Information in this paragraph are typical points to check on site during loading. Up-to-date inspection sheets will be provided on site by start-up manager.
UPPER TRAY INSTALLATION NOTES | TOWER INTERNALS
There are following installation notes and inspection points for Upper Tray of tower internals.
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UPPER TRAY PREPARATION BEFORE INSTALLATION
- Catapac removal and packing in dedicated boxes.
Catapac Trolley A & B removal. -
PANEL INSTALLATION
- Panel laying down on trestles at ground.
- Panel punch mark checking & cleanness inspection.
- Panel Upper & lower screen inspection at around.
- Panel nozzle closure with plastic caps.
- Neoprene sheet installation on panels.
- Panel lifting & laying down on beams.
- Panel positioning with metal spacers.
- Panel rocking detection / Shim plate tack welding.
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PANEL FIXING
- Panel Bolting.
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ROPE PACKING
- Panels – Shell – Center pipe Rope packing.
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UPPER TRAY SEALING
- Welding of Seal plates on panel frame.
- Welding of Seal Angles plates on welding rings of shell and center pipe.
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INLET BOX DISTRIBUTOR INSTALLATION
- Upper tray clearing out.
- Storage of manifold piping inside tower through top manhole.
- Inlet box distributor installation with gasket (scaffolding).
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UPPER PIPING MANIFOLD INSTALLATION
- Upper piping positioning / tack welding.
- Upper piping manifold welding / dye checking.
- Center pipe connection installation.
- Upper tray cleaning.
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CENTER PIPE / UPPER MANIFOLD PIPING / UPPER TRAY TESTS
- Center pipe leak test.
- Upper manifold piping and upper tray mechanical / leak tests.
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CLIP INSTALLATION
- Clip adjustment & positioning / Tack welding / inspection.
- Clip welding / inspection.
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EQUILIBRIUM DEVICE INSTALLATION
- Equilibrium device installation / inspection.
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TOP FLANGE INLET INSTALLATION
- Inlet box distributor cleaning.
- Top flange inlet insertion / bolting.
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TOWER FINAL CLOSURE.
- Final inspection.
- Top manhole closure.
LOWER TRAY INSPECTION POINT | TOWER INTERNALS
INTERMEDIATE TRAY INSPECTION POINTS | TOWER INTERNALS
TRAY PANEL INSTALLATION
Procedure |
Hold points |
| – Preparation Remove Catapac from platform, Trolley A & B. All panels must be clean, dry, free of rust. All nozzles covered with plastic cap and adhesive tape. Splash plate in place installed at ground. Blank off sample points and equilibrium device nozzle with blind flange and new gaskets. |
Dry air in service Panel conditions at ground Panel nozzle covers Gasket type |
| – Cleanliness During panel installation, avoid any sieve surface disturbing and ensure there is no foreign material falling down into the sieve bed. Remove tape/cap covering threaded holes just before panel positioning. Leave the piece of rope until stud bolt screwing. |
Upper face of beams Upper face of support rings Upper face of annular chambers hreaded holes (main beams and secondary beams) |
| – Panel lower screen Before positioning, each panel lower screen must be inspected carefully with a flash light ( damages done during handling) – Flatness and stability of panels Check the good contact between panels, beams and support rings. If there is any rocking, insert and tack weld shim plate on outside edge f the frame. |
Panel 1A to 8B |
| – Gap between panels Install spacers for positioning and maintain the position with clamps. |
Gap between panels must be 15 mm max. |
| – Gap between panels and shell Maintain a minimum gap on shell side for the rope. |
Gap between panels and shell must be 10 mm min. |
TRAY PANEL FIXING
Procedure |
Hold points |
| – Preparation Once all panels are properly installed, clear one by one the tap hole for stud bolt. Clean the tap hole blowing dry air. |
Panel positioning especially around bolting slots. Cleanness of tap holes Cleanness of stud bolt/ nuts |
