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The Process Plant LayoutThe Process Plant Layout

and Piping Designand Piping Design

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Process Plant Layout and Piping Design Agenda

Introduction to PlantIntroduction to Plant

Layout DesignLayout Design

Plant LayoutPlant Layout

SpecifcationsSpecifcations

Plot PlansPlot Plans

CompressorsCompressors

DrumsDrums

ReactorsReactors

TowersTowers

StructuresStructures

ExchangersExchangers

FurnacesFurnaces

PumpsPumps

Pipe RacsPipe Racs

InstrumentationInstrumentation

Process Li!uidProcess Li!uid

Storage Tan Storage Tan 

Pipe Stress "nalysisPipe Stress "nalysis

#nderground Piping#nderground Piping

$hat is a Process Plant %$hat is a Process Plant %

&iscellaneous&iscellaneous

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Pumps

 The Process Plant Layout and Piping DesignCourse

&ain &enu&ain &enu

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Introduction to Pump

Terminology• Pumps – the purpose of pumps is to makefluids flow. Pumps do this by adding energyto the fluid. Added energy increases pressure.luid flows from high pressure to low pressure. Pumps add energy by centrifugalaction! by pistons! and by rotary action.

•Centrifugal pump – this is the most commontype of pump in a process plant. A dri"er!usually an electric motor but sometimes aturbine! whirls an impeller around the centrala#is of the pump. As the fluid enters the sideof the impeller casing through the suctionno$$le! the impeller scoops the fluid up!whirls it around the casing and hurls the fluidout of the discharge no$$le.

• Reciprocating Pumps – used for "iscousfluids or for small amounts of fluid flow%such as for process additi"es& add energy byusing a piston instead of the impeller found incentrifugal pumps. luid pulsations can cause"ibrations in the piping system.

• Rotary Pumps – these pumps are usedfor highly "iscous li'uids that a high(speed impeller cannot )push*. The li'uidis pushed through the pump casing bygears! "anes! or cams.

• Horizontal and Vertical Pumps –+ori$ontal pumps are the most common.+ori$ontal pumps ha"e the dri"er and theimpeller at the same ele"ation connected by a hori$ontal coupling. ,ertical pumpsha"e the dri"er abo"e the impeller.,ertical pumps are used when -P+re'uirements make using hori$ontal pumps impractical.

• Net Positive Suction Head ( -P+ is

one of the most important terms adesigner has to know. -P+ is a measureof the pressure drop of the li'uid as itmo"es form the inlet of the pump to theeye of the impeller. -P+ is acharacteristic of the pump and is usuallydetermined by manufacturer testing.

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Introduction to Pump

Terminology %cont&• Vapor pressure – /hen the pressure in the pump suction line falls below the "apor pressure of a li'uid! the li'uid changes to"apor. The pump cannot pump "apor andthus becomes )"apor bound*

• Available NPSH – this term refers to the net

 pressure a"ailable in a gi"en system! basedon "essel pressure and static head! minus theli'uid "apor pressure and functional losses inthe system. The designers goal is to maintaine'uipment heights and minimi$e pumpsuction piping to ensure that the a"ailable

 -P+ is greater than the re'uired -P+.Insufficient -P+ can reduce pump capacity

and efficiency and lead to ca"itation damage.• Cavitation – The rapid collapse of "apor

 bubbles that can produce noise! result in aloss of head and capacity! and create a se"ererosion of the impeller and casing surfaces inthe ad0acent inlet areas.

• Alloable Nozzle Loading – This is thema#imum amount of stress that the pipingconfiguration may impose on the pumpsuction and discharge no$$les! as set by the"endor! client or code.

• AP! "American Petroleum !nstitute#

pumps – this term refers to the hori$ontal!single(stage pumps found in the petroleum.The standard de"eloped by "endors!contractors! and users entitled 1API 234 –5entrifugal Pumps for 6eneral 7efineryer"ice8 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&

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Horizontal Centrifugal Pump

Double-acting Piston Pump

Rotary Pumps

Inline Centrifugal Pump

Sump Centrifugal Pump

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Introduction to Pumps Terminology

%cont&

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Introduction to Pumps

Design Tips

• Pump Locations along a rac$  –  9eep in mind that in setting the pump

location your ob0ecti"e is to minimi$e thelength of suction piping while stillmaintaining enough piping fle#ibility that

the no$$le loads are low during operation.Locating the pumps under the rack is oneway to achie"e this goal. The problemwith pumps under the rack is the potentialfor hydrocarbon leaks onto the pumpmotor which may create safety and:ormaintenance problems.

 –  ;ou can locate pumps outside of the rack

%which is often what your client willre'uire&. /hen you do this! be sure thatyou ha"e accounted for the au#iliary steelthat may be needed to support pipinggoing to and from the pump to the piperack.

• Pump Locations near e%uipment –  Pumps operating with e#changers and

drums that are located in "erticalstructures can be placed beneath thestructure. +ydrocarbon leakage is usuallynot a concern in that type of situation.

 –  5entrifugal pumps in a "acuum ser"icetypically ha"e to be located "ery close ordirectly beneath the suction sidee'uipment! which is normally a tower.

