Distillation Systems / Heat Exchanger Systems

1. Vertical Tower: Normally vessel components are described using common

terms such as shell, head, nozzle, and support. Some vessels will also have
special terms based on function. Typical special terms include the following.
Flash Section is the area or zone of the fractionation vessel where the primary
feed enters the vessel. Fractionation Section is the portion of the vessel that
includes the trays. Stripping Section is a place in the vessel that includes the
introduction of supplementary heat such as high temperature steam. Surge
Section is the bottom portion of the vessel that normally includes the main
outlet nozzle, which is connected to the bottoms pumps.
o Common problems with vertical vessels: Most important is schedule
crunch. Vessels scheduled for purchase too early requiring firm
orientations with very little backup information. The information
required is approved and issued documents for Design P & I D,
Exchanger type and location, flare header and location of pressure safety
valves. Thin wall vessels not able to support load on pipe supports. High
wind presence requiring extra guides. Late changes to pressure safety
valve sizing, prompts changes to pipe support and guides on line to flare.
Late change to control valve location criteria, due to which flashing
service are required to be located to elevated platform on vessel, with
line downstream of valve self drain to vessel. Reboilers requiring spring
mounted supports have to be moved due to tight piping and differential
growth. High steam out temperature requires extra flexibility in the
piping. Extra heavy object removal is difficult if there is increase in
excess load of Davit load capabilities.
o Vertical Vessel Orientation: The ladder approach at grade should be
free of obstructions and easily accessible. Verify preferred location with
Project requirements. The Manhole orientation should be oriented in the
back half of the vessel toward the access way. The manholes should be
arranged with consideration to the type of load handling device. You
should maintain one centerline if monorail is used, one or two
centerlines if davit is used, no specific restriction if crane. Load drop
area should be located on the main access side. Level instruments should
be located on or near the front half of the vessel and visible from the
main operating aisle. The piping risers to and from the vessel should be
located to the front half of the vessel for easy routing to the pipe way and
equipment.
o Manholes: Manholes will influence the entire vessel orientation to a
certain degree. The location of the manholes must be compatible with
the location of the tray down comers. The down comers in turn influence
 the location of the process and instrument nozzles. The preferred
elevation of manholes above the platform is 2 feet 6 inches from the
centerline. The limits are minimum 6 inches from the top of the platform
to the bottom of the flange, or maximum 4 feet from the top of the
platform to the bottom of the flange. Verify preferred location with
Project requirements. Platforms may not be required for manholes that
are 15 feet or less above grade, unless a platform is required for another
reason such as an instrument. Verify preferred location with Project
requirements. Space and clearances are important around manholes.
Check flange swing and tray lay down space.
o Ladders and Platforms: Check to see that the approach to the ladder at
grade is clear of all obstructions and hazards, the entry onto each
platform is clear and not blocked by level or other instruments, the entry
onto each platform is clear and not blocked by an open manhole flange,
there is a clear path from one down ladder to the next down ladder for
unobstructed travel during emergencies. Platforms may need to be added
or extended for access to operating valves, spec blinds, or instruments.
Special platforms are often required at the channel end of a thermo-
siphon reboiler or other equipment that is mounted directly into or onto
the vessel. Investigate lining up and connecting platforms servicing
equipment, such as Reboilers or Accumulators, which are located in
adjacent structures but related to the vessel. Maintenance criteria at
Reactors often require platforms large enough and strong enough for
large flange or head lay down in addition to catalyst storage and
handling. Check the location and size of the pipe penetration holes
through platforms. The opening is to be one inch larger in diameter than
the flange or pipe plus insulation, which ever is greater. Provide proper
routing and support for all lines regardless of size. Do not route small
lines vertically behind the ladders. Do not route small lines vertically
between the vessel shell and the inside radius of the platforms. Do not
route small lines vertically up the outside of the platforms in line with or
close to the manholes. Ladder access openings must be fitted with a
safety gate. Check for proper clearance for gate swing. Some processes
are subject to periods of hazardous operations. Ladders and ladder cages
may need to be designed for operators with self-contained suits and air
packs.
o Reboilers: Reboilers will be either Fired or Heater Type, Thermosiphon
which can be vertical or horizontal shell & tube type, or Kettle type
which can be horizontal shell & tube type. Fired Reboilers shall be
located a minimum of fifty feet from the vessel. Piping to and from any
type of reboiler will be hot, and have sensitive flow conditions. The
 Kettle or Thermosiphon Reboiler elevation is set by Process and
indicated on the P&ID.
