Chapter (10 )

PUMP PIPING
Introduction
• There are many factors that affect the
operation of a pump.
• Important factors are total head, speed,
liquid properties, and physical
arrangement/system connection.
• Included in the category of arrangement
and connection are the suction conditions.
• Excessive suction lift, shallow inlet
submergence, or insufficient Net Positive
Suction Head available (NPSHA), all
spell serious trouble from vibration,
cavitation, lowered capacity, and reduced
efficiency.
• While the Engineer may not have large
control over some of the inherent process
factors, with planning and foresight many
times the pump suction conditions can
be optimized in the design stage.

• This course offers ideas and summarizes

generally accepted guidelines of
practical consideration in pump
suction arrangements.
 Piping
• Pumps are not
constructed as pipe
anchors.
• Make sure that the
piping to the pumps is
in exact alignment with
the pump flanges and
imposes no
uncontrolled stress on
the pump unit.
• General
• 1.Both suction and discharge pipe must be
supported independently from the pump unit.
• 2.Allowable forces and moments according to
standards must be considered.
• 3.No uncontrolled forces must occur when
handling hot liquids.
• 4.Connections must be provided for draining and
flushing the pump before disassembling. Consider
possible problems when draining jacketed pumps.
• 5.Flange gaskets must be resistant to the pumped
liquid.
A few things you should know
about your pump's piping
system
• 1- There should be at least 10 diameters of
pipe between the suction of the pump and
the first elbow.
• This is especially critical in double-ended
pump designs as the turbulent inlet flow can
cause shaft thrusting, and subsequent bearing
problems.
• If an elbow must be installed be sure it is in a
plane at right angles to the pump shaft to
prevent an uneven flow to both sides of a
double suction impeller.
• 2- Pipe from the pump suction flange to
the pipe rack, not the other way around.
• 3- Make sure eccentric reducers are not
installed upside down at the pump
suction. The top of the reducer should go
straight into the suction flange.
• 4- Piping should be arranged with as few
bends as possible. If bends are necessary
use a long radius when ever possible .
• 5- If an expansion joint is installed in the piping
between the pump and the nearest point of anchor
in the piping, It should be noted that a force equal
to the area of the expansion joint (which could be
a lot larger than the normal piping size) times the
pressure in the piping will be transmitted to the
pump proper. Pipe couplings that do not provide
an axially rigid connection have the same affect.
If an expansion joint or non-rigid coupling
must be used, it is recommended that a pipe
anchor be installed between it and the pump.
• 6- Be aware that radial forces are being
generated in the pump housing from the
pressure in the piping system acting on the
volute area. The magnitude and direction
of the forces is dependent upon the piping
arrangement along with the areas and
pressures involved.
• 7- It is always a good idea to increase the
size of the suction and discharge pipes at
the pump nozzle in order to decrease the
head loss from pipe friction.
• 8- Suction piping should be at least one
size larger than the suction flange at
the pump.
• 9- If increasers are used on the discharge
side to increase the size of discharge
piping, they should be installed between
the check valve and the pump.
• 10- Both a check and gate valve should be
installed in the discharge piping with the
check valve placed between the pump and
the stop valve to protect the pump from
reverse flow and excessive back pressure.
Manually operated discharge valves that
are hard to reach should have some facility
for quick closing. A sprocket rim wheel
and chain or a remotely operated motor
are two alternatives you might consider.
• 11- Suction piping must be kept free of
air leaks.
• 12- The installation of check valves
should be avoided in the suction piping
although they are often used to reduce the
number of valves that have to be operated
in switching between series and parallel
pump operation.
• 13- A foot valve is often installed in the
suction piping to aid priming. Do not
install them if the pump is operating
against a high static head because failure
of the driver would allow liquid to rush
back suddenly causing water hammer.
This is especially true for vertical turbine
and submersible pumps that are not
designed for use with a foot valve.
• 14- Foot valves should be of the low loss
flap type rather than the multiple spring
variety and have a clear passage for the
liquid at least the same area as the suction
piping.
 A close-up of foot valve:
spring is visible.

Inside view of foot valve:

plate rests on the seat of
valve due to force exerted by
spring
• 15- A horizontal suction line should have a
gradual rise or slope to the pump suction.

• 16- Cast iron pumps should never be provided

with raised face flanges. If steel suction or
discharge piping is used, the pipe flanges should
be of the flat face type and not the raised face
type. Full-faced gaskets must be used with cast
iron flanges.

