Tower Piping PDF

BECHTEL
PLANT DESIGN & PIPING

ENGINEERING DESIGN GUIDE FOR
FRACTIONATION TOWERS
3DG P22 001, Rev. 00, 12/92
Prepared by: E.F. Bausbacher
Approved by: E.F. Bausbacher
TABLE OF CONTENTS
Page No.
LIST OF FIGURES
1.0
PURPOSE
2.0
INTRODUCTION
3.0
TERMINOLOGY
3.1
3.2
3.3
3.4
Safety
Operation
Maintenance
Economics
4
4
4
5
4.0
INITIATE TRAYED TOWER LAYOUT
4.1
4.2
Establish Tower Elevation

Establish Tray Orientations
6
6
5.0
TOWER LAYOUT FROM TOP DOWN
5.1
5.2
5.3
Vapor Overhead Line

Top Head Platform
Closed Relief System
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5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
Reflux Nozzle
Instrument Nozzles
Preferred Component Locations
Miscellaneous Nozzle Considerations
Tray Details
Packed Bed Sections
Platform Details
Optimizing Tower Layout
Reboiler and Pipe Support Considerations
9
9
10
10
11
12
12
13
13
6.0
REFERENCE DRAWINGS
14
PAGE 2 OF
LIST OF FIGURES
Figure 1
Establish Tower Elevation
Figure 2
Set Tray Orientation
Figure 3
Alternative Methods of Reboiler Support
Figure 4
Feed Nozzles
Figure 5
Manway Locations
Figure 6
Vapor Overhead Line
Figure 7
Top Head Platform
Figure 8
Figure 9
Reflux Nozzle
Figure 10
Instrument Nozzles
Figure 11
Preferred Component Locations
Figure 12
Miscellaneous Nozzle Considerations
Figure 13
Tray Details
Figure 14
Packed Bed Section
Figure 15
Platform Details
Figure 16
Optimizing Tower Layout
Figure 17
Reboiler and Pipe Supports
Figure 18
Trayed and Packed Towers
PAGE 3 OF
1.0
PURPOSE
To provide a layout designer with the guidelines to develop a comprehensive
fractionation tower design which considers safety, operation, maintenance and
economics.
2.0
INTRODUCTION
The philosophy addressed in this guide primarily deals with trayed fractionation
towers. It is the responsibility of the Plant Design and Piping group to develop
a layout based upon a combination of certain specific rules and logic. The
optimum tower design is achieved through a trial and error approach when not
governed by specific industry codes and regulations. This includes striking a
balance between setting tray orientations, use of internal piping, and proper
grouping of valves and instruments to minimize platforming requirements.
3.0
TERMINOLOGY
3.1
Safety
Design of towers must give proper attention to safety for all plant personnel
who will be required to work within its confines. As one travels from grade to
the upper most platform, the area must be free of dangerous obstructions when
attempting to gain access to values, instruments or exit the tower in an
emergency.
3.2
Operation
Modern technology rarely requires constant attention on trayed towers. When
required, access to valve handwheels and instrumentation should be placed in
such a way that a minimum amount of time is required to perform the function.
3.3
Maintenance
Features to be considered for towers include providing davits at the top of
towers for handling large relief valves, placing manways in a way to facilitate
removal of internals to grade, locating davits or hinges on manway covers in a
way it does not obstruct other required maintenance or access, provide
PAGE 4 OF
removable platform sections if necessary to accommodate maintenance below,

etc.
3.4
Economics
Financial impact of one design over another is one feature that is often
overlooked when engaged in development of a tower layout. Setting the
bottom tangent line at the true minimum elevation; arranging internal and
external piping in such a way that platforming can be minimized and weighing
the cost of increasing the vessel wall thickness to directly support a vertical
reboiler over a support from grade requiring foundations, steel structure, etc.
4.0
INITIATE TRAYED TOWER LAYOUT (Refer to Figure 18)

