GS 146-1

COLUMN INTERNALS

September 1995

Copyright © The British Petroleum Company p.l.c.

Copyright © The British Petroleum Company p.l.c.
All rights reserved. The information contained in this document is subject
to the terms and conditions of the agreement or contract under which the
document was supplied to the recipient's organisation. None of the
information contained in this document shall be disclosed outside the
recipient's own organisation without the prior written permission of
Manager, Standards, BP International Limited, unless the terms of such
agreement or contract expressly allow.
 BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING

Issue Date September 1995

Doc. No. GS 146-1 Latest Amendment Date

Document Title
COLUMN INTERNALS

(Replaces BP Engineering Standard 168)

APPLICABILITY
Regional Applicability: International

SCOPE AND PURPOSE

This document covers general requirements for the design, fabrication, supply, testing and
installation of trays, packings and other column internals.

AMENDMENTS
Amd Date Page(s) Description
___________________________________________________________________

CUSTODIAN (See Quarterly Status List for Contact)

Fluid Separation
Issued by:-
Engineering Practices Group, BP International Limited, Research & Engineering Centre
Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM
Tel: +44 1932 76 4067 Fax: +44 1932 76 4077 Telex: 296041
 CONTENTS

Section Page

FOREWORD ............................................................................................................... iii

1. INTRODUCTION................................................................................................... 1
1.1 Scope 1
1.2 Application of this Specification........................................................................... 1
1.3 Quality Assurance................................................................................................ 1

2. COLUMN TRAYS.................................................................................................. 1
2.1 General Arrangement and Size Requirements....................................................... 1
2.2 Fractionator Tray Design Details ......................................................................... 2
2.3 Materials and Thickness....................................................................................... 4
2.4 Structural Details................................................................................................. 5
2.5 Clamping and Bolting Arrangements.................................................................... 7
2.6 Seal Welding ....................................................................................................... 8
2.7 Manways and Access........................................................................................... 8
2.8 Gasketting ........................................................................................................... 8
2.9 Drainage.............................................................................................................. 9
2.10 Tolerances for Fabrication and Assembly .......................................................... 9
2.11 Vortex Breakers ............................................................................................. 10
2.12 Blanking on Sieve or Valve Trays ................................................................... 11
2.13 Tray Installation.............................................................................................. 11
2.14 Reflux Inlets ................................................................................................... 11
2.15 Feed Inlets ...................................................................................................... 12

3. PACKED COLUMNS........................................................................................... 13
3.1 General Arrangement......................................................................................... 13
3.2 Materials and Thickness..................................................................................... 13
3.3 Structural Detail ................................................................................................ 14
3.4 Packing.............................................................................................................. 14
3.5 Distributors - Gravity......................................................................................... 14
3.6 Distributors - Pressure ....................................................................................... 16
3.7 Ancillary Equipment .......................................................................................... 16
3.8 Tolerances ......................................................................................................... 17

4. ACCUMULATOR TRAYS .................................................................................. 17

4.1 General Arrangement......................................................................................... 17
4.2 Manways and Access......................................................................................... 17
4.3 Structural Requirements .................................................................................... 18
4.4 Seal Welding ..................................................................................................... 19

GS 146-1
Column Internals PAGE i
5. VESSEL FEATURES ........................................................................................... 19
5.1 Internal Pipes..................................................................................................... 19

6. DESIGN, DELIVERY AND INSTALLATION ................................................... 20

6.1 Design calculations ............................................................................................ 20
6.2 Drawings ........................................................................................................... 20
6.3 Finishing, Handling and Storage......................................................................... 21
6.4 Testing and Inspection before Installation .......................................................... 22
6.5 Testing and Inspection after Installation. ............................................................ 23

7. GUARANTEES..................................................................................................... 23
7.1 Mechanical ........................................................................................................ 23
7.2 Process .............................................................................................................. 24

8. REGIONAL ANNEX ............................................................................................ 24

8.1 USA .............................................................................................................. 24

APPENDIX A.............................................................................................................. 25
DEFINITIONS AND ABBREVIATIONS .............................................................. 25

APPENDIX B.............................................................................................................. 26
LIST OF REFERENCED DOCUMENTS............................................................... 26

GS 146-1
Column Internals PAGE ii
 FOREWORD

Introduction to BP Group Recommended Practices and Specifications for Engineering

The Introductory Volume contains a series of documents that provide an introduction to the
BP Group Recommended Practices and Specifications for Engineering (RPSEs). In
particular, the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in
the Introductory Volume provide general guidance on using the RPSEs and background
information to Engineering Standards in BP. There are also recommendations for specific
definitions and requirements.

Value of this Guidance for Specification

This document covers the major requirements of column internals appropriate to all BP
Businesses. Adherence to the procedures will ensure that the equipment is fit for purpose
whilst being cost effective

Application

This Guidance for Specification is intended to guide the purchaser in the use or creation of a
fit-for-purpose specification for enquiry or purchasing activity.

Text in italics is Commentary. Commentary provides background information which supports

the requirements of the Specification, and may discuss alternative options.

This document may refer to certain local, national or international regulations but the
responsibility to ensure compliance with legislation and any other statutory requirements lies
with the user. The user should adapt or supplement this document to ensure compliance for
the specific application.

Principal Changes from Previous Edition

This is a new BP Guidance for Specification which incorporates the substance of three
previous standards listed below:

BP (America) Refining Practice RP 7-2-2 (Fractionating Trays and Column Packing) - April
1992.

BP Chemicals Engineering Standard ES/ENG/520/01 (Column Internals) - April 1987

BP Engineering Standard No 168 (Distillation, Absorption and Extraction Column Internals) -

April 1987.

GS 146-1
Column Internals PAGE iii
Specification Ready for Application

A Specification (BP Spec 146-1) is available which may be suitable for enquiry or purchasing
without modification. It is derived from this BP Group Guidance for Specification by
retaining the technical body unaltered but omitting all commentary, omitting the data page and
inserting a modified Foreword.

Feedback and Further Information

Users are invited to feed back any comments and to detail experiences in the application of BP
RPSE's, to assist in the process of their continuous improvement.

For feedback and further information, please contact Standards Group, BP International or
the Custodian. See Quarterly Status List for contacts.

