Line Sizing Design Guide, Rev 1

Bayu-Undan Gas Recycle Project
Design Guide
Line Sizing Design Guide
Document No.: BUGEN-00-10-N01-0100
20 May 1998 February 2000
DOCUMENT NO.: BUGEN-00-10-N01-0100

REVISION DESCRIPTION ORIGINATOR CHECKER APPROVAL DATE CLIENT DATE
ACCEPTANCE
A Issued For Review G Turner J Hathway 25\11\97
B Issued for Approval G Turner J Hathway M Reilly 17/12/97
0 Approved for Design G Turner P Broderick M Reilly 20/5/98
1 Re-issued, Approved for J Wong P Broderick P Broderick 22/2/00
Design
BAYU-UNDAN UPSTREAMGAS RECYCLE PROJECT - PRELIMINARY ENGINEERING
SYNOPSIS
This Design Guide addresses the design guidelines to be used in sizing of all process and utility lines on
the Bayu-Undan Platforms.
Calculation methods and general sizing criteria are presented for the common types of lines required to
be sized during the course of detailed design.
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CONTENTS
1 GENERAL............................................................................................................................... 1
1.1 Piping Sizes............................................................................................................................. 1
1.2 Piping Valves and Fittings....................................................................................................... 2
2 DESIGN CRITERIA - LIQUIDS............................................................................................... 3
2.1 Single Phase Liquid Lines....................................................................................................... 3
2.2 Liquids Flowing By Pressure (Pressure Letdown)...................................................................6
2.3 Gravity Flowlines..................................................................................................................... 6
2.4 Vertical Downflow (Liquids from Drain Boxes)........................................................................6
1.5 Static Accumulation................................................................................................................. 7
1.6 Seawater / Firewater............................................................................................................... 7
1.7 Drains...................................................................................................................................... 7
1.8 Tank Overflows........................................................................................................................ 8
3 DESIGN CRITERIA - SINGLE PHASE VAPOUR LINES........................................................9
4 DESIGN CRITERIA - GAS/LIQUID TWO PHASE LINES.....................................................11
4.1 Flow Patterns......................................................................................................................... 11
4.2 Erosion................................................................................................................................... 11
1.3 Line Sizing............................................................................................................................. 12
5 DESIGN CRITERIA - RELIEF AND DEPRESSURING LINES.............................................13
5.1 Relief Valve Inlet Lines.......................................................................................................... 13
5.2 Relief Valve Outlet Lines....................................................................................................... 13
5.3 Flare Headers and Sub-Headers........................................................................................... 14
5.4 Flare Stacks.......................................................................................................................... 14
5.5 Blowdown Inlet Lines............................................................................................................. 14
5.6 Blowdown Outlet Lines.......................................................................................................... 14
5.7 High Pressure Vents.............................................................................................................. 14
5.8 Atmospheric Tank Vents........................................................................................................ 14
6 CALCULATION METHODS................................................................................................... 16
6.1 Valves and Fittings Equivalent Lengths.................................................................................16
7 DESIGN MARGINS............................................................................................................... 18
ATTACHMENTS
A. ATTACHMENT (A) : EQUIVALENT LENGTH OF VALVES AND FITTINGS

B. ATTACHMENT (B) : SIDE OUTLET LIQUID CONNECTIONS CAPACITY CHART
C. ATTACHMENT (C) : BOTTOM OUTLET LIQUID CONNECTIONS CAPACITY CHART
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1 GENERAL
This guide presents pressure drop and velocity criteria for the sizing of lines on offshore platforms and
other similar facilities (eg. FPSO). Engineers are expected to use the criteria presented in this guide
tempered with judgement when selecting line sizes.
Lines shall be sized such that process pressure drop requirements are satisfied. In general, when both
allowable pressure drop and allowable maximum velocity are shown, the more stringent of the two
should control.
Piping is to be sized for the controlling operating case determined by analysis of the flowrates, operating
pressures and temperatures for all identified operating modes according to the guidelines below.
Consideration is also given to start-up and shutdown conditions and other off-design operations where
these significantly impact on line sizing. For gas and two phase lines, particular attention is to be given
to the effects of changes in operating pressures, temperatures and gas composition with time.
A 20% design margin is applied to pressure drops for the purposes of comparison with the guidelines
for pressure drop per 100 m. If 1.2 times the calculated pressure drop only marginally exceeds the
guideline then engineering judgement is to be used in selecting the line size (this criteria shall not be
applied to flare system pressure drop calculations).
No provision for future increased capacity is made.
Sizing criteria is based on pressure drop, recommended velocity, erosion and noise constraints in
accordance with the guidelines given below. Critical lines, eg pump suctions, relief, vent and blowdown
lines, are recorded as ‘critical’ on the linelist. The Process Department will approve layout isometrics of
critical lines based on rigorous pressure drop calculations.
Long pipelines are excluded from the scope of this philosophy. These are to be sized rigorously.
1.1 Piping Sizes

