Ammonia Convertor Basket Replacement,

Repair of Convertor Shell

&
Associated Work during Forthcoming ATR.

Introduction

Indo Gulf Fertilizers Limited (IGF) is engaged in production of Ammonia & Urea at its
plant located on Lucknow – Sultanpur highway & 90 Km away from Lucknow. During the
forthcoming Turnaround the old two bed Ammonia convertor catalyst basket S-200
(HTAS design) shall be replaced with Single bed S-50 (HTAS Design) in existing
convertor shell. Also there is crack in shell 5th CS weld joint up to depth of 50 mm from
inside & 1000 mm long.

Procedure for Replacement Activity

Pre Shutdown Activity

 Ground preparation for main & tailing crane as marked up in drawing no

 Mobilization activity for Tools & Machinery, manpower & execution staff.
 All scaffolding for Convertor & piping work.
 Fabrication of inspection cage & support for center pipe.
 Laying of mat plate for crane movement.
 Assembly of main & tailing crane & load test.
 Shifting and placement in vertical position of existing basket container to
the foundation.
 Welder Qualification.
 Final checking of crane movement area.
 Issuing & shifting of cone for handling basket from IGL store.
 Review of activity scheme & JSA.
 Shutdown Activity

Job Code Activity Remarks

SDA1 Removal of instrument items
SDA2 Removal of structure if required
SDA3 Removal of insulation, where shell to be repaired
SDA4 De-bolting & Removal of convertor top cover by the
help of EOT crane
SDA5 1st bed temporary cover placement
SDA6 Cutting & replacement of Control valves & allied piping
work as described in Enquiry document
SDA7 Removal of 1st bed & placement the same in between
two convertors with help of EOT crane
SDA8 Installation of temporary cover on 2nd bed
SDA9 Removal and placement of 2nd bed inside the container
SDA10 Supporting of convertor shell on hydraulic jack before
repair work
SDA11 Cutting & removal of convertor bottom lip seal and
piping
SDA12 Inspection of convertor shell and rectification of CS weld
joint including DHT, grinding, preheating, welding, SR,
NDT etc. Also checking of glands & if required same
shall be replaced with new one.
SDA13 Removal of hydraulic jacks after shell CS weld joint
repair
SDA14 Lifting of & placement of new basket container along
with basket to container foundation
SDA14A Installation of new basket in convertor shell
SDA15 Placement of top cover after catalyst loading
SDA16 Fixing of insulation old / new which removed for shell
repair work
SDA17 Fixing of insulation old / new which removed for shell
repair work
SDA18 Tightening of bolts as desired
SDA19 Placement of 1st bed inside the container and associated
assembly work and removal from foundation
SDA20 Placement of old and new basket container to
designated place
SDA21 Fixing of instruments
 Details of Equipments to be handled

Sl. Wt
Description Remarks
No. (Mt)
1. Old Container Ø 3.0m x 28.0m 17.0 Shifting & Vertical placement
2. Convertor Top Cover Ø 4.0m 25.0 Removal & re-erection
3. 1st Basket Ø3.0m x 8m 25.0 Removal & placement in container
4. 2nd bed basket Ø 3.0m x 28m 65.0 Removal & placement in container
5. New Basket & container Ø3.0mx 28m 65.0 Shifting & Placement on foundation
6. New Basket Ø 3.0m x 28m 46.0 Installation in convertor shell
Shifting & placement of old container Space which is allotted
7. 108.0
with basket Ø 3.0m x 28m (approximately 100 m away)
Lowering, shifting of new empty Space which is allotted
8. 20.0
basket container. (approximately 100 m away)
9. Torque Tightening of Top cover studs
10. Torque Tightening of bottom studs
Execution Staff

Sl. No. Designation Nos. Remarks

1. Construction Manager 1
2. Lead Engineer 1
3. Execution Supervisor 4
4. Safety Supervisor 2
5. QA / Qc Engineer 1
4. Foreman 2
Allotted for Day for Day &
5. NDT & SR Technician 5
Night Shift.
6. HR & Administration 2
7. Electrician 2
8. Crane Operator Crew 5
9. Hydra Operator 2
10. Store 1
Execution Manpower

Sl. No. Designation Nos. Remarks

1. Mill Wright / General Fitter 2
2. Piping Fitter 4
4. High Pressure Welder 5
5. Tack Welder 2
Allotted for Day for Day &
6. Grinder 6
Night Shift.
7. Gas Cutter 2
8. Rigger 24
9. Helper 12
10. Scaffolder 6
 Tools / Machinery / Consumables

Sl. No. Description Unit Qty Remarks

1. Crawler Crane 400 Mt No 01
2. Crawler Crane 150 Mt No 01
3. Hydra No 01
4. Welding Rectifier 400 Amps No 10
5. Grinding Machine No 08
6. Gas Cutting Set Set 04
7. Electrode Backing Oven No 01
8. Electrode Oven No 05
9. SR Equipments Set As required
10. RT Source (Cobalt 60) Set 01
11. Wire Rope Sling Ø75mm Pair 01
12. Wire Rope Sling Ø65 No 03
13. Wire Rope Sling Ø25 Pair 02
14. ‘D’ Shackle 120 Mt Pair 01
15. ‘D’ Shackle 80 Mt Pair 01
16. ‘D’ Shackle 50 Mt Pair 01
17. Nylon Rope Mtr Lot As required
18. Scaffolding Pipes No Lot As required
19. Scaffolding Clamps No Lot As required
20. Steel Chali No Lot As required
21. Aluminum Ladder No 03
22. Fitter Tool Box (Complete Set) No 06
23. Measuring Tools No As Required
24. Hydraulic Jack 50 Mt No 02
25. PPE’s No As Required
26. Spanner Set Set As required
27. Purging Paper Roll As required
28. UT Machine (Digital) Set 01
29. Hardness Tester (Digital) Set 01
30. Construction Electrical Facility Set 02
31. Wooden Sleeper No 30
32. Crane Mat Plate No 04
33. Welding Electrode Pkt Lot As required
34. O2 / DA / Argon Gas Cylinder No Lot As required
35. Cutting & Grinding Wheel No Lot As required
36. Welding Accessories Set Lot As required
37. TIG Set Set 06
38. Fire Retardant Cloth No Lot As required
Tentative Schedule
CRANE PLACEMENT SCHEME