Piping and Pipeline Calculations Manual - Construction, Design, Fabrication, and Examination

323 Pages·2010·7.321 MB·English

by  Ellenberger, J. Phillip

PIPING AND
PIPELINE
CALCULATIONS
MANUAL
Construction, Design, Fabrication,
and Examination
J. P E
HILLIP LLENBERGER
AMSTERDAM (cid:127) BOSTON (cid:127) HEIDELBERG (cid:127) LONDON
NEW YORK (cid:127) OXFORD (cid:127) PARIS (cid:127) SAN DIEGO
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Notices
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Library of Congress Cataloging-in-Publication Data
Ellenberger, J. Phillip
Piping and pipeline calculations manual : construction, design fabrication, and
examination/Phillip Ellenberger.
p. cm.
Includes bibliographical references and index.
ISBN 978-1-85617-693-4 (alk. paper)
1. Pipelines–Design and construction–Handbooks, manuals, etc. 2. Piping–Design
and construction–Handbooks, manuals, etc. I. Title.
TJ930.E438 2010
621.8’672–dc22 2009040487
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Preface
What are the necessary requirements to move from a piping or pipeline
system idea to its completion? The basic premise of this book is that at
the heart of those requirements are a series of calculations, which cover a
wide range of subjects.
In any pipeline system, the core of the system itself is the piping, which
is its skeleton. However, as with any skeleton, there must be other ele-
ments to include before the system can become the final entity that was
the original idea.
Pipe is basically a transport structure. To determine what that structure
requires would involve what it is intended to transport. While it is impor-
tant to have knowledge of how the medium to be transported is gener-
ated, this book does not address that area. Generation of that comes from
another field of expertise.
A pipe system has a beginning, an ending, and a path between the two
points. To transport the medium—liquid or gas—some definition of
temperatures, pressures, amount to be transported per unit of time, and
the energy required to accomplish the transport need to be, at least par-
tially, established. Many of these will be considered as a given in this book
and the methods of calculating the other elements are discussed and
explained.
The base codes for the design of a new system, and the ones used in
this book as the reference source, are the B31 piping codes of the American
Society of Mechanical Engineers (ASME). The B31 piping codes consist of
several sections or books that describe the requirements for systems of a
specific type. These can readily be broken into the two basic types—a
piping system and a pipeline system.
The differences between the two are that a piping system can be generi-
cally defined as being inside a localized area to connect various vessels
that are for reaction and/or storage. A pipeline system is more like a pure
transport medium between two geographical positions. Within both are
elements of the other. There are many pipelines within a plant or localized
area, and along the pipelines between distant points are stations that have
piping systems necessary for some pipeline element such as a compressor
station.
ix
x PREFACE
For these reasons, the various sections or books of the B31 codes allow
piping system owners to determine which code would apply to their
particular project. In making this decision the owners are also advised to
take into account which code the jurisdiction(s) for their projects might
consider applicable.
All system requirements basically set standards of calculation to estab-
lish a safe end result. Those qualification standards are outlined with
specific calculation procedures in the codes. Some things are required
to be taken into account without details of how to consider them. Some
calculations require base calculations to arrive at the point where the code
calculation can be used. In this book, we address many of the grayer areas.
As one goes through the steps of meeting the requirements of particu-
lar codes, he or she will also find many other standards included by refer-
ence. This is a practical way for the codes to cover many common elements
in the design and construction of a system. Any calculations required for
the component that are covered by the referenced standard need not be
outlined in the code. The use of that component needs no further proof
of compliance with the code than its compliance with the standard. Since
different standards provide different methods of providing the calcula-
tions, those differences are also addressed.
The B31 piping codes are primarily construction codes for new facili-
ties. They can be used successfully in replacing or extending a piping
facility. With few exceptions, notably the pipeline sections, there are no
maintenance and ongoing requirements. The pipeline sections have rela-
tively extensive detailed requirements for continuous maintenance. There
is a growing set of postconstruction requirements, some of which are
published, that give methodologies for repairing and assessing the need
for repairs. Some small offerings detail the methodology for certain more
complex areas of analysis, and these are discussed in this book.
It should be noted that some of the calculations provided are not neces-
sarily required by the codes. However, one must really understand those
calculations to have the depth of understanding needed to do a good job
when performing the calculations required.
Part I of this book provides an overview of the codes and standards,
including what they are and what they aren’t. It provides a detailed dis-
cussion of the “metric problem.” Chapter 3 discusses piping materials, as
well as other materials, that might be required to complete a system.
