DOC. NO.

: VD-MS-002-01-012

CONTRACT NO. :
ARL/HEC/ISOM(DHDS)-
PPE/8114-02(05) OFSR /2013

Document Title: Installation Instruction

Project Document No.: VD-MS-002-01-012

ITEM: COLUMN INTERNALS VENDOR DATA STATUS

□1 : APPROVED
OWNER: Attock Refinery Limited □2 : APPROVED AS NOTED
□3 : NOT APPROVED
CONTRACTOR PO NO.: □4 : INFORMATION ONLY
ARL/HEC/ISOM(DHDS)-PPE/8114 NOTE: Permission to proceed does not
-02(05) OFSR/2013 constitute acceptance of approval of design
details, calculations, analysis, test methods or
materials developed/selected by the Supplier
and does not relieve the Supplier from full
compliance with contractual obligations..

REVIEW DATE :
ENGINEER LEAD ENGINEER

0 2014-03-13 FOR CONSTRUCTION T.L.LEE J.P.SONG Y.B.YUN

A 2013-11-21 FOR APPROVAL T.L.LEE J.P.SONG Y.B.YUN

REV DATE DESCRIPTION PREP CHKD APPROVED

AMT PACIFIC CO., LTD.

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INSTALLATION INSTRUCTION
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ADVANCED MASS TRANSFER TECHNOLOGY
for Column Trays Page 2 of 13

CONTENTS

1. Scope
1.1 General
1.2 Health and Safety Precautions

2. Preparation of Installation Work

2.1 General
2.2 References
2.3 Storage & Carrying of Parts
2.4 Bolting Assembly
2.5 Cleanness of Tray and Vessel inside

3. Installation Work Procedure

3.1 Starting of Procedure
3.2 Check of Tray Support welded to vessel shell
3.3 Installation Work Procedure on Each Tray
3.4 Installation of other trays

4. Inspection
4.1 Level of Tray Floor
4.2 Level of Outlet Weir & Downcomer
4.3 Dimensional Inspection
4.4 Visual Inspection

5. Final Check and Cleaning

6. Inspection Record

Appendix A-1 : Tolerance List

A-2 : Illustration for Notation in Tolerance List
A-3 : Sample sheets of Inspection Report of Column Trays
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ADVANCED MASS TRANSFER TECHNOLOGY
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1. SCOPE

1.1 General

This instruction covers general requirements for field installation of AMTP sectional
trays and the other column internals except cartridge trays and reactor internals.

1.2 Health and Safety Precaution

- Same as para. 2.3.6)

- Same as para. 2.5.3)
- Same as para. 3.2.1)

2. PREPARATION OF INSTALLATION WORK

2.1 General

A set of AMT Pacific’s installation drawings including a part list drawing is furnished
with each shipment.

All component parts of trays shall be installed in accordance with drawings

concerned and within tolerances indicated Appendices A-1 and A-2. Prior to
commencing installation work the following shall carefully be performed :

- Review over all drawings concerned in order to confirm all marks, kinds,
and quantity of parts, position and direction to be placed, and method of
installation work.

- Confirm the number of parts delivered, according to "Packing List".

- If any questions are found, they shall be solved with direction of supervisor.

2.2 References

The drawing to be used for installation of trays consists of the following :

1) "Tray Installation Layout " drawings provides general installation information,

such as tray part nomenclature installation notes, gasketing location (when
required), whole layout, and shows various installation assembly details for
joint portions of tray parts and installation numbers.

2) "Tower attachment" drawings show the supports welded to vessel where tray
parts will be installed.

3) "Parts list" & “Bolting Assembly “ drawing lists :

- All of the various parts that make up the completed trays.

- All assemblies details with each description.
- Assemblies chart with quantity of each assembly for each type of tray.
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2.3 Storage and Carrying of parts

1) Small parts such as bolts, nuts, washers, clamps, and seal plates shall be
stored in order that they may be used immediately when required.