o Pipe Supports and Guides: Piping is responsible for locating the pipe
supports and guides on vessels and for defining the size and loads on the
pipe supports on vessels.
o Piping Flexibility: Piping must determine the operating thermal growth
of the vessel. The vessel will have a series of temperature zones from the
bottom to the top. The differential expansion between the piping risers
and the vessel must be checked to prevent over stressing the piping or
the vessel shell. The routing of cooler reflux lines must consider the total
growth of the hotter vessel. Potential for differential settlement needs to
be investigated. Each piping system or line needs to be considered
individually.
o Instrumentation: The high and low level alarms need to be carefully
considered because they will set the elevations of the level instruments.
Orientation of level instrument connections needs to consider the
internals. All instruments shall be accessible. Watch out for space
requirements for gage glass illuminators. Temperature indicators and
thermo well connections will require removal space.
o Electrical: Space shall be allocated for conduit runs up the vessel. These
conduits will carry power to platform lights, gage glass illuminators, and
in some cases electrical tracing. Conduits are also required for controls
and for instrumentation cables.
o Piping Valves: Valves are meant to be operated. To operate them, they
must be accessible. 2 inch and smaller valves may be considered
accessible from a platform or ladder. 3 inch and larger valves shall be
accessible on a platform.
o Miscellaneous Piping issues: Lines to and from vessels may be subject
to conditions such as 2 phase flow or vacuum. Some Pressure Safety
Valves relieving to atmosphere will require snuffing steam. The steam
pressure in the line must be adequate to reach the top of the vessel. Large
overhead lines verses location of Pressure Safety Valves, require special
attention for function and support. Vertical vessel piping needs to be
checked for heat tracing requirements. A tracer supply manifold may
need to be added at the top of the vessel.
o Ease in Construction: All vertical vessels shall be reviewed for ease in
construction. This review needs to consider receiving logistics lay down
orientation, lifting plan, pre-lift assembly items. Pre-lift assembly items
may include Piping, Platforms, Ladders, Internals, Paint, Insulation.
o Fire Protection: Some vessels may require special insulation for fire
protection, fire monitor coverage and sprinkler systems.
o The other Components include the following:
Trays: The type of trays, the number of trays, and the number of
passes are not the specific responsibility of the piping layout
designer. However, there is the need to know about it. A common
understanding of terminology will improve communications and
prevent errors. The common tray parts are
Tray support Ring: The tray support ring or Tray ledge is
technically not a part of the tray itself. The tray support ring
is only there to support the tray. If there are no trays, then
there is no need for tray support rings, therefore tray rings
are linked to the trays. Tray support rings are normally a
simple donut shaped strip welded to the inside of the
vessel. They could also be in the shape of an inverted L
welded to the vessel wall. Problems arise when the
Designer does not allow for the tray support device.
Tray Deck: One or more sections, consisting of plates,
forming a horizontal obstruction throughout all or part of
the vessel cross section. The trays will normally be
constructed to form one or more flow patterns called
passes. The purpose of tray deck is to provide a flow path
for the process commodity and contain the fractionation or
separation device. A Weir is a low dam on a tray to
maintain a liquid level on the tray. Down comer is the
primary liquid passage area from higher tray to another
lower tray. Valves are also tray hardware device. Bubble
Caps is another tray hardware device. Draw off is a way to
remove liquid from the vessel. Trough is a way to collect
and move liquid from one point to another. Riser is a
device to channel vapor from one lower point to a higher
point. Seal Pans is a device with a liquid seal that prevents
vapors from passing. Beams & Trestles is a devices that
support trays or other types of internals in very large
diameter vessels. Baffles is a separation device inside a
vessel.


Tray Pass Patterns: The trays and the related down

comers can be arranged in a wide verity of patterns.
Typical Tray arrangement is Single Pass which is a quite
common. This tray pass arrangement has one feed point,
one flow direction, and one down comer. The single pass
tray will normally be used on small diameter vessels and
the smaller diameter of a Coke Bottle vessel. Cross-Flow
and Multiple Pass trays come in two pass, three pass, four
pass, and on and on. These will normally be found in the
larger diameter vessels. Multiple pass trays require multiple
feed and draw off arrangements. The more passes, the more
complex the orientation problems. Reverse Flow or Single
Pass, Radial Flow, Circumferential Flow, Cascade Flow are
 rare. The single pass tray will have a single down comer.
