PUMPS

&
PUMP PIPING
By,
Sandeep More
Associate Engineer
Piping Department
Date 4
th
Dec 2006
Contents Contents
Pump Pump
-- Introduction to Pumps Introduction to Pumps
-- Classiication o Pump Classiication o Pump
-- Industry Codes & Standards Industry Codes & Standards
-- Selection Criteria or Pumps Selection Criteria or Pumps
-- NPSl & Caitation NPSl & Caitation
-- Deinitions Deinitions
Pump Piping Pump Piping
Suction piping or horizontal pumps Suction piping or horizontal pumps
Discharge piping or horizontal pumps Discharge piping or horizontal pumps
Arrangements o piping or pump handling hot suctions. Arrangements o piping or pump handling hot suctions.
Side suction & side discharge pump Side suction & side discharge pump
Vertical In line pumps Vertical In line pumps
Vertical pump ,\et \ell pump, Vertical pump ,\et \ell pump,
Vertical Barrel type or Cane pump Vertical Barrel type or Cane pump
Multi Serice pump Multi Serice pump
Reciprocating pump Piping Reciprocating pump Piping
Metering Pump Metering Pump
Pumps in the 1ankage Area Pumps in the 1ankage Area
Auxiliary pump piping arrangement Auxiliary pump piping arrangement
Pipe ent & drain System Pipe ent & drain System
Pump Location & Arrangement Pump Location & Arrangement
Pump Surrounding Support Pump Surrounding Support
ntoduction 1o Pump : ntoduction 1o Pump :
Pump is a mechanical deice used to add kinetic and potential energy to a
liquid or the purpose o moing it rom one point to another. 1his energy will
cause the liquid to do work such as low through a pipe or rise to a higher leel and
Pump gies pressure to luid passing through it and discharges the luid to the
outside.
Deinition :
Pumps are classiied on the basis o :-
1he applications they sere,
1he liquids they handle,
Orientation & Construction
No. o stages, No. o casings, 1ype o couplings ,Rigid , llexible,
1) D,vavic
2) Di.tacevevt
Classification Of Pump :
namic Pumps :
In which energy is continuously added to
increase the luid elocities within the machine
to alues greater than those occurring at the
discharge such that subsequent elocity
reduction within or beyond the pump produces
a pressure increase
isplacement Pump :
In which energy is periodically added by application o
orce to one or more moable boundaries o any desired
number o enclosed, luid-containing olumes, resulting
in a direct increase in pressure up to the alue required
to moe the luid through ales or ports into the
discharge line
1, Classiication by suction type :
- Single suction type
- Double suction type ,or big olume pump,
2, Classiication by the pump installation method :
- Vertical pump type
- lorizontal pump type
Other Classification :
Classification b structure and operation method :
Type
Classification
by structure
Classification
by operation metbod
$pecifics
lositi\e
displacement
pump
leciprocating
pump
- liston pump
- llunger pump
- Diapbragm pump
Tbis type of pump sucks in fluid tbrougb
reciprocating mo\ement of piston or plunger,
and discbarges fluid by pressing witb required
amount of pressure. lt is used wben bigb
pressure is required e\en tbougb tbe amount of
discbarge is small.
lotary
pump
- Gear pump
- $crew pump
- \ane pump
Tbis type of pump sucks in fluid tbrougb tbe
rotation mo\ement of rotor, and bas tbe
ad\antage of little pulsation due to tbe special
cbaracteristics in operation.
inetic pump
Centrifugal pump
- ladial flow
- \olute pump
- Mixed flow
pump
- Axial flow
pump
Tbis type of pump transfers energy to fluid
tbrougb centrifugal force by impeller rotation or
tbrougb tbe cbanges of size and direction of
section area of passage, and
con\erts \elocity energy pressure energy in \olute
cbamber or diffuser.
$pecial pump
- `et pump
- Gas lift pump
- Vesco pump
Tbis type of pump bas a efficiency and is not
used except for a special purpose.
evtrifvgat Pvv
A centriIugal pump transIorms mechanical energy Irom a rotating impeller into a
kinetic and potential energy required by the system.
