Generally, drums are cylindrical hollow steel vessels used in process plants as intermediate containers that receive liquid from distillation and condensing equip- ‘ment. Drums also collect liquid from vapor circuits and pump it to other process groups, disposal, or product storage. They are also used for chemical and catalyst storage, steam generation, and deaeration of boiler feed water. This chapter highlights the general requitements for drum plant layout and provides in formation required 0 locate nozzles, instruments, piping, and controls for platforming and operator and maintenance access TYPES OF DRUMS ‘The drums discussed in this chapter are process unit drums that are used for refluxing, surge, suction, and general liquid collection, Drums in these services can generally be divided into ewe categories: horizontally and vertically mounted. Drum internals are far less sophisticated than the components found inside the distillation tower and are limited 10 demister pads, baffles, vortex breakers, and distribution piping. Ex: hibic 5-1 shows 2 yypical vertical compressor suction Ligue wd Ligyip LeveL, 7" iC VApee out CHAPTER Drums cieum, and Exhibit 5-2 shows a horizontal reflux drum. When specified, steam drums and deaerators are usually furnished as a proprietary item, Layout is lim ited to confirmation of nozzle and support locations t0 suit piping and structural configurations and platform- ing for operator and maintenance access. Exhibit $3 illustrates a ypical deaerator arrangement wes! baw saves, EXHIBIT 5-2 ‘Typical Horizontal Reflux Drum teve LC) $iStwence kiguip our Od92. ena ENT EXHIBIT 5-3 Typical Deaerator Arrangement LOCATION OF DRUMS Drums are iocared within a process unit either adia- cent to related equipment (e.g. the reflux drum) oF as a sandalone operation (eg. 2 condensate collection drum). When operating within process sequence of related items (e.g,. pumps, condensers, and towers), the drum should be positioned to facilitate an orderly“ and economic piping interconnection berween itself and those items Within the conventional inline provess unit, drums and their related items are generally located on either side of a central pipe rack serviced by auxiliary roads for mainteriance access, In certain cases (eg, for Nash drums and deaerators), drums can be located above the pipe rack, In chemical plants, drums are generally located at all levels of enclosed or open-sided struc- tures. For example, Exhibit 5-4 shows the drum Joca- tion in a tower reflux system, Exhibit 5-5 shows the compressor suction ddeums, and Exhibit 5-6 shows the drum locations in an enclosed chemicat plant structure Pracess Plant Layout and Piping Design EXHIBIT 5-4 Drum Location in a Tower Reflux Systems Bettons Saar’ EXHIBIT 5-5 ‘Suetion Drum | asf penFREESTANDING ELEvaTio foo ARCTZE Elevation and Support towers, drum ns are dictated by the net positive suction head (NPSH), as illustrated in Ex hits minimum clearance, common platforming, and maintenance and operacor access, Within sirue tures, especially chemical facilities, drums could be wated above the minimum requirements 10 accom Simita 33 EXHIBIT 5-6 Drum Locations in an Enclosed Chemical Plant =, 2 Structure rea) Trica) modate floor space availability. Drums for chemical collection systems are generally located below ground in concrete pits, as shown in Exhibit 5, Methods of support are influenced by the size and Jocation of the drum, Similar to rowers, large vertical drums are supported by Hf size permits, small vertical drums may be supported by legs, as shown in Exhibit 5-9, or by lugs if elevated within a structure, a5 Dreme34. EXHIBIT 5-7 Net Positive Suction Head Blevation EXHIBIT $-8 Elevation Requirements for an | Requirements for a Horizontal Dram ‘Underground Drum pe ye Shares ea fom BreveTion SET Gy RnQeSGRouND PENG ® EXHIBIT 5-10 Sample LagSupported Drum | 1 i. q Ie } x4 . shofte slovouwerse qo 52 2 Leae Les Han SofoAWie TER, cams 255 Minintiin Sample Saddle Supported SOSMIXIMUM = Drum DE RADI 14" Tgreucrames Process Plant Layout and Piping Devin@ EXHIBIT 5-12 Drum Elevation Skerch USE Tae ereverions ea820 sal ‘63750 08 3S EXHIBIT 5-13 Typical Process Vessel Sketch for 4 Horizontal Drum shown in Exit 510. Horizontal drums are usally Suppoted by saddles from concrete pits or sel frames if elevated within a structure, as illustrated in LEshibics11-Legsupported drums should not be used in reciprocating compressor cies The ist sep te drum layouts seting the heght of the drum. To do this. the plant layout designer re quires the following information: “+ Drom dimensions Type of heads > support deta. 2 NSH requirements of pump. “+ Bottom outlet size. The cenverline elevation of the drum, as illustrated in Exhibit 5-12, was set using the following listed infor ‘mation (itis recommended that a freehand:skerch be used for this exercise} + Drum dimensions—4-ft (1,220-mm) diamet ,050-mm) length, Support details—Saddles and concrete piers. * NPSH—9 ft (2,700 mm). * Boom outlet—4 in, * Location—Freestanding. * Minimum clearance—7 ft (2,100 mm). NOZZLE LOCATIONS Drum dimensions, nozzle sizes, and, if required, inter- nals are shown on the process vessel sketch furnished by process engineering and included in the process “TEb\ ba bh 2% se eeerce ts 26 | vate? our 