Installation

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Spliteks is a technology and engineering centre and the direct successor to the Russian division of the Sulzer Group. Sulzer Chemtech LLC’s operations in Russia since 1990 built up unique experience, created a team of professionals, preserved in-depth expertise and established manufacturing capabilities. Today, high-tech equipment is manufactured at our own modern plant in Serpukhov and professionally installed at customer sites.

A full range of installation work for column, reactor and separator internals, including dismantling, installation of new internals, and repair and replacement of welded attachments.

Key Services

Dismantling old internals

Professional dismantling of existing structures using specialised tools and equipment, minimising the risk of damage to equipment and structures

Installation of new internals

High-quality installation of new components, ensuring reliable and durable column operation

Ability to perform associated and auxiliary work

Equipment cleaning, restoration of the cladding layer, on-site machining of the flange sealing surface, installation of a nozzle to the Customer’s design, and tightening of the flanged joint to the required torque as agreed with the Customer.

Repair and replacement of welded attachments in columns, reactors and separators

Results & Benefits

Improving equipment efficiency

Shorter repair periods between turnarounds

Minimised equipment downtime

Warranty for the work performed

Value for You

Competent installation teams certified by NAKS

One supplier—full responsibility for all work

700+ successful installations and repairs

In-house inspection and installation procedures

Option to arrange a consignment warehouse at the Spliteks site to store manufactured replacement internals until repair work begins.

Example of solution implementation

Client request:

Manufacturing and supply of column internals for three phases of a stable gas condensate fractionation and transshipment complex at the port. Urgent supply and installation of column internals for the damaged main fractionator of Phase 2

Spliteks decision:

Design and engineering. Optimal process operating conditions were calculated to achieve the guaranteed capacity and product quality.
Manufacturing in Serpukhov. A complete set of main fractionator internals was manufactured within 1 month and delivered to the customer’s site
Installation. Replacement of the damaged internals of the main fractionator was completed within 1 week, with the required guarantees provided.

Result

The unit is equipped with the most advanced mass-transfer internals, installed within 1 week.
Integrated solutions (engineering, manufacturing and installation) made it possible to promptly replace the equipment in an emergency, significantly reducing the customer’s losses caused by unit downtime.

About

Quality control at every stage: from welding to heat treatment

High-quality installation begins with the thorough preparation of equipment components. Semiautomatic welding is widely used at the manufacturing site to provide reliable joints between parts made from different grades of steel. Post-weld heat treatment is mandatory for critical assemblies and vessels operating at high pressure, as well as when hydrogen sulphide is present in the process medium. This procedure relieves residual stresses caused by welding and restores the metal’s original properties, which directly affects operational safety.

Installation of internals in column equipment

The installation of internals in columns begins by using a geodetic survey to check that the unit has been correctly installed on its foundation. The vertical alignment of the unit and the tightening of the anchor bolts are checked and documented in a report. The level of the supports is then checked if they were welded at the manufacturer’s plant, or the positions of support rings to be welded are marked out. The next stage is the installation of the internals, on which the efficiency of the mass-transfer processes directly depends.

The main technical requirements for this stage include:

Horizontal alignment of trays inside the column.
Assembly of internals in accordance with the installation instructions.
Secure fastening of the devices to prevent vibration during the process.

The company’s specialists install mass-transfer column trays—sieve, valve and bubble-cap trays—with particular care. The separation performance of the column, and therefore the purity of the products obtained in the unit, depends on the accuracy with which the internals are assembled.

Installation team expertise and technical equipment

High-quality work is ensured by professional teams specialising in the installation of internals. The welders are NAKS-certified, while the fitters hone their skills not only at customer sites but also in the company’s own workshop during the manufacture and trial assembly of internals. In addition to assembly itself, the teams provide a full range of services: from equipment cleaning to installing nozzles in accordance with the customer’s design, tightening flanges to the specified torque, machining the sealing faces of flanges and manways, and restoring the cladding layer.

All construction codes and regulations are strictly observed when the work is organised, and the installation method statement includes detailed lifting arrangements for the main internal components and scaffolding.