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Pumps
Table of Contents
1. General
2. Centrifugal Pumps
3. Reciprocating Pumps
4. Rotary Pumps
5. Pump Drivers
1. General
1.1 Definition
In this context a pump is defined as a machine used to generate a pressure differential in order to propel liquid through a piping
The three basic types of pump are centrifugal, reciprocating, and rotary. See below figures.
Centrifugal pumps are the most common. They are more economic in service and require less maintenance than other types.
Rotation of the impeller blades produces a reduction in pressure at the center of the impeller. This causes liquid to flow onto the
impeller from the suction nozzle thrown outwards along the blades by centrifugal force leaving the blade tips via the pump volute
Reciprocating pumps are used where a precise amount of liquid is required to be delivered, also where the delivery pressure
required is higher than can be achieved with other types. The liquid is moved by means of a piston in a cylinder after being drawn
into the cylinder, through an inlet valve, as the piston moves down the cylinder. As the piston moves back up the cylinder the liquid
The liquid is ejected from the cylinder into the piping system in pulses which are transmitted to the suction and discharge piping,
thus hold downs could be required on the piping system. Rotary pumps are used to move heavy or very viscous fluids. These
employ mechanical means such as gear, cam and screw, to move the fluid.
2. Centrifugal Pumps
Centrifugal pumps must have their suction lines flooded at all times.
The suction piping has to be designed to avoid cavitation or prevent vopour entering the pump. Therefore, suction lines should fall
The minimum vertical height required from source to pump suction is called the Nett Positive Suction Head, (NPSH). This is
critical for efficient pump operation and must not be reduced. Vessel elevations are often dependent on the NPSH of its
associated pump. See below figures.
There are three basic types of centrifugal pumps. Horizontal drive shaft with pump drive mounted remote from the line, vertical
drive shaft with pump and drive mounted on the line, vertical barrel type with direct immersion suction facility. In each case the
The most common is the horizontal with its shaft in the horizontal, vertical in line pumps have their shafts vertical and the pump
is installed in the pipe line, as a valve must be. Vertical can pumps are usually single stage, but horizontal and vertical can types
Line Size
Suction piping is usually one or two line sizes larger than the pump suction nozzle size. Suction piping more than two sizes larger
Centrifugal pumps are supplied with suction nozzles on the end of pump casing, axially in line with impeller shaft, also on top or
side of pump casing. Usually pumps are specified with end or top suction for general services. Side suction pumps, with side
discharge are frequently selected for large water duty. Also side suction - side discharge pumps can be obtained in multi-stage
form for higher pressure differentials. These pumps tend to become very long, so if plot space is tight, consideration should be
given to purchasing the pump in vertical form with a sump at grade. See below figures.
Consistent with good piping practice, pump suction lines should be as short as possible, but with enough flexibility to absorb any
pipe movement caused by temperature differentials and to maintain pump nozzle loads to within those permitted by pump vendor.
Due to suction line being larger than the suction nozzles, reducers are required in the line. Reducers should be as close as
possible to nozzle. Eccentric reducers will be used with the flat on top for horizontal pumps. See below figures. For pumps with
suction and discharge nozzles on top of casing, care must be taken to ensure that the flats on eccentric reducers are orientated
so that suction and discharge lines do not foul each other. See below figures.
All pumps must have a temporary startup strainer in the suction line to prevent any pipe debris damaging the pump. Strainers will
be located between pump suction block valve and pump. Strainers are available in the following styles : flat, basket, conical and
For basket and conical types a removable spool piece must be provided downstream of suction block valve, which must not
interfere with line supports. Both types have the advantage that the piping is left undisturbed and strainer element can be
removed simply by removing the blind flange on the tee, thus leaving the piping and supports undisturbed. See below figures.
Line Size
Generally, discharge piping is one or two sizes larger than the pump discharge nozzle size.
Discharge Line Fittings
Due to discharge line being larger than the discharge nozzle eccentric reducers are required in the line. Reducers should be as
close as possible to the nozzle, with top suction - top discharge pumps, care must be taken to ensure that the flats on eccentric
reducers are orientated so that the lines do not foul each other.
A pressure gauge is located in the discharge line, and should be upstream of the check and gate valves which are usually flanged
together with a dripring between them. When a level switch for pump protection is installed in the discharge line, upstream of
To enable good access to valve handwheels and ease of supporting, the discharge line should be turned flat after reducer, and the
line angled away from the nozzle to enable the line to be supported from grade. See below figures.
Avoid supporting large lines from piperack structures if possible, this enables minimum size beam sections to be used and better
This type of pump is usually installed in a large duty service with large bore lines. Never connect an elbow flange fitting makeup
to the nozzle of suction line coming down to the pump. Supply a straight piece of pipe two pipe diameters long between the nozzle
and elbow.
The two diameter pipe length can be eliminated if the elbow is in the horizontal, only eliminate pipe length if available space is
Vertical pumps, also called can type or barrel type are used when available NPSH is very low or nonexistent.
This type of pump is mounted directly into the pipe line, as a valve would be. For smaller sizes, the piping system supports the
pump and motor, thus it is essential that the line is supported local to the pump to prevent the line moving when the pump is
removed. Also ensure that there is good access to pump for maintenance and withdrawal with no overhead obstructions for lifting
out pump. Larger size in-line pumps have feet or lugs on the casing for supporting from grade or steelwork.
