Catalyst Procedure

The drawing, design and details given on this format are the property of ESSAR OIL LIMIED.
They are merely loaned on the borrower’s express agreement that they will not be reproduced, copied,
CATALYST LOADING & UNLOADING PROCEDURE
DESULPHURISER REACTOR (R 1A/B)

HYDROGENATOR REACTOR (R 201)
HT SHIFT REACTOR (R 200)
STEAM REFORMER (H001)
RELOCATED HYDROGEN MANUFACTURING UNIT

exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
UNIT No - 052
DOCUMENT NO.
R E O - P C _ 0 5 2 - P R O - 0 0 1 - 0 0
(REFER DOCUMENT NUMBERING SYSTEM FOR DETAILS)

DATE OF ISSUE: 02.05.2009
REFINERY EXPANSION OPERATIONS
ESSAR OIL REFINERY, VADINAR
PREPARED BY CHECKED BY APPROVED BY

D N JADEJA H UPADHYAY S MATH
ESSAR OIL LIMITED

Error! AutoText entry not
REFINERY EXPANSION
defined.
OPERATIONS
CC: cc
The drawing, design and details given on this format are the property of ESSAR OIL LIMITED... They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or
used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
DATE
02-05-2009
FOR ISSUE
DETAILS OF REVISION
ESSAR OIL LIMITED

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DESULPHURISER REACTOR (R 1A/B)
INDEX
PAGE
CLAUSE DESCRIPTION
NO
1.0 CATALYST LOADING PROCEDURE 4
1.1-MECHANICAL DRAWING & NOZZLE SCHEDULE 4
1.2- CATALYST PHYSICAL & CHEMICAL ROPERTIES 5
1.3-PRELIMINARY CHECKING 6
1.4-LOADING PROCEDURE 7
1.5-CATALYST LOADING PRECAUTIONS 8
1.6-CHECK LIST FOR CATALYST LOADING 9-11
1.7-FINAL LEAK TEST 12
2.0 CATALYST UNLOADING PROCEDURE 13
2.1-INTRODUCTION 13
2.2-SAFETY 13
2.3-UNLOADING PROCEDURE 14
3.0 CATALYST LOADING EQUIPMENT AND SCOPE 15-18
4.0 MATERIAL SAFETY DATA SHEET FOR CATALYST 19-22
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REFINERY EXPANSION OPERATIONS defined.
1.0 Catalyst Loading Procedure:-
1.1 Mechanical Drawing & Nozzle Details for R-201:-

Mark Qty Size Sch. Rating Facing Type Remarks

A 1 4” 120 300# R.F. W.N. GAS INLET
B 1 4” 120 300# R.F. W.N. GAS OUTLET
C 1 2” 160 300# R.F. W.N. DRAIN
D 1 20” STD WT - - - ACCESS HOLE
M 1 20” XHVY 300# R.F. W.N. MANHOLE
V 4 4” 40 - - - VENT HOLE
H 1 10” XHVY 300# R.F. W.N. HAND HOLE
S 1 12” STD.WT - - - SKIRT
SLEEVE FOR
DRAIN
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Mechanical Drawing & Nozzle Schedule for R-1B:-
Mark Qty Size Sch. Rating Facing Type Remarks

A 1 4” 120 300# R.F. W.N. GAS INLET
B 1 4” 120 300# R.F. W.N. GAS OUTLET
C 1 2” 160 300# R.F. W.N. DRAIN
D 1 20” STD WT - - - ACCESS HOLE
M 1 20” XHVY 300# R.F. W.N. MANHOLE
V 4 4” 40 - - - VENT HOLE
H 1 10” XHVY 300# R.F. W.N. HAND HOLE
S 1 12” STD.WT - - - SKIRT
SLEEVE FOR
DRAIN
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1.2 Catalyst Physical & Chemical Properties:-

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Alumina Ball Specifications:-
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1.3 Preliminary Checking:-
¾ Plant has been cleaned and reactor is inspected.
¾ Reactors internal are uninstalled and reactor is isolated from plants with blind at the inlet and
outlet nozzles.
¾ Insure that catalyst containers/ drums should always be handled carefully, in order to avoid
breakage of the particles.
¾ Catalyst must not be exposed to moisture and air; it has to be stored in tightly closed
containers under roof.
¾ During loading operation, the catalyst and screening facilities have to be protected against
rain.
¾ Dust and broken particles have to be removed following the procedure for the individual
catalyst.
¾ The catalyst can be charged either by using basket or by means of loading chute.
¾ Immediately after catalyst loading the reactor has to be closed and purged with nitrogen to
protect the catalyst against water, air, dirt and foreign matter.
¾ Reactor must be kept under slight nitrogen pressure until it is ready to be taken into service.
¾ A complete record of the amount of loaded catalyst has to be kept, and 01 kg sample of each
catalyst is to be kept after loading.
¾ Walking planks or “snow shoes” must be used inside the reactor to avoid crushing of the
catalyst particle.
¾ Personal involved with handling of catalyst must be familiar with the safety data sheets for
the relevant catalyst.

