TRAINING MANUAL- PIPING DOC No.

: 29040-PI-UPS-1005

Rev. : R0
PIPING STUDY
Uhde India Limited PUMP (CENTRIFUGAL) PIPING Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

List of drawings 2

1.0 General 3

2.0 Location 3

3.0 Steps to do Pump Piping 4

4.0 Pump Piping 4-5

5.0 Suction Basin of Pump 6

Applicable Revision:
Prepared: Checked: Approved:

Date: Date: Date:

First Edition: R0
Prepared: AKB Checked: TNG Approved: RUD

Date: Date: Date:

File Name: Server: PUNE: KUMUS 207 VKO: KUMUS 209
 TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1005

Rev. : R0
PIPING STUDY
Uhde India Limited PUMP (CENTRIFUGAL) PIPING Page : 2

SR.NO. DWG.NO. DESCRIPTION

1 CPP1 CENTRIFUGAL PUMP

2 CPP2 TYPICAL CENTRIFUGAL PUMP

3 CPP3 FLUID FLOW IN A CENTRIFUGAL PUMP

4 CPP4 TYPICAL PUMP LOCATION - PLAN

5 CPP5 TYPICAL ACCESS FOR MAINTENANCE

6 CPP6 TYPICAL PUMP LOCATIONS - ELEVATION

7 CPP7 AIR POCKETS IN SUCTION PIPING

8 CPP8 TYPICAL PUMP SUCTION & DISCHARGE PIPING

9 CPP9 ELBOW AT PUMP SUCTION

10 CPP10 TYPICAL AUXILLIARY PUMP PIPING

11 CPP11 MAINTENANCE AND OPERATIONAL ACCESS REQUIREMENTS

12 CPP12 TYPICAL SUCTION / DISCHARGE PIPING, PLAN & ELEVATION

13 CPP13 TYPICAL SUCTION / DISCHARGE PIPING, FRONT VIEW

14 CPP14 MULTIPLE PUMP INSTALLATIONS (VERTICAL PUMP)

15 CPP15 SUMP DIMENSIONS, PLAN VIEW, WET PIT TYPE PUMPS

16 CPP16 TYPICAL SUMP WITH PUMP

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1.0 GENERAL
The design of a piping system can have an important effect on the successful operation of a
centrifugal pump. Such items as sump design, suction piping design, suction and discharge pipe
size and pipe supports must all be carefully considered. A typical horizontal centrifugal pump
installation is illustrated in Fig.CPP1, CPP2, CPP3.

Selection of the discharge pipe size is primarily a matter of economics. The cost of various pipe
sizes must be compared to the pump size and power cost required to overcome the resulting
friction head.

1.1 The suction piping size and design is far more important. Many centrifugal pump troubles are
caused by poor suction conditions.

1.2 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. Suction pipes should be as short and as straight as possible.
Suction pipe velocities should be in the 1.0 - 1.5 metre per second range, unless suction conditions
are unusually good. Higher velocities will increase the friction loss and can result in trouble some
air and vapour separation. This is further complicated when elbows or tees are located adjacent to
the pump suction nozzle. In that case uneven flow patterns or vapour separation keeps the liquid
from evenly filling the impeller. This upsets hydraulic balance leading to noise, vibration, possible
cavitation and excessive shaft deflection. Cavitation, erosion damage, shaft breakage or
permature bearing failure etc. may result.

1.3 On pump installations involving suction lift, air pockets in the suction line can be a source of
trouble. The suction pipe should be exactly horizontal or with a uniform slope upward from the
sump to the pump as illustrated in Fig.CPP7. There should be no high spots where air can collect
and cause the pump to lose its prime. Eccentric rather than concentric reducers with flat side top
should always be used.

1.4 If an elbow is required at the suction of a double suction pump, it should be in a vertical position if
at all 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 as illustrated in Fig.CPP9.

