Eg.

- The candle smoke rises in a smooth

plume for the first few centimeters and then
starts fluctuating randomly in all directions as
it continues its rise.
After exhaustive experiments in the 1880s,
Osborne Reynolds discovered that the flow regime
depends mainly on the ratio of inertial forces to
viscous forces in the fluid. This ratio is called the
Reynolds number and is expressed for internal flow
in a circular pipe as
Allowable
Velocity
for Pipe
Sizing
 If the flow rate is known, by selecting the velocity from
the table, the inside pipe diameter can be calculated as

Based on the results, nearest Pipe Size can be selected

from ASME B36.10.

Then Calculate the thickness as per IBR/ASME

T = (WP x Do / 2fE + WP) + C

Where, T=Thickness required as per IBR, 1950, mm

WP=Working pressure, kg / sq cm, (g)
Do=Outside diameter of pipe, mm
f=allowable stress at working metal temperature, kg/sqcm
E=Joint efficiency = 1.0 for seamless pipes
C=Allowance (as per IBR) = 0.75 mm
Based on the above results, nearest pipe thickness
(Schedule) can be selected from ASME B36.10.

Then with the selected pipe Outside Diameter and

the pipe thickness as per ASME B36.10, the actual
velocity, V can be calculated as

Where,
pipe diameter = inside diameter of the pipe (m)
flow rate = fluid flow rate (m3/hr)
velocity = fluid velocity (m/s)
Example:
Fluid-Steam, Pressure=130 Bar, Temp.= 540 deg.C, Flow rate=
550 TPH
Solution: Sp. Vol = 0.026 m3/kg
∴ Flow rate = 550 x 1000 x 0.026
= 14300 m3/hr
Let, velocity = 50 m/s
Pipe Diameter = √ (4x14300)/(πx50x3600)
= 0.318 m

Selected Pipe OD = 350 NB , Selected Thk = 31.75 mm

Pipe Diameter = 356 – (2x31.75) = 292.5 mm
Actual Velocity = 59.1 m/s

Selected Pipe OD = 400 NB , Selected Thk = 36.53 mm

Pipe Diameter = 406 – (2x36.53) = 333 mm
Actual Velocity = 45.63 m/s
Pressure drop caused in pipes by fluid friction
for fully developed flows is described by
Darcy Weisbach Equation.

where,
hf= Head Loss (m)
f= Friction Factor
L= Pipe Length (m)
V= Average velocity (m/s) (As calculated above)
D= Internal Diameter (m) (As Calculated above)
g= Gravity (m/s2)
The friction factor f is a function of pipe
roughness Ɛ, inside diameter D and the
Reynolds Number Re.

The friction factor is presented on Moody

Chart giving f as a function of Re with Ɛ/D as
a parameter.
Another way of calculation friction factor is
Colebrook equation.

The Swamee–Jain equation is used to solve

directly for the friction factor f . It is an
approximation of the implicit Colebrook
equation.
For new pipes friction factor can be considered
as below
 Pressure drop or head loss is proportional to the
velocity in valves or fittings. It can be assumed that
pressure drop or head loss due to flow of fluids in
turbulent range through valves and fittings is
proportional to square of velocity.

 To avoid expensive testing of every valves and every

fittings that are installed on pipeline, the experimental
data are used. For that purpose resistance coefficient K,
equivalent length L/D and flow coefficient Cv are used.
These values are available from different sources like
tables and diagrams from different authors and from
valves manufacturers as well.
Kinetic energy, which is represented as head due to
velocity is generated from static head and increase
or decrease in velocity directly is proportional with
static head loss or gain. "Velocity head" is:

Where, v= velocity of fluid (m/s)

g= gravity (m/s2)

The head loss due to resistance in valves and fittings

is:

where, K= resistance coefficient

Head loss due to friction in straight pipe is
expressed by the Darcy equation:

Hence,

The ratio L/D is equivalent length in pipe diameters

of straight pipe that will cause the same pressure
drop or head loss as the valves or fittings under
the same flow conditions.
The equivalent ratio (Le/D) for various valves and
fittings can be computed as per the table below.
Hence, the equivalent length can be calculated
as:
Le = (Le/D) ratio as per the table x D
(Inside Diameter of pipe)
The resistance due to sudden enlargements
may be expressed as:

