T-HbI-06 Installation instructions for Trays Page 1 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

List of contents

1 Overview of all trays ............................................................................................................2

2 General Installation Information for Trays.........................................................................3
2.1 This installation manual .........................................................................................................3
2.2 Safety .....................................................................................................................................3
2.3 Space Requirements .............................................................................................................3
2.4 Boxes/Crates .........................................................................................................................3
2.5 Documents .............................................................................................................................3
3 Installation Preparation .......................................................................................................4
3.1 General Notes ........................................................................................................................4
3.2 Staging Area Preparation .......................................................................................................4
3.3 Tray Pre-Assembly (Mock Up) ...............................................................................................5
4 Installation of Tray Panels ..................................................................................................6
4.1 General Notes ........................................................................................................................6
4.2 Conventional or Truncated Downcomer Tray(s) ....................................................................6
4.2.1 General Notes ........................................................................................................................6
4.2.2 Examples ...............................................................................................................................7
4.3 Assembly of Tray Panels with Hanging Construction ............................................................7
4.4 Assembly of Tray Panels with Main Beam(s).........................................................................8
4.4.1 Installation of the beam(s) ......................................................................................................8
4.4.2 Assembly of tray panels with beam(s) ...................................................................................9
4.5 Connections ...........................................................................................................................9
4.5.1 Bolt Torque ............................................................................................................................9
4.5.2 Assembling of typical bolting connection used for trays.........................................................9
4.5.3 Tray manway assembly .......................................................................................................10
4.5.3.1 TYPICAL PERIPHERY BOLTING (EXAMPLE) ...............................................................................10
4.6 Installation of snap-in valves ................................................................................................11
5 Final inspection ..................................................................................................................12
Appendix A. Tolerances for Conventional Trays () .................................................................13
A.1. One pass trays .....................................................................................................................13
A.3. The tolerance shown under Appendix A. (A.1) applies to 2/3/4 pass trays also. .................14
Appendix B. Vessel Tolerances.................................................................................................16
B.1. General ................................................................................................................................16
B.2. Vessels with Internals ..........................................................................................................16
 T-HbI-06 Installation instructions for Trays Page 2 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

1 Overview of all trays

1P tray (Std. design) Extended design Type-B(Hanging design)

Two pass tray (Extended) Std. design (with Inlet panel) Type-B(Hanging design)

Three pass tray (With Inlet Panel) (Extended)

Four pass tray (Extended) Std. design(with Inlet panel) Type-B (Hanging design)
 T-HbI-06 Installation instructions for Trays Page 3 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

2 General Installation Information for Trays

2.1 This installation manual

For each different tray and / or internal layout, you will be working with specific drawings supplied by
Sulzer. This manual complements the project specific drawings as a general guideline. For a proper
installation, you must work according to the specific drawings for the trays you are installing.

2.2 Safety

Proper safety precautions and the use of proper PPE (Personal Protective Equipment) must always
be considered before starting any equipment installation. Safety precautions and PPE must be
according to site requirements and must be coordinated with the site safety authorities. Site specific
regulations must be followed.

Sulzer Field service has its own safety requirements in place in addition to the site specific
requirements. For Sulzer, SAFETY has the utmost importance. Should you have questions or
concerns related to field safety, please call our HOTLINE.

2.3 Space Requirements

The staging area for the equipment should be as close as possible to the column to minimize material
movement. As well, the storage area for the shipping crates containing the equipment should be as
close as possible to the staging area.

2.4 Boxes/Crates

It is recommended that the boxes or crates containing the equipment are stored under cover.
Additional recommendations for box / crate storage,

- One crate can be stacked on top of another to a height of two crates.

- Heavy crates or boxes to be placed separately and handled carefully.
- Inventory check of the equipment to be executed according to packing lists supplied in advance.
- Opening of boxes/crates is only recommended near the staging area just before installation to avoid
pilferage or loss of hardware or parts.

2.5 Documents

Typical documents shipped with the equipment,

- Packing lists.
- A complete set of assembly drawings for the products being installed.
 T-HbI-06 Installation instructions for Trays Page 4 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

3 Installation Preparation

3.1 General Notes

- The requirement for scaffolding needed for proper and safe installation of the equipment must be
evaluated and determined during the planning stage of the turnaround.

- It is important to verify in advance of the installation that all the necessary tray parts are available in
the boxes per the packing list for each respective column(s).

- Prior to any modification(s) to the tray parts at site, approval must be received from the
equipment vendor's engineering department.

- It is strongly recommended to complete a pre assembly (mock-up) of the equipment outside of the
tower before installation begins. Experience has shown that completing a mock up of the equipment
can reduce installation time.

- Check to ensure all equipment drawings are available before the start of the installation.

- Get acquainted with Sulzer drawings and reading the equipment BOM.

- The assembly drawings of equipment must be read in conjunction with the packing list to properly
identify each part by its reference number. Each tray part is marked with its reference number.