A minimum line size of NB 40mm shall be used for all main process and utility piping to ensure
adequate mechanical integrity. 25mm NB lines are acceptable, where protection and/or support is
provided, for instrument air and chemical injection.
Minimum connection size for instruments and bleed connections (e.g. at relief and control valve
assemblies) shall be 40 mm (50 mm for thermowells and sample probes).
Non-standard pipes sizes shall not be used except where equipment connections and drilling piping
systems require these sizes. Transition to standard commercial pipe sizes shall be made as close to the
equipment as practical.
The following non-standard line sizes will not normally be used :
32 mm (1¼”) , 65 mm (2½”) , 89 mm (3½”), 125 mm (5”), 178 mm (7”), 229 mm (9”), 550 mm
(22”).
The minimum nozzle size allowed on vessels and heat exchangers will be 50 mm NB.
1.2 Piping Valves and Fittings

For detailed piping calculations the resistance of all bends, fittings, and valves can be calculated as
equivalent length as per section 6.0.
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For initial calculations where the number and type of fittings are unknown, the equivalent length of
piping shall be obtained by multiplying the piping run obtained from a preliminary layout drawing by
the factors in Table 1.1.
Table 1.1
Multiplying Factor For Piping Length
Approximate Pipe Length (m) 30 60 150
Pipe NB (mm)
75 and smaller 1.9 1.6 1.2
100 2.2 1.8 1.3
150 2.7 2.1 1.4
200 and greater 3.4 2.4 1.6

2 DESIGN CRITERIA - LIQUIDS
2.1 Single Phase Liquid Lines

Guidelines for the recommended pressure drops and velocities in piping are given in Tables 2.1 and 2.2
for boiling and non-boiling liquids. For non-boiling liquids, the fluid temperature shall be at least 15 C
below the fluid bubble point. In systems where sand may be present, a minimum velocity of 1 m/s is
required to minimise sand deposition in the lines.
For all pump suction lines, available NPSH must be greater than the required NPSH for the pump by a
margin of 1 metre of liquid. The available NPSH will be calculated at the maximum pump flow rate.
For pump suctions handling boiling fluid, lines shall be sized such that the total frictional pressure drop
does not exceed 0.6m of head of the fluid.
For reciprocating pumps, specific attention must be given to the sizing of suction and discharge piping
due to the effects of pulsation and acceleration head. The latter is directly proportional to pipe length,
velocity, pump speed and type of pump. In general, lines need to be sized for lower flowing velocities
than for centrifugal pumps.
Lines for potable water, fresh water and glycol/water mixtures shall be sized as per the criteria in Table
2.1.
Salt water lines, including produced water, shall be sized according to Table 2.3. (Note: for super-
austenitic stainless steel piping in sea-water service, flow velocity is not constrained by an erosional
limit. For GRE piping the velocity limit is 4.5 m/s maximum).

Table 2.1
Recommended Velocity and Maximum P for Carbon Steel Liquid Lines
HYDROCARBONS
Type of Service Velocity m/s Maximum P bar/100m
General Recommendation
Liquid Density, kg/m3
1600 1.5-2.4 1.1
800 2-3 0.9
320 3-5 0.3
Pump Suction See Table 2.2 See Table 2.2
Pump Discharge See Table 2.2 See Table 2.2
Liquid from condenser 1-2 0.1
Refrigeration Lines 0.6-1.2 0.09
Gravity Rundown Lines 1-2.5 0.033
Liquid Feed to Towers 1.2-2 0.06 - 0.1
Liquids to Reboilers 0.9 - 1.8 0.02 - 0.06
WATER LINES
General Recommendation 0.6-4.8 0.06-0.45
Service Diameter, mm
25 0.6-1
50 1-1.5
100 1.5-2.1
150 2.1-2.7
200 2.5-3
250 3-3.7
300 3.7-4.3
400 3.7-4.6
500+ 3.7-4.9
Pump Suction See Table 2.2 See Table 2.2
Pump Discharge 1.5-3, refer also to Table 4.2 See Table 2.2
Boiler Feed 2.5-4.5
Cooling Water 3.6-4.8 0.45