Centriugal Pump
lorizontal Centriugal Pump
Reciprocating pumps :
W %hese are commonly used to move viscous liquids, inject chemicals or additives
into a system.
W #eciprocating pumps are used where a precise amount oI liquid is required to be
a delivered, also where the delivery pressure required is higher than can be
achieved with other types.
Reciprocating Piston 1ype Pump
orizontal & Vertical #eciprocating pump
#4tar, Pvv :
#otary pumps are used to move heavy or very viscous Iluids such as
grease, asphalt, heavy Iuel oil and sometimes heavy crude oils.
Gear Pump
Screw Pump
merican Petroleum nstitute (P
. 6, Centriugal Pumps or Petroleum, leay Duty Chemical, and Gas Industry Serices`.
2. 64, Positie Displacement Pumps - Reciprocating`.
3. 65, Positie Displacement Pumps - Controlled Volume`.
4. 66,Positie Displacement Pumps ,Rotary,
5. 6. General Purpose Gear Units or Reinery Serice`.
6. 68, Liquid Ring Vacuum Pumps`
. 682, Shat Sealing Systems or Centriugal and Rotary Pumps`.
merican Societ of Mechanical Lngineers (SML
. B3.M, lorizontal Lnd Suction Centriugal Pumps or Chemical Process`.
2. B3.2M, Vertical In-Line Centriugal Pumps or Chemical Process`
Process ndustr Practices (PP
. RLSP3l-9, Speciication or lorizontal Lnd Suction Centriugal Pumps`.
2. RLSP3V-9, Speciication or Vertical Centriugal Pumps`.
ndustr Codes and Standards : Ref : GLMS P-G-2
Selection Criteria Ior Centrifugal, Reciprocating, nd Rotar Pumps
efinitions
. Casing, Axially Split - Pump case split parallel to pump shat.
2. Casing, Radially Split - Pump case split transerse to pump shat axis.
3. Diuser -
Pump design in which the impeller is surrounded by diuser anes where the gradually enlarging passages change
liquid elocity head into pressure head.
4. Double Acting - Liquid is discharged during both orward and return strokes o the piston.
5. Duplex - Pump with two plungers or pistons.
6. lead, Acceleration - Pressure change due to changes in elocity in the piping system.
8. Impeller - Bladed member o rotating assembly o a centriugal pump which imparts orce to liquid.
9. Net Positie Suction lead ,NPSl, -
1otal suction head in meters ,eet, o liquid absolute determined at suction nozzle and reerred to datum
eleation, minus the apor pressure o liquid in meters ,eet, absolute. 1he datum eleation is the shat
centerline or horizontal pumps, the suction nozzle centerline or ertical in-line pumps, and the top o the
oundation or other ertical pumps.
. Net Positie Suction lead Aailable ,NPSlA, -
NPSl in meters ,eet, o liquid determined by Purchaser or the pumping system with the liquid at rated low
and
normal pumping temperature.
. Net Positie Suction lead Required ,NPSlR, -
NPSl in meters ,eet, determined by Supplier testing, usually with water. NPSlR is measured at the
suction lange and corrected to the datum eleation. NPSlR is the minimum NPSl at rated capacity required
to preent a head drop o more than 3 ,irst stage head in multistage pumps, due to caitation within pump.
2. Recirculation -
Controlling the quantity o low through a pump by bypassing discharge liquid back to suction.
4. Simplex - Pump with one plunger or piston.
5. Single Acting - Liquid is discharged only during orward stroke o the piston.
6. 1hrottling - Controlling low rate by reducing cross-sectional low area, usually by partially closing a ale in the
discharge piping.
. 1otal Dierential lead ,1Dl, - Pressure required in meters ,eet, o head that the pump must produce. 1he
head at the discharge pump lange minus the head at suction lange.
8. 1riplex - Pump with three plungers or pistons.
L1 POS1'L SUC1O HL (PSH
1he net positie suction head ,NPSl, is the absolute pressure iv ece.. 4f tbe tiqvia ra4r
re..vre that is aailable at the pump suction nozzle to moe the liquid into the eye
o the impeller.