7 tens ear eo co =e ae F-Pt eee release package. Exhibit 5-13, shows a typical process vessel sketch for a horizontal drum. The following information is required in order to position drum nozzles * Process vessel sketch, * Instrument vessel sketch. * Piping and instrumentation diagrams * Plant layour specification. + Nozzle summary. * Insulation requirements, * Plot plan, Exhibit 5-14 depicts the preferred nozzle locations for horizontal drums ‘The preferred location for level instrament is away from the turbulence at the liguid outlec nozzle. Al though the vessel is provided with a vortex breaker, instruments should be set in the quiet zone of the vessel—for example, on the opposite side of the weir i cor baffle or near the vapor outlet end, Process nozzles should be located a minimum from the tangent line Steam-out connections should be located at the end ‘opposite the maintenance access and vent in the bot DrampeiaGe , Dinnetess+ "oo ns Beat} VApo@ out ® ©@ SApoLEs Paki LiQuio our De NezLe DaweTe EXHIBIT 5-15 Typical Hillside Nozze ANID ARD. Noz2L& STANDOUT Proce Plant Layout and Piping Dest: EXHIBIT 5-14 Preferred Nozzle Lacailons for 2 biguip/vAr ee ist Horizontal Drumm ALTERNATIVE Mans TENANCE Ce cecaTions a) Dakin tom section of the drum. Pressure instruments should be located anywhere in the vapor space, preferably at the top section of the drum. Temperature instruments should be located anywhere in the liquid space, pref erably at the botiom section of the drum. The vent connection should be located in the top section of the drum at the end opposite the steam-our connection ‘The drain should be located in the bonom section of the drum, “To faciliare specific elevation requirements for level instruments or positioning a maintenance access, nozzles may be located off the main axis. These noz- ides are generally referred to 2s hillside nozzles. A typical hillside nozzle is shown in Exhibit 5-15, Tall vertical drum nozzles should be elevated and oriented using the tower subject as 2 guide. It should be noted, however, that nozzle locations ate not restricted by internal components, as is the case for the distillation tower. More information on vertical drums is available in Chapter 10, Towers, The nozzles shown in Exhibit 5-16 were positioned «@ using the guidelines discussed in this chapter as well © PRID—Exhibit 5.28 eice crmation contained inthis book. The infor.» Nozzle summmary_—-Exhibie 5.13 ution required can be located a5 follows * Plant layout specification —Chapter 2 * Process vessel sketch—Exhibit 5-13, * Insulation—-No requirements, * Instrument vessel sketch—Exhibit 5-29, * Plot plan—Exhibie 5-4 rams See 37Tor HEAD PLATFORM EXHIBIT 5-17 BELLE aL ALTESNATIVE pospRoeM Besigil. Platform Arrangement at a Horizontal Drum MAN OPEZATINIG. PLATFORM LEVEL EXHIBIT 5-18 Platform Arrangement at a Vertical a Pe a A \ if \ slau : wen ese PLATFORM ARRANGEMENTS Platforms are required at drums for access to valves, instruments, blinds, and maintenance accesses. Ex: hibit $-17 illustrates a platform arrangement at a hori- zontal drum, and Exhibit 518 displays the arrange- ment for a vertical drum. Process Plant Layout and Piping Design Lappet, For tal vertical drums, platforms are usually circu lar and supported by brackets anached to the shell of the drum, Plaforms at horizontal drums are usually rectangular and are supported by brackets attached t0 the concrete piers supporting the drum or trunnions lttached to the shell of the drum, or by structural steel supported from grade, Drums located in structures, if size permits, use the structure floor for access £0 Com trols. Top head platforms on horizontal and vertical ingtallaions are supported by trunnions attached 10 the vessel head, Generally, access to freestanding drum platforms is by ladder. Typical drum platform arrangements are shown in Exhibit $-19. Platform elevations for drums are set by the items that require operation and maintenance. On tall vert: cal and high elevated horizontal drums, the platform elevations are determined by a maximum ladder run of 30 ft (9,150 mm). Exhibit 5-20 illustrates horizontal eum platform and ladder elevation requirements Platform floor space requirements are dictated by op erator access to controls, instruments, and mainte: nance accesses. Exhibits 5-21 and 5-22 show platform floor space requirements for horizontal and vertical‘etme EXGIBIT 5-19 Typical Drum Platform 1 WD TOR HEAD PLatRogM SuPPaR Te Faganions | sucrearey row /supmeereo aon [suppoetso\ ream CONCRETE PIERS TRUNNION a. Horizontal Drum Platform Supports TOP HEAD eurTRoRM § eT Reom suppeeT @ eT iid vepeeL, up ER b. Vertical Drum Platfo-m Supports aL aR ih d. Common Platform GRADE Drums c. Structure-Lecated Dram100 ‘STEP-THEOUGH cappea Run ioc" 3060 MAINTENANCE. ASCESS. Bioles.of 215 Jo 61S Pies Lappe Run oo! installations. For tal vertical drums, platforms should be arranged using the tower subject as « guide; this is covered in Chapter 10 Exhibit 5-23 depicts a horizontal drom platform 2e- rangement that was designed using the guidelines in this chapter. This information can be found as follows + Process vessel sketch—Exhibit 5-13. + Drum elevation —Exhibit 5-12. + Plot plan—Exhibic 5-4 * Type of support—Saddles and concrete piers PIPING ARRANGEMENTS