SECTION 1 EQUIPMENT IN PLANT DESIGN Equipment Function and TerminologyEQUIPMENT FUNCTION AND TERMINOLOGY VESSEL Vessels are either horizontal or vertical and are basically cylindrical in shape with enclosed ends, usually dished heads and are designed and manufactured to ASME. Pressure Vessel codes. Their function can be one of heating, separating, blending etc and the size and shape will depend on these and other process conditions. The piping designer is responsible for the orientation and placement of all nozzles and vessel clips which are used for ladders and platforms. It is essential that the designer fumish this information to the fabricator prior to manufacture of the vessel or the Engineer will be subject to back charges. This task is not to be taken lightly as it will determine how the piping is going to be run, ‘Vessels take on the name of the function they are performing to the process, typically these are: FRACTIONATING TOWER Is a vertical vessel with internals, either trays or a packing, and towers are given names according to the function they are performing, I.e. a Depropanizer fractionates out propane. OVERHEAD ACCUMULATOR Is a horizontal vessel that it accumulates the overhead product from the Fractionating ‘Tower after it passes through a condenser. “Te Layout of Piping Spt: And Proce Equipe MEAD!) Orpiniaed Gyr EDSASIASDN GHD EDS SeutesCo,Ud. ED Keowledge Pe Lit Sige re Notes om nk ne mete, in a ED KNOWLEDGE JULY 2008EQUIPMENT FUNCTION AND TERMINOLOGY HORIZONTAL VESSELS OR DRUMS Are relatively large diameter cylindrical pressure vessels used for a variety of process functions. Their height above grade is usually determined by the NPSH requirements of the pumps in the liquid outlet line or the gravity flow requirements to other equipment. And they are supported by the use of saddles (see left picture) The arrangement of connections on the vessel is dependent on process requirements, access to valves and instruments and general maintenance, The use of platforms and ladders in elevated drums is essential and they should be positioned according to the priorities listed in the preceding paragraph. The pictures below show two horizontal pressure vessels, of note is that in the left picture the support saddles are higher than normal and on the right there is a manhole and a lifting lug located at one dished head. See Horizontal Drums Topic —~ “The Layout of Piping Sytem And Prove: Equpricnt (M21) Ovasied By-EDS ASA SONBHD EDS Solo Go, id, ED Kade Pe Li [Nivharenod Rept ous bespouanorcped ay aby a en eg see ea cpa, aN naan ai ‘pe, othe ot pa ep ED KNOWLEDGE SULY 2008EQUIPMENT FUNCTION AND TERMINOLOGY HORIZONTAL VESSELS OR DRUMS HeRETAL Be Widen & saeOEIATES gz = & ED KNOWLEDGE JULY 2008 4EQUIPMENT FUNCTION AND TERMINOLOGY VERTICAL VESSELS OR TOWERS ; te x OL als ~|-s|ssh = & a sfslo|s[s/—| Level Gace: 77 |e neavy curt 4 er a t List cur a] INTERMEDIATE CU vest LJ Sa sein = “soT10Ms pur Access DOOR oniver VENT. saat ake kine: access The Layo of Piping Ses And Proce Eeupnen (MEA) Metadata cna padi nyt et EDRNOWLEDGE JULY 2008, Oreaited By: EDS ASIA SDN BHD EDS Seluters Ca, Lid ED Krewedge Pe Ld ven rch peng tig onloadPIPE RACKS and YARD PIPING ALLOY PIPING Run piping straight and shortest route possible, alloy to take preference over carbon steel within reason. ie. route alloy piping first, carbon steel piping will follow. Ells versus Bends - use elbows generally Avoid tangential welds. TANGENTIAL, WELD Specification breaks - carbon stee! to alloy. Piece of carton steel pipe to be welded to alloy flange by Fabricator to avoid dissimilar field welding. Carbon steel branch connections on alloy lines - make branch, alloy header spec. for frst portion to give strength at header, ALLO STEEL HERE, \ ema N\A. “Te Layout of Piping Syrtens Aad Process Euipmest (MPI21) —_Ongzed BY EDS ASIA SDN BHD EDS Soltis Co, Lek ED Kavwledge Fe Lad Athena Repeated py omy yma gen eh neg barron ED KNOWLEDGE JULY 2008 28PIPE RACKS and YARD PIPING ALLOY PIPING a Cast transition pieces are sometimes required where two different alloys are joined, as opposed to a straight weld, this is due to the two alloys reacting together and forming a corrosive environment. b. Check if cold spring is to be used, It is used to control the movement of an pipe subject to thermal growth. Discuss with Stress Engineer © If Schedule 160 alloy nipples are called for, check if this schedule is available. 4 18/8 piping. A special fabrication spec. is usually issued for austenitic stee! piping. This spec shows permissible fabrication details. ©. Alloy support trunnions may be required as integral part of fabrication. Check with Support Group and add to isometric. ne ALLOY TRUNNION \ SUPPORT STEEL PIPE _RUN The Lnouofiping Systema AndTeoce: Eguipment(MEN2I) Orgaizal By: EDS ASIA SDNBHD EDS SoluioesCa,Led_ ED Keewledg: Pe Li lager Hopatcong terpenes a en meh posing tng rma er ED KNOWLEDGE JULY 2008 29,PIPE RACKS and YARD PIPING ALLOY PIPING a 18/8 piping, 750°F, and above. Where branch lines are smaller than header size, make connection by use of (A) reducing tees (B) weld-o-lets. b. Reinforcing pads shall not be used unless specific approval is given and if ~ required by piping code. © Check all material on isometrics at least twice before signing drawings as checked. It, is most important that alloy material is absolutely correct. “The Layot of Figg Syste And Proce Eien (ME®2I) Organized By: EDS ASIA SDNBHD EDS Soins Co, Ud ED Kaowlege Pa Led ‘Mga need Spar eee may beret orsapadinay fro) mae, mcg ene, ane, ying eg eration ne ‘em bp eis amine ote EDRNOWLEDGE JULY 2008 30PIPE RACKS and YARD PIPING ALLOY PIPING The following are austenitic steels: 18% chrornium- 8% Nickel Steels (ANST types 302, 303, 304, 321, 307), 16% Chromium -13% Nickel-Molybdenum steels {ANSI types 316 and 317) = 25% Chromium - 12% Nickel Steels = (ANSI type 309) 25% Chromium-20% Nickel Steels (ANSI type 310) Layout of Piping Sytem And Proce Equipment (MENDI) Organized By-EDS ASIA SON HD EDS Solas Co, Lid ED Keowldge Pe Led snd oun. cv ahs sear ny wenn sn ih eS wn EDKNOWLEDGE JULY 2008 31PIPE RACKS and YARD PIPING Trenched Piping (Civil Department, ‘= In most plants, trenches are avoided due to problems associated with this type of pipeway: High initial cost Fire hazard Where trenchers are used to route lines such as: Pump out lines Chemical sewers Chemical drains Trenchers must be enough to allow sufficient clearance between trench wall and piping 150 mm between outside of pipe and inside of wall is the minimum acceptable clearance This will allow for installation of piping, painting and future maintenance. See below figures, Total width of trench required may be determined by using method detailed above. Piping Department will advise Civil Department of requirements. tans And rece Equipment MEDI) Orgad By EDS ASIASON BHD EDS Selwins Ca, Lid ED Kaowlege Pe Lud cau ey breed pd nay omy any mata tng secon, mechan pny eno renee EDKNOWLEDGE 1ULY 2008 32PIPE RACKS and YARD PIPING LINE SPACING = Use Company job specifications = Line location in a trench carrying a number of lines should be carefully chosen for maximum piping economy consistent with stress requirements, if any. © Open trenches require drains to stop accumulation of surface water. Trench bottom should be sloped towards drain points. In this case, pipe supporting is by means of angle stect or I beams set into the walls, allowing bottom for free drainage to nearest drain point. = This method allows drainage of a trench by a minimum of drain points between each pipe support as would be the case of solid concrete pipe supports built up from the tench. Before proceeding on trench drainage check with coordination procedure and Civil Department for water table level. = Safety Precautions = Most trenches have either a cover of concrete slabs or a grating. © Where flammable liquids are carried in trenched lines, a fire break is provided at suitable intervals along a trench and at each intersection. This generally consists of two concrete walls 1 M- 1.25 M apart, with the space in between filled with sand, Where highly flammable gasses are carried, the whole trench, after installation of piping, is back filled with sand. Piping will advise Civil Department of requirements, ‘The Layoa fing Symone And Proc Euipment (MEI) Organised By EDS ASIA SDN BHD EDS SoluionsCo, Lak ED Knowiege Pi ‘signs med No pat rena bempead endian oy wank ng sane xh hep eg nortan [ED KNOWLEDGE /ULY 2008 33PIPE RACKS and YARD PIPING Underground Piping = Keep buried piping to a minimum. Generally only sewer drain lines and fire mains are located below ground. In some cases due to Client or climate requirements, cooling water lines are also buried below the frost line. = With future maintenance in mind, buried lines should be located well clear of foundations, and if running side by side, well spaced out. A minimum of 300 mm clearance is necessary between foundations and lines and between the lines themselves. = Above ground safe drain-tails will enter below ground drain line via a tundish (concentric reducer normally) or if a sealed system and cooling water lines by a flanged stub raised above ground. = Flanged connections should be a minimum of 300 mm above prevalent grade level. It is advantageous to set a common level for all these take offs at the outset of the job. When locating tie-in connections to underground systems, especially from elevated drain points, and adjacent to equipment plinths, ensure adequate clearance. = All buried steel pipes should have applied a corrosion resistant coating and wrapping. = Deep valve boxes for buried lines should be designed with ample room inside the box for a maintenance man to bend over and use wrenches for tightening flanges of re- packing valves. Consideration should be given to the use of concrete pipe in lieu of square boxes. = The criteria for a good underground piping design should be ease of maintenance. Piping should be so spaced as to allow easy digging out and replacement of faulty sections; for this reason, never run underground piping under or through foundations. ‘The Lott Piping Syste And Process Equipment (MEF21) __OrisedBy’ EDS ASIA SDNBHD EDS Seats Co,Lid. ED Knowledge PL Alger Napetn cna oy tren ay mr ag scan, me tog keine EDKNOWLEDGE LILY 2008 34PIPE RACKS and YARD PIPING Underground Piping GRATING OR CONCRETE coveR The Layout of Piping Sytens And Poses Exum (ME®21) _ Orgmizel By: EDS ASIA SDN BMD EDS Scteas Go Lid ED Knowle Pe Li ‘Aligarraued Nop scone nny bend cpa ay Cm ay maak ding ee maha py eg hr Se ihre per en eon abe oe [EDKNOWLEDGE JULY 2008 35PIPE RACKS and YARD PIPING PROJECT WORKSHOP Page 25 consists of a P&ID containing 4 pieces of equipment and 3 centrifugal pumps. The equipment consists of a Condenser (horizontal exchanger), Reboiler, Depropanizer (vertical column) and a Horizontal Drum. Page 26 contains a Plot Plan of the P&ID showing the pipe rack and equipment in various locations. Alll topics are covered under their respective sections. The project is to complete a piping arrangement drawing from the P&ID and Plot Plan as the various applicable topics are completed. This portion of the project shall involve the design and placement of piping on the piperack which is a single level rack 20’-0” wide and 15’-0" to the top of steel. “Te Lyoa of Piping Syions And Process Equipment MEA2I) Orisa By’ EDS ASIA SONBHD EDS Sulatone Cn, Lid ED Knnafdge Pe Ld [Abvgnt rue No pat arcu mat ny tered pd ny mri as ag eae, canal Pyne a [ED KNOWLEDGE JULY 2008 36PIPE RACKS and YARD PIPING P&ID OF DEPROPANIZER AREA. [prey DS ASISSONBHD GDS otnsCa, ED oni Pe it erbyany men lig dren. acne peg eh -EDRNOWLEDGE JULY 2008, 37PIPE RACKS and YARD PIPING PROJECT WORKSHOP - RACK PIPING = The first task is to allocate segments on the piperack for different lines (ref. page 5) = The headers running through the depropanizer area and having line branches servicing the equipment are Steam, Condensate, Cooling Water supply and return, and various process lines. © Also we must allocate space for electrical cable tray and instrumentation. The cooling water headers should be located on the same side of the rack as the process area which is on the south side of the rack. = The steam and condensate headers and any hot process lines will be located on the North side of the rack to allow for expansion loops if required, = We shall leave a space 2°-6” wide in the centre of the rack for cable tray. = Research the section on page 19 to understand the layout procedure. Sita aaces ee SECLION 8 ec eleeRac Lakes “To Layout Piping Systeme And Proves Exsipment MEP) Orga Aman oe rc a eee pny fem By: EDS ASIASON BHD EDS Selwions Co, Lid. ED Knowledge Pe Li my mao eng een schanen phaesjingrkg krnae EDKNOWLEDGE JULY 208 38PIPE RACKS and YARD PIPING PLAN AT PROCESS UNIT 39 ED KNOWLEDGE JILY 2008PIPE RACKS and YARD PIPING PIPING ARRANGEMENT - PLAN EDS Saluions Co, Lid. ED cl pang ig EDKNOWLEDGE JULY 2008 40PIPE RACKS and YARD PIPING PIPE RACKS and YARD PIPING Before routing piping, a priority list must be put together listing in order lines that, should be run first, Le. process requirements, hot lines, large bore lines, alloy lines, lines requiring special routing for pressure drop reasons, pump suction lines. If we look at the P&ID on the next page there is a steam line $2-8"-B4A supplying heat to the Reboiler E-110 through the channel end bottom nozzle. This line is branching from the steam header S1-12°-B4A which is located on the piperack There is an orifice flange FE 211 on the line before the Reboiler. The return steam line from the reboiler RS3-8"-B4A_ ‘The Layou ef Pipe Systems And Frees Equgmen (MEAD) Orpaized By: EDS ASIA SON BMD EDS Sours Co, Lid [Avspstrensed pnt coe ray teeter pena ro) ey ane ng ste: mah pong eninge ara ‘Gente bauer ween pron cbc pr EDKNOWLEDGE JULY 2008PIPE RACKS and YARD PIPING CHECK LIST FOR PIPE RACKS 1 Use line spacing chart to ensure that all lines can be contained within rack. 2 Determine piperack elevations, normally bottom level of rack is 15 ft (000mm) above grade, depending on mobile equipment used to access pumps and equipment located under rack. — Flat turns for branch lines are not permitted. If the rack runs North/South then all East/West branch lines running to and from equipment etc. must, run, usually, 3 ft above or below. 