1he dierence between NPSla and NPSlr is less than .3 .m at the time o
checking endor data sheet | that is, NPSla- NPSlr ,.3 m,|,
decision on NPSl test shall be made according to Lngineering Speciication SLS-
GA-2L and API 6.
Pumps where dierence between NPSlA and NPSlR is less than .6 meter are
not acceptable.
1he diameter o the pump suction port is usually bigger than the discharge or exit
diameter in order to minimize the kinetic energy head entering the pump, because
this kinetic energy decreases the maximum suction lit and enhances caitation.
NPSl Required d
NPSlr okl
\here, l : Pump dierential head
o : Caitation coeicient o 1homa
NPSl Aailable d

NPSla ,P - P2, k --- - zP l

Sp.Gr
\here, P : Pressure at suction liquid leel ,,,
P2 : Vapor pressure at suction temperature ,,,
zP : Pressure drop in suction line ,,,
l : leight between the normal liquid leel and pump centerline ,m,
Pump Dierential lead d

l ,Po- Ps, k----

Sp.Gr
\here, l : lead ,m,
Ps : Pump suction pressure ,,,
Po : Pump discharge pressure ,,,
Sp.Gr : Speciic graity at pumping temperature
C'11O
Deinition: Knocking due to ormation and subsequent collapse o apor bubbles.
,Indication: Noise,
Caitation is caused by the ormation o apor bubbles in a high-elocity, low-pressure
region and by the subsequent collapse when the bubbles moe to a higher pressure region.
Caitation can cause excessie erosion and ibration.
\ith moderate caitation in a centriugal pump, the pump will sound as though it is
pumping grael or a slurry o sand and grael.
Seere caitation will cause the discharge pressure to all and become highly erratic and
produce both low and pressure pulsation.
Cavitation occures due to :
Pump caitation can result rom insuicient aailable NPSl
ligh pump-suction elocities and long piping increase pressure luctuations in the
pump.
Vacuum systems seem more prone to unpredictable caitation than pressure systems.
Methods to avoid Cavitaion:
NPSla ,P,suction, - P,saturation, ~ NPSlr
Increase NPSla by
- Increase pressure at suction o pump
- Decrease liquid temperature
- Reduce head losses
- Reduce NPSlr ,Depends on Impeller inlet, Impeller design,
Pump low rate, impeller speed, type o liquid,
PUMP PIPING 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 Flexibility of Suction Lines
Piping lexibility aects pump location.
Pump suction lines should be as short as possible, but with enough lexibility. Pump suction lines should be as short as possible, but with enough lexibility.
I possible , do not oerlap the pump and pipe support oundations, as it causes I possible , do not oerlap the pump and pipe support oundations, as it causes
structural design problems in combining oundations. structural design problems in combining oundations.
Suction Line Iittings Suction Line Iittings ::
Reducers should be as close as possible to the pump suction nozzle so that Reducers should be as close as possible to the pump suction nozzle so that
pump suction will not stared. pump suction will not stared.
Use Lccentric reducer with llat Surace up. ,lSU, Use Lccentric reducer with llat Surace up. ,lSU,
Always use long radius elbow. Always use long radius elbow.
Air pocket ormed along upper side o pipe by concentric
reducer.
Strainers : Strainers :- -
Strainers will be located between pump suction block ale and pump. Strainers will be located between pump suction block ale and pump.
1ype o strainer 1ype o strainer
, 1emporary strainer , 1emporary strainer
2, Permanent strainer 2, Permanent strainer
onical strainers onical strainers are longer than the basket type. are longer than the basket type.
1hese are used on suction lines 2` and larger. 1hese are used on suction lines 2` and larger.
lor lor basket and conical tpes basket and conical tpes a remoable a remoable
spool piece must be proided downstream o spool piece must be proided downstream o
suction block ale suction block ale
Flat strainers Flat strainers use with ery use with ery
short suction lines where no short suction lines where no
debris is expected debris is expected
athtub or tee type strainers athtub or tee type strainers as most as most
expensive , it does not require unbolting and expensive , it does not require unbolting and
removing spool piece to remove the strainer. removing spool piece to remove the strainer.