¾ Personal involved with handling of catalyst must wear suitable personal protective
equipments.
¾ Before entering inside the vessel % of oxygen should be >19.8% inside the vessel.
¾ Check the quality of alumina/ceramic balls if they are broken, they must be stored and fines
must be removed.
¾ Ensure that all necessary safety and PPE should be available as well as communication
system
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1.4 Catalyst Loading:-
¾ The catalyst is loaded after blowing, cleaning and drying of upstream and downstream piping.
¾ Before loading of catalyst man hole should be opened first..
¾ Inspect the interior of each reactor, to ensure that the vessel is clean, dry and free from loose
scale and debris.
¾ It is essential that the charging level is clearly defines, so as to avoid under-or overfilling.
¾ It should be checked that the thermo wells are installed as specified (including gaskets) and
that the catalyst retaining plate and the blind flange on the unloading handhold are installed.
¾ All measurements should be made from a fixed reference point at the top of the vessel
although guidance marks may be made on the vessel internal by means of blackboard chalk.
¾ For charging heights and weights see the corresponding catalyst data sheets Weight of
catalyst, vendor batch number and any other relevant catalyst data should be recorded.
Make sure that the required amount of catalyst and support is loaded
¾ Install a large funnel 18 to 24 inches in diameter at the top, tapering down to four to six
inches at the bottom, in the manhole above the bed. To the bottom of the funnel, attach a
canvas sock or hose arrangement of sufficient length to reach the bottom of the reactor.
¾ Hoist catalyst or support balls up in buckets and pour into the funnel. As the level builds up in
the vessel, raise the funnel and withdraw the chute so that the catalyst/support will flow out.
¾ Keep the chute full all times so catalyst does not drop more than about 12 inches.
¾ Level the catalyst or catalyst support bed every 3 feet of height increase. If it is necessary
for a man to enter the vessel during loading, precautions must be taken so that he does not
stand directly on the catalyst.
¾ A board must be placed over part of the bed to distribute his weight. After all of the catalyst
and catalyst Support balls have been loaded, disconnect the air hose, Close the bottom
drain and secure manholes.
¾ Refer to operating and instruction manual supplied by catalyst vendor for detailed
procedures.
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1.5 Catalyst Loading Precautions:-
¾ The loading operation should be conducted with reasonable speed; to ensure the catalysts
does not pick-up and undue of moisture from the air.
¾ The vessel must be loaded carefully to minimize physical damage to the pellets during
loading and to prevent catalysts alteration in normal operation. Careful loading will avoid
serious operation problem caused by poor packing of the bed.
¾ The free fall of catalyst should not exceed 500mm to prevent breakage.
¾ The bottom and top screens must be checked.
¾ Larger hopper should be used to move the catalyst from the ground to the filling manhole.
¾ The hopper should be equipped with loading chute of correct diameter and sufficient length.
¾ Personnel handling the catalysts during the loading must wear dust masks.
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1.6 Check List For Catalyst Loading:-
Sr Activity Description Action By
No
Preliminary Checking SI PO FO M
A Reactor
1 Check whether the reactor has been isolated. The swing elbow at
the outlet should be blinded
2 Open the top manhole by removing the flange connection at the
inlet distributor
3 Check whether the oxygen content inside the reactor is above
19.5%, if not aerate the reactor from the outlet flange through
an air hose
4 Remove the five concentric support rings together with the

baskets
5 Ensure that wooden covers are placed over the baskets
6 Inspect outlet collector & screen on it

7 Check for the proper seal welding of the screen and its
fastening on the outlet collector
8 Check for uniform slot openings on the outlet collector
9 After inspecting the plug, close the cover of the pipe tightly
and ensure that its slots sit precisely on the grooves in the
Pipe.
B Alumina balls & catalyst
1 There are two types of alumina balls- One of diameter 13-

6mm
2 There are two types of catalyst also: Actisorb C-L2 & Actisorb
S2(C7-6)
3 Ensure the availability of all necessary safety & personnel

protection equipments like gloves, dust masks, respirators,
safety harness as well as means of communication like radios
C Precaution to be taken while loading

1 Do not roll catalyst drums as it may cause catalyst attrition
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2 Maximum permissible free fall height of the catalyst is 0.5 meter
3 In case of rain stop loading
4 No foreign material like pieces of sleeve, walking boards, tools

etc must be left inside the reactor
5 Dust masks should be worn inside the reactor
6 Special loading device checking for availability

7 A stationary hopper should be built on site above the reactor.
8 A slide valve must be fitted to it
9 The hopper legs must be long enough to allow for access into
the reactor
10 Canvas sleeves with adequate length of 150 mm diameter
11 A mobile hopper with capacity to hold 3 drums of catalyst
12 A lifting device (crane or a system of winches) to lift the mobile

hopper from the ground level
13 Temporary shelters should be erected on top of the reactor

and at ground level to protect catalyst from rain
14 A vacuum cleaner should be available to eliminate dust and

catalyst fines inside the reactor
15 Device for tooling, lighting, dust masks, respirators, safety

harness should be available
Sampling bottles for catalyst must be available
D Loading of the reactor

1 Catalyst sampling
2 Take small amount of catalyst from all the catalyst drums and
make two representative samples of minimum 1 kg
3 Transport the 13 mm size alumina balls by the mobile

hopper to the top of the reactor
4 Open its slide valve and transfer the contents to the stationary
hopper
5 Fill the alumina balls on the collector tray to a height of 3/4"
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6 Rotate the sleeve to uniformly distribute the alumina balls
7 Level this layer using a broom
8 The personnel inside the reactor should stand on a wooden
board above the catalyst
9 In a similar fashion transport and fill the 6 mm alumina balls

to a height of 1/4" above the previous layer
E Catalyst loading
1 Load the catalyst inside the reactor by
rotating the sleeves
2 Level the catalyst after each meter

3 Retract the sleeve by one meter at this point
4 Now fill this catalyst in this way up to 2.9 meters of the

internal height of the reactor
F Catalyst loading
1 Arrange and fill at ground level this type of catalyst into the
mobile hopper
2 Transport and fill the stationary hopper at the top of the

reactor
3 Fill the C-L2 catalyst over the previous layer of S2(C7-6)
4 Check if wooden covers are placed over the baskets, If not,

cover them
5 Continue loading the catalyst around the baskets to the level

Specified.
6 Level the alumina balls

7 Remove the wooden covers of the debris basket
8 Reassure that no tools are left inside the reactor
9 Record the volumes of alumina balls, catalyst loaded,
manpower used, time taken for loading
10 Install the inlet distributor at its position
11 Box up the top manhole

