROCARBON 360 263 62.3 4265
TOTAL LIQUID 40.9 10.8 99.3 0.660 360 263 46450 1685 5598.0 556109 151 83.71
163 GAS TO DEC4 CONDR 47.8 2.510* 177 261 16.93* 10* 1858.8 88785 190 16.85
HYDROGEN 177 261 83.2 168
HYDROCARBON 177 261 1775.6 88617
164 MTL TO DEC4 TRIM CONDR 47.8 118 257 1858.8 88785 51 4.55
TOTAL VAPOR 32.2 1.589* 118 257 2.53* 2* 277.7 8931 169 1.51
HYDROGEN 118 257 74.1 149
HYDROCARBON 118 257 203.6 8782
TOTAL LIQUID 4.519 14.2 50.5 0.496 118 257 10098 322 1581.1 79854 38 3.04
EQUIPMENT DUTY 1.44
165 MTL TO DEC4 RCVR 47.8 100 250 1858.8 88785 35 3.10
TOTAL VAPOR 27.5 1.320* 100 250 1.80* 1* 197.6 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5284
TOTAL LIQUID 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
166 OVHD GAS FR DEC4 RCVR 27.5 1.320* 100 250 1.80* 1* 197.5 5427 162 0.88
HYDROGEN 100 250 71.1 143
HYDROCARBON 100 250 126.5 5283
182 DEC4 OVHD GAS TO FUEL 27.5 0.263* 83 40 1.80* 6* 197.5 5427 162 0.88
HYDROGEN 83 40 71.1 143
HYDROCARBON 83 40 126.5 5283
167 LIQ FR DEC4 RCVR 4.507 14.2 50.2 0.509 100 250 10568 327 1661.3 83358 27 2.23
168 LIQ FR DECR OVHD PUMP 4.507 14.2 50.2 0.511 100 310 10568 326 1661.3 83358 27 2.23
171 NET DEC4 OVHD LIQ TO CV 4.507 14.2 50.2 0.511 100 310 1528 47 240.2 12052 27 0.32
LS-R00-37
Pro-Rate Pressure Drop Formula
For piping and velocity related equipment (vessels,

fired heaters, heat exchangers, flow meters):
0 .2
lb / hr2   ρ1  
2
µ
 2  ∆P1
∆P2 =    
 lb / hr   ρ  µ 
 1   2  1 
When you assume density and viscosity do not change

significantly, then:
DP2 (110% flow) = DP1 * (1.1)2 = DP1 * 1.21
DP2 (60% flow) = DP1 * (0.6)2 = DP1 * 0.36
Hydraulic Tabulation - Start Solution
H y d ra ulic Circuit De s c rip tion: D e b u ta nize r N e t Ov e rhe a d Liquid to LP G S to ra g e
Norma l Ca s e De s ig n Ca s e Alte rna te C a s e

Equip m e n t Id e n tific a tion Line S ize /\P /100' E s t Eq ft 100% 110% 60%
inc h e s psi /\P Inle t /\P Inle t /\P Inle t
psi P re s s psi P re s s psi P re s s
p s ig p s ig p s ig
PRC 250.00 250.00 250.00
Line 157 10 0.14 5.0 0.01 250.00 0.01 250.00 0.00 250.00
D e b u ta nize Air Co n d e n s e r 4.00 249.99 4.84 249.99 1.44 250.00
Line 164 8 0.11 277.1 0.29 245.99 0.36 245.15 0.11 248.56
De b uta nize r Trim Co n d e n s e r 8.00 245.70 9.68 244.80 2.88 248.45
Line 165 8 0.09 264.7 0.23 237.70 0.28 235.12 0.08 248.45
S ta tic H e a d (S G =0.229, 27.6 ft) 2.74 237.47 2.74 234.84 2.74 245.57
De b u ta nize r R e c e ive r 0.00 234.73 0.00 232.10 0.00 242.75
Line 167 8 0.03 390.8 0.13 234.73 0.16 232.10 0.05 242.75
S ta tic H e a d (S G =0.509, 20.42 ft) -4.50 234.60 -4.50 231.94 -4.50 242.70
De b uta nize r Ove rhe a d P umps ? 239.10 ? 236.44 ? 247.20
Line 168 6 0.14 310.4 0.43 ? 0.52 ? 0.15 ?
Flo w Orific e 1.00 ? 1.21 ? 0.36 ?
Line 150 6 0.14 47.1 0.06 ? 0.08 ? 0.02 ?
Ne t Ovhd / R e flux S p litte r 0.00 ? 0.00 ? 0.00 ?
Line 151 3 0,18 30.0 0.05 ? 0.07 ? 0.02 ?
Flo w Orific e 1.00 ? 1.21 ? 0.36 ?
Line 171 3 0.18 125.0 0.23 ? 0.27 ? 0.08 ?
Contro l Va lve ? ? ? ? ? ?
Line 183 3 0.18 525.0 0.95 ? 1.14 ? 0.34 ?
BL:Ne t Ovhd to LPG storage 0.00 ? 0.00 ? 0.00 ?
Line 152 3 0.18 22222.0 40.00 ? 48.40 ? 14.40 ?
LP G s to ra g e 0.00 260.00 0.00 260.00 0.00 251.00
Solution
Hydraulics - Final Thoughts
n The Hydraulic Flow Diagram is a useful road map

