The Process Plant Layout

and Piping Design

Process Plant Layout and Piping Design Agenda

What is a Process Plant ?
Introduction to Plant
Layout Design
Plant Layout
Specifications

Reactors
Towers
Pipe Racks
Structures

Plot Plans

Underground Piping

Compressors

Instrumentation

Drums

Process Liquid
Storage Tank

Exchangers
Furnaces
Pumps

Pipe Stress Analysis

Miscellaneous

Pumps
The Process Plant Layout and Piping Design
Course

Main Menu

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Introduction to Pump
Terminology

Pumps the purpose of pumps is to make

fluids flow. Pumps do this by adding energy
to the fluid. Added energy increases pressure.
Fluid flows from high pressure to low
pressure. Pumps add energy by centrifugal
action, by pistons, and by rotary action.
Centrifugal pump this is the most common
type of pump in a process plant. A driver,
usually an electric motor but sometimes a
turbine, whirls an impeller around the central
axis of the pump. As the fluid enters the side
of the impeller casing through the suction
nozzle, the impeller scoops the fluid up,
whirls it around the casing and hurls the fluid
out of the discharge nozzle.
Reciprocating Pumps used for viscous
fluids or for small amounts of fluid flow
(such as for process additives) add energy by
using a piston instead of the impeller found in
centrifugal pumps. Fluid pulsations can cause
vibrations in the piping system.

Rotary Pumps these pumps are used

for highly viscous liquids that a highspeed impeller cannot push. The liquid
is pushed through the pump casing by
gears, vanes, or cams.
Horizontal and Vertical Pumps
Horizontal pumps are the most common.
Horizontal pumps have the driver and the
impeller at the same elevation connected
by a horizontal coupling. Vertical pumps
have the driver above the impeller.
Vertical pumps are used when NPSH
requirements make using horizontal
pumps impractical.
Net Positive Suction Head - NPSH is
one of the most important terms a
designer has to know. NPSH is a measure
of the pressure drop of the liquid as it
moves form the inlet of the pump to the
eye of the impeller. NPSH is a
characteristic of the pump and is usually
determined by manufacturer testing.

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Introduction to Pump
Terminology (cont)

Vapor pressure When the pressure in the

pump suction line falls below the vapor
pressure of a liquid, the liquid changes to
vapor. The pump cannot pump vapor and
thus becomes vapor bound
Available NPSH this term refers to the net
pressure available in a given system, based
on vessel pressure and static head, minus the
liquid vapor pressure and functional losses in
the system. The designers goal is to maintain
equipment heights and minimize pump
suction piping to ensure that the available
NPSH is greater than the required NPSH.
Insufficient NPSH can reduce pump capacity
and efficiency and lead to cavitation damage.
Cavitation The rapid collapse of vapor
bubbles that can produce noise, result in a
loss of head and capacity, and create a sever
erosion of the impeller and casing surfaces in
the adjacent inlet areas.

Allowable Nozzle Loading This is the

maximum amount of stress that the piping
configuration may impose on the pump
suction and discharge nozzles, as set by the
vendor, client or code.
API (American Petroleum Institute)
pumps this term refers to the horizontal,
single-stage pumps found in the petroleum.
The standard developed by vendors,
contractors, and users entitled API 610
Centrifugal Pumps for General Refinery
Service is used to specify pumps for
purchase. To a plant layout designer, an API
pump is a large, refinery-type pump.

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Introduction to Pumps
Terminology (cont)
Inline Centrifugal Pump

Horizontal Centrifugal Pump

Double-acting Piston Pump

Rotary Pumps

Sump Centrifugal Pumps

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Introduction to Pumps Terminology

(cont)

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Introduction to Pumps
Design Tips

Pump Locations along a rack

Keep in mind that in setting the pump
location your objective is to minimize the
length of suction piping while still
maintaining enough piping flexibility that
the nozzle loads are low during operation.
Locating the pumps under the rack is one
way to achieve this goal. The problem
with pumps under the rack is the potential
for hydrocarbon leaks onto the pump
motor which may create safety and/or
maintenance problems.
You can locate pumps outside of the rack
(which is often what your client will
require). When you do this, be sure that
you have accounted for the auxiliary steel
that may be needed to support piping
going to and from the pump to the pipe
rack.

Pump Locations near equipment

Pumps operating with exchangers and
drums that are located in vertical
structures can be placed beneath the
structure. Hydrocarbon leakage is usually
not a concern in that type of situation.
Centrifugal pumps in a vacuum service
typically have to be located very close or
directly beneath the suction side
equipment, which is normally a tower.
When locating pumps beneath a tower be
sure to account for the potential of spring
cans that support the pump causing the
pump to be elevated higher than normal.
Also, pumps on springs have a tendency
to vibrate depending on flow rate. The
potential for vibration on spring mounted
pumps should be discussed with both
your stress engineer and your process
engineer on the project

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Introduction to Pumps
Design Tips (cont)

Pump Locations by type

Vertical pumps are more expensive than
horizontal pumps. Yet vertical pumps can
be the right solution when you have
problems achieving NPSH requirements.
For example, between a horizontal
centrifugal pump and a horizontal vessel
you would measure the NPSH distance
you have between the centerline elevation
of the pump shaft and the bottom tangent
line of the vessel. If you were using a
vertical pump instead, you would
measure the distance between the bottom
impeller of the vertical pump which can
be located below grade. This would lower
the elevation of the horizontal vessel and
save significant structural costs.