- tpe strainer to permit sericing o the
strainer. Also, a blow-o connection may be
proided in the end cap to lush the strainer.
Block Vale :-
Suction line should hae positie shut o ale, use gate ale at the Up stream
o strainer.
Pump ales are operating ales, thus keep them as low as possible
Consideration of Cavitation
Caitation occurs when NPSlr is larger than NPSla. Caitation occurs when NPSlr is larger than NPSla. Caitation reduces the Caitation reduces the
perormance o pump, causes ibration or noise and corrodes the materials. perormance o pump, causes ibration or noise and corrodes the materials.
1hereore, minimize pressure loss on pump piping and, care shall be taken to 1hereore, minimize pressure loss on pump piping and, care shall be taken to
aoid driting on the nozzle. aoid driting on the nozzle.
Minimum required straight pipe on suction nozzle to preent driting Minimum required straight pipe on suction nozzle to preent driting
$uction type
lequired straigbt
pipe on suction
lemarks
End suction 2D `D $ee figure 1.
$ide
suction
$ingle suction 2D and o\er
$ee figure
2-1 and 2-2.
Double suction
1JD and o\er or insertion of
rectifying plate
Top
suction
$ingle suction 2D and o\er
$ee figure `.
Double suction 1JD and o\er
D- Suction Nozzle Size
igure 1. End suction piping igure 2-1. Side suction piping
Or inserts rectiying plate
,eccentric suction : 2D and oer,
ligure 2-2. Side suction piping
Consideration o
straight pipe at
suction side is not
necessary or
straight-up or
straight down.
Single
Single suction
: 2D and oer
Double suction
: D and oer
igure 3. %op suction piping
Consideration o air pocket on suction line
, Allow approximately ,2,5 o slope on suction line toward suction resource
i suction resource is lower than pump suction nozzle.
2, Allow ,2 and oer o slope on suction line toward pump at acuum tower.
,2 and oer
3 , I gate ale is to be installed on the line whose suction resource is located lower than the pump
suction nozzle, ale stem shall be horizontal.
Suction piping on tower or essel :
Vortex breaker is installed on tower or essel nozzle connected to pump nozzle.
1pical rrangement rawing
1. PUMP SUC% LE
orizontal
Vertical
A, lorizontal 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
ertical ane.
,C, May be installed with or without spool piece but 2 pipe diameters
spool is preerred.
- Ilexibilit of pipe for pump alignment after piping
Iollowing diagrams indicate correct and incorrect methods of attaching suction
piping
Shows proper method o connecting pump suction to a suction
header in order to aoid air pockets.
Represents a common error made suction piping to a centriugal
pump by placing piping oer an embankment o a reseroir, or
other obstruction.
ischarge Piping for Horizontal Pumps :-
Line Size :
Discharge nozzle size is normally smaller than the suction nozzle size.
ischarge Line Iittings :
Normally we use concentric reducers in the discharge.
But i 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 o the check
and gate ales
Check 'alve is used in a pump discharge line to preent backlow in to the pump
causing the impeller to turn backwards and possible ruining the bearings.
Block valve Isolate the pump rom piping to proide maximum access or both in
place or maintenance or remoal.
Pump ischarge Line
1) 1 1/2 and Under
2) 2 and Larger
Use Swing / all %ype Check valve Use inged Ilapper Check valve
3) 4)
lor ligher line size 8` and aboe
5)
Handling Hot suctions :
I essel suction nozzle is higher
\hen header going to the two pump
is at same eleation as suction nozzle.
1hese are used or ery hot larger piping
Side Suction nd Side ischarge Pump Side Suction nd Side ischarge Pump (Ior utilit Water Lines
1hese are used or large duty dierential pressure and large bore lines, the pressure 1hese are used or large duty dierential pressure and large bore lines, the pressure
dierence between the pump suction and discharge , and are usually multi dierence between the pump suction and discharge , and are usually multi--stage pumps, stage pumps,
the liquid going through seeral stages o increasing the pressure beore reaching the side the liquid going through seeral stages o increasing the pressure beore reaching the side
discharge nozzle. No o ells should be optimize allowable nozzle loading. discharge nozzle. No o ells should be optimize allowable nozzle loading.
