APPROVED
First Deputy Director General -Chief Engineer
O.ISC "Naftan"
G.I, Plastinin
20rs
TECHNICAI, REQUIREMENTS (TR)
for execution of work on unloading of non-regenerated catalysts and subsequent loading of
fresh catalysts at Diesel Fuel Hydrotreatment Unit L-2417 (Block No. 1), OJSC ,,Naftan"
I
General provisions
1.1. Customer
-
Open Joint-Stock Company "Naftan", Novopolotsk, Republic of Belarus (OJSC "Naftan,,).
1.2, Scope of procurement
The Work on unloading of non-regenerated catalysts and subsequent loading of fresh catalysts
at
Diesel Fuel I{ydrotreatment rJnit L-2417 (Block No.1) of oJSC "Naftan,, (hereinafter the
Work;
the Unit).
1.3. Purpose of the Work
The Work is required for OJSC ,,Naftan" due to the necessity to unload spent non-regenerated
catalyst and inerl materials from reactors R-l and R-2, that shall be dismantled and pit out
of
operation, an<l for subsequent loading of fresh catalyst and inert materials into newly instalied reactor
of a larger volume R-201 .
1,4.
Work. Period of the Work implementation.
Execution of the Work involves implementation of a complex of work on unloading of
Scope of the
spent
catalysts and inert materials from the Unit reactors to be dismantled R-1, R-2, sorting of inert ceramic
materials (ceramic balls) by size, cleaning of the reactor, and subsequ..ri luy"r]by-luy",. loading
(including detrse loading) of inert materials and catalyst into new reactor R-201.
From this point onward "catalyst" shall mean a catalytic system consisting of main cata.lyst,
catalytic active materials/layers, guarcl layers, inert materials such as ceramii ialls, serving as
support and top layers.
List of main activities ensuring implementation by the Contractor of the above Work including
description of the methods of work and requirements to the Work and its quality are given in clause
1,6 of the prer;ent TR.
The weight of catalyst to be unloaded from reactors R-l, R-2 of the Unit according to reports of
previous loading not registering its weight variation during operation is 30,618.2 kg.
The weight of the catalyst for loading depends on its grade and vendor. Due to the fact that
purchasing of a new catalyst is not complete yet, the weight of the catalyst for loading into
reactor R201 is assumed tobe220,000 kg on the basis of catalyst dry weight. Thsexact catalysiweight shall
be
defined upon its loading into the reactor. For the pu{pose of calculation of a commercial proposai
the
value of 220,000 kg shall be taken as a basis in terms of catalyst dry weight.
Some vendors may supply catalyst
for loading with
organic impregnation serving for
preservation of the catalyst while handling prior to its first heating in the reactor. The quantitv
and
weight of such impregnation is not taken into account during catalyst purchasing. It il applied in
arbitrary percentage ratio to the weight of main catalyst and is desorbeb from thi catalysi volume
during the first process heating of the reactor.
PLEASTI: NOTET
For coffect accounting of purchasecl and loadecl catulyst the calculation
of the cost of executed
work shall be done on the basis of the actual rtry quantifii (weight)
of loaded catalyst, weight oJ.
unloaded catalyst and quantity of mobitizations, rh) dry catalysr
weight shall be given in catalyst
supplier's strreciJications, ancl in consignment notes. ittt ,Agnt
o] unbactecl catalyst shall be
accepted according to reports of previous loading without rigistuirng
weight variation during
operation.
Expected number of mobilizations
execution an<l their time is as follows:
of Contractor's personnel and equipment to the site of work
one mobilizatron during the period from 15 June till 20 August
2016*.
Quantity of catalyst unloaded / loaded by reactors, periods for the work execution and
other
summary dataarc given in Table 1 ( with notes and clarifications)
in clause 1.5 of the present TR:.
1.5. site and quantity of unloaded / loaded catalyst. summary
data.
Reactor equipment of the Unit consists of typical reactors
with fixed catalyst bed and axial feed
injection (loading diagrams are attached, new ioading diagrams shall
tentatively correspond to
attached diagrams and shall be provided upon catalyst prJcurement).