4 Allow space for cable trays and instrument lines, 8. Check with adjacent areas to determine if they have any lines that run along your section of piperack. 6. Allocate sections on rack for certain lines e.g. steam and other hot lines that may require loops to be located on one side of the rack, 1 Group utility lines. 8 Group process lines. “The avout Piping Stems And Process Equipe (MEAZI) Organized BY-EDS ASIA SDN BHD EDS Sobions Co, Lid ED Krowledge Me Lat ‘Minguntasned Regine nem brgpatesrsapesinayfrevory wf my, eg oe made ei ego meena rhe ED KNOWLEDGE JULY 2008 42PIPE RACKS and YARD PIPING CHECK LIST FOR PIPE RACKS 9 Process and relief lines are placed next to the large bore lines and utility lines are positioned in the centre of the rack. The positioning of individual utility headers will depend on what side of the rack most of the branch connections are running to. 10. Cooling water lines should be located to one side of the rack, that side being where there are more branches to and from equipment. 11, Locate lines with orifice taps to outside of rack for maintenance/accessibility 12. Large bore lines should be located on the outside of the rack to reduce the bending moment on the beam. Check if future piperack expansion is planned before using flat turns. 13, If flanges are located in the line make sure that any flanges on neighbouring lines are staggered to minimize spacing. 4, All insulated lines must sit on shoes (see company spec. for height of shoes, normally 4”) BHD EDS Seluions Co, Lid. ED Kaede Pe Lid The Lajow of Ping § ing lem teeing eng erat ie ‘agate Ro pan ED KNOWLEDGE JULY 2008, 4BPIPE RACKS and YARD PIPING CHECK LIST FOR PIPE RACKS 15. ‘Small bore lines that may not span the distance between bents (columns) may be supported from larger bore lines if acceptable to client. 16, Loading at anchors on the piperack must be given to structural department to size steelwork accordingly. V7. In a multi level rack the steam and condensate lines are on the top level along with other utility lines excepting the cooling water which is on first level close to the equipment they serve. The preferred location of the electrical cable tray is on the top level, alternate being outside the first level. 18. Check steelwork clearances for addition of: a. Fireproofing. b. Brackets, ete. ‘he Layout ofipng Systems And Pees Egipmest(MEV2I) Organized By DS ASTA SON BHD EDS Solutions Co, Lid ED Knowledge PeeLid Arh ved Rape scr ey brain my fm ora mene ncaa Uae Meas poring oir nema er [ED KNOWLEDGE JULY 2008 44SECTION 3 PLOT PLANS AND EQUIPMENT LAYOUTPLOT PLANS & EQUIPMENT LAYOUT PLOT PLAN ED KNOWLEDGE JULY 2008 3PLOT PLANS & EQUIPMENT LAYOUT PLOT PLANS Plot plans are considered key documents to projects and are normally initiated in the pre- contract, conceptual and development stages of a proposal. After the contract is awarded for engineering, plot plans are developed at a rather rapid pace with very limited information. This early stage plot plan usually is very limited in detail, containing only enough dimensional daia to define the outer limits of the available property selected for plant development. Located within the boundaries of the — available property, rough equipment sizes and shapes are pictorially positioned. along with anticipated pipe rack configurations, structure shape and rough sizes. The plot plan at this level of detail is then used for constructability evaluation and is normally submitted to the client for approval Once approved by the client, almost every group including Engineering, Scheduling, Construction, Operations, Cost Control, Estimating and Material Control use the plot plan as a pictorial reference for their work. At this point, the plot plan becomes a universal document used by all groups to interface with one another and the client. Development of the plot plan in the very early stages is usually accomplished through the use of preliminary project design data, approximate equipment sizes and a process flow diagram to establish rough sketches. These sketches are used to determine structure configuration and relative equipment positioning. The plot plan is then "proven" by using a process flow diagram, marked up to depict the more expensive piping, such as alloy or large diameter piping. This “high dollar” = piping is usually marked in a point-to-point fashion in a specific color on a print of the plot plan. The balance of the process piping is then point-to-point connected in another color to prove the cost effectiveness of the selected equipment arrangement. “The Layeat of Piping Systems And Prose Equipmers(MEVII) _Orgaied By EDS ASIASON BHD EDS Slaions Co, Lid. ED Keoweige Pe Lid Ath eed ie pute eo oat ot ope ay ot WY esting Ee. hans pulsing nS afi el ia oct tr ste sos on ED KNOWLEDGE MULY 2008, 4PLOT PLANS & EQUIPMENT LAYOUT PLOT PLANS = The plot plan is a dynamic document, evolving through the life of a job. Some of the more common names and descriptions used during this evolution process are as follows: © Proposal Plot Plan - used to establish the basis of bid work. © Approval Plot Plan - offered to the client for his concurrence of available space, perimeter roads, adjacent inhabited areas and interface points with the remainder of the complex. © — Overall Plot Plan - a small scale depiction of utility, storage, and loading facilities as associated with the process plant. © — Sectional Plot Plans - the overall plot plan broken into manageable size drawings. © Planning Plot Plan - an agreed-upon arrangement which usually starts the work of most groups that rely on equipment positioning, © Production Plot Plan - an update of the planning plot plan after enough study work has been completed to establish firm location of equipment. This plot plan is the basis for beginning detailed design work. Construction Plot Plan - releases the constructor to begin activities related to equipment location, such as roads, pile driving, underground piping, foundations, etc. Itis the single document containing all equipment, structure and road locations, © — Final or "As Built” Plot Plan - a plot plan normally provided by the responsible engineering company that reflects the completed project as constructed. This plot plan is maintained by the client for future expansion work requirements or other business needs. ‘The Layontof ping Sysens And Proves Supren (MERI) Onygsied By: EDS ASIA SON BHD — EDS SolsuonsCo, id. ED Kuowiede Pe Lid heen Ne coe sy bee pl ay yma, on ere nal ppg, dg on ‘SD KNOWLEDOE JULY 2008 5PLOT PLANS & EQUIPMENT LAYOU PLOT PLANS Major Roles of a Plot Plan Plot plans are essential for obtaining permits and determining environmental and personnel safety. They are the key documents used in assessing fire protection, During the engineering and construction phases of a job, many owners use the plot plan as a basis for evaluating the level of completeness of agreed upon work. The document thus becomes a measuring device for progress payments. Prevailing winds and tower and structure heights must be considered in developing a plot plan. Although wind direction is never constant, prevailing wind is used as a basis to evaluate safety within the client’s complex, as well as the safety of neighbors should a spill, release or fire occur. Tower and structure height and their positioning are major considerations, especially when units are located near airports or in flight paths, Climatic considerations also play a major role in plot plan development. Extreme sun exposure in desert areas or near the equator may require shelters to protect operators and maintenance personnel from high temperatures. Conversely, special considerations must be given to plants located where extreme cold, ice or snow may be prevalent. Under the most extreme conditions, many equipment items requiring frequent visits by personnel are enclosed by heated shelters. These shelters are sometimes connected by tunnels, suitable for human passage. In many cases, plant utilities are run within the confines of these tunnels to guard against freeze-up and to conserve energy for producing utilities, streams. “The Layout of Piping Sptoms And Paces Equipment ESD) Orzanaad By EDSASASDNBHD EDS SobionsCo, (18. ED Kacwege Pre Lad Alpes Nanterre open eno mee cng ee nh en eg emi l ED KNOWLEDGE JULY 2008 6PLOT PLANS & EQUIPMENT LAYOUT PLOT PLANS Economy of Plot Plans Plot plan economy is directly linked to the ability to develop process modules. Process modules can then be related to actual plot plan configurations and in some cases NS integration of equipment items can eliminate the need for interconnecting piping. The level of talent required to develop plot plans and the interaction of the plot designer with process and equipment personnel often result in new and innovative equipment integrations and configurations. “The Layau of Piping Sens And Proves Equpmca MERZI) Organized By:EDS ASIA SON BHD EDS SolaioasCo, td ED Knowledge PreLid “ls eh sane oe Eom ny wan cg ae eri wind ED KNOWLEDGE RLY 208,PLOT PLANS & EQUIPMENT LAYOUT PLOT PLANS AND EQUIPMENT LAYOUT = The functional arrangement of equipment shall be initially determined by the flow sequence and operating procedures. = As far as possible, equipment shall be arranged in logistic process sequence for short piping connections and case of operation. = Ifpossible a central pipe rack should be located to carry headers that distribute pipes to and from the process equipment and lines that run from equipment to equipment. = Pumps can be arranged in rows close to and on either side of a central piperack. = Exchangers and vessels are grouped together forming outer rows on bath sides, ‘The Layout of Ping ystems And Pree Eeuipnen (MEA2I) Organized By EDS ASIA SDNBMD EDS Seluions Co, Lil ED Kaowedge Pe Lid [ivereacs Report cw eyed ep amr i me dig dna mee, pacing eg dane een EDKNOWLEDGE JULY 2008 8PLOT PLANS & EQUIPMENT LAYOUT The purpose of any drawing is to communicate information to the construction personnel, office people, customers and other interested parties. = The equipment plot plan is probably the most carefully scrutinized drawing the piping department will make. = Unit plot plans are used for: = (a) equipment location = (b) foundation location = (c) excavation drawings = (d) paving plan = (e) P&ID transposition vem Aad Proves Eaupment(MEA21) _OxpaiaedBy-EDS ASIASDN BHD EDSSolwionsCo, Lid. ED Knowle Pre Ld ce une nay ended ropa ay fee eco cnn poy ong era ‘geen ED KNOWLEDGE JULY 2008 9PLOT PLANS & EQUIPMENT LAYOUT Equipment Plot Plan = Equipment plot plans are drawn to scale, usually 1” = 20ft or if possible 1” = L0ft on one sheet of paper, = Plot plans should show all equipment, buildings, major structures, pipeways, roads, accessways and any other important item. = True North arrow and Plant North arrows should be shown. = Piperacks are shown by centreline only. = Show simple single line representation of all equipment with centrelines and equipment numbers. ‘The Layout of Piping Systems And Process Equipment (ME¥21) Oxgnized BEDS ASIA SON BHD EDS Solgors Co,Ltd ED Knowledge Pe Lad [ignored Re guna eens na ny Weep epedinny for yy ang cnc shel sig en ara eee ‘un nore pres somone pot EDKNOWLEDGE JULY 2008 10PLOT PLANS & EQUIPMENT LAYOUT SPECIFIC CONSIDERATIONS = — Some important aspects of the process units to be considered while developing the unit layout are as follows: = Pumps can be arranged in rows close to and on either side of a central pipe rack Exchangers and vessels are grouped together forming outer rows on both sides. Fired heaters are kept at one end of the unit at a certain minimum distance from the remainder of the equipment. = Prevailing winds at the site should be identified to permit proper orientation of furnaces, flares, dusty operations (such as sulfur handling) and cooling towers. = Erection problems should be anticipated for all equipment, As far as possible, towers, reactors and other fixed equipment must be located away from congested areas in the plant to permit erection at any stage of construction, this will enable the erection work to progress without interference or holdups. Exchangers and other equipment that need to be serviced with large mobile cranes must be located along the periphery of the plot. “The Layout of Piping Syne And Prose Equpment(MEAZ1) Orginied Hy: EDS ASIASDN BHD FDS SouionsCo, ted. ED Kavelege Pi Lad ‘lotr pcan yearn eng wen rece rin mE SED KNOWLEDGE JULY 008, ittPLOT PLANS & EQUIPMENT LAYOUT SPECIFIC CONSIDERATIONS = Maintenance methods for each type of equipment should he established. Equipment requiring frequent attention should have easy accessibility. = Arrangement of equipment having removable parts, wherever possible, should be made in such a manner as to facilitate removal without dismantling long lengths of pipes, etc. Free access for hoisting the equipment is also necessary. = Spacing within battery limits between individual process equipment should be sufficient to avoid compounding fire exposure problems between the individual items besides allowing maintenance, etc. There are no set formulae for minimum spacing since it varies with each unit. = Large and heavy equipment sometimes can require very large foundations. The layout engineer must have an approximate idea of sizes of foundations for equipment. Interference of foundations should be avoided particularly for rotating equipment. ‘The Layou of Piping Sites And Process Equipment (MER21) —_Ovganael By: EDS ASIA SDN BHD EDS Soluions Co.Ltd. ED Kaowedge Petal ‘A at No ete aoe ee may beeen mo 4 a eee Wea ng grin er ‘ponte fanaa pte peso oe mer ED KNOWLEDGE JULY 2308 12PLOT PLANS & EQUIPMENT LAYOUT SPECIFIC CONSIDERATIONS = Pipe racks in individual units normally run centrally within that unit, thereby splitting the unit into two or more areas of equipment. These major pipe racks should remain as unexposed to process equipment as possible = Critical piping circuits such as transfer lines from fired heaters, condensing vapor lines, etc., need to be identified and have adequate space provided = — Compressors should be located downwind and sufficiently far away from the heaters. = Pumps should not be clustered in one area simply because they happen to fit or the arrangement appears orderly, the high pressure charge pumps should be isolated from major process equipment and other pumps. = NATIONAL FIRE PROTECTION ASSOCIATION CODES NFPA 30 Flammable and Combustible Liquid Code "he Lyn Piping Systema And Poses Exuipmai MEAD) Organized By: EDS ASIA SDN RAD EDSSnaions Co, Lak ED Knowieege Pe Let ‘inte Napa te my dct epee aba es ok, mS pa eg omen nee ED KNOW.EDGE JULY 2008 13PLOT PLANS & EQUIPMENT LAYOUT PROCESS PLANT DEFINITIONS Battery Limits - The boundaries of a process area that establish the outer limit for location of equipment associated with a complete process or a group of integrated processes that must be shut down together for turnaround or isolated in the event of an emergency Combustible Liquids - High-flash liquids (closed-cup flash point 100°F (38°C) or higher) when handled at a temperature lower than the flash point minus 15°F (8°C). Flammable Liquids - Low flash liquids (closed-cup flash point less than 100°F (38°C), and high-flash liquids (closed-cup flash point 100°F (38°C) or higher) when handled at a temperature above or within 15°F (8°C) of their flash points. Flammable Materials - Flammable liquids, hydrocarbon vapors, and any other vapors that are readily ignitable when released to atmosphere (e.g. hydrogen, carbon disulfide). High-Flash Stocks - Stocks with a closed-cup flash point equal to or greater than 100°F (38°C). Light Ends - Hydrocarbons having a Reid Vapor Pressure (RVP) of 15 psia (103 KPA) or greater. Includes liquids with pentane and lighter components. Pure hydrogen is excluded from the definition. Low-Flash Stocks - Stocks with a closed-cup flash point less than 100°F (38°C). Pipeband - A pipeway, piperack, or sleeperway containing piping. Process Vessel - Any vessel, drum, column, tower or reactor associated with the processing or handling of hydrocarbons in a process area. ‘The Layout of Piping Sven And Process Equipment (MES21) Organized By: EDS ASIA SDNBHD EDS Slations Co, L.ED Knowledge Pe id ign pte a opp iy ye ocho ei pp deg ed ED KNOWLEDGE sULY 2008 14PLOT PLANS & EQUIPMENT LAYOUT BASIC DESIGN CONSIDERATIONS OBJECTIVES OF SPACING DESIGN The objectives of the spacing recommendations in this section are as follows: To permit access for firefighting, fire trucks and other emergency equipment. To permit access for operators to perform emergency shutdown actions in a fire situation, To minimize involvement of adjacent facilities in a fire and hence prevent further equipment failures. To ensure that critical emergency facilities are not subject to fire damage. To separate continuous ignition sources from probable sources of release of flammable materials, To avoid danger of nuisance to persons or facilities beyond the adjacent property lines. To minimize exposure of facilities to adverse consequences resulting from events external to the site. To permit access for normal operation and maintenance. To permit access for turnaround maintenance aetivities. To permit turnaround maintenance activities to be carried out without impact to adjacent, non-involved units ‘The Layout of Piping Systers And Proves Equipment (MEA2I) Onin By: EDS ASTA SDN BHD EDS Soins Co, Lu ED Knowledge Pe Led ‘Alig ed Roget ones bereede oben em sf mee eng cee, ees hors Heng ron et ED KNOWLEDGE JULY 2008 15PLOT PLANS & EQUIPMENT LAYOUT DEVIATIONS FROM SPACING STANDARDS Where spacing is reduced significantly below the recommended distances, it is usually necessary to compensate for the increased degree of risk by providing additional safety features such as fireproofing, water sprays, firefighting equipment, emergency shutdown facilities, etc. Reductions below recommended spacings should not be made, however, unless reviewed and approved in accordance with the plants processes for management of change or accepting Design Practice deviations, as appropriate. Factors which affect layout and spacing and which may justify deviations include the following: Physical Limitations on plot space available, e.g., roadways or boundaries of existing facilities. Special Hazards - Increased spacing may be justified where special hazards or incentives to minimize fire losses apply, or where continuity of operations is a prime consideration (¢.g., certain chemical plants or LNG facilities). Flexibility - Space requirements for future expansion, which may be a complete unit or individual equipment items. Onstream Maintenance - This requires access space for personnel and equipment to individual items of equipment, and also separation of units within the plant which may be individually shut down for turnaround. ‘The Layentof Piping Systems And Process Euipmeat(MEN2I) _Organiel By EDS ASIA SDNBED EDS SslusensCo, Lid ED Knowl ‘tegen net a Str pe Gem yy a eh nk. Me, an Ma [ED KNOWLEDGE JULY 2008 16PLOT PLANS & EQUIPMENT LAYOUT DEVIATIONS FROM SPACING STANDARDS Topography has a major influence on safety of layout design in sloped areas. For example, location of separators depends on sewer drainage, and the possibility of major tank spills gravitating downhill to process areas must be avoided. Local conditions may dictate that site security be greater than normal, requiring LS increased spacing between the plant facilities and the property lines. Safety and public relations factors associated with the type of adjacent property must be taken into consideration in the plant layout design. Distance from the plant facilities to the property line must be sufficient to prevent danger or nuisance to the neighbors and vice-versa. The spacing required depends on the type of plant nearest to the boundary, and the nature of the adjacent property, e.g., industrial or residential. In residential areas, additional space for screening may be required. Generous spacing would also be advisable where the adjoining land is undeveloped but is subject to future development. Special Cases - In certain cases, such as small independent chemical plants handling materials with flash points above 100°F (38°C), reductions below the recommended spacing distances may be justified where the associated risk is limited. “The Layont of Piping Sees And Prove Equipment (MEAZI) _Orgpized By EDS ASIASDNBHD EDS SoluionsCo, tid. ED Knowledge Pr [Alnghtrssed No at to ane ne may Serta apein ane ara mes, eg decane Mn acting EN Mme OE EDKNOWLEDGE 1ULY 2008 7PLOT PLANS & EQUIPMENT LAYOUT GENERAL ONSITE LAYOUT Within the unit plot, the location of the major facilities, i.e., control house, electrical substation, fired heaters, compressors, etc.,should be designed not only in accordance with the spacing standards, but also with consideration of proximity to adjoining facilities, location of roadways, prevailing wind direction, site topography, ete. Whenever practical, locate process units, utility, flare and other areas with similar open flames at a higher elevation than tank farms and other bulk quantities of hydrocarbons; this minimizes the potential for ignition of hydrocarbon vapor releases or liquid spills. Where it is not feasible to locate tank farms at elevations lower than process areas, increased fire protection measures may be required to offset the increased potential for ignition. These measures may include all or some of the following: Diversion diking High capacity drainage systems Vapor detection placed at potential release points Additional fire protection systems such as foam, water sprays or similar protection measures Similar precautions for spills and vapor releases are needed when siting plants that will contain extensive quantities of toxic materials. Prevailing wind should be considered when locating ignition sources such as fired heaters and flares. Areas with high concentrations of personnel, such as office buildings, shop areas and existing neighboring community areas, should also be considered. in reference to prevailing wind to reduce potential exposures. ‘Te Layout of Piping Sytem And Process Equipment MEIDI) —_Orgiaed By EDS ASIASDN GHD EDS Solus Co, id ED Kaowieége Pe Lid ‘ieee pet be pc cpm oy ye ag cs ce pong. rire ED KNOWLEDGE IULY 2008 18PLOT PLANS & EQUIPMENT LAYOUT GENERAL ONSITE LAYOUT ‘The overall layout of the process area must be subdivided with accessways for firefighting, turnarounds, fire risk areas, and maintenance in accordance with the following: 1. Access for Firefighting - 20 ft (6 m) minimum width accessways for firefighting are required and these are normally arranged in a rectangular pattern such that the shorter dimension of each rectangle does not exceed 100 ft (30 m). Consideration should be given to limiting the longer dimension of each subdivision to 400 ft (120m) by the inclusion of additional firefighting accessways where necessary. 20 ft (6 m) of clear space under an overhead pipeband (including the case where air-fin exchangers are located above the pipeband) is acceptable as firefighting access on one side only of an area subdivision. 2. Turnaround Isolation - 50 ft (15 m) separation between groups of equipment which shut down separately for turnaround [75 ft (22.5 m) for light ends units 3. Process Area Subdi is for Determining Fire Water Rates - 50 ft (15 m) minimum separation between process area subdivisions which are used as the bases for determination of fire water application rates. 4, Access for Mobile Equipment for On-Stream and Turnaround Maintenance - 20 ft (6 m) minimum accessways are required to allow mobile equipment to reach equipment for maintenance. 5. Fire Risk Areas for the Sizing of Safety Valve Headers - In laying out a unit plot plan, 20 ft (6 m) accessways are provided for maintenance. These unit areas, surrounded by at least 20 ft (6 m) clear spacing on all sides, are the maximum areas which can reasonably be expected to be totally involved in a single fire. These areas are used to determine the combined requirement for pressure relief due to fire exposure. This should not be confused with the areas used to determine fire water and sewer capacities, which are defined as plot subdivision areas ‘he Layout of Piping Systeme And roses Epes (MEAD) Orguized By EDS ASIA SDNBED EDS Solatons Co, Lid. ED Knowledge Pe legged Neptune Meese ro A ee. a ein, en eke eT EDKNOWLEDGE JULY 2008, 19PLOT PLANS & EQUIPMENT LAYOUT ONSITE SPACING - EXXON [__seacws [stance ni | {TEM A Gas Compressors General -ihere hee ae several lage compresersin aunt usualy economical fr opersbon and aitnance to ocala ‘hemin one ees. Aseodatadeeercodles, cckcut chums, tc, maybe located he compreter area and need net comely ‘ithe 257 5m) epacng to non-associted ecupment, prodedthat hey donot rest acess fr efigong and Maintenance (generly, spacing of 101018 (ta 4S ms tice) ‘Access trfratging mus be avaable on et east ao sdes. Compressor atentston should consider the pasty of ‘massive mechanical falure in reaton to surrounding equiment. ‘Compressors hendeg inert aces rary be spaced coer than fs shown for gat compressors, unis they ae in a srvice te i eee toate ‘Protects highiwesent compressor equipment fom tres mwohng ober ‘eqipmant and vice-versa, Smal team reece motor diver censors do 20 150 i ies) nay be ed os ures pacng endocton p ‘Provide access for operation and maintenance. Congresses may be yoxnedin the same riskares Frama (G36 Comeressoxs} From 8 (Orvers Cher han Steam or Mate) *s ‘engiaete eae "Aton spetng febove he bast: spaang for onale ppebands) is ‘ntanded a protc png tom petantaty large compressor Ses. Pipebands do not pose asgncat isk to compressors and reduced ‘pacng (below the bas spacing for compressors appropiate. Where the compressors equipped wit pronlns for eutomatc shuts, isolation and lowdown in the event of fre, spcing canbe reduced to 10ft(3mi, Provides pedng between equpmentanding hysrocarbone rom sources tin ages, dec oges, Seam ot ores mantnance spacing imizes darage te iver ncse ot fred neat fe From (Fred heaters) FromW ons Ppsbands) “aon space above te base spacing for one pipebands} is intended to prt ing tom potently age tes divers, fpebands do not pose asgilcat skin drivers and reduced spacing {bon the baie spacing for vers) is appopite. Where te ive is ‘adoped wih provisons for automat shutfoun,olaton and baowdon in the evantat ae, spacing canbe redued to 10°8(3 "The Lavo of Piping Syste And Pres Equipment (MES2I) _Orgmined By-EDS ASIA SDN HD EDS Sstaiont Co, Ld ED Knowledge Pe Lit gerard Ronco meres open mys gc rg an [ED KNOWLEDGE MULY 2008 20PLOT PLANS & EQUIPMENT LAYOUT ONSITE SPACING - EXXON ITEM E -Ale Fin Coolers And Plate Heat Exchangers “General -Alrfn exchangers, wih their extenalve heat wansfe ertaces, are highly vulnerable to falure under fie expoaure. A *eerTed tocation for afin ss the opposde side of ractonatng towers, away fore fred heaters. They should not be located ar any of he folowing: 1, Pumps or compressors handing Raabe materi, 2. Drums or heat exchenge containing tarnmable meters, unis they ae pat fhe same process untae the af coder. 