Table 2.2
Allowable Pressure Drops and Velocities in Piping for Centrifugal Pumps
Maximum Velocity m/s Allowable P bar/100m

Pipe NB Pump Suction Pump Suction
mm Pump Suction Pump Boiling Sub-cooled Pump
Discharge Liquid Liquid Discharge
<100 1.0 1.8 0.01-0.05 0.05-0.14 0.23-0.35
100 1.4 2.5 0.01-0.05 0.05-0.14 0.23-0.35
150 1.5 3.0 0.01-0.06 0.05-0.14 0.23-0.35
200 1.8 4.3 0.02-0.06 0.11-0.23 0.35-0.45
>200 1.8 5.0 0.02-0.07 0.11-0.23 0.35-0.45
Table 2.3
Allowable Velocities in Piping for Salt and Produced Water
Pipe NB Maximum Velocity

mm m/s
25 1.2
50 1.8
75 2.5
>100 3.0

2.2 Liquids Flowing By Pressure (Pressure Letdown)

These lines will generally be sized using the guidelines in Table 2.1. These guidelines may be exceeded
where there is sufficient pressure drop available, subject to the following:
a. The maximum allowable velocity is not to be exceeded. Two phase lines are considered in 4.0.
b. Lines upstream of pressure letdown valves shall be sized to prevent vapour flash ahead of the
valve.
c. Lines containing boiling fluids with flowmeters shall be sized as for pump suction lines in Table
2.2. The positive head available over the fluid vapour pressure at the meter inlet shall be in
excess of the meter range. The requirements of the particular installation shall be reviewed with
the Lead Instrument Engineer.
d. Where pressure drop is critical the line should be sized such that the actual pipe frictional
pressure drop does not exceed 50% of the available pressure drop.
2.3 Gravity Flowlines

Gravity flowlines shall be sized using a maximum pressure drop of 0.03 bar/100m equivalent length
(based on 1:100 slope). This may be exceeded for sub-cooled liquids with large available heads.
Caution should be taken to prevent flashing in barometric legs. Pipes with a diameter below 200 mm
shall be designed for 50% full of liquid, while pipes with a diameter of 200 mm and greater shall be
designed for 75% full of liquid.
2.4 Vertical Downflow (Liquids from Drain Boxes)

In addition to the sizing criteria given for gravity flowlines (section 2.3), the Froude Number for vertical
downflow service shall be less than 0.3 to avoid air entrainment (self-venting downflow). For fully
flooded vertical downflow, the Froude number shall be greater than 0.6.
FR = V
(gu D) ½
Where FR = Froude Number
V = Velocity (m/s)
  l  g 
gu = g  
 l 
l = density of liquid (kg/m3)

g = density of gas or vapour (kg/m3)
g = 9.81 m/s2
D = internal pipe diameter (m)
At Froude numbers less than 0.3 vapour bubbles will rise and the pipe will be self venting.
Gravity flowlines shall be sized to avoid the formation of syphons and to avoid pulsation and vibration.
One of the following methods can be adopted dependent on the individual engineering circumstances:
 Install a syphon breaker at the system high point.