Usually this type of pump is installed in cooling tower water circulating service, retention ponds, and applications where NPSH is
low and suction is taken from a sump below grade. In most cases, there is no suction piping to be considered, but the discharge
line must be routed to ensure good access for pump maintenance, with no overhead obstructions for pump removal by a crane.
3. Reciprocating Pumps
There are three classes of reciprocating pumps, piston, plunger and diaphragm.
Piston pumps are generally used where medium to high delivery pressures are required, such a high pressure flushing of vessel
interiors, etc. These can be obtained in multi-cylinder form and can be single or double acting. Plunger pumps are usually used for
metering or proportioning.
Frequently a variable speed drive or stroke adjusting mechanism is provided to vary the flow as desired.
Diaphragm pumps are invariably air driven and very compact, also there are no seals or packing exposed to the liquid being
pumped which makes them ideal for handling hazardous or toxic liquids. These are often used for sump pump out. See below
figures.
4. Rotary Pumps
Gear pumps are usually employed to pump oils and nonabrasive fluids.
Screw pumps are usually used to pump heavy viscous fluids and nonabrasive sludges. Apart from maintaining good access to
pumps for operation and maintenance each case should be treated on an individual basis.
5. Pump Drivers
The three most common types of driver are the electric motor, diesel engine, and steam turbine.
5.2 Electric motors are the most common pump driver and are of the totally enclosed, flame proof type suitable for zone 1 use.
Their sizes range from small to very large which require their own cooling systems.
5.3 Diesel engines are usually to be found as drivers for fire-water pumps which are housed in a separate building away from the
main complex.
5.4 Steam turbines used for pump drivers are ussualy single stage and the pump that they drive are invariably for standby service
(spare).
The steam inlet nozzle is usually on the right hand side when viewed from the pump coupling end of the turbine with the exhaust
on the left hand side as standard. Turbines can be purchased with inlet and exhaust on the same side. This means that the piping
designer can place the exhaust connection either on the same or opposite side from the inlet. Generally opposite side location of
Steam inlets are furnished with strainers as part of the turbine for protection against pipe debris, therefore inlet piping must be
Steam supply to turbines must be moisture free at all times, otherwise damage to the turbine will occur if condensate enters the
turbine while it is running. To separate condensate from steam a boot-leg must be installed up stream of the inlet block valve.
The two basic turbine installations are manual startup or automatic startup. The manual startup will have a gate valve in the
steam supply near the turbine inlet. Upstream of the block valve a boot-leg must be installed with connections for blow-down and
steam trap to remove any condensate in the steam supply. For automatic startup the gate valve is replaced with remote operated
control valve, the boot-leg and traps are still required upstream as for manual startup.
Steam traps should be provided to keep the turbine casing free from condensate. These can be installed at the casing low point if
a connection is provided or, on the outlet piping if the casing drains into the outlet system.
Note there must be a trap before any vertical rise which could form a pocket where condensate could collect.
On automatic startup a warm-up bypass must be provided around the control valve. This bypass is usually a “1” globe valve, and is
partially opened to allow steam to keep the turbine constantly warm and slowly turning to prevent the shock of hot steam
For manual startup it is recommended that a warm-up bypass be installed, but the job flowsheets will govern.
When a warm-up bypass is installed a steam trap on the casing keeps the system free of condensate. See below figures.
Turbine exhausts are routed either to a closed exhaust steam system or to atmosphere. When exhaust is to a closed system there
must be a block valve between turbine and main header, this block is always open during normal conditions and only closed for
turbine maintenance or removal. Thought should be given to locating exhaust block valve on the piperack immediately before
lines enter main header, this will prevent accidental closure of this valve. If the exhaust line is routed to atmosphere, the steam
trap on turbine casing will not be installed, but replaced by gate valve partially open to allow condensate to drain off from casing.
Most small turbine casings are split along their horizontal axis and enough space above the turbine should be kept clear to allow
for the top section of casing to be lifted clear of rotor by crane. See below figures.
Most pumps require external services to be piped to them for bearing cooling, bearing lubrication, seal flushing, venting and
draining.
These requirements will be shown on utility flowsheets, and it is the piping designers responsibility to ensure that the actual
geographic location of pumps with harnesses are correctly shown on the flowsheets. Though should be given to running
subheaders to groups of pumps that have harness requirements. These subheaders must be sized and marked on flowsheet
masters. Because branch lines to individual pumps are small diameter, i.e. 6 mm, it is advisable to take branch connections from
the top of subheaders. This will eliminate pipe debris getting into the branch line and into the pump bearings, etc.
Care should be taken to ensure harness piping does not interfere with good operation and maintenance space.
Gear-Type Rotary Pump Having Two Impellers
Conical And Basket Strainers
The above diagrams indicate correct and incorrect methods of attaching suction piping.
Fig. 1 Shows air pocket formed along upper side of pipe by sing concentric reducer.
Fig. 2 (A) Horizontal ell directly into pump suction results in an unbalanced thrust on pump bearings. (B) Use spool piece 3 pipe
diameters long or long radius ell with center vertical vane. (C) May be installed with or without spool piece but 2 pipe diameters
spool is preferred.