Piping at drums should be arranged in. conjunction’ with nozzle locations, platform arrangements, and the Process Plant Layout and Piping Devigh VeuT, INGTRIMENIT, ING @ VALE Recess erences EXHIBIT 5-20 Horizontal Drum Platform and Ladder Elevation Requirements @ 260 "wor of couceete MAINTENANCE AccESS, VALVE, ENGTRoMsmT ACCEhs ws Ih wre@MeoiATE PLATFORM Suit MAKI Lappe@ wont drums’ location to related equipment. Piping should be positioned to facilitate ce installation of supporss, ‘with sufficient flexibility :0 absorb any excessive stresses during operation. ~iping at tall vertical drums should be arranged in ace: «dance with the guidelines given in Chapter 10. If required, piping ® horizontal freestanding deums should be suppored from the shell of the drum, the plaform stee!, or the concrete piers sup- porting the drum. Piping associated with drums lo- cated within structures should be supported from the structural steel. Exhibit 5-24 shows typical pipe sup- ports ata horizontal drurm, and Exhibit 5-25 shows a typical pump suction arrangement. Relief valves that are open t0 the atmosphere on low elevated horizontal or vertical drums should be positioned to allow the discharge piping to be routed101 1h VENT EXHIBIT 5-21 Be Mi, Horizontal Drum 150 PREGSUGE INSTRUMENT ——Plalorm Floor Space ‘Area Requirements Tempegatuge fA INET Rome arr Lappee UNE UP PLATFORM, wink SHELL oF DeumLoz EXHIBIT 5-22 Vertical Dram Platform Floor Space Arca Requirements et Levee vert s Renee vave Teupresrsee $ Pees ‘iereuneners sie RAoWS} EXHIBIT 5-23 Horizontal Drum Platform Arrangement | SuPrERTS FeoM PLATFoem BeAcKET ee Process Plant Layaus and Piping Design EXHIBIT 5-24 Horizontal Drum Pipe suppoeTs ezom — Sepports supPoet FROM oneeeTe PegEXHIBIT 5-25 Pump Suction Arrangement to a convenient, safe location. Closed system relief valves should be located at a convenient platform adja- cent to the drum above the relief valve header. Relief valve inlet piping more than 20 f (6,100 mm) long should be checked by the systems engineering group to determine whether the line size needs ¢o be in. creased for pressure drops, Exhibit 5:26 shows typical arrangements for both systems The piping arrangement shown in Exhibit $.27 was designed using the guidelines in this chapter. The ce: Quirements can be found a follows * Process vessel sketch—Exhibit 5-13, * Nozale locations—Exhibit 5-16. * Instrument vessel sketch—Exhibit 5.29 + PRID—Exhibie 5.28 * Equipment arrangement—Exhibit $4 * Platform arcangement-—Exhibit 5.23. EXHIBIT 5-26 Retief 103 Seneca renantnetrnanentnrmsine enna * Nozzle summary—Exhibit 5.13, * Drum elevation—Bxhibit 5-12, + Plant layout specification —Chaprer 2. The sample piping and instrumentation diagram dis- cussed in this chaprer is ilusteated in Exhibit 5.28 DRUM INSTRUMENTATION Level, pressure, and temperature instruments are used ‘© control the operation of the drum and should be placed in a position for optimum operation and main: tenance. Instrument requirements are usually high- lighted on an instrument vessel sketch furnished by the instrument engineer assigned to the project. Ex. hibit 5-29 is a typical instrument vessel sketch Level ‘controllers, switches, and gauges are either located individually or grouped feom a common bridle or standpipe. The controller must be operable from grade or a platform; switches, gauges, and pres sure and temperature connections may be operable from a ladder if no platform is available at the re: quired elevation, ‘The instrument arrangement shown in Exhibit $30 was designed using the guidelines in this chapter as follows: * Nozzle locnions—Eshibit 5. * Instrument vesse! sketch—Exhibit 5 * Platform arrangement-— Exhibit 5-23. + Piping arrangement—Exhibit 5.27, = Drums104 ‘EXHIBIT 5-27 Sample Drum Piping ‘Acrangement PuatreeM El. a eed Process Plant Layout and Piping Destene Anvespaite Qstegt Mess 105 BGUBIT 5.28 Sample Piping and Bicone! nscrumentation Diagrara £200 QVERIEAD comvause NERNEAD coms piusER 8 FEED -P-gol-o) Feom. 2283/6 Tet ROM __p.207- at eS 7 Ae Pel Tae alu EXHIBIT 5.29 | ‘Sketch | ® {lee a Drums106, EXHIBIT 5-31 Simple Horizontal Dram Davie “Arrangement " Swe! paMeres, aS MAENTENANCE, Maintenance of drums is limited 10 removal of such ‘exterior components as large relief or control valves for offsite repait. Handling of these items can be achieved either by fixed davits or by mobile equip: ment. Davit arrangements for tall vertical drums ‘Should be in accordance with tower requirements. Da tits are nos usually furnished at horizontal drum: ee Froces Plant Layout and Piping Design EXHIBIT Instrument Arcangement EXWIBIT $32 Drum with Mixer107 EXHIBIT 5.34 Nozzles ¢sAooLe6 Sample Sloping Drum Te Be Peepeuoieutag PUTFORM to Be HogiZemTat. aT _ required, they should be arranged in accordance with, those in Exhibit 5-31 Removal space should be provided above drums furnished with mixers. If the drum is located within a structure, a removable section of the floor above should be provided. Exhibit 5-32 illustrates a drum with a mixer. ' FURTHER CONSIDERATIONS For various process reasons, horizontal drums often are furnished with what appears to be a small vertical rum, called a boot, atached to the underside of the vessel. Because the boot is inaccessible to the main drum