2.0 LOCATION

2.1 Common location of pumps in chemical and petrochemical plant is under the piperack at grade.
Pumps are to be placed close to and below the vessels from which they take their suction in order
to have net-positive suction head (NPSH) required by the pump.

2.2 Any reduction in suction line size required at pumps should be made with eccentric reducers, with
flat side up to avoid accumulation of vapour pocket. Changes in direction of suction lines should
be at least 600mm away from the pump suction.

2.3 Pumps should be arranged in line with drivers facing the access gangway. Clearances and piping
should provide free access to one side of the driver and pump. There must be good access to
gland / seal and coupling where most of the maintenance and adjustments are done.
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2.4 With normal piperack column spacing of 6m, it is generally found that only two pumps of average
size can be arranged between the columns, with a preferred clearance of 1m between the pumps.
The clearance between any structure / steel work and the pump discharge line shall be 0.75m
minimum. For small pumps upto 18 KW, clearance between pumps should be 0.9m minimum. A
space of 2 - 2.5 m should be provided for working aisle.

A typical arrangement of pumps is illustrated in Fig.CPP4, CPP5, CPP6.

2.5 Means of lifting should be provided for pumps or motor weighing more than 25Kg.

3.0 "STEPS TO DO PUMP PIPING"

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.

Step 11 : Keep necessary insert plate on the foundation block for support of push button switch,
small lines for flushing / cooling manifold.

4.0 PUMP PIPING :

4.1 HORIZONTAL CENTRIFUGAL PUMP :

A typical horizontal centrifugal pump suction and discharge piping arrangements is illustrated in
Fig.CPP7.

4.2 Pump suction piping shall be as short as possible and shall be arranged so that vapour pockets
are avoided.

4.3 Reducers immediately connected to the pump suction shall be eccentric type flat side up to avoid
accummulation of gas pocket.
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4.4 For end suction pumps, elbows shall not be directly connected to the suction flange. A straight
piece 3 times the line size shall have to be provided at the suction nozzle. This is illustrated in
Fig.CPP8.

The effect of elbow directly on suction is illustrated in Fig.CPP9.

4.5 For top suction, pump elbow shall not be directly connected to suction flange. A straight piece of
minimum 5 times the nozzle size shall have to be provided at the suction nozzle.

4.6 T-type strainers are to be used for permanent as well as temporary to avoid disassembly of suction
piping for strainer cleaning.

4.7 Piping shall be so arranged that forces and moments imposed on the pump nozzles do not exceed
the allowable values specified by the vendor.

4.8 When a suction vessel operates under vacuum the vent connection of the pump has to be
permanently connected to vapour space of the suction vessel to allow possible filling of the pump
with liquid before it is started.

4.9 For pumps handling hot fluid, the first factor concerns the support of pump piping which often
includes large expansion loops for flexibility. When the pumps are located below the piperack (to
reduce possibility of hydrogen leakage over motor), support becomes easy otherwise the designer
should consult stress engineer for best location of stops and hanger. With the optimum layout and
support, it is to be ensured that the loadings on the pump nozzles are not exceeded beyond the
allowable limits.

4.10 Piping configuration for a group of pumps of similar size shall follow identical pattern and the stress
analysis of one pump piping should be applicable to the other pumps.

4.11 Auxilliary Pump Piping Arrangements :

The auxilliary piping are usually cooling water to mechanical seals, bearings, stuffing boxes, gland
quench and lantern rring flush.

When pump fluid is used, a line is attached to the vent connection on the pump case. The
circulated seal fluid has to 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.

Various auxilliary piping plan is recommended in API 610 for proper selection according to design
requirements.

4.12 Pump vendors usually supply the auxilliary piping and the neat arrangements of these piping and
its support are to be ensured by the designer while reviewing the vendor document. Fig.CPP10
illustrates one typical auxilliary pipig arrangement on the pump base plate.

4.13 A typical arrangement for piping and valves operation is illustrated in Fig.CPP11 with maintenance
and operation access.