Fig. 3 Shows proper method of connecting pump suction to a suction header in order to avoid air pockets.
Fig. 4 Represents a common error made suction piping to a centrifugal pump by placing piping over an embankment of a reservoir,
or other obstruction.
SUCTION PIPING: The suction piping should be as direct and short as possible. In general it should be one or two sizes larger than
pump nozzle. If changes from one pipe size to another are necessary, standard reducers should be used. Correct and incorrect
MANUAL START-UP
Table of Contents
1 Introduction
4 Model Packing
6 Model Transport
7 Insurance of Model
8 Attachments
1 Introduction
The design model is to be used as a detailed engineering tool as well as a construction and planning aid for the job when shipped
to the site.
Shipping the model to the construction site requires custom-built crates to accommodate the different sizes of model tables, and
special care handling because of the value and fragility of the models.
Prior to actually placing the model in either a crate or on board the transportation carrier, the following steps should be taken.
Reapply cement to each and every bond joint on the model; structure, equipment, pipe joints, duct-work, etc.
Add any necessary cross bracing, corner triangles, or supports (all represented as fictitious members) to the model -
structure, equipment, piping, etc. - at points where the strength of the model is inadequate. These points may occur
where the glued joint is of a small cross-sectional area and requires reinforcement, or where the weight of a model
component might cause considerable damage if it were to break loose during transit.
Apply nylon filament tape to sections of the model to keep model split levels from separating. The number of floors to
be taped to one another depends on how many section are to be shipped or placed in a crate as a unit. Nylon tape can
Models having a multi-storey building structure normally cannot be shipped as a unit because of the crate size, model
weight and limitations imposed by the carrier. Therefore, it is advisable that the model floors be fastened in some
manner to a 1/2” thick plywood sheet to act as a base. The plywood should extend approximately 1” beyond the model
An important factor to be recognized is that the model must not be made into a rigid system. Some flexibility and movement is
Remove the legs from the model base and tape the legs together in pairs.
Travel Time.
Cost Factors. Model value - replacement value and engineering backup in case of total model loss and differential
transportation costs.
There are two basic types of transportation available for transporting models; truck and air. Truck transportation, generally in
moving vans, is most commonly used. Train and nautical transport will be avoided.
Shipment by van generally eliminates the need for crates. The truck bed is covered with thick foam padding and the models are
placed on the foam in such a way that they do not touch the sides of the vehicle or other bases. Rolls of foam can be placed
between model bases and the sides of the van. Tie-downs are not required. This method provides door-to-door service and direct
loading and unloading. The cost of crating is avoided if there are few limitation on the size of the model shipped.
Van shipment is usually more expensive than air freight and the delivery time is usually longer especially if long distances are
Air freight is relatively inexpensive especially over long distances. The service is reliable and relatively unaffected by weather
conditions. However, all models must be crated and the crate size is limited by the size of the cargo door of the aircraft used.
This method also requires multiple handling operations and local trucking at both the origin and the destination, greatly
increasing the risk of accidental damage. Air freight is used extensively for overseas shipments.
4 Model Packing
Crates are fabricated to contractors specification (see Attachment 1). The inside crate size should allow 50 mm on all sides of
the model base. An exception to this rule occurs when a model has an overhang which requires an adjustment to crate size.
The model tables are individually crated. Knowing this, and the size of the model table, the crate sizes can be pre-calculated and
arrangements for shipping can be made with the airlines cargo section, or any model contract mover. Sometimes an extra crate
may be needed for the removal sections of the model if there is insufficient space on the model table to ship the sections.
Crates will have three perspex windows (top, side, side) 300 mm x 300 mm for customs control.
Crate dimensions will be measured by crate fabricator and are his responsibility.
Place a copy of model uncrating instructions on the side of the side of the crate in a waterproof envelope.
Address the crates and prepare the shipping documents, such as packing slips, bill of lading, and declared value, as required.
In air shipment, volume is the main factor not the weight, as is usual in over-the road shipment. The air shipment crates should
not be made oversized in any case. The crates are pelletized and smaller crates are placed on the top of bottom crates.
Fragile
Weight
Dimensions
6 Model Transport
If going by road the freighter may use a van/lorry which is enclosed and waterproof. If by roadship - road to destination the
arrangements re. the ship must be roll on, roll off type, to reduce possible damage to model.
Each model base will than be independently fixed rigid to the floor of the van/lorry using wooden battens of size 100 mm x 38
mm. These wooden battens will be fixed securely either directly to the floor or the sides of the van/lorry.
Model table supporting legs will be removed from the model bases and securely taped to respective model bases.
The model bases will then be positioned in the van/lorry on the foam padding so as to avoid contact with other bases being
transported simultaneously.
If it is felt that certain structures or other high items may be subject to movement caused by vibration set up by the moving
vehicle then all reasonable precautions will be taken to minimize this. These measures, as a minimum, will be the tapping down
Personnel from Piping Group should accompany model when in transit to site, in order to control handling and be present when
model is removed from cases. (Note. providing freedom of travel allowed in country of destination).
