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Master Pipe / Line Sizing As a Process Engineer

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Based on 40 ratings
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Boostrand Training

Pipe sizing is one of the first major activities a process engineer carries out during the preparation of the P&ID.

Pipe size is an important factor for a well-designed process. It shall affect fluid velocity, pressure drop, flow regime,…etc.

A poorly sized pipe can cause disturbance to the whole process and may lead to plant shutdown in critical cases.

Pipe size also has a lot to do with cost, oversizing a pipe means extra cost, more complex pipe design, more foundation, even sometimes process issues.

Read more

Pipe sizing is one of the first major activities a process engineer carries out during the preparation of the P&ID.

Pipe size is an important factor for a well-designed process. It shall affect fluid velocity, pressure drop, flow regime,…etc.

A poorly sized pipe can cause disturbance to the whole process and may lead to plant shutdown in critical cases.

Pipe size also has a lot to do with cost, oversizing a pipe means extra cost, more complex pipe design, more foundation, even sometimes process issues.

In this course, you'll learn how to choose the correct pipe size that works with the corresponding fluid service and compare it with the main criteria which are:

  1. Velocity

  2. Pressure drop

  3. Two-phase flow regime criteria.

Through this course, we shall see:

  1. How to calculate the velocity and pressure drop of a fluid in the pipe.

  2. Then after calculating the parameters, we'll see the expected criteria range for each service, so that we can compare them with our calculated parameters.

  3. We'll see also what are the two-phase flow regimes and how we should deal with them.

  4. Finally, I'll give some examples for pipe sizing. This shall include an Excel sheet that can give guidance on how to size pipes in the future.

So cannot wait to see you in the course, and I hope it shall give you added value.

Disclaimer:

Please note that the Excel sheets were made just for educational purposes. If you shall use it to validate a process or purchase equipment or piping, then you should validate it yourself, and using it shall be upon your sole responsibility.

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What's inside

Learning objectives

  • Learn how to calculate the main parameters used for pipe sizing for liquid, gas and two phase flow
  • Know the common velocity criteria used for judging a pipe size for different fluid services
  • Know the common pressure drop criteria used for judging a pipe size for different fluid services
  • See how two phase flow regimes affect the pipe
  • See some examples of choosing the suitable pipe size and how the chosen criteria affects the pipe diameter

Syllabus

Introduction

Pipe sizing is one of the first major activities a process engineer shall carry out during the preparation of the P&ID.

Pipe size is an important factor for a well-designed process. It shall affect fluid velocity, pressure drop, flow regime,…etc. A poorly sized pipe can cause disturbance to the whole process and may lead to plant shutdown in critical cases.

Pipe size also has a lot to do with cost, oversizing a pipe means extra cost, more complex pipe design, more foundation, even sometimes process issues.

Read more

The main pipe sizing criteria are:

Velocity

Pressure drop

Flow regimes for two phase flow

Sizing criteria are mainly based on common practice, so they vary between companies. Accordingly these criteria must be confirmed in every project.

There are various types of flow regimes for a two phase flow. It can be :

Wave flow

Stratified flow

Bubble flow

Annular mist flow

And slug flow which is the most dangerous one.

Slug flow is undesirable as it can cause vibration and severe damage in the pipe

How to calculate inside pipe diameter from nominal diameter and pipe schedule?

How would valves, elbows, tees and other fittings affect the pipe equivalent length?

To calculate the pipe size, you can use the equations used to calculate velocity and pressure drop. For two phase flow, more complex equations are used.

I shall give here some excel sheets used, you can also use some online tools as Checalc.com or a mobile app as Process Engineer Toolbox which is available on IOS and Android.

This is an example of a performance curve for a centrifugal pump provided by the pump manufacturer. It represents the flow versus head curve.

As we notice in the curve that as the pump flow increases, it will give less head which means less pressure. This shall happen when the resistance at the pump discharge decreases, may be the control valve opens or less destination pressure or for whatever reason.

We can determine the expected operating point when plotting the system curve showing the static and dynamic losses.

The static losses simply represent the maximum elevation at pump discharge which is a constant head, so let’s add it here.