12 Remove the blind at the swing elbow flange at the outlet
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1.7 Final Leak Test:-
¾ After the catalyst loading is completed, the tightness of the reactor has to be ascertained.
¾ The reactor is isolated and pressurized with air to the maximum pressure available or compatible with
the equipment.
¾ The tightness is considered satisfactory when the pressure loss is less than 0.05165kg/cm2/hour, over
four consecutive hours.
¾ After the leak test the reactor is purged with nitrogen until the oxygen content is 0.2% volume
maximum.
¾ If for any reason the leak test of the unit as described earlier has not been performed yet, proceed to an
overall leak test of the unit, reactor included.
¾ After the leak test the reactor is isolated by blinds if start-up is not going to take place immediately
and kept under a nitrogen atmosphere.
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2.0 Catalyst Unloading For Desulphuriser Reactor-R 1A/B:-
2.1 Introduction:-
The pressure drop across the catalyst beds will increase over a period of time due to the build up of
dust, deterioration of the catalyst, operating mishaps, etc. Eventually the increase in pressure drop
will reach a point where the plant must be shut down and the catalyst screened to restore the bed to
its normal operating parameters. Screening of the first catalyst layer is required more frequently
than the others because any dirt entering the reactor tends to plug this catalyst layer. A crust may
also form on the top layer of the first catalyst bed due to operating problems. In this case the
pressure drop across the catalyst bed will increase rapidly over a short period of time. Catalyst may
need to be removed in order to facilitate repair or inspection of the reactor. This is common in the
post and grid type reactors where collapsing of the grid supports may occur. The most common
method of removing catalyst from the reactor is by vacuum extraction. Removal by hand can also
be done but this is usually restricted to smaller reactors and is more labor intensive. Screening of
catalyst is usually done when the reactor has cooled down permitting entry without special
protective clothing. Hot entry can be done but requires special procedures and equipment. The
following provides a general procedure for the unloading of catalyst from the Desulphuriser
Reactor. The user must adapt the following procedures to their specific situation.
2.2 Safety:-
Catalyst dust is toxic and special safety precautions are required for all personnel involved in the
screening operation. Material Safety Data Sheets (MSDS) should be reviewed prior to commencing
the operation.
Personnel shall wear as a minimum dust respirators, protective goggles, gloves and disposable
protective clothing. Externally supplied breathing air is highly recommended for those personnel
working in the converter.
Standard vessel entry procedures should be followed at all times. This should include as a
minimum:
• Routine testing of oxygen levels inside the reactor

• A person stationed outside the reactor man way to monitor the workers inside the vessel.
This individual should be equipped with rescue gear and an independent air supply.
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2.3 Unloading Procedure:-
¾ Plant has been cleaned and reactor has to be inspected.

outlet nozzles.
¾ Vessel keep under N2 atmosphere till the catalyst oxidized.
¾ Vessel is being inspected for any damage before unloading is being started so that remedial
measures on operation as well as maintenance side can be planned.
¾ During catalyst unloading process, Video camera is to be kept in side the reactor for
monitoring internal activity from outside
¾ 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
¾ 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
¾ The temperature and oxygen monitoring in the reactor.
¾ Life support system with its components must be as per international safety standard for
working in the inert atmosphere.
¾ Start unloading the alumina ball from the top manhole by using a vacuum machine.
¾ Keep the unloaded alumina ball in separate drums and screened in order to reuse it.
¾ Continue the spent catalysts unloading.
¾ Once the alumina ball and catalyst are completely removed, thoroughly clean the catalyst
support grids/plate. Clean the bed separation plate located below the catalyst bed as well.
¾ Perform an inspection of the reactor and initiate any repairs as required. Carefully check for
mechanical damage and areas where gas bypassing can occur
¾ Dump the spent catalysts into nitrogen-blanketed metal drums.
¾ Unload the bottom layer of alumina balls and store it in a separate drum.
¾ Clean inside the reactors for inspection.
¾ Catalyst screening operations should be halted if there is a possibility of exposing the
catalyst to any form of precipitation (rain, snow, etc.)
¾ Catalyst from each bed should be kept separate from each other.
¾ Catalyst samples should be taken to be analyzed for activity.
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3.0 Catalyst Loading Equipment:-
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List of Equipment and Tools needed for Catalyst Loading:-
ITEM EQUIPMENT OR ACTIVITY Essar Oil Limited ECIL

1.0 GENERAL ITEMS
1.1 General Utilities:(nearby reactor area)
1.1.1 . Air (6-10 bar) X
1.1.2 . Electricity (220/240v 400/440v)
1.1.3 . Water X
1.1.4 . Nitrogen purge (incl. ground) and blanket 500Nm3 / Hr
1.2 New Catalyst (in jumbo bags/Drums) X
1.3 New Ceramic Balls, various dia (in drums)
1.4 Mech. Activities (spading, elbow de/re-tensioning etc.) X X
1.5 Exterior lighting at reactor
1.6 Scaffolding as required X
1.7 Provision drinking water at reactor area
1.8 Sanitary facilities (showers, toilets) within the plant X
1.9 Drums (and weather protection) for spent catalyst
1.1 Disposal spent catalyst X
1.11 Fire Fighting (standby personnel & equipment)
1.12 Final Site Clean Up X X
1.13 Pallets
2.0 MANPOWER: (Day & Night coverage) X
2.1 Specialised Staff: X

2.1.1 Catalyst Technician X
2.2 Ground Support & Logistic Staff: X
2.2.1 Ground Support Foreman
2.2.2 Ground Support Assistants X
2.2.3 Forklift Driver X

2.2.4 Truck Driver (drums from/to stores) X
2.2.5 Crane Driver
2.3 PPE for all CRIN paid Personnel X
2.4 Air fares Specialised Staff
2.5 Board & Lodging Specialised Dense Loading Staff X
2.6 Board & Lodging Catalyst Staff X
2.7 Local & in Plant Transport Specialised Staff (ditto) X
Local & in Plant Transport for Local Staff X
3.0 CATALYST UNLOADING & LOADING (Day & Night) X
3.1 1No Flatbed Truck (catalyst from/to storage area) X X
3.2 1No Telescopic Crane (capcity as rqd re load & reach)
3.3 Forklifts (min 2.5T-moving drums at reactor area) X
3.4 *B/A Module (see footnote)
3.5 Ground Communications Equipment (Walkie Talkies) X
3.6 Reactor Entry Ladder X
3.7 Screening M/c - Multideck SWEECO X
3.8 HP filling compressor X
3.9 BA Bottles
3.10 Loading socks X
3.11 Mechanical Hand Tools (incl. pneumatic)
3.12 Hydraulic Bolt Tensioning/Torquing Tools & Procedures X
3.13 Air Hose 3/8in & 3/4in
3.14 Air Manifolds X
3.15 Chain blocks
3.16 Reactor internal lighting (24V) c/w transformers X
3.17 Rope
3.18 Cleaning rags and detergent X
3.19 QA Documentation (i.e. loading logs)
3.2 Dense Loading Machine x 2 Certified Operators X
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4.0 Material Safety Data Sheet for Catalyst:-

