Course contents
The training program will be conducted in 10 modules. One module per day. Two modules per week. Each module will take about 3 hrs.
Day 1: Module -1: BFD, PFD, Legends & Symbols, PID
| 1 | Legends & Symbols. Typical legends and symbols. Explanation of legends and symbols with respect to various standards. |
| 2 | Legends & Symbols. Typical legends and Symbols. Explanation of legends and symbols with respect to various standards. |
| 3 | PFD: Typical drawing of PFD. Contents of PFD. Representation of legends & symbols in PFD. H&MB representation and contents on PFD. Requirements of various standards to be included in PFD |
| 4 | P&ID: Typical drawing of P&ID. Contents of P&ID. Representation of legends & symbols in P&ID. Requirements of various standards to be included in P&ID |
Day 2: Module -2: Line Sizing
| 1 | Pressure drop calculations as per SHELL DEP and various models used for pressure drop calculations. |
| 2 | Pipe schedule, Piping class etc. Line sizing criteria for liquid lines, Friction factor, Gas lines, liquid lines, steam lines and Gas-liquid two phase line sizing as per API 14E. Codes and standards requirements. Velocity criteria as per standards for various cases. Demonstration of line sizing through manual calculations. |
| 3 | Equivalent length definition and explanation with respect to SHELL DEP |
Line Sizing in Process Engineering: The Key to an Optimised Plant Design!
Piping constitutes 5-15% of total plant investment, making line sizing a critical aspect of process engineering. Choosing the right pipe size, material selection, flow velocity, and pressure drop directly impacts cost efficiency, process safety, and technical performance in industries like oil and gas, chemical processing, and pharmaceutical manufacturing.
Key Considerations for Effective Line Sizing:
✔ Velocity Control: Maintain flow rates within safe limits to enhance piping system performance and prevent erosion.
✔ Pressure Drop Analysis: Minimise energy loss while ensuring smooth fluid transport across pipelines.
✔ Material Selection: Choose chemical-resistant and high-pressure-rated materials for longevity and process reliability.
✔ Valve & Fitting Optimisation: Reduce friction losses, flow disruptions, and pressure fluctuations in process design.
✔ Compliance with Industry Standards: Follow ASME, API, NFPA, and ISO guidelines to meet technical requirements.
Optimised piping design improves plant efficiency, process safety, and operational reliability. Whether you’re a process engineer, piping design engineer, or chemical engineer in oil & gas, mastering line sizing is essential for career growth and engineering excellence!
Line sizing calculations:
Line sizing calculations involve factors such as fluid type, operating conditions, and safety margins, making it a fundamental topic in process design engineering courses and interview questions. Modern tools like Aspen HYSYS are widely used for line sizing in process design, enabling precise simulations and optimisation.
Categories of Line Sizing
Line sizing can be broadly categorized into single-phase and two-phase flow systems.
A. Single-Phase Line Sizing
In single-phase flow, the fluid consists of either liquid or vapor without phase changes.
- Liquid Line Sizing
- Ensures optimal velocity to prevent excessive pressure drop and erosion.
- Helps maintain process efficiency and avoid solid settling.
- Vapor Line Sizing
- Accounts for compressibility effects and pressure loss.
- Designed to minimize turbulence and energy loss over long distances.
B. Two-Phase Line Sizing
Two-phase flow involves simultaneous transport of liquid and gas, requiring specialized design considerations based on flow regimes.
1. Two-Phase Flow in Horizontal Pipelines
As vapor flow rate increases, different flow patterns emerge:
- Bubble Flow – Gas bubbles disperse throughout the liquid phase.
- Plug Flow – Vapor forms alternating slugs with liquid.
- Stratified Flow – A distinct liquid-gas interface is established.
- Wavy Flow – Vapor velocity causes waves at the liquid interface.
- Slug Flow – Waves grow into slugs that occupy the full pipe diameter.
- Annular Flow – Liquid forms a thin film along the pipe walls, with gas flowing centrally.
- Dispersed Flow – High vapor velocity entrains liquid droplets.
2. Two-Phase Flow in Vertical Pipelines
- Bubble Flow – Vapor rises as dispersed bubbles in the liquid phase.
- Slug Flow – Bubbles merge into large slugs dominating the cross-section.
- Annular Flow – A thin liquid film forms along the pipe walls, with gas flowing at high speed.
- Mist Flow – Liquid fully entrains as fine droplets in the gas stream.
Key Considerations in Line Sizing
1. Economic Considerations
- Pipe diameter selection affects capital costs for piping and supports.
- Advanced process design methods optimize costs while maintaining efficiency.
2. Velocity and Pressure Drop Calculations
- Critical for gravity-driven flows where pressure loss needs to be controlled.
- In line sizing calculations, excessive velocity may lead to higher energy consumption and flow restrictions.
3. Structural & Mechanical Requirements
- Pipe material and minimum pipe size standards (e.g., 1.5 inches on pipe racks) must be considered.
- Process design engineering programs cover material selection criteria for various industries.
4. Handling Unusual Flow Situations
Proper line sizing in process design helps mitigate challenges such as:
- Vortexing – Swirling motion causing efficiency loss.