• 17- The optimum control valve location is within

five feet (1,5 meters) of the pump discharge to
prevent too much surging of fluid in the system
when the discharge is throttled.
• 18- The optimum pipe size will consider the
installed cost of the pipe (the cost increases with
size) and the pump power requirements (the
power required increases with pipe friction)
– Try to limit the friction loss at design flow to
2-5 feet for each 100 feet (1-2 meters for each
30 meters) of pipe).
– To prevent the settling of solids you need a
minimum velocity of about 4 to 7 feet per
second (1.5 to 2.5 meters per second)
– Velocities of no more than 10 feet (3 meters)
per second are recommended in the suction
side piping to prevent abrasive wear.
PITFALLS OF PUMPPIPING
• There are three major problems
associated with poor pump piping.
1. There is a scarcity of accessible
information available on the topic.
2. No one pays any attention to it when
installing a pump.
3. It can remain undetected and cause
repetitive pump failures for many
years.
• As a consequence of 1 and 2 above, most
pumps are piped up incorrectly.
• In fact when we look at the way many
pumps have been installed, it resembles a
“plumbers nightmare.”
• Many pumps appear as if they’ve been
squeezed into a corner out of the way,
and the pipes threaded in and out, without
any consideration for fluid flow patterns.
• There will be many who read this column
and realize, to their horror, that some of
the most problematic pumps in their plant
don’t follow any of the basic rules of
pump piping. Why?
• Let’s Get Practical! If you were installing
a new pump in a new system, where
would you go for information on how the
pump piping should be arranged?
• Most of us would refer to the pump’s
Installation, Operation and Maintenance
(IOM) Manual.
• Unfortunately, that won’t provide a lot of
information, as most of the pump
companies used to subscribe to an
attitude of limiting their responsibility
within the confines of the suction and
discharge nozzles of the pump.
• Although this attitude is fast
disappearing, the change has not yet
reached most of the IOM Manuals.
• As a consequence, accurate and complete
information is still severely limited, and a
high proportion of the pumps inmost
industries are installed with
inappropriate piping arrangements
that result in premature failure.
• The major problem with this condition is
that it positions the root cause of the
pump failure outside the physical
confines of the pump itself, thus making
it difficult to source for the unwary and
inexperienced.
• The “pitfalls of pump piping” easily can
be avoided by following a few
straightforward rules.
Rule No. 1
• Provide the suction side with a straight run of
pipe, in a length equivalent to 5 to 10 times the
diameter of that pipe, between the suction
reducer and the first obstruction in the line
(Fig. 1).
• This will ensure the delivery of a uniform flow
of liquid to the eye of the impeller, which is
essential for an optimum suction condition.
• (The experienced engineer will note that this
contradicts the information given in most IOM
Manuals, where it states that the suction piping
should be “as short as possible.”)
Rule No. 1
Rule No. 2
• The pipe diameter on both the inlet and the
outlet sides of the pump should be at least one
size larger than the nozzle itself.
• On the horizontal inlet side, an eccentric
reducer is required to reduce the size of the
pipe from the suction line to the inlet nozzle.
• By positioning the reducer with the flat side on
top as shown in Fig. 1, it eliminates the
potential problem of an air pocket in a high
point in the suction line.
• A concentric increaser can be used on the
vertical discharge.
Rule No. 3
• Eliminate elbows mounted on, or close to, the
inlet nozzle of the pump.
• Much discussion has taken place over the
acceptable configuration of an elbow on the
suction flange of a pump. Let’s simplify it.
There isn’t one!
• There is always an uneven flow in an elbow,
and when one is installed on the suction of any
pump, it introduces that uneven flow into the
eye of the impeller.
Rule No. 3
• This can create turbulence and air entrainment,
which can result in impeller damage and
vibration.
• The problem is even greater when the elbow is
installed in a horizontal plane on the inlet of a
horizontal double suction pump as shown in
Fig. 2.
• This configuration introduces uneven flows
into the opposing eyes of the impeller, and
essentially destroys the hydraulic balance of
the rotating element.
Rule No. 3
Rule No. 3