for setting up hydraulics, and also a good tool for
tracking the status of the Project Design
n Hydraulic calculations determine the requirements
for pumps, compressors, and control valves, to ensure
good operation at flow rates different from normal
n Discovering a shortage of pump head is much
cheaper if caught in the hydraulic tabulation than
when operating the unit
n Hydraulic calculations can be a trouble shooting tool
for existing hydraulically limited systems
Questions?

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Training Services

n Guides and Approximations

n Reduce Time for Line Sizing

n Computer Not Required

n Good Judgment and Experience

n Use “normal” flow rates and “normal”

n Consider effect of:

n Pressure Drop in psi/100 Feet

n Velocity in Feet Per Minute

n Liquid Density (as Specific Gravity)

n Minimum size rack piping 1“

n Minimize purchasing, detailing and inventory

n For 2" and smaller pipe size, Schedule 80

n Pipe Outside Diameter (O.D.) is constant

n Economics and decision factors are different

n Line size can often be smaller than for new

n The general equation for pressure drop of a

∆P = Pressure Drop (psi)

n By rearrangement of the equation, we can

n The equation then becomes:

Which plots as a straight line on a Log-Log

n Chart ∆P is based on a liquid with a kinematic

(Correction is for turbulent flow, Reynolds

n The general equation for pressure drop of a

∆P = Pressure Drop (psi)

n For small changes in flow, W, assume the friction

n This plots as a straight line on a Log-Log graph

n Flowing Quantity 40,000 lb/h

n A compressible fluid cannot move faster than

n For a typical Cp/Cv of 1.1, the speed of sound

n If total line ∆P < 10% of upstream absolute

– See chart: Pressure Drop for two phase in

1. Calculate fictitious all vapor pressure drop,

2. Calculate fictitious all liquid pressure drop,

3. Calculate the ratio ∆P*G/∆P*L

4. Calculate the actual liquid volume fraction

5. Using these last two values and chart,

6. Calculate two-phase pressure drop, ∆PTP

∆PTP = (∆PTP / ∆P*L )x ∆P*L

n Find a Schedule 80 pipe size that will result in

n Annular or mist flow is usually assured if the

total lbs hr 227650

10” Schedule 80 pipe cross area = 0.4989 sq.ft.

Check further by use of flow regime map PD 901

n Calculate Chart Coordinates

Annular flow is indicated

n Tables give pressure drop and velocity for various

n Engineer needs to be familiar with the reasonable

n Line sizing design criteria, which are based upon

n Assumptions for Economic Pipe Sizing

Vacuum Service Vapor Lines 4% of Absolute P

Feed to FCC Fractionator/Main Column 0.10 Velocity, ft/sec < 110

n ∆P charts give pressure drop for 100 feet of

Crane Co. “Flow of Fluids through Valves, Fittings and Pipe,”

Globe Control Valve

Pipe: Control V alve to Size = 3 inch (D=0.25)

Quantity Type of Fitting Equiv. Length (each) Equiv. Length

6 90 deg Ells 20D 30

Equivalent Straight Pipe

Length Pipe: Split To storage to

Problem Quantity Type of Fitting Equiv. Length (each)

4 90 deg Ells 20D

Pipe: Pump Discharge to Size = 3 inch (D=0.25)

3. Calculate the ratio ∆PG/∆PL

∆PTP = (∆PTP / ∆PL )x ∆PL