Travel by air - the same applies (i.e. personnel to travel with model from office to airport to witness cases being loaded. If cases
are interchanged en route Constructors Personnel should be there to witness transfer and again personnel available at
destination to supervise off-loading. Aircraft should be met to see off-loading and loading on lorry for final journey to site.
Once received at site the DESIGN MODEL will be required to be housed in a temporary building close to the unit being erected.
This building will require to be well ventilated, water proofed and have a source of heat supply to prevent condensation damage
to the mode.
Whilst the model is retained in the temporary building it is the responsibility of the Company Construction Supervisor to ensure
So as to minimize the possibility of damage to the model it is recommended that only supervisory personnel are allowed
unrestricted access to the model. All other personnel are to be accompanied on visits to the model.
All damage occurring to the model is to be reported immediately so that qualified personnel may carry out repairs and ensure
that all at all times the model is an accurate portrayal of the subject unit.
Design changes to the model once delivered to site will be resisted. Any changes that are agreed to will be the subject of a
Project Change Notice and will require to be approved by Company Project Manager. All design change requests must be made in
Upon completion of the erection of a subject unit the model will be removed from the temporary building and placed in a final
location.
At this stage the model will be formally handed over to the Client.
7 Insurance of Model
The design model will be covered by an insurance policy held by Company responsibility for shipment a special insurance will be
Insurance cover for the model will be as a maximum - for total destruction. The declared value of the model should only be the
cost of the material and only the cost of an after the fact model (a model built only after the drawings are completed). No design
To enable insurance claims to be instigated it is imperative that all damage is reported immediately howsoever caused.
8 Attachments
1. Introduction
2. General
3. General Safety
4. Lines
5. Valves
6. Heat Exchangers/Reboilers
8. Vessels/Columns
9. Furnaces/Boilers
11. Electrical
12. Instrumentation
13. Civil/Structural
14. Attachments
1. Introduction
The purpose of this document is to lay down a review procedure to ensure that the desired level of quality for the creation of a
piping 3D is carried out in the engineering office and that sound design criteria for operability, safety and maintenance have been
observed.
This check list may also be used for the recording of the check, appropriate space is left for any comments against a checked
Additionally the form “Internal 3D Model Review” (see Attachment 1) and the form “Approved 3D Model Revisions from Internal 3D
2. General
Check if “Interference Checking” facility has been run, if so, ask to see a printout of the report.
Check the 3D model against the latest issue of the plot plans, engineering and utility flow diagrams and line tables.
Follow the line up systematically and pay strict attention to details since many accidents are caused by seemingly minor items.
Mark on the engineering flow diagram all the lines, fittings and instrumentation which have been checked.
Make sure that when a modification, addition, elimination or reduction is considered, that is suits its purpose, is practical and
Use this procedure for a number of items which can not be shown on diagrams. Please note that the checklist does not pretend to
Check that start up and shutdown problems have been considered and drain and let-down facilities have been provided.
Check the accessibility for operation, maintenance with mobile equipment and inspection.
Check that access ways and roads provide ample head room for vehicles, mobile equipment, etc. required for efficient and safe
The policy of access to valves, blinds, manways, instruments, etc. shall been established during 3D model creation. Check 3D
Package units are not normally modelled in detail and are usually show as a block. Ensure adequate space is available for access
Check location of particularly noisy equipment, valves, etc. in relation to the frequency of visits by operating and maintenance
Check the space required around fired heaters for soot blowing and decoking and clearance for burner removal.
Check that air fine coolers can be installed or handled during maintenance of plant by means of a mobile crane.
Check that adequate clearance and maintenance access is provided for plug removal tube cleaning, motors, V-belts, fans.
The 3D model shall also indicate junction boxes, cable trays and trunks, switch gears and power stations, control room, local
Check at final stage the package units, if vendor information has been included in the 3D model (use certified vendor drawings of
lay out and detailed piping showing all instruments and local panel).
3. General Safety
Check that fire hydrants are not positioned at the ends of, or in the line with the ends of, horizontal vessels.
Check elevated equipment’s and platforms for the proper escape routes. Ensure unobstructed and short escape routes at grade.
Check that ladders and staircases have been installed on the outside of structures. Are staircases provided with turnaround
landings?
Does escape traffic have to pass through structures? Check companies and/or governmental regulations for safety.
Check that remote shutdown and valve closing devices are installed at safe locations. Check that equipment concerned can be
Check that safety showers and eye baths are located near equipment containing aggressive chemicals (e.g. caustic, ADIP, MEA,
Check accessibility of the unit for mobile fire-fighting equipment and rescue work.
Check that emergency/smothering steam header block valves are at safe distance from protected equipment (e.g. in hydrogen
service or near fired heaters). A steam header block valve station could be fire shielded, if required, by brick or concrete wall.
Make sure that operators manipulating drain valves can see the emerging affluent. The required level gauges shall be visible and
Check that utility stations have been provided, including those at the main operation platforms, e.g. for the connection of steam
lances.
Check barometric seal height of vacuum for liquids other than water. Ensure that the liquid can be drained as well. Important for
Check that steam exhaust cannot cause personnel hazards either from spraying droplets of hot water or causing icy or wet
surfaces.
Check that steam rings are foreseen at flanges in overhead lines of thermal cracking units and for lines in hydrogen service.