4.14 A typical suction and discharge piping arrangement with common platform for operation of valves
connected to two adjacent pumps is illustrated in Fig.CPP12 and CPP13.
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5.0 SUCTION BASIN OF PUMP

5.1 The basin for the intake of centrifugal pump shall be designed and sized properly for smooth
function of the pump. The recommendations of hydraulic institute is illustrated in Fig.CPP14.

5.2 The flow of fluid to the suction bell should be even, smooth and stream lined without any vortices.

5.3 A typical sump with the components and relative dimensions of clearance and submergence is
illustrated in Fig.CPP15.

5.4 For multiple pump installations with high capacity pumps, the analysis of a proposed intake design
are often made by use of a scale model of the intake basin with all parts such as baffles, screens,
gates, separating walls etc.

The large basin is required to ensure low inlet velocity (approx. 2 ft. per sec.) and to eliminate
vortexing at the bell mouth.

5.5 A typical sump pit with pump is illustrated in Fig CPP16. This sump is the collection pit of waste
material coming thru a pipeline. A screen at the mouth of the pump avoids choking / fouling of the
pump during operation. The discharge of the pump may go to a slope tank / pond / waste-removal
tanker.
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DWG. NO. : CPP1

CENTRIFUGAL PUMP

DISCHARGE
(LIQUID OUTLET)

DRIVE ELECTRIC MOTOR CASING VENT

IMPELLER

COUPLING SUCTION
(LIQUID INLET)

CASING

CASING DRAIN

COUPLING GUARD STUFFING BOX DRAIN

BASE PLATE
BASE PLATE
DRAIN

ELEVATION
CL DISCHARGE

ELECTRICAL TERMINAL BOX COUPLING GUARD

BASE PLATE

CL MOTOR C
CL PUMP L SUCTION

AUXILLIARY
PIPING C
L BASE PLATE
DRAIN

PLAN
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DWG. NO. : CPP2

TYPICAL CENTRIFUGAL PUMP

SEALING AREA

DISCHARGE

THROAT STUFFING BOX OR SEAL CHAMBER

ROTARY IMPELLER

GLAND

SHAFT
SUCTION EYE

CASING

CENTRIFUGAL PUMP, LIQUID END

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DWG. NO. : CPP3

FLUID FLOW IN A CENTRIFUGAL PUMP

DISCHARGE

CASING

IMPELLER VANES

SUCTION EYE

IMPELLER
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DWG. NO. : CPP4

TYPICAL PUMP LOCATION PLAN

EQUIPMENT LINE

3A

3B

4A

4B
1A

1B

2A

2B

C
L OF DISCHARGE
NOZZLE
750 750

C
L OF PIPERACK
COLUMN
C
L OF DISCHARGE
NOZZLE

PUMP ACCESS WAY

CL OF PIPERACK
COLUMN

CL PUMPS
(IN LINE)
10C
10A

10B
9C
9A

9B

C
L OF DISCHARGE
NOZZLE
5A

5B

6A

6B

EQUIPMENT LINE

7A 8A

8B
7B
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DWG. NO. : CPP5
TYPICAL ACCESS FOR MAINTENANCE
BUNDLE
PULSATION DAMPENER LENGTH
C
L
ALLOW ADEQUATE ACCESS TO MOTOR
EXCHANGERS
CL
COMPRESSOR HOUSE

CL CHANNEL
NOZZLES
CABLE TRAYS (TYP)
AIR FIN. COOLER

ENSURE CLEARANCE BETWEEN PLATFORMS

C TOWER
L

CL KO DRUM

C TOWER
6000

L
DROP OUT
AREA

DROP OUT
AREA
C TOWER
L
CL TOWER
C
L PUMP
(TYP)

NO PERMANENT STRUCTURE
FOR BUNDLE REMOVAL
C
L DRUM

L
UP
(TYP)

