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Reliance Engineering Associates Private Limited

PIPING DESIGN GUIDE

P-EP-PL-041-0A

Piping Design Pumps

REV

DATE

ISSUED AS STANDARD

KS

MGC

MGC

REVISION

BY

CHKD

APPR

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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.

Codes and Standards


a) P-GS-PL-003
b) P-SS-PL-015

Piping Design & Plant Layout.


Specification for Piping Stress Analysis

c) P-SS-PL-019
d) P-EP-PL-065
e) API-610

Pipe support standards.


Small bore Piping design Guide.
Centrifugal Pumps for Petroleum ,
Heavy Duty Chemical and Gas
Industry Services

f) ASME B73.2

Vertical inline pumps for chemical process


service
Horizontal end suction pumps for chemical
process service

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

Allowable Nozzle Loading


The allowable nozzle loading is the maximum amount of stress that the
pump suction and discharge nozzles can withstand, as set by the vendor,
client, or code .The discharge and suction piping cause considerable
stress on the pump nozzles which shall be brought within the allowable
nozzle loading by proper layout.

4.5

Net positive suction head ( NPSH )


The total absolute suction head , in meters ( feet ) of liquid ,determined at
the suction nozzle and referred to the datum elevation, minus the vapour
pressure of the liquid, in meters ( feet ) absolute. The datum elevation is

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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

Net Positive Suction Head ( available )


The available NPSH is the net pressure available in a given system based
on vessel pressure and static head, minus the liquid vapor pressure and the
functional losses in the system. The goal is to maintain equipment heights
and minimize pump suction piping lengths, and bends to ensure that the
available NPSH is greater than the required NPSH. Insufficient NPSH can
reduce pump capacity and efficiency and lead to cavitation

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

API 610 (American Petroleum Institute)


This standard is based on the accumulated knowledge and experience of
manufactures and users of centrifugal pumps. The objective of this
standard is to provide a purchase specification to facilitate the
manufacture and procurement of centrifugal pumps for use in petroleum,
chemical, and gas industry services.

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4.10

AVS(American Voluntary Standard) Pumps


This standard, issued by the hydraulic institute, outlines several pumps
with standard dimensions. They are interchangeable for a given size,
regardless of who builds the pump, with no effect on foundation , piping
design, or type of electric motor used.

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.

End suction Top discharge pump

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Top suction Top discharge pump

Side suction Top discharge pump

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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

A typical centrifugal pump performance characteristic is shown below. Total


head , power absorbed are plotted against flow. These are the working
characteristics of the pump. Pump efficiency derived from flow, total head and
power is also plotted against flow to locate the best efficiency point ( BEP ) and
indicate the pumps most effective operating range.

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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

Pump piping layout


General guidelines
Following sketch (sketch-1) shows a portion of a typical plot plan with
few Equipments, pipe rack etc shown. For equipment spacing pl refer ,
plant layout and piping specification number P-GS-PL-003, GE Gap
guidelines, and/or OISD 118.

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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

In this section of the document different types of piping layouts to suit


various horizontal centrifugal pumps are being described.
6.2.2 End suction - top discharge pumps
Valve hand wheel shall be oriented in such a manner that clear access to
the valves and pump is ensured. The suction line valve shall be installed
with the stem in the horizontal position, (i.e. install valve in the vertical
run of pipe wherever possible).
6.2.3 Special attention must be given to the suction strainer to allow removal for
cleaning. The drain connection from the strainer assembly shall have a
break flange immediately after the isolation valve and the drain line shall
be routed in such a way that the strainer can be removed with ease for
maintenance. Sketch no 2& 3 shows an example of suction strainer
installation. Strainers shall be located at grade for easy maintenance.
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.2.9

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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6.2.10 Top suction top discharge pumps