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HYDROGENATOR REACTOR (R 201)
INDEX
PAGE
CLAUSE DESCRIPTION
NO
1.2- CATALYST PHYSICAL & CHEMICAL
29
ROPERTIES
2.1-INTRODUCTION 38
2.2-SAFETY 38
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outlet nozzles.
rain.
catalyst.
catalyst particle.

equipments.
must be removed.
system
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1.4 Loading Procedure:-
scale and debris.
procedures.
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1.6 CHECK LIST:-
Sr No Activity Description Action By
A Reactor
1 Check whether the reactor has been isolated. The swing elbow
at the outlet should be blinded
2 Open the top manhole by removing the flange connection at
the inlet distributor
an air hose

baskets

Pipe.
1 There are two types of alumina balls- One of diameter 13-

6mm
2 The Catalyst is using HD Max-300TRX(C20-7-03TRX)


2 Maximum permissible free fall height of the catalyst is 0.5 m
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The drawing, design and details given on this format are the property of ESSAR OIL LIMITED... They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or 3 In case of rain stop loading


the reactor
12 A lifting device (crane or a system of winches) to lift the

mobile




1 Catalyst sampling

hopper
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E Catalyst loading


F Catalyst loading
mobile hopper

reactor
3 Fill the HD Max Catalyst 300TRX(C20-7-03TRX)

cover them

Specified.


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the equipment.
maximum.
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2.0 Catalyst Unloading For Hydrogenator Reactor-R 200:-
2.1 Introduction:-
following provides a general procedure for the unloading of catalyst from the Hydrogenator
Reactor. The user must adapt the following procedures to their specific situation.
2.2 Safety:-
the operation.
minimum:

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outlet nozzles.
appliances
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3.0 Catalyst Loading Equipment & Scope:-

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1.0 GENERAL ITEMS
1.1.1 . Air (6-10 bar) X
1.1.2 . Electricity (220/240v 400/440v)
1.1.3 . Water X
1.13 Pallets


2.2.5 Crane Driver
3.9 BA Bottles
3.15 Chain blocks
3.17 Rope
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HT SHIFT REACTOR (R 200)
INDEX
PAGE
CLAUSE DESCRIPTION
NO
1.2- CATALYST PHYSICAL & CHEMICAL ROPERTIES 48
2.1-INTRODUCTION 56
2.2-SAFETY 56

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outlet nozzles.
rain.
catalyst.
catalyst particle.

equipments.
must be removed.
system
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1.4 Catalyst Loading:-
scale and debris.
procedures.
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1.6 CHECK LIST FOR CATALYST LOADING:-
Sr No Activity Description Action By
A Reactor
1 Check whether the reactor has been isolated. The swing elbow
at the outlet should be blinded
2 Open the top manhole by removing the flange connection at
the inlet distributor
an air hose

baskets

Pipe.
1 There is 13mm of alumina balls
2 catalyst also: Shift Max 120(C12-4)


2 Maximum permissible free fall height of the catalyst is 0.5

meter
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3 In case of rain stop loading


the reactor
12 A lifting device (crane or a system of winches) to lift the

mobile




1 Catalyst sampling

hopper
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E Catalyst loading


F Catalyst loading
mobile hopper

reactor
3 Fill the Shift Max 120(C12-4) catalyst.

cover them

Specified.


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the equipment.
maximum.
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2.0 Catalyst Unloading For HT Shift Reactor-R 201:-
2.1 Introduction:-
following provides a general procedure for the unloading of catalyst from the HT Shift Reactor.
The user must adapt the following procedures to their specific situation.
2.2 Safety:-
the operation.
minimum:

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outlet nozzles.
appliances
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3.0 Catalyst Loading Equipment:-
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1.0 GENERAL ITEMS
1.1.1 . Air (6-10 bar) X
1.1.2 . Electricity (220/240v 400/440v)
1.1.3 . Water X
1.13 Pallets


2.2.5 Crane Driver
3.9 BA Bottles
3.15 Chain blocks
3.17 Rope
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STEAM REFORMER (H001)
INDEX
PAGE
CLAUSE DESCRIPTION
NO
1.0 GENERAL 69-71
2.0 PREPARATION 72
2.1-SCREENING AND CLEANING OF CATALYST 72
2.2-WEIGHING AND SOCKING OF CATALYST 72-73
3.0 STEAM REFORMER & REFORMER TUBE LAYOUT 74-75
3.1- CATALYST PHYSICAL AND CHEMICAL PROPERTIES 76-78
3.2- CATALYST LOADING PRINCIPLES FOR H-001 79
3.3- CATALYST LOADING PROCEDURE FOR H-001 80-81
3.4- LOADING PRECAUTIONS 82
4.0 ∆P MEASUREMENT ACROSS THE EMPTY TUBES 83-85
5.0 CATALYST UNLOADING FOR STEAM REFORMER H-001 86