GS 146-1
Column Internals PAGE iv
1. INTRODUCTION

1.1 Scope

This Specification covers general requirements for the design,

fabrication supply, testing and installation of trays, packings and other
column internals.

1.2 Application of this Specification

This Specification shall be applied as the sole means of specifying

column internals to a manufacturer, and forms a working document
which shall be transmitted directly to manufacturers' without being re-
written as a project or contractor document.

1.3 Quality Assurance

Verification of the vendor's quality system is normally part of the pre-qualification

procedure, and is therefore not specified in the core text of this specification. If
this is not the case, clauses should be inserted to require the vendor to operate and
be prepared to demonstrate the quality system to the purchaser. The quality system
should ensure that the technical and QA requirements specified in the enquiry and
purchase documents are applied to all materials, equipment and services provided
by sub-contractors and to any free issue materials.

Further suggestions may be found in the BP Group RPSEs Introductory Volume.

2. COLUMN TRAYS

2.1 General Arrangement and Size Requirements

2.1.1 For vessel of 840 mm (33") diameter and larger, tray panels,
downcomer sections and other tray components shall be of sectional
construction with sections removable through the vessel manways.

2.1.2 When a lifting beam is not available within the column, formed deck
sections shall have a maximum component weight of 50 kg and a
maximum length of 3000 mm (118").

A minimum number of plate sections shall be used in the floors of

downcomers and accumulator trays.

2.1.3 When a lifting beam facility can be provided within a column, the length
and weight restrictions shall be governed by the ability to install
sectional components with the vessel in both the horizontal and
vertical.

The factors which govern the maximum weight/length are those necessary to ensure
safe working in a confined space.

GS 146-1
Column Internals PAGE 1
2.1.4 All tray components shall be designed to permit installation and
removal from the top side.

To design the internals to be installed from both sides is an expensive addition that
should be avoided unless absolutely necessary.

2.1.5 For vessels smaller than 840 mm diameter, cartridge tray assemblies
shall be provided and the vessel shall be flanged to permit installation
and withdrawal of the cartridge.

Cartridge trays are invariably assembled in the fabrication shop.

2.2 Fractionator Tray Design Details

2.2.1 Sieve tray deck hole sizes should normally be selected between 4 mm
and 12 mm (5/32 - 1/2") diameter. Larger hole sizes shall be used
when the specification sheet specifies a fouling or corrosive service.
The ratio of the hole pitch to hole diameter shall be a minimum of 2.0.

Hole sizes larger than 25 mm (1") are more likely to weep, will restrict capacity
and cause a lower efficiency. They are not normally used.

2.2.2 Holes in sieve trays shall be formed with the punch exit on the
upperside of the tray. The manufacturer shall ensure through
fabrication and installation that this requirement is met for all deck
sections. Burrs on the sieve tray holes which would cause injury to
personnel, should be removed.

2.2.3 On sieve and valve trays the hole area shall be uniformly distributed in
the contacting area approximating equilateral triangular pitch. Hole
area per tray shall be within ±1% of the area specified.

2.2.4 In the closed position the valve shall not make full peripheral contact
with the tray deck.

Valve caps should be provided with an indentation which prevents such peripheral
contact and thus helps to prevent the valve from sticking closed.

2.2.5 Trays having more than two passes should be designed for equal
bubbling area per pass rather than equal flow path length per pass
subject to a minimum flowpath length of 450 mm (18").

In some multi pass designs this may cause problems with meeting minimum manway
dimensions. In such cases this should be discussed with the owner..

2.2.6 Trays with three or more passes shall be provided with vapour and
liquid balance ducts.

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Column Internals PAGE 2
 These are tubes or ducts that connect the different vapour flow areas such that
pressures over the columns are equalised. The design should be discussed with BP.

2.2.7 Trays shall be designed to handle the vapour and liquid loads given on
the tray data sheets. Standard sieve tray performance data shall be
specified on an FRI basis.

It is recognised that proprietary trays using sieve decks will be designed according
to the manufacturer's own procedures and in this case the basis used for
calculating jet flood, entrainment, maximum sustainable loading and downcomer
backup shall be provided to the purchaser.

2.2.8 Where the column is to be used offshore it may be subject to sway. In

such cases the trays should be designed such that they operate
satisfactorily within the sway tolerances approved by BP.

In the absence of stated tolerances, a sway of ±0.5 degree may be assumed in

addition to the conventional fabrication tolerances used although it will be
necessary to consider motion in all six axes and, to some extent, the accelerations
and periods of motion. It is the responsibility of the manufacturer to ensure that
the hydraulic design meets these criteria.

2.2.9 No sieve tray shall be designed for more than 80% (FRI basis) of jet
flood. Where sieve trays are used for vacuum service a maximum of
75% (FRI basis) of jet flood shall be used. No valve tray shall be
designed for more than 85% of jet flood. Where valve trays are used
for vacuum service a maximum of 77% of jet flood shall be used.

2.2.10 Downcomer clear liquid back-up shall be limited to a maximum percent

of tray spacing plus weir height as listed below:-

Downcomer Backup Criteria

System Pressure Maximum %
Liquid Backup
barg psig
< 2.0 < 30 60
2.0 to < 5.5 30 to < 80 55
5.5 to < 10 80 to < 150 50
10 to 14 150 to 200 45
> 14 barg > 200 40

2.2.11 Where the design liquid loading on a straight segmental overflow weir
would be less than 0.9 litre/min. cm (0.6 USGPM/inch), 'picket fence'
type overflow weirs shall be provided. The minimum horizontal
distance between pickets shall be 50 mm (2"). The minimum vertical
height of picket above the weir shall be 150 mm (6"). The effective
weir rate at normal design flows shall be no less than 0.9 litre/min. cm
(0.6 USGPM/inch).

GS 146-1
Column Internals PAGE 3
2.2.12 If the method of weir attachment is such that gaps could be left
between the weir plate and the shell wall and/or between the weir plate
and the tray weir edge, slide plates shall be provided to seal these gaps.

2.2.13 For sloped or stepped downcomers, the bottom downcomer area must
not be less than 50% of the top downcomer area.

In many cases the difference will be 20-40%.

2.2.14 Side downcomers shall be no less than 150 mm (6") in horizontal

distances from the column shell. This distance to be measured at the
centre line of the downcomer perpendicular to the inside face of the
downcomer.