6.2.11 To meet straight length requirements, suction valve and strainer need to be
placed at a higher elevation and hence requirements of platform shall also
be considered for operation/ maintenance purpose. Platform structure shall
not interfere with accessibility / maintainability of pumps.
6.2.12 Platform structure shall be designed in such a manner that it will take
care of pipe supports also if required.
6.2.13 Inter distance between pumps may be more due to the requirement of
CPSs and/or platform.
6.2.14 Discharge line can be taken to grade for keeping the check valve/ isolation
valve in accessible location and also for providing simple supports like
trunnion supports etc.
6.2.15 Preliminary piping study layout shall be prepared before finalizing the
pump spacing to arrive at an optimum spacing between pumps
considering requirement of pipe support structure etc.
6.2.16 Following is an example(sketch no.- 7 ) of top suction top discharge
pump piping

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6.2.17 Side suction side discharge pumps.


Spacing between pumps shall be more due to straight length requirements.
This shall be confirmed with the manufacturer. Normally 5 times the
diameter of suction pipe size is followed.
6.2.18 Valves and strainer can be placed at accessible location and hence
platforms are not required.
6.2.19 Access to coupling shall not be blocked while routing discharge piping so
that maintenance requirements are not hampered.
6.2.20 A preliminary piping layout shall be prepared before finalizing pump
spacing.
6.2.21 Following are some of the examples (sketch no.8& 9 ) of side suction
side discharge pumps.

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6.3
6.3.1

Vertical centrifugal pump piping.


Vertical Centrifugal Pumps may be inline, can (self-contained) or sump
pumps. Inline pumps are mounted in the line and supported by the piping.
A pedestal is often required for larger in line pumps or where the load is
too high for the nozzles to handle. Inline pumps help solve many stress
problems usually encountered in hard mounted pumps. The designer must
consider access for maintenance and operation in the same way as for
horizontal pumps.
6.3.2
Vertical can type pumps are installed in a concrete cylinder but the
process fluid is completely contained in the pump can. They are used
when there is a high NPSH requirement or at surface condensers servicing
large steam turbine driven compressors. This allows the compressor
/driver and its associated surface condenser to be mounted at a lower
elevation. The same is true for a vessel connected to a vertical can pump.
The primary concern for the designer is to provide adequate overhead
clearance to remove the pump for maintenance. Allowable nozzle loads
for vertical can type pumps are usually higher than for equivalent
horizontal centrifugal pumps.
6.3.3 Vertical sump pumps are usually to pump waste products or water from a
collection sump/pit. The primary concern is to provide adequate overhead
clearance to remove the pump for maintenance.
6.3.4
Some examples of vertical inline/sump pumps piping are included in
(sketch no 10 & 11) for better understanding.
6.4.

Reciprocating pumps piping


Reciprocating pumps are used when high head is required. These pumps
require a pressure relief valve (PRV) to be installed between the pump and
the discharge block valve. The PRV can be external, in the piping, or
built-in integrally with the pump casing. Due to the pulsating action of the
reciprocating pumps, the designer must consider space requirements for
pulsation dampeners. These are usually furnished with the pump but take
up additional more maintenance than other pumps. Do not install any bend
(i.e. 90 degree elbow) directly adjacent to the pump discharge. The
discharge pulsation dampener must be installed as close to the discharge
as possible. Pl refers (sketch no.12 for typical reciprocating pump piping.

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6.5

Rotary pump piping


Rotary pumps are required for very heavy or viscous fluids, They deliver a
constant pulsation-free flow. Piping for these pumps are very similar to
that of centrifugal pumps but is characterised by the absence of block
valves in the suction and discharge piping. If block valves are used, a
pressure relief valve must be installed between the pump discharge and
the block valve. The PRV discharge is usually routed back to the pump
suction.

6.6

Cooling tower pump piping.


A typical layout is attached in sketch no. 13 for cooling tower pump
piping. It is to be noted that the arrangement of pumps are slightly
different from that of a layout within unit areas.
Tank farm piping.
A typical layout is attached in sketch no. 14A & 14B for tank farm pump
piping. In the attached sketch top suction- top discharge pump is shown,
but other type of pumps also can be used , for e.g. end suction/side suction
pumps.

6.7

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7
7.1

7.2
7.3
7.4
7.5

7.6

7.7

Pump piping supports.


