Tower Internals Heavy Equipment Arrangements in Plants & Refinery Site
Facilities on site (Adsorbers are erected). All facilities lay out and dimensions to be prepared by Contractor and submitted to AXENS for comments.
I. At Ground
(1) Multi-purpose facilities
- Road paving is completed.
- Suitable cranes fitting with specification, shared for sieve operations and panels installation.
- Typically the crane should be capable to lift up to 1200 Kg to 50 meters. To fit with the Catapac apparatus nominal flowrate (15 m3/h), minimum of one sieve big bags every 4 minutes shall feed the receiving hopper. Duration of the transfer of a big bag from the sieve storage shelter to the receiving hopper should be as short as possible. This includes for each bag:
(1) Prior loading, bags are weighted and stored inside the bags temporary shelter.
(2) Lifting from ground to the top platform,
(3) Positioning below the hoist, using roller on the top platform,
( 4) Lifting using the top hoist and position the bag above the top hopper,
(5) Emptying in the hopper,
(6) Lifting the empty bag and its removal to a convenient location
(7) Then being ready for the new bag. Typically two cranes (1 per adsorber) are used to lift all necessary internals as well as the sieve big bags for loading. The crane must be permanently available to lift the big bags and the main equipment needed for trays installation.The main estimated characteristics of the most important pieces
to lift (to be checked with manufacturers) are:
✓ Truck(s) with required lifting device to be able to unload on the unpacking area, panels crates, piping crates, beams crates, sieve containers, etc …. Due to limitation on the possible lifting device of such crates transportation trucks, it might be needed to use either one of the two cranes dedicated to the lifting for internals or sieve, or to use an additional crane when crates unloading is necessary, if the two permanent cranes are already fully used.
✓ The lighting will be such that the crane operator will have no problems during night time to lift any material required (panels, piping, sieve, etc … ). (Owner or subcontractors to provide)
(2) Facilities related to sieve loading.
✓ A sieve big bags storage shelter (waterproof).
Refer to figures 4, 5 and 6 (tray panels facilities shelter) for main description of the items applicable to sieve big bags storage shelter Specifications
• Closed, covered and rainproof. A roof opening is necessary to be able to lift the big bags. This opening shall be able to be covered very quickly in case of sudden rain and shall be, once covered, rainproof.
• One side door, curtains protected against rain, large enough to allow the fork lift to easily enter to store the big bags. The location used for the fork lift from the sieve containers to the weighting machine location to the inside of the shelter shall be concrete paved.
• Concrete floor to prevent the dust accumulation.
• Suitable to store the number of big bags (no stacking allowed) corresponding to one bed volume minimum.
• Every big bag will lie on a wooden pallet.
• The shelter shall have sufficient room to allow a convenient handling of the big bags using fork lift and allow the inspection of the big bags.
• Space shall be calculated large enough in order that sieve big bags will not be stacked. It is not allowed to stack the sieve bags.
11. A strain gauge or a weighting balance shall be available to weight the big bags. Range from 0 to 1100 kg accuracy 1 Kg.
• A scale (range 0-400 kg, accuracy I kg) to weight sieve in excess at the end of loading of one bed.
• A concrete area on one door side of the shelter designed and assigned to receive the big bags, to handle them with the fork lift truck or with the crane. The wooden pallets stay at ground when the big bags are lifted.
Utilization of the shelter in operation
• To store and protect the big bags against any rain, after unloading from the relevant containers.
• Unpacking of the big bags.
• Checking of integrity of the big bags.
• Weighting all the big bags to detect any abnormality in the weight which will indicate moisture adsorption. Above 1015 Kg, bags are discarded.
• The big bags will be handled with a fork lift and will be lifted by the crane to the top unloading platform of the adsorbers following the sieve loading procedure. (see fig 6)
• Temporary storage of sieve in excess from the previous loaded bed.
✓ One weighting device, balance or a digital electronic weighting device directly attached to the hook of the cranes.(In that case at least one crane is used for weighting any time it is necessary to do it. This is done in advance of the next scheduled bed loading.
Weight has to be recorded for each bag. The accuracy of the weighting device shall be I kg maximum for a weight of big bags around I 005 Kg maximum packaging included. Any big bag over 1015 Kg packaging included is discarded.
✓ At least one fork lift to get the big bags out of their containers, to weight them and to temporarily store them in the big bags temporary shelter. Fork lift to be able to lift the big bags one by one for weighting and temporary storage in the big bags shelter.
Fork lift is prohibited to handle the tray panels.
(3) Facilities for trays and beams installation
✓ 6 temporary containers which are typically devoted to
(1) all gaskets
(2) the whole internal piping to be installed in the next bed.
1 container to be foreseen for each adsorber (marked A or B).
(3) glass fiber rope and related tools
( 4) spares parts and materials, like clips, bolts, nuts, shims, clamps, spacers, loading material like rake, walking board, plates, etc. 1 container to be foreseen for each adsorber (marked A or B). Power shall be available inside any of the containers used as a temporary storage for all necessary material.
(Owner or subcontractors to provide)
• A location for inspection, leak testing and potentially cleaning of the internal piping including flexible hoses shall be provided.
