PIPING DESIGN MANUAL

PUMP PIPING (Draft copy)

Revisio Date Description Prepared Checked Approved

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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 manual 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 & STANDARDS

a. API 610 – Centrifugal pumps for petroleum, petrochemical and natural gas industries
b. API 686 – Recommended practice for machinery installation and installation design

4. SAFETY, OPERATION & MAINTENANCE

Personnel safety shall be considered while doing the piping layout/locating valves & strainers to
provide clear access near pumps for operation/ maintenance as well as egress in an emergency.
Care must be exercised not to create tripping hazards with auxiliary piping.
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.
Piping shall be arranged 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.

5. DEFINITIONS

5.1 Net positive suction head (required)

 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 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, 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.

5.2 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.

5.3 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.

5.4 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.

6. 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.
6.1 Centrifugal pumps are the most common. They are more economic in service and require less
maintenance than other types. Rotation of the impeller blades produces a reduction in pressure at
the center of the impeller. This causes liquid to flow onto the impeller from the suction nozzle
thrown outwards along the blades by centrifugal force leaving the blade tips via the pump volute
finally leaving the discharge nozzle, in a smooth, non-pulsating flow. Centrifugal pumps are
available in End suction Top discharge, Side suction Side discharge, Top suction Top discharge
and Side suction Top discharge nozzle configurations.

6.2 Reciprocating pumps are used where a precise amount of liquid is required to be delivered, also
where the delivery pressure required is higher than can be achieved with other types. The liquid
is moved by means of a piston in a cylinder after being drawn into the cylinder, through an inlet
valve, as the piston moves down the cylinder. As the piston moves back up the cylinder the liquid
is discharged at a pre-set pressure controlled by delivery valve. A single acting, simplex pump
would produce flow for only ½ of each cycle. By using a multiple number of cylinders to overlap
the individual cylinder flows, the pumps’ flow pulsation can be reduced. There are three classes
of reciprocating pumps, piston, plunger and diaphragm.
Piston pumps are generally used where medium to high delivery pressures are required, such a
high pressure flushing of vessel interiors, etc. These can be obtained in multi-cylinder form and
can be single or double acting. Plunger pumps are usually used for metering or proportioning.
Diaphragm pumps are invariably air driven and very compact, also there are no seals or packing
exposed to the liquid being pumped which makes them ideal for handling hazardous or toxic
liquids. These are often used for sump pump out.

6.3 Rotary pumps are used to move heavy or very viscous fluids. These employ mechanical means
such as gear, cam and screw, to move the fluid. 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. Gear
pumps are usually employed to pump oils and nonabrasive fluids. Screw pumps are usually used
to pump heavy viscous fluids and nonabrasive sludges.
RECIPROCATING PUMP
 ROTARY PUMPS

Sliding Vane Pump External Gear Pump

Rotary Lobe pump operation

6.4 Selection of Pumps

Following chart gives an idea of selection of pumps. One of the most important factors 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.
7. PUMP PIPING LAYOUT
7.1 General steps involved:
Step 1: Collect the P&ID and the pump data sheet.
Step 2: Study the pump data sheet and collect the similar (capacity / head) pump dimensions /
nozzle position.
Step 3: Analyse the location and the space provided in the unit plot plan w.r.t. suction and
discharge line routing.
Step 4: Review the maintenance / operation space around and lifting facility.
Step 5: Locate the control station, Electrical push button station, Electrical-trench, process fluid
drain, flushing / cooling connection as required for the pump model.
Step 6: Check elevations of all valve handwheels on suction as well as discharge line and
provide common platform for valve operation, if required.
Step 7: Make Iso sketch for suction and discharge line with all the items as per P&ID and
discuss with process engineer for any change.
Step 8: Finalise supports of the line and issue for stress analysis, if required.
Step 9: Get the stress analysis report for Nozzle loads. Compare the allowable loads with the
actual load for any change & finalisation.
Step 10: Finalise location of pump / drain or trench / Electrical cable route and issue civil
information to civil for foundation design.
7.2 Guidelines and considerations:
7.2.1 Pumps carrying hydrocarbons and materials above 230ºC shall not be located below
pipe racks, structures, air fin cooers and vessels. Those in non-flammable service may be
located beneath the pipe rack without obstructing the access bay, other maintenance
requirements of the respective process unit.
7.2.2 Pump shall be located as closed 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.
7.2.3 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/ civil pipe support requirement
etc. must be considered.
7.2.4 The suction pipe should never be smaller than the suction nozzle of the pump and in most
cases, it should be at least one size larger. Eccentric reducers rather than concentric ones must
be used in suction lines with flat side upwards. This is to prevent any entrained vapours in the
liquid from accumulating in the high point.
7.2.5 If an elbow is required at the suction of a double suction pump, it should be in a vertical
position if possible. Where it is necessary for some reason to use a horizontal elbow, it should
be a long radius elbow and there should be a minimum of five diameters of straight pipe
between elbow and the pump suction.
7.2.6 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.
7.2.7 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. Pumps in vaccum service must be located very close to the suction
source.
7.2.8 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.
7.2.9 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.
7.2.10 Some of the pump piping layout 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.