The 2, 3, or 4 pass tray will have the same number of down
comers as passes. The number of passes and number of
down comers will have a big effect on the orientation.
Some towers may have more than one Tray pass
configuration. They may have single pass in the top Trays
and two-pass Trays in the bottom. The change from one
pass configuration to another is chance for error. The
alignment of the single pass tray will normally be
perpendicular to the two pass trays.

Tray Types: There is what would be considered Standard

Trays, and there are also high efficiency trays. Standard
Trays have an open down comer with no separation
occurring in the down comer area. This tray is the old stand
by and has been used for many years. High efficiency
Trays have a sealed down comer with separation occurring
in the down comer. This tray type is fairly new. It will most
likely be used on most new vessels in the future. It is also
the type of tray that is favored on revamp projects to get
more out of an existing tower.
Tray hardware devices: The normal trays inside the
typical vertical vessel will contain openings or holes and
may be fitted with a fractionation or separation device. This
device is what will accomplish the purpose of the vessel. If
these devices are not present or do not function properly
then the product is not made. There are some common tray
devices. Bubble Cap which is used mostly on revamps.
Simple, and common method to facilitate the separation
process. The Bubble Cap will normally be a round cup
shaped cap inverted over a short and smaller diameter
chimney. The skirt area of the inverted cap may be plain or
have open or closed slots. Box Cap is very much like the
common Bubble Cap except it is square. Tunnel Cap will
be a long narrow rectangular shape. Uniflux Tray is a series
of overlapping and interlocking plates. In cross section the
Uniflux tray will have the shape of a reclining squared off.
The valve tray is common and has small flat metal plates
fitted over the holes in the trays. The plate is loose to move
up and down, but is retained in position by a clip type
device. Vapor pressure under the valve plate causes it to
 rise and gravity brings it back down. The second common
is sieve tray which has holes and nothing else. The hole
size is calculated to provide a fragile balance between the
liquid head above the tray and the vapor pressure under the
tray.
Column Internal piping:
Weirs: There may be a number of places where weirs are
used. The simple weir to provide proper tray flooding will
normally not cause any design problems. There are also
some special purpose weirs that may effect the location of
nozzles. In most cases the existence of special purpose
weirs will not be known at the start of the Vessel
orientation activity.
Down comers: Down comers can come in a verity of
shapes also. They straight across in the horizontal direction,
or they can be bent. They can be straight up and down in
the vertical direction, they can be sloped, slanted or
tapered, or they can be a combination. These variations will
all impact the orientation to some extent. The major impact,
by the down comer on the orientation is the geometry or
location of the vertical plane itself. The orientation of the
down comers will have a direct relationship to the
orientation of certain nozzles and manholes.
Other Tray Terms: Some other terms that will be found relating
to trays. Sump is a sealed down comer type area that is designed
to provide a retention volume for some purpose. Seal Pans is a
portion of a tray that is set deeper than the rest of the tray to form
a seal for the down comer from the tray above. Side Draw Tray is
an arrangement that allows the removal of a specific liquid
product. Chimney Tray is a full circumference tray fitted with
long open pipes to allow vapor to pass from below the tray to the
space above. Baffles are plates installed in the vessel for a specific
purpose. Impingement Plates are somewhat like a baffle but
normally a plate installed in the vessel at the inlet to prevent
blowout to devices located on the opposite side of the vessel. Tray
manholes are there in most, if not all, trays, where it will have a
removable panel somewhere in the tray to allow inspection
passage without dismantling the total tray.
Vessel Support: There is a wide variety in the methods used to
support vessels. Each of these support types may also have
variations. The tall towers are generally supported by skirts.
 Horizontal storage tanks are supported by integral steel saddles.
Reactors are supported on lugs. Receivers and feed tanks are
supported on legs or are portable on casters. Pads are welded on
vessels which are supported on concrete saddles. Direct bury
method is used for underground tanks. The method of vessel
support depends on various factors. These factors include process
function, operation access, maintenance clearances, ease of
constructability, and cost. Meeting the positive criteria for all or
the majority of these factors will drive the support method. Each
of these vessel support methods has their own good points and
bad points. The Tall Skirt is the most common because it meets
more of the preferred criteria than the others do. The primary
methods of support are Skirts. Tall Skirt on foundation at grade
are most common. Short Skirt on elevated pier foundation, table
support, or structure. The minimum height of the skirt is normally
set by process based on the Net Positive Suction Head
requirements of the pumps or for the reboiler hydraulic
requirements. The designer may need to increase the skirt height
due to vertical distance required by pump suction line geometry,
Vertical distance required by reboiler line geometry, Operator
aisle headroom clearance, and suction line entering the pipe rack
without pockets. The approval of the Process engineer, Project
Manager, and the Client will be required for any increase to the
skirt height. The skirt will have one or more access openings and
will have skirt vents. Skirts of vessels in refineries or other plants
processing flammable commodities will normally be fireproofed.
