CR Asia Group

Work Instruction for

Catalyst Loading by Dense method (Multi Bed) in Inert
Atmosphere
1. Objective
This work instruction is to ensure that the task is performed safely with no
impact on personnel and environment.
2. Scope
This work instruction is applies to all CR Petrochem, however does not apply
when standard entry conditions are exceeded where additional PPE is required.
3. Reference document
NA
4. Form
4.1 F-CH-01
4.2 F-CH-04
4.3 F-CH-06

Blind Register
Loading Report
Entry Log

5. Definition
6. Responsibilities
6.1 Project / Division Manager is responsible to review customer requirements
and to assign subordinates to perform work efficiently and safely. Keep monitoring
operation performance, assist with problem solving and liaise with the customer.
Review reports after job completion.
6.2 Superintendent / Engineer / Supervisor is responsible to complete site
survey and specify scope of work to estimate and plan resources required
(manpower, tools, equipment and sub-contractor) Supervise subordinates to
ensure that all work is carried out efficiently and safely, perform safety audits
within work area and conduct safety toolbox talk before starting work.
6.3 Foreman / Technician / Workers are responsible to follow strictly each step
of this instruction and perform work that is assigned by their supervisor.
7. Procedure Steps
7.1 Preparation & Safety
7.1.1 Hold the JSA prior to Job set up
7.1.2 Hold the tool box talk immediately prior to starting the entries & before
every shift. Record the data in Safety Tool Box Form.
7.1.3 Take a valid permit for execution of job.
7.1.4 Brief all the crew on the safety precaution
7.1.5 Ensure the respirator is suitable for Job Execution.
7.1.6 Ensure that all the equipment like Vacuum Unit, Cyclone ,Demountable
Vacuum Pipe, Vacuum Hose, Dust Collector, Inside Lightening ( 24 Volt),dense

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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Copy Number :

Issue Number :

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CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (Multi Bed) in Inert
Atmosphere
loading device other safety equipment set as per requirement, screening
machine, lifting tools tackles, rescue equipment
7.2 Blinding of reactor
7.2.1
Ensure de-pressurization of all work-related lines with
mechanical/maintenance dept. of client.
7.2.2 Procure blinds list and physically identify blinds to be installed under CLIENT
presence
7.2.3 Working platform is to be fully secure and safe for work
7.2.4 Request for scaffolding if required at any locations.
7.2.5 Procure work permits with RA and blind list.
7.2.6 Brief all crew on the safety precautions laid out on the permit.
7.2.7 Establish what service the lines have been in and have the correct personnel
protective equipment in-place.
7.2.8 Un-bolting is to be performed using the tensioning/torqueing tools as
directed by CLIENT.
7.2.9 Usage of hammer (extreme cases like non-assembly of torqueing/tensioning
tools with the nuts/bolts) is to be done only after acquiring permission from
CLIENT.
7.2.10
Bolts and nuts removed are to be placed in trays.
7.2.11
Spilt product from flanges to be collected by
trays placed underneath the flange and adequately disposed.
7.2.12
Before starting to remove final bolts, ensure
that all necessary safety measures are being taken, and correct PPEs.
7.2.13 Single line BA mask to be used depending on the Conditions.
7.2.14
Bolts farthest from manpower are to be
removed initially such that no harm arises from exit of materials, if any.
7.2.15
Before removing all bolts, ensure that all
points on the flange are adequately supported.
7.2.16
Proper gaskets to be installed alongside the blinds.
7.2.17
Bolting performed as per the sequence to be
followed after alignment of the flanges.
7.2.18
Check all blinds after completion for client
approval prior to accepting signatures from all concerned departments on
the blinds-list.
7.2.19
House-keeping of the particular work area
7.3 LINING UP EQUIPMENTS IN REACTOR
7.3.1.The following are the general procedures for lining up equipment for catalyst
change outs for reactors. There are usually two methods employed to unload
catalyst. These are vacuuming and bottom dumping.
7.3.2. The general procedures for preparation for this work include:
Ensure that all permits are in place.
Set up site office, containers etc.

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (Multi Bed) in Inert
Atmosphere
Establish communications and cordon off area in agreement with client.
Line up and secure vacuum equipment and associated pipe work.
Set up ground support equipment etc.
Set up dust collection equipment and ducting.
Establish a stockpile of empty drums or containers around reactor base.
Ensure all PPE is being worn and is suitable.
Dust Collectors are functioning correctly.
Take catalyst samples as required.
Ensure QA/QC is being followed.
Keep area clean and SAFE.
Line up Life Support Equipment and test (only to be carried out by certified
personnel).
Nitrogen Lances operable.
7.4 INITIAL GAS TESTING REACTOR
7.4.1 The following is the standard outline of requirements for testing of
atmospheres in Confined spaces prior to personnel entry. These limits are for
entry without gas suits.
7.4.2 This procedure is implemented to ensure that our personnel do not become
exposed to gases or chemicals that will be immediately dangerous to life and
health.
7.4.3 The following tests are carried out to ensure all personnel are aware or the
dangers involved.
Oxygen Content: Inert Entry <3 %
Temperature: < 40 deg. C
Hydrocarbons: 1% Volume
LEL: <10%
Hydrogen Sulphide: 10ppm
Carbon Monoxide: 50ppm
Benzene: 5ppm
Carbonyls: 0.1ppm