The following approach is recommended when the design of a fractionation
tower is initiated.
4.1
a.
Verify all documentation to be used is the latest available issue.
b.
Set tower bottom tangent line elevation (see 4.1).
c.
Establish tray orientation based upon review of all governing criteria (see
4.2).
d.
Start layout by working from the top of tower downward (see 5.0).
e.
Utilize internal piping whenever possible to maximize exterior layout.
f.
Work closely with stress/support engineers throughout design.
g.
When locating nozzles and manways, be sure vessel internals, such as

tray supports or internal piping or tray configurations will not impede
maintenance or operation.
Establish Tower Elevation - Figure 1

The three prime factors listed below should be considered when attempting to
set the bottom tangent line elevation include:
PAGE 5 OF
4.1.1 Pump NPSH

The Process/Project engineer is responsible to supply the pump NPSH
requirements for all pump circuits.
4.1.2 Thermosyphon Reboiler Requirements
The project process engineer is responsible to establish the dimension from the
vessel tangent line to the centerline of a thermosyphon reboiler. When a
vertical reboiler is used, adequate clearances must be given to remove the
lower channel section.
4.1.3 Piping Clearances
Should the pump head requirement or reboiler dimension be a non-issue in a
layout, operator clearance under the liquid outlet line to adjacent equipment
may be the factor which sets the tangent line elevation. All factors must be
reviewed before a final elevation can be transmitted to a vessel vendor. Should
none of the above factors be relevant, the vessel tangent line may be set at the
minimum practical elevation.
4.2
Establish Tray Orientations

a.
The two primary piping circuits which normally impact tray orientation are
the feed nozzle and reboiler connection.
b.
The feed nozzle may have one or a multiple of external connections with
an array of internal piping configurations. See Figure 4. Three typical
feed arrangements are:
(1)
single feed nozzle with two possible orientations.
(2)
double feed nozzle with two possible orientations.
(3)
single feed nozzle with a multiple of orientation options.
A designer should investigate which single feed nozzle arrangement (#1

or #3) would be most advantageous for the optimum tower layout, should
this option be possible.
PAGE 6 OF
c.
For Bechtel preferred internal piping and tray details see Drawings B501, 502, 503 and 504.
d.
Should the feed nozzle not be a deciding factor, refer to the reboiler
piping requirements in paragraph e.
e.
Since the preferred reboiler piping arrangement is the most direct route,
coming off the bottom tray downcomer now comes into play in setting
tray orientations. A stress engineer should approve the proposed layout
before assuming the selected nozzle location will work for the piping.
Scheme (A) in Figure 2 is an example of an optimum design for the
reboiler inlet line. Scheme (B) shows one of a number of arrangements
for the reboiler return line. Tray orientations are unaffected by draw-off
nozzles located in the bottom head of the tower. These nozzles may be
located at any orientation to suit.
f.
Method of support for vertical reboilers needs to be established as soon

as reliable design data becomes available. See Figure 3. Direct support
off the vessel are shown in scheme (A) and (B) which will require a
thicker wall thickness, but a normally less complex piping system.
Scheme (C) shows an independent support from grade. While it
normally does not effect the vessel wall thickness, it requires a support
structure, foundations and generally a more complex piping system to
compensate growth differential between the tower and the stationary
structure. Refer to 5.12, paragraph a.
g.
One remaining item to establish at this time is to set the general

