ENGINEERING STANDARD FOR PROCESS DESIGN …

1 IPS-E-PR- 440 This STANDARD is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner. Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in any retrieval system or transmitted in any form or by any means without the prior written consent of the Iranian Ministry of Petroleum. ENGINEERING STANDARD FOR PROCESS DESIGN OF PIPING SYSTEMS ( PROCESS PIPING AND PIPELINE SIZING) ORIGINAL EDITION MAR. 1996 This STANDARD specification is reviewed and updated by the relevant technical committee on Aug. 2003(1) and Aug. 2012(2). The approved modifications are included in the present issue of IPS. Mar. 1996 IPS-E-PR- 440 1 FOREWORD The Iranian Petroleum standards (IPS) reflect the views of the Iranian Ministry of Petroleum and are intended for use in the oil and gas production facilities, oil refineries, chemical and petrochemical plants, gas handling and processing installations and other such facilities.

2 IPS are based on internationally acceptable standards and include selections from the items stipulated in the referenced standards . They are also supplemented by additional requirements and/or modifications based on the experience acquired by the Iranian Petroleum Industry and the local market availability. The options which are not specified in the text of the standards are itemized in data sheet/s, so that, the user can select his appropriate preferences therein. The IPS standards are therefore expected to be sufficiently flexible so that the users can adapt these standards to their requirements. However, they may not cover every requirement of each project. For such cases, an addendum to IPS STANDARD shall be prepared by the user which elaborates the particular requirements of the user. This addendum together with the relevant IPS shall form the job specification for the specific project or work.

3 The IPS is reviewed and up-dated approximately every five years. Each standards are subject to amendment or withdrawal, if required, thus the latest edition of IPS shall be applicable The users of IPS are therefore requested to send their views and comments, including any addendum prepared for particular cases to the following address. These comments and recommendations will be reviewed by the relevant technical committee and in case of approval will be incorporated in the next revision of the STANDARD . standards and Research department , Street14, North kheradmand Karimkhan Avenue, Tehran, Iran . Postal Code- 1585886851 Tel: 88810459-60 & 66153055 Fax: 88810462 Email: standards @ Mar. 1996 IPS-E-PR- 440 2 GENERAL DEFINITIONS Throughout this STANDARD the following definitions shall apply. COMPANY : Refers to one of the related and/or affiliated companies of the Iranian Ministry of Petroleum such as National Iranian Oil Company, National Iranian Gas Company, National Petrochemical Company and National Iranian Oil Refinery And Distribution Company.

4 PURCHASER : Means the Company" where this STANDARD is a part of direct purchaser order by the Company , and the Contractor where this STANDARD is a part of contract document. VENDOR AND SUPPLIER: Refers to firm or person who will supply and/or fabricate the equipment or material. CONTRACTOR: Refers to the persons, firm or company whose tender has been accepted by the company. EXECUTOR : Executor is the party which carries out all or part of construction and/or commissioning for the project. INSPECTOR : The Inspector referred to in this STANDARD is a person/persons or a body appointed in writing by the company for the inspection of fabrication and installation work. SHALL: Is used where a provision is mandatory. SHOULD: Is used where a provision is advisory only. WILL: Is normally used in connection with the action by the Company rather than by a contractor, supplier or vendor. MAY: Is used where a provision is completely discretionary.

5 Mar. 1996 IPS-E-PR- 440 3 CONTENTS : PAGE No. 0. INTRODUCTION .. 5 1. SCOPE .. 6 2. REFERENCES .. 6 3. DEFINITIONS AND TERMINOLOGY .. 7 4. SYMBOLS AND ABBREVIATIONS .. 7 5. UNITS .. 10 PART ONE : PROCESS PIPE SIZING FOR PLANTS LOCATED ONSHORE-SINGLE PHASE 6. GENERAL SIZING CRITERIA .. 11 7. FLUID FLOW .. 11 8. REYNOLDS NUMBER .. 11 9. FRICTION 11 10. FLUID FLOW CALCULATIONS .. 12 11. SINGLE PHASE LIQUID FLOW .. 12 12. FITTINGS AND VALVES .. 13 13. SPECIAL CONDITIONS .. 13 Water Flow .. 13 Pump Suction Lines .. 13 Cooling Water .. 14 Limitations Owing to Erosion Preventive Measures .. 14 Other Matters .. 15 14. SINGLE PHASE GAS FLOW .. 16 A Practical Way to Calculate Gas Flow in Pipeline .. 16 Steam Flow .. 17 Flow Induced Noise .. 17 PART TWO : PROCESS PIPE SIZING FOR PLANTS LOCATED OFFSHORE 15. SCOPE .. 19 16. SIZING CRITERIA-GENERAL .. 19 17. SIZING CRITERIA FOR LIQUID LINES .. 19 General .. 19 18. PUMP PIPING.