platforming, special consideration must be given to the arrangement of additional platforming fo Access to the instrumentation on the boot Exhibi shows a typical deum boot layout In certain cases, drums must slope, as shown in Exhibit 534. If the nozzles are not perpendicular to the horizontal plane, all vertical piping runs from these nozzles must be calculated because they will be offset at an angle The dimensions, clearances, and guidelines high- lighted in this chapter are an example of wine can be used for Grum arrangement. The plant layout designer should be familiar with company and client standards, however, before proceeding with drum lavout and should coordinate the effort with such supponing ‘roups as vessel, systems, process, and instrument en= gineering DraisHeat exchangers are similar to pumps and vessels in that they are widely used in most process plans, The control of heat within any facili is an imporcant pare of plant operation, whether by direct application (eg, in a furnace) or by heat interchange (eg., in a shell and tube exchanger). The principal application of a heat exchanger is to maintain a heat balance through the addition or removal of heat by exchange with out. Side sources or berween streams of ewo different oper- sting temperarures. ‘This chapter highlights the general layout require. ‘ments for heat exchangers. also identifies the infor. CHAPTER Exchangers ‘mation cequired by che plant layout designer to locate, elevate, operate, and maintain the most common ex. changers and to position the piping and controls asso- ciated with these items. The most common applica. tions for heat exchangers, illustrated on a process flow diagram in Exhibic 6-1, are: * Cooler—Cools process streams by transferring heat *0 cooling water, atmosphere, and other media, * Exchanger—Exchanges feat from a hot t0 a cold process stream, * Reboiler—Boils process liquid in tower bottoms us- EXHIBIT 6-1 Exchanger Applications Diagram | ‘Shown on a Process Flow | OSLER cunee REFEGec ANT 109Lio EXHIBIT 6-2 Common Heat Exchengers a. Shell and Tube Exchanger e. Air Cooter Exchanger ing steam, hot oil, or a hot process stream as the anures by evaporating a refrigerant. heating medium. + Heater—Heats a process stream by condensing EXCHANGER CONSTRUCTION steam + Condenser —Condenses vapors by transferring heat ‘The most common heat exchangers used in process- 10 cooling war, atmospheric aie, or other media. ing faciliies are illusiated in Exhibit 62 and dis + Chiller —Coois a process sizeam to very low temper- cussed in the following sections Process Plant Layout and Piping Desigiii HoRiZonTAL VEeTicAL EXHIBIT 63 BAFFLE BAFFLE Sample of Tube and Shel | LTHRE Sipe SHEL Sipe. Exchanger Passes Apenhie 8 eee foes BaBTeN hay hemrars pel acted Toe emer twee temzeura, veereat pleats wie a Soe erect eaenee TE es | SAELES ee HEAD. io \ = HEAD. he ro \ ea 5 = = eer coves = St) }- SS SHELL FLOATING \ eens iene lec TUbE siDe ) SHELL Sipe ERED THRE suepect / |_SHELL Noz2Le seep eee Shell and Tube Exchangers Shell and tube exchangers are elongated steel cylin- drical vessels containing bundles of parallel tubes Lig. vid passes through the inside of the shell over the exerior sie ofthe tubes, with another liquid passing through the interior of the tubes, causing the neces ange of heat berween the two liquids. The xls ofthe exchanger can be designed to ecommodate several passes on the tube side. Mult pile passes on the shell side can be achieved by instal ing baffles parallel 1o the tubes, Baffes may also be stalled inside the shell, perpendicular to the tubes, to direct the liquid in the shell against the tubes. Mult. ple passes are used 10 increase the fluid velocity or t0 improve the flow path, causing increased heat recov ery. Exhibit 6:3 shows an exchanger with mwo passe the tube side and one on the shell side The shells of most heat exchangers are constructed enless pipe for small diameters and shaped welded steel plates for the larger sizes, Tube bundle sizes can vary from 8 10 96 in (200 mm © 2,400 mm) in diameter and from 6 to 50 f (1,800 mn to 15,000 mm) in length. The ends of the shell can be designed 10 accommodate welded, dished. or flanged shell covers a5 well as flanged or welded heads. Both the tube side and the shell side of the exchangers have inlet and Duitlet nozzles positioned to provide the required flow through the exchanger. The unit is supported at the shell by attached saddles for horizontal installations and by lugs for vertical arrangements, Tube bundles are made up of many small-diameter wes that are expanded into tube sheets at each end of the bundle ‘One end is usually Fixed: the other is allowed to float for expansion. For the more simplified Utube ar rangement, only one tube sheet is used, which is inte grated with the channel head, Exhibit 64 shows a typi cal shell and tube exchanger identifying the key items of construction With many shells, shell 1d head coversLi2 EXHIBIT 6-5 Typical Shell and Tube Exchanger ‘Arrangements a. U-Tube b. Fixed Tube cc. Kettle ‘Process Plant Layowt Piping Design available, exchangers can be arranged in various com- binations to provide a wide range of services. The U- tube, fixed tube, and ketle arrangements are illus- trated in Exhibit 65, Plate Exchangers Place