1he two 1he two--diameter pup can be eliminated i the elbow rom the suction nozzle is diameter pup can be eliminated i the elbow rom the suction nozzle is
horizontal. horizontal.
1his pump is horizontal split case .
1he top case can be remoed or maintenance on
this type o pump .
keep the top o the pump clear.
'ertical n-Line Pumps : ( Hdrocarbon Services
1he main adantage o this type o pump is to
Lliminate many stress problems
Location when there is no oundation required
1his type o pump is mounted directly into the pipe line. lor smaller sizes, the piping
system supports the pump and motor.
lor heay or Larger size in-line pumps oundation will be required
'ertical Barrel 1pe or Can pump Dry well Pump ) : D Tank )
1his type o pump is installed in cooling tower water circulating serice, retention
ponds and suction is taken rom 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 or pump maintenance
Pumps can be used or more than one serice, such as pulling suction rom one
source and discharging to three dierent locations or multi-serice suction, which
using a pump or more than one serice.
Multi Service Pumps
Multi - Service Pumps :-
Reciprocating Pump Piping :
W 1hese lines should run close to the ground so that hold-downs can be used.
Suction and discharge piping to positie displacement reciprocating pumps shall
contain hold down restraints on piping to minimize the potential o pulsation
loading on pump nozzles should pulsation dampeners become inoperatie.
1o minimize the damaging eects o water hammer and other impulse type loading
on pump nozzles, Use swing type check ales in discharge lines in the
ertical position aboe rigidly supported elbows so that hammer loads may
be distributed to grade or steel.
Reciprocating Pump Piping
1hese pumps measured accurate flow rates that can be adjusted in operation to 1he
me provide a wide range oI varying Ilow rates.
Metering system is to control liquid discharge under a variet of back pressure
conditions according to precise olumetric requirements.
Since metering pumps permit little or no backlow, they are especially useul or
injecting liquids into containers or Ilow lines against high pressures.
Metering Pump :
Reciprocating Metering Pump
Installation o Dampers and Back Pressure Vale
Pulsation amper :
1he damper contains a diaphragm or bellows isolating the metered liquid rom an
air or gas padded chamber. its use eliminates hydraulic hammer, established more aorable
NPSl conditions on the inlet side o the pump, and allows use o smaller pipe size by
reducing peak liquid elocity and acceleration.
lor location o pumps in the tank arm area:
. Group together i economical
2. Make accessible or maintenance and operation
3. Locate outside o dyke area
In the routing o the suction lines, the preerred method would be to drop rom
the tank to the pumps. Aoid a direct run rom the tank into the suction nozzle. 1his can
cause problems in oerstress o the pump connection.
Pumps in the 1ankage rea :
Support o Piping In the tankage area, the supporting o piping is normally by:
Pipe sleepers
lield supports
Many pumps hae auxiliary piping that is supplied by the endor or the engineering Many pumps hae auxiliary piping that is supplied by the endor or the engineering
contractor . contractor .
\hen pump luid is used a line is attached to the ent connection on the pump case. \hen pump luid is used a line is attached to the ent connection on the pump case.
1he circulated luid must be sent back to the pump stream and return to the seal to 1he circulated luid must be sent back to the pump stream and return to the seal to
pump internal clearances. pump internal clearances.
In iscous or high temperature hydrocarbon liquids the seal luid medium circulates In iscous or high temperature hydrocarbon liquids the seal luid medium circulates
rom an external source through connections on the pump seal . 1his medium may be rom an external source through connections on the pump seal . 1his medium may be
clean gas or oil . clean gas or oil .
In ig the cooling water in and out o this particular pump is rom aboe grade , In ig the cooling water in and out o this particular pump is rom aboe grade ,
howeer many cooling water systems are below grade so the piping layout designer must howeer many cooling water systems are below grade so the piping layout designer must
ind suitable location or this connection. ind suitable location or this connection.
uxiliar Pump Piping rrangement :
uxiliary Pump Piping
Pipe 'ent nd rain Sstem :
W Are provide to escape air or vapour trapped in the casing.