Capsulated downcomers are exempted from this specification. The spacing

between interior downcomers on proprietary multi-pass trays is often small, but
these are acceptable.

2.3 Materials and Thickness

2.3.1 The minimum design thickness of tray components shall be as follows:-

Thickness Thickness
Material mm nearest Material mm nearest
gauge gauge
Carbon steel 3 mm 10 Aluminium 2 mm 14
Stainless steel 2 mm 14 Nickel Alloys 2 mm 14
Monel 2 mm 14 Hastelloy 1.5 mm 16
Copper 2 mm 14 Zirconium 1.5 mm 16

2.3.2 The thickness of pressed alloy steel bubble caps and the riser thickness
shall not be less than 1.5 mm (0.059") and 2.0 mm (0.079")
respectively.

2.3.3 The thickness of proprietary valve units shall be set by the manufacturer
based on process requirements for the tray.

2.3.4 More than one weight of proprietary valves shall normally be achieved
by using thicker gauge material. The spot welding of a single weight
on a standard valve is an alternative but in cases where severe corrosion
is anticipated any weights shall be fully seal welded.

2.3.5 In all cases proprietary valve units shall be manufactured from

corrosion resistant material for the intended duty and stainless steel is a
minimum requirement.
Carbon steel valve units should never be used.

GS 146-1
Column Internals PAGE 4
2.3.6 Tray rings and downcomer bolting bars shall be in the same material as
the vessel. Tray rings and downcomer bolting bars for clad or lined
vessels shall be in the same material as the vessel cladding or lining,
subject to thermal stress limitations.

2.3.7 The dimensions of the tray support rings and downcomer bolting bars
shall be provided by the manufacturer.

The following minimum and maximum dimensions shall be used:-

Minimum excluding
Ring
Column ID Width thickness corrosion Maximum
allowance Thickness
mm mm Corrosion Other
resistant material
material
mm ins. mm ins. mm ins.
less than 900 40 6 0.24 6 0.24 15 0.59
901-1800 50 6 0.24 6 0.24 15 0.59
1801 - 3500 65 6 0.24 6 0.24 15 0.59
3501 - 6000 75 6 0.24 10 0.39 20 0.79
above 6001 100 6 0.24 10 0.39 20 0.79

2.3.8 Vessel Corrosion allowance shall apply to all surfaces of welded-on

items in contact with the process fluids.

2.3.9 Vessel Corrosion allowance shall apply to one side of all removable
support beams. Vessel Corrosion allowance does not have to be
applied to replaceable/removable tray parts.

2.3.10 For trays of corrosion resistant materials all bolting shall be of the same
material as the removable internals with which it is connected .

2.3.11 Monel valve trays are prohibited.

2.4 Structural Details

2.4.1 Loose beams unsupported by shell brackets are not acceptable.

In the context of deck support beams, a loose beam is defined as a completely

separate member whose position is maintained only by tray to support ring clamps
and tray to beam clamps.

2.4.2 Certain larger diameter columns will require support beams that are
distinct members separate from the stiffened tray sections. These

GS 146-1
Column Internals PAGE 5
 separate beams, whether rolled joists or channels, shall be securely
restrained against vertical and horizontal movement.

2.4.3 At least 360 mm (14") clearance shall be maintained between the

bottom of the beams and the tray deck below when the main beams are
located at right angles to the liquid flow direction on the tray below.
This applies to both integral stiffeners and separate beams. Beams
running parallel to the liquid flow on the tray below are not subject to
the clearance requirement.

2.4.4 The design load shall include the weight of the internal element (with its
corrosion allowance) plus the following uniform downward loads at
design temperatures.

(a) Fractionation trays. The greater of 1470 N/m2 (150 kg/m2, 30

psi) or the weight of water 50 mm (2") over the highest weir
setting.

(b) Areas under downcomers. The greater of 2940 N/m2 (300

kg/m2, 61 psi) or a head of water one half the height of the
downcomer.

(c) Draw-off pans. The greater of 6865 N/m2 (700 kg/m2, 143 psi)
or a head of water to the top of the pan.

(d) Total draw-off trays. The greater of 6865 N/m2 (700 kg/m2,
143 psi) or a head of water to the top of the vapour riser or the
overflow weir.

(e) Baffle tray with a weir. The greater of 6865 N/m2 (700 kg/m2,
143 psi) on the projected area or the weight of water 50 mm
(2") over the weir height.

(f) Vacuum residue stripping trays where steam stripping is used.

An upward force of 49 N/m2 (5 kg/m3, 1.0 psi) shall be used.

Calculations shall exclude the corrosion allowance.

2.4.5 Stiffeners or a retaining device shall be provided on downcomers to

limit the horizontal movement of the bottom edge of the downcomer
when the bottom section of the downcomer exceeds both 250 mm
(10") in depth and 600 mm (24") in length.

2.4.6 Structural shapes or clips shall be provided along the bottom edge of
the downcomer to ensure proper clearance between the bottom of the
downcomer and the tray deck. The design and installation of these
shapes or clips shall be such as to not interfere with the liquid flow

GS 146-1
Column Internals PAGE 6
 exiting from under the downcomer. These clips may also be designed
to satisfy 2.4.5.

2.4.7 Adjustable weirs are not acceptable unless specifically required by the
project.
The specification of adjustable weirs is now an uncommon practice due to the ease
with which these can be incorrectly installed or otherwise maladjusted during
operations. The levelness of the tray therefore depends on the levelness of the tray
support ring and this requires an appropriate check.

2.4.8 Tray support rings shall be welded to the wall of the vessel to provide a
flat support for the assembled tray sections. The upper surface of the
tray support ring shall conform to the stated tray elevation. The ring
shall be level to within the tolerances given in 2.10.4.

2.4.9 When the data sheet specifies a corrosive or vibrating service no

notched corners shall be provided. All corners shall be formed using a
5 mm (0.2") radius minimum; minimum bend radii shall be three plate
thickness.

2.5 Clamping and Bolting Arrangements

2.5.1 Downcomers shall be designed to ensure that no vapour by-pass will

occur. Where the downcomer is assembled in sections the top section
shall be bolted through at least two matching holes or horizontal slots
in the bolting bar and the plate. One clamp or bolt hole shall occur as
close to the end of each section as possible. Bolts or clamp pitch shall
be a maximum of 100 mm (4"). All bolt holes shall be sealed by
washers.