2) Large parts such as tray floor plates and downcomers shall carefully be
classified into each group of same kind of parts and stored in good order.
Those large components shall be stored and handled carefully so that they
shall not be deformed or damaged.

3) Do not stack Valve Deck Sections face to face, as the valve units will interlace
and the deck sections can not be separated. Use care in handling valve deck
sections to prevent from bending the legs of valve units. Till the completion of
the tray installation, the valve units of the tray shall be made to move freely,
but shall be kept from separation.

4) During installation work, all small parts of trays shall be carried with suitable
container.

5) Parts shall not be left alone on the ground around the tower.

6) Lifting work of internal parts into tower shall be carefully performed so that
container or parts of internals do not fall down during the work.

7) Parts shall be cleaned and free from dust, sand, slug, and other foreign
materials, when inserting them into tower.

2.4 Bolting Assembly

1) Do not over torque bolting. Recommended torque of M10 (3/8") tray bolting
is 7 through 11-Ft-1b (1.0 through 1.5 Kg-m). Torque should be reduced by
3-4 foot pounds (0.4-0.55 Kg-M) for softer material such as aluminum.

2) It is strongly urged that all bolts or nuts be oiled before installation.

This prevents galling of the threads during installation and makes possible
the removal of threaded bolts at some future maintenance period.

3) Care should be taken to use the proper length bolts, proper clamps, and
size of washers or other hardware at the various places on the trays as
called for on the drawings. Misuse of the hardware items could results in
undue shortages, and could cause delays in completion of tray installation.

4) For speedy installations use air or electric bolt or nut drivers with torque
control. (bolts must be oiled)

2.5 Cleanness of Trays and Vessel inside

1) Tray installation works inside of vessel shall wear clean clothes and shoes
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to keep cleanness of tray and vessel inside. Do not work in wet inside vessel.

2) Before starting the tray installation, provision shall be made to prevent any
articles from dropping inadvertently into the bottom nozzles.

3) It is recommended that tray installers working inside vessel do not have

any unnecessary things in his pocket such as coin, excessive bolts and nuts,
and a tiny foreign materials to prevent fall down during installation.

3. INSTALLATION WORK PROCEDURE

3.1 Starting of Installation

1) It is recommended that a tray be set up on the ground before actual installation

of the tray is started in the tower. This will very helpful in familiarizing the
workmen with the tray design and location of the various parts.

2) Tray installation should be started from bottom side to top side of tower in
general so that the installers will have head room in the process of installing
the tray. Tray installation can also be started at other elevations in the tower if
proper safety precautions are taken to protect the tray installers at the lower
level.

3.2 Check of Tray Support welded vessel shell

1) Before starting the trays installation, tray support ring shall be cleaned and free
from dust, sand, slug and other foreign materials before installation of tray
parts.

2) The dimensions of tray supports shall be checked before installation of trays.

3) Level of support rings shall be checked using a manometer at least at four

points. The level tolerances shall be within the value specified in Appendix
A-1, unless otherwise specified.

3.3 Installation Work Procedure on Each Tray

1) Major Beam

When major beams are used for large diameter tower trays, install these first.
The level and twist of beam shall be checked at ground before installing into
tower.

a) Generally, the beams are bolted to foot rest and/or bolting clips welded to
the tower wall.

b) Check for correct installation of the beams before installing the other parts.
The top surface of the upper beam flange should be in plan with the top of
the tray support ring. The location of beam with respect to thediametrical
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distances from tower wall and/or between beams should be checked

before tightening.

c) Care should be taken to prevent the beams fall down during installing.

2) Downcomer

Start the installation of downcomers from the bottom side, keeping the
clearance between the downcomer and the tray below. Then tighten
the bolts temporarily to the clamping bars.

3) Downcomer Truss

Place both ends of the outlet weir portion of downcomer truss onto the
support ring taking care to coincide with connection bolt holes.
After checking their correction :

a) Tighten the through bolts on the outlet portion to the clamping bars,

b) Tighten the through bolts on the downcomer truss portion to the

clamping bars,

c) Tighten the clamping bolts on the downcomer to the clamping bars,

d) Tighten the through bolts on the joggled portion of downcomer truss

to the downcomer.