5.1- INTRODUCTION 86
5.2- SAFTEY 86
5.3- UNLOADING PROCEDURE 87
6.0 EQUIPMENT LIST& SCOPE FOR LOADING & UNLOADING 88-89
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The drawing, design and details given on this format are the property of ESSAR OIL LIMITED... They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or 1.0 General:-
Catalyst can be loaded by three procedures traditional UNIDENSE™ loading, Socks method,
Spiral method.
In this chapter general description of catalyst loading by Unidense technology & Socks method
given.
About Unidense Technology
The UNIDENSE™ technology is a loading method for primary reformer catalyst tubes which is
simple and faster then the traditional "sock" loading method. Catalyst is slowly filled into the tube
through a specially designed funnel and the loading rope is gradually pulled out of the tube as the
catalyst layer builds up. The brushes with flexible springs reduce the speed of the catalyst particles
so that breakage is avoided. With the UNIDENSE™ technology the catalyst particles will have a
free fall of approx. 0.5 m from the lowest brush to the catalyst surface. This gives a "low intensity"
filling and the particles will come to rest before being interlocked by other particles. Hence, there
will not be any risk for bridging, and vibration of the tubes is not necessary.
The UNIDENSE™ technology ensures a filling without extra voids and a high uniform density along
the full length of the tubes is obtained. The catalyst is charged from buckets and the time
consuming and expensive socking of the catalyst is avoided. Weighing of catalyst loaded in each
tube is not always necessary and is made in only a few tubes or at the client’s request.
When more than one type of catalyst is to be loaded in the tubes with the UNIDENSE™ technology
the level for each type is easily adjusted by marks on the loading rope, and frequent measurement
of loaded outages are therefore not necessary. We have experience from an emergency loading
with 5 different types (shapes and sizes), including used and screened catalyst, and the final
pressure drop variation was less than ± 5 %.
Our guaranty for the variation in pressure drop measurement of the loading is that the final result
shall be within ± 5 % of the average. However, a variation of ± 3 % or less is a realistic target when
a careful loading has been made. The pressure drop is normally measured with the plant's own
equipment and personnel as a quality control, and is normally taken during night in order to
minimize variations in temperature and barometric pressure.
With the UNIDENSE™ technology we often experience that more catalyst (3 to 7 %) is loaded than
with the "sock" method and vibration. This is due to the uniform packing of the catalyst, which will
minimize the settling of the catalyst during operation. We have experience from one plant with
many starts and stops that the settling of the catalyst was even and only a few inches in all the
tubes. The increase in density seams not to result in increased pressure drop in the reformer as
normally should.
Benefits with Unidense Technology
Socking of catalyst and weighing of the socks prior to loading is time consuming and is avoided with
the UNIDENSE™ technology. However, the catalyst has to be brought to the tubes, and we have
good experience with transfer of the catalyst in bags with up to approx. 30 kg. Bagging of the
catalyst is much faster than filling a large number of socks and only a few bags need to be weighed.
We have also very good experience by using hoppers and charging the catalyst directly in buckets
which is carried to the tubes.
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The drawing, design and details given on this format are the property of ESSAR OIL LIMITED... They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or The UNIDENSE™ technology is a fast loading method. The actual time for loading a tube with
UNIDENSE™ vary depending on the tube dimensions and is for a 4" i.d. tube less than 10 minutes
including the final outage measurement. A reformer with 300 to 400 tubes is normally completed in
3 to 4 shifts of 12 hour. The time it takes to complete the reformer loading with the UNIDENSE™
technology is often less than half of the time for sock loading.
Often the time to replace the primary reformer catalyst is the critical item in a maintenance plant
stop and reducing the down time is the operator’s main goal. Even using less man-hour for catalyst
replacements is a great benefit.
Pressure drop of the tubes has proved to be within a narrow range with the majority within ± 2,5 %
variation around the average pressure drop. Rarely tubes have pressure drop outside of ± 5 %,
and most of the reformers have been completed without reloading of tubes. Since reloading of
tubes is avoided, no expensive catalyst is wasted.
Often when a "sock" loading is made problems like loosing a part of a sock or a full sock into the
tube happens. Sometimes the sock opens during lowering into the tube and catalyst has free fall
causing catalyst breakage. The way the vibration is made varies from team to team leading to large
variations in loaded density and pressure drop. Adjustment of the loading by vibration and
reloading of tubes is time consuming and may delay start up of the plant. Such or similar problems
are avoided by the UNIDENSE™ technology, and very seldom tubes need to be emptied and
reloaded. We see only positive effects and no negative risks of using the UNIDENSE™ technology
compared with the "sock" loading method.
The even and stable pressure drop results in even tube wall temperatures and the high uniform
loaded density will ensure a long life of the reformer tubes and allow for improved conversion and
increased throughput. UNIDENSE™ technology contributes to extended operating periods.
In summary the main benefits with the UNIDENSE™ technology are:
- No need for socking/weighing of catalyst - Time and manpower saving prior to loading
- Catalyst delivered in drums / bags - Lower costs
- No need for vibration or hammering - no damage to tubes, insulation and structure
- Less risk for refilling of tubes - less problems during the loading and less waste of catalyst
- Uniform high loaded density and uniform pressure drop - prolonged tube life and potential for
increased production
- No bridging or extra voids - less settling and less tendency to hot spots
- The loading can be completed in less time - reduced down time and labour cost
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About Sock Loading Method
The traditional "sock" loading method results in a loose filling. When the catalyst flushes out of the
sock this will be a "high intensity" filling and the catalyst particles will interlock and form bridges.
Vibration will remove some of the bridges and increase the density. After the plant is started, the
tubes will expand and some bridges may break and cause settling of the catalyst and possibly new
bridges and hot spots. When vibration is used on the top of the tube it is obvious that the effect of
the vibration in the lower/bottom part of the tube will be less. We have experienced that settling of
the catalyst after a "sock" loading has been to such an extent that the catalyst level has been inside
the fired zone and resulted in overheating of the top part of the tubes.
This document describes how catalyst is loaded and unloaded in the Steam Reformer H-001by
means of traditional Sock Method.
Each tube in the steam reformer must be packed uniformly with catalyst in such a way that all of the
tubes offer a similar resistance to the flow of process gas, so the process gas will be evenly
distributed over the reformer. If the flow is not balanced, catalyst in some tubes will tend to be
overloaded with gas flows, while those tubes with low gas flows may tend to overheat. The simplest
way to check the packing of a tube is to measure the pressure drop though it.
The inside of all reformer tubes should always be visually inspected before any catalyst loading
takes place. It is quite common to find pieces of cardboard or other debris during this inspection.
Today inspection are also executed bye viber objective inspection, there are specialist companies
for this kind of inspectctions.