 Size the line for all expected flow rates such that frictional forces offset gravitational forces thus
avoiding sub-atmospheric pressures at the top of the pipe.
 Install a back-pressure control near the base of the line.
 Size the line as self venting as above.
2.5 Static Accumulation

The maximum velocity in lines entering/leaving tanks containing hydrocarbons, and not installed with a
gas blanket will be limited to 1 m/s in the first 10m of line to/from the tank in order to reduce the
accumulation of static charge. This criteria applies to tanks containing flammable fluids such as diesel,
jet fuel etc.
2.6 Seawater / Firewater

If the design of seawater and firewater piping systems is based on the use of copper nickel pipes then
the following criteria will apply :
 For constant duty systems (i.e. the seawater system) the maximum velocity shall not exceed 3 m/s.
 For intermittent duty systems (i.e. the firewater system) a maximum velocity of 7.5 m/s shall be
used.
For alternative materials of construction (eg. GRP, FRP) the maximum velocity is 4.5 m/s in continuous
service and 7.5 m/s in intermittent service subject to vendor confirmation.
2.7 Drains
To avoid deposits of solid particles sewage, closed and open drains shall be designed for the minimum
fluid velocities given below:
Table 2.4
Minimum Velocities for Drain Lines
Service Min Velocity (m/s)
Sanitary Drains 0.8
Oily Water Drains (Open Drains) 0.9
Other Drains 1.1
However a minimum size of NB 100mm shall be used for the header and NB 75mm for the sub-headers.
2.8 Tank Overflows

Overflows are sized for the maximum net inflow to the tank taking full advantage of the available head
above the overflow.
For overflows through vertical internal pipes, use the Francis formula,
Q  K * D* H 1.5
Q = flowrate (m3/hr)

D = pipe internal diameter (mm)

H = liquid height above top of overflow pipe (mm)
K = constant = 6.575 x 10-4 (for above units)
For overflows from side outlets, and bottom outlet capacities, see Attachments B and C.

3 DESIGN CRITERIA - SINGLE PHASE VAPOUR LINES

For lines in which it is required to maintain ‘low’ pressure drops, eg main gas path lines, refer to the
recommended fluid pressure drops in Table 3.1 below. Additional criteria are applied to compressor
lines to limit noise and vibration. Pressure drop may be calculated using methods for incompressible
flow if the pressure drop does not exceed 10% of the upstream absolute pressure. Process lines which
are subject to greater pressure losses are anticipated to be short lines and should be sized on a case by
case basis.
Table 3.1
Recommended Velocity and Pressure Drop for Single Phase Vapour Lines
(excluding Vent lines)
Operating Pressure Bara Maximum Velocity m/s Pressure Drop bar / 100m
(Notes 1, 2) (Note 3)
General Recommendation
<3.5 0.057 – 0.085
3.5-10 0.085 – 0.103
10-40 0.103 – 0.267
40-150 0.267 – 0.453
Over 150 0.453
Compressor Lines
Suction 20
Discharge 30
Anti-surge recycle 75
Capacity Control recycle 40
Notes:
1. Reciprocating compressor lines should be sized on a conservative basis with maximum velocities of
12 m/s.
2. The velocity of gases containing wet carbon dioxide is not to exceed 18 m/s where film-forming
corrosion inhibitor is being used. At velocities above this limit corrosion inhibitor loses its
effectiveness.
3. Friction drop criteria need not be considered for a line with a control valve having a large pressure
drop e.g. compressor recycle, vent to flare, etc.
4. For continuous flow (including lines in flare systems) the vapour velocity should not exceed the
erosional velocity as calculated in section 4.0 below. The calculated velocity shall not exceed either
the maximum recommended velocity or the erosional velocity. For intermittent flow where pressure
drop is not a consideration (eg. Compressor capacity control recycle lines) the velocity should not
exceed 40 m/s.

In addition to the velocity and pressure drop criteria, the maximum allowable vapour velocity relating to
the acceptable noise levels should not normally be exceeded. This velocity is calculated by the formula:
Vmax = 198.5 ( )-0.506
where Vmax = Maximum allowable vapour velocity (m/s) based on
a noise limit of 85 dBA @ 1m
 = Gas density at flowing conditions (kg/m3)
When the vapour velocity exceeds Vmax for noise limits, consideration should be given to the routing of
the pipework, and addition of acoustic insulation on the piping, before significantly increasing the line
size.