ACCESS STAIRWAY
MIN. CLEARANCE OF
CL DRUM
ALL OBSTRUCTIONS

C
L TANK

EQUIPMENT ALIGNED
ON COMMON TAN LINE

RACK PLATFORM 750 PREFERRED

FOR BL VALVES
L DISCHARGE

C ROADWAY
L
C

DIMENSIONS ARE IN MM. 6000

MAX.
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DWG. NO. : CPP6

TYPICAL PUMP LOCATIONS - ELEVATION

AIR COOLER

3000

750 750
3000

PUMP (TYP)
ACCESS WAY

5A-5B IA-IB 4A-4B 7A-7B

PUMPS PUMPS PUMPS PUMPS
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DWG. NO. : CPP7

AIR POCKETS IN SUCTION PIPING

CHECK VALVE

GATE VALVE

ECCENTRIC
REDUCER(FST)

LONG RADIUS
ELBOW

(1a) CORRECT

FOOT VALVE
(IF USED)

STRAINER

CHECK VALVE

GATE VALVE
ECCENTRIC
REDUCER
SUCTION PIPE SLOPES
UPWARDS FROM SOURCE
OF SUPPLY

LONG RADIUS
ELBOW

SLOPE

(1b) CORRECT

FOOT VALVE
(IF USED)

STRAINER
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DWG. NO. : CPP8
TYPICAL PUMP SUCTION AND DISCHARGE PIPING

4
4

PI
6 PI

6
1

5 TEMP SUCTION
TEMP SUCT. STRAINER
STRAINER
5
1
1

END SUCTION -TOP DISCHARGE SIDE SUCTION - SIDE DISCHARGE

(BASIC INSTALLATION) (BASIC INSTALLATION)

1) PIPE SUPPORTS (REST/GUIDE)SHALL BE PROVIDED AT PUMPS TO MINIMIZE

WEIGHT AND THERMAL STRESSES BEING APPLIED TO PUMP NOZZLES
(NOT TO EXCEED MANUFACTURER'S RECOMMENDATION). LOCATION AND TYPE OF
SUPPORT MUST BE APPROVED BY PIPING STRESS ENGINEER.
2) REMOVABLE SPOOL PIECES IN SUCTION PIPING SHALL ALLOW FOR INSTALLATION
AND REMOVAL OF TEMPORARY SUCTION STRAINERS.
3) PIPING SHALL BE DESIGNED AND ARRANGED SO THAT CLEARANCE IS PROVIDED
FOR REMOVAL OF PUMPS AND / OR DRIVERS. FOR END SUCTION PUMPS THE
SUCTION COVER AND PUMP IMPELLER SHALL BE REMOVABLE WHILE THE SUCTION
AND DISCHARGE VALVES ARE IN PLACE.
4) VALVE HANDWHEELS SHALL BE ORIENTED WHENEVER PRACTICAL TO BE CONTAINED
WITH IN THE PERIMETER OF THE PUMP.
5) PERMANENT SUCTION STRAINERS MAY BE REQUIRED AND SHALL BE SHOWN ON FLOW DIAGRAM.
6) SUITABLE TEMPORARY SUPPORTING FACILITIES AT SUCTON LINES WHEN REMOVING STRAINER.

MOTOR

CL PUMP

PLAN VIEW DO NOT LOCATE HANDWHEELS

(TOP SUCTION-TOP DISCHARGE) OVER DRIVER OR COUPLING

CL PUMP

MOTOR

PLAN VIEW
(END SUCTION-TOP DISCHARGE)
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DWG. NO. : CPP9

ECCENTRIC REDUCER-
WITH TOP HORIZONTAL
MUST BE MIN.
5D

ELBOW MUST BE
VERTICAL WHEN
NEXT TO PUMP

(2b) WRONG

(2a) PERMISSIBLE

ELBOWS AT PUMP SUCTION

EFFECT OF ELBOW DIRECTLY ON SUCTION

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DWG. NO. : CPP10

TYPICAL AUXILLIARY PUMP PIPING

COOLING WATER SUPPLY AND RETURN

CASING VENT

VALVE STEM LEAK OFF

CASE DRAIN

STEAM CHEST DRAIN

PEDESTAL COOLING WATER
BEARING COOLING WATER
STUFFING BOX DRAIN

ELEVATION END

COOLING WATER (IN-OUT)