3. Any drums or heat exchangers containing tamimable materials above GO0°F (216°C) or above their autagniton temperature, whichever isiowet, 4. Preferably, a fins shold not be lacated aver r wih 10ft (3m) honizortalyof major pipebends except when a beta layouts not avatsble, because ofthe maintenance ditties that are introduced in adaton tothe re involvement hazard, |e ate located then the foowing requvemen's must be applied: ‘4 There should be at eas (25 m) of heed room between the weet pat atte arf cecler and me top of ne pe eck ». Flanges, vlves and etraneous meni ict associated wih the a fn cool should not ba ocated directly below ne ir cacer or tin 10 (3 m) horizontally beyond iin al reckons ¢. Normal horzontsl spacing requirements fram bam the alrfn cede and the pipebanc to axjacent equipment must be met 4 Access must be provided for mobie equipment fer remave and replacement of metore and afin ants, Supports forthe ai cooler and pipeband must be freproced in accordance with the requrements of1P 14-4, or gsketd plate exchangers, the flowing precautions ae recommended to ensue a ste and relate Hate heat exchanger ont 4. Spacing requirements fora cooled heat exchangers shouldbe appl to pate exchangers handing temmate fits, 2 tin lammebe service an looted less than 20 (6 m)nodzanuay from equpment with & high poten offre (IP 143-1), plate exchanger should be Srprooted. ‘3. See ERAE Report No. EE ATE.AT. Fire Solely cf Pate Heat Exchangers, fractions inornton 1043) ‘Minimizes damage to ai fins, since they are more vulnerable to damage from fire exposure than shed and tube exchangers ‘ir dlscharged frm afns should not create operating or mantenance problems on ether aqupment in structures. Layout of Piping Systeme Ard Proves Exupmen (MEI21) Onpnized By:EDS ASTA SON BHD EDS Solions Ca, Lid ED Knowledge Pe Ld Aig pth com treetops mer ego eying iran oe FED KNOWLEDGE JULY 2008 2PLOT PLANS & EQUIPMENT LAYOU' ONSITE SPACING - EXXON Rove cg os digas Dichage dap cn nfciated rom exchanger leakage uness a water disengaging dum inetaled petesm. Equipe ft des pea aun dic ‘andis ower than be cooing tower may be spaced 8015) ay, and eupment tht represents potntial soure of gion or sshigher man te - tower shout be spaced {00 (30m) way. Spacing end kcaton should ‘abo be select to mime corcion, ce formation and visibly probleme that may result tomimpingement of he cooing aver exhaust plume on adjacent high structures. ITEM G - Process Vessels Below 600°F (316°C) And Below Autolgition Primarily to pronde acess for operation and maintenance. Alo alows sare acess fo fretting, For very lage vessels, suchas cre desatters, consider providing alow toe-wvall rcund the vease! e minimum of ‘0. rom he vessel wale. The are nse the toe wal shoul be ‘gr8ded to dein to one or mara sealed catch basins located near the toe- veal No ober exupmnent shouldbe inated within the te wal ‘Beagrie And Pses Brie MBI) Gilby EDSASTASDNBED "EDS Stes Co La ED Kno Pea ‘tegen Rago ry amon py esr yn ky ee mt aso eg nn er [ED KNOWLEDGE JULY 2008 22PLOT PLANS & EQUIPMENT LAYOUT ONSITE SPACING - EXXON Fired Heaters General - Since fired heaters are a constant source of ignition, their location must be carefully selected. Where practical they should be located on the upwind side of a unit, near battery limits, with consideration given to the effects of adjacent units as well as the equipment in the same unit The top of a fired heater stack should be at least 10 ft (3 m) higher than any equipment within a horizontal distance of 50 ft (15 m) and at least 10 ft (3 m) higher than any working platform that is regularly used by operating or maintenance personnel (once per day or more), and is within a horizontal distance of 100 ft (30 m). Basic 50” (15m) Separates equipment handling flammable material from a constant source of ignition, Spacing also minimizes damage to other equipment in case of a fired heater fire. Process Vessels Below 600°F(316°C) 50° (15m) As an exception, fuel gas knockout drums should be spaced as close as possible to their respective fired heaters, subject to a minimum of 10 ft (3 m). ‘Orsaired By: EDS ASTA SON BHD EDS Soins Co, Lx ED Knowledge Pe The Layou of Piping Systems And Process Eeupmet (MEH nay mr yy eh ning see. eh, yO ‘iat Roger nat ero EDKNOWLEDGE JULY 2008 23PLOT PLANS & EQUIPMENT LAYOUT ONSITE SPACING - EXXON Fired Heaters ‘As required Fired heaters that handle flammable or combustible liquids in the tubes or that shut down individually for tumaround require 25 ft (7.5m) spacing if coil inlet pressure is less than 1000 psig (6900 kPa). Fired heaters having coil inlet pressures equal to or greater than 1000 psig (6900 kPa) require 50 fi (15 m) spacing regardless of fluid handled or turnaround considerations. If none of these conditions apply, only normal maintenance spacing is required Pumps handling flammable liquids above 600°F (316°C) or above AIT 25 (7.5) Minimizes damage to equipment in case of fired heater fire. Fired heaters do not represent a source of ignition, since the stocks in the pumps are already above their auto-ignition temperature. Equipment handling non-flammables) 15° (4.5m) Minimizes damage to equipment handling non-flammables in case of fired heater fire. Equipment higher than 10 ft (3 m) should be spaced 25 ft (7.5 m) from fired heaters having liquid in the tubes. Externally insulated vessels operating above 600°F (316°C) or above AIT. 15 *(4.5m) Externally insulated catalytic reforming (e.g- POWERFORMING) reactors and their associated fired heaters which handle only vapor in the tubes may be spaced 8 ft (2.4 m) apart. Internally insulated vessels operating above 600°F (316°C) or above AIT. 25° (7.5m) Internally insulated catalytic reforming (e.g. POWERFORMING) reactors and their respective fired heaters which handle only vapor in the tubes may be spaced 15 ft (4.5 m) apart, Onsite pipebands 20 (6) Minimizes involvement of pipe band in fired heater fire. This spacing does not apply between a fired heater and its own individual process and utility lines. ‘And Paces Equipment (MERI) Orgaized By: EDSASIA SON HD EDS Soaions Co, Lid. ED Krew! [vgn ued Reparhrcourt nytereneed opt nay Cam” an mash bin ein. mune psig ero orn [ED KNOWLEDGE 1ULY 2008, 24PLOT PLANS & EQUIPMENT LAYOUT PROCESS EQUIPMENT “Lomein ens ode Eaten (MEI) PRESSURE VESSELS The Vessels and Mechanical Engineering Depts. furnish the layout personnel with the physical sizes of the pieces of process equipment. They also indicate the space requirements for maintenance access. Their work is affected in particular by codes, standards and regulations The overall length or height of a pressure vessel, and therefore its space requirements in the layout, will depend not only on its capacity but also on the shape of the heads at the end. And if the vessel has more than one diameter, the configuration of the transition sections connecting those of different diameters is also taken into account. The requirements of the ASME Boiler and Pressure Vessel Code must enter into the selection of a vessel configuration tht will yield an economical design. HEAT EXCHANGERS For a tubular heat exchanger, both the ASME Boiler and Pressure Vessel Code and the Tubular Exchanger Mfts. Assn. (TEMA) standards will affect the space requirements in the layout. The ASME Code will influence the selection of the shape of the exchanger heads and the configurations of any transition sections between different diameters, thus fixing the overall length or height of the equipment, The overall length will depend also on the design of the tubesheets in accordance with the TEMA standards. Furthermore, the space envelope to accommodate the maximum outside diameters of the unit will depend on the design of the bolted flanges for the shell, channels, and bonnets, as dictated by the ASME Code. EDSASIASON BHD EDS SolaionsCo, Ld. ED Knowledge Pe Lid ii eevee ean Rog anand ‘une ott pene pemaonsre pone EDKNOWLEDGE JULY 208 2PLOT PLANS & EQUIPMENT LAYOUT PROCESS EQUIPMENT ‘The Layout of Piping Systems And Process Equipment MEA21) Ori STORAGE TANKS For a storage tank, the required internal volume often can be obtained with any one of the many different combinations of diameter and height. The configuration finally selected will depend both on the space available in the layout and on costs of the possible tank designs, all of which must meet the requirements of API ‘Standard 620 or API Standard 650. Plant layouts are also affected by wind and seismic loads on pressure vessels and tanks. The ASME boiler and pressure vessel codes and API Standards 620 and 650 require that these effects be considered, in addition to internal pressure. In some cases, for example, it may be preferable to divide a tall distillation column into two shorter columns, so as to avoid massive foundations and anchor bolting, flared skirts, and unreasonable shell plate thickness near the bottom, even though additional plot space and piping will be required. Considerations of wind, weight, and seismic loads also can influence the decision ‘to support a vessel or heat exchanger at grade or instead at a higher elevation in a structure. Again, the stresses due to all loadings must be limited to allowable values specified in the applicable codes = and _ standards. By-EDSASIASON BHD EDS Saluiars Co, Lud EDKrowldge Pe Led Mkt Roget cnn om tetrad etna my wy rae gene meee hap ene ern et ED KNOWLEDGE /ULY 2008, 26PLOT PLANS & EQUIPMENT LAYOUT EQUIPMENT STACKING = A degree of equipment stacking is necessary to achieve a reasonable utilization of plot space, but the potential heavy fire involvement of equipment stacked in several layers must be avoided. The following restrictions apply: = 1, Maximum Height - Avoid stacking more than three levels of equipment. S = 2. Special Restrictions - Do not locate equipment over any of the following: 2 a, Pumps or compressors handling flammable materials. ab. Air fin exchangers, a, Heat exchangers or drums containing flammable material above 600°F 316°C) or above its autoignition temperature, whichever is lower. tof Pa Syn And Proce Eeppme(MEN2I) Orit BY. EDS ASIA SON BHD EDS Salatons Ca. ‘ns nou pe te pmo bese ED KNOWLEDGE JULY 2008 2PLOT PLANS & EQUIPMENT LAYOUT SPECIFIC CONSIDERATIONS PML.