The fireproofing is normally a two inch thick layer of a concrete
type material applied to the outside of the skirt. Check for the
specific type. Some materials may require up to 6 inch to obtain
the required fire rating. Legs can be installed on foundation at
grade. Lugs on vessels can be put on elevated pier foundation,
table support, or structure.
Load Handling Devices: Load handling devices are required for
Vertical Vessels if the vessel is over thirty feet tall or the vessel
has removable trays and internals. The vessel has components like
Pressure Safety Valves, control valves which require frequent
removal for routine maintenance and if the components weigh 100
pounds or more. Davit is a small somewhat inexpensive device
used for lifting and supporting heavy objects up and down from
elevated platforms. Limited to a fixed reach. Monorail is a more
expensive method, which is a girder provided along floor ceiling.
 Crane is a far more expensive method and is dependent on
availability. If a davit or monorail is not installed then a crane
with the required reach and load rating must be rented or an
alternate method must be jury-rigged. Any jury rig method will
have a high potential for accident and injury. When a Davit is to
be included the location, swing, the clearance height including
lifting device, the reach of the removal items, and maximum load
of external items must be determined and furnished. When a
Monorail is to be included the platform, and monorail support
configuration, the clearance height including lifting device, the
reach to the drop zone, the maximum load of external items where
vessels will determine weight of internals, must be determined
and furnished to the Vessels engineer.
Pipe supports and Guides: The Pipe Supports and Pipe Guides
for the piping that is attached to the vessel is the responsibility of
the Piping Group. You are the Piping engineer and you need to
make sure it is properly supported and guided. The rule is that all
lines shall be properly supported and guided. One key element of
the Pipe Supports and Pipe Guides is the L dimension. The L
dimension is the distance from the outer diameter of the back side
of the pipe to the outer diameter of the vessel. This dimension
should be as small as possible but not less than required for
maintenance. The rule of thumb for the L dimension is 12 inches
minimum and 20 inches maximum. Dimensions of under the 12
inches and over the 20 inches are sometimes allowed. For
example, if fitting make up results in an L dimension of 12 inches
do not add a spool piece and extra weld. Lines should be
supported as close to the nozzle as possible. The type of support is
based on the weight of what is being supported. It may be just a
straight pipe dropping down the side of the vessel. Or, it may be
much more. Pipe supports attached to a vessel must be evaluated
for the shell thickness, orientation, elevation, the L dimension, the
weight of the basic pipe and fittings based on size and wall
schedule, the weight of the water during hydro test, the weight of
the insulation if any, the weight of any added components such as
block valves, control valve stations, relief valves, etc. There
should be clearance to other objects like seams, Stiffener rings,
Nozzles, Clips, Pipe Lines, Platforms. Pipe supports and guides
should be staggered vertically for clearance from supports or
guides on other lines running parallel.
 Platforms, Ladders, and Cages: Platforms with access ladders
must be provided as required for access to manholes, operating
valves, and instruments as defined in the project criteria.
Normally objects below 15 feet from grade will not require
permanent platforms and ladders. These objects are judged
assessable by portable means. Check the Project design
requirements. Platform spacing shall be even foot increments
when multiple platforms are serviced from a single ladder. The
platforms shall be arranged to allow a minimum 7 feet headroom
to underside of any obstruction, minimum 2 feet 6 inches radial
width for primary egress path which is inside distance of platform
to outside distance of platform, minimum 2 feet 6 inches clear
distance between ladders. There should be no obstructions in path
between primary egress ladders. Maximum 30 feet vertical travel
length of ladder should be between platforms. Side step off at all
platforms which is step through ladders, are considered dangerous
and therefore should be avoided. This requirement should have
been reviewed with the Client and defined in the Design Criteria.
Combining with platforms on other vessels when potential for
improved operations or maintenance exists. Flanges of top head
nozzles shall be extended to provide access to bolts. Minimum 1
foot 6 inches clearance around objects if for maintenance access
only.