2.5.2 Where carbon steel decks are specified, the non-threaded components
of clamping assemblies may be fabricated from carbon steel. Threaded
components shall be compatible with the process requirements and the
bolting material shall be AISI 304 stainless steel as a minimum.

2.5.3 Where the decks are specified in stainless steel, the clamp assemblies
shall be fabricated from the same material.

2.5.4 The maximum pitch between clamps shall be 180 mm (7") in the tray
active area and 100 mm (4") on the downcomer bolting bars and,
where used, on the downcomer floor. Each separate tray and
downcomer section shall have a clamp located as close to each corner
as possible.

2.5.5 The bolting for attaching major beams shall be provided with double
nuts or equivalent device.

GS 146-1
Column Internals PAGE 7
2.5.6 Fasteners must not be welded to tray components.

2.6 Seal Welding

Where seal welding is required, for various tray sections please refer to
Section 4.4.

2.7 Manways and Access

2.7.1 Tray manways shall provide a minimum access opening size of 380 mm
x 600 mm (15" x 24").

2.7.2 Tray manways shall be removable from both above and below the tray,
unless access is only from one side. The bolting shall be designed for
positive closure orientation.

2.7.3 Tray manways shall be vertically aligned to allow maximum working

access.

This clause is given in order to ease maintenance. The growing legalisation to

stagger manways on alternate trays so that injury due to a fall is minimised may
become an important issue in some projects. Advice must be sought in cases of
dispute.

2.7.4 A tray manway shall be provided on each liquid pass.

2.7.5 Where practicable, access through an accumulator tray shall be via one
or more risers. The cap(s) covering the riser(s) concerned shall be
detachable.

Where a riser is used as a manway, its width shall not be less than 450
mm (18") in the longer direction and 380 mm (15") in the shorter
direction. The top of such a riser shall have a welded brim bar to
prevent injury to personnel. The maximum width shall be governed by
the need to provide an adequate number of risers to ensure good
vapour distribution.

2.7.6 Minimum inter-tray work space shall be 300 mm (12").

2.8 Gasketting

2.8.1 Gaskets shall not be used to seal the tray active area.

2.8.2 Gaskets shall not be used to seal horizontal downcomer plates and
bolting bar junctions and any baffling that may be used in the base of
the column.

2.8.3 Gasketted joints for total draw-off trays are permitted.

GS 146-1
Column Internals PAGE 8
 Where a stringent (Cat 1) leak test is required, gaskets may not be used as it is
impossible to achieve a suitably leak tight tray.

2.8.4 Gasket material shall not contain any asbestos and shall be an asbestos
substitute suitable for both the process fluid and steam, up to the vessel
design temperature.

2.8.5 The use of packing, cements, caulking, etc. to achieve liquid or vapour
tightness or for any other purpose is prohibited.

2.8.6 Tray spacing requirements shall be as follows:-

Tray location Spacing

Above top tray A minimum of 1.5 times the normal tray
spacing
Feed tray Normal tray spacing plus 150 mm (6 in)
whichever is the greater.
Shell manhole Manhole internal diameter plus 150 mm (6
in) or the design tray spacing, whichever is
greater.

The feed tray spacing should not be less than 600 mm (24").

2.9 Drainage

2.9.1 Trays shall have drain holes only where items, e.g. bubble caps, giving a
positive seal are used.

2.9.2 All seal pans and sumps shall have drain holes. Holes, where
appropriate, shall be located in the pan floor closest to the column
centre where appropriate to avoid vapour ingress into the downcomer
liquid.

2.9.3 For weir loads exceeding 1.2 m3/h.m3 (.5 USGPM/ft2) the drain hole
area should be based on 0.1% of the area to be drained. For lower weir
loads the basis should be 0.01%. Hole diameter should be between 5-
13 mm (0.2" - 0.5"), limited to a maximum of 2 holes per section.

2.9.4 Drain holes shall not be provided on trays or pans having a nozzle
positioned so as to allow complete drainage.

2.10 Tolerances for Fabrication and Assembly

2.10.1 The mean outlet weir height shall be set within ±2.5 mm (0.1") of the
specified value. The difference between the maximum and minimum
height dimensions shall not exceed 3.0 mm (0.12").

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Column Internals PAGE 9
2.10.2 When inlet weirs are used, the height tolerance shall be ± 3.0 mm
(0.12").

2.10.3 The under-downcomer clearance shall be set within + 3.0 mm (0.12")

or - 0.0 mm of the specified value.

2.10.4 Tray levelness and tray support levelness between high and low points
on the vessel circumference shall be:-

Column diameter Maximum out of level

mm ins. mm ins.
< 1000 41 3 0.12
1000 to < 1800 71 4 0.16
1800 to < 3500 138 5 0.20
+3500 138 6 0.24

2.10.5 The location of tray support rings shall be set within the following
specified distances:-

(a) ± 6 mm (0.24") from the reference plane with the maximum

high to low difference not exceeding 6 mm (0.24").

(b) ± 3 mm (0.12") top of support to top of adjacent support.

2.10.6 The maximum uncovered joint opening between tray sections shall be 5
mm (0.2") in the shorter direction and 25 mm (1") in the longer
direction. The sum total of the areas of uncovered joint openings on
any one tray shall not exceed 1% of the active hole area on that tray.

2.10.7 The minimum overlap between the support ring and the outside
diameter of trays, pans and similar items shall be 20 mm (0.8").

2.11 Vortex Breakers

2.11.1 Vortex breakers shall be fitted in all vessels at nozzles leading to pump
suctions. They are also required at all other pipe outlets where swirl
may interfere with the separating of phases, e.g. in the separation of
water in oil-water separators.

Vortex breakers may be of the cross type or grating type. The choice is usually
made according to the space available.

2.11.2 Vortex breakers shall be fitted to all internal pipes discharging liquid
from accumulator trays.

GS 146-1
Column Internals PAGE 10
2.12 Blanking on Sieve or Valve Trays

2.12.1 Blanking of active holes shall be achieved using flat plate blanking
strips bolted to the tray. Blanking strips shall be distributed uniformly
in the active area and should be between 40 mm (1.6") to 100 mm (4")
wide, so as to completely cover holes.

2.12.2 Blanking strips shall be installed at right-angles to liquid flow, covering

complete rows if practicable.