- Preventative Maintenance Several organizations have published guidelines for PMI programs, including the Pipe Fabrication Institute (PFI Standard ES-42); the American Petroleum Institute (API Recommended Practice 578); and the American Society for Testing and Materials (ASTM Standard E1476-97). These protocols cover the testing of raw materials, in-process parts, and finished goods. Te aon fing Stns Ant Paes Ee ‘cen mb ep wie pono pode ‘Orgs y EDS ASIASON BHD EDS: ED Krowiedee Pe nacre. reese phere tr ee ED KNOWLEDGE sULY 208 28PLOT PLANS & EQUIPMENT LAYOUTPLOT PLANS & EQUIPMENT LAYOUT ONSITE EQUIPMENT SPACING - METRESPLOT PLANS & EQUIPMENT LAYOUT OFFSITE EQUIPMENT SPACING - FEETPLOT PLANS & EQUIPMENT LAYOUT PLOT PLAN EDRNOWLEDGE JULY 208 32SECTION 4 PIPE SUPPORTPIPE SUPPORTS wm Q) @) @ (6) 6) a (8) oe (10) One of the primary considerations in running piping is that of supporting the system, Some general pointers are listed here: Where possible run the piping in groups for easier supporting, Piping that is run horizontal in groups should have a common B.OD. elev. and if run vertical the back of pipe should be at a common co-ordinate. This is so that pipes can sit on a support ie, steel Consideration must be given to the expansion of hot lines and equipment (consult stress department). Insulated lines sit on pipe shoes 4" high. Piping should be routed so that it runs close to steelwork or other supporting structures, Piping 2” and smalter is often field supported. Keep the support as simple as possible. The placement of supports (pipe spans) is governed by charts which have been developed for the project - see page 5. The use of anchors and guides must be decided by the pipe supporting group in conjunction with the stress department Dummy legs may be used to support piping at horizontal elbows. (e.g. in pipe racks) "Te Layoat of Piping Sytena And Poses Exuipment(MEI2I) _Oratted By EDS ASIA SDN BHD EDS Solutions Co, Lid. €D Kaowlege Pie Led [vgs ved pte hs tae ae easy my yen. etn eee mecha hg ar nanan de ‘post oh rw pra oe pone EDKNOWLEDGE N.Y 2006 2PIPE SUPPORTS (11) Base ells are a common method used to support piping at pumps. (12) _ Every effort should be made to eliminate piping loads being transferred to equipment nozzles. (13) _Allllines above 90 degrees C are subject to expansion which may damage piping and equipment, consult with stress analyst. (14) Hangers may be used to support piping, they come in 3 types, they will be covered beginning on pagelé. Constant Load Hanger Vatiable Spring Hanger Rod Hanger ‘reaite By EDS ASIA SDNRHD EDS Selatont Co Keonsdee Pe ED RNOWLEDGE JULY 208PIPE SUPPORTS RECOMMENDED PIPE SPANS SUGGESTED MINIMUM SPACING BETWEEN PIPE SUPPORTS FOR STRAIGHT PIPE RUNS OF STANDARD WALL AND HEAVIER PIPE. * NOMINAL PIPE SIZE MAXIMUM SPAN 112" In 2 13 3" 13 a 17 e re 3" zy 10" 28 12" 30" 14" 32 16" 35: 18" a7 20" 39" 24" ro = Above spans are for pipe filled with water and containing no valves or fittings, pipe supports may be of friction type where the pipe rests on steel or they may be hangers. This chart is a rough guide and all supports should be checked by the pipe support specialist or group to make sure that no undue loading is transferred to places where it will hurt. The Layoutef Ping Systems And Poses Eames (MEN21) Orgad By: EDS ASIASON BHD EDS Salons Co, Lid_ ED Kowledge Pe Ld tir Rope etic epee yer ma iy dc atl pari enn ire [ED KNOWLEDGE JULY 2008 4PIPE SUPPORTS B31.1 PIPING CODE SUGGESTED SPANS ANSI/ASME 911-1986 EDITION faa (2) an increase 10 80% of the minimum yield strength at room temperature during hydrostatic test- Ing, Where the material allowable test has been ett lished in accordance with the rules of (C) sbove, the allowable ses valve during bydrootatic toting shall not exoeed 16,000 pa (110.3 MPs). 1213 Temperatare Limitations Parts of supporting elements which are subjected principally to bending or tension loads snd which are fabjected 1o working temperatures for which carton eel ir not recommended shall be made of suitable ly see, or ahll be protected wo thatthe temperature ‘Of the supporting member wil be maintained witha the Sppropeate texperature limit ofthe material. 2214 Hanger Adjustments Hangers used forthe support of piping, 244 in. NFS ‘and larger shal be designed to permat adjustment after ‘rection while supporting the load. Serewed djst- {ments shal have Ghreaded parts to conform to ANSI Bi Cast 2 ft turnbuckles and adjusting nuts shall have ‘the fall length of thread in engagement. Means shall be ‘provided for determining thet fll thread length i in Eagagement All terew and equlvalent adjustments ‘hal be provided with sultable locking devices 1215 Hanger Spacing ‘Supports for piping with the longitudinal ais in ap- proximately » horizontal position shall be spaced to Drevent excessive tag bending and sheat stresses inthe Ping, with special consideration given where compo: fen such as Ranges and valves, impose concentrated ioada, Where calculations are aot made, suggested ‘maximum spacing of uppers for stander snd heavier Dineare gvenin Table P23. Vereal supports shall be paced to prevent the pipe from being overntrented from the combination ofall loading effects. 1216 Springs ASME CODE FOR PRESSURE ‘ase 215 SUGGESTED PIPE SUPPORT SPACING oni war ABL7A Anchors and Gules (A) “Anchors, guide, pivots and restraint hal be designed to secure the desire points of piping in cela- tively fixed pontions, They shal permit the piping ‘erpand and contrac (ely in diestions away from the Stchored or guided point and shall be structurally su ble o withstand the thrusts, moments, and ether fads Imposed. 2) Rolling or siding supports shall permit free movement ofthe piping, oF the piping shall be designed ‘oinclude the imposed load and fictonal resistance of these types of supports, and aimensions shall provide {or the expected tnovernent of the supported piping ‘Material and lubricants aed lading supports shal it point of ‘hort and guides shal be provided where necesy 10 iret the expansion into the jolat or hose astembly. ach anchors shal be designed to withstand the force Spetied by the manufacturer forthe design conditions ‘Torhich the joint or hoe asembly i210 Be used. IT “Te Layout of Piping Sytrne Aad roses Exuipmens(MFA2I) Organized By EDS ASIA SDN BHD EDS Seton: Co, Lid. ED Kaowiede iL [Avge ut oa tne ened pe mc eo een, mania phasing eigen a ED KNOWLEDGE sULY 2008PIPE SUPPORTS PIPE SPACING WITHOUT FLANGES NOTE as AMAATON 8 BAD OF HE 2A SED USO EATON PRLLOMRRG RELATE THCKIMSEAS TO TARAATED YALE? 1 a Tee be a ga ag ep ye Tia JOS UTE HOES MCAEACE G4 AECRONGL, ERE ie POP FREES WF anes ARE HERES 7 ARES A MES USTED WME EATON ELREE PIPE SPACING WITH 150 # FLANGES “The Layon of Piping Seema Ard Proves Equpment(MEA?I) Orgad By-EDS ASIA SDNBKD EDS Seaton Co,Ltd. ED Krowige Pe La ‘Alaghaaned Ke pata cout ney eel wean an omy ny mews, ea leo. Moa Aa. Erni a ee ‘yonmn thon te pro oon ope [ED KNOWLEDGE JULY 2008PIPE SUPPORTS OVERHANGING BENDS Let Pt eee ae ee ee ee EE ES eugene : ED KNOWLEDGE JULY 2008PIPE SUPPORTS PIPE SHOES = Pipe shoes are used to provide a means of supporting insulated piping, The shoe will sit on the support steel rather than the insulation. They are normally 4” (100mm) high. = When the pipe is insulated it is hot and subject to expansion and the shoe allows it to move on its support (Le. steel) = As the shoe protrudes through the insulation, slots for insulation bands which hold the split insulation together must be provided in the shoe. = Double shoes with angles and struts are shown for larger pipe. SUT FIR TSULATION BANDS 3 TRY Ie? ie THU a PIPE SHDES ‘Oguz By EDS ASIA SDNBHD EDS Sulton’ Co, Lid. ED Kooulege PeLié mary ay ann hg eon met cp, ekg rman an a ‘The Liou Ping Sytens And Process Equipment (MEN Mighorgeet Neat tec nay seen [ED KNOWLEDGE JULY 2008 8PIPE SUPPORTS PIPE SHOES - FRICTION Friction > Displacement causes piping to move over sliding supports Friction forces are in one direction when the pipe is heating and in the opposite direction when cooling > The coefficient of friction used for steel on steel ranges from 0.3 to 0.5. Friction » The coefficient of friction can be reduced to 0.1 by using PTFE or graphite impregnated plates friction to 0.05 Th Loafing Stee And Peis Eaiome(NE21) rene By: EDS ASIA SON BHD EDS Slatns Co. Li ae Sepa ecu ta te open ny er a) ee aig enc, cna pron, ot [ED KNOWLEDGE JULY 2008PIPE SUPPORTS PIPE SUPPORTS- Base Elbows = The most common support on end suction pump lines that drop vertically to the ‘pump are base elbows, they are also used at control sets. = The support pipe is welded to the outside of the pipe elbow and a base plate is welded to the bottom of the support pipe. Depending on the design conditions the base plate may be: (a) Bolted to the steel or foundation. (b) Permitted to slide on the steel or concrete, the latter would involve the use of a bearing plate and possibly a teflon pad to reduce friction. fam vans ena sa eat BASE ELL. SUPPORT The Layout Piping Systm And Pres Eup (MER began Nope tar cae nat ny pate op ‘pu herb pres pron ft oan ED KNOWLEDGE 1ULY 2008, 20d By EDS ASIA SDN BD ens, lagen meu ocala 7 OMT PIPE SUPPORT max LINE SIZE-12" TYPICAL SUPPORT AT TEES. OR PUMP NOZZLES (TOP DISCHARGE) [EDS Scions Go, lad ED Knowledge Pe Lid 10PIPE SUPPORTS PIPE GUIDES ore evecare # Tals CLEARANCE Way BE tusREAseD WHEN REQUIRED FUR PIPE MOVEMENT Lies ton eae LAA INSULATED LINES The Layout of Ping Sten An rset Exapmest(MEA21) OrgaizedBy EDS ASIA SDNBND EDS Solutions Co, Lid. £D Knowledge Pe Li Algarve optic eddy my em ogi en hig ng om ED KNOWLEDGE JULY 2008 iPIPE SUPPORTS VERTICAL PIPE GUIDES AND ANCHORS These types of anchors and guides are used in lines running vertically up or down towers or tanks. Ifthe tower is subject to vertical expansion and the pipe nozzle is high on the tower then the pipe must be anchored as close to the nozzle as possible and then guided as it runs down the tower. See diagram. 2 VERTICAL LINES The Layout Ping Systems And Press Equipment ME ED KNOWLEDGE TULY 2008, Ls HF mausin wves )_Orgties By EDS ASIA SDNBHD EDS SelutonsCo,Lid ED Knowledge Pe LidPIPE SUPPORTS PIPE RESTRAINTS Restraints are a method of restricting the movement of piping in a particular direction(s). An example is shown on the following page. wrt VN zie 27 5 f i 1 — lil SECTION ‘Aca’ 2 THRU 6 Bs TT" iON “C=C Be THRU! 18° ‘The Layout of Piping Stems And Paces Eauipnen(MEH2)) greet Rept acon me pened ED KNOWLEDGE JULY 208 ‘Orguized By EDS ASIA SDNBHD EDS Ssltion Co, EDKaowedge Pe Lid in erg leon eet 1BPIPE SUPPORTS PIPE RESTRAINTS LIMIT STOPS f ah i ao py a SECT ‘O-F ‘SECTION E-€" INSULATED LINES err pp re ee ‘pues ston be ron [ED KNOWLEDGE JULY 2008 cape ay fom er iPIPE SUPPORTS DUMMY LEG SUPPORTS PRIOF) | SANE BOP aS PIPE DUMMY LEG SUPPORT Proce Eaupment (MEI) seen nyicta EDKNOWLEDGE JULY 2008 15PIPE SUPPORTS ALLOY PAD WITH C.S. SHOE INCONEL SADDLE, CS. SHOE WELD TO PIPE i INCONEL PIPE “Ths Layout of Piping Sytem And roses Exuipmest(MEA2I) _Cipaized By EDS ASIA SDN'BHD EDS SoltionsCo, Lid. ED Knowledge Lid “Argh nee Ns pt here smn bemreteed oped Sm or omens, met pling rig ana ‘pam mth Oa ono saa see oS ED KNOWLEDGE JULY 2006 16PIPE SUPPORTS ROD HANGERS ‘The pipe attachment and structural (beam) attachment of a rod hanger assembly should allow the hanger to swing to allow for axial movement in the pipe where there is horizontal pipe expansion, It should be noted that horizontal motion of the hanger will result in a resultant vertical movement as shown below. The subsequent horizontal forces should be checked as they may cause harm to the piping system. eK eae | Teno ra an la yy LU meow WE £). = ver TRAVEL oa PPE WW coLo PUStTIOY IPE 08 HOT OSTTION ROD HANGERS The Lajow of Ppag Spates And Paces Equine (MEI) Onan Ds Alegheed No pul he cers at my beter cpt aay Ker yy ems in setae seh pa "ED KNOWLEDGE JULY 2008 ASIA SDNSHD — EDSSoluioasCo, L.ED Knowledge Pe Lid 7PIPE SUPPORTS VARIABLE SPRING HANGERS AN PIPE caw L ed MOVENENT DOWN HOT POSITION COLD POSITION VARIABLE SPRING HANGER Lo! PORTED IN HOT POSITION "ED KNOWLEDGE JULY 2008 18PIPE SUPPORTS Fi 6, Fig, 8-268, Fig, 98, Trp Spring and Qvale S59 Spring Hangers a ONemeon | "pa amen cyan ee esau fi > Consider ordering gat springs presell0 mua? caldiod = iy 7 Use travel slops to. swggat camry load during hydrotest | oer | eho am ic teammate Re | mmsamy sour vette seprpgrige hy ee wane Scie o i a = | Cemonermam rave jemi arene ‘connie (a nacatneiny |dtorerierttcte, |aereae Ce arco Spring H iseomeroncre ‘pring Hangers |seeeseet ere somes Vist rhc | reat oe |eteeeeemeees |: Semaceaaa he jn Irion ancmaiea Le a Fanaecreecmeet [Pssevetecrecmeeeente, |[Eearonommeneeenest | Sey ee. pa ent re re |Seeumminrs eenre ara G = sancaty th Serene yl (Semana OI sores Ceemeet Shy Sinaia ipa Vaile Sping Hanger Islan nd emer) ott | eon Ndebagseaasinconesen) TecLaew ot Pig Sens Andee Ene (MEII) | One NBGA NRNBULODS Seletees Ca, Li HOB cry al Aap tts os and eons indienne cement inte nernminm nnn Eicaceaarenes woe “ 5 oem Osetra pease Epona mina o fener @ gee a Secgeeenanesy Ea enti Rete tae em eset es, amar secant ete, oa Se ay Pe Om sie 2 Bi Msgr apc rnd cena mere nan NR sag [ED KNOWLEDGE JULY 2008, 19PIPE SUPPORTS VARIABLE SPRING HANGERS = Variable spring hangers are recommended for general use in non critical piping and where vertical movement is small on critical piping. = Acceptable practice is to limit the amount of supporting force variation (difference between hot load and cold load) to 25% for critical piping systems on horizontal piping. = The amount of variation can be calculated by multiplying the spring scale in Ib/inch by the amount of vertical expansion in inches. The spring scale is published in the manufacturers catalogue. = The main problem with variable spring hangers is that this variation in load must 20 somewhere, it is transferred to the nearest restraint or equipment which may cause damage both to the equipment and/or piping system. = Calculating the variability in accordance with MSS SP-58: = V= (Hot load ~ Cold load) x 100 Hot load = However the load margin between the maximum load, either hot or cold, and the Joad at the maximum limit of the operating range must also be considered. This Joad margin should be greater than the weight of the hanger hardware that is supported by the spring, e.g. clamps and hanger rods used to connect the piping to the spring. If the total piping loads plus the load of the supported hanger hardware cannot be accommodated within the spring hangers’ operating range an alternate spring hanger design should be considered. pens And Pricer Equipment (ME®21) Onn De Sniania, Lad Bradys Peak Set pcan ace ee ea Re aeRORTe TR 20 [ED KNOWLEDGE JULY 2e08 20PIPE SUPPORTS SELECTION OF A VARIABLE SPRING HANGER FROM THE BERGEN-POWER CATALOGUE VARIABLE SPRING SUPPORTS: ‘SIZE AND SERIES SELECTION PROCEDURE “The Hey criteria in selecting the sae and series of Variable