Temporary storage of the piping being done in the dedicated containers as explained above.
• A tray panels facilities shelter (waterproof), Specifications
• Closed, covered and rainproof. A roof opening is necessary to be able to lift panels, beams, etc. In case of sudden rain this opening it shall be easily covered very quickly and shall be rainproof.
• Sliding or curtain door(s) to allow access on both sides. Full rain protected and full width access from the unpacking area shall be available as well.
• Lighting to be powerful enough to be able to make panels inspection and working during night time.
• Concrete floor to prevent the dust accumulation.
• A concrete area assigned to receive the crates containing the panels, to handle them with the travelling gantry or with the crane after inspection.
• This paved area, could be used to unload the piping crates. The piping being moved to their relevant storage containers after completion of thorough inspection of all the piping, welds included. As already mentioned, a special location, shall be provided for the possible cleaning of the piping if it needs to be.
• Equipped with a travelling gantry crane able to move on the full length and full width of the shelter from the unpacking area up to the roof opening.
• Travelling gantry crane must be able to turn down panels to enable inspection on each side of panels.
• Following materials have to be foreseen:
(1) A work-bench with dry air and power.
(2) A travelling gantry crane able to travel full length and full width of the shelter, equipped with an electrical travelling block suitable to handle the panels and the beams
(3) GTA W welding machine for any repairs to be done in the screens ( distinct machine in addition to the GTAW machine used at the top platform for piping welding inside the adsorbers). This GTAW machine is also used for corner tabs welding.
( 4) Steel trestles to install a complete tray and to enable a proper inspection of the panel both faces.
(5) A desk.
(6) 2 sets of neoprene sheets adjusted for each type of panel (Plus one spare). Utilisation of the shelter in operation
• Unpacking and unwrapping the panels from the crates for a full tray.
• Unpacking the beams from the relevant crates
• Potentially piping unpacking.
• Individual inspection of the panels (flatness, integrity of the screens … ) in accordance with the panel inspection check-list.
• Repair of damage if any.
• Moving the panels below the roof opening to be lifted in sequence Etc….
✓ A beam facilities shelter (waterproof),
Refer to figure 4, 5 and 6 (tray panels facilities shelter) for main description of the items applicable to beam facilities shelter Specifications
• Closed, covered and rainproof. A roof opening is necessary to be able to lift panels, beams, etc. In case of sudden rain this opening it shall be easily covered very quickly and shall be rainproof.
• Sliding or curtain door(s) to allow access on both sides. Full rain protected and full width access from the unpacking area shall be available as well.
• Lighting to be powerful enough to be able to make panels inspection during night time.
• Concrete floor to prevent the dust accumulation.
• A concrete area assigned to receive the crates containing the beams, to handle them with the travelling gantry or with the crane after inspection.
• Equipped with a travelling gantry crane able to move on the full length and full width of the shelter from the unpacking area up to the roof opening.
ii. At top platform of adsorbers
A working floor binding both adsorbent towers is required at top of the adsorbers. This working area shall be large enough to allow all operations at the top including, Catapac maintenance and protected area for grinding of the internal piping (Upper tray). All necessary space for material storage in coffer or whatever shall be available.
(1) Specification of the top platform and associated facilities
The top platform is divided into two parts:
✓ One part in front of the adsorbers is dedicated to unloading the panels, the beams, the big bags, etc …. and is equipped with rollers which allow to direct the relevant equipment to the relevant adsorbers hoists.
The total amount of waiting sieve big bags on the rollers of this unloading platform, could be up to about l 0, at the top platform. Special care of the platform load calculation shall be taken.
The dimensions of this platform are defined by the measurements of the pieces of equipment to handle.
✓ The second part, called the working platform, will be large enough around the adsorbers to be able to properly store, work and handle as many as a total of about 30 people working on both adsorbers.
✓ A rain, heavy fog and sand storm proof shelter covering the top of both adsorbent towers and the linking working platform between them. (Normally the unloading part of the platform is not protected against the rains as the loading and installation of any internals is prohibited in case of rain (In addition if a roof cover is installed above this unloading part of the top platform, cranes will have difficulties to unload their charge. To maintain proper access to the big bags and the pieces of equipment, the shelter must be closed by curtain doors.
ii. At top platform of adsorbers
A working floor binding both adsorbent towers is required at top of the adsorbers. This working area shall be large enough to allow all operations at the top including, Catapac maintenance and protected area for grinding of the internal piping (Upper tray). All necessary space for material storage in coffer or whatever shall be available.
(1) Specification of the top platform and associated facilities.
The top platform is divided into two parts:
✓ One part in front of the adsorbers is dedicated to unloading the panels, the beams, the big bags, etc …. and is equipped with rollers which allow to direct the relevant equipment to the relevant adsorbers hoists. The total amount of waiting sieve big bags on the rollers of this unloading platform, could be up to about l 0, at the top platform.
✓ Special care of the platform load calculation shall be taken.
The dimensions of this platform are defined by the measurements of the pieces of equipment to handle.
