PUMPS

&
PUMP PIPING
By,

Sandeep More
Associate Engineer
Piping Department

Date 4th Dec 2006

Contents

 Pump

- Introduction to Pumps
- Classification of Pump
- Industry Codes & Standards
- Selection Criteria for Pumps
- NPSH & Cavitation
- Definitions

 Pump Piping

 Suction piping for horizontal pumps

 Discharge piping for horizontal pumps
 Arrangements of piping for pump handling hot suctions.
 Side suction & side discharge pump
 Vertical In line pumps
 Vertical pump (Wet Well pump)
 Vertical Barrel type or Cane pump
 Multi Service pump
 Reciprocating pump Piping
 Metering Pump
 Pumps in the Tankage Area
 Auxiliary pump piping arrangement
 Pipe vent & drain System
 Pump Location & Arrangement
 Pump Surrounding Support
Intoduction To Pump :

Definition :

Pump is a mechanical device used to add kinetic and potential energy

to a liquid for the purpose of moving it from one point to another. This energy
will cause the liquid to do work such as flow through a pipe or rise to a higher
level and Pump gives pressure to fluid passing through it and discharges the
fluid to the outside.

Classification Of Pump :

Pumps are classified on the basis of :-

• The applications they serve,
• The liquids they handle,
• Orientation & Construction
• No. of stages, No. of casings, Type of couplings (Rigid , Flexible)

1) Dynamic
2) Displacement
 Dynamic Pumps : Displacement Pump :

In which energy is continuously added to In which energy is periodically added by

increase the fluid velocities within the application of force to one or more movable
machine to values greater than those boundaries of any desired number of enclosed,
occurring at the discharge such that fluid-containing volumes, resulting in a direct
subsequent velocity reduction within or increase in pressure up to the value required to
beyond the pump produces a pressure move the fluid through valves or ports into the
increase discharge line
Other Classification :

     1) Classification by suction type :

 
            - Single suction type
            - Double suction type (for big volume pump)
 
                      
    2) Classification by the pump installation method :
 
            - Vertical pump type
            - Horizontal pump type
Classification by structure and operation method :
 

 
 
Classification
  Classification
Type Specifics
by structure
  by operation method
 
 
 
 
 
  This type of pump sucks in fluid through
  reciprocating movement of piston or
- Piston pump
Reciprocating
  plunger, and discharges fluid by pressing
- Plunger pump
pump   with required amount of pressure. It is
- Diaphragm pump
  used when high pressure is required even
  though the amount of discharge is small.
Positive  
displacement  
pump  
 
 
 
 
This type of pump sucks in fluid  through
  - Gear pump
Rotary the rotation movement of rotor, and has
  - Screw pump
pump the advantage of little pulsation due to
  - Vane pump
the special characteristics in operation.
 
 
 
 
 
 
 
 
 - Radial flow This type of pump transfers energy to fluid
- Volute pump through centrifugal force by impeller
- Mixed flow rotation or through the changes of size and
Centrifugal pump
   pump direction  of section area of passage, and
- Axial flow converts velocity energy pressure energy in
   pump volute chamber or diffuser.

Kinetic pump

- Jet pump
This type of pump has a efficiency and is not
Special pump - Gas lift pump
used except for a special purpose.
- Wesco pump
Centrifugal Pump :

A centrifugal pump transforms mechanical energy from a rotating impeller into a

kinetic and potential energy required by the system.

Horizontal Centrifugal Pump Centrifugal Pump

Reciprocating pumps :

• These are commonly used to move viscous liquids, inject chemicals or additives
into a system.

• Reciprocating pumps are used where a precise amount of liquid is required to be

a delivered, also where the delivery pressure required is higher than can be
achieved with other types.

Reciprocating Piston Type Pump Horizontal & Vertical Reciprocating pump

Rotary Pump :

Rotary pumps are used to move heavy or very viscous fluids such as
grease, asphalt, heavy fuel oil and sometimes heavy crude oils.

Gear Pump Screw Pump

 Industry Codes and Standards : Ref : GEMS P-G-2
American Petroleum Institute (API)

1. 610, “Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry Services”.

2. 674, “Positive Displacement Pumps - Reciprocating”.

3. 675, “Positive Displacement Pumps - Controlled Volume”.

4. 676,“Positive Displacement Pumps (Rotary)

5. 677. “General Purpose Gear Units for Refinery Service”.