Before catalyst charging begins, catalyst tubes, outlet pigtails should be tested,
To ensure that they are clear from any obstructions. To check this, a pressure drop test should be
carried out, using the pressure drop device as mentioned before. The pressure drop test is done,
bye blowing a constant quantity of air or nitrogen through each tube with the inlet pigtails suitably
plugged and the outlet ends open to atmosphere. Remove manhole cover on Process Gas Waste
Heat Boiler.
The constant quantity of air or nitrogen is obtained by the critical flow through the orifice of the
pressure drop measurement device, keeping the supply pressure constant (7.0 kg/cm2g).
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2.0 Preparations:-
The below chapter deals with the preparations which should be made prior to loading.
2.1 Cleaning and Screening of Catalyst:-
Even though the almost care is taken during transport of the catalyst, both to and within the site
boundaries, the drums may contain a small percentage of dust and fines.
The simplest and most effective method of cleaning the catalyst is to pass the catalyst down an
inclined sieve. If the catalyst has been subject to extreme rough handling, the cleaning can be
effected by blowing with clean dry air in order to remove dust and fines.
The mesh size of the sieve should be approximately one half of the minimum external catalyst
dimension. Dimensions of recommended mesh apparatus are given below:
16 X 8 16 X 11 20 X 18
Approx.mesh(mm) 4-5 5-6 9-10
The sieving operation should take place on the ground in a screened-off area.
Personnel involved in the operation should wear gloves and dust masks.
2.2 Weighing and Socking of Catalyst:

It is recommended that catalyst should be loaded via polyethylene or canvas socks and in order to
cut down the loading time, we suggest presoaking the whole catalyst charge prior to loading.
In most case, the reformer catalyst charge consists of two or more different catalyst types and/or
sizes. Due to small variations in particle and loading densities, it is not possible beforehand to
predict the exact quantity of each catalyst type to be loaded into each tube. Base on the expected
density of the catalyst and the size of the socks available, the quantity of each catalyst type to be
loaded is calculated and distributed into a suitable number of socks.
The accuracy of the weight of catalyst per sock should be better than ±0.1kg
In order to distinguish between various types or sizes of catalysts, socks of different colors or
lengths could be applied.
In general, the “lay-fat-width” of the socks used should be 1.3 to 1.4 times the inner diameter of the
reformer tubes. The thickness of polyethylene socks should be minimum 0.2mm.
Suitable specifications of the polyethylene socks are thus:
Tube diameter,mm(in) 71(2.8) 100(4) 125(5)

Lay-flat width,mm(in) 100(4) 135(5 ¼) 175(7)
Loaded sock length, m(ft) 1.5-2.2(5-7) 1.2-1.8(4-6) 0.9-1.3(3-4)
Weight per sock, kg 4-6(9-13) 6-8(13-18) 6-8(13-18)
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Set Up for Screening, Weighing, and Socking of Catalyst:-
Explanation to the figure:-

The drums are brought to the platform “A” and put on the inclined screen “B” where dust and fines
are removed.
On platform “C” the catalyst is put into a bucket “D” which is weighted (weight E).
The catalyst is then put into the funnel “F” under which the sock”G” is placed
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3.2 Catalyst Loading Principles for H-001:-
The normal method of charging reformer tubes is with pre-filled polythene socks or canvas socks to
fill at site. The catalyst to be loaded shall be inspected prior to charging and any fines which could
cause an excessive pressure drop when charged should be screened out. The reforming catalyst
should be weighed before charging to provide a check on the quantity of the catalyst loaded to each
tube.
It is important that the catalyst is uniformly loaded in the reformer as this ensures an even pressure
drop and thereby an even gas flow distribution.
The loading principle applied for the Steam Reformer is based on the idea that each catalyst pellet
must drop freely for 500 mm prior to landing on the catalyst surface. The falling height causes the
pellets to impact the packed bed with sufficient energy to vibrate the top layer of the bed, thereby
ensuring a high loading density. On the other hand the impact speed is too low to cause breakage
to the pellets.
The controlled free drop height stated above is accomplished by using special loading tubes, which
are inserted from the top of the Steam Reformer down to just above the catalyst bed surface. The
loading tubes are fitted with an internal spiral. The spiral forces the pellets to roll along the tube
inner diameter rather than to fall freely and vertically. Hereby the velocity of the pellets is limited.
Initially, the loading tubes will be so long that they reach from 1.5 m above the Steam Reformer
bottom to outside the reformer, i.e. approximately 12.5 meters.
The catalyst falls into the loading tubes from a loading box with carefully sized compartments
matching the demand for catalyst at the specific position. The flow out of the compartments can be
blocked by means of relative movement of matching whole plates. As the loading progresses, the
loading tubes are gradually withdrawn and shortened so that a pellet free falling height of roughly
500 mm is always respected.
Catalyst loading can be performed with the Steam Reformer internal positioned in the pressure
shell or in the maintenance structure.
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3.3 Catalyst Loading Procedure - Step by Step:-
It is recommended that the reformer tubes will be loaded in either two or three stages (50 &100
percent or 30, 60 & 100 percent). A complete loading of the Steam Reformer comprises the
following steps:
¾ Cleaning of the reformer inlet piping, distributor and hairpins must be finished prior to catalyst
loading in order to avoid dirt blowing to the catalyst
¾ Prior to loading it must be checked that the catalyst tubes are clean and free of grease
¾ The catalyst retaining grid and the blind flange on the unloading hand hole are installed.
¾ Correct installation of the grid in the bottom of the tubes should be verified
¾ When the catalyst is charged into the reformer tubes, it is important that the catalyst is not
dropped from more than 500mm.
¾ The catalyst is loaded to abt. 820 - 850 mm distance from the tube top flange.
¾ Space specified above is required to finally install the insulation inserts (length 800 mm) in
the top section of each reformer tube.
¾ The catalyst pellets must not be allowed to form bridges across the tubes, as this leads to
empty regions in the tubes and overheating during operation.
¾ When using sock method for loading catalyst in the reformer tubes, it is important to ensure
that the socks are of the correct size so that they will slide easily up and down the tube when
they contains catalyst.
¾ Weight of catalyst, vendor batch number and any other relevant catalyst data should be
recorded
¾ Keep the sock full at all times so catalyst does not drop more than about 12 inches.
¾ When the sock has reached the bottom of the tube, the cord is withdrawn with a sharp tug,
which allows the bottom end of the sock to unfold and the catalyst to fall gently into the tube.
¾ As the catalyst is loaded, it is necessary to vibrate the tube to give uniform packing and
ensure even gas distribution.
¾ Take some random sample from the charged catalyst.
¾ After completion of catalyst loading in tubes its necessary to carryout Pressure Drop
Measurement Test on Filled Tubes to insure that there is no voids have been formed as a
result of bridging of particles and that he catalyst has not been disintegrated too much as a
result of careless loading or excessive tube vibration.
¾ Pressure Drop Measurement Test across each loaded tube are carried out in the same way
as described under pressure drop measurements on empty tubes.
¾ Any tube has an up normal pressure drop reading it should be hammered well or unload and
re-load.
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Reformer Tube Sock Loading:-H-001:-
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3.4 Loading Precaution:-
¾ Check each tube to ensure that it is clear of any blockage to the support grid and the inlet
and exit pipe work.
¾ If a sock loading method will be used, care must be taken to avoid the opening
prematurely. The height of fall should be limited to 50cm maximum.
¾ Periodically, the tube should be vibrate to settle the catalysts by using a soft hammer to
hit the top flange of tube 3-5 times after each sock is loaded excessive vibration can lead
to catalyst breakage which must be avoided.
¾ The vibration routine should determine by trial on one or two tubes. After loading for each
sock, the tube should hit 3 times and the catalysts depth checked. If there was no further
settling 3 hammer blows are sufficient after each sock.
¾ With each catalysts layer, it is important to endure that each tube is loaded with catalysts
in the correct order.
¾ The pressure drop of the tube should be checked after the second layer of the catalyst
has been loaded. Adjustment of any low pressure deep tubes should be made by limited
additional vibration, if there is further settling, additional catalysts should be added.
¾ After the upper half of the catalysts is loaded, a further process of checking pressure drop
and adjustment should be made if any tubes remain above 105% of the median pressure
drop and then these tubes should be discharge and reloaded.
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4.0 Pressure Drop Measurements across Empty Tubes:-
The purpose of this procedure is to determine whether the outlet hairpin/outlet system is obstructed
or not. For reformer designs without outlet hairpins, the pressure drop should be equal to the “zero”
pressure drop of the ∆P equipment. For the designs, the pressure drop should be uniform and low.
The pressure drop is measured across empty tubes and taken down on a log sheet for each
individual tube.
A suitable device for pressure drop measurement is described below