Code Name Plate: Every vessel will have a Code Name Plate. On
a vertical vessel the code name plate must be on the pressure
containment part of the shell. It cannot be attached to the skirt.
The best place for the code name plate on a vertical vessel is 2
feet 6 inches above the horizontal centerline of the surge section
manhole. Make sure the location selected is accessible on grade or
on a platform.
o Transitions for Coke Bottle Vessels: The cone or transition piece for
regular and inverted Coke Bottle vessels may come in the following
shapes:
Flat side: It has a cone is cut from flat plate and formed to a
simple cone. There is no knuckle radius at the top or bottom of the
cone. The connection to the straight shell of the vessel is an
angled weld. Usually there is a reinforcing ring on the shell very
close to the shell and cone junction.
Shaped side: The cone is cut from flat plate and rolled to a
shaped cone. There is a knuckle radius at the top and bottom of
the cone. The cone has a straight tangent at the top and bottom to
 match the shells. The connection to the straight shell of the vessel
is a common butt weld.
o Lined Vessels: Some vessels will be lined. Linings may be metallic,
plastic, or glass. Welding to the vessel shell after initial fabrication is not
allowed. Some vessels will have flanged connections that are larger than
24 inches. These connections will occur at connections for piping,
reboilers, or other equipment. Flanged connections over 24 inches do not
have a single standard and need to be defined for specific type.
o Maintenance Aisles at grade: Equipment maintenance aisle for
hydraulic crane with a 12 Ton capacity should have a minimum
horizontal clearance width of 10 foot or 3 meters and a minimum vertical
clearance of 12 foot or 3.5 meters. Where a fork lift and similar
equipment of 5,000 pounds or 2300 kilograms capability, is to be used
the minimum horizontal clearance should be 6 foot or 2 meters and the
minimum vertical clearance should be 8 foot or 2.5 meters. Where
maintenance by portable manual equipment like hand trucks, dollies,
portable ladders or similar equipment, is required the minimum
horizontal clearance should be 3 foot or 1 meter and the vertical
clearance 8 foot or 2.5 meters. Operating Aisle at grade should have a
minimum width of 2 foot or 800 millimeters and a headroom of 7 foot or
2.1 meters.
2. There are a number of nozzles on a reaction vessel or distillation tower.
o Overhead Vapor Outlet Nozzles: The overhead vapor outlet nozzles on
a vertical vessel can have some latitude when it comes to attachment
location. The attachment connection can be direct to the top head of the
vessel or may be from the side. When the connection is from the side
there will normally be a pipe inside the vessel angled up to the top head
area. Small vapor outlet nozzles from small diameter vessels can be
located out the side of the vessel and still be cost effective. Large
diameter vapor outlet nozzles on large diameter vessels will be more cost
effective if attached to the top head. The line is then looped over to the
selected pipe drop position to go down the vessel.
o Feed Inlet Nozzles: All vertical fractionation vessels will have a feed
inlet nozzle. This feed nozzle is special and critical on some vessels.
Refinery Crude columns and Vacuum columns are examples that have
this type of nozzle. This nozzle installation is characterized by the
attached line originated at a fired heater, High temperature, High
velocity, Mixed phase flow. It may require internals such as a distributor
pipe or impingement plate. A Feed Transfer nozzle will normally be the
key nozzle for any large fractionation vessel. Normally any side inlet
 orientation is possible but in most cases this will then dictate the tray
orientation.
o Liquid (secondary) Inlet Nozzles: A normal liquid feed nozzle will not
have the same complexities as the Feed Transfer type. This nozzle
installation is characterized by the attached line originated at an
exchanger, hot but not overly high on the temperature scale, some may
have potential for mixed phase flow, normal line velocity. It may require
vessel internals such as a distributor or inlet pipe. Watch Instrument
connections should be in relationship to Inlets and reboiler returns.
o Reflux Nozzles: A normal reflux nozzle will not have the same
complexities as other nozzles. This nozzle installation is characterized by
the attached line originated at a pump, low on the temperature scale, all
liquid flow, normal line velocity. It may require internals such as a
distributor or inlet pipe. Multiple pass trays will require a more complex
distributor or inlet pipe than a single pass.