What about the dynamic losses? These shall comprise the pipe losses, control valve pressure drop and other equipment or flow element losses, these shall directly depend on flow rate, their curve will look like this.

As we see here, we can get the dynamic losses, adding them to the static head, we can get the total head losses.

And here we get the operating point

So what if we want to to change the operating point? Let’s close the control valve for example, this means that dynamic losses shall increase. So the curve shall look like this.

And this shall be the new operating point at a less flow rate. If we want to increase the flow rate, let’s open the valve, so the curve shall look like this and we can get larger flow rate as the system resistence decreased..

The control valve inherent characteristics provided by the valve manufacturer are relative to the valve only.

But in the actual case, the valve is not alone, there is a system upstream the valve and a system downstream the valve.

So here comes an important concept which is the control valve authority. This represents the fraction of control valve pressure drop to the total system pressure drop.

We can see it in the this equation.

So when talking about the inherent valve characteristics, it is considering the whole pressure drop is only in the valve, which means that the valve authoity is 1.

But when we put the valve in the system, we have lower pressure at the valve inlet, this is because of there is a pressure drop in the upstream piping or equipment.

Also because there is a pressure drop downstream the valve, this means that there will be a higher backpressure on the valve.

So we will have less pressure drop to be exerted by the valve and depending on the flow rate, the losses in the upstream and downstream will vary, which will result in the variable pressure drop across the valve. So in this case which is the actual case as no one installs the valve alone, the valve authority is less than one

Let’s even explain it in deep, we have a control valve on pump discharge.

So we have a pump curve where the pump head decreases as the flow increases.

We have control valve upstream piping pressure drop and downstream piping pressure drop.

Now let’s plot the pump curve.

Then let’s plot the head losses in the upstream and downstream piping on the curve.

So at a low pump flow, the pump gives us higher head, and at the same time, we have low system losses. So we shall need the control valve to exert a high pressure drop. At low system resistance, the control valve authority will approach to one.

But when we need a high flow, the pump shall give us less head, and the system losses will increase. This will lead to a low valve pressure drop and the authoritiy will drop.

Traffic lights

Read about what's good
what should give you pause
and possible dealbreakers
Explores pipe sizing, which is a core activity for process engineers during P&ID preparation, ensuring a solid foundation in essential engineering practices
Covers velocity, pressure drop, and two-phase flow regimes, which are critical criteria for effective pipe sizing and process design
Includes an Excel sheet for pipe sizing guidance, which can be a practical tool for engineers in their daily work and project execution
Examines the effect of pipe size on pump and control valve hydraulics, which is essential for optimizing system performance and preventing operational issues
Discusses two-phase flow regimes and how to avoid slug flow, which is crucial for preventing vibration and damage in piping systems
Uses Excel sheets for educational purposes only, requiring users to validate the results independently for critical applications, equipment purchases, or process validations

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Reviews summary

Practical fundamentals of pipe sizing

According to learners, this course offers a solid foundation in pipe sizing for process engineers. Students particularly appreciate the practical examples provided, which help illustrate theoretical concepts. The included Excel sheet is frequently highlighted as a very useful tool for applying the learned principles in practice, though some note it serves primarily an educational purpose and may require validation for critical applications. Reviewers find the explanations of velocity and pressure drop calculations clear and concise, making complex topics accessible. The section on two-phase flow regimes is also mentioned as a valuable addition. Overall, it is seen as a beneficial course for understanding the core aspects of pipe sizing relevant to P&ID development.
Excel tool for learning, requires external validation.
"Note that the Excel sheets are for educational purposes only and require your own validation."
"The disclaimer about validating calculations is important for real-world projects."
"While useful for learning, don't rely solely on the sheet for critical design."
Provides a solid understanding of core principles.
"Gave me a strong foundation in the basics of pipe sizing."
"This course is excellent for anyone needing to learn the fundamentals."
"Solid review of the key factors in pipe sizing."
"It provides a good starting point for learning this topic."
Concepts are explained in an understandable way.
"The explanations of pressure drop and velocity calculations were very clear."
"Instructor did a good job explaining complex topics simply."
"The course content is easy to follow and understand."
"I appreciate the straightforward approach to explaining the sizing criteria."
Provides a helpful tool for calculations.
"The Excel sheet provided is a great bonus and helps in practicing the calculations."
"The sheet makes the process of pipe sizing calculation much easier to understand."
"This tool is valuable for future reference and application."
"I found the Excel sheet to be a useful starting point for my own work."
Helps apply concepts to real engineering tasks.
"The course is very helpful and practical. I can now do pipe sizing using the methods described."
"Gives a good grasp of the practical side of pipe sizing, especially for P&ID work."
"I learned practical tools and strategies that I could apply immediately to my work as a process engineer."
"The examples provided are very realistic and helpful for understanding the application of the concepts."

Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Master Pipe / Line Sizing As a Process Engineer with these activities:
Review Fluid Mechanics Fundamentals
Strengthen your understanding of fluid mechanics principles, which are essential for grasping the concepts of velocity, pressure drop, and flow regimes in pipe sizing.
Browse courses on Fluid Mechanics
Show steps
  • Review key concepts like viscosity, density, and pressure.
  • Practice solving problems related to fluid flow and pressure drop.
  • Familiarize yourself with different types of fluid flow (laminar, turbulent).
Read 'Piping Calculations Manual'
Supplement your learning with a comprehensive guide to piping calculations, covering various scenarios and providing practical examples.
View Transmission Pipeline Calculations and... on Amazon
Show steps
  • Study the chapters related to fluid flow, pressure drop, and pipe sizing.
  • Work through the example problems to reinforce your understanding.
  • Use the book as a reference for specific calculations and design considerations.
Solve Pipe Sizing Problems Using Excel
Reinforce your understanding of pipe sizing calculations by working through practical problems using the provided Excel sheet or other similar tools.
Show steps
  • Use the Excel sheet to calculate pipe sizes for different fluid services.
  • Vary the input parameters (velocity, pressure drop) and observe the effect on pipe diameter.
  • Compare your results with manual calculations to verify accuracy.
Three other activities
Expand to see all activities and additional details
Show all six activities
Study 'Process Engineering and Design'
Gain a broader perspective on process engineering principles and how pipe sizing fits into the overall design process.
View Alter Ego: A Novel on Amazon
Show steps
  • Read the chapters related to fluid flow, piping design, and equipment selection.
  • Pay attention to the sections on pressure drop, velocity, and two-phase flow.
  • Consider how pipe sizing affects other aspects of the process design.
Develop a Pipe Sizing Calculator
Solidify your knowledge by creating your own pipe sizing calculator using a programming language or spreadsheet software.
Show steps
  • Choose a programming language or spreadsheet software.
  • Implement the equations for velocity, pressure drop, and two-phase flow.
  • Create a user interface for inputting parameters and displaying results.
  • Test the calculator with various scenarios and validate the results.
Optimize a Piping System Design
Apply your knowledge to a real-world scenario by optimizing the design of a piping system for a specific process.
Show steps
  • Select a process with a defined piping system.
  • Gather data on fluid properties, flow rates, and pressure requirements.
  • Use pipe sizing calculations to determine the optimal pipe diameters.
  • Consider factors such as cost, pressure drop, and flow regime.
  • Document your design choices and justify your recommendations.

