How Do Engineers Prepare Tower Internal Replacement Data for a Revamp Project?
Replacing tower internals in an existing packed tower is different from designing a new tower.
In a revamp project, engineers must work with existing equipment limitations, including:
- Existing tower dimensions
- Available installation access
- Current internal arrangement
- Actual operating conditions
Insufficient project information can lead to:
- Incorrect internal design
- Installation difficulties
- Fabrication changes
- Project delays
Therefore, collecting accurate replacement data is one of the most important steps before starting a tower revamp project.
Why Is Data Collection Important for Tower Internal Replacement?
A replacement project must consider both:
Existing Tower Conditions
Such as:
- Tower diameter
- Manway size
- Internal supports
- Existing damage
and:
New Operating Requirements
Such as:
- Higher capacity
- Better efficiency
- Different process conditions
A new internal design must fit the existing tower while achieving the required performance.
What Information Should Engineers Prepare Before a Revamp Project?
1. Tower General Information
Engineers should provide:
- Tower name or service
- Tower inside diameter
- Tower height
- Number of packed sections
- Installation location
This information helps suppliers understand the overall equipment configuration.
2. Existing Internal Arrangement
Existing drawings are extremely valuable.
Engineers should provide:
- Internal layout drawings
- Packing support arrangement
- Distributor location
- Redistributor position
- Mist eliminator position
This allows suppliers to evaluate:
- Replacement feasibility
- Installation method
- Required modifications
3. Manway and Access Information
Installation access is critical for revamp projects.
Engineers should provide:
- Manway size
- Manway location
- Internal access limitations
- Available lifting conditions
This affects:
- Segment design
- Component size
- Installation sequence
4. Existing Packing Information
If replacing packing, engineers should provide:
- Current packing type
- Packing size
- Material
- Packing height
- Operating history
This helps evaluate:
- Whether the existing design was suitable
- Whether a higher-performance alternative is possible
5. Operating Data
Actual operating conditions are essential.
Required information may include:
- Gas flow rate
- Liquid flow rate
- Pressure
- Temperature
- Fluid composition
Without operating data, it is difficult to evaluate:
- Hydraulic performance
- Capacity limitation
- Material requirements
6. Current Performance Problems
Engineers should describe why the revamp is required.
Common reasons include:
Capacity Limitation
Examples:
- Cannot increase production
- Flooding occurs earlier
- High pressure drop
Efficiency Reduction
Examples:
- Product quality decreased
- Separation target cannot be achieved
Mechanical Problems
Examples:
- Corrosion
- Internal damage
- Packing collapse
How Do Engineers Evaluate Existing Tower Internals?
1. Check Internal Condition
Engineers review:
- Corrosion
- Deformation
- Fouling
- Damage
2. Review Hydraulic Performance
Important parameters include:
- Pressure drop
- Flooding tendency
- Gas-liquid distribution
3. Compare Original Design With Current Operation
Engineers evaluate:
- Original design capacity
- Current operating conditions
- Process changes
This helps identify whether the problem comes from:
- Equipment limitations
- Operating changes
- Internal degradation
What Data Is Needed for Different Tower Internal Replacements?
Packing Replacement
Required:
- Tower diameter
- Packing type
- Packed height
- Support condition
- Operating data
Distributor Replacement
Required:
- Liquid flow rate
- Tower diameter
- Installation height
- Existing support arrangement
Mist Eliminator Replacement
Required:
- Gas flow rate
- Droplet requirements
- Available installation space
- Material requirements
Support Grid Replacement
Required:
- Packing weight
- Tower diameter
- Existing support structure
- Loading requirements
Common Mistakes During Tower Revamp Preparation
Starting Fabrication Without Checking Existing Drawings
Old equipment drawings may not fully represent actual site conditions.
Providing Only Product Requirements
For example:
“I need a new distributor.”
is not enough.
Engineers need:
- Tower size
- Flow conditions
- Installation limitations
Ignoring Installation Restrictions
A component may perform well but cannot be installed through the available access.
Replacing Only One Component Without Checking the System
Packed tower performance depends on:
- Packing
- Distributor
- Support system
- Mist elimination
The complete system should be evaluated.
What Information Should Be Included in a Tower Internal RFQ?
A complete RFQ should include:
Equipment Information
- Tower drawing
- Diameter
- Manway information
- Existing internals
Process Information
- Gas flow
- Liquid flow
- Temperature
- Pressure
- Chemical composition
Performance Requirements
- Capacity target
- Efficiency target
- Operating problems
Project Requirements
- Material requirement
- Inspection requirement
- Delivery schedule
- Installation limitations
How DAIER Supports Tower Revamp Projects
DAIER supports existing tower replacement projects including:
- Random Packing Replacement
- Structured Packing Replacement
- Liquid Distributor Upgrade
- Redistributor Replacement
- Packing Support Grid
- Hold-down Grid
- Mist Eliminator Replacement
- Tower Internals
For revamp projects, engineers can provide:
- Existing tower data
- Installation conditions
- Operating problems
- Performance targets
DAIER can support engineering evaluation and customized fabrication based on actual tower conditions.
Specs and test data available upon request.