Effect of Elbow
Directly on
Suction
Unbalanced loading of a double suction impeller due
to uneven flow around on elbow adjacent to the
pump.
Rule No. 3
• Under these conditions, the overloaded bearing
will fail prematurely and regularly if the pump
is packed.
• If the pump is fitted with mechanical seals, the
seal will usually fail instead of the bearing--but
just as regularly and often more frequently.
Rule No. 3
• When it is absolutely essential to position an
elbow on the inlet of a double suction pump, it
must be located at right angles to the shaft.
• The only thing worse than one elbow on the
suction of a pump is two elbows on the suction
of a pump-- particularly if they are positioned
close together, in planes at right angles to each
other.
• This creates a spinning effect in the liquid that
is carried into the impeller and causes
turbulence, inefficiency and vibration.
Rule No. 4
• Eliminate the potential for vortices or air
entrainment in the suction source.
• If a pump is taking its suction from a sump or
tank, the formation of vortices can draw air
into the suction line.
• This usually can be prevented by providing
sufficient submergence of liquid over the
suction opening.
• A bell-mouth design on the opening will
reduce the amount of submergence required.
• This submergence is completely independent
of the NPSH required by the pump.
Rule No. 4
• Great care should be taken in the design
of a sump to ensure that any liquid
emptying into the sump does so in such a
manner that air entrained in the inflow
does not pass into the suction opening.
• Any problem of this nature may
require a change in the relative
positions of the inflow and outlet if the
sump is large enough, or the use of
baffles.
Rule No. 5
• Arrange the piping in such away that there
is no strain imposed on the pump casing.
• Piping flanges must be accurately aligned
before the bolts are tightened and all piping,
valves and associated fittings should be
independently supported without any strain
being imposed on the pump.
• Any stresses imposed on the pump casing
by the piping reduces the probability of
satisfactory reliability and performance.
Rule No. 5
• As there is an exception to almost every
rule, the A.P.I. 610 Specification identifies
a maximum level of forces and moments
that may be imposed on the pump flanges.
• These must be acceptable to any pump
being sold into the petroleum industry, or
any related industry, using that
specification.
• As a consequence, all API. pumps are of a
much more robust and heavier design than
their ANSI size equivalents.
Conclusion
• Piping design is one area where the basic
principles involved are frequently ignored,
resulting in problems such as hydraulic
instabilities in the impeller, which translate
into additional shaft loading, higher vibration
levels and premature failure of the seal or
bearings.
• As there are many other reasons why pumps
could vibrate, and why seals and bearings fail,
the trouble is rarely traced to incorrect piping.
Conclusion
• It has been argued that because many pumps
are piped incorrectly, yet are operating quite
satisfactorily, piping procedure is not
important.
• That doesn't make a questionable piping
practice correct, it merely makes it lucky.
Conclusion
• Any piping mistakes that are made on the
discharge side of a pump, frequently can be
accommodated by increasing the
performance of that pump.
• Problems on the suction side however, can be
the source of repetitive failures, which may
never be traced back to that area and could
continue undetected for many years to come.
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 :
ƒ Piping flexibility affects pump location.
ƒ Pump suction lines should be as short as
possible, but with enough flexibility.
ƒ 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 :-
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 larger.

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
Strainers :-

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.
Strainers :-
SUCTION PIPING
ARRANGMENT
Figure 1. End suction piping
 Or inserts rectifying plate
(eccentric suction : 2D
and over)

Figure 2-1. Side suction piping

Consideration of
straight pipe at
suction side is not Figure 2-2. Side suction piping
necessary for straight-
up or straight down.
 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
Pumps in Parallel Arrangement
1. PUMP SUCTION LINE
Horizontal
1. PUMP SUCTION LINE
Vertical
 Following diagrams indicate correct and incorrect
methods of attaching suction piping.

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
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
Following diagrams indicate correct and incorrect
methods of attaching suction piping.

Represents a common error made suction

piping to a centrifugal pump by placing piping
over an embankment of a reservoir, or other
obstruction.
 Following diagrams indicate correct and incorrect
methods of attaching suction piping.

Always use an eccentric reducer at the pump suction when

a pipe size transition is required. Put the flat on top when
the fluid is coming from below or straight and the flat on
the bottom when the fluid is coming from the top. This will
avoid an air pocket at the pump suction and allow air to be
evacuated
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.
Discharge Piping for Horizontal Pumps :-

• 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

Use Swing / Ball Type Check valve

Pump Discharge Line
2) 2 NB and Larger

Use Hinged flapper Check valve

Pump Discharge Line

3)
Pump Discharge Line

4)
Pump Discharge Line

5)
Pump Discharge Line
Pumps in the Tankage Area
 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
 Pumps in the Tankage 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.
 Pumps in the Tankage Area
• Support of Piping In the tankage area, the
supporting of piping is normally by:

– Pipe sleepers
– Field supports
Pump Surroundings Support
 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.)

 Pump Surroundings Support
(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.
 Pump Surroundings Support
(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.
 End
of
Chapter (12)