Career center

Learners who complete Master Pipe / Line Sizing As a Process Engineer will develop knowledge and skills that may be useful to these careers:
Process Engineer
As a process engineer, you're at the heart of designing and optimizing industrial processes. This role demands a strong understanding of fluid dynamics, pressure drop, and pipe sizing, all crucial for efficient and safe operations. This course is directly relevant, as it covers the essential pipe sizing activities that a process engineer undertakes when preparing Piping and Instrumentation Diagrams. Knowing how to select the correct pipe size is vital, and this course helps one understand the criteria, including velocity, pressure drop, and two-phase flow, to ensure process integrity, avoid disturbances, and prevent plant shutdowns. The course's focus on calculating parameters, understanding criteria ranges, and addressing two-phase flow regimes makes it highly valuable. Furthermore, the inclusion of practical examples and Excel sheets enhances its applicability to real-world process engineering challenges.
See salaries and explore the career path for Process Engineer
Piping Designer
A piping designer is responsible for creating detailed layouts and specifications for piping systems within industrial facilities. Accurate pipe sizing is critical to this role, ensuring that systems function efficiently and safely. This course provides a solid foundation in pipe sizing principles, covering essential aspects such as velocity, pressure drop, and flow regimes. The course addresses the activities that one undertakes during the preparation of P&ID, and this is directly relevant to the responsibilities of a piping designer. The course's emphasis on calculating parameters and understanding criteria ranges is particularly beneficial. Moreover, the practical examples and Excel sheets can serve as valuable tools for piping designers as they develop detailed designs and specifications.
See salaries and explore the career path for Piping Designer
Mechanical Engineer
Mechanical engineers design, develop, and test mechanical and thermal devices, including fluid transport systems. This course may be helpful for mechanical engineers working on designs involving fluid flow. One will learn how to calculate parameters such as velocity and pressure drop, then will learn the expected criteria range for each service. The course may help mechanical engineers understand the importance of pipe sizing and how it affects fluid velocity and pressure drop. The information on two-phase flow regimes may be very helpful. The course will contribute to the knowledge base required for mechanical engineers to design effective fluid transport systems.
See salaries and explore the career path for Mechanical Engineer
Chemical Engineer
Chemical engineers apply principles of chemistry, physics, and engineering to design and operate chemical processes. This course could be useful for chemical engineers involved in designing and optimizing fluid transport systems. The course's focus on pipe sizing, velocity, pressure drop, and two-phase flow provides relevant knowledge. The course may help chemical engineers understand how to select the correct pipe size and compare it with established criteria. Also, the use of Excel sheets for guidance on pipe sizing is a significant benefit. The course may assist chemical engineers in ensuring efficient and cost-effective chemical processes.
See salaries and explore the career path for Chemical Engineer
Instrumentation and Control Engineer
Instrumentation and control engineers design and maintain the systems that measure and control industrial processes. This course may be useful for understanding how pipe sizing affects the performance of control loops. The course's coverage of pressure drop, flow regimes, and their effect on control valve sizing is particularly relevant. The course may help in understanding how to calculate the control valve coefficient, and the role of the valve authority. The examples of control valve calculations on pump discharge may be beneficial. One in this role may be able to better ensure that processes operate safely and efficiently.
See salaries and explore the career path for Instrumentation and Control Engineer
Plant Engineer
A plant engineer is responsible for maintaining and optimizing the operation of an industrial plant. This course could be useful for understanding how pipe sizing affects plant performance and reliability. The course may help plant engineers learn how to identify and address issues related to pipe sizing, such as excessive pressure drop or flow instabilities. The course's inclusion of practical examples may also be helpful. Because plant engineers look at the entire plant system, it would be beneficial for them to understand the activities a process engineer undertakes when preparing the P&ID.
See salaries and explore the career path for Plant Engineer
Reliability Engineer
Reliability engineers focus on improving the uptime and safety of industrial equipment and processes. This course may be useful for understanding how pipe sizing affects the reliability of fluid transport systems. The course may help reliability engineers identify potential failure points related to pipe sizing and implement preventive measures. The material discussing slug flow, which can cause vibration and severe damage in the pipe, will be valuable. This course may contribute to the prevention of costly downtime and safety incidents.
See salaries and explore the career path for Reliability Engineer
Project Engineer
Project engineers manage engineering projects from conception to completion. This course may be helpful for project engineers involved in projects that include piping systems. The course may provide a better understanding of the factors that influence pipe sizing decisions and the potential impact on project costs and timelines. Being able to work with process engineers and piping designers more effectively can contribute to project success. One may be able to contribute to more efficient and cost-effective projects.
See salaries and explore the career path for Project Engineer
Consulting Engineer
Consulting engineers provide expert advice on a variety of engineering topics. This course may be valuable for consulting engineers who specialize in fluid transport systems or process optimization. The course may enhance the consulting engineer's knowledge of pipe sizing principles and best practices. It may improve their ability to provide informed recommendations to clients. This ultimately enhances the value that they provide.
See salaries and explore the career path for Consulting Engineer
Simulation Engineer
Simulation engineers develop and use computer models to simulate industrial processes. This course may be useful for building accurate models of fluid transport systems. The course's focus on calculating velocity, pressure drop, and two-phase flow can improve the accuracy of simulations. The simulation engineer may be able to create more informative and reliable simulations. This may ultimately lead to better designs and operational decisions.
See salaries and explore the career path for Simulation Engineer
Sales Engineer
Sales engineers sell technical products or services to industrial clients. This course may be helpful for sales engineers who sell piping systems or related equipment. The course may improve their understanding of pipe sizing principles and how they relate to customer needs. Sales engineers who understand pipe sizing can engage in better discussions with clients, and demonstrate the value of their offerings. This may lead to more successful sales and stronger customer relationships.
See salaries and explore the career path for Sales Engineer
Estimator
Estimators calculate the cost of engineering projects. This course may be helpful for estimators who need to estimate the cost of piping systems. The course may improve their understanding of the factors that influence pipe sizing decisions and the impact on material costs. The course can contribute to more accurate and reliable cost estimates. This is essential for successful project bidding and execution.
See salaries and explore the career path for Estimator
Technician
Technicians install, maintain, and repair industrial equipment. This course may be useful for technicians who work with piping systems. The course may provide a basic understanding of pipe sizing principles and how they relate to system performance. This understanding can contribute to more effective troubleshooting and repairs. This may ultimately result in improved system reliability and reduced downtime.
See salaries and explore the career path for Technician
CAD Drafter
CAD drafters create technical drawings using computer-aided design software. This course may be useful for CAD drafters who create drawings of piping systems. The course may provide a basic understanding of pipe sizing principles and how they relate to drawing specifications. One may be able to more accurately interpret engineering designs and create detailed drawings. This is crucial for ensuring that piping systems are installed correctly.
See salaries and explore the career path for CAD Drafter
Data Analyst
Data analysts examine data to identify trends and insights that can improve business decisions. This course may be useful for data analysts who work with data related to industrial processes. The course may provide a basic understanding of pipe sizing principles and how they relate to process performance. Understanding relationships between pipe characteristics and performance may allow for better insights. This can inform data-driven decisions that improve efficiency and reduce costs.
See salaries and explore the career path for Data Analyst