Pump Piping
Do you understand how your specific
client plans on doing the maintenance
for these pumps? Are they going to use a
cherry picker or some kind of A-Frame?
Is there the potential for replication of
this piping layout elsewhere in the plant?
For large numbers of similar systems it
may be worth while to design for the
largest pipe size and highest temperature
and layout all 'close' systems the same
way.

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Introduction to Pumps
Design Tips (cont)

Pump Piping Supports

Pump Piping
When laying out piping on vertical
Has the stress engineer determined the location of
suction and vertical discharge
the supports? For most centrifugal pumps the stress
centrifugal pumps, assure that the
engineer is responsible for locating the support and
flanges on the larger valves do not
guide scheme and determining the loads on those
interfere with each other. If they do
supports. The location of these supports can affect
interfere, but only slightly, the use of
how you layout the pipe, and vice versa. Here are
eccentric reducers on both suction and
some simple rules to follow that will help you
predict where the supports will be.
discharge lines may offer enough offset
to provide the clearance you need.
For end and side suction pumps, expect an adjustable
or spring support to be placed at the first elbow.
Centrifugal pumps with side suction
Since both these types of supports typically need at
nozzles are particularly prone to
least 12(300mm.) clearance, maybe more, expect a
cavitation. A generally accepted rule of
dummy leg off the first riser from the suction nozzle
thumb is to make sure a minimum of
ONLY IF your bottom of pipe coming from the
five diameters (5D) of straight run is
suction nozzle is low to the grade.
added to the line before it reaches the
On a vertical discharge line some designers turn the
suction nozzle
pipe fitting to fitting to the horizontal plane until the
discharge piping clears the foundation then turn up.
When a pump suction line comes from
It is at this second elbow transitioning from the
below grade, be sure to orient the
horizontal to the vertical plane that a vertical dummy
reducer at the pump nozzle with the flat
leg going to a spring can or adjustable support can
side up.
be located.

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Introduction to Pumps
Design Tips (cont.)

Pumps located
partially under
piperack.
Pumps located
under piperack.
Pumps located
outside of rack.
Pumps located
under a structure.

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Introduction to Pumps
Design Tips (cont.)
Typical Centrifugal
Pump Auxiliary Piping
Layout

Typical Centrifugal Pump

Primary Piping Layout

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TYPICAL PIPING FOR CENTRIFUGAL PUMPS

Most pumps used in industry are of the centrifugal type. Typical piping and fittings required
at a centrifugal pump together with the valves necessary to isolate the pump from the
system.
The check valve is required to prevent possible flow reversal in the discharge line. A
permanent in-line strainer is normally used for screwed suction piping and a temporary
strainer for butt-welded/ flanged piping. The temporary strainer is installed between flanges.
A spool is usually required to facilitate removal.
Although centrifugal pumps are provided with suction and discharge ports of cross sectional
area large enough to cope with the full rated capacity of the pump, it is often necessary with
thick fluids or with long suction lines to use an inlet pipe of larger size than the inlet port, to
avoid cavitation. Cavitation is the pulling by the pump of vapor spaces in the pumped liquid,
causing reduction of pumping efficiency, noisy running and possible impellor and bearing
damage.
Most pumps have end suction and top discharge. Limitations on space may require another
configuration, such as top suction with top discharge, side suction with side discharge, etc.
Determination of nozzle orientation takes place when equipment layout and piping studies
are made.

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AUXILIARY, TRIM, or HARNESS PIPING

Pumps, compressors and turbines may require water for cooling bearings, for mechanical
seals, or for quenching vapors to prevent their escape to atmosphere. Piping for cooling
water or seal fluid is usually referred to as auxiliary, trim, or harness piping, and the
requirement for this piping is normally shown on the P&ID. This piping is usually shown in
isometric view on one of the piping drawings.
In order to cool the gland or seal of a centrifugal pump and ensure proper sealing, it is
usually supplied with liquid from the discharge of the pump, by a built-in arrangement, or
piped from a connection on the pumps casing. The gland may be provided with a cooling
chamber, requiring piped water. If a pump handles hot or volatile liquid, seal liquid may be
piped from an external source.

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DRAINING
Each pump is usually provided with a drain hub 4 to 6 inches in diameter, positioned about 9
inches in front of the pump foundation on the centerline of the pump. The drain hub is piped to
the correct sewer or effluent line. If two small pumps have a common foundation, they can
share the same drain hub.
Most centrifugal pumps have base plates that collect any leakage from the pump. The base
plate will have a threaded connection which is piped to the drain hub. Waste seal water is also
piped to the drain hub.