Spring suppor is acioe Keown ar Variable, This is al: gS ai a 5 af 4 Z| : 7 th = 4 = z E 2 z g cas | aaa = = seman | masae|eoaas Zz & oO 12 [ED KNOWLEDGE 1ULY 2008‘Stagg Nopen teen trae om CENTRIFUGAL PUMPS Friction Loss in Pipe Fittings in terms of equivalent feet of straight pipe, ‘These data may be applies to wn Liquid wr gst | Exande eires 6 | ‘ela hm ate ht Pe egy Srng | Gite I tae ie side | leod | re | ED KNOWLEDGE JULY 2008 yO ON a | a al | Ma |, fe 4 wail f | wba > 4 Ha) ae) gt] 8 ay) Bt) 89 i > i | 4. i a lh Tt a w (a jos > 4 mi | i jw [is 4 w]e [a a a ]m im | 4 ja [ss [at | io ay bed otra pote Ove 0, "Toc I end kil at "ead by ‘ iad nung eco aera Cit No Cab el Tue Tarn, Sh Pan eo, 2D, tad det ‘Rot ei team, CHARTS Te Lnow fying Sens And ois pment (MEN21) Onis By: EDS ASIASDNBHD EDS Sewons Co, ad ED Koowage Pe Li Ta arb nen ihe ee, mebane ppyig raking rman 1BCENTRIFUGAL PUMPS ss aoa CAMERON HYDRAULIC DATA a3 mea CHARTS rect alpen MEA) HDS ASIASONHD | EDS Se Co | ED Kao PL opel inmy om hy a en ling eo, mec tein rang ian ee ED KNOWLEDGE JULY 2008, 14CENTRIFUGAL PUMPS DESIGN FACTORS THAT CONTRIBUTE TO CAVITATION = BAD SUCTION PIPING LAYOUT = Ifa piping layout is such that air may be entrained in the piping = ie, Eccentric reducers installed the wrong way round thereby creating pockets, where air becomes entrapped. = Piping rising before the suction nozzle = Leakage through piping joints that allow air to be drawn into the pipe — “The Layout af Piping Systems And Process auipment (MEN (ed By,EDSASTASON BHD EDS Solutions Co, tid. ED Keone Pe Lid Ove Avner ho tei ee opin ten a ei nen Peg egw ED KNOWLEDGE UL 2008 15CENTRIFUGAL PUMPS HORIZONTAL PUMPS END SUCTION ANSI PUMP Coupling Pettey Solaire Ca, Lud EDKooaedge Pe Lid ‘en sn, mac phspyng Sige fra el ED KNOWLEDGE JULY 2008 16CENTRIFUGAL PUMPS ANSI PUMP DIMENSIONS INCH SIZE Y vl 1 L = I { I | WW RR J | i ji __] avo. Ee $e De on ss amin wanders i me EE oo ut 0 tm ey a a re a en ee ee ee ea ar kgf te ee eet oe es ae a Se ea hi tam gor am! oe Sa ie ae oe ae AB 2x 1X Oe A Ake mm 4 et ee oe ada ia oa eae woe egaeigd was: a ee ee ee ee naa oa SueR SE SESE me ees oo ee aera in gat ee ee ia a i es me BU Sie a oe ake wens eclogite lis eie ieee ueally iRise BE iat Teigaunyyom MinGnESIGE NO) pany Bs AON poeta Rola Pa Alita reves Nopetot acre at bevel edi ay fy my es ag ees Mesaneh nen. etg aeon and ra ‘etn mtn te oro pemoen erode [ED KNOWLEDGE JULY 2008 17CENTRIFUGAL PUMPS HORIZONTAL CENTRIFUGAL PUMPS LOCATION AND LAYOUT = Locate the pump as close as possible to the to the source of liquid being pumped (tanks, sumps ete.) while allowing for expansion or tank settlement, = The spacing of pumps shall be arranged to provide clearance of 30”- 40” (750 -1000mm) between any projection e.g. piping, foundations of adjacent pumps or pipe rack columns etc. Sufficient clearance around pumps should be left to enable maintenance to be carried out = When possible the plan centre line of all top discharge nozzles should be kept in line. = Motors should be located so they can be easily maintained and removed by the use. of lifting gear or mobile equipment, Observe a clearance of 3-0” (900mm) at the rear of the motor for access. = Leave vertical clearance over pumps to allow for removal of pump and motor for servicing “The Layoa of Pong Systems And Process Equipment (ENDI) Organized By EDS ASIA SDNBHD EDS Slaons Co, Lid ED Koowlege Me Lid “lane ptt cs a bolo mn mn cig cat er ot han me [FD KNOWLEDGE JULY 2008, 18CENTRIFUGAL PUMPS EXXON STANDARDS Pumps Handling Flammable Liquids Above 600°F (316°C) Or Above Autoignition a ‘Gane Hot paps arg areas eal anazeated hr rk Decose eth tod ol aging he leak ous. Tha gna cosets hm, Pung andng Fara Conus Nts Eel Boh 00 (16° and ation mpm a aso apical hl ues, TS] Sepals push ip fe pela an poes acs r frighng, Arnis day ober equpment When apurp a ‘ssp ae goed a coe fie azar oral separaon betwen fem maybe jsf omit koto ho em ding, Spacing maybe edad TO) war pray conragels rove one pgs. suns T osiwcen sews {TEMO -Punps Handing Flaatle Or Combustible iui Belaw 60 (18°) And Bulow Autoignition “Gawral- Pars ard tabi coe rail ae ale oqoet sous lake ard shod be cate frat practical fomcontuons oa oigtn. Thay sod nt be cataract eigen, ih as ‘overs, rus, bands incre avid rence cf such eee Ao, soul be aed cer of ‘ished buon otha ty can ba reached bya smal ae. A premade pnp isc the oppat se of lowers evay For fe eses nine pugs seid be ete he ame seg purps or pacing pues Provides aces frfreghing and inmizsdanage neste offe. Punpe elo auton emer rot pesntas gata fri as one contest gids below 800° (318°0) and below AT) From WW (Onsite 10) ‘Spacing may be reduced to 5 {1.5 m) if fire water spray coverage is Pom) pried ae ngs Tos Layout of Pipi Sven And ros Eanes QER2}) — Craniaed By-EDS ASIA SDN BHD EDS SelmionsCo, Lak EDKuowdge Pe Lad epee oan em ory ay eng ete eh apg cr ail eee ‘ge eee ‘pee sans prea pmo ot pt EDKNOWLEDOE JULY 2008, 19CENTRIFUGAL PUMPS EXXON STANDARDS ITEM O. Pumps Handing Fizmable Or Combvatble igs Below SU (316°C) And Below Autlgnion Cenwrl- Pars andi arial or cobusiie malaise wave Feuer sures eatape and road metre be cated as far spacial orn continuous sources fig, They shout rl be cle brea aber eaten. such as lovers, cus, pears inorder o aol evar of we quent Ale, they tous be cated ear of overhead oberucons so that ey canbe reached a sallcrane. A prefered cao or puns is one oposite of towers avay ore eas, nie uns shouldbe rete he same as requ pumps fo spacing proses. OCR) | Provides acess or fraighing ard ris dare ncae offre. Pups below atin terperatre dot peso as great fish as tose she agian ampere. Provides aces fi operation and rabteranc, 3 From (Onate 1003) | Spacing ry be ediced oS H(i fre water spray coverages geben) proved nthe pur. TEN GG Man Fe Pup 1S0(45) | Pres pcg beter re pugs ard maj pa nupmentn tyerocarin service open os fe puns fam re ngs ‘Special purpose fire pumps. for speci ans, may be spaced csr to uncle fies, Fram Coning Coming tower res ae lati, ence spacg maybe ede a Tower) 008G0m), teed (008 9m) 25(75) | Raat year minimum sk. Spacg prevents clson dagen case ol cerarent The Layout of Piping Systems And Proce Equipment (MERI) Onpnaed By EDS ASIA SDN BHD Alege pein yyy aml ems ue yi erg iran nd TES Seats Co_ Ls ED Krowedge Pe Led [RD KNOWLEDGE JULY 2008 20CENTRIFUGAL PUMPS VERTICAL INLINE PUMPS Slatens Co, tid EDKaontedge Pe Lid cane pcg eg enna ea EDENOWLEDGE JULY 2008 21CENTRIFUGAL PUMPS VERTICAL PUMPS LOCATION AND LAYOUT = Vertical inline pumps are the most economical pump installation as they are installed in the piping run and can be supported by the piping up to and including 6” nozzle size. = Bases should be supplied for larger pumps, however they are not as large as for horizontal pumps. = Unlike horizontal pumps their alignments are not affected by small piping movements. = When the pump is supported by piping, pipe supports should be installed on both sides of the pump as close to the nozzles as possible. = Supports should be resting type, NOT ANCHORS. “he Lajeu of ip Sytens Aad Proves Equipmet (MEDI) Orgniaed By: EDS ASIA SDNBHD EDS Sins Co, Lad, ED Knowledge Pe Lad Aree Reena erenet esp ecb ng, mn de [BD KNOWLEDGE JULY 2008 22CENTRIFUGAL PUMPS VERTICAL PUMPS [ala oal lal 82 | on Spe fade armen MEP) Oped EDS AIASON OND | EDS el se Rf cna Str crn fra} a eden ne a Co, Lid, ED Knowledge Pe Lae neti von ea ED KNOWLEDGE 1ULY 2008 2CENTRIFUGAL PUMPS A FEW THINGS YOU SHOULD KNOW ABOUT YOUR PUMP'S PIPING SYSTEM “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. +Pipe from the pump suction flange to the pipe rack, not the other way around. *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. *Valve stems, T Branches and elbows should be installed perpendicular to the pump shaft, not at right angles. «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. “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. 'ASIASDNBHD EDS Solaions Co. id, ED Knowledge Pe Lid The Lavou of Piping Stes An Proce Easiest (MEX21) Ora [Mgr Re pe oh one yer apedaay fo ‘San abou te ee te rato por ED KNOWLEDGE JULY 2008 24CENTRIFUGAL PUMP: A FEW THINGS YOU SHOULD KNOW ABOUT YOUR PUMP'S PIPING SYSTEM “Itis 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 “Suction piping should be at least one size larger than the suction flange at the pump. «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. “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. Suction piping must be kept free of air leaks «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. +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 "ED KNOWLEDGE JULY 2008 25CENTRIFUGAL PUMPS A FEW THINGS YOU SHOULD KNOW ABOUT YOUR PUMP'S PIPING SYSTEM + 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 horizontal suction line should have a gradual rise or slope to the pump suction. + 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. + 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. + 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) oTry 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). oTo 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) oVelocities of no more than 10 feet (3 meters) per second are recommended in the suction side piping to prevent abrasive wear. “Th Layout of Piping Syme And Process Equipment (MES2I) Organized By EDS ASIA SDN BHD EDS Soins Co. Lid ED Knewlape Pe Lid ‘Mgmnt ett or bran ery mn ge, me pg Me inn nee "ED KNOWLEDGE 1ULY 2008 26CENTRIFUGAL PUMPS PIPING AT PUMPS - SUCTION Eccentric reducers shall be used on pump suction lines where necessary, in order to eliminate pockets, they shall be installed as follows: ‘Where suction piping is rising to the pump - Flat on Top Where suction piping running horizontal to the pump - Flat on Top ‘Where suction piping is dropping to the pump - Flat on Bottom All suction lines should be kept as short as possible to reduce pressure drop due to friction, ‘Temporary Strainers shall be fitted in all pump suction lines, downstream of the block valve, for start up operation. A removable spool piece should be provided in the piping for strainer removal Where permanent Y type strainers are used, check clearance for removal of basket. “The Layout of Piping Syn And Proce Eguipmert(MEN2I) Organized By EDS ASIA SDN BHD EDS Sites, Led ED Keewladpe Pe Lud ‘Atogh eed Regul sunt ny bees pinay Eom ry ay ne ang On man pci tg cadena ee ‘uum, wtb ro mann fe pe ED KNOWLEDGE JULY 2006 27CENTRIFUGAL PUMPS PIPING AT DOUBLE SUCTION PUMPS = Ifthe pump has a suetion nozzle at the side (double suction pump), a straight run of 5 pipe diameters is required between the nozzle and an elbow which is not at 90° to the drive shaft. DOUBLE SUCTION PUMP ‘The Lajou of ping Systems And Process Exupmest (MEAD) Oxpnizeé By:EDS ASIA SONBHD EDS Solutions Co, Lid. ED Knowledge Pe Lad Mir ope ey pin frm ny et eg can nl Po me nn te EDKNOWLEDGE JULY 2008 28CENTRIFUGAL PUMPS PIPING AT DOUBLE SUCTION PUMPS 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 three diameters of straight pipe between the elbow and the pump as shown in Fig 2 for low suction energy pumps, and five pipe diameters for high suction energy pumps. Fig 3 shows the eftect of an elbow directly on the suction. The liquid will flow toward the outside of the elbow and result in an uneven flow distribution into the two inlets of the double suction impeller. Noise and excessive axial thrust will result. 