P-EP-PL-041-0A
REV
DATE
ISSUED AS STANDARD
KS
MGC
MGC
REVISION
BY
CHKD
APPR
Page 1
CLIENT
Contents
1. Purpose..........................................................................................................................................
2. Scope.............................................................................................................................................
3. Codes & standards .........................................................................................................................
4. Definitions ....................................................................................................................................
5. Different type of pumps
6. Pump piping layout
7. Pump piping supports
8. Auxiliary piping
9. Stress analysis for pumps
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1.
Purpose
This specification covers general guidelines for various pump piping
layouts. Examples of various layout sketches are attached which will be
helpful for the piping designer/engineer to implement a proper layout.
These guidelines are developed considering plant safety, operation /
maintenance aspects and meeting statutory requirements of various
national and international codes/standards. The design must reflect
consistency in approach in order to result in a quality design .
2.
Scope
This design guide is concerned with the design of piping layouts for
various category of pumps. The Plant layout and Piping group is
responsible for developing a comprehensive, safe and well thought out
design. That includes meeting various codes, manufacturer and/or client
requirements for nozzle loads on the pump as well as stress allowable for
the piping system. Support of the piping system must be given careful
consideration during the layout of the piping. This is a joint effort of the
piping designer and the pipe stress / support engineer. Proper design of
the piping must allow good access to the pump for operation and
maintenance.
3.
c) P-SS-PL-019
d) P-EP-PL-065
e) API-610
f) ASME B73.2
g) ASME B73.1
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4.
Definitions
4.1
Safety
Proper consideration for personnel safety shall be considered while doing
the piping layout/locating valves & strainers in such a manner that clear
access is provided near pumps for operation/ maintenance as well as
egress in an emergency. Care must be exercised not to create tripping
hazards with auxiliary piping.
4.2
Operation
Pumps normally require minimal attention during operation. Valves,
strainers etc must, however, be located for easy access. Where valves
cannot be operated (i.e. above 2 meters) from grade, suitable platform
shall be provided depending upon the operation requirement.
4.3
Maintenance
Piping shall be arranged in a manner to allow adequate access to the pump
avoiding excessive dismantling of the piping system to satisfy
maintenance requirements. The coupling between the pump and its driver
must be accessible for alignment/dismantling purpose etc. Pump seal
access must also be considered since seal failure is the most common
cause of maintenance.
4.4
4.5
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the shaft center line for horizontal pumps, the suction nozzle center line
for vertical inline pumps and the top of the foundation for other vertical
pumps.
The manufacturer usually tests the pump with water at different capacities,
created by throttling the suction side. When the first sign of vaporization
induced cavitation occurs, and that pressure is converted into head. This
head number is published on the pump curve and is referred as net
positive suction head required ( NPSHr ) or sometimes in short as the
NPSH.
4.6
4.7
Vapour pressure
When the pressure in the pump suction line falls below the vapour
pressure of a liquid , the liquid flashes, or changes to vapour. Because no
ordinary pump can handle only vapour, liquid flow to the pump falls off
and the unit is said to be vapour bound.
4.8
Cavitation
Cavitation is the phenomenon caused by vaporization of a liquid inside a
pump. When the pressure at any point drops below the vapour pressure
corresponding to the temperature of the liquid being pumped, vaporization
of the liquid will occur. Small cavities of vapour thus formed move with
the flow through the pump until a region of higher pressure is reached.
The higher pressure causes the vapour cavities to collapse with
tremendous shock on the surrounding metal.
4.9
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4.10
5.
Pump Types
Pumps are generally classified as Centrifugal, Rotary or
Reciprocating pumps depending upon the process requirements. Pumps
may be of motor driven or turbine driven type. Most commonly used
pumps in the refinery industry are of Centrifugal type.
5.1
Centrifugal pumps
Centrifugal pumps employ centrifugal force to develop a pressure rise for
moving a fluid. The Centrifugal pumps will usually be of Horizontal,
Vertical Inline, Vertical Can type. Following are some of the figures
showing various type of pumps.
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5.2
In the following sketches some of the important parts of pumps are marked
like suction/discharge nozzles, bearing housing, seal gland etc.