2.12.3 For trays using circular valves, valves shall be removed prior to
blanking.

2.12.4 Blanking shall not be used to adjust installed hole area to the specified
design value.

2.13 Tray Installation

2.13.1 The manufacturer shall supply an installation procedure for each type of
tray to be supplied to include tolerances for installation and cross
referenced with drawings.

2.13.2 When tray installation takes place with the vessel in the horizontal
position, the manufacturer shall supply an installation procedure which
takes account of the vessel diameter and the out of roundness of the
vessel in the horizontal.

All sections of the trays including tray manways shall be fitted when
traying takes place in the horizontal.

2.13.3 The manufacturer shall supply the following extra material to allow for
field losses during installation:-

(a) Bolt, nuts and washers 10%

(b) Tray clamps 3%

(c) Gasketting material 20%

Operational spares are not required.

2.14 Reflux Inlets

2.14.1 Refluxes shall enter an inactive tray area behind an inlet weir or false
downcomer acting as a seal dam. The inlet pipe shall be either an open
ended 'T' or a slotted branch distributor.

The choice will depend on the need to maintain a certain minimum exit velocity.

GS 146-1
Column Internals PAGE 11
2.14.2 The seal dam height shall be 50 mm (2") greater than the inlet pipe
nominal diameter up to a maximum dam height of 200 mm (8").

2.14.3 Branch pipe velocities shall be a maximum of 1 m/s (3.3 ft/sec) and slot
velocities a maximum of 2 m/s (6.6 ft/sec).

2.15 Feed Inlets

2.15.1 Liquid feeds shall enter through an open ended branch to discharge
vertically downward into the downcomer of the tray above the desired
feed location or via a slotted branch distributor discharging onto the
active side of the downcomer at the desired feed tray level.

It is recognised that a number of variations in design may be used. These should be

carefully reviewed.

A distributor shall be used when flashing of liquid in the downcomer

could result in premature flooding.

2.15.2 Two phase, vapour-liquid, feeds shall enter the tray zone via a slotted
branch distributor which discharges against a wear plate attached to the
downcomer bolting bars.

2.15.3 Wear plate thickness shall be a minimum 5 mm (0.2"); spacers shall be

provided to hold the wear plate off the downcomer.

2.15.4 Vapour inlets shall normally be a plain open inlet nozzle. The inlet
nozzle shall be oriented approximately at right angles to the flow of
liquid on the tray above.

2.15.5 For liquid feed pipes which cross the tray active area the minimum
clearance from the bottom of the pipe to the tray below shall be
350 mm (14").

2.15.6 High velocity (i.e. approaching sonic velocity) vapour inlet lines shall
be designed to dissipate the energy. The inlet pipe shall be sized to
limit the fluid velocity to a maximum of 70% sonic velocity. A
minimum straight run of 2 m shall be provided to the column entry and
the feed shall enter the tower tangentially. A hood shall be provided
extending at least to one quarter of the column circumference from the
column inlet point.

2.15.7 For high velocity inlets the minimum distance from the top of the inlet
pipe to the seal pan of the tray above shall be the greater of one pipe
diameter or 500 mm (20"). The minimum distance from the bottom of
the inlet pipe to the surface of any liquid below shall be the greater of
two pipe diameters or 600 mm (24").

GS 146-1
Column Internals PAGE 12
3. PACKED COLUMNS

3.1 General Arrangement

3.1.1 All non random packing elements, support grids or structures, and
distributor systems and hold down grids shall be of sectional
construction with sections removable through the column manways.
Column manways shall be provided at the distributor system.

3.1.2 When a lifting beam is not available within the column any component
section referred to in 3.1.1 shall have a maximum weight of 50 kg (110
lb.) and a maximum length of 3000 mm (118"). All other components,
excluding structural beams, shall have a maximum weight of 120 kg
(265 lb.) and a maximum length of 4000 mm (157").

When a lifting beam facility can be provided within a column the weight
and length restrictions shall be governed by the ability to install
sectional components with the vessel in the vertical.

The factors which govern the maximum weight/length are those necessary to ensure
safe working in a confined space.

3.1.3 Gravity distributors shall be provided as standard. Justification shall be

provided for any alternative offered.

The quality of the liquid distribution is the key factor to good packing performance.
More even liquid distribution can be achieved with gravity distributors. Particular
emphasis is necessary in distillation duties where efficiency is important.

3.2 Materials and Thickness

3.2.1 The standard material for all items referred to in 3.1.1 and random
packing elements shall be stainless steel. The specific grade of stainless
steel or alternative material shall be suitable for the process fluid.

Carbon steel may be suitable for the process fluids and carbon steel will not rust
less than stainless steel. Carbon steel is not recommended because of the
maintenance requirements. It is very difficult to prevent surface rust by excluding
air/water in a maintenance condition when column man entry is necessary.

3.2.2 The thickness of packing shall be specified so that the maximum

distortion of packing elements at the bottom of the tallest packed
height shall be no more than 2% of the corresponding standard
dimension.

Distortion under compression will effect both the efficiency and the hydraulic
capacity of a packing.

The thickness of packings shall be determined by the manufacturer and shall

conform to his current practice. This will depend on the grade, and therefore

GS 146-1
Column Internals PAGE 13
 rigidity, of the packing grade used. It is frequently 0.15 mm (0.006") but may with
some packing be as low as 0.1 mm (0.004") thick.

3.3 Structural Detail

The design load shall include the weight of the packing elements plus
the weight of the process fluid when the section is operating in the fully
flooded regime. The minimum process fluid at flood shall be taken as
equivalent to 10% of the packing volume.

3.4 Packing

3.4.1 The supply of random packing shall be made only on the basis of filling
a given column diameter to a given depth. The manufacturer shall be
responsible for the supply of sufficient packing to take account of any
settlement allowance or dimensional variations.

Column sections are often non-circular and the packing elements per unit volume
quoted by manufacturers are averages. The supply of additional packing at the
outset is more cost effective than the remedial work necessary to meet the specified
height. Packing performance is almost always expressed in terms of packed height.

3.4.2 The depth of packing for each bed shall be stated by the manufacturer
to provide the number of mass transfer stages required and to prevent
physical distortion of the packing in service.

