Swan Enterprises Private Limited
EIL Job No. - B018-911-CT-PR-6870-0308
Petrochemical Expansion Project at Bhatinda
JOB PROCEDURE
Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
TABLE OF CONTENT
Sr. No. Topic
1. Purpose
2. Reference
3. Safety
4. Responsibility
5. Storing/Handling of Parts
6. Tools and tackles
7. Pre-Shut Down Activities
8. Shut Down Activities
9. Welding of NEW TSRBB
10. Finishing and Cleaning
11. Inspection
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
Equipment Details
Column Description Number
Column Number Column ID Type of Internals Brief Scope of Work
of Trays
Sieve Trays and Installation of new
911-CC-2202 LP Depropanizer 3600/ 3000 50
Valve Trays Trays
Installation of new
911-CC-4001 Deethanizer 5300 Valve Trays 68
Trays
Installation of new
911-CC-4201 Debutanizer 3400 Valve Trays 44
Trays
Installation of new
Dilution Steam
911-VV-1401 5500 Valve Trays 3 Trays and associated
Drum
internals
Installation of new
912-CC-2702 ROG Depropanizer 4100/ 2400 Valve Trays 41
Trays
Butene Degassing Installation of new
930-CC-1008 762 Cartridge Tray 18
Column Trays
Hexene Degassing Installation of new
930-CC-1027 897 Cartridge Tray 18
Column Trays
ICAE Degassing Installation of new
930-CC-1421 433 Cartridge Tray 15
Column Trays
Installation of new
935-CC-9301 Recycle Column 1500 Valve Trays 26
Trays
Installation of new
935-CC-9302 Butene-1 Column 1100 Valve trays 20
Trays
Bubble cap Trays,
Installation of new
Caustic/ Water Valve Trays
911-CC-2101 6700 18 Trays and associated
Wash Tower Packing and
internals
associated internal
Installation of new
Ethylene
911-CC-4002 6200 UOP MD Trays 187 Trays and associated
Fractionator
internals
Installation of new
Extractive
915-CC-5501 2500 GT-OPTIM Trays 73 Trays and associated
Distillation Column
internals
GT-OPTIM, Installation of new
Solvent Recovery
915-CC-5502 2100 Packing and 17 Trays and associated
Column
associated internal internals
Installation of new
915-CC-5506 Benzene Column 2000 GT-OPTIM Trays 63
Trays
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
1. Purpose
The purpose of this document is to serve as a training material. In addition, an important purpose
of this document is to ensure consistency in site installation checking and review of installed
Trays and tower Internals. This is necessary so as to ensure that the requirements of approved
drawings are met, and equipment perform as per design specification
Mass Transfer products are made for specific requirements every case is unique. This document
produces a general guideline which is common for all. These common steps/procedures are
gathered to generate this manual keeping aim in mind for ease of control and use.
It is responsibility of Installation Vendor to ensure that all Components are fitted as per
drawings/Standard/Specification and 100% checked by Installation vendor’s Supervisor and
Engineer In-Charge. Records of installation and quality check shall be maintained by installation
vendor duly counterchecked by Engineer In-Charge as per the inspection report format.
Review by specialist shall be subsequently carried out.
2. References
All document in this manual need to be referred along with drawings prepared for the particular
job. Please obtain and refer following documents during the planning and execution stage of
installation work.
a) EIL Approved Drawing
b) EIL Standard 6-14-0003, 6-14-0007, 6-14-0008, 6-14-0009, 6-14-0011
c) UOP Fieldwork Procedure
d) Fieldwork Procedure
e) Packing List
f) Packing Slip
3. Safety
We at Swan firmly believe in that injury, occupational illness as well as environmental incidents
is preventable and safety of the employees, contract workers & all construction works has to be
taken care off. To achieve this, the company will effectively take the following steps
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
a) Company will be trying to reduce the possibility of accident occurrence and improve and
maintain safe environment
b) Work environment will be monitored, and safe & healthy working conditions will be
maintained.
c) Imparting relevant training of employees and contractors
d) Providing personal protective equipment like safety shoes, helmet, boiler suit and tool &
tackles to conduct all work in safe manner and to ensure integrity of assets.
e) No job will be considered being rightly done unless worker has followed the safety
precaution and rules to protect himself and his colleague.
f) Safety is an operating function and all levels of line management will have a primary
responsibility for implementation of safety program.
g) Communicating the learning points from investigations of incidents in similar industry to
all employees and taking steps to prevent such occurrence in its works
h) Identifying and evaluating health risk related to its operations and carrying out pre
employment and periodic medical checkup of its employees.
i) Keeping abreast of latest international codes, standards and practices and adopting the
same where applicable.
For HSE & Rescue Plan kindly refer documents submitted to EIL HSE dept.
4. Responsibility
The Site In-charge is responsible for day to day effective implementation of the procedure and
that all the relevant staffs are aware of their responsibility.
The Site In-charge is responsible of the quality of the works executed in the field and
therefore, for the proper application of this field inspection coordination procedure. He is to
be aware of the requirement of the company standard engineering procedure and to ensure
their implementation in the field. He is also responsible for timely submission of all QC
related documentation viz QAP/ITP etc.
