Line Sizing and Hydraulic Calculation for Engineer

Course Overview

This two-day course provides a comprehensive understanding of line sizing and hydraulic calculations for liquid and gas pipelines used in industrial processes. The course emphasizes the theoretical principles, practical methodologies, and industry standards required for effective pipeline design. Participants will explore key factors such as fluid properties, pressure drop calculations, material selection, and cost optimization. Through interactive workshops and case studies, participants will develop skills to design safe, efficient, and cost-effective piping systems.

Learning Objectives

By the end of this course, participants will be able to:

1. Understand the fundamental principles of fluid flow and their applications in line sizing.
2. Calculate appropriate pipe sizes for liquid and gas pipelines based on flow rate, velocity, and pressure drop requirements.
3. Apply industry-standard equations such as Darcy-Weisbach, Hazen-Williams, and Manning equations in hydraulic calculations.
4. Analyze the effects of erosion, cavitation, water hammer, and surge pressures on pipeline design.
5. Use an iterative design process to balance safety, operational efficiency, and cost.
6. Select appropriate pipe materials and schedules based on design conditions and industry standards.
7. Perform cost estimations for pipeline installation and operations.

Target Audience

• Process Engineer
• Piping Engineer
• Mechanical Engineer
• Graduate Engineer

Course Duration: Standard Program 2 days (16 hours)

Course Modules

1. Introduction to Line Sizing
   • Overview of piping systems in process industries
   • Importance of proper line sizing in design and operation
   • Objectives of line sizing (safety, efficiency, cost, and reliability)
   • Key design standards and codes (e.g., ASME, API, ANSI)
2. Fluid Properties and Flow Fundamentals
   • Types of fluids (liquids, gases, two-phase flow)
   • Key fluid properties
     • Density, viscosity, and compressibility
     • Surface tension (for multiphase flow)
   • Laminar vs. turbulent flow regimes
   • Reynolds number and its significance in fluid flow
3. Basics of Line Sizing for Liquids
   • Key considerations in liquid line sizing
     • Flow rate
     • Velocity (recommended ranges for different fluids)
     • Pressure drop (frictional losses and minor losses)
   • Equations and methods
     • Bernoulli’s equation (energy conservation)
     • Darcy-Weisbach equation for friction loss
     • Minor loss calculations using K-method and Crane’s method
   • Safety factors in design (erosion velocity, cavitation, etc.)
4. Pressure Drop Calculations
   • Friction factor determination
     • Moody diagram
     • Haaland and Colebrook-White equations
   • Pipe roughness and material considerations
   • Effect of pipe length, diameter, and fittings on pressure drop
   • Impact of elevation changes on pressure drop
5. Introduction to Gas Line Sizing
   • Key differences between liquid and gas line sizing
   • Compressibility effects and their impact on gas flow
   • Recommended velocity ranges for gas systems
   • Methods for gas line sizing
     • Isothermal vs. adiabatic flow
     • Use of Weymouth and Panhandle equations for pipelines
6. Two-Phase Flow Basics
   • Characteristics of two-phase flow (liquid-gas)
   • Flow patterns and their impact on line sizing
   • Introduction to two-phase flow models
     • Homogeneous model
     • Lockhart-Martinelli correlation
7. Special Considerations in Line Sizing
   • Erosion velocity limits (API RP 14E)
   • Cavitation and its prevention in liquid pipelines
   • Surge pressure and water hammer effects
     • Joukowsky equation
     • Mitigation strategies (valve closure rates, surge tanks)
   • Pipe material selection based on operating conditions (corrosion, erosion, temperature, pressure)
8. Hydraulic Calculation Methods
   • Overview of key hydraulic calculation methods
     • Darcy-Weisbach Equation
     • Hazen-Williams Equation
     • Manning Equation (for open channels)
   • When and how to apply these methods
   • Comparison of methods (advantages, limitations, and practical use cases)
9. Iterative Design and Cost Optimization
   • Iterative process for line sizing
     • Balancing pressure drop, velocity, and cost
     • Evaluating pump/compressor performance with pipeline design
   • Cost estimation for pipelines
     • Material and installation costs
     • Operational costs (pumping/compression energy)

Key Takeaways

• Understanding of Line Sizing Fundamentals: Gain a strong foundation in fluid flow principles, Reynolds number, and pressure drop considerations.
• Hands-on Calculation Skills: Learn to apply equations (e.g., Darcy-Weisbach, Hazen-Williams) and tools for real-world line sizing and hydraulic calculations.
• Special Considerations: Learn to mitigate erosion, cavitation, and water hammer, ensuring pipeline reliability and safety.
• Practical Design Process: Understand how to balance velocity, pressure drop, and cost through an iterative pipeline design approach.
• Material Selection: Select the appropriate pipe material and thickness based on industry standards and operating conditions.
• Cost Optimization: Gain insights into cost estimation for both installation and operational phases of pipeline systems.

For further inquiries or to customize the training for your organization, please contact us.