6. 681, “Liquid Ring Vacuum Pumps”

7. 682, “Shaft Sealing Systems for Centrifugal and Rotary Pumps”.

American Society of Mechanical Engineers (ASME)

1. B73.1M, “Horizontal End Suction Centrifugal Pumps for Chemical Process”.

2. B73.2M, “Vertical In-Line Centrifugal Pumps for Chemical Process”

3. Process Industry Practices (PIP)

1. RESP73H-97, “Specification for Horizontal End Suction Centrifugal Pumps”.

2. RESP73V-97, “Specification for Vertical Centrifugal Pumps”.

Selection Criteria For Centrifugal, Reciprocating, And Rotary Pumps
Definitions
1. Casing, Axially Split – Pump case split parallel to pump shaft.

2. Casing, Radially Split – Pump case split transverse to pump shaft axis.

3. Diffuser –
Pump design in which the impeller is surrounded by diffuser vanes where the gradually enlarging passa
ges change liquid velocity head into pressure head.

4. Double Acting – Liquid is discharged during both forward and return strokes of the piston.

5. Duplex – Pump with two plungers or pistons.

6. Head, Acceleration – Pressure change due to changes in velocity in the piping system.

8. Impeller – Bladed member of rotating assembly of a centrifugal pump which imparts force to liquid.

9. Net Positive Suction Head (NPSH) –

Total suction head in meters (feet) of liquid absolute determined at suction nozzle and referred to da
tum elevation, minus the vapor pressure of liquid in meters (feet) absolute. The datum elevation is the
shaft centerline for horizontal pumps, the suction nozzle centerline for vertical in-line pumps, and the
top of the foundation for other vertical pumps.

10. Net Positive Suction Head Available (NPSHA) –

NPSH in meters (feet) of liquid determined by Purchaser for the pumping system with the liquid at
rated flow and
normal pumping temperature.
11. Net Positive Suction Head Required (NPSHR) –
NPSH in meters (feet) determined by Supplier testing, usually with water. NPSHR is measure
d at the suction flange and corrected to the datum elevation. NPSHR is the minimum NPSH at rate
d capacity required to prevent a head drop of more than 3% (first stage head in multistage pumps)
due to cavitation within pump.

12. Recirculation –
Controlling the quantity of flow through a pump by bypassing discharge liquid back to suction.

14. Simplex – Pump with one plunger or piston.

15. Single Acting – Liquid is discharged only during forward stroke of the piston.

16. Throttling – Controlling flow rate by reducing cross-sectional flow area, usually by partially closin
g a valve in the
discharge piping.

17. Total Differential Head (TDH) – Pressure required in meters (feet) of head that the pump must p
roduce. The
head at the discharge pump flange minus the head at suction flange.

18. Triplex - Pump with three plungers or pistons.

NET POSITIVE SUCTION HEAD (NPSH)

•            
The net positive suction head (NPSH) is the absolute pressure in excess of the liquid
vapor
• The difference between NPSHa and NPSHr is less than 0.3 ∼ 1.0m at the tim
e ofpressure that is available at the pump suction nozzle to move the liquid into the eye
ofchecking
the impeller.
vendor data sheet [ that is, NPSHa­ NPSHr 〈   (0.3 ∼ 1m)],
decision on NPSH test shall be made according to Engineering Specification S
ES-
GA-201E and API 610.

• Pumps where difference between NPSHA and NPSHR is less than 0.6 meter a
re
not acceptable.

• The diameter of the pump suction port is usually bigger than the discharge or e
xit
diameter in order to minimize the kinetic energy head entering the pump, beca
use
this kinetic energy decreases the maximum suction lift and enhances cavitation
.
《  Pump Differential Head 》
                                            10
                     H 〓  (Po­ Ps) × ────
                                          Sp.Gr
                      Where,   H  : Head (m)
                              Ps : Pump suction pressure   ( ㎏ / ㎠ )
                              Po : Pump discharge pressure ( ㎏ / ㎠ )
                           Sp.Gr : Specific gravity at pumping temperature
《  NPSH Required 》
 
                     NPSHr 〓  σ× H
 
                     Where,   H  : Pump differential head
                              σ : Cavitation coefficient of Thoma

《  NPSH Available 》
 
                                                10
                     NPSHa 〓  (P1 ­ P2) ×  ─── ­ △P ＋  H
                                               Sp.Gr
 
                     Where,   P1 : Pressure at suction liquid level      ( ㎏ / ㎠ ) 
                              P2 : Vapor pressure at suction temperature ( ㎏ / ㎠ ) 
                             △P : Pressure drop in suction line         ( ㎏ / ㎠ ) 
                               H : Height between the normal liquid level and pump centerline (
m)
 CAVITATION

• Definition: Knocking due to formation and subsequent collapse of vapor bubble

s. (Indication: Noise)

• Cavitation is caused by the formation of vapor bubbles in a high-velocity, low-

pressure
region and by the subsequent collapse when the bubbles move to a higher press
ure region.