✓ The second part, called the working platform, will be large enough around the adsorbers to be able to properly store, work and handle as many as a total of about 30 people working on both adsorbers.
✓ A rain, heavy fog and sand storm proof shelter covering the top of both adsorbent towers and the linking working platform between them. (Normally the unloading part of the platform is not protected against the rains as the loading and installation of any internals is prohibited in case of rain (In addition if a roof cover is installed above this unloading part of the top platform, cranes will have difficulties to unload their charge. To maintain proper access to the big bags and the pieces of equipment, the shelter must be closed by curtain doors.
✓ Hoists shall be cable type with two speeds: high speed for long displacement and low speed for positioning.
✓ Hoist must be able to load two secured baskets fitted to go inside the adsorbers through the top manway and transport – 3 people in/out of the adsorbers. Refer to figure 12 (page 54) for baskets description.
✓ Rollers to be able to roll and position the big bags right below the relevant hoist for both adsorbers A & B.
✓ Two receiving hoppers equipped with a ladder to access the upper part. After the completion of a bed loading, the sleeve between the hopper and the Catapac is cleared out to recover the non-used sieve. To be provided by the adsorbers supplier according to AXENS recommendations.
✓ A location dedicated to the storage and the potential maintenance for the 2 Catapac apparatus. A special support is to be installed at this location to allow Catapac maintenance or stand by after getting it out of the adsorbers. The Catapac sieve loading machine (AXENS furniture) is installed inside the adsorbers on a platform suspended from the adsorbers top head.
The design of this structure has to take into account the partial dismantling of trestles ( at least one side) during steps of installation and removing of apparatus, in order to avois any damages on the Catapac wheels.
Two complete supports as presented here above have to be foreseen (1 for each adsorber).
iii. Inside adsorbers
(1) Facilities related to first inspection of adsorbent tower
- Full secure scaffolding, with platform at each bed levels, and ladder connecting all platforms to be installed. (Owner or subcontractors to provide). Such structure will be needed for inspection of the inside of both adsorbers by AXENS, prior to start the Lower Tray installation. This inspection is performed to check:
- All support rings levelness and horizontality.
- All beams support weldings and levelness.
- Cleanliness of all annular chambers. To do this it will be necessary to at least open one or two nozzles for each annular chamber, then to close the nozzles again until internals installation work reaches the relevant level.
- Sieve sampling devices proper location,
- That all dump or extra nozzles are externally installed with properly rated flanges and gaskets.
- That all weldings are still proper after transportation and erection of the adsorbers,
- Centering of the Center Pipe,
- There is no rust spot on any part of the adsorbers shell, Center Pipe shell and top and bottom heads.
- The cleanliness of the adsorbers.
(2) Facilities related to sieve loading and CATAPAC.
V The top part of the ladder between the center pipe and Catapac platform shall be removable to allow the Catapac trolley to come below the top manway for installation using the top winch. (see figure 14 page 57)
(3) Facilities for transportation material and personnel
✓ A shuttle (steel wire basket) to lift conveniently and safely 3 or 4 persons, the materials necessary during the sieve levelling and the tray assembly (neoprene sheets, working boards, piping and tools). To be provided by Owner/subcontractor.
✓ Center Pipe
• A ladder hooked on the center-pipe
• The ladder will be sectioned in several parts (as many parts as beds). Each part will be dismantled following the progress of the bed loading.
(4) Facilities for beams and trays installation
✓ Center Pipe
• The temporary beams used to straighten the center pipe during transportation (see section 3.a.2 ) will also be used during internal installation. In any case, they must not be installed on the way of the ladder and of the pieces of^equipment to lift through the top manway.
Top head
• A platform supporting the Catapac apparatus with 2 trolleys to move it horizontally and to allow the sieve loading control of the bed. Refer to the AXENS PROCESS DAT A BOOK for the full specification of this Catapac platfonn ( dwg E/15 and E/16 of the adsorbent towers data sheet).
• A ladder to access from the edge of the manhole to the Catapac platform.
• A removable safety ladder to access from the Catapac platform to the center pipe ladder.
• A circular trolley with cable hoist. Cable hoist and trolley must be equipped with remote control from the bottom of the vessel. It is used for panels and beams installation
o Chain blocks shall be provided to be able to adjust the position of beams or panels to install them. The chain blocks are used at the level where the installation is going on.
✓ Bottom head
After total adsorbers inspection is completed at the satisfaction of all parties, then the complete scaffolding is removed except for the bottom head where the following items are kept:
• A temporary scaffolding or floor to allow beams and lower tray panels installation and bottom manifold assembly. The beams, the panels and the pipes will be introduced through the top manhole.
• The bottom manhole will be used during this step to allow internal access for personnel, small pieces of material and supplies.
✓ Bottom head
After total adsorbers inspection is completed at the satisfaction of all parties, then the complete scaffolding is removed except for the bottom head where the following items are kept:
• A temporary scaffolding or floor to allow beams and lower tray panels installation and bottom manifold assembly. The beams, the panels and the pipes will be introduced through the top manhole.
• The bottom manhole will be used during this step to allow internal access for personnel, small pieces of material and supplies.