Be alert for equipment supported on continuous platforms when sections of these platforms are supported on structures subject
Check that continuously operating vent stack are higher than the highest nearby structure (within a safe distance).
Check the location of liquid relief valves, since its actual height influences the required set pressure.
Check the location of toxic gases (h4S, VCM etc.) monitoring points if applicable.
Check that drains of light hydrocarbons (propane, butane) are protected against freezing (e.g. double valves).
Check that levers of plug-and ball valves are not hampering operators on walkways or platforms, levers shall move in the same
Check that steam for purging of lines and equipment (e.g. snuffing steam, emergency steam) is dry, provide automatic trap
Check that process ventlines are routed and oriented to safe locations, (3 meter above highest platform), watch nearest platforms
Check location of manholes with platforms and ladders in respect to safe escape route.
In case of location of water cooled equipment at high elevated platforms, check if the normal cooling water pressure is suitable
To prevent vacuum in equipment located at high elevations, due to siphon operation of the fluid, install a vacuum breaker to suck
4. Lines
Check that piping entering and leaving the unit is logically grouped together.
Check that valves, blinds, flushing/drain and instrument connections are properly located. Check especially so called manifolds
and large control valves. Check in cases where spades are used ISO spectacle blinds, that piping system are flexible enough to
Check elevation of overhead piping and horizontal clearance of access and/or walkways.
Check that dead ends have been avoided. Check if system can be flushed and drained.
Check that vapor lines (inclusive steam) branch off from the top of main lines. Prevent pockets in vapor lines. Keep lines sloping
Check that piping subject to thermal expansion is flexible enough. Are supports adequate?
Check if nozzles and branches on expanding piping are not installed near obstructions, support beams, etc. (to avoid ripping off).
Are these lines properly anchored. Are stresses on equipment nozzles within limits.
Check for pockets in vapor lines where condensation may occur. Has external heating been applied on those pockets which can
not be avoided?
Check that long lines attached to small bore nipples are properly supported to prevent breakage due to vibration.
Check that lines do not pass through table top, but run alongside. If impossible group lines together passing via a sleeve.
Check that dead end sections have been avoided (e.g. in water lines).
Check that piping has been designed to permit easy drainage, venting, flushing, testing, maintenance, insulation, painting.
Check position of eccentric reducers. Normally straight side on bottom of horizontal lines except in pump suction lines where
Check that small bore cooling water lines branch off from top of the header. (This to prevent plugging).
Check that stripping steam lines are short and horizontal or sloping from the last valve.
Ascertain that two phase flow vertical piping has been checked for flow stability.
Check that high temperature and special material lines have been stress analyzed.
Check absorber gas feed inlets for pockets near the inlet to avoid absorbent in the gas line.
Check that piping with instrument connections has been laid so that these connections are easily accessible. Check if necessary
Check anchoring of piping discharging to atmosphere. Pay special attention to screwed piping.
Check that vacuum equipment steam jets has been hooked up directly to the steam mains, i.e. without any intermediate
connections which may suck in air. This is not applicable for vacuum pumps.
Check (for the same reason) that venting of the gas compressor suction piping has been avoided.
Check that service stations have been properly located. Design also for winterizing (water/steam/air in one insulated box).
Check for rotary equipment that suction and discharge piping are properly supported.
Check that thermosiphon reboilers have been located such that minimum pipe distances and equal vapor distribution are
achieved.
Check required straight piping runs to distributor piping in distillation columns. Only in vertical plains are bends allowed within
If a vent is required on an exchanger for periodically purging of noncondensable vapors, this vent valve shall be accessible, vent
Check piping arrangements on shell and tube side of exchangers carefully for correct flow of fluids and proper operation of
exchangers.
If symmetrical piping hook up is required to exchangers, airfines or double suction of pump, check this carefully.
Check location of break flanges on piping at shell and tube exchangers and aircoolers to facilitate bundle removal.
Check that number of passes in a heater are shown and if necessary check that piping is symmetrical.
Check that location of isolating valves and valves of snuffing steam and emergency steam are at 15 meter distance from the
Avoid dead legs in heavy fuel oil lines and waste gas lines.
In case of steam jacketed sulphur lines provide T-pieces or cross pieces at the end for cleaning the sulphur lines by rigging.
Check location of relief valves and their good accessibility for servicing.
Check location of local panels for safe operation and good accessibility.
5. Valves
Check that valves in overhead pipe tracks have been avoided to the maximum extent.
Check that chain operated valves have been avoided where possible.
Check that all valves are installed with the steam installed with the stem pointing upwards or horizontally.
Check that hand wheels are easily accessible for operation and yet not obstructing walkways or platforms.
Check that valves for emergency operations are workable grade level.
Check that valves that need frequent attention are easily accessible.
Check when reduced port valves are installed, that piping is self draining on both sides of the valve.
Check that hot oil block valves are well accessible in view of fire risk.
Check that control valve assemblies are located at ground level or on first platform (except when required otherwise for process
reasons).
Check that installation of valves outboard of elevated platforms has been avoided.
Check that valves or double block and bleeders have been installed in utility connections to process equipment and lines.
Check that spring loaded and/or extra block valves have been used where valves may freeze-up when draining or sampling.