4 DESIGN CRITERIA - GAS/LIQUID TWO PHASE LINES
4.1 Flow Patterns

Two phase flow in pipes can be classified by flow patterns which describe the type of flow exhibited,
with different flow patterns identified for horizontal and vertical flow. The flow patterns are determined
from standard flow pattern maps.
4.2 Erosion
High velocities in 2 phase lines can cause rapid wear by erosion. The velocity at which erosion may
occur is calculated by the formula given in API RP14E, i.e.
C
Ve =
m
Ve = erosional velocity (m/s)

C = constant (empirical)
m = mixture density (kg/m3) at operating pressure and

temperature
(gas density should be used for single phase gas
lines).
m can be calculated from the equation in API RP14E, or estimated by the following:
m = g (1-) +  l
Where  = liquid volume fraction

g = gas density (kg/m3)
l = liquid density (kg/m3)
Alternatively the mixture density can be determined from the HYSYS simulation program.
The following values of “C” shall be used:

For nominally solids free conditions (defined as less than one part per thousand barrels for liquid flow,
and 0.1 lb/MMscf for gaseous flows):
Carbon steel C = 135 (continuous) (Note 1)
C = 150 (intermittent)
13% Cr steel C = 300 (continuous) (Note 1)
Austenitic/duplex steels and nickel alloys C = 350 (continuous) (Note 1)

For Bayu-Undan, wellstream fluids shall be assumed as nominally solids free and the above “C” values
shall be used.
For absolutely solids free conditions:
Non-corrosive gas/condensate C = 400 (continuous) (Note 1)
Notes:
1. “C” values recommended by EEMUA (Publication No. 194 – “Guidelines for Material Selection
and Corrosion Control for Subsea Oil and Gas Production Equipment”).
4.3 Line Sizing

The following criteria can be used to size two phase lines on platforms. Subsea and long flowlines are
excluded from this procedure and should be sized using proprietary software eg. PIPESIM.
a. Calculate the erosional velocity and determine the minimum pipe size required to avoid fluid
erosion.
b. Check the flow pattern to ensure that slug flow is avoided - annular mist flow is preferred.
However, if slug flow cannot be avoided due to erosional velocity constraints, then the slug flow
regime has to be accepted.
c. Calculate the pressure drop either using the method outlined in API RP14E or by use of
proprietory software (ESI, HYSYS, PIPESIM).
Wellhead flowlines, production manifolds and other lines transporting gas and liquid in two phase flow
where significant pressure drop is available, are generally sized on the basis of flowline velocity. This
velocity shall not exceed the erosional velocity as calculated in Section 4.2.
Calculation of static head resistance in two phase systems should consider the fluid to be all liquid since
this is likely to occur at some stage of platform operation. Static gain should be treated with caution
since flashed vapour present may not necessarily recondense in the downcomer pipe.
Slug flow with resultant pressure pulsation and vibration is to be avoided. Problems are most likely in
lines from exchangers where partial vaporisation or condensation has occurred. In comparison,
equilibrium fluids which are continuously flashing with vapour expansion are usually relatively stable.
Where slug flow is expected to be a problem, consideration should be given to equipment layout, e.g.
locate exchanger near terminus so that the liquid vapour line is as short as possible. In all cases
however it is good engineering practice to layout piping so that it is self venting to the terminus (i.e. no
pockets).

5 DESIGN CRITERIA - RELIEF AND DEPRESSURING LINES

Vapour flow in relief and depressuring lines is treated as adiabatic compressible flow. The size of flare
headers, subheaders and individual relief valves may be estimated by the method of Lapple (refer API
RP521) or by more rigorous proven computer methods. The guidelines given below should be followed.
A detailed network analysis will be undertaken during the detailed engineering phase for all controlling
relieving/depressuring cases in order to ensure that the maximum allowable back pressure at each
individual relieving device is not exceeded.
Calculations will be performed in accordance with API RP520/521, or by use of recognised software
eg. FLARENET.
5.1 Relief Valve Inlet Lines

The inlet line pressure drop is to be less than 3% of set pressure calculated at set pressure conditions
assuming flow based on installed relief valve area. The inlet line shall not be smaller than the inlet
flange of the relief valve. For pilot operated relief valves, inlet line pressure drops in excess of 3% may
be used if this helps to avoid long lengths of large piping (large in this case means one size up from PSV
inlet flange size). Consult the Lead Process Engineer or Discipline Supervisor to agree on percentage
figure to use in such situations.
5.2 Relief Valve Outlet Lines

The discharge line shall not be smaller than the outlet flange of the relief valve. The computation of the
allowable pressure drop using the required relief capacity is as follows:
5.2.1 Conventional Valves