Part II covers some specific calculations and their formulas and has
examples of how to do such calculations.
The Appendix contains a set of charts, graphs, and other helpful tables
and guides that should make doing some of the calculations easier or
faster. In this computer/calculator age, some tables and graphs are still a
good way to look at alternative solutions to a problem before going into
an in-depth mathematical analysis.
PREFACE xi
Acknowledgments
Writing a book is a complex process. This is especially true of writing
a book on a technical subject. Essentially, the writing itself is the most
complex portion of the process. It is hoped that I have enough expertise
on the subject that what is said here has authority. The mere fact that one
writes, or can type on a computer keyboard, use a pencil, or whatever
method by which the words are created is not sufficient.
It would be impossible to describe the hundreds, maybe thousands, of
people who have influenced my life. It surely includes in some small
degree everyone I’ve ever met, every book I’ve ever read, every experi-
ence I’ve ever had, and every question I’ve ever asked. My most recent
contacts are always forefront in my memory, but as the twig bends, so
the tree grows. That is to say, I surely have left out some in thanking the
individuals who have had an important influence on the writing of this
book. For that omission I can only apologize and hope that they will
understand.
Most certainly, I would like to thank everyone on the many code and
standards committees I have had the opportunity to serve as a member
with. Those discussions, disagreements, and enlightenments on an
obscure point have served well on my path, as well as being enjoyable. I
thank the folks who employed me, plus those who have worked by my
side, in this great venture. I also thank those who allowed me the oppor-
tunity to perform the requirements and make the mistakes that helped
me improve my knowledge. I thank the customers and fellow employees,
whose suggestions, questions, and sometimes skepticism, caused me to
sharpen my views and defend my positions or make them better. I would
be foolish not to include the friends and loved ones who bore with me in
the frustrations and joys of the journey.
When it comes down to it, the act of writing is a solitary effort. However,
that solitude is surrounded by those unnamed legions. Paraphrasing the
modern lingua franca of technology, it might be called “cloud writing.” To
be sure, the words I chose, the formulas I chose, and the errors are mine.
However, the success is from the cloud.
Contents
Preface ix
PART I
INTRODUCTION
Chapter 1: Major Codes and Standards 3
Chapter 2: Metric versus U.S. Customary Measurement 13
Chapter 3: Selection and Use of Pipeline Materials 21
PART II
CONSTRUCTION AND DESIGN FABRICATION
Chapter 4: Piping and Pipeline Sizing, Friction Losses,
and Flow Calculations 35
Chapter 5: Piping and Pipeline Pressure Thickness
Integrity Calculations 57
Chapter 6: Straight Pipe, Curved Pipe, and Intersection
Calculations 85
Chapter 7: Piping Flexibility, Reactions, and Sustained
Thermal Calculations 119
Chapter 8: Pipe-Supporting Elements and Methods
Calculations 145
Chapter 9: Specialty Components 161
Chapter 10: High-Frequency versus Low-Frequency
Vibration Calculations 181
Chapter 11: Occasional Loads Calculations 199
vii
viii CONTENTS
Chapter 12: Slug Flow and Fluid Transients Calculations 225
Chapter 13: Fabrication and Examination Elements Calculations 241
Chapter 14: Valves and Flow Control Calculations 263
Appendix: Charts, Graphs, and Other Helpful Guides 281
Bibliography 355
Index 357
C H A P T E R
2
Metric versus U.S.
Customary Measurement
OVERVIEW
Whenever one writes anything that includes a measurement system in
the United States, he or she is confronted with the problem of presenting
the data and calculations. This is especially true when writing about codes
and standards. Most U.S. codes and standards were originally written
some time back when metrics were not necessarily the dominant world
system.
The metric system itself has several minor variations that relate to the
base units of measure. This will be discussed more thoroughly in the fol-
lowing. The system has evolved to the point that basically only three
countries do not use it as their primary measurement system: Myanmar,
Liberia, and the United States. It is now known as the International System
of Units (SI).
The United States has played with converting to the SI system for
as long as I have been working in this field, which is a long time. Ameri-
cans have not made the leap to make it our primary system. This lack of
tenacity in converting to this system is difficult to understand completely.
The most plausible argument revolves around the installed base of
measurement and a modicum of inertial thought regarding that seem-
ingly inevitable conversion.
To those who have worked with the SI system it is immensely preferred
in its decimal conversion from larger to smaller units. What could be
13
© 2010 Elsevier Inc.