The resistance due to sudden contraction may

be expressed as:
Hence, the total frictional drop through piping
is:

We will get HL in m. To convert it to kg/cm2 ,

we need to multiply the above calculated
value with density or divide with Specific
Volume.
Continuation from Previous example;
If Pipe = 350 NB, thk = 31.75 mm; V= 59.1 m/s
Pipe ID = 292.5 mm
If Pipe = 400 NB, thk = 36.53 mm; V= 45.63 m/s
Pipe ID = 333 mm

Length of pipe = 130 m; No. of 90° Elbows = 5;

No. of 45° Elbows = 2; No. of Gate Valves = 2;
No. of Expander = 1, Size = 350 NB x 400 NB

For 90° Elbows Le/D = 20

For 45° Elbows Le/D = 16
For Gate Valves Le/D = 8

∴ Le (for all fittings) = (5x20+2x16+2x8) x 0.333

= 49.28 m
For expander,
d1= 292.5 mm
d2= 333 mm

K1= 0.053

Friction factor for 400 NB = 0.014

Hence, total frictional drop

HL = 0.014 x (130+49.28) x 45.632 + 0.053 x 45.632

2 x 9.81 x 0.333 2 x 9.81

= 799.87 + 5.62
= 805.49 m = 805.49 / (0.026 x 10000) = 3.098 kg/cm2
Alternate method of calculating pressure drop
is Hazen William’s equation.

Where,
hf = head loss over a length of pipe, m
L = length of pipe, m (meters)
Q = volumetric flow rate, m3/s (cubic meters per second)
d = inside pipe diameter, m (meters)
C = Roughness Coefficient
Recommended values of C are 150 for plastic & copper
piping, 120 for new steel piping, down to 100 & below for
badly corroded or rough pipe.
PRDS (Type-I)
In this type, coolant is introduced into the downstream of
the pressure control valve through a separate connection,
i.e. pressure reduction is done external to the
desuperheater. The pressure control valve shall form part
of a pressure control loop consisting of a pressure sensor
(mounted downstream of DS) and a separate controller.

PRDS (Type-II)
This is an integral type PRDS, i.e. the pressure control action
and water spray take place in the same unit. Thus, this type of
PRDS will essentially consist of a pressure control valve with
inlet & outlet for the process medium, a nozzle for the
entry of the coolant. The coolant will enter through the
valve and will be sprayed in the low-pressure area of the
process medium.
Inlet Steam Flow rate = Mi , Outlet Steam Flow rate = Mo
Spray water Flow rate = Mw
Inlet Steam Enthalpy = Hi , Outlet Steam Enthalpy = Ho
Spray water Enthalpy = Hw

Mi + Mw = Mo ………………………………. Eqn. 1
Mi x Hi + Mw x Hw = Mo x Ho ………….. Eqn. 2

Inlet Steam Conditions;

Pressure = 42 kg/cm2 (g), Temp = 380°C
Hi = 755.74 Kcal/Kg

Outlet Steam Conditions;

Pressure = 4 kg/cm2 (g), Temp = 156°C (Atleast 5° above
saturation temp.)
Mo = 30 TPH, Ho = 658.68 Kcal/kg
Spray water Conditions;
Temp. = 60°C, Hw = 60 Kcal/kg

Steam inlet flow rate & Spray water flow rate needs to be
calculated.

Mi + Mw = Mo
Mi + Mw = 30 ……………………………………… Eqn. 1

Mi x Hi + Mw x Hw = Mo x Ho
Mi x 755.74 + Mw x 60 = 30 x 658.68 ………. Eqn. 2

Solving both the equations,

Mi = 25.8 TPH & Mw = 4.2 TPH
Spray Water pressure:

Minimum water pressure required for combined PRDS:

Top Entry : Pw = [(Pi + Po)/2] + 7 Bar

Bottom Entry through stem : Pw = Po + 7 Bar

Bottom Entry through nozzle: Pw = (Pi / 2) + 7 Bar