3.4.3 The manufacturer of structured packing shall ensure that peripheral

sealing is provided at each layer to minimise vapour by-pass due to
column ovality, manufacturing tolerances, etc.

Peripheral sealing should be provided at each layer around the complete

circumference. The sealing medium should be in contact with both the column wall
and the packing. Visual inspection at installation will be required to check this.

3.5 Distributors - Gravity

3.5.1 The liquid distribution to the top of the packed bed shall be uniform
over the vessel cross section for the whole design operating range.
This uniformity of flow shall be maintained as the liquid impinges on to
the top of the packed bed.

3.5.2 The outermost liquid distribution points shall be placed as close as

practicable to the vessel wall and the following maximum dimensions
shall be used.

Random packing Structured packing Maximum distance from

nominal size surface area vessel wall
mm ins. m /m3
2 ft2/ft3 mm ins.

GS 146-1
Column Internals PAGE 14
 < or = 26 < or = 1.0 > 261 > 80 20 0.8
27 to 61 1.0 to 2.4 121 to 260 37 to 79 30 1.2
> 61 > 2.4 < or = 120 < or + 37 40 1.6
Grid type Use manufacturers
limit

The area irrigated by the distributor shall be a minimum of 95% of the

tower cross sectional area, as defined by a circle linking the outermost
distribution points.

Particular attention shall be given to ensure that flow from the

outermost orifices is not blocked by the presence of any other piece of
equipment in the column.

3.5.3 Distributors shall be provided with means of levelling.

3.5.4 The design of the gravity distributor and any associated parting boxes
shall allow them to be levelled to within the tolerances specified in 3.8.

3.5.5 Liquid supply to the parting box shall be so arranged that aeration of
the liquid in the box and liquid swirl shall be minimised.

3.5.6 Distributor design shall be subject to a minimum orifice diameter which

will be a function of the process fluid characteristics. This minimum
diameter shall not be less than 2 mm (0.08").

Despite best efforts to filter all liquid streams entering packed columns, industrial
fluids are not sufficiently clean to operate for prolonged periods with orifices below
2 mm (0.08") diameter. In many cases this chosen orifice diameter will be greater
than this minimum and must always be considered at the design stage, bearing in
mind the nature of the fluid being distributed and the process environment.

3.5.7 All orifices shall be formed with the punch exit on the liquid outlet side
of the distributor.

Small irregularities during manufacture are to be minimised near orifices so as to

minimise differences in exit flow rates. Where orifices are laser cut this clause
need not apply. Drilled holes should not be used other than in tube distributors.

3.5.8 The manufacturer shall provide within the distribution system a means
to minimise particulate fouling of the distributor and define the method
of cleaning such systems.
Even in the cleanest process duties periodic cleaning will be a requirement.
External filters on all liquid feed lines should always be provided and located as
close as is practicable to the feed point. The filters will extend the period between
cleaning.

3.5.9 Covers shall be provided on all final distributor channels.

GS 146-1
Column Internals PAGE 15
3.5.10 A minimum liquid depth of 30 mm shall be used in parting box or
distributor channels.

A minimum depth is necessary to minimise variations in head along the length of

the channels.

3.6 Distributors - Pressure

3.6.1 Spray nozzle distributors shall be designed so that the theoretical

coverage ratio is a minimum of 3 where the coverage ratio is defined as
the ratio of the total geometrical spray footprint area to the column
area. Nozzles shall be arranged so that there are no unirrigated areas.
Circular full cone spray nozzles shall be used.

The exact locations of nozzles to achieve the most uniform coverage is a function of
the characteristic of the particular nozzle selected. This is an area which should be
discussed with the owner.

3.6.2 Where ladder type distributors are selected, and where plain holes are
used, all internal burrs shall be removed which would otherwise affect
the liquid flowrate. Any pipe system shall have a vent hole to prevent
accumulation of vapour.

3.6.3 Feed pipework to the distributor shall be sized to limit the maximum
velocity to 1.5 m/s (4.9 ft/sec).

3.6.4 For fouling services the minimum free passage through the spray nozzle
shall be equivalent to a diameter of 3 mm (0.12").

In many cases larger free passages will be required.

3.6.5 External filters shall be provided to prevent passage of material that

might otherwise block the nozzle. The mesh size should be one third of
the nozzle free passage diameter.

3.7 Ancillary Equipment

3.7.1 All packed beds shall be provided with a bed limiter, the design of
which will be a function of the particular packing and distributor type
being used. In all cases the bed limiter design shall be such as to offer
the minimum possible coverage of the packing below. In this context
angle sections are not acceptable.

Where structured packing is used, any bars constituting the bed limiter
shall be orientated so that they do not lie along joins between adjacent
blocks of packing.

GS 146-1
Column Internals PAGE 16
 3.7.2 Support grids shall be such as to impose the minimum resistance to
vapour flow.

3.8 Tolerances

The elevation difference between low and high points in the gravity
liquid distributor shall not exceed 2 mm (0.08").

4. ACCUMULATOR TRAYS

4.1 General Arrangement

4.1.1 Accumulator tray risers shall be uniformly spaced over the tray.

The total riser area shall be consistent with the requirements of the column duty.
Thus in vacuum operation and operations where minimum pressure drop normally
is required, a maximum riser area is to be used consistent with the restraints
imposed by mechanical considerations.

4.1.2 Accumulator trays used for all vacuum columns and/or where all liquid
leakage has to be avoided, shall incorporate the following features:-

(a) chimney caps vee shaped.

(b) vapour emergence area at the pouring end, or ends, of the cap
shall be fully blanked.

(c) risers oriented to be parallel to the general flow of liquid across

the tray.

These requirements are made to minimise the possibility of liquid re-entrainment

and to minimise liquid residence time, a factor particularly required in high
temperature vacuum service.

4.1.3 Accumulator tray caps shall be oriented so that liquid pouring from one
cap shall not enter the vapour emergence area of an adjacent cap.

4.2 Manways and Access

4.2.1 Where practicable, access through an accumulator tray shall be via one
or more risers. The cap(s) covering the riser(s) concerned shall be
detachable.

Where a riser is used as a manway, its width shall not be less than
450 mm (18") in the longer direction and 380 mm (15") in the shorter
direction. The top of such a riser shall have a welded brim bar to
prevent injury to personnel.

GS 146-1
Column Internals PAGE 17
 The maximum riser width should be governed by the need to provide an adequate
number of risers to ensure good vapour distribution.