In outside installations in freezing climates, provide a valved drain from the pumps casing.

Provide a short spool for a -inch drain between the on/ off valve and the check valve, to drain
the discharge line. If the valve is large enough, the drain can be made by drilling and tapping a
boss on the check valve, in which instance no spool is required.

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INSTALLATION

Do not route piping over the pump, as this interferes with maintenance. It is better to bring
the piping forward of the pump.
Leave vertical clearance over pumps to permit removal for servicing sufficient headroom
must be left for a mobile crane for all but the smaller pumps, unless other handling is
planned.
If pumps positioned close to supply tanks are on separate foundations, avoid rigid piping
arrangement, as the tanks will settle in the course of time.
Locate the pump as closely as practicable to the source of liquid to be pumped from storage
tanks, sumps, etc., with due consideration for flexibility of the piping.
Position valves for ease of operation placing them so they are unlikely to be damaged by
traffic and will not be a hazard to personnel.
The foundation may be of any material that has rigidity sufficient to support the pump
baseplate and withstand vibration. A concrete foundation built on solid ground or a concrete
slab floor is usual. The pump is positioned, the height fixed (using packing), and the grout is
then poured. Grout thickness is not usually less than one inch.
A pit in which a pump is installed should have a drain, or have a sump that can be drained or
pumped out.
Make the concrete foundation at least as large as the baseplate, and ensure that concrete
extends at least 3 inches from each bolt.

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VALVES

Valves are line size unless shown otherwise on the P&ID.

Use tiling disc or swing check valves for preference.
Do not use globe valves for isolating pumps. Suction and discharge line isolating valves are
usually gate valves, but may be other valves offering low resistance to flow.
SUCTION LINE
To avoid cavitation, the pump must be at the correct elevation, related to the level or head of
the liquid being pumped. If the location of the pump has not previously been established on
an equipment arrangement drawing, refer to the engineer involved.
Eccentric reducers are used, and are arranged to avoid: (1) Creating a vapor space. (2)
Creating a pocket which would need to be drained. These conditions set the configuration of
the reducer - that is, whether it is to be installed top flat or bottom flat.

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Suction Line (Cont.)

If a centrifugal pump has the suction nozzle at the end (in line with the drive shaft), an elbow
may be connected directly to the nozzle at any orientation.
If a pump has the suction nozzle at the side with spilt flow to the impellor provide a straight
run of pipe equal to 3 to 5 pipe diameters of the suction line to connect to the nozzle.
Alternately, and elbow may be connected to the suction nozzle, but it must be arranged in a
plane at 90 degrees to the driving shaft, to promote equal flow to both sides of the impellor. If
an elbow must be in the same plane as the driving shaft of the pump, consider the use of
turning ( or splitter) vanes to induce more even flow. Uneven flow causes damage to the
impellor and bearings.
Route suction lines as directly as possible so as not to starve the pump and incur the
risk of cavitation.
If the pump draws liquid from a sump at a lower elevation, provide a combined foot
valve and strainer. A centrifugal pump working in this situation requires priming
initially provide for this by a valved branch near the inlet port, or by other means.
Provide a strainer in the suction line. Do not place a temporary startup screen
immediately downstream of a valve, as debris may back up and prevent the valve
from being closed.

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DISCHARGE LINE
The outlet pipe for centrifugal and other non-positive displacement pumps is in most cases
chosen to be of larger bore than the discharge port, in order to reduce velocity and
consequent pressure drop in the line. A concentric reducer or reducing elbow is used in the
discharge line to increase the diameter. There is no restriction on the placement of elbows in
discharge lines as there is in suction lines.

Provide a pressure connection in the discharge line, close to the pump outlet. It may be
necessary to provide a short spool for this purpose if there is no pressure point tapping on
the pump discharge nozzle.
For locations of drain connections in the discharge line, see figures.
PUMPS WITH SCREWED CONNECTIONS
A pump with screwed connections requires unions in the suction and discharge lines to
permit removal of the pump.

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Centrifugal Pump Piping in Elevation

Flanged Butt-Welded Piping

Screwed Piping

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Piping to Centrifugal Pump - Alternatives

Discharge
Manifold
Screwed
Piping

Flanged ButtWelded Piping

Socket-Welded
Piping

Centrifugal Pump Piping in Elevation

Centrifugal Pump Piping in Plan

Centrifugal Pump Piping in Plan

Centrifugal
Pump
Piping in
Elevation

Centrifugal Pump Piping in Plan

Centrifugal Pump Piping in Elevation

Centrifugal
Pump Piping
in Plan
(at Reboiler)

Centrifugal Pump Piping in Elevation (at Reboiler)

Metering Pump
Piping in Plan

Metering Pump Piping in Elevation