Check location /installation of check valves in ditch. lines of pumps or near connection of lines, for example connection of
condensate lines from traps to condensate collecting header near to the header.
Check levers of plug-or ball valves, these shall not obstruct walkways, platforms etc. Levers shall move in the same plane as the
6. Heat Exchangers/Reboilers
Check that piping arrangement is acceptable with respect to the removal of shell and channel covers as well as the withdrawal of
tube bundles.
Check whether bundles can be pulled and lowered safely from platforms and stacked arrangements (obstructions, hydrants).
Check stacked heat exchangers for the possibility of oil spills on hot equipment beneath it, especially during maintenance work.
For a thermosiphon check reboiler check the elevation difference between draw-off pan and reboiler for driving force
If a vent is required on the exchanger for periodically purging of noncondensable vapors, this vent valve shall be accessible. Vent
Cold fluid enters the exchanger at the bottom and leaves it from the top
Check symmetrical piping hook-up to several bundles in an airfin cooler or to exchangers in parallel operation. Dead legs in
capped headers shall be kept to a minimum or be avoided, use elbow ISO tees at the end of the header. Pockets in outlet piping of
aircooled or water cooled condensers must be avoided as well as in the hot vapor bypass lines.
Check that high points in pump suction lines have been avoided
Check volumes which must be drained when a filter or a pump needs to be opened
Check that pumps can be safely and easily handled for maintenance
Check that facilities have been provided for gradual heating prior to start
Check hookup of suction line on double suction pump. Piping layout to be as follows for side inlet:
Straight length from suction flange until bend to be 3D (D = diameter nozzle pipe), no reducer allowed.
For top inlet straight length = 5D if suction line runs in length direction of pump motor and 3D if suction line runs in
same plane as pumps impeller(s). Upstream of the bend in the suction line the strainer, valve etc. can be installed.
Check that pump operating under vacuum are provided with high point vents, which are connected via a vent line to the top of
suction vessel
If pump handle liquids with temperatures above auto-ignition, this pumps shall be located in safe-areas (not underneath pipe rack)
and widely spaced from other pumps. Good accessibility for fire fighting is required and above pumps a sprinkler system shall be
installed
Piping to compressors. Pockets shall be prevented, lines shall be slope to suction drum and suction line shall mostly be
Check that sufficient space is available for removal of filters from strainers
If two pumps are parallel operating the piping hookup at suction and discharge side shall be symmetrical.
On reciprocating compressors safety valves must be located upstream of the discharge block valve.
8. Vessels/Columns
Check positions of drain nozzles. Keep them clear from areas where heavy equipment such as fork lift trucks may work
Check that instrument tappings and local instruments are readily accessible
Check that the lines can follow the expansion when heating up/ cooling down. Pay special attention to supports on hot
respectively cold structures. Check free movement of platforms
Check that the layout of platforms , ladders, piping, relief sets, etc. is in accordance with the specified basis for wind and
Check location and elevation of all piping- and instrument nozzles against requisition of equipment and drawing
Check that spectacle blinds or spades are installed (indicated) at the nozzles for pressure test or isolation purposes. Normally
Stripping steam to the columns shall be dry; install KO pot at grade provided with automatic steam traps and drain valve and
provide a minimum distance insulated steamline in vertical run without pockets to the steam inlet nozzle of the column.
Check that consideration has been given to loading and unloading of catalysts, packing, internal etc.
9. Furnaces/Boilers
Check that piping does not obstruct observation windows, access doors, header box covers, etc
Check that piping at burners is arranged so that insertion/removal of lighting torches and burner guns is not hampered
Check that heavy fuel and LBF system are sufficiently segregated
Check that provisions are made to adequately prevent liquid fuels from entering steam and gas system
Are locations of flame arrestors, straight pipe length etc. of low pressure and waste gas in accordance with
specifications?
Check that emergency/smothering steam valve manifolds are at safe distance. Steam shall be dry. Install upstream of manifold at
Check that :
Check that fuel and atomizing steam cocks are within hand reach when looking at the burners through the observation windows
Check that safety logic (for heater start-up and shut-down) is not located below (vertical) furnace. Normally such a logic is
located in a local panel at safe distance (15 meter) from a fired heater
One complete burner hookup shall be shown per heater including all instruments and all provisions for safe startup, operation and
Check heater or boiler location for maintenance and construction accessibility and also for decoking, regeneration or soot
blowing activities.
Check that inlet lines to relief valves are self draining into process equipment.
Is its proper functioning not hampered by the nature of the process fluid? The allowable pressure drop across the inlet line of
relief valve is limited to 3% of the set pressure (at maximum capacity). If pressure drop is too high, the line size shall be
increased.
Check accessibility of the relief valves for maintenance and inspection. Check if relief valves have been installed at proper
Check pressure relief discharging to atmosphere for safe location and direction.
Check that discharge pipe is drainable. If so, does drain not impinge on other equipment? Have measures been taken to avoid
Check that the tail end of vent pipe is within the action radius of fire extinguishing equipment. If not, has a snuffing steam
Check that length of piping is minimized for safety relief valves discharging into a closed system.
Check that outlet line from relief is self draining into flare header. Check if connections are made on top of the flare header.
