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Hydraulic Basis
Client : OPaL
Job No : SC-2252
Ⅰ. General
The Hydraulic Calculation Basis is intended to describe a criteria to determine a pipe size and differential pressure of
pump, compressor and control valve and flow regime analysis of two phase flow for Dual Feed Ethylene Cracker
& Associated Units Project in Dahej, Gujarat, India.
Hydraulic calculation is to select the optimum line size within the available pressure drop.
This document will be developed throughout the detail engineering phase of the project if necessary.
4. Calculation Tool
HYTOS to be used for calculation of pump loop and control valve loop.
In house line sizing program to be used for Simple single phase line sizing (utility service)
5. Consideration
1. Compressor loop, cracked gas loop and pump suction lines to be calculated using isometric drawing.
Linde K value (resistance coefficient) in Attachment #3 can be considered for optimizing the line size with the approval
of manager.
2.If VDB stream datasheet is available as MS Access or Excel format, using simple data extraction program, make easy
input the process data into HYTOS.
3. If the process data is not available until calculation, use the reference data from experienced project(ex. TASNEE)
4. The hydraulic result shall be always checked with that of reference project experienced(ex. TASNEE) before
confirm or report to manager, especially the comment's from Linde shall be checked.
5. During initial hydraulic calculation or line sizing, if the calculation result is in the marginal area against criteria,
take conservative position. ( ex. calc result velocity 2m/s - 2", criteria : 2.1m/s -> take 3" for design)
6. After initial calculation finishes, the process datasheet for r otating will be prepared and it will be revised according to
calculation result with newly available information.
7. KEEP hydraulic calculation status summary list.
8. If required, the result to be checked based on the criteria of licensor(Linde).
9. design margin : Linde's M/B case vs. owner's design margin -> to be discussed and decided
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In order to ensure the carry over of the coke particles, the decoking line should be sized so that the decoking gas
reaches a velocity as close as possible to 70 m/sec during the decoking step under which the maximum volume flow is
present (maximal velocity= 75 m/sec for discontinuous flow). Detailed instruction to be provided by Linde.
5. Roughness
0.00015 m for carbon steel and 0 m for stainless steel
Cracked gas line, where a roughness of 1.0 mm should be considered
6. Equivalent Length
▶ In general, the equivalent length is estimated by multiply a factor to the straight length, including vertical or
horizontal line from plot plan considering fittings and valves in lines for preliminary hydraulic calculation for
initial calculation because ISO drawings for hydraulics are not available.
- For Lines in process unit, equivalent length = straight length x 3
- For interconnecting lines on the pipe rack, equivalent length = straight length x 1.5
▶ For the critical lines such as compressor loop, big line size, pump suction and low pressure system, preliminary
isometric drawing should be used for equivalent length estimation.
▶ For final hydraulic calculation, the equivalent length is calculated with straight length plus equivalent length corresponding
to pipe fittings and valves based on the ISO drawing for hydraulics when it is available.
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Control valves should be designed to be approximately 70% open at normal flow rates. Maximum opening under all
operating cases shall not exceed 90%.
For reciprocating pumps, these should be provided with discharge relief valves, the pressure of which should
be set to avoid the pump over-pressurizing any system into which it discharges.
10. Pump NPSH, Low Liquid Level in Suction Vessel & Pump centerline (2830-8110-PD-0002, sec 4.8.1.3)
In order to avoid the possibility of cavitation and vibration in centrifugal pump, the size of pump suction pipe and elevation
of suction vessel shall be decided considering NPSHa is greater than NPSHr by pump manufacturer plus a safety factor
as below.
NPSHa ≥ NPSHr + 1.0 m (safety factor)
up to design capa. for boiling, dissolved gases, foaming another liquids
NPSHa ≥ NPSHr + 2.0 m (safety factor)
up to design capa. for BFW pumps of initial stage, it can be reduced with vendor data and ISO dwg.