At the time of piping layout, the type of support, support locations,
configuration of support, constructability etc shall be taken care by
layout engineer and also ensure that information to Civil Dept. regarding
CPSs shall be forwarded in advance.
Supports shall be designed strictly according to the restraint
conditions in the piping flexibility analysis.
First support from pump nozzle shall be adjustable type so that
piping can be adjusted with the nozzle concerned while aligning .
Trouble free supports which are simple, easy to manufacture and
install shall be used .
Some of the examples of commonly used pipe supports
including shoe support, guide, line stop etc. are attached in sketch
no.15A & 15B
Discharge piping shall be taken to grade or shall be supported from
overhead structure. It shall be noted that break flange shall be provided in
the first spool from discharge nozzle. This allows piping at the pump to be
removed for maintenance.
When differential settlement is a problem, the pump suction piping shall
be supported from the pump foundation. This can be accomplished by
extending the foundation as shown below.

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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

Auxiliary piping for pumps.


Auxiliary piping include pump vent lines, drain lines, seal flush lines,
cooling water lines etc.
Cooling water is required for cooling mechanical seals, bearings, stuffing
boxes etc. Various flushing and cooling schemes are available to combat
various environments that are hostile to the mechanical seal face integrity.
A mechanical seal has a rotating face and a stationary face. Numerous
means such as bellows, wedges, and O- rings are used to seal the rotating
face ( seal head ) against the shaft sleeve.
In all cases of auxiliary pump piping , the plant layout engineer must
carefully review the vendor drawings and P&IDs to ensure that all
requirements of cooling have been covered.
Some of the seal flush plans (as per API 610) and mechanical seal
arrangement are shown below.
Sketch no 17A & 17B shows the General arrangement of of an end suction
pump showing all nozzles including auxiliary nozzles and seal pot
arrangement and seal flush plan.

RECIRCULATION IS FROM A PUMPING RING IN THE SEAL CHAMBER THROUGH A COOLER


AND BACK TO THE SEAL CHAMBER.THIS PLAN CAN BE USED ON HOT APPLICATION TO
MINIMIZE HEAT LOAD ON THE COOLER BY COOLING ONLY THE SMALL AMOUNT OF LIQUID
THAT IS RECIRCULATED (DIAL THERMOMETER (TI) IS OPTIONAL)

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USES AN EXTERNAL RESERVOIR TO PROVIDE BUFFER FLUID FOR OUTER SEAL OF AN


UNPRESSURIZED
ARRENGEMENT.DURING
NORMAL
OPERATION
CIRCULATION
IS
MAINTAINED BY INTERNAL PUMPING RING.THE RESERVOIR IS USUALLY CONTINUOUSLY
VENTED TO A VAPOUR RECOVER SYSTEM AND IS MAINTAINED AT A PRESSURE LESS THAN
THE PRESSURE IN THE SEAL CHAMBER (PRESSURE SWITCH AND HEAT EXCHANGER ARE
OPTIONAL)

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9.1

9.2

Stress analysis for rotating equipments ( pumps )

External loads imposed by piping on nozzles of rotary equipments shall be


less than the specified allowable loads. Examples of rotary equipments are
centrifugal pumps, turbines, compressors. If excessive loads are imposed
misalignment may result that affects mechanical operation and can cause
excessive vibration. A close alignment between rotary and static parts
shall be maintained. The provision for expansion of casing and
maintaining close clearances requires that the force and moments due to
piping are limited. Deformation of casing also may happen due to
excessive nozzle loads.
Piping connected to centrifugal pumps
Considering the coordinate system used as per API 610 , for horizontal
pumps, the pump shaft is parallel to X axis, Z - axis is in the vertical
direction and Y axis in the transverse direction.Pl see the attached
sketches. Allowable forces and moments shall be twice the values as
given in the following table as per Jamnagar spec.

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9.3

General philosophy to be followed while carrying out the analysis for


pumps
For stress analysis ref. Procedure no.(P-EP-PL-118-00)

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