AMMONIA SYNTHESIS CATALYST UNLOADING / LOADING

JOB IN AMMONIA PLANT

1.0Work Description :

Replacement of about 29 M3 of KMI / KMIR Iron base ammonia synthesis catalyst from 1350 MTPD capacity two bed Haldor Topsoe S-200 Ammonia synthesis reactor including mechanical work involved in opening/boxing up, catalyst unloading and loading within 12 days on round the clock working basis.

2.0 Reactor details :

Basket type : Haldor Topsoe S200 basket.

Bed wise catalyst volume

1st bed : @ 10 m3 (KMIR)

2nd bed : @ 20 m3 (KMI).

 Details of pressure vessel:

Inner Dia, mm: 2035.

Inner length, mm: 17350.

Mechanical design pressure kg/cm2: 260.8

 Weight of top cover: 26.5 MT

3.0 Scope of work :

Ammonia synthesis catalyst being highly pyrophoric in nature, complete unloading and handling must be carried out in inert nitrogen atmosphere only by OSHA certified technicians in accordance with international safety standards. The contractor shall have to take all the safety precautions and persons working have to use life support equipment as per OSHA guide lines for working under N2 atmosphere. Also loading of the catalyst being critical activity due care is required. All the safety rules and procedures of GNFC will be followed while carrying out the job. While the job, Contractor will have to ensure that entire job to be completed in smooth way without damage to the equipment and persons working. Any damage to the equipment/piping/instruments etc. shall be recovered from contractor.

The total job to be performed by contractor broadly consists of :

Thermocouple / well removal and Top cover lifting.

Catalyst unloading in inert atmosphere with your vacuum machine. Loading of catalyst. All internals opening/boxing up required to be done to complete the job of replacement.

Inspection and repair of internals like Ist / IInd bed wire mesh and its internals /attachments etc.

Following items of work will be in the scope of contractor:

Tools and tackles for opening & boxing of the Reactor.

Two nos. of Catalyst unloading Vacuum machines, its connecting accessories. Vacuum machine maintenance and required connections will be done by the contractor.

All general safety equipment and special equipment required for working under nitrogen atmosphere like life lines, BA sets and other required equipment will be brought by the contractor.

All safe electrical fittings and lighting arrangement required for the work will be brought by the contractor. Also special communication devices required for the job will be brought by the contractor.

Any special equipment required for monitoring the activity of the person working in side the reactor will be arranged by the contractor.

  • Items required other than above to perform the job.