Size the discharge line from conventional valves to limit the backpressure to less than 10% of the set
pressure (gauge).
5.2.2 Balanced Valves

The maximum backpressure on a bellows type PSV may be limited by the bellows design pressure.
Limit backpressure to 30-50% of set pressure (gauge).
5.2.3 Pilot Operated Valves

The maximum backpressure for pilot operated type PSVs shall be limited to 50% of set pressure
(gauge).
Where there are a number of valves discharging into the same manifold, caution should be exercised to
ensure that the backpressure in the manifold allows all relief valves to discharge properly.
The recommended maximum Mach number is 0.75 calculated at rated flowrate and downstream
junction with header conditions. Back pressure based on installed critical area shall be checked to
confirm it is below the system design pressure.
Note that Mach number for vapour lines is calculated from the following equation :
vs   RT
where vs = sonic velocity (m/s)

ratio of specific heats for the gas (cp/cv)

R = individual gas constant = 8314/M (J/kg K) where M = gas molecular weight
T = absolute temperature (K)
5.3 Flare Headers and Sub-Headers

The equivalent length of headers and sub-headers should be determined as per section 6.0.
The maximum Mach number is 0.5-0.75 calculated at design flowrate at the downstream end of line
conditions.
5.4 Flare Stacks

Flare Stack Diameter is generally sized on a velocity basis although pressure drop should be checked.
For stable flare burning in pipe flares, API 521 recommends 0.5 Mach for a peak short term infrequent
flow, with 0.2 Mach maintained for the more normal and possibly more frequent conditions.
Requirements for pipe flares and other proprietary designs should be discussed with the vendor.
5.5 Blowdown Inlet Lines

The maximum velocity should be limited to 60 m/s, calculated at peak (initial) blowdown rate.
5.6 Blowdown Outlet Lines

The recommended maximum Mach number is 0.5-0.75 calculated at peak (initial) blowdown rate and
downstream junction with header conditions.
5.7 High Pressure Vents

Vent stack diameter is generally sized on a velocity basis although pressure drop should be checked.
Since there is no requirement to maintain a stable flame, the vent tip can be sized for sonic velocity.
This minimises the size and provides gas dispersion. An allowance must be made in the pressure drop
calculation for the pressure discontinuity which occurs at the tip when sonic velocity is established.
5.8 Atmospheric Tank Vents

Non-refrigerated atmospheric tank vents are sized on the basis of maintaining an operating pressure that
the tank can safely withstand. Flowrates are determined by consideration of thermal inbreathing and
outbreathing, maximum fluid inflow or outflow, and vapour production resulting from fire exposure.
Refer to API RP 2000 Venting Atmospheric and Low Pressure Storage Tanks for design details.
5.9 Caisson Vents

Total air displacement from within the caisson is calculated as sum of:
1. displacement due to swell in caisson (swell within caisson considered as 1/6th of maximum wave
height)
2. displacement caused by incoming liquid
3. displacement caused by entrained air

Caisson vent line is sized to suit total displaced air flow rate while conforming to the velocity/pressure
drop criteria in Section 3.0.

6 CALCULATION METHODS
For the purposes of calculating line sizes and pressure drops the following calculation methods shall be
used:
Single Phase Lines - In-house validated spreadsheets
- ESI Software
Liquid Network/Pump - FLUIDFLO
Circuits (seawater, cooling
medium, heating medium
pumps)
Two Phase Lines - In-house validated spreadsheets
- ESI (horizontal lines only)
- PIPESIM where applicable.
Firewater Systems - HYENA or equivalent.
Flare Networks - FLARENET or equivalent.
6.1 Valves and Fittings Equivalent Lengths

Equivalent lengths shall be determined either from Crane, Flow of Fluids Through Valves, Fittings and
Pipes, Technical Publication 410M, or from Attachment A. Roughness factors for pipe are detailed in
Table 6.1.
Table 6.1
Roughness Values
Material/Application Roughness (mm)
Carbon Steel 0.0457
Carbon Steel Flare/Vent Headers (Heavily Corroded) 0.457
Stainless Steel Flare Headers (Hot Rolled, Longitudinally Welded) 0.0457
Stainless Steel (New Seamless, Cold Drawn) 0.0406
Duplex Stainless Steel 0.0406
Galvanised Carbon Steel 0.1524
Epoxy Lined Pipe 0.1524
Glass Reinforced Epoxy (GRE) 0.0053
Copper-Nickel lines will be sized using the Hazen-Williams formula. In this case, a Hazen-Williams
‘C’ value of 140 is used in calculations as recommended in the NFPA Handbook.
The roughness of Coflexip flexible pipes is calculated as follows:
E = D
250 D in mm - for roughbore flexible pipe with a stainless steel carcass.
For smooth flexible pipe (thermoplastic lined) E = 0.0048 mm.