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5.3
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5.4
Multistage pumps
Pump efficiency deteriorates rapidly as specific speed decreases. The
problem now becomes one of devising a pumping arrangement that offers
good efficiency at acceptable NPSHr. This can be achieved by developing
the required head over more than one stage, thus lowering the head per
stage to maintain the desired specific speed. Generally a multistage pump
is used to develop the required head. Occasionally when service
conditions dictate, individual pumps in series are employed.
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5.5
5.6
Reciprocating pumps
Reciprocating pumps use pistons, plungers, diaphragms or other devices
to displace a given volume of liquid during each stroke of the unit.
Reciprocating pumps create and displace their displacement volumes by
the action of reciprocating element. Plungers, diaphragms etc are single
acting, i.e., each element can discharge in one direction only. Pistons can
be either single or double acting.
By their very nature reciprocating pumps produce pulsating flow. A single
acting ,simplex pump would produce flow for only of each cycle. By
using a multiple number of cylinders to overlap the individual cylinder
flows, the pumps flow pulsation can be reduced. Pl refer sketch number
for reciprocating pump piping
Rotary pumps
If a single service is desired to define rotary pump usage, it is to pump
viscous liquids.
A series of fixed or controlled displacement volumes move continuously
and at essentially constant speed within the pump. Further movement
captures the volume within close clearances and brings it to the discharge
region. Rotary pumps use gears , vanes, screws, cams, etc, in a fixed casing
to produce positive displacement of a liquid.
Following are some of the examples of rotary pumps
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5.7
Selection of pumps
Following chart gives an idea of selection of pumps. One of the most
important factor of selection of pumps is flow regulation. The energy added
by centrifugal pumps varies with through flow, hence their flow regulation is
low. ( flow varies widely with system resistance). In reciprocating and rotary
pumps the energy depends upon system resistance while the mean flow
remains practically constant. Their flow regulation is thus very high. If the
service requires high flow regulation , reciprocating /rotary pump is the
appropriate choice.
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5.1
6
6.1
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6.1.1 Pump location will affect the piping routing and supporting. Pumps
carrying hydrocarbons and materials above 230 degree C shall not be
located below pipe racks, structures, air fin cooers and vessels. Those in
non-flamable service may be located beneath the pipe rack without
obstructing the access bay, other maintenance requirements of the
respective process unit.
6.1.2 Pumps shall be located as close to the source of suction in order to
minimize pressure drop in the system. The line size and temperature will
be the determining factors in piping layout.
6.1.3 A preliminary piping layout ( study layout ) shall be made to determine
the requirement of spacing between pumps especially in case of side
suction/ side discharge, top suction/ top discharge pumps where straight
length requirement / platform / CPS requirement etc have to be
considered.
6.1.4 Reducers in pump suction lines shall be as close as possible to the pump
suction/discharge nozzles.
6.1.5 Eccentric reducers in pump suction lines shall be flat on top in order to
prevent any entrained vapours in the liquid from accumulating in the high
point ( if installed bottom flat ) and thus causing cavitation in the pump.
Pumps in boiler feed water service operating close to vapour pressure of
the liquid are susceptible to this type of problems.
6.1.6 Reducers in pump discharge should be concentric in most cases. Eccentric
reducers may be used in both suction and discharge piping for top suction/
top discharge pumps in order to obtain clearance between suction and
discharge piping.
6.1.7 Consideration must be given to lube oil and seal oil systems and any
cooling water requirements. Care must be exercised not to block access to
the pump seals and bearings when routing these lines.. The pump data
sheet should always be reviewed to make sure these requirements are not
missed. For very large pumps these may be separate on skids.
6.1.8 When developing an equipment layout in pump areas, the layout designer
must envision potential obstructions around the pumps (e.g. large block
valves, steam turbine piping, and tee-type pipe supports from grade). As
per Oil Industry Safety Directorate stipulation ( OISD 118 ) 1mtr (
1000mm ) is the minimum accepted spacing between pumps.