| – Stud bolt screwing Once a tap hole is clear and inspected, start screwing stud bolts. In the event that bolting is not possible, check the cleanness or try another stud bolt. Stud bolt must be entirely screwed up (tips should not be higher than frame upper edges to allow seal plate welding). |
Stud bolt height within frame |
| – Bolting Install washer and bolt the nut maintaining the bolt from its tip. Tackweld bolt and nut. |
Bolt tightening New washers to be used |
ROPE PACKING
Procedure |
Hold points |
| – Rope packing : Rope packing must be done following the attached procedure. |
Wrapping & condition (clean and dry) & type & diameter Quality of Rope cutting ( cut clean through) No free space |
| – Rope packing between panels The first row must be packed carefully against the rope arrestor in order to prevent the rope going through it. |
Last row of rope must be flush to upper edge of panel frame. Gap after rope packing : 15 mm Max |
| – Rope packing between panels and center pipe Install 1 row of rope to compensate the height of rope arrestor. If clearance between center pipe and panels is larger than 15 mm, then install 30 mm and 8 mm diameter ropes if necessary. If clearance smaller than 8 mm, then install 8 mm diameter rope. |
Rope packing between center pipe and new angle plates |
| – Rope packing between panels and shell Install I row of rope to compensate the height of rope arrestor. If clearance between shell and panels is larger than 15 mm, then install 30 mm and 8 mm diameter ropes if necessary. If clearance smaller than 8 mm, then install 8 mm diameter rope. Complete the rope filling up to the top of panel frames. |
Last row of rope must be properly Inserted. |
| – Rope packing around stud bolt Fill all space around stud bolt |
Packing all around stud bolts. |
UPPER TRAY SEALING: SEAL PLATE & SEAL ANGLE PLATE WELDING
Procedure |
Hold points |
| – Seal cover plate welding on panel frame Follow typical sequence of tack-welding: tackweld point pitch= 150 mm Then continuous welding to tight the tray |
Dye test checking |
| – Seal angle plate welding on center pipe and shell welding ring Follow typical sequence of tack-welding: tackweld point pitch= 150 mm Then continuous welding to tight the tray |
Dye test checking |
UPPER PIPING MANIFOLD INSTALLATION
Procedure |
Hold points |
| – Preparation Identify marking on pipes before mounting. Remove all nozzle covers. |
New gasket to be installed |
| – Center pipe connection | Gasket type Bolting tightness |
| – Tray Cleaning / scaffolding dismounting Remove scaffolding, vacuum clean all tray surface |
Cleanliness |
INLET BOX DISTRIBUTOR INSTALLATION
Procedure |
Hold points |
| – Preparation Clear out all tray surface and vacuum clean all dust on shell. Use air extractor during dust removal. Inspect upper manifold piping at ground. Store all big pieces of piping manifold inside the tower on upper tray. Install scaffolding. |
Cleanliness of shell and tray. Piping condition (cleanliness, rust free, dry). |
| – Inlet box distributor installation Position inlet box distributor on the flange under the feed inlet. Install with appropriate gasket (150# RF W.N. flange). Tighten bolting. |
Cleanliness Gasket type and positioning Inlet box orientation Bolting tightness |
CENTER PIPE/ UPPER MANIFOLD PIPING/ UPPER TRAY TESTS
Procedure |
Hold points |
| – Center pipe leak test Follow AXENS’s procedure |
|
| – Upper tray/ manifold piping mechanical/ leak test Follow AXENS’s procedure |
EQUILIBRIUM DEVICE INSTALLATION
Procedure |
Hold points |
| Gasket positioning Gasket type Bolting tightness |
Piping condition (cleanness, rust free, dry Flange cleanness |
| – Equilibrium device installation / bolting | Gasket type Gasket positioning Bolting tightness Bolting on lugs |
| -Top head flush inlet connection (2 in. ) | Piping assembly after tack welding. Dye check Welding quality Gasket type Gasket positioning Bolting tightness |
| -Sampling connection (3/4 in.) | Piping assembly after tack welding. Dye check Welding quality |
TOP FLANGE INLET 16″ INSTALLATION
Procedure |
Hold points |
| – Preparation Vacuum clean from outside the inlet box distributor. Clean, brush rust if any on the top inlet flange. |
Inlet box distributor cleanness Top flange inlet cleanness |
| – Top flange inlet insertion / bolting | Gasket positioning Gasket type Bolting tightness |
FINAL INSPECTION I TOWER FINAL CLOSURE
Procedure |
Hold points |
| – Final inspection | Cleanliness Gaskets installation Sample connections |
| -top manhole closure | Gasket position, type |