The Site In-charge based on site is responsible for implementing the company Quality
Management System and ensuring implementation of all contractual quality requirements. He
shall assist the Engineer for the timely submission of Quality Documentation/ Deliverable. He
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
shall ensure all hold and witness points are adhered to and customer is given sufficient notice
for the inspection.
5. Storing/Handling of Parts
Large such as Tray Decks, Downcomers, Beams, Distributions Pipes etc. shall carefully be
stored and handled so that they shall not be deformed nor damaged.
Small parts such as bolts, nuts washers, clamps etc. shall be restored in suitable boxes or
containers with identification tags or markers, so that the necessary part can be found easily.
No parts shall be place directly on the ground.
6. Tools and Tackles
All lifting equipment (Web sling, Chain Block, Winch Machine etc.), Full Body Harness, Fall
Arrester, required for the job shall be approved by recognized TPI by Punjab Government
before starting of Job and same shall be conveyed to EIL/HMEL separately.
Electrical Tools Shall be certified by HMEL/EIL before start of Job and same shall be
conveyed to EIL/HMEL separately. Hand tools like Spanners, hammers etc. and all other
items will be physically inspected by our Safety and Execution team before starting of Job.
7. Pre-Preparation Activities
1. Gate Pass Arrangement -
Prerequisite - Accidental Insurance, Labor License, Police Clearance, Medical Fitness,
Fire and Safety Clearance of HMEL/EIL.
2. Receive Drawings and visit site.
3. Receive material, move materials to site and verify quantity of material received as per
packing list for each box in presence of Client Project Engineer and In case of any
damage and discrepancies immediately inform in writing to the Concerned Project
Management Team and Engineer.
Prerequisite – Packing list.
4. Study drawings and identify each piece of the tray/tower internal with the item number
w.r.t. its location on the General Arrangement Drawing ,Study inspection Sheet for
Support Ring and Installed Tray Levelness Record and scope of job in details, In case of
any deviation, Inform Concerned Team immediately.
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
Prerequisite - As Built Drawing/ Available Drawings from Client.
5. Arrangement of Power connection, Light, Air Exhaust Fan etc.
6. The GA Drawings provided shall be referred and mock up assembly shall be performed
for one odd and one even tray and shall be shown to the Client Project Engineer. Wooden
Spacer blocks can be created to be used later.
Prerequisite - As Built Drawing/ Available Drawings from Client.
7. Ensure that protective oil coating is removed from carbon steel tray/tower internal parts
prior to initiating installation of trays and tower internals in the tower. (For suggested
procedure for removal of linseed oil coating, refer clause 14.0 of this specification).
8. Installation Activities
1. Levelness of support rings & various dimensions of bolting bar welded to the tower shall
be checked and it shall be ensured that these are as per relevant drawings and within
specified tolerances. In case of any deviation observed, this would be reported to
EIL/HMEL. Levelness of support ring and other dimensions of bolting bar shall be
recorded in Format attached in EIL Specification No. 6-14-0016.
2. For UOP ECMD trays, inspection by Swan Team (Levelness of Support Rings,
Measuring Column ID at each ring at various orientations, Distributor Trough Support.
Piping Support Chimney Tray Supports and New Nozzle, etc) shall be done and
Inspection report shall be prepared. Report of levelness of each ring to be signed by
Client/EIL Project Engineer,
Prerequisite - Laser leveler, Measuring Tape, Inspection Report Format.
3. Installation of Winch Machine for material movement from Ground to manhole of
column.
4. Installation of Tray with Seal Pan.
Installation of Valve Trays
a. Installation of trays shall progress upwards from lowest in the column.
b. Lattice girder shall be Fitted/fully installed (including welding), if any.
c. After that seal pan below bottom tray shall be fitted and leak tested, if provided.
d. Major beam shall be fitted, if any.
e. Downcomer for bottom tray shall be fitted first.
Where no down comer support stools are provided
(a) First top section of downcomers for one tray shall be fitted by considering
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
following:
i) Level exit weir base (top) with top of support ring and/or support beam top
surface.
ii) Bolting securely in position.
(b) Fit bottom downcomer sliding plate into position, position bottom of plate in
downcomer support bracket while fitting on tray below. Check clearance under
downcomer bottom edge.
Where downcomer support stool is provided
(a) Place shims, as necessary, under top downcomer section to bring exit weir base
(top) exactly in level with support ring and/or lattice girder/major beam (if
provided) and then bolt downcomer sections including exit weir securely. Tack
weld/bolt shims in position.
(b) Fit bottom-sliding plate of downcomer in position in downcomer support bracket,
set clearance under downcomer plate within plus or minus 1/8" (3mm). The
clearance obtained should be maintained as near constant across the width as
possible
Downcomer Vent Tubes
(a) One top section of center/off-center downcomer shall be installed as stated above
and then position tube as per the drawings provided.
(b) Top section of opposite side downcomer shall also be fitted as stated above and
Again position tube as per the drawings provided .
(c) Place shims, as necessary, between vent tube flanges and tighten the bolts.