The pressure drop across the tubes should be checked with equipment delivering a constant flow of
air through the tubes.
The principle is that an orifice is designed as a “critical flow nozzle” i.e. sized in such a way that the
air flow through its throat is supersonic. This will ensure that the flow will depend only on the
upstream pressure.
In order to accomplish this, the upstream pressure (absolute) should be at least twice the
downstream pressure (atmospheric pressure plus pressure drop across the catalyst).
Further the orifice open area should be at least 5 times smaller than the pipe in which it is placed.
The standard of the industry an apparatus consisting of the following elements:

¾ Pipe
¾ Valve
¾ Upstream pressure gauge
¾ Restriction orifice
¾ Downstream pressure gauge
¾ Expandable rubber bung equipped with eccentric device for easy expansion
¾ The pipe: The pipe would normally have an inner diameter of 25-50mm (1-2”). The pipe ID
should preferably be at least 5 times the orifice size.
¾ The valve: A standard globe valve for easy regulation of upstream pressure.
¾ The upstream pressure gauge: The upstream pressure gauge should be a precision gauge
(0.5% accuracy). The upstream pressure should preferably be 70-80% of the full-scale
reading. The upstream pressure would typically be between 2 and 4 kg/cm2
¾ The orifice: The flow through the orifice is approximately linearly dependent on the upstream
pressure and the orifice size. The pressure drop across the catalyst will be dependent on the
tube ID and of course, the catalyst sixe and loaded height.
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For a normal size primary reforming catalyst, we would find the following orifice sizes suitable when
The drawing, design and details given on this format are the property of ESSAR OIL LIMITED... They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or operating at an upstream pressure of 2-4 kg/cm2g.
Tube ID(mm) 70 80 90 100 120 140

(inch) 2.8 3.2 3.5 3.9 4.7 5.5
Orifice size(mm) 5 6 6 7 8 9
(inch) 3/16 1/4 1/4 5/16 5/16 11/32
¾ Downstream pressure gauge: The downstream pressure gauge should also be of the
precision type (0.5% accuracy) and the reading should preferably also be 70-80% of the full-
scale reading for the fully loaded tube.
When selecting the above mentioned orifice sizes, the following gauges are recommended:
Up stream pressure
Kg/cm2g 2 3 4
Up stream gauge range
Kg/cm2g 0-3 0-4 0-5
Down stream gauge range
Kg/cm2g 0-1 0-1.5 0-2.0
¾ Test before use: It is important that the pressure drop device is designed without undue
restriction downstream the orifice, so that the pressure drop across the device itself is small
compared to that of the filled catalyst tube. This “built-in” pressure drop is checked by
blowing air through the equipment at the same rate as would later be used when checking
the pressure drop through the tubes. This “zero” figure should be small.
¾ Special notes: If supersonic flow is not achieved, the orifice diameter should be decreased
of the upstream pressure could be increased with due consideration to the accuracy
deliberations mentioned above.
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Sketch of ∆P Measurement Equipment:
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5.0 Catalysts Unloading For Steam Reformer-H-001
5.1 Introduction:-
following provides a general procedure for the unloading of catalyst from the Steam Reformer.
The user must adapt the following procedures to their specific situation.
7.2 Safety:-
the operation.
minimum:
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¾ Reformer internal is uninstalled and reformer is isolated from plants with blind at the inlet and
outlet nozzles.
¾ Reformer keep under N2 atmosphere till the catalyst oxidized.
¾ Reformer is being inspected for any damage before unloading is being started so that
remedial measures on operation as well as maintenance side can be planned.
¾ Catalyst unloading job is in inert atmosphere and confined reformer. The risk factors involved
appliances
emergency call and shall remain present on Reformer top
¾ The temperature and oxygen monitoring in the reformer.