Liquid level in suction vessel and pump centerline shall be considered as follows, refer to datasheet for level inform. ;
- Tangent line in vertical vessel
- Bottom line in horizontal vessel
- LLL in Tanks
- Pump impeller center line for horizontal pump
- Pump suction nozzle center line for vertical pump
The following elevation for pump center line shall be assumed untill vendor information is available
M3/h Centerline elevation
up to 45 0.76 m
45 -225 0.91 m
225-2270 1.07 m (+ 0.3 m)
2270-4540 1.37 m (+ 0.3 m)
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Attachment #1
Recommended High limit for Line Sizing (2830-8110-PD-0002, sec 4.9.1)
1. Liquid Flow
The guidelines cover most normal situations for systems within unit battery limits, but they may not be applicable for all
cases. For critical services and long headers, the total pressure drop in the system must be checked to ensure the
system meets the design pressure balance, whether or not individual process lines meet the pressure drop and velocity
criteria given here. This standard may not apply to critical services, such as slurry lines or high pressure piping, for which
reference should be made to additional standards.
2) Pump Discharge Lines (Line sizing is a trade-off between piping installation costs and operating costs.)
Materal Type
Flow rate Carbon Steel Alloy
(bar/100m) (bar/100m)
For liquid lines with orifice plates, if the liquid velocity is too high, swaged-up meter runs may be required. Velocities for lines
containing orifice plates shall be limited to:
2” and over < 3.4 m/s
Except 14” and over Sch. 80 < 3.1 m/s
In cases where higher velocities are essential the Instrument Group should be consulted.
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Attachment #2
Recommended High limit for Line Sizing (2830-8110-PD-0002, sec 4.9.1)
2. Vapor
The guidelines cover most normal situations for systems within unit battery limits, but they may not be applicable for all
cases. For critical services and long headers, the total pressure drop in the system must be checked to ensure the system
meets the design pressure balance, whether or not individual process lines meet the pressure drop and velocity criteria
given here. For long vapour lines, such as flare headers or vacuum transfer lines, when the ΔP > 10% P, a compressible
flow calculation procedure should be adopted.
1) Hydrocarbon Lines
DelP/100m bar
Item Velocity m/s Remark
(approx.)
10 to 35 barg 0.68
10 to 35 barg 0.68
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Attachment #3
Linde K value
In this attachment Resistance Coefficients which can be employed for a preliminary sizing of the lines are supplied.
The actual coefficients for the different pipe fittings, valves, filters, etc, should be determined by SECL according to the piping
components (type, quality, etc) to be used for this specific job (once the manufacturers information is available), and to the
Piping Specifications.
When a decision is met concerning the suppliers of piping material for the various pipe classes, it is advisable to develop a
summary of Resistance Coefficients to be used for the pressure drop calculations. This summary can have the form as
supplied in this attachment, and its level of detail / accuracy should be determined according to the following criteria:
- Expected savings by the use of a more accurate coefficient,
- Cost (time required) of determining an accurate coefficient,
- Pipe class and line size,
- Purpose of the calculation (e.g. normally the "real" or greater coefficient is to be used for line sizing, but the "real" or smaller
coefficient should be used when searching for the maximum possible flow through a line for example),
- Number and type of piping components in the line, and the proportion of pressure loss originated by them in relation to the
total pressure loss,
- Total pressure loss available, and
- Accuracy of the pipe routing considered for the calculation.
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d) Expansion pieces:
Note: in the following Resistance Coefficients only the friction portion is considered.
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e) Reduction pieces:
Note: in the following Resistance Coefficients the friction loss and the loss due to the pressure head variations
are considered. The coefficient K1 is referred to D1.
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f) T-pieces:
The Resistance Coefficients are expressed as a function of the relation of flows Ga / Gz. (same line sizes at z, d & a)
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Attachment #4
-The depth of the draw-off pan to be 1 – 1½ times the nozzle diameter. The minimum allowable depth is 200mm.
- Allowable velocity may vary from 0.7 m/s to 1.2 m/s depending on the nozzle size
(See Attachment 1 –Capacities of Side- an Draw-off Nozzles).
- The nozzle is to be swaged down to a line size which will not exceed 0.1 bar/100m pressure drop. The swage is to occur at a
point in elevation 1.2m below the nozzle draw-off. Only lines 0.2m and larger are to be swaged down, small lines will be
maintained at nozzle size to the pump or first exchanger
(See Attachment 2 - ‘Typical Swaged Lines After Side-pan Draw-off Nozzle’).
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Attachment #5
Special Cases
Nitrogen as purge gas in the Flare System: min. velocity=0.03m/sec
Inlet of process steam traps: max. velocity = 0.5 m/sec
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