orientation of manways, as shown in Figure 5. The most common
location is opposite the piperack or that direction maintenance is most
likely to be performed. When selecting the orientation, be sure entrance
into the tower is not obstructed by internal piping, downcomers, tray
supports and is over the tray below avoiding the downcomer area as
much as practical. Swing manway cover away from high activity area
and away from ladders when possible.
5.0
TOWER LAYOUT FROM TOP DOWN
5.1
Vapor Overhead Line
PAGE 7 OF
The first order of business is to select the routing of the vapor overhead line.
This line is normally run to a condenser located in an adjacent structure or over
the piperack directly in front of the tower. Consideration for flexibility will most
likely determine what segment of the tower facing the piperack the line will be
located. See Figure 6. The most direct route may apply if no flexibility concern
exists, assuming the line can span the horizontal distance from the tower to the
condenser header. Locating the line along the 0 axis would provide a
moderate "leg" for stress while routing the line away from the condenser would
allow greater flexibility should it be necessary. This issue must be worked with
a stress engineer as the design is developed. The vapor overhead line may
exit the tower in one of two general locations. The most common is shown in
scheme (A) off the top head. A variation of this design would be the elimination
of the flanged nozzle for a butt weld connection for very large O.D. lines. This
would most likely require client approval, but should be considered for
economic reasons. The second approach, scheme (C), utilizes an internal pipe
exiting the top side of the vessel just below the tangent line. This design may
eliminate the need for a top head platform. As with all lines at similar
equipment, the piping will be supported as close to the top tangent or nozzle as
possible. Additional items normally found on vapor overhead lines may
include, temperature connections, inhibitor injections, relief valves and vents.
5.2
Top Head Platform

Potential variations found at top head platforms are shown in Figure 7. The
relief valve system is the next feature to be considered. It may be an open or
closed system, with or without block valves and bypass. Scheme A shows the
two variations for an open system, without block valves. The ideal location for
the relief valve would be off the top of the overhead line, discharging at least
10'/3M above the platform assuming there are no other platforms at higher
elevations in close proximity to this point. Should the valve be too high, the
inlet line can come off the vertical portion of the overhead line which would
enable the valve to be set at a lower elevation.
Davits for tower maintenance are commonly located on the top head platform.
They handle vessel intervals and large relief valves, 4" x 6" and above. The
davit should preferably be located in a corner of the platform. It must be able to
swing over the relief valve to be maintained and be moved to the specified drop
zone for tower maintenance. The centerline elevation must permit the lifting
PAGE 8 OF
device to clear the highest item to be handled. The lifted load of the heaviest
single component must be identified either from the vessel engineer or relief
valve vendor. The vessel vent should be located in the most convenient place
to accommodate operator maintenance and access on the top head platform.
5.3

Closed relief systems require special consideration before the valve or valves
can be located. See Figure 8. Will there be an economic advantage to locate
the valve at a lower platform elevation? Can a lower platform accommodate
the relief valve without significantly increasing steel cost which may offset any
piping material saving by being set at the lower elevation? Both options should
thoroughly be investigated before taking the design further down the tower.
5.4
Reflux Nozzle
Figure 9 shows variations of internal piping arrangements for the reflux nozzle.
Scheme A and B are fixed arrangements, while scheme C enables the reflux
nozzle to be oriented at any desired orientation within a 270 arc. This offers
multiple opportunities to develop an optimum layout for the reflux line.
5.5
Instrument Nozzles - Figure 10.

Pressure and temperature connections on trayed towers require special
attention when attempting to set nozzle locations. Pressure connections are
located in the vapor space just below the designated tray as shown on the P&I
diagrams. They should not be located in the downcomer area. Temperature
connections must be located in the liquid space or 2"/.050 above the
designated tray in the downcomer area. It is important to check the length of
the thermowell. It may interfere with the downcomer as shown in the auxiliary
plan. An alternate solution is shown by setting the nozzle in the "hillside
position." This approach is only recommended if the length of the thermowell
can not be reduced. Level instruments such as controllers and gauge glasses
are commonly located on bridles in the liquid section, at the bottom of the
tower. The elevation of these nozzles is determined by the amount of liquid
being controlled for maximum operation. The specific elevations required are
shown on the vessel instrument sketch. A preferred and alternate location is
shown if a baffle plate is required.
PAGE 9 OF
5.6
Preferred Component Locations - Figure 11.