7 DESIGN MARGINS
In view of the space and weight limitations on the Bayu-Undan facilities, line sizes must be kept to a
minimum consistent with the correct operation of the platform. Care should be taken to ensure that
design margins are not ‘doubled up’, thus unnecessarily increasing line sizes.
All pressure drop calculations shall include a 20% design margin on pressure drop to allow for
manufacturing tolerances and deterioration of the new pipe with scale, rust etc. (This criterion shall not
be applied to flare system pressure drop calculations).

ATTACHMEN T (A)
EQUIVALENT LENGTH OF VALVES AND FITTINGS
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Equivalent Length of Valves and Fittings in Metres
Enlarger Reducer
Short Long Hard Soft 90 º miter bends Sudden Std red. Sudden Std red.
45 º Ell Rad Ell Rad Ell T T Equivalent Length in terms of small d
Globe Valve or Ball Check
Nominal Pipe Size (mm)
Gate or Ball Valve

Swing Check Valve
Angle Valve
Threaded
Plug Cock
Threaded
Threaded
Threaded
Threaded
d/D = 1/4
d/D = 1/2
d/D = 3/4
d/D = 1/2
d/D = 3/4
d/D = 1/4
d/D = 1/2
d/D = 3/4
d/D = 1/2
d/D = 3/4
Welded
Welded
Welded
Welded
Welded
3 miter
4 miter
2 miter
Valve
40 16.8 7.9 4.0 2.1 0.3 0.3 0.6 0.9 1.5 0.6 0.9 2.4 2.7 0.6 0.9 1.5 0.9 0.3 1.2 0.3 0.9 0.6 0.3 0.3
50 21.3 10.1 5.2 4.3 0.6 0.6 0.9 1.2 1.5 0.9 1.2 3.0 3.4 0.9 1.2 2.1 1.2 0.3 1.5 0.3 0.9 0.9 0.3 0.3
65 24.4 12.2 6.1 3.4 0.6 0.6 1.5 0.9 3.7 0.9 2.4 1.5 0.6 1.8 0.6 1.2 0.9 0.6 0.6
75 30.5 15.2 7.6 5.2 0.6 0.6 1.8 1.2 4.3 1.2 3.0 1.8 0.6 2.4 0.6 1.5 1.2 0.6 0.6
100 39.6 19.8 9.8 9.1 0.9 0.9 2.1 1.5 5.8 1.5 3.7 2.4 0.9 3.0 0.9 1.8 1.5 0.9 0.9
150 61.0 30.5 14.6 21.3 1.2 1.2 3.4 2.4 8.5 2.4 5.5 3.7 1.2 4.3 1.2 2.7 2.1 1.2 1.2 0.3
200 79.2 38.1 19.5 36.6 1.8 1.8 4.6 2.7 11.3 2.7 7.6 4.9 1.5 5.8 1.5 3.7 2.7 1.5 1.5 0.6
250 100.6 48.8 24.4 51.8 2.1 2.1 5.5 3.7 14.3 3.7 9.4 6.1 2.1 7.3 2.1 4.6 3.7 1.8 1.8 0.6
300 121.9 57.9 29.0 51.8 2.7 2.7 6.7 4.3 16.8 4.3 8.5 6.4 6.1 11.3 7.3 2.4 8.5 2.4 5.5 4.3 2.1 2.1 0.6
350 137.2 64.0 32.0 24.4 3.0 3.0 7.9 4.9 18.9 4.9 9.8 7.3 6.7 12.8 7.9 2.7 6.1 4.9 2.4
400 152.4 73.2 36.6 44.2 3.4 3.4 8.8 5.5 21.9 5.5 11.6 8.2 7.3 14.3 9.1 3.0 7.3 5.5 2.7
450 167.6 85.3 42.7 48.8 3.7 3.7 10.1 6.1 25.0 6.1 12.8 9.1 8.5 16.2 10.7 3.4 7.9 6.1 3.0
500 198.1 91.4 47.2 64.0 4.3 4.3 11.0 7.0 27.4 7.0 14.0 10.1 9.8 18.3 11.6 4.0 9.1 7.0 3.4
550 209.7 102.1 51.8 68.6 4.6 4.6 12.2 7.6 30.5 7.6 15.8 11.0 10.4 19.8 12.8 4.3 9.8 7.6 3.7
600 228.6 112.8 56.4 77.4 4.9 4.9 13.4 8.2 33.5 8.2 17.1 11.9 11.0 21.3 14.0 4.6 10.7 8.2 4.0
750 95.1 6.4 6.4 16.8 12.2 42.7 12.2 21.3 15.5 13.4
910 7.6 7.6 20.1 14.3 51.8 14.3 25.6 18.3 15.8
1067 9.1 9.1 23.5 16.8 61.0 16.8 29.9 21.0 19.5
1220 10.7 10.7 26.8 19.8 67.1 19.8 34.1 24.7 21.9
1375 12.2 12.2 30.2 21.3 76.2 21.3 38.4 27.4 24.4
1525 13.7 13.7 33.5 24.4 79.2 24.4 57.9 30.2 28.0
Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 19 Rev 1 Rev 01