6.1.9 Auxiliary piping shall be neatly routed along the base-plate and shall not
extend across the operating floor. This piping shall not obstruct inspection
covers, bearing caps, upper halves of casings or any other items which
require access for operation or maintenance. In order to avoid a fire
hazard, lubricating oil, control oil and seal oil pipes shall not be routed in
the vicinity of hot process or hot utility pipes .
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6.1.10 Cooling water pipes to pumps and compressors shall not be less than
20NB. Pipes 25NB or less shall have the take-off connection from the
top of the header in order to prevent plugging during operation.
6.1.11 When flexibility loops are required between pumps, it is necessary to
partially run the lines over the pump and driver. Every effort must be
made to minimize maintenance obstructions by running the piping either
outside the area directly over the pumps or at a high enough elevation to
permit the removal of the pump or driver.
6.1.12 The pump shall be placed in such a manner so that the suction nozzle
elevation is always below the vessel/tank nozzle and suction pipe shall be
routed so that there is no pockets.
6.1.13 Pumps in vacuum service present special problems. Since the system
operates at a negative pressure and very high temperature, the pumps must
be located very close to the suction source. This is often directly below the
tower or immediately outside the tower support columns. Pumps located
directly beneath the tower can be mounted on a special spring base.
6.1.14 In some rare cases one pump is installed as a common spare between two
other pumps in different services. The pump must be manifolded in such a
way to accomplish this.
6.1.15 Pumps may be single-stage or multi-stage. Multi stage pumps are usually
side suction side discharge. These pumps require significantly more space
and faces layout problems. There is usually a straight run requirement
(example, 5 pipe diameters) between the suction flange and the first elbow
as shown in Sketch no-7. Due to the heavier casing design for high
pressures, allowable nozzle loads are often higher for multi-stage pumps
making pipe stress problems somewhat easier to resolve.
6.1.16 The location of valves, strainers, spacers/blinds etc. needs special
consideration. The option of placing the valves at a higher elevation and
providing an operating platform has got its own advantages and
disadvantages. If valves are provided at a higher elevation the accessibility
for the pumps is enhanced but the operability of the valves becomes
difficult.
6.1.17 Some of the Pump Piping layouts generally used are represented in the
following pages. It shall be noted that even if the type of pump is same,
different piping layouts may be followed. So it is not always necessary
that same layout shall be followed for same type of pumps, but is
governed by various factors such as temperature, requirement of vertical
strainers etc.
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6.2
6.2.1
Centrifugal Pumps.
Horizontal centrifugal pumps. These types of pumps are the most
commonly used pumps in any industry. Horizontal type pumps are usually
of four types: See paragraph no 5.1
a) End suction top discharge
b) Side suction top discharge
c) Side suction - side discharge
d) Top suction top discharge
Discharge piping shall be taken to grade for making valves accessible and
also for easy supporting.
In general, for this type of pumps platform requirements are not necessary
for both suction and discharge piping.
Care shall be taken while routing discharge line not to block access to
couplings.
Do not route the suction / discharge piping above the prime mover,
otherwise it may create a hindrance while dismantling the prime mover.
Small bore piping ( auxiliary piping ) shall be routed in such a manner that
tripping hazards are avoided. (pls see sketch no. 13)
Some of the examples of end suction top discharge pump piping are
shown in sketches 4,5 & 6.
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SKETCH-2
SKETCH-3
Fixing arrangement of strainer element within a TEE
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6.3
6.3.1
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6.5
6.6
6.7
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7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
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7.8
7.9
7.10
7.11
The Rests, Guides, Line stops etc shall be judiciously chosen so that after
the stress analysis changes are minimized. The addition/relocation of any
pipe support on a later stage can alter the basic civil design.
Since spring support is very frequently used for high temperature piping
provision for the same shall be envisaged during the initial layout itself.
The supports shall be located in such a manner so that it should not be a
hindrance for the removal of pump parts, accessibility near the pumps or
obstruction to personnel movement around the pumps.
Preference for simple supports should be always given over other type of
supports like struts, which are costly, difficult to install and maintain. Use
of a good layout goes a long way in minimizing the use of complex
supports.
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8
8.1
8.2
8.3
8.4
8.5
8.6
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9.1
9.2
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9.3
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