4.2.2 Where the height of a riser used as a manway exceeds 450 mm (18") an
internal rung ladder shall be provided as necessary, with strengthening
of the riser.

4.3 Structural Requirements

4.3.1 Major beams shall be attached by bolting to vertical brackets or foot

step brackets, welded to the vessel shell. Bolt holes in brackets or
beams shall be slotted to allow for thermal expansion of the beam.
Methods of restraint which rely on indirect fastenings are not
acceptable.

Other methods of restraint may be used providing that both horizontal and vertical
movement of the beam is limited to that strictly required to contain the effects of
thermal expansion.

4.3.2 The deflection of assembled deck sections at operating temperature

shall not exceed a value of 1/900 of the column diameter. Where a
corrosion allowance is used, the calculations for deflection shall be
made on the corroded thickness.

4.3.3 All elements shall be designed for a concentrated maintenance load of

150 kg (330 lb.) at any point on the installed assembly, based on the
allowable stress at 40°C (104°F). Calculations shall exclude the
corrosion allowance.

4.3.4 The design load shall include the weight of the internal element (with its
corrosion allowance) plus the following uniform downward loads at
design temperatures.

The greater of 6865 N/m2 (700 kg/m2, 143 psi) or a head of water to
the top of the vapour riser or the overflow weir. Calculations shall
exclude the corrosion allowance.

4.3.5 Allowable stresses for metals shall be as per the vessel code used for
the column design and construction, such as for example ASME Code
or BS 5500.

4.3.6 The distance between the upper edge of an accumulator tray riser cap
and the underside of the tray above or packing support above, shall not
be less than 300 mm (12"). When the riser is used as a manway the
minimum distance shall be 450 mm (18").

4.3.7 The manufacturer shall ensure that the trusses above the riser caps of
accumulator trays do not obstruct the flow of vapour from the risers.

GS 146-1
Column Internals PAGE 18
 Such structural members shall be oriented so that they are parallel to,
and whenever possible immediately above, the riser caps.

4.4 Seal Welding

4.4.1 All joints in seal pans and discharge pans shall be fully seal welded.
The minimum design thickness of seal pans and discharge pan
components shall be 3 mm (0.12"). Trays designated as total draw-off
trays shall be designed to have all seams continuously welded, including
seams in risers and the peripheral seal with the tray support ring.

Accumulator trays with clamps and bolting have often failed in service. The
presence of gasketting has often made failure more likely. Fully welded
construction has proved to be the solution to minimising failures. Long experience
has shown that provided the tray is designed for full seal welding, damage due to
thermal stresses will not occur even though there may be some minor localised
panel buckling.

4.4.2 Seal welding shall normally be using a continuous fillet weld above the
attachment and an intermittent weld below. Where the duty is specified
as corrosive, continuous fillet welds should be used above and below.

4.4.3 Welding operators and procedures shall be qualified in accordance with

the vessel code used for the column construction, such as Section IX of
the ASME Boiler and Pressure Vessel Code or BS 4870/4871.

4.4.4 All welding shall conform to BS 5500 or ASME Section VIII.

4.4.5 Accumulator trays shall be designed to be fully seal welded, including

the periphery. The peripheral support shall normally utilise a
conventional tray support ring welded to the vessel wall and not to any
cladding which may be present.

5. VESSEL FEATURES

5.1 Internal Pipes

5.1.1 Internal distribution pipes shall have flanged and gasketted connections
to facilitate installation and removal.

5.1.2 Internal piping shall be the same nominal alloy as the inside surface of
the vessel. For ferric, austenitic or high alloys, such as Inconels, the
minimum wall thickness shall be schedule 10 or 3/16th inch (4.7mm),
whichever is less. For carbon steel or low chrome steels, the minimum
wall thickness shall be schedule 80.

GS 146-1
Column Internals PAGE 19
 5.1.3 Internal flanges shall be ASME/ANSI Class 150 weld neck or slip-on
type unless otherwise approved. Internal flanges shall be of a
compatible metallurgy with the material specified for the internal pipe.
Internal flange bolting shall be sequentially tightened, and double nuts
used to prevent loosening.

5.1.4 When an internal distributor or sparger is of the 'bayonet' type, the

external flange shall be marked in such a manner that the position of the
slots or holes will be known from the outside of the vessel.

6. DESIGN, DELIVERY AND INSTALLATION

6.1 Design calculations

The results of the rating calculations and related mechanical data shall
be summarised on the data sheets. The information shall be furnished
to the owner's engineer for their review prior to commencement of
fabrication.

6.2 Drawings

6.2.1 The following dimensions shall be referenced to the tray floor and be
consistent with the process and mechanical data sheets:-

(a) Weir heights

(b) Clearance under the downcomers

(c) Splash baffles

6.2.2 Plan and elevation drawings shall be provided by the manufacturer for
approval by the purchaser before fabrication commences, indicating
materials specifications and all design and assembly dimensions. These
drawings should contain the following minimum design information,
where applicable, relating to every separate design section of the tower.

(a) clearance under the downcomer.

(b) inlet and outlet downcomer area.

(c) effective exit weir length.

(d) exit weir height.

(e) sieve hole diameter.

(f) valve type (reference number).

GS 146-1
Column Internals PAGE 20
 (g) valve thickness.

(h) actual number of sieve holes on valves.

(i) normal tray spacing.

(j) correct bolting torque requirements.

(k) level tolerances (distributors).

(l) fluid densities at operating conditions.

(m) maximum and minimum design liquid flowrates (distributors).

(n) elevation and orientation (in diagram) of the tray.

Note:- the above measurements shall apply to actual sizes as used for
process design, and not to measurements that might be used for
fabrication purposes.

6.2.3 One original transparency and two copies of each Final Fabrication
drawing shall be supplied to the Owner.

6.2.4 The orientation in degrees, and the elevation, shall be marked on all
drawings where appropriate.

6.3 Finishing, Handling and Storage

6.3.1 With the exception of packings, all items of equipment shall be marked
with a part number for identification and easy assembly. Like parts may
bear the same number. Supporting documentation will cross reference
between assembly procedures and drawings. Structured packing
elements shall not be individually marked, but only the housing
container. Items shall normally be marked by metal-stamping. For
materials subject to stress corrosion cracking these shall be marked
using an electric discharge pen (pyrograph) or equivalent.