DOI: 10.1016/B978-1-85617-693-4.00002-X
14 2. METRIC VERSUS U.S. CUSTOMARY MEASUREMENT
simpler than converting a length measurement from something like
1.72 kilometers to 1720 millimeters? Compare that to converting 1 yard,
2 feet, and 6 inches to 66 inches or 5.5 feet.
On the other side, there is the problem of what you grew up with.
It is rather like translating a language that is not your native language.
You first have to get the words into some semblance of your native
tongue. As one becomes fluent in another language, he or she can begin
to think in that language.
HARD VERSUS SOFT METRIC CONVERSION
All of this is a descriptive example of some of the difficulties of convert-
ing an ASME code into a metric code. The generic classification of this
problem is hard versus soft conversions. The terms hard conversion and
soft conversion refer to approaches you might take when converting an
existing dimension from nonmetric units to SI. “Hard” doesn’t refer to
difficulty, but (essentially) to whether hardware changes during the met-
rication process. However, the terms can be confusing because they’re not
always consistently defined and their meanings can be nonintuitive.
It’s simplest to consider two cases: “converting” a physical object and
conversions that don’t involve an object.
When converting a physical object, such as a product, part, or compo-
nent, from inch-pound to metric measurements, there are two general
approaches. First, one can replace the part with one that has an appropri-
ate metric size. This is sometimes called a hard conversion because the
part is actually replaced by one of a different size—the actual hardware
changes. Alternatively, one can keep the same part, but express its size in
metric units. This is sometimes called a soft conversion because the part
isn’t replaced—it is merely renamed.
If the latter sounds odd, note that many items’ dimensions are actually
nominal sizes—round numbers that aren’t their exact measurements—
such as lumber, where a 2 × 4 isn’t really 2 by 4 inches, and pipe, where
a 0.5-in. pipe has neither an inside nor an outside diameter of 0.5 in. With
pipe, the international community has come to a working solution to this
anomaly because comparable SI pipe has different dimensions than does
U.S. schedule pipe.
An even more difficult problem comes about when one is determining
nonproduct-type decisions while making pipe calculations. For instance,
how does 1720 mm compare to 5.5 ft in your sense of the two distances?
That is to ask, which is longer?
The answer is 1720 mm converts mathematically to 5.643045 ft.
However, for few of us, even those who have worked with but are not
I. INTRODUCTION
SI SYSTEM OF MEASUREMENT 15
fluent in metrics, the answer is not obvious—until we do the conversion.
We may sense that they are close. In some calculations 5.643045 may not
make a significant difference. In others, it may make the difference
between meeting or not meeting a certain requirement.
This points to another problem in working with things developed in
one system as opposed to other systems. As it relates to conversion, there
can be many decision-like problems. If for some reason we were deve-
loping a U.S. customary design and arrived at an answer that came to
5.643045 ft, we might call it any of several dimensions in our final deci-
sion. This would depend on the criticality of the dimension in the system.
Where we are concerned with a dimension that only needs to be
within the nearest 1 in. to be effective, we might chose 55 (5 ft, 7.5 in.)
8 8
or 53 (5 ft, 9 in.). The original 5.643 can be converted to something within
4
1 of an inch as 5 ft, 723 in. Mind you, all this is for converting 1720 mm
32 32
into U.S. customary dimension. A similar exercise could be presented for
converting something like 53 (5 ft, 9 in.) into millimeters, which would
4
be 1752.6 mm. One would then have to make comparable decisions about
the criticality of the dimension.
SI SYSTEM OF MEASUREMENT
It was previously mentioned that there are several metric systems.
Fortunately, they are not as complex as the U.S. customary system (USC).
For instance, in distance measurement the name and unit of measure
changes with the size of the distance. We have miles, furlongs, chains,
yards, feet, inches, and fractions of an inch, all of which can be converted
to the other, but not in a linearly logical base 10 fashion as the SI system
does.
The different systems in metric are centimeter, gram, and second
system. Another is the kilometer, kilogram, and second system. It can be
noted that the major difference in the base unit system is a different
length, which essentially just changes the prefixes, as the decimal relation-
ship is constant. It is just up from centimeters to kilometers or down from
kilometers to centimeters.
The International System of Units (SI) includes some other base units
for use in other disciplines:
1. Meter, the distance unit.
2. Kilogram, the weight and force unit.
3. Second, the time unit. Interestingly, a second in France is the same as
a second in New York.
4. Ampere, the electrical unit.
I. INTRODUCTION