80 Mist Seca Aer oaMe (2 WONG Fig. 2 Elbows At Pump Suction Fig, 3 Effect of Elbow Directly ‘on Suction “os Layot of Piping Syste And Proce Ease (MEAN) Orpmnied By EDS ASIASON BHD EDS Solutions Co, inane Ropes eet om Me ge en ED Keowiedge Pe Led ED KNOWLEDGE UL 2008, 29CENTRIFUGAL PUMPS PIPING AT PUMPS = Donot run piping over pumps, as this will interfere with maintenance. = Provide a pressure connection in the discharge line as close to the nozzle as possible = Locate all block valves as close to the pump nozzles as possible. = Piping at pumps shall be designed to allow for sufficient support and flexibility to prevent overstressing the pump nozzles. Even small movements in the piping which impose loads on purhp nozzles will cause pump misalignment. = The use of chain operated valves should be kept to a minimum. “Te Layout of Piping Sytems Aad rots Equipment (MEH2I) —Oganied By EDS ASIASDN BHD EDS SoluionsCo, ad, ED Knowledge Pi Ltd “Mla poet snare pny oa nh an he rn [ED KNOWLEDGE JULY 2008 30CENTRIFUGAL PUMPS PIPING AT PUMPS Check the following for maintenance clearance: = Adjacent equipment and or valves/piping for clearance = Valve heights for operation and pump maintenance = Piping adjacent to pumps, ensure that spool pieces are provided for removal of pump casing ete. “The Layo of Pig Stems And Process Equipment (MIDI) Onanzed BY EDS ASTA SDN'BHD EDS Soluions Co, id. ED Knowledge Pe Lad MeN tan co a eegeetcpy mcry y m bnge ee eg era ED KNOWLEDGE JULY 2008 31CENTRIFUGAL PUMPS PUMP FOUNDATIONS AND ALIGNMENT = Minimum pump foundation elevations are generally 6” (150mm), however the client may use standards that differ. Generally the centre line elevation of all centrifugal pumps should be maintained at 2’-0” (600mm) above grade, dependent on minimum foundation elevations being maintained. = The foundation may be of any material which is sufficiently rigid to withstand vibration and support the baseplate. = Normally a concrete foundation on a conerete slab floor or on solid ground is usual. However in the case of pumps that are located outdoors a spread footing is necessary. Toe Layout of Piping Syste And Proves Eappme (MEDI) OnpniedBy:EDS ASTASONBHD EDS Solutions Co, Lid, ED Krowldge Pe Li tiga Repo ergenesteps hay hemor msg rr int ping eg ena [ED KNOWLEDGE JULY 2006 32CENTRIFUGAL PUMPS PUMP FOUNDATIONS, GROUTING AND ALIGNMENT = Grouting should be applied to a minimum thickness of 1” between the top of the pad and the pump baseplate. This will absorb shocks and vibrations from the pump and aid in the pump alignment. = Anchor bolts should be used to locate the pump to the concrete foundation. BASE \ i crour FOUNDATION ‘The forces and vibrations present in our rotating equipment must be absorbed by the foundation or they will be transmitted to the mechanical seal and pump bearings, causing higher stresses and premature failure of one or both of these components. The foundation must be at least five times the mass of the hardware attached to it". You can refer to this, paper for additional information ‘The grout, in conjunction with the anchor bolts and shims will act as the connector between the pump base and the foundation ensuring that the forces and vibrations will be absorbed and dampened as much as possibic. This grout can be installed before, during or after the installation. The Lavou of Piping Systems And Proven Ensen (MEADI) OxgalzedBy-EDS ASIASON BHD EDS Solutions Go, Lid. ED Kronidge Pe Lt “Misa pacman selon mary a ig ne mc pg eg oma [ED KNOWLEDGE JULY 2008 33CENTRIFUGAL PUMPS PUMP FOUNDATIONS, GROUTING AND ALIGNMENT. In the past, iron filled and gas expansive inorganic grouts were employed, causing frequent replacement. Modern grouts, when properly installed can last for ten or fifteen years, or the expected life of most pump and motor combinations. In the following paragraphs we will be looking as some of these modern grouts to help you in making your final selection, Regardless of the brand you select you are going to have to consider the "pour ability” of the grout to avoid air pockets and voids that can become trapped between the pump base and the foundation it will rest upon. Shrinkage is another consideration along with chemical compatibility and resistance to "creep" ‘You should also consider that in many process plants the floors are constantly wet, from pump and valve leakage, steam leaks and wash down hoses. Be sure the grout you select will not be damaged by this additional moisture. “The Lye of Piping Syatne And Proves Equipment (MEDI) Onaned By: EDS ASIA SONBHD EDS SolstonsCo, Lid. ED Knowledge Pe ‘hegre Ropes nn eect ri rma es Het ce neck Poo teen ED KNOWLEDGE JULY 2008 34CENTRIFUGAL PUMPS PUMP FOUNDATIONS, GROUTING AND ALIGNMENT Most of the modern grouts fall into two categories: Cement plus a natural or metallic aggregate. +Significantly lower in cost than the epoxy type. In many cases it is only one third of the cost. *They can easily be mixed at the installation site. By changing the amount of water you can easily change the "pour ability”. *Curing takes longer than the epoxy type and this can be an important consideration in many applications. *Chemicals can be added to the mixture to generate heat and accelerate the curing time, but the proper amounts are often hard to calculate. «Pouring forms are needed, but waxing of the forms is seldom needed, +The foundation surface must be clean and saturated with water at least twenty four (24) hours prior to the grouting application. *Chemical resistance of these grouts is rated poor to fair. +Replacement is simplified because the grout does not bond to metal. Epoxy grout, consisting of three parts : a resin, a hardener, and an aggregate. “All of the parts are usually pre measured so it is hard to make a mistake. +The cost can be high. As much as three times as much as the cement types, and waste is always a problem. slt sets in about twelve hours so you can get "on line" a whole lot faster. “Because it is so hard it can be very difficult to replace. «This type is often your best choice for aggressive chemicals. +Excellent for high electrical resistance. This helps if the welder is using the pump for a ground and he is about to weld the bearings to the shaft in the process. +Pouring forms must be waxed or wrapped in polyethylene to make removal easier. The Layout of Pi ‘Orme y EDS ASIASON BHD EDSSlaions Co, sd EDKrowledye eee Mowe tcc ray re palm ym nin st en ein rg it ie tems And Process Eqsipment MEN ED KNOWLEDGE JULY 2008 35CENTRIFUGAL PUMPS HORIZONTAL CENTRIFUGAL PUMP BASE AND SUPPORTS SEE | SUPPORT ™ VMN GROUT fa enn DRAIN HUB“ ABT_9" IN FRONT OF rap CENTRIFUGAL PUMP BASE AND SUPPORTS f \ ANCHOR BOLTS THINIMINUM 3*BETWEEN BOLT ¢ AND END OF PAD Egupreen (MEDI) Organized By:EDS ASIA SDN BHD EDS Solas Co, reine pe n aye aCENTRIFUGAL PUMPS GUIDES AT PUMP SUCTION NOZZLES. = Inatypical Pump suction layout, One way of relieving high forces and moments at the suction nozzle of a front suction pump is to fit a guide which is made to very close tolerances and which has an appreciable length. = This guide is then capable, so the argument goes of absorbing any terminal moments in addition to the side shear forces ; the pump may therefore be considered protected from the effects of the piping loads whilst the guide construction permits free movement of the nozzle arising from the expansion of the pump casing. = In general, stress engineers would prefer to see additional piping flexibility as a means to reducing pump ,nozzle loads in preference to the arrangement just described Check upward growth of pump nozzle before using this support “The Layout of Piping Stes And Proves Exsipmen(MEPD1) Ousized By EDS ASIA SDNBHD EDS Selon Co, EDKoowdge Pi Lid Ant suevet So purl cont nena beneponcedorop laa fu oy nes og eon, Man Psp, er eon ea ED KNOWLEDGE JULY 2008 37CENTRIFUGAL PUMPS PIPING AND SUPPORTS AT VERTICAL INLINE PUMP. care SuPTRIS CQ mae ume mast amt VERTICAL INLINE PUMP The Layout ot Ping Ssens And Process Equpmen(MES21) Orprined By EDSASIA SDN BED EDS Solnions Co. Lud ED Krowalge Pe Lid ‘Alten ened opel ha carne ny nent pe ay fan ory) mere ening cee, ete ssp ry ‘yma oar nn pmcson eve ED KNOWLEDGE JULY 2008 38,CENTRIFUGAL PUMPS PIPING ARRANGEMENT AT HORIZONTAL CENTRIFUGAL END SUCTION PUMPS sucrioN Le DISPAARGE Line | fee toe vive see, ReO-FOT, ace VALE eal i \ — x \ a raweoeaee G__paesane cae \ (mn sane ore io of cee wear AI 2 eff SUCTION LIFT FLOODED SUCTION PIPING ARRANGEMENT AT PUMPS STRAINER & FULT VALVE ED KNOWLEDGE JULY 2008 39CENTRIFUGAL PUMPS PIPING ARRANGEMENT AT HORIZONTAL CENTRIFUGAL END SUCTION PUMPS |. gener src. seyenase ioe Tear f Pring Sem And Proce ‘Miner Ropar ‘ewe wan he par oe pena erode MER) Cris Dy EDSASTASONBAD _ EDS oi CoLW. ED Kaci eit em ay my mong ecm pig gehen ee [ED KNOWLEDGE 1uLY 2008CENTRIFUGAL PUMPS PIPING ARRANGEMENT AT HORIZONTAL CENTRIFUGAL PUMP TOP SUCTION AND DISCHARGE eo oon Nt : T Oe SUCTINN AND DISCHARGE FuNP PIPING ABOVE 120 DEGREES CIUS MOE THAT PIPING {5 LOOPED BACK OVER PUNE A21D MOTORS TO ALLOW FOR ExPaiSiON Co, ED Kaowiedge Pee Lad [ED KNOWLEDGE JULY 2008 4CENTRIFUGAL PUMPS HORIZONTAL CENTRIFUGAL PUMPS END SUCTION a nO |_ teenie sien | | Ee a En. su 120 JESREES CELCIUS WAERE EXPANSION LODPS ABE LOCATED {TION AND TOP_BISCHARCE PUNE PIPING ABOVE le FRONT OF PUMPS ED KNOWLEDGE JULY 2008 MERI) Cyd BEDS ASTASDNEHD EDS sin Ca yy ment cee ihCENTRIFUGAL PUMPS PIPING AT P.D. PUMPS P.D. VANE PUMP P.D. pumps must have a by pass running from discharge piping to suction piping because unlike i centrifugal pumps they will not run | against a closed valve and the pressure will build up until something gives. POSITIVE DISPLACEMENT PUMPS: P.D. LOBE PUMP “The Layout fing System And Pree Equipment (MEA2I) Organized By:EDS ASIA SDNBHD EDS Solutions Co, tid ED Knowledge Pi Lat [Nlnght renee Naparcf ncn ney broad oe em orb mln ene, meh Po ‘pane wie pr eos poe [ED KNOWLEDGE 1ULY 2008 3CENTRIFUGAL PUMPS PIPING AT P.D. PUMPS This article reviews the specific requirements for the selection and sizing of pulsation dampeners to reduce the fluid pressure pulsations generated by positive displacement reciprocating pumps. {t includes analyses of the nature of pressure pulsation and explains the advantages of using pulsation dampeners and suction stabilizers. Sizing procedures for dampeners illustrate how their application improves suction and discharge control in reciprocating pumps, reduces pressure pulsations, increases Net Positive Suction Head (NPSH), and makes the service life of pumps longer and more efficient. Wak ose AL MSs Mom Pau Fe Sheth) 2, ere q Vans q i" (2 cot shagmen as HT Dgtsonetinn Paw Sol anbely om Crank he “The Layout of Piping Systems And Pree Buipent (MEN!) iis Repti cn ang bmp en ens reo al "ED KNOWLEDOE IULY 2008 44CENTRIFUGAL PUMPS COMBATING PULSATION The primary purpose of pulsation control for reciprocating pumps is to attenuate or filter out pump-generated pressures that create destructive forces, vibration and noise in the piping system. Every reciprocating pump design has inherent, built-in pressure surges. These surges are directly related to the crank-piston arrangement (Figure 1). Fluid passing through a reciprocating pump is subjected to the continuous change in piston velocity as the piston accelerates, decelerates, and stops with each crankshaft revolution. During the suction stroke, the piston moves away from the pump’s head, thereby reducing the pressure in the cylinder. Atmospheric pressure, which exists on the surface of a liquid in a tank, forces liquid into the suction pipe and pump chamber. During the discharge stroke, the piston moves toward the pump’s head, which increases the pressure in the cylinder and forces the liquid into the discharge pipe. This cycle is repeated at a frequency related to the rotational speed of the crank. At every stroke of the pump, the inertia of the column of liquid in the discharge and suction lines must be overcome to accelerate the liquid col-umn to maximum velocity. At the end of each stroke, inertia must be overcome and the column decelerated and brought to rest. The designer must compare pump pulsation frequencies to pipe span natural frequencies of vibration and avoid any resonance taking place. ‘A key benefit of pulsation control is the reduetion of fatigue in the pump’s liquid end and expendable parts. Reducing the pressure peaks experienced by the piston will in tum reduce the power-end peak loading. “The Layout of Piping Sats And ocess Equipment MEDI) Onpanaed Dy EDS ASIA SDN BHD EDS Sowios Co. ED Knowledge Pa Lad ie at Rupee co wy pene pio oy mot nag nt el maid anne ED KNOWLEDGE ruby 2008 45CENTRIFUGAL PUMPS COMBATING PULSATION Control of Pulsation with Dampeners ‘Successful control of damaging pulsation requires careful selection of pulsation dampeners and proper location of those dampeners in a piping system. The earlier pressure pulsation analysis showed that dampeners will reduce the level of pulsation and consequently pressure fluctuations. With lower pipe vibration and noise, wear at the pump, risk of cavitation, and metal fatigue will be less as well. (There are several OSHA standards dedicated to the control of industrial noise in the workplace. | One of the most practical and inexpensive ways to meet OSHA noise level requirements and achieve the overall performance improvement of reciprocating pumps is installation of pulsation dampeners on suction and discharge systems). "The Layer of Pig Systems And Proce Equipment (MERZI) OrgaiedBy-EDS ASIA SDNEHD —EDSSoluonsCoLed_ ED Knowledge he La {ivoire Ro pean aye pt my fry yen ees eh Paced on nd ED KNOWLEDGE JULY 2008 46CENTRIFUGAL PUMPS TURBINES = In critical process lines it is essential that the process not be disrupted by power failure, it is therefore common practice to have a spare pump with a steam turbine driver as opposed to an electric motor. = Observe a clearance of 1500mm at the rear of the turbine for access. PIPING AT TURBINES = Piping at turbines should be designed to allow for sufficient supporting to prevent overstressing of turbine nozzles. = Turbines are normally supplied with an integral strainer, but where these are not supplied a Y-type strainer shall be fitted as close to the turbine nozzle as possible. = Block or control valves on the turbine inlet lines should be located in a horizontal position so that the condensate in the line can be drained. A steam trap should be fitted upstream of the valve. “Te Layout Piping Sytems And Poses Eqipent(MEA2I) Organized By-EDS ASIASON BHD EDS Solutions Co,Ltd. ED Knee Pie Ltd “gir pc tana eran olen oe ne an eo ei ema eg era EDKNOWLEDGE MIL 2006 a7CENTRIFUGAL PUMPS STEAM TURBINE PIPING vt ee age i et oh A oo | - Pr 7 ot ee 6 ace a6 Pret ane ue pues al el sth Is r : yi uit (MEF) Organi By: EDS tin oad i far man ED RNOWLEDGE LY 2008 48CENTRIFUGAL PUMPS CHECK LIST FOR PUMP PIPING 1. Check maintenance clearances, (Removal of Motor, ete.) a, Valve heights - for operation and pump maintenance, b. Piping adjacent to pumps ¢, Adjacent equipment locations for clearances, 2, Vertical pumps - assure clearance above pump for removal, 3. Valve handwheels generally to extend over pumps and not into walkways, etc 4. Provide spool pieces above vertical nozzles for removal of pump casing, etc. (Check valve can sometimes be used for this purpose), 3. Check pump nozzles - special thicknesses, integral studs, etc “The Layout of Piping Syrens And Proves Equipment IMEVDI) _Oxaized By EDS ASIA SDN'BHD EDS Solutions Co, Lid. RD Kevulege Pi Ld [Mhigntnune purer ce ny bsepecid es inay Emory any ws ting cst. hn ong eo rane se [ED KNOWLEDGE JULY 2008 49CENTRIFUGAL PUMP: CHECK LIST FOR PUMP PIPING 6. Avoid pockets in lines 7. Reducers in suction lines . Eccentric reducers to be flat side down at suction nozzle when . suction line falls to pump. . Eccentric reducers to be flat side up at suction nozzle when . suction line rises to pump. 8 “T" type strainers - check clearance for removal of basket. 