7.3 Horizontal Centrifugal pumps:

7.3.1 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).
7.3.2 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. Strainer shall be located at grade for easy maintenance.
7.3.3 Discharge piping shall be taken to grade for making valves accessible and also for easy
supporting.
7.3.4 In general, for this type of pumps platform requirements are not necessary for both suction
and discharge piping.
7.3.5 Care shall be taken while routing discharge line not to block access to couplings.
7.3.6 Do not route the suction/discharge piping above the prime mover, otherwise it may create a
hindrance while dismantling the prime mover.
7.3.7 Small bore piping (auxiliary piping) shall be routed in such a manner that tripping hazards are
avoided.
7.3.8 Top suction- top discharge pumps
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.
7.3.9 Platform structure shall be designed in such a manner that it will take care of pipe supports
also if required.
7.3.10 Inter-distance between pumps may be more due to the requirement of civil pipe support
and/or platform.
7.3.11 Discharge line can be taken to grade for keeping the check valve/ isolation valve in accessible
location and for providing simple supports like trunnion (dummy leg) supports.
7.3.12 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.
7.3.13 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.
7.3.14 Valves and strainer can be place at accessible location and hence platforms are not required.
7.3.15 Access to coupling shall not be blocked while routing discharge piping so that maintenance
requirements are not hampered. A preliminary piping layout study shall be prepared before
finalizing pump spacing.
7.4 Vertical Centrifugal pumps:
7.4.1 Vertical Centrifugal Pumps may be inline, can or sump pumps. Inline pumps are mounted n
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. In-line 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.
7.4.2 Vertical can type pumps are installed in a concrete cylinder but the process fluid is
completely contained in the pump can. They are used where 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.
7.4.3 Vertical sump pumps are usually to pump waste products or water from a collection sump/pit.
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.

7.5 Reciprocating pumps piping:

7.5.1 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 vale. The PRV
can be external, in the piping, or built-in integrally with the pump casing.
7.5.2 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 a 90º elbow directly adjacent to
the pump discharge. The discharge pulsation dampener must be installed as closed to the
discharge as possible.

7.6 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.
COOLING TOWER PUMP PIPING
8. PUMP PIPING SUPPORTS
8.1 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 ensure that information to Civil
department regarding civil pipe supports shall be forwarded in advance.
8.2 Supports shall be designed strictly according to the restraint conditions in the piping flexibility
analysis.
8.3 First support from pump nozzle shall be adjustable type so that piping can be adjusted with the
nozzle concerned while aligning.
8.4 Trouble free supports which are simple, easy to manufacture and install shall be used.
8.5 Discharge piping shall be taken to grade or shall be supported from overhead structure. The
breakup flanges shall be provided in the first spool from discharge nozzle. This allows piping at
the pump to be removed for maintenance.
8.6 The rests, guides and line stops shall be judiciously chosen to minimize changes post stress
analysis.
8.7 Since spring supports are very frequently used for high temperature piping provision for the same
shall be envisaged during the initial layout itself.
8.8 The supports shall be 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.
8.9 Preference for simple supports should be always given over other types of supports like struts,
which are costly, difficult to install and maintain. A planned layout goes a long way in
minimizing the use of complex supports.

9. AUXILIARY PIPING FOR PUMPS

The auxiliary piping is usually cooling water to mechanical seals, bearings, stuffing boxes etc.
When pump fluid is used, a line is attached to the vent connection on the pump case. The
circulated seal fluid must be sent back to pump stream or referred through the seal to pump
internal clearances.
In viscous or high temperature hydrocarbon liquids, the seal fluid medium circulates from
external source through connections on the pump seal.