Use sufficient shims to fill the gap between vent tube flanges.
f. Then deck plates for bottom tray except man way deck plate shall be fitted. We
should start with placing tray decks one by one and keep all the clamps loose. When
all tray decks have been placed properly. The seating of tray decks on TSR,
Downcomer and Beam shall be checked. If any adjustment needed, it shall be done
and all the bolts shall be tightened except manway as it needs to be open for smooth
passage of man and materials. Manway shall be closed when column box up has to be
done. In case of revamp columns, mismatch may be experienced because of ovality of
column. In that case find out where dimensions mismatch are there, by comparing
measurement taken with given in GA Drawing. This will help in finding, which
section has to be modified to suit. Start placing the deck one by one and after placing
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
all the deck and sufficient adjustment at the junction, just mark the area need to be
modified and modify the section to suit.
g. Recessed seal pans shall be Leak tested after installation, wherever provided.
h. Lattice girder/major beam, if required, for tray on top of bottom tray shall be
Fitted/installed.
i. Downcomers for tray above bottom tray shall be fitted.
j. Beams and decks for tray above bottom tray except man way deck plate shall be
fitted. (However proper fitment of man way decks plate shall be ensured).
k. Each successive tray shall be fitted following the instructions stated as above.
l. All the foreign material shall be removed, and it has to be ensured that trays are clean
and unobstructed for proper performance.
Installation of Cartridge Trays
i. First Column is cleaned, and all rust and foreign particles shall be removed.
ii. Visual inspection of Surface finish shall be accomplished.
iii. Oil shall be applied on column inside wall for lubrication (If allowed by Client)
iv. Column ID shall be verified with template
v. Seal Pan shall be leak tested before assembly.
vi. All parts of cartridge tray shall be assembled at ground
vii. Stool position and orientation shall be marked on top of column.
viii. Whole cartridge tray assembly shall be lifted with suitable arrangement and align
with column opening.
ix. Tie rod shall be aligned with marking of stool at column opening.
x. Balancing and straightness of assembly has to be ensured for smooth passage
inside column.
xi. It shall be ensured that inlet pipe is facing inlet weir.
Use of Washer & Location of Nut
Unless otherwise specified on drawing, two washers (one on bolt head side & one on nut
side) shall be used for every bolt. The nut shall be provided towards the side accessible
from Tray man way. Lock nuts shall not be provided on clamp/bolting for Man way deck
plate. Nuts for supporting pipes (i.e. U clamps) shall be kept loose so as to have free
movement/expansion of the pipe.
5. Follow step 4 for all trays to be installed.
6. * Checking of levelness of tray after installation
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
7. * Inspection of Each Tray after Installation from UOP
8. Completion of installation of Trays
9. Installation of Other Tower Internals
a. Installation work shall progress upward from bottom most bed in the tower.
b. Lattice girder/major beam shall be fitted/ installed, if any.
c. Vapour distributor/chimney tray/accumulator tray shall be Installed completely
(including welding and leak testing), if any.
d. Support plate/ support grid shall be installed.
e. Then the tower shall be packed random packings in accordance with EIL spec. 6-14-
0011 titled "Specification for Packing the Tower".
In case bed is provided with proprietary packings/grid/structured packings, then the
instructions provided by the supplier shall be followed. Successive layers of
grid/structured packings may require to be rotated by specific angle as mentioned in
supplier's drawings / procedure for installation.
f. Bed limiter/hold down grid shall be installed wherever specified in drawings, in case
of random packings
Bed retainer/ distributor support grid shall be installed, in case of structured packings.
g. Distributor/redistributors shall install properly, Pan/trough type
distributor/redistributors shall be leak tested and spray header shall be hydro tested, if
specified, on the drawings.
h. Pre-distributor/feed pipe shall be fitted.
i. Instruction from point a to h above shall be repeated, for the next bed.
j. All the foreign material from respective tower internal shall be removed. It has to be
ensured that the same are clean and un-obstructed for proper performance.
10. Offering column for Post installation Inspection
11. Receiving clearance for closing of manway
12. Closing of manway and Handover of Column
9. Welding if required
Welding to be performed as per WPS and PQR
10. Finishing and Cleaning
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Swan Enterprises Pvt. Ltd.
49 & 50 Sidco Industrial Estate, Gummidipoondi - 601201 Tamil Nadu
Tel: +91-44-27922687 Telefax: +91-44-27921083
After all required tests and measurements and the correction work have been completed, all
Trays and associated internals shall be visually checked again.
All trays and associated internals shall be cleaned and all dirt loose scale, Oxides. Slugs,
oil and any parts or tool left behind shall be removed from inside the equipment.
Manway deck shall be installed after all test and inspection of trays and other internals and
cleaning is satisfactorily accepted by company representative.
11.Inspection
Inspection will be conducted as per approved ITP.
Note –
• * Activity required for ECMD trays particularly.
• The procedure and details given on this document are the property of SWAN
ENTERPRISES PRIVATE LIMITED. They are merely loaned on the borrower's
express agreement that they will not be reproduced, copied, exhibited or used, except in
the limited way permitted by a written consent given by the lender to the borrower for the
intended use.
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