- Vibration – Induced by high flow velocities.
- Water Hammer – Sudden pressure surges affecting piping integrity.
5. Velocity Requirements
- Fluid velocity must be below erosion limits to avoid pipe damage.
- In line sizing criteria, a minimum velocity of 0.9 m/s prevents solid deposition in pipelines.
6. Mode of Operation
- Higher velocities and pressure drops are acceptable in intermittently operated pipelines.
7. Equipment Limitations
- Equipment specifications, such as pumps, heat exchangers, and control valves, influence line sizing criteria.
8. Space Limitations
- In existing facilities, available space may restrict pipe size selection.
Line Sizing in Aspen HYSYS
Aspen HYSYS is a widely used tool in process design engineering courses for line sizing calculations. It provides:
- Simulation of pressure drop and velocity profiles
- Optimization of pipeline diameters
- Integration with process flow simulations
Line sizing is a crucial aspect of process design, ensuring efficient fluid transportation while balancing velocity, pressure drop, and cost-effectiveness. Whether dealing with single-phase or two-phase flow, engineers must apply line sizing criteria to determine the optimal pipe diameter.
Mastering line sizing in process design is essential for engineers working in oil & gas, chemicals, pharmaceuticals, and power plants. If you’re preparing for line sizing interview questions or enhancing your expertise through an advanced process design course, understanding line sizing calculations will give you a competitive edge.
Day 3: Module -3: Pump Sizing & Hydraulics
| 1 | Pumps suction and discharge line sizing NPSHA Calculations and demonstrations Pump KW rating calculations |
| 2 | Explanation of Pipe sizing segment and line sizing in HYSYS using the HYSYS manual. |
Day 4: Module -4: Pipenet Simulation (Standard Module)
| 1 | Introduction to Pipenet simulation. Standard, Transient and Spray modules in Pipenet simulation |
| 2 | Demonstration of Input parameters to build the network for standard module. Simple network modelling demonstration to carryout Hydraulic calculations. |
| 3 | Complex network modelling demonstration. Discussion on results and Report preparation. |
Day 5: Module -5: Pipenet Simulation (Transient Module)
| 1 | Introduction to Transient module |
| 2 | Transient Analysis network building & Demonstration |
| 3 | Surge Analysis through Pipenet -Examples. Demonstration of Surge analysis for water systems. |
Day 6: Module -6: Fire water & Foam Demand calculations
| 1 | Introduction to Fire water systems |
| 2 | Fire water Demand calculations as per NFPA regulations. Foam application rate for crude oil storage tanks. Fire water network, storage, fire water pumps, jockey pumps design calculations. |
| 3 | Hydrants, monitors and sprinklers – K factor calculations. Input parameters to Pipenet simulation |
Day 7: Module -7: Fire water Network simulation in Pipenet
| 1 | Firewater network building demonstration in Pipenet. Firewater Ring main, Hydrants, monitors etc. Demonstration in Pipenet the ring main velocities, hydrant, monitors flow, Pressure profile across the network to meet the codes & Standards. Report preparation. |
Day 8: Module -8: PSV- Definitions, Types & Set Pressure
| 1 | Various Definitions in Pressure-Relieving and Flare Systems. • Description of Various types of Relief Valve and installation in Refineries and Oil & Gas Industries |
| 2 | Why do we need to install Relief Valves • Types of Relief Valves to be installed • Why Rupture Disk is Installed • Set Pressure Calculation Procedure • When do you go for Multiple Relief Valves and set Pressure Calculation of Multiple Relief Valves |
| 3 | Emergency Depressurizing Valves and the sizing procedure • Surge Relief Valve for Liquid Systems • Surge Relief Valves for Gas System. Analysis and results discussions. |
Day 9: Module -9: PSV sizing calculations
| 1 | Sizing Procedure for Gas, Liquid System with a detailing procedure Disposal Systems • Atmospheric Discharge Procedure • PSV Discharge to closed Systems • Flare Header Calculations |
| 2 | Horizontal / Vertical KO Drum Sizing Procedure • Flare Header Purge Gas Calculations• Seal Drum Sizing etc. |
| 3 | Flare Radiation Calculation • Flare Stack Sizing Procedure •Flare Ignitors systems. • Description of Burning Pit and Sizing guidelines |
Day 10: Module -10: PSV –Flare header Sizing
| 1 | Flare Header / Piping / Mach No Calculation and Sizing Procedure for Gas-Liquid System with a detailing procedure Disposal Systems • Atmospheric Discharge Procedure • PSV Discharge to closed Systems • Flare Header Calculations |
| 2 | Demonstration of Relief Valve Sizing of Gas, Liquid, Steam and Gas-Liquid System using Manual Calculation |
| 3 | Flare Radiation Calculation • Flare Stack Sizing Procedure •Flare Ignitors Surge Relief Valve Sizing Procedure • Description of Burning Pit and Sizing guidelines |
Trainer
- Mr. Elamvaluthi Gangadaran – Lead trainer in Process Design
Price: Rs. 15,000
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Registration Open
Training Starts On March 07-2026