• Cavitation can cause excessive erosion and vibration.

• With moderate cavitation in a centrifugal pump, the pump will sound as though
it is
pumping gravel or a slurry of sand and gravel.

• Severe cavitation will cause the discharge pressure to fall and become highly erra
tic and
produce both flow and pressure pulsation.
Cavitation occures due to :

• Pump cavitation can result from insufficient available NPSH

• High pump-suction velocities and long piping increase pressure fluctuation

s in the
pump.

• Vacuum systems seem more prone to unpredictable cavitation than pressur

e systems.

Methods to avoid Cavitaion:

NPSHa (P(suction) - P(saturation) >= NPSHr

Increase NPSHa by
- Increase pressure at suction of pump
- Decrease liquid temperature
- Reduce head losses
- Reduce NPSHr (Depends on Impeller inlet, Impeller desig
n, Pump flow rate, impeller speed, type of liquid)
PUMP PIPING
Suction Piping for Horizontal Pumps :-

Line Size :

Suction piping is one or two line sizes larger than the pump suction nozzle size.

Flexibility of Suction Lines :

• Piping flexibility affects pump location.

• Pump suction lines should be as short as possible, but with enough flexibility.

• If possible , do not overlap the pump and pipe support foundations, as it causes
structural design problems in combining foundations.
Suction Line Fittings :

• Reducers should be as close as possible to the pump suction nozzle so that

pump suction will not starved.

• Use Eccentric reducer with Flat Surface up. (FSU)

• Always use long radius elbow.

Air pocket formed along upper side of pipe by concentric

reducer.
 Strainers :-
                    

• Strainers will be located between pump suction block valve and pump.
        
         
Type of strainer

1) Temporary strainer

        2) Permanent strainer   

Conical strainers are longer than the basket
type. These are used on suction lines 2” and l
arger.

For basket and conical types a removable

spool piece must be provided downstream of
suction block valve

Flat strainers use with very

short suction lines where no
debris is expected
Bathtub or tee type strainers as most
expensive , it does not require unbolting and
removing spool piece to remove the strainer.

Y- type strainer to permit servicing of the

strainer. Also, a blow-off connection may be
provided in the end cap to flush the strainer.
Block Valve :-

• Suction line should have positive shut off valve, use gate valve at the Up
stream
of strainer.
• Pump valves are operating valves, thus keep them as low as possible
 
 
 
 
 
 
Consideration of Cavitation
 
 
 
 
 
 Cavitation occurs when NPSHr is larger than NPSHa.  Cavitation reduces the
 
  performance of pump, causes vibration or noise and corrodes the materials.
Therefore, minimize pressure loss on pump piping and, care shall be taken to
avoid drifting on the nozzle.

  Minimum required straight pipe on suction nozzle to prevent drifting

Required straight         

Suction type Remarks
pipe on suction

End suction 2D ∼ 3D See figure 1.

Single suction 2D and over

Side See figure
suction 10D and over or insertion of 2-1 and 2-2.
Double suction
rectifying plate

Single suction 2D and over

Top
See figure 3.
suction
Double suction 10D and over

D- Suction Nozzle Size

 
 
 
 
  Consideration of st
 
 
raight pipe at sucti
  on side is not nece
 
  ssary for straight-
 
 
up or straight dow
  n.

Figure 1.  End suction piping Figure 2-1.  Side suction piping

Or inserts rectifying plate

(eccentric suction : 2D and over)

Figure 2-2.  Side suction piping

 Single Single suction
: 2D and over
 
Double suction
: 10D and over

Figure 3.  Top suction piping

 Consideration of air pocket on suction line
 
  1) Allow approximately 1/20∼1/50 of slope on suction line toward suction resource
       if suction resource is lower than pump suction nozzle.  
                    

2) Allow 1/20 and over of slope on suction line toward pump at vacuum tower.
                          