Check that flare lines have no pockets and that they are sloping to the flare knockout drum.
The back pressure on the relief valves (calculated during the design) shall be checked with the actual layout of the flare system.
Check destination of outlets from 1 ”x 1” thermal relief valves to atmosphere or grade for safety.
Check that valves with Castell lock system (or other system) are properly installed.
Check that safety relief valves and inlet/outlet lines adequately supported.
Check that tail pipes of relief valves require weather protection cap.
Check that the proper type of the relief valve has been specified, for example in waxy service piston type in view of plugging.
In case of 1 ”x 1” thermal relief valves, the inlet of the relief valve shall be self-draining to the process line, the discharge line can
be connected to a collecting header which shall be discharging under slope without pockets to a vessel. Check if inlet and outlet
11. Electrical
Check that cable trunkings are properly located and not obstructed by equipment etc.
Columns of pipe racks are normally used to install junction boxes for both electrical and instrumentation purposes.
Check that orientation and access is not hampered by location of control valve station, steamtracing stations, utility stations or
other piping lay-outs.
12. Instrumentation
Check that all instruments are on 3D model and have been correctly tagged.
Check that instrument cable trunkings are properly routed and in accordance with applicable instrument drawings.
Check that local control panels, main junction boxes, etc. are properly located.
Check location and accessibility for operation and maintenance of all instruments. Mind removable piping on both sides of
Check platform clearance around level gauges, control valve stations, relief valve station, especially for Camflex type control
13. Civil/Structural
Check that all structures with bracing and pipe racks are shown, inclusive fireproofing.
Check that all plinths for equipment and structures are shown.
Check location of analyzer house(s), if fast loop requirements for correct measurements (samples) will be met.
14. Attachments
The following description is a definition of each percentage complete stage of the piping 3D model. Company practice normal
Definitions
BASIC
30% Completion
Location of unit access ways for mobile maintenance and fire fighting equipment shown
60% Completion
90% Completion
Instrumentation, including cable trays 100% complete. Electrical cable trays 100% complete
100% Completion
3D model updated to latest issue of PEFS’s, PEUFS’s, line tables, arrangement drawings and final equipment drawings
4. Reviewers
5. Subjects
6. References
Often 3D model reviews are limited to checking for interferences and consistency with key project documents such as P and ID’s.
While these types of reviews are obviously required and important, limiting the reviews to “design checks” does not take
The important thing to remember is that the 3D model represents the plant that is to be built; the total end product in three
dimensions. Therefore, to fully utilize this tool, all those personnel who may have an impact, and/or who will be affected by, or
involved with the plant under design should and can contribute to the optimization of the design. The 3D model is a convenient
Who are the people, other than the design team, who can contribute ?
They include :
Construction personnel
Operators
Maintenance personnel
Technical specialists
The construction personnel can provide input that can potentially reduce construction costs and/or improve the construction
schedule.
The operating personnel must live with the plant once it is built.
Their timely input can result in a design that is most logical for operator utilization by identifying operating concepts so that
control rooms and key control stations are located on the same level, placing instruments and associated manual controls in
Often the operating personnel are presently, or have recently, operated similar types of plants and can, therefore, contribute
Incorporating operator preferences, if they do not add to costs, can also improve startup and “commitment” by these key
personnel. Conducting careful reviews with operating personnel can result in considerable savings during startup and mechanical
completion, by minimizing the usual field modifications to valving, installing bypasses and changing instrument locations.
Meaningful reviews by maintenance personnel have a much more subtle and longer range impact. Maintenance costs, and often
more importantly shutdown time for turnarounds, can be minimized if proper access, drop-out areas and monorails can be
incorporated into the design. The method of handling equipment for maintenance can best be defined by the plant maintenance
personnel based on their experience, proposed philosophy and available or planned mobile and rigging equipment.
Safety and environmental considerations are always important. The necessity of meeting ever increasing numbers of regulations
must also be checked. The 3D model allows for checking of simple safety considerations such as identifying which pipelines
should be provided with personnel protection, locating and directing the discharge of relief devices away occupied areas, as well
The role of the technical specialist is based on his experiences, feedback from similar installations and often the owner’s specific
requirements. Again this input may have a greater impact over the life of the project with fewer operating problems and longer
service. The 3D model review can also serve as a catalyst for an open exchange of ideas. In the preliminary stages, free wheeling
discussions and sharp questioning of presumptions can lead to significant design optimizing with associated cost and/or
operating savings.
The 3D model facilitates this sort of conceptual visualization and exchange of ideas. A sort of visual-verbal value analysis can be
performed by “why” questioning with the 3D model during the conceptual design stage.
Finally the 3D model as a focal point of various design inputs (structural steel, piping, nozzle orientation on vessels, etc.) is a
visual measure of design progress not unlike gauging construction progress by walking the site and seeing what has been
erected.
The various types of 3D model reviews can be segregated into three primary categories. These categories can be classified by
stage of 3D model completion, by the types of people reviewing or by the subject being reviewed. Within each of these categories
of reviews there are several different types, which are described below.
As the 3D model progresses through its various stages towards completion, periodic reviews are held.