o Draw-Off Nozzles: The purpose of this nozzle is to draw-off or remove
the primary product. They are also used to Draw-off a secondary product
to side stream stripper. May be installed with a sump to remove
unwanted water in the process stream. This nozzle is located in the
down-comer area of the column, it may be in a sump. It may be a larger
size than the normal attached line size. Some of the initial vertical drop
will be the larger size. It should be as per normal line velocity and may
require internals if multiple pass trays.
o Bottom Reboiler Feed Nozzles: The liquid outlet nozzle will normally
be in the center of the bottom vessel head. This nozzle is located in the
bottom of the surge section of the column. It may be a very large size
and has normally very low line velocity.
o Side Reboiler Feed Nozzles: This is also a potential Key Nozzle. The
liquid outlet nozzle must be oriented in the same quadrant as the bottom
down comer. This nozzle is located in the down comer area of the
column and is in a sump. It may be of a larger size than the normal
attached line size. Some of the initial vertical drop will be in the larger
size. Normally liquid flow in line is at lower velocity. Relationship to
elevation of associated reboiler is critical to nozzle elevation and
internals.
o Side Reboiler Vapor Return Nozzles: One of the primary issues with
this nozzle is the orientation relative to the other internal items and
nozzles. If not placed in the right place the velocity of the return can
blow liquid out of a seal pan or can affect the readings of any
instruments attached to the far wall. This nozzle is attached to the line
originated at a thermo-siphon or kettle type reboiler. It has a very high
 temperature, with moderately high velocity. All flow is vapor. It may
require internals such as a pipe or impingement plate. Relationship to
elevation of associated Reboiler is critical to nozzle elevation and
internals.
o Bottoms Out and Drain Nozzles: The bottoms nozzle is normally a
source for pump suction. The standard type is located in the bottom head
then piped through the skirt with a drain nozzle off the bottom out line
nozzle. This would be a combination nozzle. A variation of the bottoms
nozzle is the siphon or winter type. This type may be used with the
approval of process when bottom clearance is a problem. It is common
industry practice to avoid locating any flanged connections inside the
vessel support skirt. All flanges are subject to leaks, and vessel skirts are
classified as a confined space.
o Level Instrument Nozzles: Extreme care must be used when locating
level instrument nozzles. There are access and clearances problems that
must be considered on the outside of the vessel. There are sensing
location and turbulence problems associated with the inside of the
vessel. These nozzles must be attached in the same pressure volume of
the vessel. Lower nozzle should be in liquid of the surge section, and
upper nozzle should be in vapor space. It should be located in static area
or with stilling well. It requires external access for operation and
maintenance.
o Pressure Instrument Nozzles: Pressure readings are normally taken in
the vapor area of a vessel. Pressure connections shall be located in the
top head area, 3 to 6 inches under a tray, or well above any liquid level
in bottom section. These nozzle is generally located in a vapor space of
the vessel. It requires external access for operation and maintenance.
o Temperature Instrument Nozzles: Temperature readings are normally
taken in the liquid area of a vessel. Temperature connections shall be
located 2 to 3 inches above the top surface of a tray, in the down comer,
or well below any liquid level in bottom section. These nozzle should be
located in liquid in the down comer area. It requires external access for
operation and maintenance. It should not interfere with internals. Vapor
temperature readings may be required for some situations. When
required the preferred location is in the down comer area half way
between the two trays. Tangential or Hillside connections may be
required due to the thermowell length or to accommodate access from
the ladder and platform arrangement. With the Process Engineer's
approval investigate the possibility of raising or lowering the
temperature point one tray for better ladder and platform arrangement.
o Steam-Out Nozzles: Process plant vessels that contain hydrocarbon or
other volatile fluids or vapors will normally have a Steam Out Nozzle.
This nozzle has a number of options. A simple blind flanged valve on the
nozzle can be installed after the plant is shut down by Operations, the
maintenance group would remove the blind flange from the valve. They
then attach a temporary flange fitted with a hose coupling and proceed to
steam out the vessel by connecting a hose from a utility station. A blind
flanged valve and hard piped steam line configured with a steam block
valve and a swing elbow can also be installed. A fully hard piped
connection from a steam source can be provided. This method would
have double block valves, a bleed, and a spec blind for positive shutoff.