exchangers, shown in Exhibit 6-6, are generally used in low-pressure, low-temperature applications and are made up of end covers, carrying bars, inlet and outlet nozzles, plates, and gaskets. The exchanger plates have spacing berween them for liquid low. A ‘gasket, set into channels on the periphery of each plate, directs and contains the liquid flow distribution Port for inlet and outlet of both hot and cold liquids are stamped into the corners of each plate, When aligned, they form four distribution headers through the plate pack. Distribution of hot and cold liquids to ahernate plate flow channels is achieved by the gasket Jing patiern around each port. When the liquid is in- tended ro flow through to the next plate, the gasket is left intact around the port. Alignment is achieved by top and bottom carrying bars and slots in each plare. ‘When completely assembled, the plate pack and gs kets are compressed by bos berween the two covers. ‘Support is provided by the fixed end cover and carry- ing bar. The plate exchanger requires less installation and servicing space than do shell and tube arrange- ments of equivalent surface. Spiral Heat Exchangers Spiral heat exchangers are generally used in chemical plants and are of circular construction, consisting of an assembly of two long strips of plate wrapped to form a pair of concentric spiral passages. Alternate edges of the passages are closed, so that liquid flows through continuous channels. Removable covers are fited 10 each side of the spiral assembly for access to the spiral plate. As shown in Exhibit 6-7, the inlet and outlet nozzles are integral to the plate housing and the cov ers. The unit is supported by legs atached to the plate113 ee ee nnn ene = EXHIBIT 6-6 Pie Exchanger) foc Cpesmvcton ele housing for horizontal installations and by lugs for vertical installations. Similar to the plate exchanger, the spiral exchanger is compact and requires less in: stallation and servicing space than conventional ex changers of equivalent surface, Double Pipe Exchangers ‘The double pipe, or fintube, exchanger is used when cone liquid has a greater resistance to heat flow than another or when the surface area is small. In stich cases, the addition of fins to the inner pipe evens out the resistance to heat flow of the eno liquids, As shown in Exhibit 68, the double pipe exchanger consists of a pipe within a pipe; both pipes have a return bend at ‘one end. The inner pipe is fied with fins; the outer pipe acts as the shell. The shel! nozzles are mounted vertically from the outer pipe, and the tube nozzles ate directly welded to the inner pipe ends. The units are generally supported horizontally by brackets atwes ee. EXHIBIT 6.8 Double Pipe Exchanger Construction MEADE Box uae Sane | ceynousns —/ tached to a foundation or to the side of other equip- ‘ment suppor. Air Cooler Exchangers Air cooler units are ent from the previ- ‘ously mentioned arrangements in that the cooling agent used is circulating ar ins:cac! of liquid. As seen in Exhibit 69, an air cooler unit consists of fir-tube bundles with a header box attached to each end, sup- ported horizontally by a steel frame or structure. For the single-pass arrangement, the inlet nozzles are mounted on the top of the header box; the outlet nozzles are at the opposite end and mounted on the bowom of the header box. For the double-pass ar rangement, the outlet nozzles are located at the same end as the inlet nozzles. For additional surface area more pass adaitional unis can be Froces Plant Layout and Piping Design EXEORIT 6.9 Air Cooler Exchanger Construction Lappec installed and located side by side. Air is circulated by multiblade propellersype fans that provide forced or induced drafis, Fans can be supplied with either adjustable speed or variable-pitch ‘blades. The fan blade pitch can be changed 10 vary the airflow rare 10 compensate for rising of falling ait temperatures. Air coolers supplied with muluple fans may be operated with some of the fans shut down, Dampers, baffles, and bypasses can also be used t0 farther control liquid outlet temperature, For elevated installations, platforms are generally furnished for ac- cess to header boxes and moors. EXCHANGER LOCATION AND SUPPORT Heat exchangers are located within the conventional process unit plot area, close to related equipment, t0Lig High Peeves £ EXHIBIT 6-10 \) Excriaveees Typiel Pot Pan of Exon ecees Several Exchanges \ 6 = INa-cooleD FS Ou pensee Ee | Hq seme, Brcnincers [\ ~~ € =| a] BONNET REMOVAL TWEE Gunpie EXHIBIT 6.21 Sample Exchanger REMovAL AREA Sample Exe anne! AVIT | 4 + | | See AUXILIARY goap 0% MAINTENANCE _{- seceye way fT Bechangers116, EXHIBIT 6-12 Sample Single a Paired Exchanger Insulation HXGHBIT 6-14 Sample Structure Mounted Exchanger Installation LL) [seat 7 [een coh ilk eigen uf G=p-| suse bib EXHIBIT 6-13 Parallel and Series Exchanger Installations sence (Ne ae Keeg a Et Process Plant Layout and Piping Design support economic pipe runs, flexibility, process re quirements, and operator and maintenance access. Support of the equipment (e.g. for air coolers or vert: cal reboilers) can also influence heat exchanger loca- tion, Exhibit 6-10 depicts a typical plot plan with sev- eral heat exchanger applications, Horizontal shell and tube exchangers