Summaly data on the quantity of catalyst loaded and subject to
unloading fiom reactors (as per
previous loading diagrams according to reports of previous
loading without registering weight
variation during operation), the requiied preferential type for its
loadiig, as well as the quantity of
catalyst subiect to loading into reactor R-20i, ur" giu.n inter
alia in tubt. 1 (with notes and
clanllcatlons ).
I
!r
Table
1
Possibility of
Number
Reactor
No.
R-l
Preferential type
catalyst beds
in the
loading into
reactor
reactor
I
of catalyst
flow through
a
catalyst discharge
pipe
Dense
Yes
Weight of
catalyst
for
unloading,
kg
Estimated
Estimated
weight of
period for
catalyst
for
the Work
implementa-
loading,
kg
(mobilization)
13,629.2
tion
Work
duration
days xx
June
August
R-2
R-201
of
catalyst unloading
fiom reactor by
means of its free
3
Dense
Yes
Dense
Yes
TOTAL:
Notes and clarifications to Table
2016r.*
16989
Max.14
220,000
30,619.2
220,000
l.
- More precise period for the work execution is still to be determined since it
depends on the
period of reactor R-20lcommissioning. The Customer shall
notify the Contractor of such a period not later
than in May 2,016.
*x - Contractor's waiting time between
activities at the Unit within the agreed schedule shall not be
deemed as downtime due to the fault of oJSC "Naftan". OJSC
'Naftan" shall Jo its best to minimize the
above waiting 1.ime of the Contractor.
1'
Total weight of the catalyst expected for loading is assumed to
be 220,000 kg, actual weight of
catalyst for loading can differ from the initially expected weight
due to possible variation in
density of catalysts provided by different manuf:acturers.
2' Calculation of the loaded catalyst quantity shall be done on dry basis only, inclnding
calculation for the purposes of payment for the work,
3.
4'
5'
Calculation of the unloaded
work) sha, be u.,.pt.J
?J,JffJXT-::til:TJffi:l
variation during its operation
In case of impregnated catalysts for.Lading at the Unit^catalyst
density shall be calculated by
dry weight of the catalyst to avoid discrJpancies. References
to the density of the loaded
impregnated catalyst are allowed
To determine the exact quantity of the loaded catalyst
during loading it is required that the
contractor complies with the requirements specified in
clause tlo.z. orile present TR.
u"
3il1:
l'6' List of activities required for execution of the work by the
contractor
methods
description and requirements to the work and its quarity.
1.6, L An'ival of contractor's personnel
and equipment to the Site.
1.6.2. Installation of Contractor,s equipment.
1'6'3' Unloading of spent catalyst and inert materials from
the Unit reactors:
passes in distributor plates under a nitrogen
of
: _opening
atmosphere,
includins
by method of vacuum degassing.
remains
till their complet
discharge pipe, which preve.
contr :tor's personnel should enter the
reactor and level the layer of spent catalyst using
a spade or other appropriate tool for the
purporie of its charging to the discharge pipe.
reactor's bottom to. the discharge pipe (while finishing
the unloadlngi;
using the method specified below in clause 1.6.5 of
thi rR.
inserled in 200 liter metal drums (insert polyethylen.
uug, into drums,
bags up, close drums with covers, stick a tag).
fill in catalyst,
tie the
L6.4. Internal cleaning of the Unit reactors (dry cleaning):
cleaning
till
complete freeing).
vacuum cleaning
till
complete freeing).
dust remains detected caoabl
.
assembling of t-he plate and
o1
-;3i:i:tt-bling
and subsequent
Customer' s specialists).
1.6.5. Sorting of inert materials (ceramic balls):
'6'6' Loading of fresh catalyst and ceramic balls into the unit's reactor (it is mandatory
to observe
the requirements to the method of loading given
below in clause 1,6,7 of the TR):
|
layers.
supporl plate.
shall be agreed with the Customer beforehind: required
sizes, volume and configuration).
beds
manll
layers
the loading method and s-pecification for t[e catalyst by the
catalyst
f inert balls on the top layer of the catalyst, Leveling of ceramic bals
bed.
1'6'7' Requirements to the quality of work on catalyst loading,
description of loading method,
geomerri
check
ding, and in
"#:;;,T"lill:,,l:
cas
ith the presenl. TR
Customer.
contractor according to loading diagrams and by
by the Customer.
