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 SAN FRANCISCO (cid:127) SINGAPORE (cid:127) SYDNEY (cid:127) TOKYO Butterworth-Heinemann is an imprint of Elsevier Butterworth-Heinemann is an imprint of Elsevier 30 Corporate Drive, Suite 400 Burlington, MA 01803, USA The Boulevard, Langford Lane Kidlington, Oxford, OX5 1GB, UK © 2010 Elsevier Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions. This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. 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 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. For information on all Butterworth–Heinemann publications visit our Web site at www.elsevierdirect.com Printed in the United States 10 11 12 13 14 10 9 8 7 6 5 4 3 2 1 Working together to grow libraries in developing countries www.elsevier.com | www.bookaid.org | www.sabre.org 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