The vessel steam out nozzle should be located near the bottom surge
section manhole on vertical vessels.
o Manholes: Manholes are also considered a nozzle. They just do not have
any pipe attached to them. They are however, a very complex piece of
the vessel orientation puzzle. The types of manholes normally relate to
the method of cover handling provided. Manholes come in the following
types. A Manhole may be hinged for side mount, for top mount, or for
bottom mount. A Manhole may have davits for side mount or top mount
only. A Plain Manhole may be for side mount, for top mount, or for
bottom mount. The manhole orientation in top or non tray section of a
vertical vessel is somewhat flexible. Normally any orientation is
possible. However, the orientation of the manhole should be checked to
insure that the entry path is not blocked by any internals. The Manhole
may be located in the top head on large diameter vessels if there is a
platform that is required for other items. Top Manholes on large
diameter vessels have their built in good points and bad points. The good
point is that during shutdown the open manhole provides for better
venting. It also allows for a straight method for removal and
reinstallation of the trays. The bad point is that ladder access must be
provided down to the top tray, and the manhole is competing with the
other nozzles for the space on the vessel head. Orientation for manholes
that are located in the tray section of the vessel is more complicated. The
location of between the tray manholes has a number of restrictions.
These restrictions include the type of trays and the tray spacing. The first
choice for the location of a manhole is between the down comers. The
last choice is in the down comer space, but behind the down comer. The
down comer would be fitted with a removable panel to allow further
access into the vessel. The location to be avoided is above a down comer
where there is the potential for falling down in the down comer space
and injury. It would be better to seek approval to move the manhole up
 or down one tray than placement over a down comer.
Manhole orientation in the surge section of a vessel is not as restrictive.
The surge section of a vessel is the bottom portion that, during operation
will contain a large volume of liquid. Any orientation is possible for a
manhole in this section. However, the location of all manholes should be
in the back half of the vessel away from the pipe way. The surge section
may have a large baffle plate bisecting the diameter of the vessel and
extending vertically many feet. A removable plate or hatch may be
installed in this baffle (by vessels) to allow access to the far side. The
vessel orientation of the manhole should not hit the baffle or be located
so close to the baffle that entrance is obstructed.
3. Supporting Equipment:
o Flare Stacks: Locate the flare stack upwind of process units, with a
minimum distance of 200 feet or 60 meters from process equipment,
tanks, and cooling towers. If the stack height is less than 75 feet or 25
meters, increase this distance to a minimum of 300 feet or 90 meters.
These minimum distances should be verified by Company Process
Engineering.
o Furnaces: Locate fired equipment, if practical, so that flammable gases
from hydrocarbon and other processing areas cannot be blown into the
open flames by prevailing winds. Shell to shell horizontal clearance from
hydrocarbon equipment should be 50 foot or 15 meters with the
exception of reactors or equipment in alloy systems which should be
located for economical piping arrangement. Provide sufficient access
and clearance at fired equipment for removal of tubes, soot blowers, air
pre-heater baskets, burners, fans, and other related serviceable
equipment. Clearance from edge of roads to shell should be 10 foot or 3
meters. Pressure relief doors and tube access doors should be free from
obstructions. Orient pressure relief doors so as not to blow into adjacent
equipment. The elevation of the bottom of the heater above the high
point of the finished surface, should allow free passage for operation and
maintenance. In case of furnace piping, locate snuffing steam manifolds
and fuel gas shut off valves at a minimum distance of 50 feet or 15
meters horizontally from the heaters they protect. Burner valves for a
floor fired furnaces should be a combination of oil and gas firing valves.
It should be operable from burner observation door platform. For those
fired by gas only, the valves should be near the burner and should be
operable from grade. Burner valve for a side fired furnaces should be so
located that they can be operated while the flame is viewed from the
observation door.
o Heat Exchangers: Heat exchangers come in a variety of designs. In a
process facility shell and tube exchangers are the most common and are
manufactured in accordance with the Tubular Exchanger Manufacturers
Association code. The most common type of industrial heat exchanger is
the shell and tube type where one stream, usually the one that leaves the
most deposit like cooling water, flows through the tubes and the other
stream goes through the shell side. This is because the tubes are easier to
clean than the shell. Provision must be made to withdraw the tubes for
cleaning and this area must be kept free of piping and other obstructions.
Shell and tube exchangers are manufactured in accordance with the
Tubular Exchanger Manufacturers Association code.
Shell and Tube Exchangers: Shell and tube exchangers should
be grouped together wherever possible. Keep channel end and
shell covers clear of obstructions such as piping and structural
members to allow unbolting of exchanger flanges, and removal of
heads and tube bundles.
