Where We Go Wrong

In Line Sizing

Dick Hawrelak

Presented to ES317Y in 1999 at UWO
Introduction

31% of large property damage
losses are caused by failures in
piping systems.
Some lines reach 60 inches in
diameter - larger than many
equipment items.

Mass and Energy Balances
MB & EB balances must include:
Normal mass balance - base case.
Start-up, shut down or upset devn.
Recycle of off-spec products.
Equipment bypass conditions.
MB for flare, fire water, sewers,
steam, condensate and CTW
headers.
Poor Line Sizing
Guidelines

Limiting line velocities not known
or ignored.
Velocity greater than 15 fps in CS
pipe can cause erosion.
Low velocities (< 3 fps) can cause
entrained solids to settle and plug
lines.

Poor Line Sizing
Engineering Discipline

Poor record keeping during Phase 3
prevents detailed follow-up in Phase
4 design stage.
PSV lines need to be checked in
Phase 4.
Pump lines need to be checked in
Phase 4.

Poor Pipe Selection

Corrosiveness of fluid unknown.
At high temps, degradation may
produce acidic components. (La.
HumbleTherm example).
Pipe not suitable for unexpected
cold temperatures.
Pipe not suitable for unexpected
extreme high temperatures.
Choked Flow Of
Compressible Fluids

Compressible fluid flow not well
understood by process engineers.
Flows at Mach 1 (Sonic Flow) can
be destructive.
Choked Flow Example 1

Choked Flow Example 2
Two-Phase Flow

Two Phase Flow not well
understood by process engineers.
Horizontal Flow - Baker Chart.
Vertical Down Flow.
Vertical Up Flow.
Baker Chart
Horizontal, Two Phase Flow
Two-Phase Flow In
Vertical Down Flow
Piping

Siphons may form readily
May have damaging pulsating flow
Vertical Down Flow
Piping

Two-Phase Flow In
Vertical Up Flow Piping

May have damaging pulsating flow
4 ft. dia. Cooling tower inlet pipe
experiences severe vibration, fails
& floods plant
Vertical Up Flow Piping

Two-Phase Flow
Pressure Drop

Two phase flow pressure drops
may be higher than expected and
thereby limit performance.
Two-Phase Flashing
Fluids

Flashing liquids often not
considered during process design.

Two phase flow can be a complex,
transient problem.
Two-Phase Flow In PSV
Systems

PSVs are usually sized for single
phase flow.
Two phase flow can occur when
vessels operated above maximum
fill limit.
Two phase flow can occur when
flows are higher than expected.
Vortex Problems

Draining water from KO Pot to
open sewer during rain storm.
Flammable vapor entrained due to
formation of liquid vortex.
Lightning strikes near plant ISBL.
Sewer explodes, wrecks cold box
in Ammonia Plant.
One operator killed.
Maldistribution

Flow in reactor manifolds.
Flows in branched piping.
Flows in shell-side of exchangers.
Water Hammer

System or vessel design pressures
exceeded when EBV suddenly
stops flow.
EO transfer example.
See computer spreadsheet design
program.
Water Hammer Results
Typical Exam Problems

Which flow regime should you
avoid for horizontal, two phase
flow?
If a liquid vortex forms on draining
from a vessel, what safety
problems can this create?
When can a PSV which is sized for
single phase flow experience two
phase flow?
Put Your Money Where
Your Mouth is!