(A) REFORMER CATALYST REPLACEMENT JOB IN METHANOL-II

PLANT.
JOB DESCRIPTION
1.00 Job :
Unloading of @ 9.9 M^3 Reformer Catalyst (Nickel base catalyst) and
loading of @ 9.9 M^3 Reformer catalyst by Unidense technology
in all 96 Reformer tubes.
2.00 Reformer Tubes details :a) Total tubes
:- 96 (24 tubes in each Row)
b) Tube I.D/Length
:- 99 mm / 13940 mm
c) Volume of catalyst :- 9.9 M^3 Total
3.00 Catalyst Unloading :-Vendor Scope.
a) Dip and pressure drop measurement of all the tubes to be taken.
b) Flexible PVC hose connections / other required connections are to be
arranged by you.
c) Unloading of the catalyst from all the tubes by running GNFC vacuum
unloading machine.
d) Catalyst support grid from the bottom is to be removed for inspection and
Bottom support grid reinstallation in each tube as per orientation.
e) Video inspection of empty tubes by Endoscopic camera is to be arranged
by you. Any scaling/dust/particles removal by vacuuming to clean the
tube from inside.
4.00 Catalyst Loading by Unidense Method :-Vendor Scope
All required tools & tackles are to be arranged by vendor. Only certified
personnel for Unidense loading will be allowed to load the catalyst. You
have to submit the bio-data & certificate for working personnel.
a) Lifting of filled catalyst drums by pneumatic pulley at reformer top.
Vendor has to make all necessary arrangements for shifting the drums at
reformer top.
b) Pressure drop and dip measurement of all 96 empty tubes along with
GNFC representative. Pressure drop and dip measuring device will be
arranged by you and all data logging in proper format.
c) Charging of fix volume of bottom catalyst in each tube by Unidense
method. Measurement of pressure drop & dip in each row after charging
bottom catalyst. If pressure drop exceeds + 3% of average value, then
catalyst will be removed and recharged.
d) Charging of fix volume of top catalyst by Unidense method in each tube.
e) Final dip and pressure drop measurement in all 96 tubes.

(B)

SYNTHESIS CATALYST UNLOADING

atmosphere)
AND LOADINGIN GNFC-METHANOL-II PLANT.

JOB

(under

N2

1.00 Work :
To unload @ 42.2 M^3 Copper base Synthesis catalyst in N2 atmosphere and
to load @ 42.2 M^3 Copper base Synthesis catalyst in normal atmosphere in
Methanol reactor.
2.00 Reactor details :a) Total separated beds :- 04
b) Bed wise catalyst volume :- 6.3 M3/10.5 M3/10.5 M3/14.9 M3 Catalyst are
highly pyrophoric in nature.
3.00 Catalyst Unloading :- (Under N2 atmosphere) Vendor Scope.
a)
Mobilization of the equipments and its testing.
w Life support unit with communication system (International standard).
w Breathing air compressor,
w All instruments to check N2, O2, Hydro Carbon and other Toxic gases.
w Loading and shifting hoppers, Drum roller bench.

f)

w Vacuum machine (stand by machine to be arranged to ensure

uninterrupted job).
During catalyst unloading process, Video camera is to be kept in side the
reactor for monitoring internal activity from outside.
Catalyst unloading job is in inert atmosphere and confined reactor. The risk
factors involved are toxicity, Fire explosion, falling, electrocution &
suffocation. Hence catalyst unloading job is to be carried out in INERT
Atmosphere, only Inert atmosphere certified (OSHA certified) technicians
shall be permitted to enter the Reactor with required life support safety
appliances. The person working in inert atmosphere must have relevant
experience of working in inert atmosphere. Stand by person is also required
to wear the same safety appliances for emergency call and shall remain
present on Reactor top.
The temperature and oxygen monitoring in the reactor.
Life support system with its components must be as per international safety
standard for working in the Inert atmosphere.
Catalyst Removal :-

g)

w First,1dia ceramic balls removal from top of the catalyst bed. Removal of
top wire mesh.
w Catalyst unloading by vacuum unloading machine.
w After removal of individual catalyst bed, instrument thermocouple will be
shifted to safe location. Catalyst support plate, man way and wire mesh to
be removed. For this job, grinding/chiseling job is to be carried out under
N2 atmosphere. Nitrogen driven chipping hammer and grinder is to be
used.
After removing all catalyst, N2 to be displaced by air in the reactor.

b)
c)

d)
e)

3.00 Catalyst Loading :Vendor Scope

a) At the time of charging skilled labours should remain inside the reactor
continuously with wearing air mask and safety belts and have to charge
catalyst as per Catalyst supplier procedure.
b) Proper communication facility will be arranged.
c) In each bed a fix volume of catalyst and alumina balls are to be charged.
d) After charging of bottom most bed, next bed is to be charged after
fixing partition plate and internals and Thermo Couples as per
Guideline.
i) For rest of 3rd, 2nd & 1st bed catalyst charging, you have to follow same
steps as mentioned above.