Optimum tower layouts generally follow the following guidelines:
5.7
a.
Plan to run piping down the tower on the side facing the pipe rack, away
from manways, instrumentation, ladders, etc. for small diameter towers of
4'/1.2 or less, lines should be grouped for common support. (See Figure
17).
b.
Locate the manways toward the maintenance access area, away from
the piperack.
c.
Locate items such as bridles with level instruments at dead end of

platforms if possible, thereby eliminating normal operator travel around
such items.
d.
Ladders should be located between the main piping area and the
segment of platforming, manways, instruments, etc.
Miscellaneous Nozzle Considerations - Figure 12

When initiating a tower layout the following information can be used to develop
nozzle locations and elevations.
a.
Projections are established from the vessel inside diameter to face of

flange, and vary depending on the nozzle size.
b.
Top head nozzles are set from the platform elevation (top of steel) to the
face of flange. The dimension varies with the nozzle rating.
c.
The maximum distance a nozzle can be set in the top head from the
vessel centerline is shown in detail "A".
d.
Platform penetrations for nozzles and lines are shown in Figure 15.
e.
Liquid outlet nozzle in the bottom head may have minimum dimensional
requirements. If a valve is bolted to the nozzle, a tower drain connection
is likely to be needed. Clearance between nozzles, and the drain nozzle
PAGE 10 OF
10
flange and skirt access opening reinforcement or fireproofing must be

checked.
5.8
Tray Details - Figure 13

There are various types of tray designs, packing, internal piping details to affect
liquid vapor contact. Common tray designs include single or double pass
bubble cap, sieve and perforated design. As the liquid flows across the tray
surface and down to the tray below through the downcomer area, the hot vapor
rises through the bubble caps and eventually out the overhead line to a
condenser. Trays are numbered, with the top tray normally being number one,
the second, number two and so on. The P&IDs will identify which tray a nozzle
is to be set at. The piping designer using the basic data outlined in this guide,
knowledge of good industry practice, safety, maintenance operation and
economics must orient all trays, locate all nozzles, piping, instruments, ladders,
platforms, davits, etc.
Another type of tray is the chimney type. When called for, the orientation of
trays above and below the chimney tray may vary as desired. Other towers
have multiple diameters. One arrangement uses a single downcomer in the
transition section, with a feed nozzle to the tray below. Another variation uses
internal piping from the downcomer to the tray below. Both enable the trays
below to be oriented differently from the upper section of the tower. This
enables a designer to optimize the external layout for piping, platforms, ladders,
etc.
5.9
Packed Bed Sections - Figures14 and 18

Packed bed sections use metal rings for liquid vapor contact instead of trays.
The rings are packed into specific sections of the tower, called beds, supported
by cross grid bars. They are spaced close enough together to prevent the rings
from falling through. The supports are designed to allow vapor to rise and
liquid flow down. Liquid is fed in at the top of each bed through a distributor
pipe. Unlike trayed towers, there are no special orientation considerations of
these beds, distributor or packing supports.
5.10 Platform Details - Figure 15
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11
Tower platforms should enable plant personnel to work safely during normal
operations and maintenance, without being costly and excessive in size. The
minimum size for top head, crossover or normal operations can be seen in this
figure. Bracket spacing should be standardized whenever possible. Ladder
runs must adhere to certain industry and code regulations as shown in the
elevation view of the tower. No single ladder may not exceed 30'/10.0. Should
a ladder service more than one platform, the platforms must be set at an
elevation that is consistent with the rung spacing of 12"/.300. Dimension "A"
shall be in even increments or rung spacing. Avoid setting two platforms
serviced by one ladder at the same elevation for operator safety. Elevation
difference must be 2'/600 minimum.
Ladder cages are not needed for platforms whose elevation is under 20'/6.10.
Step through ladders are permitted. One rule to remember when designing
any platforming: never force plant personnel to go up a higher elevation, when
attempting emergency egress off a tower.
Platform penetration sizes should be consistent with the specifics of each case.
Clearance should be given to bare pipe, insulated pipe, and flanged
connections as necessary. It is not necessary to allow for clearance of
insulation on flanges, since it is likely the insulation will be removed prior to
removal of the flanged pipe.
5.11 Optimizing Tower Layout - Figure 16
Typical issues a designer must confront include such things as:
a.
A process suggested arrangement for a feed nozzle would put the block
valve away from any planned platforming. By employing one of the
alternate feed nozzle arrangements, the internal pipe can be set at any
desired orientation. This would put the block valve over the desired
platform layout.
b.
The reboiler draw-off nozzle has a major impact on tray orientations. Be