 
 
 

 
  1/20 and over
 
 
3  ) If gate valve is to be installed on the line whose suction resource is located lower than the pump
suction nozzle, valve stem shall be horizontal.

 
                             
 
 
 
 
 
             
 
 

               
 
               

 
 
 
 
Suction piping on tower or vessel :
 
 
   
 
                         Vortex breaker is installed on tower or vessel nozzle connected to pump
nozzle.
                        
 
Typical Arrangement Drawing
 1. PUMP SUCTION LINE
  
 Horizontal Vertical
Following diagrams indicate correct and incorrect methods of attaching suction piping.

Shows proper method of connecting pump suction to a

suction header in order to avoid air pockets.

A) Horizontal ell directly into pump suction results in an unbalanced

thrust on pump bearings.
(B) Use spool piece 3 pipe diameters long or long radius ell with
center vertical vane.
(C) May be installed with or without spool piece but 2 pipe diameters
spool is preferred.
- Flexibility of pipe for pump alignment after piping

Represents a common error made suction piping to a centrifugal

pump by placing piping over an embankment of a reservoir, or
other obstruction.
Discharge Piping for Horizontal Pumps :-

• Line Size :
Discharge nozzle size is normally smaller than the suction nozzle size.

• Discharge Line Fittings :

• Normally we use concentric reducers in the discharge.

• But if a clearance problem comes up between the suction and discharge piping ,
then we use o eccentric reducer

• A pressure gauge is located in the discharge line, and should be upstream of the check
and gate valves
• Check Valve is used in a pump discharge line to prevent backflow in to the pump
causing the impeller to turn backwards and possible ruining the bearings.

• Block valve Isolate the pump from piping to provide maximum access for both in
place for maintenance or removal.
 Pump Discharge Line

   1) 1 1/2 NB and Under

2)  2 NB and Larger

Use Swing / Ball Type Check valve Use Hinged flapper Check valve
3) 4)

5)

For Higher line size 8” and above

Handling Hot suctions :

When header going to the two pump

is at same elevation as suction nozzle.

These are used for very hot larger piping

If vessel suction nozzle is higher

 Side Suction And Side Discharge Pump (For utility& Water Lines)
 These are used for large duty differential pressure and large bore lines, the pressure
difference between the pump suction and discharge , and are usually multi-stage
pumps, the liquid going through several stages of increasing the pressure before
reaching the side discharge nozzle. No of ells should be optimize allowable nozzle
loading.

 The two-diameter pup can be eliminated if the elbow from the suction nozzle is
horizontal.

This pump is horizontal split case .

The top case can be removed for maintenance on
this type of pump .
keep the top of the pump clear.
Vertical In-Line Pumps : ( Hydrocarbon Services)

The main advantage of this type of pump is to

• Eliminate many stress problems

• Location when there is no foundation required

• This type of pump is mounted directly into the pipe line. For smaller sizes, the piping
system supports the pump and motor.

• For heavy or Larger size in-line pumps foundation will be required

Vertical Barrel Type or Can pump ( Dry well Pump ) : ( CBD Tank )

• This type of pump is installed in cooling tower water circulating service, retention
ponds and suction is taken from a sump below grade.

• In most cases, there is no suction piping to be considered, but the discharge line must
be
routed to ensure good access for pump maintenance
Multi - Service Pumps :-

• Pumps can be used for more than one service, such as pulling suction from one
source and discharging to three different locations or multi-service suction,
which
using a pump for more than one service.

Multi – Service
Pumps
Reciprocating Pump Piping :

• These lines should run close to the ground so that hold-downs can be used.

• Suction and discharge piping to positive displacement reciprocating pumps shall

contain hold down restraints on piping to minimize the potential of pulsation
loading on pump nozzles should pulsation dampeners become inoperative.

• To minimize the damaging effects of water hammer and other impulse type loading
on pump nozzles, Use swing type check valves in discharge lines in the
vertical position above rigidly supported elbows so that hammer loads may
be distributed to grade or steel.

Reciprocating Pump Piping

Metering Pump :

• These pumps measured accurate flow rates that can be adjusted in operation to
The
me provide a wide range of varying flow rates.

• Metering system is to control liquid discharge under a variety of back pressure

conditions according to precise volumetric requirements.

• Since metering pumps permit little or no backflow, they are especially useful for
injecting liquids into containers or flow lines against high pressures.