3.2 Staging Area Preparation

- Important! Avoid unnecessary opening and/or emptying of boxes randomly or removing equipment
with part numbers that do not cross-match with the assembly drawings of the equipment being
installed. Such actions will lead to missing or lost parts.

- Select the boxes/crates which contain the required parts for the tray(s) being assembled and move
these boxes/crates to the staging area. The packing list and equipment assembly drawings must be
used to identify the proper boxes/crates.

- Arrange the boxes sequentially to match the sequence of tray installation.

- Check the parts count per the BOM of the drawing in conjunction with packing lists inside the
boxes/crates to ensure all parts are available.

- Remove the parts from the respective boxes/crates to match the installation sequence of tray(s)
which you are planning to assemble.

- Do a mock-up of the tray assembly adjacent to the column area for easy access.
 T-HbI-06 Installation instructions for Trays Page 5 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

3.3 Tray Pre-Assembly (Mock Up)

- Before starting the installation inside the tower, it is recommended to complete a mock-up all tray
parts on the ground adjacent to the tower. This procedure eases installation of trays inside the
column.

- The equipment mock-up should be done in line with the each relevant tray assembly drawing.

- Remove parts from the appropriate box/crate which are required for the equipment mock-up.
- Do not use bolts, nuts or gaskets for the mock-up.

- Pre-assemble the tray panels loosely, do not tighten them together. If possible depending upon
space, pre-assemble two trays at once.

The mock-up provides a visual display for each type of equipment assembly which will be installed in
the tower helping the installer to understand how the equipment will fit when installed inside the
tower.
 T-HbI-06 Installation instructions for Trays Page 6 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

4 Installation of Tray Panels

4.1 General Notes

- Before starting equipment installation, the appropriate reference point has to be located inside the
column.

- As standard practice, installation usually starts at the bottom of the column and moves towards the
top. However this may change based on actual situation of the tower. The location of vessel
manways can impact the installation sequence.

- To assemble the first tray it is often necessary to setup scaffolding in the column. The requirement
of scaffolding may vary and depends on the actual situation. For many installations, scaffolding may
not be required. For example, an existing welded chimney tray can act as platform for the installation
of tray(s) above.

- Install in such way that one tray or tray part is pre-assembled on the ground while the other part is
installed in the column.

- An assembled tray can serves as a floor or platform for the next higher tray(s).

- Levelness or Evenness of the tray deck should be within the limit specified on Appendix-A.
Ensure that levelness is not affected due to work during installation.

- For maintenance loads, structural components (including tray integral truss) are designed
for concentrated load of maximum 135 Kg(300 Lbs) applied at any point on the tray deck
including beams (includes Dc truss as beam) at ambient temperature. INSTALLER MUST NOT
EXCEED THIS INSTALLATION LOAD LIMIT.

4.2 Conventional or Truncated Downcomer Tray(s)

4.2.1 General Notes

- For orientation and location of trays see the general arrangement drawing and the tray-drawing(s).

- For Item numbers of tray parts see the tray-drawing(s).

- Install Downcomer(s) bolted with bolting bar, radial or inlet panel and work towards the centre of the
tower. See the Typical example of 4P (4-pass) tray below. Same sequence applies to 1 pass, 2 pass
and 3 pass including high capacity trays.

- During tray panel assembly, the tray clamps can be assembled simultaneously.

- All clamps and/or bolts should be fastened by hand only, in order to adjust position of tray panels
during installation.

- The bolt assembly to the respective tray must be followed per drawing.
 T-HbI-06 Installation instructions for Trays Page 7 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

4.2.2 Examples

Assembly. direction
Bolting
bar

Downcomer
panels.

Conventional 4-pass tray assembly Typical conventional DC

Typical Truncated Downcomer

4.3 Assembly of Tray Panels with Hanging Construction

For hanging construction design, NO INSTALLATION LOAD BE APPLIED until Downcomer,

inlet panel and hangers are installed together.
 T-HbI-06 Installation instructions for Trays Page 8 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

4.4 Assembly of Tray Panels with Main Beam(s)

4.4.1 Installation of the beam(s)

For orientation and location of beam see the general arrangement drawing and the tray drawing(s).
This is typical example of 1 and 2 beams and it can have more than 2 beams and hence installer to
follow the drawing. For larger diameter, the beam can be Lattice type structure. See next page for
typical sketch.
Example of 1-beam

± 2 mm
Example of 2-beams

Check level difference between top side support ring and top side beam ± 2 mm. If necessary provide
seam to level within the allowed limit.
After beam installation check dimensions "A" or "B", which are very critical as this reduces overlap
with ring or beam flange or increases on other panel.
Verify the dimension A or B: - Must be within ± 3 and ± 5. See also Appendix-A for various
diameter range for bolting of Downcomer.
Beam to be bolted to column attachments.
 T-HbI-06 Installation instructions for Trays Page 9 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

4.4.2 Assembly of tray panels with beam(s)

After beams are installed and levelled within the allowed limit, install the downcomer(s) and level with
beam flange/ring.
The remaining installation sequences to be followed per clause 4.1.