6.3.2 A list with the part numbers of the items within the container shall be
provided both inside and outside all packing containers.

6.3.3 As far as possible the manufacturer shall pack containers so that

unpacking for installation shall be consistent with the order of
installation in the column.

GS 146-1
Column Internals PAGE 21
6.3.4 Structured packings shall be packed in weather proof boxes. Consistent
with standard box sizes, elements which make up complete vessel cross
sections shall be packed together for large diameter vessels.

6.3.5 Random dumped packings shall be packaged in bags, and shall be

clearly marked with the part number of the item.

6.3.6 Carbon steel parts shall be protected in a dry storage area. Austenitic
stainless steel components shall never be exposed to wetting by salt
water or salt spray. Protective packaging or a suitable removable
coating shall be used to prevent such exposure.

6.4 Testing and Inspection before Installation

6.4.1 One tray per type, including accumulator trays, shall be assembled in
the manufacturer's shop to the extent necessary to check dimensions.
Examination shall be by the purchaser or his representative.

6.4.2 All accumulator trays shall be subject to a water leak test at site. The
permitted leakage shall be as per the schedule below:-

Leakage Maximum acceptable

category Typical service rate of level drop
mm/h inches/hour
1 vacuum towers:-
lowest distillate 10 0.4
draw
2 vacuum towers:- 50 2.0
except category 1
3 all other columns 200 8.0

The water leak tests will be made (with drain holes plugged) at the overflow weir
height or chimney height, as applicable.

6.4.3 One gravity distributor per type as used for fractionation service shall
be tested with water in the fabrication shop before dispatch. Liquid
inlet means to the distributor parting box shall be the same as that to be
used in the column. The tests shall be performed at design maximum
and minimum flowrates as follows:-

(a) Measurement of the uniformity of flow from the parting box or

predistributor.

Samples should be taken from each part of the parting box that
discharges into a separate channel.

GS 146-1
Column Internals PAGE 22
 Acceptance criteria: Liquid distribution at 50% of the maximum design
flowrate, or a specified minimum design flowrate, to be within + or -
4% of the mean.

(b) Samples taken at no less than 10 random locations over the

cross-sectional area of the column according to the following
schedule:-

Approximate number of
Column diameter
holes from which liquid is
mm ins collected from each location
< 900 < 36 1
900 - 1800 36 - 70 5
> 1800 >70 10

Acceptance criteria. Liquid distribution at 50% of the maximum design

flowrate, or a specified minimum design flowrate, to be within ± 6% of
the mean.

(c) Measurement of liquid depth at each end and at the centre of

each channel.

Acceptance criteria: The distance between the liquid level and parting
box/channel/pan top must be a minimum of 10% of the parting
box/channel/pan depth. Under no conditions will an overflowing
system be accepted.

6.4.4 When a spray distributor is used for a VDU wash zone, or similar zone,
it shall be tested with water in the fabrication shop before dispatch.
Tests shall be performed at design maximum and minimum flowrates.
A nozzle inlet pressure versus flowrate relationship shall be derived.
Nozzle dimensions shall be checked against manufacturers data.

Acceptance criteria: At any pressure the flow shall be within 20% of

the stated catalogue value.

6.5 Testing and Inspection after Installation.

Weld spatter on downcomer bolting bars shall be removed to ensure a

flush seal.

In the event that the downcomer does not form a continuous seal with
the bolting bars, the downcomer shall be reassembled using a gasket.

GS 146-1
Column Internals PAGE 23
7. GUARANTEES

7.1 Mechanical

7.1.1 The manufacturer shall guarantee all items supplied by him against
defective material, poor workmanship, improper design and failure
within design loadings.

7.1.2 The manufacturer shall repair or replace free of charge any defective
material or workmanship found within the guarantee period.

7.2 Process

7.2.1 The manufacturer shall guarantee the ability to handle the vapour and
liquid loads over the specified operating range whilst retaining
efficiency, when hydraulic loadings are supplied by the purchaser.

7.2.2 The manufacturer shall guarantee the separation and the hydraulic
throughput when the process design and the hydraulic design is his
responsibility.

7.2.3 The manufacturer shall replace free of charge any new items required to
meet the process guarantees.

7.2.4 The manufacturer shall guarantee that the design and fabrication of
liquid distributors for packed columns will meet the criteria for
acceptance given in section 6.4.3 and 6.4.4.

7.2.5 Any modification necessary to meet the leak tightness qualification

given in section 6.4.2. shall be made free of charge by the
manufacturer.

8. REGIONAL ANNEX

8.1 USA

Where tray spacing is 915 mm (36") or greater an access ladder shall be

provided at each tray manway.

This is a requirement of BP's refineries in the USA which at the moment (Sept '95)
is not strictly required elsewhere.

GS 146-1
Column Internals PAGE 24
 APPENDIX A

DEFINITIONS AND ABBREVIATIONS

Definitions

Standardised definitions may be found in the BP Group RPSEs Introductory Volume.

gravity distributor: liquid distributor using only hydrostatic head

grid packings: ordered packing manufactured from cut out metal strips

manufacturer: manufacturer of column internals

owner: the operator of the column

pressure distributor: liquid distributor with pressurised head

random packing: packing manufactured as discrete elements distributed randomly

structured packing: ordered packing manufactured from pressed sheet metal sheets

Abbreviations

CS Carbon steel
FRI Fractionation Research Incorporated
HF Hydrofluoric acid

GS 146-1
Column Internals PAGE 25
 APPENDIX B

LIST OF REFERENCED DOCUMENTS

A reference invokes the latest published issue or amendment unless stated otherwise.

Referenced standards may be replaced by equivalent standards that are internationally or

otherwise recognised provided that it can be shown to the satisfaction of the purchaser's
professional engineer that they meet or exceed the requirements of the referenced standards.

British Standards

BS 4870 Approval Testing of Welding Procedures

BS 4871 Approval Testing of Welders Working to Approved Welding Procedures

BS 5500 Unfired Fusion Welding Pressure Vessels

BS 5750 Quality System for design, development, production installation and Part 1
servicing.

American

ASME Section V111 Pressure vessels, Division 1 and Division 2

Section 1X Welding and Brazing Qualifications

GS 146-1
Column Internals PAGE 26