Reciprocating Metering Pump

Installation of Dampers and Back Pressure Valve
Pulsation Damper :

The damper contains a diaphragm or bellows isolating the metered liquid from
an air or gas padded chamber. its use eliminates hydraulic hammer, established more
favorable NPSH conditions on the inlet side of the pump, and allows use of smaller pipe
size by reducing peak liquid velocity and acceleration.
Pumps in the Tankage Area :
For location of pumps in the tank farm area:

1. Group together if economical

2. Make accessible for maintenance and operation
3. Locate outside of dyke area

In the routing of the suction lines, the preferred method would be to drop from
the tank to the pumps. Avoid a direct run from the tank into the suction nozzle. This can
cause problems in overstress of the pump connection.

Support of Piping In the tankage area, the supporting of piping is normally by:

• Pipe sleepers
• Field supports
Auxiliary Pump Piping Arrangement :
 Many pumps have auxiliary piping that is supplied by the vendor or the engineering
contractor .

 When pump fluid is used a line is attached to the vent connection on the pump case.

 The circulated fluid must be sent back to the pump stream and return to the seal to
pump internal clearances.

 In viscous or high temperature hydrocarbon liquids the seal fluid medium circulates
from an external source through connections on the pump seal . This medium may
be clean gas or oil .

 In fig the cooling water in and out of this particular pump is from above grade ,
however many cooling water systems are below grade so the piping layout designer
must find suitable location for this connection.
Auxiliary Pump Piping
Pipe Vent And Drain System :

• Are provide to escape air or vapour trapped in the casing.

Seal Flushing
PIPE VENT AND DRAIN SYSTEM FOR PUMP:
Pump Location & Arrangement :

 Install on the place where access is easy during the operation.

 Sufficient space shall be provided at and around pumps to enable maintenance and
removal of all internal and external parts.

 The minimum walkway clearance around pumps will be 2'-6”.

 The pump should be located as close as possible to the source of suction. The main
reason for this is to minimize pressure drop. This keeps line sizes and equipment
elevations to a minimum.

 Minimum clearance of 3'-0" is required between pumps, adjacent equipment,

foundation or other obstructions.

 Pumps should be located inboard of overhead pipe rack as much as possible in

order to save the required plant area.
 For maintenance of the pumps located under the pipe racks or steel structures,
maintenance beam or hook shall be planned upward of the pump unless;
(1) Access way of maintenance vehicle is provided under the pipe rack.
(2) Access of automobile crane is possible.

 Maintenance space 1000 mm required around pump and without major

disassembly.

 Pumps shall generally be lined up in parallel with the pipe rack to maintain a
uniformity of location.

 Pump discharge points to be fixed in a line below pipe rack and to be about 500
mm away from pipe rack bay.

 In hydrocarbon or other flammable fluid service, threaded construction shall not be

used for piping connected to pump, including branch piping within 6 feet of pump
suction or discharge flanges or through suction or discharge block valves, which
ever is greater. Socket weld unions are acceptable.
Pump Spacing & Height of Pump foundation
 Pump Spacing :-

Suction pipe size (B) Up to 2 2-5 6 - 10 12 - 14 16 - 18

1500 2000 2500 3000 4000
Pump spacing (mm)

 Height of pump foundation :-

  Height of pump foundation shall be 100∼300mm from ground level or floor
level if it is on the paving or inside of building. But it shall be 300 ∼500mm for the
area where flood is expected.

Others :
1) By-pass line which is installed on pump discharge line shall be routed without
     pocket.                                     
 2) Avoid installation of chemical or water supply line near the suction nozzle of
reservoir so that air shall not be sucked in.         
 Pump Surroundings Support :-  
 
  Support regarding of eccentricity of pump :
        (1) Support shall be installed so that pipe and valve may not load on the pump
nozzle.

(*) Support nozzle surroundings. (But, do not exceed 1m.)

(2) Suction line and discharge line shall be supported respectively.

(3) If support is installed right close to suction or discharge nozzle, it shall be minutely
adjustable type so that centering can be convenient.

(4) A support installed around suction or discharge nozzle shall be such a type that piping
         can be removed and pump can be dismantled easily.
 
Un-necessary support with respect to         
the load on pump nozzle  :-

Although support would not seem to be necessary with respect to the load on pump
nozzle, indicate it on the drawing considering the temporary support of piping during
the time of pump maintenance.  
Thank you