BASE PLATE
DRAIN

PLAN
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DWG. NO. : CPP11

MAINTENANCE AND OPERATIONAL ACCESS REQUIREMENTS

`T' TYPE SUPPORT

PUMP PLOT
AREA

PLAN

ARRANGE SUITABLE PLATFORM

.. FOR OPERATION HEIGHT > 1500
HEIGHT 1500 MAX.
OPERATION

ELEVATION
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DWG. NO. : CPP12

TYPICAL SUCTION/DISCHARGE PIPING PLAN AND ELEVATION

C PUMP
L

FO

FO

CL PUMP

PLAN

CL PUMP SUCTION
EL. VARIES

ELEVATION B
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DWG. NO. : CPP13

TYPICAL SUCTION/DISCHARGE PIPING - FRONT VIEW

CL DISCHARGE
CL MIN. FLOW

CL HC DRAIN
CL SUCTION

PI
C SUCTION

CL SUCTION
L

1750 2500
(TYP)
6000
(TYP)

FRONT VIEW
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DWG. NO. : CPP14

MULTIPLE PUMP INSTALLATIONS (VERTICAL PUMP)

B D
ALT.
W

Vs=1fps Ve = 2fps & up

if A = less than 4W
Ve
W = (See Figure 2.26)
w =11/2 to 2D

D A
RECOMMENDED A NOT RECOMMENDED

Add wall thickness

to CLdist. round off For B & C,
to give wall ends see Figure CPP15

B NOT RECOMMENDED
RECOMMENDED

D A

Max. = 15 A
Preferred = 10 2

Y
RECOMMENDED C NOT RECOMMENDED
Y D

V1
Z
P

V
Z

D U Y

Baffles, grating or strainer should be introduced across inlet NOT RECOMMENDED UNLESS :
channel at beginning of maximum width section
Z = 2.5W or more (W = As per Figure 2.26) or
Z/P 1.0 1.5 2.5 4.0 10.0 V 1= 0.2 lps or less and
Y = Same as chart to left
Y 2W 3W 4.5W 5.5W 9W W = (refer to figure CPP15) U = Is greater than 40
V 1 2 4 5 6 RECOMMENDED D
NOT RECOMMENDED

V = 2 lps
Min. 2F

V up to 8 lps

RECOMMENDED E NOT RECOMMENDED

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DWG. NO. : CPP15

SUMP DIMENSIONS, PLAN VIEW, WET PIT TYPE PUMPS

PUMP
W/2

SINGLE PUMP
W
FLOW

W/2
W

TRASH RACK
SCREEN
MULTIPLE SUMP
W

FLOW

B Y

OPTIONAL PARTIAL DIVIDERS (INCREASE DIMENSION "W"

BY THE DIVIDER THICKNESS) REQUIRED ABOVE 5000 GPM

A SCREEN

B Y
TRASH RACK

MIN. WATER LEVEL

S

NOTE: 10 OR LESS PREFERRED

WITH 1 FT./SEC VELOCITY MAX.
C

AT SCREEN LOCATION
SHOWN. 15 MAX. WITH
VELOCITY REDUCED TO 0.5 FT./SEC
D

SUMP DIMENSIONS, ELEVATION VIEW, WET PIT TYPE PUMPS

D = (0.744Q) 0.5 RECOMMENDED S = D + 0.574Q/D 1.5

W = 2D WHERE
Y > 5D S - INCHES
A > 5D Q - FLOW (GPM)
C = 0.3D TO 0.5D D - INCHES
B = 0.75D
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DWG. NO. : CPP16

TYPICAL SUMP WITH PUMP

MOTOR

DISCHARGE NOZZLE

FLOAT

DRAIN OR
COLLECTION LINE

PUMP WITH STRAINER