4) Tray Floor

a) Tray floors shall, at first, be tightened (slightly) temporarily with clamps

and bolts on the connections for tray floors to support ring, tray floors to
downcomer, and tray floors to tray floors.
b) Care shall be taken so that tray floors are not to be in a twist or strain due
to the peripheral tray clamps being too tight.

c) Trays should be packed (gasketed) only as called for on the drawings.

d) After checking their corrections, tighten the bolts on the connections for
tray floors to tray floors and tray floors to downcomer.

5) Manway

All parts of trays shall be completely installed and inspected with

the exception of installation of tray manways.
Afterwards manway shall be installed.
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3.4 Installation of other trays

1) Bubble Cap Trays

a) Bubble caps shall be installed on the bubble decks in the manner

specified on the applicable drawings before installing the tray decked
inside tower.

b) Adjustment of bubble cap clearances shall be done in accordance

with the job specification and /or applicable drawings.

c) Do not over torque the bolting of the cap. The torque recommended
with 3/8” cap bolting are 6 ~ 8 ft-lb, unless otherwise specified.

2) The other internals than trays such as draw-off pans, accumulators, chimney
trays, feed distribution pipes, baffles, etc. shall be installed individually to each
component, depending upon the position, orientation, dimension etc. according
the applicable drawings.
In general, it is preferred to have such components installed before laying out
the tray decks, where possible, unless they are located apart at top or bottom of
the tower.

4. INSPECTION

The following items shall be inspected and recorded during and after assembling.

4.1. Level of tray floor

The level of tray shall be checked using a manometer at five points

(Min. One at middle and Min. four at corners) to each pass. (Refer to Fig.1)

WATER DEVICE

SCALE

TRANSPARENT PVC
TUBE REINFORCED
WITH STEEL WIRE

SINGLE FLOW TYPE DOUBLE FLOW TYPE

FIGURE 1
The maximum out-of-level shall not exceed the tolerance stipulated
appendix A-1 & A-2.,Part ‘A’.
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4.2. Level of Outlet Weir and Downcomer.

The level of outlet weirs and downcomers shall be checked using a manometer
at three points (both ends and center of outlet weir and downcomer) to each
pass. (Refer to Fig.2)

OUTLET WEIR
SCALE

TRANSPARENT PVC
TUBE REINFORCED
WITH STEEL WIRE

FIGURE 2
The maximum out-of-level shall not exceed the tolerance stipulated
appendix A-1 & A-2. ,Part ‘B’.

4.3 Dimensional Inspection for Downcomer.

In addition to the above, dimensional inspections for the following items

shall be made with a manometer steel ruler or suitable gauge against
the tolerance stipulated in Appendix A-1 & A-2.

1) Outlet Weir Height

The outlet weir height from the tray floor shall be measured at three
points (Same as para. 4.2 above) to each pass. (Refer to Fig.3)
This shall also apply to the measurement of the outlet weir height for
the seal pan.
OUTLET WEIR
SCALE

DIMENSION TO BE MEASURED

FIGURE 3

The maximum deviation from the specified height shall not exceed the tolerance
stipulated in Appendix A-1 & A-2.,Part ‘D’.
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2) Clearance Between the Outlet Weir and Downcomer

The difference in height between the top edge of the outlet weir and
the bottom edge of the downcomer shall be measured using a manometer
at three point both ends and center of outlet weir and downcomer.

OUTLET WEIR DOWNCOMER

TRAY FLOOR

DIMENSION TO BE MEASURED

FIGURE 4

The maximum deviation from the specified height shall not exceed the
tolerance stipulated in Appendix A-1 & A-2.,Part ‘C’.

4.4 Visual Inspection

Visual inspection shall be made for the flatness of tray floor. Correct use of
clamping devices, etc. Tightness of bolts shall be made using hammering.