ATTACHMENT (B)
SIDE OUTLET LIQUID CONNECTIONS CAPACITY CHART
Rev 1
/conversion/tmp/scratch/462273052.doc
February 2000
ATTACHMENT (C)
BOTTOM OUTLET LIQUID CONNECTIONS CAPACITY CHART
Rev 1
/conversion/tmp/scratch/462273052.doc
February 2000

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Bayu-Undan Gas Recycle Project

Line Sizing Design Guide

Document No.: BUGEN-00-10-N01-0100

20 May 1998 February 2000

DOCUMENT NO.: BUGEN-00-10-N01-0100

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Rev 01

A. ATTACHMENT (A) : EQUIVALENT LENGTH OF VALVES AND FITTINGS

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Rev 01

1.1 Piping Sizes

1.2 Piping Valves and Fittings

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 1 Rev 01

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 2 Rev 01

2 DESIGN CRITERIA - LIQUIDS

2.1 Single Phase Liquid Lines

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 3 Rev 01

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 4 Rev 01

Maximum Velocity m/s Allowable P bar/100m

Pipe NB Maximum Velocity

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 5 Rev 01

2.2 Liquids Flowing By Pressure (Pressure Letdown)

2.3 Gravity Flowlines

2.4 Vertical Downflow (Liquids from Drain Boxes)

l = density of liquid (kg/m3)

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 6 Rev 01

2.5 Static Accumulation

2.6 Seawater / Firewater

2.8 Tank Overflows

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 7 Rev 01

D = pipe internal diameter (mm)

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 8 Rev 01

3 DESIGN CRITERIA - SINGLE PHASE VAPOUR LINES

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 9 Rev 01

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 10 Rev 01

4 DESIGN CRITERIA - GAS/LIQUID TWO PHASE LINES

4.1 Flow Patterns

Ve = erosional velocity (m/s)

m = mixture density (kg/m3) at operating pressure and

Where  = liquid volume fraction

The following values of “C” shall be used:

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 11 Rev 01

4.3 Line Sizing

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 12 Rev 01

5 DESIGN CRITERIA - RELIEF AND DEPRESSURING LINES

5.1 Relief Valve Inlet Lines

5.2 Relief Valve Outlet Lines

5.2.1 Conventional Valves

5.2.2 Balanced Valves

5.2.3 Pilot Operated Valves

where vs = sonic velocity (m/s)

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 13 Rev 01

ratio of specific heats for the gas (cp/cv)

5.3 Flare Headers and Sub-Headers

5.4 Flare Stacks

5.5 Blowdown Inlet Lines

5.6 Blowdown Outlet Lines

5.7 High Pressure Vents

5.8 Atmospheric Tank Vents

5.9 Caisson Vents

Design Guide - Doc No.: BUGEN-00-10-N01-0100 Page 14 Rev 01