sure to deal with this circuit early in the tower layout.
c.
Try to plan on locating major level instruments at the dead end of

platforms. Since they project out into the operator access space, the size
PAGE 12 OF
12
of platform can normally be reduced if not required to traverse around

such items
5.12 Reboiler and Pipe Support Considerations - Figure 17.
A piping designer should have a good working knowledge of supports when
engaged in the layout of fractionation towers.
6.0
a.
Vertical Reboiler - if the reboiler is supported from the vessel, the

elevation of the lug on the reboiler must be set 1"/.025 above the
maintenance support bracket on the tower. During turnaround periods,
when the channel end must be removed for tube maintenance, the
1"/.025 gap is shimmed, thereby becoming the reboiler support.
b.
Pipe supports on large diameter towers normally consist of a structural

bracket off the tower in close proximity to the line being supported or
guided. A dummy leg is welded to the pipe at an orientation which will
allow the load to be transferred from the pipe to the vessel support
bracket.
c.
For small diameter towers, individually supporting and guiding pipe

becomes more of a problem due to its limited size. Immediately after
supporting each line close to its nozzle, the lines should be routed and
grouped as if a "vertical piperack" down the tower. By lining up the back
of pipe, common structural members may be effectively used for
supports and guides.
REFERENCE DRAWINGS
The following Bechtel drawings should as reference material when engaged in
the layout of a fractionation tower.
Subject
- Feed and Vapor Overhead Nozzles
- Transition Section
- Bottom Section
- Drawoff Details
Dwg. No.
B-501
B-502
B-503
B-504
PAGE 13 OF
13
- Manway Davits
C-509
- Davit Details
- Circular Checker Plate Platforms
- Circular Grating Platforms
M-507
M-513
M-517
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BECHTEL

PLANT DESIGN & PIPING

INITIATE TRAYED TOWER LAYOUT

Establish Tower Elevation

TOWER LAYOUT FROM TOP DOWN

Vapor Overhead Line

Establish Tower Elevation

Set Tray Orientation

Alternative Methods of Reboiler Support

Vapor Overhead Line

Top Head Platform

Closed Relief System

Preferred Component Locations

Miscellaneous Nozzle Considerations

Packed Bed Section

Optimizing Tower Layout

Reboiler and Pipe Supports

Trayed and Packed Towers

removable platform sections if necessary to accommodate maintenance below,

INITIATE TRAYED TOWER LAYOUT (Refer to Figure 18)

Verify all documentation to be used is the latest available issue.

Set tower bottom tangent line elevation (see 4.1).

Utilize internal piping whenever possible to maximize exterior layout.

Work closely with stress/support engineers throughout design.

When locating nozzles and manways, be sure vessel internals, such as

Establish Tower Elevation - Figure 1

4.1.1 Pump NPSH

Establish Tray Orientations

single feed nozzle with two possible orientations.

double feed nozzle with two possible orientations.

single feed nozzle with a multiple of orientation options.

A designer should investigate which single feed nozzle arrangement (#1

Method of support for vertical reboilers needs to be established as soon

One remaining item to establish at this time is to set the general

TOWER LAYOUT FROM TOP DOWN

Vapor Overhead Line

Top Head Platform

Closed Relief System

Instrument Nozzles - Figure 10.

Preferred Component Locations - Figure 11.

Locate items such as bridles with level instruments at dead end of

Miscellaneous Nozzle Considerations - Figure 12

Projections are established from the vessel inside diameter to face of

flange and skirt access opening reinforcement or fireproofing must be

Tray Details - Figure 13

Packed Bed Sections - Figures14 and 18

5.10 Platform Details - Figure 15

The reboiler draw-off nozzle has a major impact on tray orientations. Be

Try to plan on locating major level instruments at the dead end of

of platform can normally be reduced if not required to traverse around

Vertical Reboiler - if the reboiler is supported from the vessel, the

Pipe supports on large diameter towers normally consist of a structural

For small diameter towers, individually supporting and guiding pipe

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