 –  /hen locating pumps beneath a tower besure to account for the potential of springcans that support the pump causing the

 pump to be ele"ated higher than normal.Also! pumps on springs ha"e a tendencyto "ibrate depending on flow rate. The

 potential for "ibration on spring mounted pumps should be discussed with bothyour stress engineer and your processengineer on the pro0ect

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Introduction to Pumps

Design Tips %cont&• Pump Locations by type

 –  ,ertical pumps are more e#pensi"e than

hori$ontal pumps. ;et "ertical pumps can

 be the right solution when you ha"e

 problems achie"ing -P+ re'uirements.

or e#ample! between a hori$ontalcentrifugal pump and a hori$ontal "essel

you would measure the -P+ distance

you ha"e between the centerline ele"ation

of the pump shaft and the bottom tangent

line of the "essel. If you were using a

"ertical pump instead! you would

measure the distance between the bottom

impeller of the "ertical pump which can

 be located below grade. This would lower

the ele"ation of the hori$ontal "essel and

sa"e 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(rame<

 –  Is there the potential for replication of

this piping layout elsewhere in the plant<

or large numbers of similar systems it

may be worth while to design for the

largest pipe si$e and highest temperature

and layout all =close= systems the same

way.

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Introduction to Pumps

Design Tips %cont&• Pump Piping

 –  /hen laying out piping on "erticalsuction and "ertical dischargecentrifugal pumps! assure that theflanges on the larger "al"es do notinterfere with each other. If they dointerfere! but only slightly! the use of

eccentric reducers on both suction anddischarge lines may offer enough offsetto pro"ide the clearance you need.

 –  5entrifugal pumps with side suctionno$$les are particularly prone toca"itation. A generally accepted rule ofthumb is to make sure a minimum offi"e diameters %>D& of straight run is

added to the line before it reaches thesuction no$$le

 –  /hen a pump suction line comes from below grade! be sure to orient thereducer at the pump no$$le with the flatside up.

• Pump Piping Supports

 –  +as the stress engineer determined the location ofthe supports< or most centrifugal pumps the stressengineer is responsible for locating the support andguide scheme and determining the loads on thosesupports. The location of these supports can affecthow you layout the pipe! and "ice "ersa. +ere are

some simple rules to follow that will help you predict where the supports will be.

• or end and side suction pumps! e#pect an ad0ustableor spring support to be placed at the first elbow.ince both these types of supports typically need atleast 3?8%@44mm.& clearance! maybe more! e#pect adummy leg off the first riser from the suction no$$le-L; I your bottom of pipe coming from thesuction no$$le is low to the grade.

• n a "ertical discharge line some designers turn the pipe fitting to fitting to the hori$ontal plane until thedischarge piping clears the foundation then turn up.It is at this second elbow transitioning from thehori$ontal to the "ertical plane that a "ertical dummyleg going to a spring can or ad0ustable support can

 be located.

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Pumps locatedpartially underpiperac'

Pumps locatedunder piperac'

Pumps locatedoutside o( rac'

Pumps locatedunder a structure'

Introduction to Pumps

Design Tips %cont.&

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Introduction to Pumps

Design Tips %cont.& Typical Centrifugal

Pump u!iliary PipingLayout

 Typical Centrifugal PumpPrimary Piping Layout

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&'P!CAL P!P!N( )*R C+N&R!),(AL P,-PS

Bost pumps used in industry are of the centrifugal type. Typical piping and fittings re'uired

at a centrifugal pump together with the "al"es necessary to isolate the pump from the

system.

The check "al"e is re'uired to pre"ent possible flow re"ersal 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 re'uired to facilitate remo"al.

Although centrifugal pumps are pro"ided 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 si$e than the inlet port! to

a"oid ca"itation. 5a"itation is the pulling by the pump of "apor spaces in the pumped li'uid!

causing reduction of pumping efficiency! noisy running and possible impellor and bearing

damage.

Bost pumps ha"e end suction and top discharge. Limitations on space may re'uire another

configuration! such as top suction with top discharge! side suction with side discharge! etc.

Determination of no$$le orientation takes place when e'uipment layout and piping studies

are made.

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A,.!L!AR'/ &R!-/ or HARN+SS P!P!N(

Pumps! compressors and turbines may re'uire water for cooling bearings! for mechanical

seals! or for 'uenching "apors to pre"ent their escape to atmosphere. Piping for coolingwater or seal fluid is usually referred to as au#iliary! trim! or harness piping! and the

re'uirement for this piping is normally shown on the PCID. This piping is usually shown in

isometric "iew 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 li'uid from the discharge of the pump! by a built(in arrangement! or piped from a connection on the pump*s casing. The gland may be pro"ided with a cooling

chamber! re'uiring piped water. If a pump handles hot or "olatile li'uid! seal li'uid may be

 piped from an e#ternal source.

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DRA!N!N(

ach pump is usually pro"ided with a drain hub E to 2 inches in diameter! positioned about F

inches in front of the pump foundation on the centerline of the pump. The drain hub is piped tothe correct sewer or effluent line. If two small pumps ha"e a common foundation! they can

share the same drain hub.

