Annex ure-I

WORK DETAILS :

1.0 Work Description :

Replacement of about 29 M3 of KMI / KMIR Iron base ammonia synthesis
catalyst from Halder Topsoe S-200 Ammonia synthesis reactor including
mechanical work involved in opening/boxing up, catalyst unloading and
loading.

2.0 Reactor details :

A) Details of pressure vessel:

Inner Dia, mm : 2035.
Inner length, mm : 17350.
Mechanical design pressure kg/cm2 : 260.8
B) Weight of top cover : 26.5 MT
C) Details of S-200 basket.( outer basket)
Dia, mm : 1917
Length, mm : 16700
D) Details of catalyst beds:

Description Unit Ist Bed(top) IInd Bed(

bottom)
Diameter mm 1699/873 1769/550
Total height mm 5,675 9,160
Effective height mm 5,185 8,540
Total volume M3 9.38 20.22
Type & size of catalyst mm KMIR 1.5~3 KMI 1.5~3
Filling density kg/m3 2,220 2,850
Quantity KGs. 20,800 57,600

3.0 Scope of work :

Ammonia synthesis catalyst being highly pyrophoric in nature, complete

unloading and handling up to disposal must be carried out in inert nitrogen
atmosphere only in accordance with international safety standards. Also
loading of the catalyst being critical activity due care is required. Following
items of work will be in the scope of contractor:

1. Items to be arranged by contractor:

Tools and tackles for opening of the top cover.

Catalyst unloading Vacuum machine, its connecting accessories
including PVC hoses to vacuum machine, power cable for power
connection to machine etc. will be arranged by the contractor. 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.

Estimation of quantity of liquid nitrogen required for complete job.

Items required other than above to perform the job.
2. Opening of Rector top cover

Opening of the top cover, lifting and placing at suitable location

Removal of associated instruments like thermocouple as required

Fixing of temporary lid on reactor
3. Preparations for Unloading and safe working

Catalyst unloading vacuum machines will be brought by the contractor in
good working condition.

Connection of vacuum machine with accessories for catalyst unloading
from Ist bed.

Inertisation of the reactor with nitrogen.
4. Work under inert atmosphere and catalyst unloading:

Opening of basket cover and I st bed covers

Unloading of catalyst from I st bed with vacuum machine by trained
workers for the job under experienced supervisors.

Once first bed unloading is completed, disconnection of hoses and
removal of temporary cover. Removal of Ist bed basket from the reactor,
maintaining N2 atmosphere inside reactor.

Opening of 2nd bed top covers in N2 atmosphere with required PPEs &
communication devices. Re-fixing of temporary cover and connections
with vacuum machine.

Unloading of catalyst with vacuum machine from II nd bed by trained
workers for the job under experienced supervisors.

Once total catalyst is removed preliminary inspection will be carried out
by GNFC and if required total basket will be removed from the reactor for
further inspection. Otherwise catalyst charging job can be started. This
being optional activity, separate rates can be given for removal and
refixing of second bed basket.
5. Catalyst Loading and boxing up:

The metallic drums arranged by GNFC at site will be opened by the
contractor and screening of the catalyst will be done at top floor.

Loading of KMI catalyst will be done in the II nd bed according to loading
procedure provided by M/s. Topsoe, maintaining required loading
density.

After completion of loading of II nd bed, top cover of II nd bed to be
boxed up. I st bed with internals is to be placed, aligned and fixed back in
the reactor.

Loading of KMIR catalyst in first bed according to loading procedure
provided by M/s. Topsoe, maintaining required loading density.

After completion of catalyst loading boxing up of first bed top cover and
finally boxing up of the Reactor top cover. Also fixing back of all
instruments and thermocouples/wells as and when required.

Following items will be under scope of GNFC:

1. Overhead lifting crane with 60 MT capacity is available at the site structure.

2. Fresh catalyst drums in required quantity will be arranged by GNFC at site.
3. Liquid nitrogen in required quantity as specified by the contractor will be
arranged by GNFC at site. Low pressure nitrogen will be supplied
accordingly.
4. Spent quenched catalyst will be disposed by GNFC suitably.
5. Required electrical power connection points will be provided by GNFC.
6. Heavy equipment like fork lift and crane will be arranged by GNFC
according to requirement given along with offer.
7. Utilities like air, fire water, service water etc. Will be arranged by GNFC.

4.0 General conditions:

1. Complete job including opening, unloading, loading and boxing up is to be

completed within 9 days. Job will be carried out on round the clock
working basis.
2. These catalyst are pyrophoric nature, 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.
3. The job of unloading, loading of catalyst and mechanical work involved
may also be supervised by Topsoe or GNFC supervisor and guidelines
given will be be followed accordingly.
4. All the safety rules and procedures of GNFC will be followed while carrying
out the job.
5. All skilled labours along with competent supervisor shall be engaged for
this job who should be OSHA certified. No subcontractor shall be allowed.
6. Mini general conditions of contract & labour laws will be applicable to you.
7. You shall be ready in all respect to take up the job at short notice of fifteen
days.
8. Following documents are to be provided along with this work proposal.

Safety procedure for work in N2 atmosphere.

Sketch and list equipment of life Support system.

Reference list of work carried out in N2 atmosphere.

Schedule of work activity and equipment arrival.
8 No advance will be paid to you for the commencement of the job.
 Annex ure-II

Format for Commercial offer:

The break of total price should be given in following parts:

1. Charges for opening and boxing up of Reactor top cover & related instuments
including tools and equipment required for the same.
2. Charges for hiring of equipment required like mechanical items and
safety/communoication tools etc. for unloading and loading of catalyst from I & II
beds as well as removal and refixing of I st bed basket.
3. Charges for services / labour for the unloading and loading of catalyst including
associated mechanical work.
4. Charges for removal and refixing of II bed basket. This is the optional activity will
be done if required.
5. Service tax applicable.
6. Total amount for the complete job excluding removal and refixing of the II bed
basket.

Vendor List : R401/R701 catalyst replacement

(1)
PLANT- TECH INDUSTRIAL SERVICES LTD.
Plot No.245, Baiksmpady Industrial area,
New Manglore, 575 011,
Karnataka, INDIA Kind Attn. :-Mr. Ajith Sequeira, M D
Fax : 0824 2406533 Phone : 0824 2400961
E-mail :PTG@plant-techgroup.com

(2)

M/s Contract Resources Petrochem Services (India) Pvt. Ltd. (M/s CRPS),
32, Vasant, Prof. N.S. Phadke Marg,
Andheri (East),
MUMBAI - 400 069 Kind Attn. :- Mr. Dhiraj Shetty ,Mr. CM Handa,
Fax No : 022-26821317 Phone : 022 55701556/57
E-mail : crindia@crasianet