Seal Ilushing
PPL 'L1 R SS1LM IOR PUMP:
Install on the place where access is easy during the operation. Install on the place where access is easy during the operation.
Suicient space shall be proided at and around pumps to enable maintenance and
remoal o all internal and external parts.
1he minimum walkway clearance around pumps will be 2'-6`.
1he pump should be located as close as possible to the source o suction. 1he main
reason or this is to minimize pressure drop. 1his keeps line sizes and equipment
eleations to a minimum.
Minimum clearance o 3'- is required between pumps, adjacent equipment,
oundation or other obstructions.
Pumps should be located inboard o oerhead pipe rack as much as possible in order Pumps should be located inboard o oerhead pipe rack as much as possible in order
to sae the required plant area. to sae the required plant area.
Pump Location rrangement : Pump Location rrangement :
lor maintenance o the pumps located under the pipe racks or steel structures, lor maintenance o the pumps located under the pipe racks or steel structures,
maintenance beam or hook shall be planned upward o the pump unless, maintenance beam or hook shall be planned upward o the pump unless,
,, Access way o maintenance ehicle is proided under the pipe rack. ,, Access way o maintenance ehicle is proided under the pipe rack.
,2, Access o automobile crane is possible. ,2, Access o automobile crane is possible.
Maintenance space mm required around pump and without major disassembly. Maintenance space mm required around pump and without major disassembly.
Pumps shall generally be lined up in parallel with the pipe rack to maintain a Pumps shall generally be lined up in parallel with the pipe rack to maintain a
uniormity o location. uniormity o location.
Pump discharge points to be ixed in a line below pipe rack and to be about 5 mm Pump discharge points to be ixed in a line below pipe rack and to be about 5 mm
away rom pipe rack bay. away rom pipe rack bay.
In hydrocarbon or other lammable luid serice, threaded construction shall not be
used or piping connected to pump, including branch piping within 6 eet o pump
suction or discharge langes or through suction or discharge block ales, which eer
is greater. Socket weld unions are acceptable.
Pump Spacing Height of Pump foundation Pump Spacing Height of Pump foundation
Pump Spacing : Pump Spacing :--
Suction pipe size ,B, Suction pipe size ,B,
Pump spacing ,mm, Pump spacing ,mm,
leight o pump oundation : leight o pump oundation :--
leight o pump oundation shall be leight o pump oundation shall be 3mm rom ground leel or loor 3mm rom ground leel or loor
leel i it is on the paing or inside o building. But it shall be 3 leel i it is on the paing or inside o building. But it shall be 3 5mm or the 5mm or the
area where lood is expected. area where lood is expected.
Up to 2
1500 2000 2500 3000 4000
2 - 5 6 - 10 12 - 14 16 - 18
Others Others ::
, By , By--pass line which is installed on pump discharge line shall be routed without pass line which is installed on pump discharge line shall be routed without
pocket. pocket.
2, Aoid installation o chemical or water supply line near the suction nozzle o 2, Aoid installation o chemical or water supply line near the suction nozzle o
reseroir so that air shall not be sucked in. reseroir so that air shall not be sucked in.
Support regarding o eccentricity o pump : Support regarding o eccentricity o pump :
,, Support shall be installed so that pipe and ale may not load on the pump nozzle. ,, Support shall be installed so that pipe and ale may not load on the pump nozzle.
,, Support nozzle surroundings. ,But, do not exceed m.,
,2, Suction line and discharge line shall be supported respectiely.
Pump Surroundings Support :-
,3, I support is installed right close to suction or discharge nozzle, it shall be ,3, I support is installed right close to suction or discharge nozzle, it shall be minutely minutely
adjustable type so that centering can be conenient. adjustable type so that centering can be conenient.
,4, A support installed around suction or discharge nozzle shall be such a type that piping
can be remoed 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 o piping during
the time o pump maintenance.
%W3 WA