¾ For removal of catalysts from the reformer tubes a vacuum device should be used.
The catalysts are sucked up through the hose to a cyclone.
¾ Special care should be taken to avoid over stressing the casing of the furnace by
Excessive loads during the unloading.

¾ Perform an inspection of the reformer and initiate any repairs as required. Carefully check
for mechanical damage and areas where gas bypassing can occur
¾ Clean inside the reformer for inspection.
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6.0 Equipment Requirements for H-001 Catalyst Loading:-

1.0GENERAL ITEMS
1.1General Utilities:(nearby reactor area)
1.1.1. Air (6-10 bar) X
1.1.2. Electricity (220/240v 400/440v) X
1.1.3. Water X
1.1.4. Nitrogen purge (incl. ground) and blanket 500Nm3 / Hr X
1.2New Catalyst (in jumbo bags/Drums) X
1.3New Ceramic Balls, various dia (in drums) X
1.4Mech. Activities (spading, elbow de/re-tensioning etc.) X
1.5Exterior lighting at reactor X
1.6Scaffolding as required X
1.7Provision drinking water at reactor area X
1.8Sanitary facilities (showers, toilets) within the plant X
1.9Drums (and weather protection) for spent catalyst X
1.1Disposal spent catalyst X
1.11Fire Fighting (standby personnel & equipment) X
1.12Final Site Clean Up X
1.13Pallets X
X
1.14Apparatus for ∆p measurement on reformer tubes
X
1.15Canvas socks for loading of reformer tubes or unidense
1.16Hammer for vibration on reformer tubes rubber or leather X
faced. X
2.0 MANPOWER: (Day & Night coverage)
X
Catalyst Technician
2.1.1 X
2.2.1 Ground Support Foreman X
2.2.2 Ground Support Assistants
X
2.2.3 Forklift Driver
X
2.2.4 Truck Driver (drums from/to stores)
X
2.2.5 Crane Driver
X
2.3 PPE for all CRIN paid Personnel
X
X
2.5 Board & Lodging Specialised Dense Loading Staff
3.0 CATALYST UNLOADING & LOADING (Day & Night)
X
3.1 1No Flatbed Truck (catalyst from/to storage area)
X
X
3.3 Forklifts (min 2.5T-moving drums at reactor area)
3.5 Ground Communications Equipment (Walkie Talkies)
3.6 Reactor Entry Ladder
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The drawing, design and details given on this format are the property of ESSAR OIL LIMITED... They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or 3.8 HP filling compressor X
3.9 BA Bottles X
3.11 Mechanical Hand Tools (incl. pneumatic) X
3.13 Air Hose 3/8in & 3/4in X
3.15 Chain blocks X
3.17 Rope X
3.19 QA Documentation (i.e. loading logs) X
3.2 Dense Loading Machine x 2 Certified Operators NA
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7.0 Material Safety Data Sheet for Catalyst—G-90:-
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Material Safety Data Sheet for Catalyst C11-NK:-
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Catalyst Procedure

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The drawing, design and details given on this format are the property of ESSAR OIL LIMIED.

CATALYST LOADING & UNLOADING PROCEDURE

DESULPHURISER REACTOR (R 1A/B)

RELOCATED HYDROGEN MANUFACTURING UNIT

(REFER DOCUMENT NUMBERING SYSTEM FOR DETAILS)

REFINERY EXPANSION OPERATIONS

ESSAR OIL REFINERY, VADINAR

PREPARED BY CHECKED BY APPROVED BY

ESSAR OIL LIMITED

ESSAR OIL LIMITED

REFINERY EXPANSION OPERATIONS

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1.1 Mechanical Drawing & Nozzle Details for R-201:-

Mark Qty Size Sch. Rating Facing Type Remarks

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Mark Qty Size Sch. Rating Facing Type Remarks

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ESSAR OIL LIMITED

REFINERY EXPANSION OPERATIONS

ESSAR OIL LIMITED

REFINERY EXPANSION OPERATIONS

the relevant catalyst.

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¾ The bottom and top screens must be checked.

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4 Remove the five concentric support rings together with the

5 Ensure that wooden covers are placed over the baskets

6 Inspect outlet collector & screen on it

8 Check for uniform slot openings on the outlet collector

B Alumina balls & catalyst

1 There are two types of alumina balls- One of diameter 13-

3 Ensure the availability of all necessary safety & personnel

C Precaution to be taken while loading

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3 In case of rain stop loading

4 No foreign material like pieces of sleeve, walking boards, tools

5 Dust masks should be worn inside the reactor

6 Special loading device checking for availability

8 A slide valve must be fitted to it

10 Canvas sleeves with adequate length of 150 mm diameter

11 A mobile hopper with capacity to hold 3 drums of catalyst

12 A lifting device (crane or a system of winches) to lift the mobile

13 Temporary shelters should be erected on top of the reactor

14 A vacuum cleaner should be available to eliminate dust and

15 Device for tooling, lighting, dust masks, respirators, safety

D Loading of the reactor

3 Transport the 13 mm size alumina balls by the mobile

5 Fill the alumina balls on the collector tray to a height of 3/4"

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9 In a similar fashion transport and fill the 6 mm alumina balls

2 Level the catalyst after each meter

4 Now fill this catalyst in this way up to 2.9 meters of the

2 Transport and fill the stationary hopper at the top of the

3 Fill the C-L2 catalyst over the previous layer of S2(C7-6)

4 Check if wooden covers are placed over the baskets, If not,

5 Continue loading the catalyst around the baskets to the level

6 Level the alumina balls

10 Install the inlet distributor at its position

11 Box up the top manhole

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