Preliminary reviews take place once the plant arrangement and equipment arrangement have been established. Various
alternates may be shown as part of the review process. In this type of review, particular attention is paid to the plant layout with
regard to access to equipment, bay spacing, flow of materials and personnel, open versus enclosed structures and other macro-
Agreement must be reached at this review prior to starting any detailed design. One of the most costly errors in an engineering
construction project is to begin detailed design in an area where the equipment arrangement philosophy has not been adequately
reviewed and agreed upon and is therefore subject to later changes. Preliminary reviews should be held as early as possible
during the project but adequate time should be allowed for evaluating numerous alternates.
Intermediate reviews take place when the final structural steel, final equipment and the majority of the major piping runs, duct-
work, instrument and electrical trays have been MODELLED. The primary purpose of these reviews is to review the routings to
insure that process integrity has not been compromised, that the pipe, duct-work and tray runs are in accordance with the
minimum cost criteria established for the project and to observe any potential interferences in the operability or maintainability,
Final reviews are held when the 3D model has basically been completed. This occurs when all equipment, piping, valves,
instruments, electrical, structural and other items have been MODELLED IN THE PDS ENVIRONMENT. In this review, the items to
be reviewed will include such things as the location and orientation of valve hand wheels for operability, the location of local
Agreement on the location of all these critical items should precede the start of piping isometrics EXTRACTION or the preparation
of instrument location plan drawings, if required.
4. Reviewers
3D model reviews will vary in their approach and level of detail depending upon the function of the reviewer. Different reviewers
will be looking for items that impact their areas of responsibility and, as such, will look at the 3D model in different ways.
Members of the construction organization are primarily interested in the constructability of what is being designed. They must
impact upon both the labor and material cost aspects of installing a particular design. They must contribute to the design
sufficiently to insure that the plant will be efficiently and safely constructed.
In particular, construction personnel will be concerned with items such as available space for setting equipment into the
structures, access to pipe racks with mobile equipment or the use of cable trays for wire as opposed to individual conduits.
The plant people are primarily concerned with how easily the plant is to operate and maintain. Operations personnel will be
looking for designs which minimize operator attention, which provide compact areas for their operators to concentrate efforts on
The maintenance staff has a view point more closely aligned with the construction people. Since they will have to remove
equipment set in place by construction, they will be looking for access aisles, space for movement of portable equipment,
uncomplicated piping and instrument installations, platforms and the like. Maintenance personnel will also be concerned with
Various specialists groups will review the 3D model for impact on their area of responsibility. Groups concerned environmental,
process safety and industrial hygiene aspects of the plant should impact on the design. Environmental personnel will be
concerned about curbing and trenching to contain spills. Process safety personnel will review such things as the proximity of
Representatives from both engineering and operating management generally will review the 3D model from a separate and
distinct view point. Rather than involve themselves in the minute details of the design as shown on the 3D model, these people
They will look at the 3D model as a whole to insure that the design meets the general criteria established by their respective
groups. Management will also review the 3D model to insure that each group under their area of responsibility has contributed to
This group maintains the primary responsibility for impacting on the design through 3D model reviews. In addition to reviewing
the 3D model from the standpoint of process integrity, the system technical or design engineer must also consider all of the items
covered by specialty groups discussed above. While it is not possible for this person to penetrate at the same level as the
specialty group, it is important that he participate in all reviews and understand and coordinate required 3D model revisions.
5. Subjects
A review for process integrity will focus on those items which affect the process performance and reliability.
Minimizing flat, horizontal surfaces, reducing the required number of equipment support legs, pouring of tapered concrete into the
bottom of building columns, designing with enclosed, tubular supports rather than with angle iron are typical items that will be
explored during a clean design review. While clean design is critical in food and pharmaceutical type plants it is significant in
virtually all installations where dirt buildup will effect equipment operation and eventually process performance.
Cost effectiveness 3D model reviews are held to insure that minimum cost practices are being carried out to the maximum extent
within the constraints of the project. Examples of this are: reviewing the 3D model to minimize the number of bends or changes in
elevation made by piping, reviewing equipment layout to reduce the size of the building and reviewing cable tray runs to optimize
routing.
Obviously, there are constraints to the minimum cost approach which may preclude cost is a constraint. However, these
constraints should only be considered when deciding to make a change and should not be taken into account while trying to
5.3 Environmental
Environmental review will focus on the effects of the plant design on the environmental. The 3D model makes it easy to visualize
the enclosed areas which must be vented and the areas around potential spills. These are the types of items that should be
covered and resolved during an environmental review. This type of review should also cover the design of environmental
5.4 Safety
Safety reviews are extremely important and should be carried out in extreme detail. Review of mobile equipment traffic patterns,
proximity of combustible materials to potential spark generators, proximity of toxic materials to personnel, ladder and platform
installations and "head knockers" are typical areas that should be examined during a safety review.
5.5 Constructability
The ease of constructing a facility is the prime concern during a constructability review. The ease of bringing large process
equipment into structures, the erection sequence of structural steel, the advantages of running wires in trays as opposed to
individual conduits are typical of those items covered in a constructability review. Of course, process integrity, cost and other
A detailed checklist ref. 6.1 exist which gives guidelines of subjects to be covered during the 3D model review.
6. References
Percentage Completion