9 Steam lines to drivers: a. Check drainage of steam lines, valves, etc. b. Check turbine casing drains, to be piped up or plugged off. ¢. Trap before control valve. 10. Desurgers - locate as close as possible to pump discharge nozzle. "The Layo of Piping Syatcns And Process Equipment MER2I) Organ BEDS ASIA SDN BHD EDS Sohrious Cot. ED Knowledge Pe Ltt “iviterneret he couse nay Spe pny yy een ee, mechan Poin 1S fra en EA ‘Seok wtb ep ue ot a ED KNOWLEDGE JULY 2008 50CENTRIFUGAL PUMPS CHECK LIST FOR PUMP PIPING 11. Flexibility: a Suction lines generally to be short and rigid. b. Check lines which are manifolded for flexibility and tolerance stack up. 12. Pump starters - check size and location, show on key plan. 13. Check that pump drains do not foul electrical gear, ete. 14. Check position of cable trenches relative to drains, ete. 15. Trenched piping eliminate branch trenches where possible and any unnecessary concrete form work. 16. If suction or discharge piping is smaller than pump nozzles, notify Analytical Section. Orsaizd By: EDS ASIA SDN BHD EDS Solos "ED Koowdpe Pe Lid ‘Alvige eared No puis one rotmabmoel or edie fo ss ng eon, hs pocapeg eigen snd ‘Soom nts te rororae pom Fee EDKNOWLEDGE JULY 2008 StCENTRIFUGAL PUMPS FORCES AND MOMENTS ON PUMP NOZZLES = The flexibility problem with pump piping is nearly always aggravated by the fact that in order to reduce the pressure drop in the suction line, it is made one or two sizes larger than the nozzle on the pump, with a local reducer at the pump. This could mean, for example, that the forces and moments associated with the flexibility of, say, an 8” diameter pipe have to be applied to a 6” diameter pump nozzle. = Coming to the numerical values which apply, these usually come from one of the three main sources: “The Layo of Piping Systens And Process Equipment MEN2I) Organi By: EDS ASIA SDNBHD EDS Sohons Co,Lkl ED Knowledge Pec Lab ‘Algo art of hor ney egret reopen, hanya men pep ee srt ee ‘paneer eprom pron hepa [ED KNOWLEDGE JULY 2008, 52CENTRIFUGAL PUMP 1) THE PUMP MANUFACTURER = The limiting values may be stated on the outline drawings or they may be indicated in the quotation documents. = Manufacturers would ideally like no forces or moments applied to the flanges of their pumps and their requirements often appear to be severe, However they will usually make concessions and it is common practice to limit bending moments in the adjacent piping to an equivalent stress of 5000 psi. ‘The Loot Piping Systems And Proves Equipment (MERZ!) —_Organited By EDS ASIASON BHD EDS Solos Go, Lid. EDKoowledge Pi Ltd Might Rope meat pl ey emt yma nhc mah nang. ek natn [ED KNOWLEDGE JULY 2008 53CENTRIFUGAL PUMPS 2) THE CLIENT «= The Stress Engineer should ensure that the clients requirements are met and he should be consulted on this matter. = Many of the Petrochemical Industries major operators have incorporated into their own engineering standards, values for maximum loading that they are prepared to - sanction. = The tendency at present is, however to refer to the third source: “The Layout of Piping Sptons And roca Equipment (MEDI) Organized BY EDS ASIA SDNBHD EDS Solions Co, Lid. ED Xavwlege Pe Li ‘iv eued a arta can may bere orelinay moo bea ic meh poten ed oe dee ‘em ston eprops ee [SD ENOWLEDGE ALY 208 54CENTRIFUGAL PUMPS 3) AMERICAN PETROLEUM STANDARD API 610 ‘Centrifugal Pumps for General Refinery Service’ is representative. If no other guidance is available then compliance with these standards is an acceptable answer to queries regarding pump nozzle loadings, = The following criteria may be applied, in the absence of API.610: “Te Layout of Fiping Syates And Proce uipment(MEV2I) _Oxanined By EDS ASIA SDN BHD — EDS-SionsCo, LM _ ED Knowleye Pe Lid ‘loghtrard Ropactncnacertraecil ena nem edger ane tying eg ie EDKNOWLEDGE ULY 208 55CENTRIFUGAL PUMPS AMERICAN PETROLEUM STANDARD API 610 = For pumps with 4” discharge nozzles or smaller, (suction nozzles may be larger), with cases constructed of carbon or alloy steel the forces and moments should not exceed the undernoted values. = Shear force on any flange, = parallel to shaft= 160 Ibs. per inch diameter. = perpendicular to shaft= 130 Ibs. per inch diameter. = Maximum resultant Shear force = 2000 Ibs. = Axial load on any nozzle = 200 Ibs. per inch dia, (except in the case of a top nozzle where the upward force must not exceed 100 Ibs. per inch of nominal diameter). ‘= Inno case must the tension or compression force exceed 2000 Ibs. The Layout of Piping Systems And Proves Equipment (MERIT) Oruiaed BY EDS ASTASONBHD EDS Sots Co,tud_ ED Knowledge Pe Lid ‘mane Np come abr epetnn fm ry myn ing ern, che iso ori nen ED KNOWLEDGE JULY 2008 56CENTRIFUGAL PUMPS NOT! = Unit stresses in the pipe connected to each nozzle are limited to 1/3 x allowable ‘hot’ stress for piping 4” dia, and over. = But 1/2x the allowable ‘hot’ stress for pipe under 4" dia. = The stresses are to be taken from the applicable code. The Lyoat of Piping Systema Ad rocer Euipment(MEV21) Organized: EDS ASIA SDN BHD EDS\SolwionsCo, Lal ED Knowledge Pr Lid iognaet Ropnfucomassung tpn pany former nee gc mee pg ebro EDKNOWLEDGE JULY 2008 57CENTRIFUGAL PUMPS EXAMPLE = Acentrifugal pump has a 6" nom. dia. suction flange and operates at 600 °F. = What are the maximum forces which may be applied using the API 610 Standards, and what maximum stress is permitted in the suction pipe at the nozzle?, The pump case is made from steel to specification fe ASTM A216 Gr. WCB. = Maximum allowable shear force parallel to shaft = 6 x 160 = 960 Ibs. = Maximum allowable shear force normal to shaft = 6 x 130= 7801bs. = Resultant shear force permitted = (9607+ 7802)!2 = 1237 Ibs. (under 2000 Ibs) = Allowable stress for ASTM A216 Gr. WCB. at 600 °F = 14,350 psi = Maximum stress allowed in pipe at nozzle (based on Std. Wt. pipe) . 14,350 * 1/3 = 4783 psi po Pipi ‘ghar Houten out ey ered cpl ney fcr my mans eg eon, man peeping. eo fra dea ‘nse nour ere pec Re pe Systems And Proven Equipe! (MEI) Organized By-EDS ASIASDN BHD EDS-SoluiousCo, ul ED Keowleége Pee Lit ED KNOWLEDGE ULY 2008 58CENTRIFUGAL PUMPS API 610 [API STANDARO 610 REACTION UMITS FOR HORZONTAL ENO SUCTION PUMPS. ‘5.5 Extemal nozzie orcas and moments [55:1 Steet and alloy steet horizontal pumps and ther baseplate and vertcaly-auepended pumps shallbe ‘dasigied for eatatactory pariotmance it eubjected to tre forces and moments Tobse 4, For horizontal pumps. ‘effects of noze londe aro considered: Ditorton ofthe punp casing (eae 5.3.3 and 5.3.4) and misalignment ft Dump and driver shafts (eee 6.35). 15.4.2 Allowable forces and moments fr vertical in.ine pumps shallbe twice the values i Table 4 for side nozzt, $18.3 For pump casingn consbuctod of matoriaisotver tan sine! ot oy steel o or pumps wih nozzle larger ¢ 'DN 400 (16 NPS), the vendor shal wibmt adoyrable no2zie loads corresponding (othe format in Table 4 Tabled — Nerate eaaings ‘tunis ‘Womnal size of ange (OM) a ee ee ee ee) Forces (uj ana moments (NM) rx io 19rd tag 2497 rm 93H BETO TaD BAND Fy ee ee ee ee Fz sm 109-1789 SMD 48H GET COM Bm LO290 re tzs0 tgo0 220 s4on sm 9000 447001 THO_ 14850 Encn ade narzie 1420 2490 3780 8000 GETO TIM 8450 1780 S110 42% 667 GoM SHE 10.280 2160 2050 Sm 4450 5910 Sm STO a0 11700 12 Tao 14.260 a ey re RR 2260 3460 6.920 Each ene nozzle ee 1309-1780 3110 4.38 G57 S000 ass toz9 7 107 1420 2480-370 5340 EGTD 7120 84s 3110 4450 5340 5760 6570 Som em 1700 60 60-1430 2900 9.50 Sum S107 E270 720 yen 4760 249 2989 310 96650 720 1000 «1760 2580 3900 4610 4750 S420 sim 1800 310 716780 e210 95409020 TROTE 1 Soe Figure 20 raugh Figee 3 or onaniaoon of vaca bade X.Y. and Zh ese 3 NOTE 2 Exoh vate sha arm andes range fom mus ta vate Ao plus that we, fr enya 710 Uhelene arange tem “7% #710 “To Layout of Piping Spates And Move Eqipment(MEA2I) —_Organaed BEDS ASIASDN BHD EDS Solos Co, ed. FD Keowiege Pe id ‘ian pce abr pny ery ngs en trey eng af ee [ED ENOWLEDGE sULY 2008 59CENTRIFUGAL PUMPS API 610 ‘API STANDARD 610 REACTION LIMITS FOR HORZONTAL ENO SUCTION PUMPS (continued) Table 4 — Wate lonaings (continues) 1 UsCustomer nme i Nominal nef tang RPS) 73 Forces anemone (IPH Tac atte cae m v0 1000 ” 000200 2 1310: 90 ma 2x20 tare wom * smo 1m 2 e002 Taverna 1 ‘ woul sa) sms aho 101400 \2 1m osm) 000 m0 SH | fe mt 2 «| maa #0 5701010120 2008249 9a ae 1 a 0 my sm 170) 2000 31m 4905 47m SaD0 | ww 1 om am tom tomo 2m 2K 2700 ur wo sm 740 vam 1800 29m 3409 9D «CED! 9 1n0_ 20103600 50m) $100 _6m0_ 1200) NOIET Sa gas Riagh gre i mini e aeh h Va) | | oTE2 each ash a cles ange fom sa ae pl ata fr ep 16D cr age an = 8 {5.84 The co-acinate system(s) shown n Figure 20 tough Figute 24 shale used to apply the forces and ‘moments Tae 4 iB Armes gives methods of qualving nozie loads in excess of hose in Table 4. Thave mebiode may be sed |Wagoroved by the purchaver and the purchaser shoud then cect te piping designer accordingly, The purchaser shoud be aware tral the uve of Annes F methods can reel up to 80% greser misalignment than Would ooout ‘ing the ead of Table 4 “The Layo of Piping Syston And Process Equipmers(MEA2I) _Oranized Dy EDS ASIASDN DHD EDS Sohatons Co,Ltd. ED Knowledge Pi Led [tvghesmn Npatcos tay beds orp nay fm 9 mena ng ode mechan pty ecg amon ee ‘Sonos noun e poentam pratense ED KNOWLEDGE :ULY 2608 60CENTRIFUGAL PUMPS API 610 API STANDARO 610 REACTION LIMITS FOR HORIZONTAL. END SUCTION PUMPS (continued 6 rs. | | 1 | u PN i ( SBT | See Stat conta Besage Suton Care cigar Patt cnn “ee one ‘igure 23 — C morainate system forte teres ad memonts in Table 4— Horton pups wh Sutin and op dscharge owztes The Linon of pig Synene Ard Proce Egress MEDI) Organ By: EDS ASIA SDN BHD EDS Svlaons Co, LL ED Knowledge Pi Lid [Avsaharared ort ona ny beater spain ay ror me ng ato. ah, cg Men naman ED KNOWLEDGE JULY 2008 61CENTRIFUGAL PUMPS PUMP CURVES TOTAL HEAD IN FEET US. GALONS FER MNUTE aT AS Figure 1-13, Performance curve for Type 1.x 1 744. INSINI pump. Courtesy of Byron Jackson Pump Div "The aye of Piping Sse And Pree Equipment (MEV2I) —Oruiaed By EDS ASTA SON BHD EDS Slutons Co, Lid ED Knowledge Pe Lid Aight ne ett cnc ee yma a aera Pi won lt [ED NOWLEDGE JULY 2008 62CENTRIFUGAL PUMPS PUMP CURVES courbes de PUMP DIVISION POMPES bith eeeaeane PAGE: 2412 se == ATE: Hoy 1974 i Tee 50% 5 oy dot Sees «| eae HP. 78 HP SOS, ; Hees : 7 : scr, «B08 ROT im io” 0” ato ‘The Layoat of Piping Systeme And Pres Equipment (MEV) Tea 0060 S008 ROT HAT CAPACITY - aie ‘Orgmized By EDSASTA SON BHD —EDS-SolsionsCo, i FD Keowldge Pe Lid ised aca coe ema beraie ape mf ba e.g ean al psx Meh etn ee ‘um te pres pemisent poee [EDKNOWLEDGE 1ILY 2008 63CENTRIFUGAL PUMPS CENTRIFUGAL PUMP SPECIFICATION SHEET EQUIPMENT NUMBER: REF DRAWING No's: . EQUIPMENT DWG: — . P&ID . PIPING LAYOUT: DESIGN DATA: + LIQUID PUMPED: * VISCOSITY + VAPOUR PRESSURE: + TEMPERATURE: + SPECIFIC GRAVITY @ TEMP. » FLOW (MAX) GPM 7 (MIN) GPM + SUCTION PRESSURE PSIA + DISCHARGE PRESSURE —PSIA. = DIFF, PRESSURE: Rating/ Shutoff Feet PSI * NPSH AVAILABLE: Feet painsnsdiannstsnntaissnssasasesasssasasssssnsnsasssscesessensesseeaesn-onessiesesseesesesesese “Te Layo of Ping Systems And Proves Eqipmené(MESZI) Organized By EDS ASIASDN BHD EDS Solutions Co, Lid, ED Knowledge Pe Lid ‘Bt pcre eat pe mange oa neg EDKNOWLEDOE JULY 2008 64CENTRIFUGAL PUMPS VENDOR INFORMATION + NPSH @ REQUIRED: ibesiesecttestes (=) + TYPE OF PUMP/MODEL/NUMBER OF STAGES + RPMROTATION + EFFICIENCY/BHP at RATING/BHP MAX. + IMPELLER DIAMETER: Max/Min + IMPELLER; Eye Area/ Peripheral. Vel + WORKING PRESS:, Max/Hydrotest PSIG + CLEARANCE: Wear Ring/Bearing/Impeller + HYDRAULIC THRUST: Rating/Max/Up_ “Te Layout of Piping Syste And Proce Eqipet (MEN) Organized By-EDS ASIA SDN'BHD EDS Solutions Co,Ltd. ED Knowledge Fe Li “liuoene pater enmen trp sim ony ms gems me os enn eed ED KNOWLEDGE JULY 2008 65CENTRIFUGAL PUMPS STEAM TURBINES = The same remarks apply here that were used to define the problems relating to pump nozzles. The allowable forces and bending moments on a given size of nozzle are considerably less than for a pump, NEMA SMQ23 standards apply to Turbines and may be applied as follows: = The forces and moments acting on mechanical drive steam turbines due to the steam inlet, extraction and exhaust connections are limited by the following rule: = The total resultant force and total resultant moment imposed on the turbine at any connection must not exceed the following "The Lavon of Piping Sate And Proves euipment(MEH21) _Oxmized By’ EDS ASTA SDNBHTD EDS Solns Co, Ld lg puttin vrata opin mom nto meget rc Panag a Kowidge Pe Lid ED KNOWLEDGE JULY 2008 66