should be positioned so that the channel end faces.the auxiliary road or maintenance access way for tube bundie removal with adequate space provided at the front end of the exchanger for bonnet removal. This exchanger orientation is shown in Exhibit 6.11 Exchangers can be located as single items, in pairs (this is the most common instalation), or in larger {groups when no intermediate control is required be- tween the shell and tube streams. The single and paited installation is shown in Exhibit 6-12, Paired ex changers may operate in series, paraliel, or dissimilar services; grouped exchangers operate only in series or parallel. Exhibit 6-13 shows samples of parallel and series exchanger installations Paired or grouped exchang hould be spaced to q(rtieeeanae seta EXHIBIT 6-16 Typical Horlzontal Exchanger Suppor coueue | stg cteazmnce Flge se fipocarien Mimi SubLE Pipe gm ia allow a minimum of 18 in (450 mm) between the outside of adjacent channel or bonnet flanges to facil. tate access to flange bolts for maintenance, Space should be provided on either side of paired exchang. ers and at both ends of grouped exchangers for con- trol and operator access. Exhibit 6-14 illustrates a structure-mounted installation and its required access areas. Horizontal exchangers may be stacked 1 2 pre ferred maximum top shell centerline elevation of 12 fe (3,600 mm) from grade or platform, 25 depicted in Exhibit 6-25. Stacking of exchangers above this height ‘may require platforming for access to channel and bonner flanges and fixed handling devices. Horizontal shell and tube exchangers may be lo- cated at grade or elevated in steel or concrete struc: {ures when process requirements or space availability dictate. Suppor of horizontal exchangers, as shown in Exhibit 616, is by saddles anached to concrete piers for grade-mounted installations and by saddles at tached to steel frames in elevated installations, When possible, supporss should be inline for common foun: dation design, I process requirements permit, shell and tube ex: changers can also be mounted in’ vertical position, supported by lugs and tower nozzles in a tower-sup” Ported installation (as shown in Exhibit 6.17), within Concrete oF steel structures (as showin in Exhibit 6-18), and by concrete piers (as shown in Exhibit 619), The same considerations for maintenance, control, and op- erator access should be given for vertical installations as are for horizontal installations Spiral and plate exchangers can operate in series or parallel, bur, because of theie configuration and main- tenance requirements, it is preferable to position them as single items. Space is provided at both ar- Fangemenis for control and operator access, with enough room allowed atthe spiral exchanger to swing the cover plates open, as shown in Exhibit 6-20, and at the plate exchanger to remove the individual plates, as shown in Exhibit 621 sooo changer18 owes, Lue 2 S02iNe = PLATFORM Rebove oY 900 iol MAK tives WwirnouT Gove REMOVAL aces Air coolers are located adjacent to the equipment that they serve for piping flexibility and maintenance, ‘They can be supported from grade, at the top level of scructures, of above pipe racks, which is the most common installation, ,The tube bundle bank can be supported by steel legs from the air cooler vendor or by extending the pipe rack or structure columns to the Process Plan Layout and Piping Design vanwinionn b PiatroeM EXHIBIT 6-17 ‘Tower Supported Vertical Insealation @ ee _ATE RIOT IVE ZENE, Zee t/-ec0 Je Bf mee HiTeH PomTS Foe SovEe REMOVAL @ [300 underside of the bank Generally, the air cooler ven- dor furnishes header box and motor access platforms Ladders are provided for exit to grade to suit maxt mum ladder runs and safeny requirements. Exhibits 6.22 through 6-25 show various air cooler support and platform configurations, which include column-sup: ported, legsupported, fixed-platform, and traveling:119 EXHIBIT 6-18 Structure Supported TUBE BUNDLE Vertical Installation Removal AREA Minti nuai 4oVi.200 (ne) 4 1 Luss - | elo “poo ee yh MAXIMUM ello fo) lh # eteeccceeees eens I J " i PLATFORM | ie | | i i i oy ia!-o'/3600 Maximum 18/50 WITHOUT PLATFORM Minin Btol/a00 Muni TET q platform arrangements When designing the air cooler configuration, the plant layout designer must consider the source of the supporting cohumna. As seen in Exhibit 6-26, arrange. ment A, developed by the contractor, allows changes ‘© platforming and pipe support loading late in a pro} ect without affecting the air cooler vendor's scheduled delivery dates to the job site, In arrangement B, any such late changes would cause the air cooler vendor ‘o redesign the support legs or platforming, causing delays in delivery and exara costs NOZZLE ORIENTATION Nozzle orientation and location can affect the piping configurations at most exchanger arrangements. A de- cision by the piping designer to relocate the ex Exchanger120 . EXHIBIT 6-19 [ Plt Mounted Versca \ TUSE SuNDLE eae \| | REMOVAL AREA Minium B.0/\200 L Lures (sla? HE | L i eloVigoo MAXIMUM Pia M. i CONCRETE PIERS UT PLATFORM 900) Minnmtiom OPEZATOR Acc®Ss EXHIBIT Control and Operator : ; ‘Access in a Spiral 7 a - cover PLATE SWIG AREA (Tye) contac. SPREE (Tye) Pre eke couuMns Process Plant Layout and Piping DesignBi PLATE