-.thod,
preventing their damage, appr.ved
f each bed of the catalyst and inert materials; till
the whole cross-section of the reactor.
alyst loading every 20,'/o of the height of the bed
mer's representative,
ntractor shall meet the density value indicated in
difference between the actual andtargetdensity of
calculating the theoretical value of the catalyst density when
usin
required, based on the results of the examination the contractor
yp and sign a preliminary loading diagram.
oading. As
shall draw
l'6'8' Submission to the Customer of a repoft on the completed work including
the loading
diagram with indication of the height and weight of the loaded
catalyst, as well as of estimated and
actual density ofeach catalyst bed,
L6.9. Departure.
1'7' Responsibility with regard to the work execution on
the part of the Contractor
specified in the TR and within the time period specified irr
execution as well as operable and properly
softing of unloaded catalysts and inen mate
devices for internal cleaning of reactors a
materia.ls, transport, devices for enterins the
the executi
technical
omer,s
site
or (Contractor's Means);
hTiTir:T::':?
be
i:'",iLT
corresponding qualification' properly trained, certified and
having passed medical examination
with no contraindications to the Work execution.
The (lontractor undertakes to comply with its own instructions
and safety regulations during
the Work execution; at the same time the Contractor is obliged to ensure
compliance and
fulfillment by its personnel of the laws of the Republic of Belarus, local normative
legal acts
and customer's regulations in the course of the work execution.
The Contractor undertakes to submit to the customer in advance
its own instructionrs for
imple:mentation of the Work, requirements to the medium inside
the vessels, the levrol of
catalyst preparation, conditions which should be provided for
by the Customer to enable the
Work. implementation,
The Contractor is obliged to have and observe an instruction on
unloading of spent and loa.ding
of fresh catalyst under a nitrogen atmosphere.
The Contractor shal] have all the required permits and approvals for
execution of the purchased
work specified by the legislation of the Republic of Belarus,
The Contractor shall provide its personnel with personal protection
means for execution of the
Work; the Contractor
ensuring safity of the executed Work.
The Contractor shall
al for import and export of Contractor's Mears in
accordance with the
in the Republic of Belarus and shall bear the
responsibility for their safety.
Upon completion of the Work the Contractor shall submit to the Customer
a reporl orL the
completed work including loading diagrams for the Unit reactor
with indication of h"ight u,
well a.s estimated and actual density of each bed of the loaded catalyst.
1,8. Preliminary activities on the part of the Customer:
To enable the work execution by the Contractor the Customer shall carry out the
folloiving
preliminary activities :
of the work.
laboratory analysis;
ding to close the reactors;
max.40oC;
sonnel and equipment to the site area;
e of loading;
examination and obtaining of the first current
the Contractor's equipment;
(380/4008
AC, t6A,
22012308
AC.
10A.
pressure - 0.3 Mpa);
he personnel;
);
(to be delivered to the site area);
g personnel / stationary crane
and nozzles
materials)
for
equipment
shutoff (including correspondi mateiials);
in the operating area. The Cust
wastes, catalyst and auxiliary materials
its own expense;
remai
e wastes and sewage (packagl
a result
of the executed work, at
il'
Requirements to the Work execution. Information
on the
time.
work performance
The work shall be executed in full, with high quality,
in compliance with the requirements of the
present TR and within the time frames
stipulated i'ine schedule for the work execution
a6;reed
by the Contractor and the Customer.
It is expected that the customer shall inform the contractor of
the planned
commencement
at least 20 days beforehand.
date of the rvork
Due to a complex specific charact_er. of the enterprise
activity rescheduling of the specified
commencement date for maximum 5 days is possibie,
which stratt ue reported to the contrerctor
at least 7 days prior to the work commencement.
Attachments: loading diagrams for R_1, R_2. R_201.
Signatures:
Deputy Chief Ensineer
fr"if-l.rr
""J
Chief Process
ulo?r*i.,
production)
Engineer
A'v' Biriukov
D. A. Gimbut
Head of Production Department
for Petroleum Fuels and Aromatics
A.A. Ustinov
Deputy Head of Production Department
for Petroleum Fuels and Aromitics
V.A, Glebko
-lnrnph4enl-e-
for all
reasurerEnts
* below tangent line
CatConsult Project Engineer
Hendrik Buis