Bost centrifugal pumps ha"e base plates that collect any leakage from the pump. The base

 plate will ha"e a threaded connection which is piped to the drain hub. /aste seal water is also

 piped to the drain hub.

• In outside installations in free$ing climates! pro"ide a "al"ed drain from the pump*s casing.

• Pro"ide a short spool for a G(inch drain between the on: off "al"e and the check "al"e! to drain

the discharge line. If the "al"e is large enough! the drain can be made by drilling and tapping a

 boss on the check "al"e! in which instance no spool is re'uired.

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!NS&ALLA&!*N

• Do not route piping o"er the pump! as this interferes with maintenance. It is better to bring

the piping forward of the pump.• Lea"e "ertical clearance o"er pumps to permit remo"al for ser"icing 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! a"oid rigid piping

arrangement! as the tanks will )settle* in the course of time.

Locate the pump as closely as practicable to the source of li'uid to be pumped from storagetanks! sumps! etc.! with due consideration for fle#ibility of the piping.

• Position "al"es for ease of operation placing them so they are unlikely to be damaged by

traffic and will not be a ha$ard to personnel.

• The foundation may be of any material that has rigidity sufficient to support the pump

 baseplate and withstand "ibration. A concrete foundation built on solid ground or a concrete

slab floor is usual. The pump is positioned! the height fi#ed %using packing&! and the grout isthen poured. 6rout thickness is not usually less than one inch.

• A pit in which a pump is installed should ha"e a drain! or ha"e a sump that can be drained or

 pumped out.

• Bake the concrete foundation at least as large as the baseplate! and ensure that concrete

e#tends at least @ inches from each bolt.

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VALV+S

• ,al"es are )line si$e* unless shown otherwise on the PCID.

•Hse tiling disc or swing check "al"es for preference.

• Do not use globe "al"es for isolating pumps. uction and discharge line isolating "al"es are

usually gate "al"es! but may be other "al"es offering low resistance to flow.

S,C&!*N L!N+

To a"oid ca"itation! the pump must be at the correct ele"ation! related to the le"el or head of

the li'uid being pumped. If the location of the pump has not pre"iously been established on

an e'uipment arrangement drawing! refer to the engineer in"ol"ed.

ccentric reducers are used! and are arranged to a"oid %3& 5reating a "apor space. %?&

5reating 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 "Cont0#

If a centrifugal pump has the suction no$$le at the end %in line with the dri"e shaft&! an elbow

may be connected directly to the no$$le at any orientation.

If a pump has the suction no$$le at the side with spilt flow to the impellor pro"ide a straight

run of pipe e'ual to @ to > pipe diameters of the suction line to connect to the no$$le.

Alternately! and elbow may be connected to the suction no$$le! but it must be arranged in a

 plane at F4 degrees to the dri"ing shaft! to promote e'ual flow to both sides of the impellor. If

an elbow must be in the same plane as the dri"ing shaft of the pump! consider the use of

turning % or splitter& "anes to induce more e"en flow. Hne"en flow causes damage to theimpellor and bearings.

• 7oute suction lines as directly as possible so as not to star"e the pump and incur the

risk of ca"itation.

• If the pump draws li'uid from a sump at a lower ele"ation! pro"ide a combined foot

"al"e and strainer. A centrifugal pump working in this situation re'uires priminginitially – pro"ide for this by a "al"ed branch near the inlet port! or by other means.

• Pro"ide a strainer in the suction line. Do not place a temporary startup screen

immediately downstream of a "al"e! as debris may back up and pre"ent the "al"e

from being closed.

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D!SCHAR(+ L!N+

The outlet pipe for centrifugal and other non(positi"e displacement pumps is in most cases

chosen to be of larger bore than the discharge port! in order to reduce "elocity andconse'uent 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.

• Pro"ide a pressure connection in the discharge line! close to the pump outlet. It may be

necessary to pro"ide a short spool for this purpose if there is no pressure point tapping on

the pump discharge no$$le.

• or locations of drain connections in the discharge line! see figures.

P,-PS 1!&H SCR+1+D C*NN+C&!*NS

A pump with screwed connections re'uires unions in the suction and discharge lines to

 permit remo"al of the pump.

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5entrifugal Pump Piping in le"ation

crewed Piping

langed Jutt(/elded Piping

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Piping to 5entrifugal Pump ( Alternati"es

Screed

Piping

)langed 2utt3

1elded Piping

Soc$et31elded

Piping

Disc4arge

-anifold

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5entrifugal Pump Piping in le"ation

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5entrifugal Pump Piping in Plan

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5entrifugal Pump Piping in Plan

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5entrifugal

PumpPiping in

le"ation

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5entrifugal Pump Piping in Plan

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5entrifugal Pump Piping in le"ation

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5entrifugal

Pump Piping

in Plan

%at 7eboiler&

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5entrifugal Pump Piping in le"ation %at 7eboiler&

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Betering Pump

Piping in Plan

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Betering Pump Piping in le"ation