Integrated service
Key Services
Results & Benefits
Value for You
Example of solution implementation
Client request:
Upgrading deethaniser 2/ZOK-1 to increase its capacity by 20% above the design capacity while ensuring that the total mass fraction of methane and ethane in the deethanised condensate does not exceed 0.8%:
Spliteks decision:
- Design and engineering
- Calculation and analysis of all column operating modes. The optimal column operating mode was selected. A sophisticated column internals design was proposed and developed to ensure stable column operation at increased capacity. Unique, non-standard feed inlet devices were developed with due regard to the column shell and the arrangement of the internals
- Manufacturing in Serpukhov
- Installation. Complete replacement of the column internals and welded attachments. The duration of the work was reduced from 18 to 7 days. One week after unit start-up, the customer confirmed that the vessel had reached its operating conditions and was producing on-spec product. Following completion of the work, the customer sent letters of appreciation
The equipment was manufactured, delivered and installed ahead of the contractual schedule and in compliance with the technical specification.
Installation was completed in half the contractually stipulated time, for which a letter of appreciation was received.
Following the trial run, a capacity increase of exactly 20% above the design capacity was achieved while ensuring that the total mass fraction of methane and ethane in the deethanised condensate did not exceed 0.8%.
Integrated service by Spliteks
As a technology and engineering company and a leading Russian manufacturer of heat- and mass-transfer equipment, Spliteks (formerly Sulzer Chemtech LLC) offers an integrated service covering the entire life cycle of process units. The modern plant in Serpukhov not only manufactures high-tech equipment but also provides professional support at customer sites. The complete range of services includes installation supervision, installation, emergency repairs, maintenance and the organisation of spare-parts storage, minimising risks and improving process reliability.
Complete project support cycle
The integrated service begins with a review of the design documentation and ends with commissioning and preparation of all required reports. Spliteks specialists verify that installation complies with the technical requirements, industrial-safety standards and operating rules. This approach helps avoid typical errors when installing column, reactor and separator internals.
Installation supervision includes checking equipment completeness, inspecting welded attachments, stage-by-stage assembly supervision, hydraulic testing and preparation of acceptance certificates. Installation-supervision specialists are present on site, coordinating the customer’s installation crews and ensuring the quality of connections.
Installation and repair of internals
Installation work is performed by qualified crews with welding specialists, using welding procedures, welders and welding equipment certified by NAKS. The work includes dismantling obsolete contact elements, installing new devices, repairing welded parts, cleaning equipment, machining sealing surfaces and installing nozzles. Emergency repairs are arranged at short notice, including around the clock, with prompt manufacture of the required components and approval of the documentation.
Organisation of consignment stock and storage of manufactured spare parts
To ensure prompt support for customer sites, Spliteks organises supplier consignment stock where manufactured spare parts are stored until work begins. Consignment stock enables the customer to obtain components without paying storage costs in advance, reducing logistics and inventory expenses.
Spare parts are stored under controlled conditions to ensure their preservation. This applies to various components, from large internals to small fasteners.
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Spare-parts storage: systematic inventory control and corrosion protection
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Nut and stud storage: separate placement by size for quick access
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Internals warehouse
Spare parts are manufactured at our own facility from drawings or on-site measurements, guaranteeing an exact match with the original designs.
Maintenance and quality control
Technical support includes regular unit maintenance, diagnostics of the condition of internal components and optimisation recommendations. Commissioning completes the cycle by verifying that the products obtained comply with the process regulations. Quality control is performed at every stage in accordance with international standards.
Project implementation and cooperation
Spliteks delivers turnkey projects, from pre-design work to commissioning. The specialists train the customer’s personnel, provide operating documentation and deliver post-warranty support. This approach is particularly valuable for complex process facilities where internals play a critical role in separation and mass-transfer processes.
Customers can contact our engineers directly to order the integrated service. This makes it possible to discuss the scope of services, schedule and cost promptly and tailor the proposal to the specific needs of the facility.