Tray with beam(s)

Typical sketch of Lattice beam: Actual design may vary; refer respective drawing(s) for lattice
beam

4.5 Connections

4.5.1 Bolt Torque

All M10 (3/8") bolting should be tightened to approx. 15 to 21 Nm torque.

All M12 (1/2") bolting should be tightened to approx. 25 to 35 Nm torque.
All M16 (5/8") bolting should be tightened to approx. 61 to 85 Nm torque.

4.5.2 Assembling of typical bolting connection used for trays

The typical bolt connections for manway closing/opening and periphery clamp assembly are shown
below. For actual bolt connections follow approved tray assembly drawings that may vary depending
on the actual situation inside the column.
 T-HbI-06 Installation instructions for Trays Page 10 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

4.5.3 Tray manway assembly

Manway cover plate is placed per drawing after the final inspection is done and just before closing the
tower. For final inspection, see section 5.0.

Manway assembly (Standard) Manway assembly. (Alternate)

4.5.3.1 Typical periphery bolting (Example)

 T-HbI-06 Installation instructions for Trays Page 11 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

4.6 Installation of snap-in valves

Installation procedure of snap-in valves

Do not install the valves until the tray is completely assembled in the column.
For new jobs also the valves to be installed after tray is completely assembled at site. For Snap-in
valves, Sulzer supplies loose at site to avoid risk of popping up of the vales during handling at site.
 T-HbI-06 Installation instructions for Trays Page 12 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

5 Final inspection

On each completed level of section, Inspector should inspect systematically to ensure that:

-All parts are fitted properly as required.

-Orientation of trays matches approved drawings.

-The tray and its support levelness must be within the acceptable limit mentioned under "Appendix-
A".

-Downcomer clearance, outlet weir height and DC width are within the limit specified
under "Appendix-A".

A final inspection should be conducted before closing off the manways. Based on previous
experience, the following points should be carefully observed:
.

Evenness of trays should not be affected

All periphery clamps must be tightened due to work during installation.
Check tightness of 10% of the bolted
hardware

Clamps should be oriented radially with a Trays must be cleared of any and all loose
minimum of 15mm min. overlap on the materials (hardware, goggles protection
support ring. masks, tools, etc.) which may have
Ensure periphery clamps are not bowed adverse effect on the tray performance
upward due to over tightening or
exceeding torque limit.
 T-HbI-06 Installation instructions for Trays Page 13 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

Appendix A. Tolerances for Conventional Trays

(Dimensions are shown in mm, unless otherwise specified)

A.1. One pass trays

Tray support must present a flat surface for metal

to metal contact between tray and support.
Support shall be flat within 0.8mm (1/32 ") on any
300mm (12") chord. For tray supports and tray
decks, out of level tolerance over any diameter
shall be per Table-2.
 T-HbI-06 Installation instructions for Trays Page 14 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

For tray supports and tray decks, out of level tolerance over any diameter shall be:

Table 2

*Tolerance indicated above is from high to low point

** For Diam. >24'-0"(7315mm), installer or end user must consult Sulzer

If tray support ring is out of level beyond tolerance stated under table-2, installer or end user should
consult Sulzer to resolve this issue.
OR
Installer can weld shim of 1.5mm (1/16") thickness on top of ring until the levelness tolerance of tray
support ring and tray deck criteria is met per Table-2.

All tray supports tolerance indicated in "Appendix-A" are the responsibility of vessel vendor or the
party who has welded the supports to the tower.

A.3. The tolerance shown under Appendix A. (A.1) applies to two, three and four pass trays
also.

Two Pass trays:

Side downcomer Center downcomer

 T-HbI-06 Installation instructions for Trays Page 15 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

Three Pass trays:

Four Pass trays:

Side and center downcomer Off-center downcomer

The side view of bolting bar tolerance for two, three and four pass downcomer is same as mentioned
under Appendix A, section A.1 for one pass tray.
 T-HbI-06 Installation instructions for Trays Page 16 of 16

Sulzer Chemtech Ltd

Version Rev-1 Author Deepak Dhabalia Approval TFO T members This document is entrusted to the
recipient personally. It must not be made
available to third parties.
Date Nov-2013 Owner Kent Grove Vis/Date Oct.-2013

Appendix B. Vessel Tolerances

B.1. General

Tolerances for vessels subject to internal and/or external pressure shall be as stated in UG-80 and
UG-81 OR ASME sec VIII, DIV-I. The maximum deviation of the shell from a straight line shall not
exceed the criteria specified under ASME sec VIII, DIV-I.

B.2. Vessels with Internals

In general for trays and internals for out of roundness, height, verticality of column are to be met with
ASME sec VIII, DIV-I.
If vessels are to be fitted with special screens, Cartridge trays or trays/internals which require a more
precise fitting, then tolerances shall be in accordance with the trays/internals manufacturer's
recommendation and be specified on respective support drawings.