5. FINAL CHECK AND CLEANING

5-1 Final check

After all inspection described in Para. 4 and the corrective work have been
completed, all assembled trays and other internals shall be checked visually.

5-2 Cleaning

All trays and other internals assembled shall be cleaned and dirt, loose
scale, slag, and any parts of tools, etc. shall be removed from inside of
the tower.

5-3 Assembly of Manway Floor

Manway floor shall finally be assembled after all inspections and the
cleaning have been satisfactorily accepted by the owner.

5-4 Closure of Tower Manhole

After assembling the manway floors, the tower manhole shall be closed
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ADVANCED MASS TRANSFER TECHNOLOGY
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under witness of the owner.

6. INSPECTION RECORD

The results of following inspections shall be recorded.

1) Level Measurement

a）Tray floor
b）Outlet weir
c）Downcomer

2 ) Dimensional Measurement

a）Outlet weir height

b）Clearance between outlet weir and downcomer

3) Sample sheets of inspection record for tray and packed column internals
are attached. Other forms may be used with agreement of tray installation
supervisor if necessary.
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APPENDIX A-1

ACCEPTABLE
PART DESCRIPTION TOLERANCE
(mm)

I.D of tower up to 1800 ±3

Level of
A over 1800 to 3600 ±4.5
tray floor
over 3600 ±6

Level of I.D of tower up to 1800 ±3

B outlet weir and over 1800 to 3600 ±4.5
downcomer over 3600 ±6

C Clearance between outlet weir and downcomer ±3

D Outlet weir height ±1.5

E Clearance under downcomer ±3

F Distance from outlet weir to tower wall or Downcommer width ±10

G Bottom of downcomer above seal pan ±3

H Tray Space between tray deck and tray deck ±3

Horizontal clearance
I.D of tower up to 3600 ±3
I between downcomer and
seal pan
over 3600 ±4.5

I.D of tower up to 1800 ±3

Level and flatness of
J over 1800 to 3600 ±4.5
Support ring
over 3600 ±6

Note :

1) Level and flatness of the tray floor shall be measured at each tray pass.

2) Tolerance of level and flatness of the tray floor shall be the above value or
twenty percent of the outlet weir height, whichever is smaller.
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APPENDIX A-2
ILLUSTRATION FOR NOTATION IN TOLERANCE LIST

D
J

H
B A

E
I
C
G

SINGLE FLOW TRAY

D

F B
J A
C

H
E

I
C
G

DOUBLE FLOW TRAY

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APPENDIX A-3

SAMPLE SHEETS OF INSPECTION REPORT OF COLUMN TRAYS

Z
X X
A
D
E

F
G

PACIFIC CO., LTD.

ADVANCED MASS TRANSFER TECHNOLOGY
SEOUL, KOREA

Customer :
TOWER INTERNAL INSPECTION REPORT Date : , .
Project Name :
Name of Equipment :
(TRAY TOWER)
and Identification Job No. :

D EG F Down H B Z A
Weir Height Downcomer -comer Level on
from Clearance Width Tray Weir Tray Level on Tray Deck
Spec Tray Deck Spec Spec Spec Spac- 1 2 3 Max Spec Dia- Max
(4) (5) (6)
No. ing Diff. mete. Diff.
1 3 10 12 1 3 10 12 2 11 10 11 12
(4) (6) (7) (9) (4) (6) (7) (9) (5) (8) (7) (8) (9) 1 2 3 4 5 6 7 8 9 10 11 12
12
13
14
15
16
17
18
19
20
21
22

Z
X X Gauge Point
A

F Record by Signature
D

Y Y 10 7 4 1 10 7 4 1 Date
H

B Supervisor Signature
11 8 5 2 11 8 5 2
E

Date
12 9 6 3 12 9 6 3
F
C
G

Customer Signature
Date
View X-X View Y-Y

DUUBLE FLOW PASS TRAYS PACIFIC CO., LTD.

ADVANCED MASS TRANSFER TECHNOLOGY
SEOUL, KOREA