6 20 19. SIZING CRITERIA FOR SINGLE-PHASE GAS LINES .. 22 PROCESS Lines .. 22 Compressor Lines .. 23 20. SIZING CRITERIA FOR GAS/LIQUID TWO-PHASE LINES .. 23 Minimum Velocity .. 24 Pressure Drop .. 24 PART THREE : TRANSMISSION PIPELINES FOR: 1) LIQUID 2) GAS 21. SCOPE .. 25 22. SIZING 25 Mar. 1996 IPS-E-PR- 440 4 23. CRUDE OIL PIPELINES .. 25 25. NATURAL GAS LIQUIDS (NGL) PIPELINES .. 26 26. NATURAL GAS PIPELINES .. 26 PART FOUR : TWO PHASE FLOW 27. TWO PHASE FLOW SIZING PROCESS PIPING .. 28 Two-Phase Flow Unit Loss .. 29 28. TWO-PHASE FLOW PATTERNS .. 31 Bubble or Froth Flow .. 31 Plug Flow .. 31 Stratified Flow .. 31 Wave Flow .. 31 Slug Flow .. 31 Annular Flow .. 31 Dispersed Spray or Mist Flow .. 31 29. VELOCITY LIMITATIONS .. 31 30. MAINTAIN THE PROPER REGIME .. 32 31. DESIGN CONSIDERATIONS .. 33 APPENDICES : APPENDIX A MOODY FRICTION FACTOR CHART .. 37 Method of Solution .. 38 APPENDIX B RELATIVE ROUGHNESS CHART.

7 39 APPENDIX C HAZEN-WILLIAMS COEFFICIENT (FRICTION FACTOR) "C" .. 40 APPENDIX D RESISTANCE COEFFICIENTS FOR VALVES AND FITTINGS .. 41 APPENDIX E RESISTANCE COEFFICIENTS FOR VALVES AND FITTINGS .. 42 APPENDIX F RESISTANCE DUE TO PIPE ENTRANCE AND EXIT .. 43 APPENDIX G EQUIVALENT LENGTHS OF VALVES AND FITTINGS .. 44 Mar. 1996 IPS-E-PR- 440 5 0. INTRODUCTION This STANDARD covers single phase liquid flow, single phase gas flow, and specific cases requiring special treatment, and a brief discussion of two-phase, two component flow calculations in short PROCESS pipes. " PROCESS DESIGN of Piping Systems ( PROCESS Piping and Pipeline Sizing)" are broad and contain variable subjects of paramount importance. Therefore, this STANDARD consists of four parts as described below: PART TITLE Part One: " PROCESS Pipe Sizing for Plants Located Onshore-Single Phase" Part Two: " PROCESS Pipe Sizing for Plants Located Offshore" Part Three: "Transmission Pipeline for (1)-Liquid and (2)-Gas" Part Four: "Two-Phase Flow" The flow of liquid, gases, vapor, two-phase flow and many other fluid systems have received sufficient study to allow definite evaluation of conditions for a variety of PROCESS situations for Newtonian fluids, which will be discussed later on.

8 For non-Newtonian fluids considerable data is available. However its correlation is not as broad in application due to the significant influence of physical and rheological properties. This presentation is limited to Newtonian system except where noted. Primary emphasis is only given to flow through circular pipe and tubes, since this is the usual means of movement of gases and liquids in PROCESS plants. The basis for fluid flow follows Darcy and Fanning concepts. The exact transmission from laminar or viscous flow to turbulent condition is variously identified or between a Reynolds number of 2000 to 3000. The correlations included in this STANDARD are believed to fit average plant DESIGN with good ENGINEERING accuracy. However other basis and correlations used by designer should be mutually agreed upon. As a matter of good practice with the exercise of proper judgment, the designer should familiarize himself with the background of the methods presented, in order to better select the conditions associated with a specific problem.

9 Most published correlations for two-phase pressure drop are empirical and, thus, and limited by range at data for which they were derived. A mathematical models for predicting the flow regime and a procedure for calculating pressure drop in PROCESS pipelines are presented in this STANDARD . DESIGN conditions may be: a) Flow rate and allowable pressure drop established, determine pipe diameter for a fixed length. b) Flow rate and length known determine pressure drop and line size in the range of good ENGINEERING practice. Usually either of these conditions requires a trial approach based upon assumed pipe sizes to meet the stated conditions. Some DESIGN problems may require determination of maximum flow for a fixed line size and length; however, this just becomes the reverse of conditions above. Optimum economic line size is seldom realized in the average PROCESS plant. Unknown factors such as future flow rate allowance, actual pressure drops through certain PROCESS equipment, etc.

10 Can easily over balance any DESIGN predicated on selecting the optimum. Certain guides as to order of magnitude of costs and sizes can be established either by one of several correlations or by conventional cost estimating methods. The latter is usually more realistic for a given set of conditions, since generalized equations often do not fit a plant system. Optimum criteria for pipe size should be subject to mutual agreement between Company and designer. Unless otherwise stated, equations presented here are only used for calculating pressure drop due to friction. Therefore pressure loss or gain due to elevation must be taken into consideration where appropriate . For supplementary information regarding the mechanical part of DESIGN , reference shall be made to ENGINEERING STANDARD IPS-E-PI-240 for "Plant Piping Systems" as well. Mar. 1996 IPS-E-PR- 440 6 1. SCOPE This ENGINEERING STANDARD covers PROCESS piping DESIGN and pipeline sizing, in addition to presenting most popular pressure drop equations and fluid velocity.