Stacked Shell and Tube Exchangers: Stacked shell and tube
exchangers should be limited to four shells high in similar service;
however, the top exchanger should not exceed a centerline
elevation of 18 feet or 5.5 meters above high point of finished
surface, unless mounted in a structure.
Maintenance Requirements: Exchangers with removable tube
bundles should have maintenance clearance equal to the bundle
length plus 5 feet or 1.5 meters measured from the tube sheet to
allow for the tube bundle and the tube pulling equipment.
Minimum maintenance space between flanges of exchangers or
other equipment arranged in pairs should be 1 foot 6 inches or half
meter. Exchanger maintenance space from a structural member or
pipe should not be less than 1 foot or 300 millimeters.
o Piping at Shell and Tube Exchangers:
Reboilers: Locate kettle reboilers at grade and as close as possible
to the vessel they serve. This type of reboiler is identifiable by its
unique shape. It has one end much like a normal Shell and Tube
exchanger then a very large eccentric, bottom flat transition to
what looks like a normal horizontal vessel. You could also call it a
Fat exchanger. The flow characteristics on the process side of a
kettle reboiler are the reason for the requirement for the close
relationship to the related vessel. Reboilers normally have a
removable tube bundle and should have maintenance clearance
equal to the bundle length plus 5 feet or 1.5 meters measured from
the tube sheet.
Double Pipe Exchangers: These exchangers can be mounted
almost anywhere and with process engineer approval, they can be
mounted in the vertical when required. A G-Fin Exchanger is
recognizable by its shape. One segment looks like two long pieces
of pipe with a 180 degree return bend at the far end. It is one
finned pipe inside of another pipe with two movable supports.
 This type of exchanger can be joined together very simply to form
multiples in series, in parallel or in a combination of series or
parallel to meet the requirements of the process. This exchanger is
not normally used in a service where there is a large flow rate or
where high heat transfer is required. The key feature with this
exchanger is the maintenance. The piping is disconnected from
the tube side, which is the inner pipe. On the return bend end of
this exchanger there is a removable cover. When the cover is
removed this allows for the tube, or inside pipe to be pulled out.
This exchanger is normally installed with the piping connections
toward the pipe rack.
Plate Heat Exchangers: A plate heat exchanger is a type of heat
exchanger that uses metal plates to transfer heat between two
fluids. This has a major advantage over a conventional heat
exchanger in that the fluids are exposed to a much larger surface
area because the fluids spread out over the plates. This facilitates
the transfer of heat, and greatly increases the speed of the
temperature change. Plate heat exchangers are now common and
very small brazed versions are used in the hot-water sections of
millions of combination boilers. The high heat transfer efficiency
for such a small physical size has increased the domestic hot
water flow rate of combination boilers. The small plate heat
exchanger has made a great impact in domestic heating and hot-
water. Larger commercial versions use gaskets between the plates,
smaller version tend to be brazed. The concept behind a heat
exchanger is the use of pipes or other containment vessels to heat
or cool one fluid by transferring heat between it and another fluid.
In most cases, the exchanger consists of a coiled pipe containing
one fluid that passes through a chamber containing another fluid.
The walls of the pipe are usually made of metal, or another
substance with a high thermal conductivity, to facilitate the
interchange, whereas the outer casing of the larger chamber is
made of a plastic or coated with thermal insulation, to discourage
heat from escaping from the exchanger.
Fin Fans (Air Coolers): Air Coolers are in typically used in the
cooling of the overhead vapor from tall vertical vessels or towers
such as Crude Fractionators and Stripper Columns. The natural
flow tends to follow gravity, where the tower overhead is the high
point then down to the Air Cooler, then down to the Accumulator
and finally the Overhead Product transfer pumps. With this in
mind the Air Coolers are normally located above pipe ways. This
conserves plot space and allows the pipe rack structure with it's
foundation to do double duty with only minor up grade to the
design. If the pipe rack is not used then plot space equal to the
size of the Air Cooler is required. In addition a totally separate
foundation and stand alone structure is required. Air coolers, or
fin fans, are utilized globally in modern process facilities. Air is
quickly moved past the tube exterior by way of a large fan system.
As the product travels through the tubes, this process transfers the
heat from the product into the atmosphere. An air cooler or fin fan
unit is constructed of several hundred to several thousand
externally finned tubes. Tube dimensions typically range from 1
inch or 25.4 millimeters to 1.5 inch or 38 millimeters in diameter
and up to 75 feet or 23 meters in length.