Reading list

We've selected two books that we think will supplement your learning. Use these to develop background knowledge, enrich your coursework, and gain a deeper understanding of the topics covered in Master Pipe / Line Sizing As a Process Engineer.
Cover image
Transmission Pipeline Calculations and Simulations...
Save
Provides detailed calculations and practical examples for pipe sizing and pressure drop analysis. It covers various fluids and flow conditions, making it a valuable reference for process engineers. It is commonly used as a textbook in chemical engineering programs. It adds depth to the course by providing real-world applications and calculation methodologies.
Transmission Pipeline Calculations and Simulations...
Kindle Edition
$$$$
Cover image
Alter Ego
Save
Provides a broad overview of process engineering principles, including pipe sizing and fluid flow. It offers a comprehensive understanding of the design process and the factors that influence pipe selection. It is valuable as additional reading to broaden the understanding of process engineering. It is commonly used as a textbook in chemical engineering programs.
Alter Ego: A Novel
Paperback
$$

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Rating
4.1 Filled star Filled star Filled star Filled star Empty star
Effort
2 total hours
Via
Udemy
Instructor
Boostrand Training
Language
English
Traffic lights
Read about what's good
what should give you pause
and possible dealbreakers
Explores pipe sizing, which is a core activity for process engineers during P&ID preparation, ensuring a solid foundation in essential engineering practices
Covers velocity, pressure drop, and two-phase flow regimes, which are critical criteria for effective pipe sizing and process design
Includes an Excel sheet for pipe sizing guidance, which can be a practical tool for engineers in their daily work and project execution
Examines the effect of pipe size on pump and control valve hydraulics, which is essential for optimizing system performance and preventing operational issues
Discusses two-phase flow regimes and how to avoid slug flow, which is crucial for preventing vibration and damage in piping systems
Uses Excel sheets for educational purposes only, requiring users to validate the results independently for critical applications, equipment purchases, or process validations
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