REMOVAL OPERATOR Acc €: BIT 6-23 Controf and Operator ‘Access in a Plate +, ‘Arrangement CONTROL sPhce (typ) PIPE RACK cotumNS WouceD DeArT EXHIBIT 6-22 coal Typical Ag LER ‘Column-Supported Air Cooter arrangement @ croez : Box PLATFORM 7 Detamia : Maintenance 4 > Recess 1 DES : PLATFORM ee i : 7 4 qo ds PIPE 2. : : sruaatiesese Ve a of Pipe ghee + soprrone, Aateoeny | EES | if Lnope@ gun 5 Hil “ ee Ue122 FomceD CRAFT ‘EXHIBIT 6-23 Ae cooler ‘Typical Leg Supported Cooler Arrangement @ | toV/2ioe Wich SpbeNtoR Mece ye i uy | ae i _————— OO” MINMuind “Process Plant Layout and Piping Destan& 123 Laver te WanTevince Pustroe (rR) \ Mesoee Gox : (trey St et ; fe tpsss Bie eace | MAINTENANCE Ai ESLUMNS PLATFORM SuPrort Beam Bbanges EXHIBIT 6-24 ‘Typical Fixed Plavorm Air Cooler Arrangement124 eens EE RES ForceD DRAFT he Cooler EXHIBIT 625 Typical ‘Trveling Platform Air : Cooler Arrangement S S1EP-OFF PLATFORM EAVELING ster suproeT ZELSMNG { | oe HEADERS Bex PLATFORM Process Plant Layout and Piping Design6 a ® eA ' changer nozzles can often produce a neat and cost effective arrangement. Although the piping designer oes not have the freedom to independently relocate ‘exchanger nozzles, suggested alternate nozzle loca tions can be made to the exchanger engineer in the lerest of improving external piping arrangements— for example, alternative B in Exhibit 6-27 highlights an improved arrangement by relocating exchanger noz. ales, Exhibit 6.28 shows allowable nozzle configurs- tions. Elbow or gooseneck nozzles are especially useful in reducing the height of large stacked exchangers. Exhibit 6.29 highlights che effec of using elbow noz zles on stacked exchangers, oler ihozzle locations can also affect piping configurations. A single-pass arrangement can snake 325 EXHIBIT 6.26 Considerations for Vendor: oF Contractor Supplied Supporting Columns sureee ti soluUN of Tewee the return piping on an overhead condenser very long, and can also increase the height of the aie cooler. Reorienting the air cooler or making the unit a dow: Dle-pass arrangement can improve the piping configu ations, Exhibit 6:30 shows alternative nozzle configu: rations for air cooler piping EXCHANGER PIPING Exchanger piping must be routed in such a manner that it meets economy, flexibility, support, and oper tion and maintenance access requirements. Piping a shell and tube exchangers is positioned to allow ade quate space for removal of channel heads and shell covers. The free space atthe side of horizontal shelis changersAvreenative “6” qian d= SINGLE - SHEU DoE -pose SHE PINGLE- aes SHELL pousLe-paoe AIELL ne ( —T1 Pant p epee zeeoleg ANale-pace ole ‘Process Plant Layout and Piping Design EXHIBIT 6.27 Alternative Arrangements for Locating Exchanger Nozzles e EQHIBIT 6-28 ‘Alowable Nozse Configurations@ 127 ALTERNATIVE ‘A’ OUBIT 6-29 Effect of Eibow Nozzles fon Stacked Exchangers ALreewative "6" SNGLE-PASS OuTLEY NorZzie LecaTion: EXHIBIT 6-30 Alternative Air Cooler Iwet wozzLe Nozzle Configurations Location Dousie-pass ourter NEPELE LOCATION rower Rerun peu Oe h + can be used for placement of controls. Piping is ele. vated a minimum distance from grade or platform to provide operator headroom clearances, to offer ease ‘of suppor, and to meet designated pipe rack eleva tions. Large-diameter or more expensive piping can: not be sct to accommodate stnaller or less expensive piping. Piping connected (0 channel head nozzles should be furnished with break flanges to facilitate the removal of the.channel head. Piping ar spiral and plate exchangers is also pos: toned (0 allow the opening of covers and the removal . CE sewn / I], VW ee tt a: ze of plates, Controls at the spiral exchanger are located oon the ends of the unit, clear of the cover plate swing, area, and at the front and on one side for the plare exchanger. Piping 1s elevated in a fashion similar 10 the shell and tube arrangements. Piping attached 10 the cover plate nozzles of the spiral units is furnished with break flanges. Piping at air coolers is nor routed over tube banks or fans and should be kept clear of the designated space for motor maintenance. Exhibits 631 through 6-44 show various piping configurations for heat exchangers. Bechangers128 DOUBT 631 f egies Piping Arrangement for —gbseAtoe Horizontal Shelt and Rees ‘Tube Exchangers elke citagauce at suereets coureens rire ence 3 Petes stan Tp suce F o Eleva Tons | Winriey CusAtincs pena ms 39 ] Ss Pees 6 Process Plant Layoutand Piping Design /129 EXHIBIT 6-32 Piping Arrangement for Underground Cooling ‘Water System Use SPoot Piece foe BuyTEZELy Vauves EXHIBIT 6-33 CONDENS ATE CONDENSATE = STEAM contol, Fave oe Piping Arrangement for Steam and Condensate System Pet VALVE Ui cause T ELEVATION OF Téunwiont GQUDENSATE Pat SdPpoRT SET By Pescess ZSnoiTioNS Eebangers130 CHECK CleaRBnce EXHIBIT 6.35 Supports for a Piping Arrangement hereeweweTs sui Geaviges roe PRS ast 1 Sesame Between Pre Eke Rup | eelsdees eee old caRBon STEEL 5 i2'> Alloy ob cagtow sree, ! hat ee 12" Abboy | \_ cost-ereective BECANGEMENT pet Reboiter srtaeu sree seucdere cures TS Reboiler Process Plant Layout and Piping Design EXHIBIT 6-34 Sample of Piping Economy Arrangement EXHIBIT 6-36 Piping Arrangement for Horizontal eb EXHIBIT 6-37 Piping Arrangement for Vertical133 Hig: EMPEZATIR| AUSy Firma =XEUBIT HIGH" PRES Sue eT Arioement for High-Temperature, High-Pressure Feed Exchangers PROVIDE Looe NN FIPING FoR FLExiBnity ; PRoviCE SPemG SUPPORT aT Centee Suepeer av Cevree N EXCUANGER Cue, exe ONLY = a lot -@teie rein tf — I a 4 “ AuTERwaATive ‘A ALTERNATIVES‘ CesT EFFECTIVE fest EFFECTWE Exchangers132, Locate PPNG Seventy EXHIBIT 6-39 EentcGM Fea BASE Piping Arrangement for PLATromM Fem BASE Piping of suppoet {|—~—- costa | raid cpeaniog bec coves Pus Toon x0 Piping Arrangement for Spiral Exchangers YLT. Y gemovacre |” Br0oL freien) F & pipe ance cous \ + + + ' comT@o, VALVE Process Plant Layout and Piping Desten133 Gnome Gea | Fag ene pee eee — eee WELL. connec vn ve 7 / | iM GenT@ot VAWES EPIPE RACK COLUMNS PLAN @ ELEVATION EXHIBIT 6-42 Ai Cooler Piping Configurations i co om] Ta ASYMMETRICAL RAKE SYMmeTeiche Bae Exchangers134 EXTEND Ale eooueR Supper STEEL Te SubroeT VERHEDD LING Towee, NR cooler, cot BEFECTIVE AUTERNATWE Routine 1F PPG 15 FLEXIBLE AND GAN SPAu DigTance WitionT INTER me OATS Sureest Fo@ SLexibitiny, THE Ae coo.ee cau Gf PosiTioneo wiry We (WET Nozzues on THE Fae Centeeine OF “WE PIPE BAce coins. Fug Ai cooved Secqions Sieur BE SEA@eGATED BMD THe STEEL EXTENDED Jo suppoet TE SERHERD PIeHG. ‘Process Plant Layout anal Piping Design EXHIBIT 6-43 Overhead Pip Arrangements for 2 ‘Condensing Air Cooler@ 135 EXHIBIT 6-44 Inlet and Outlet Piping Arrangement for a Product Air Cooler Mamerain CLEABAUCE 2F OUTLET PPG AT Aw cooler PLATFORM STEEL EXCHANGER MAINTENANCE Like an automobile radiator, the internals of heat ex: changers require periodic Cleaning and repair. Iris important for exchangers and related components to be positioned to facilitate access to their internal pacts For the shell and tube heat exchangers, the tubes and the interior of the shell can be cleaned in place with high-pressure steam or water and rodding de- vices. Ifthe design of the exchanger permits, che tube bundle can also be removed for repair or cleaning Tube bundles and head and shell cavers can be re. moved by builtin fixed handling devices (e.,, davi hitch points, pulling posts), fixed structures with trol. ley beams and traveling gantry cranes, or by mobile equipment (eg, cranes and hydraulic bundle extrac- tors). Exhibits 6-45 through 6-48 provide examples of tube bundle removal equipment. Considerable saving can be achieved if the plant is serviced by mobile ‘equipment. Air cooler units are not furnished with fixed han dling devices for removal of tube bundles. Minor re- pairs (eg., tube plugging) are usually accomplished With the air cooler in place; for major repairs, air cooler sections are temoved by mobile cranes, as shown in Exhibit 649. Internal servicing at plate ex. changers can be done manually. in the event of a tube failure, individual tubes are closed by inserting a plug through the end of the header box and hammering it into place, as shown in Exhibit 6.50. The use of tube bundle extractors eliminates the need for permanent tube bundle removal structures, with considerable saving to the plant. These mechs isms weigh seven tons and are capable of pull forces ‘greater than 500,000 pounds. The extractor is lifted into position by crane and clamped to the shell flange of the exchanger, which is stripped for bundle re- ‘moval. Held in position by the crane and balanced by the extractor’s leveling cradle, the bundle is pulled out of ts shell with pull rod antachments that use hydraulic force. The whole unit is then lowered to grade and can be relifted onto a truck for offsite repair or cleaning Bchangers136, Punrronm Teowey pea herent Pome: Pause Bean cAT WALK DavIT REMOVABLE 1 suninde, FLATBED 0@ Teucw Process Plant Layout and Piping Design | (cuca Beams EXHIBIT 6-45 Bundle Pulling Post EXHIBIT 6-46 Fixed Structure with @ Trolley Beam @Tape Leweta EXHIBIT 6-47 TRoler BEAM +21o* (610) Fixed Structure with a ‘Traveling Gantry EXHIBIT 6-49 Removal of Air Cooler Sections with a Mobile Crane138 ‘Process Plant Layout and Piping Design “EXHIBIT 6-50 ‘Air Cooler Tube Plugging EXHIBIT 6-51 Bundle Removal Using an Extractor and a Mobile Crane @HYGROwiC TWEE BUNoLE ExTeacroR HYGRBNIC TUCE BUNOLE ExTeAcTOR, SIDE _viEW PLAN VIEW f) Legere Hem Re, 3 Man sipecracirs 8 ie a . 2 Fangs come 9 Range coy 19 Herat matare 10 Sing ender FRouT view 21 Tandem pumps 1 Hydra contra ver 22 se mator 28 lane ence 5 Gyndermain cr 26 pnt ar een tags 7 Man etna % Exchangers 139 EXHIBIT 6.52 Tube Bundle Exteactor Details140 EXHIBIT 6.53 Tower-Mounted Air Cooler Exhibit 651 illustrates an elevated exchanger with the ‘emractor and crane in position for bundle removal, Exhibit 652 provides details of a hydraulic tabe bun- dle extractor. ‘This chapter has highlighted the principal layout requirements for the heat exchanger configurations Process Plant Layout and Piping estan nt REN MERE ESSE EXHIBIT 654 Stab-in Rebotler most commonly used in process plans. A wide range of items, however, can be identified as heat exchange equipment for specific situations, Generally, these items have design features similar to those for com- ‘mon applications, Care should be taken o arrange the ‘equipment so thatthe basic cules for exchanger layout are followed. Exhibits 6-53 and 6-54 show examples of more unusual hear exchanger equipment ©