(NOTE: Parameters may change as per job requirement)

These limits are subject to change as regulations vary from country to country. We
believe that they are within acceptable tolerances.
All tests are carried out using either Honeywell or Dragger gas testing units (or
their equivalents) for the Oxygen and LEL. Dragger or Honeywell (or their
equivalents) test tubes are used for recording other substances. These results are
to be recorded on the Atmosphere Analysis Result Form.
The oxygen and LEL are always monitored continuously when personnel are inside
a confined space to ensure no unforeseen problems arise.
NOTE: There are other substances that from time to time may be present in the
atmospheres that we are to enter. These will be either identified by our clients or
from MSDS (material safety data sheets) supplied the client.
Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (Multi Bed) in Inert
Atmosphere
7.5 CATALYST LOADING by Dense Loading in Inert Atmosphere.
7.5.1.
The following procedure describes in detail the loading steps
recommended by dense loading OEM. As the reaction section has undergone
a special drying procedure, care must be taken to ensure that no air or
moisture enters the reactors during the catalyst loading period. It is
recommended that the reactors be loaded using dense loading apparatus .
7.5.2.
The catalyst is contained in a heavy plastic bag with an unloading
neck. This bag is inside another heat-sealed plastic bag. Care should be
taken in the drums handling so as not to break or puncture the plastic bags.
Before, during and after catalyst loading the catalyst must be
protected from moisture at all times. Any contact with water or air will result
in permanent deactivation of the catalyst.

7.5.3.

7.5.4.

The empty drums and bags should be kept to return.

7.5.5.

Preparation

7.5.6.1. Prior to the loading, preliminary checking.

7.5.6.2. The catalysts for loading, are stored by sealed plastic bags in drums.
7.5.6.3. The inert balls for top of the catalyst bed, it is recommended that these

balls be oven dried and stored in sealed plastic bags in drums similar to
the catalyst.
7.5.6.4. Sufficient dry nitrogen (less than 1 ppm wt H 2O). If not available provide

temporary piping to route nitrogen through the hydrogen dryers.

7.5.6.5. Provide emergency nitrogen storage in case of refinery nitrogen failure.
7.5.6.6. Make available several nitrogen flexible hoses. They must be specified for

nitrogen service, must be new and perfectly dry.

7.5.6.7. One standing hopper .One forklift to handle the drum pallets.
7.5.6.8. Tarpaulins should be available in case of rain or interruption during

loading.
7.5.6.9. One safety harness, portable oxygen analyzer, air packs and dust masks.

The oxygen analyzer will be used when reactors are open

for catalyst loading to make sure that no air is entering.

7.5.6.10.
7.5.6.

Catalyst Loading Procedure

7.5.7.1. The following instructions must be strictly adhered to throughout the

entire catalyst loading for the reactors. An loading specialist will be

present during the loading to advise and monitor the loading method. It is
imperative that no air or moisture enters the reactors or comes in contact
with the catalyst at any time.

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (Multi Bed) in Inert
Atmosphere
7.5.7.2. Connect the nitrogen flexible hoses from nitrogen header to drain point at

reactor bottom and to inlet pressure gauge tapping at reactor inlet line.
7.5.7.3. Start a small purge of nitrogen into the reactor bottom and out the reactor

inlet PI connection.
7.5.7.4. Unbolt and remove the reactor inlet elbow and top head. As the reactor is

opened, tightly cover the open flanges with plastic until the bottom inert
balls entry.
7.5.7.5. To install the dense loading device on the bottom bed of reactor , attach

the nitrogen connection and then attach the loading sock from the
stationary pipe above.
7.5.7.6. Set down on the top man hole the stationary steel cover, the standing

hopper and pipe catalyst loading.

7.5.7.7. At the same time, care must be taken to ensure that the sock penetrates

in the center of device. Look it through the little hole drilled on the steel
cover
7.5.7.8. Then load, drum by drum the required quantity of catalyst.
7.5.7.9. After the catalyst has been loaded install the top bed inert alumina balls

layer
Cover the man way again with plastic. Remove all the dense
loading devices off the top platform. And box up the tray sections of
respective beds.

7.5.7.10.

7.5.7.11.

Follow the steps 7.5.7.5 to 7.5.7.10 for no. of beds.

As quickly as possible after the loading is complete, install the

inlet distributor tray, reactor cover and inlet removable elbow.

7.5.7.12.

Continue the nitrogen purge at the bottom of the reactor out

through the inlet PI. Check that the purge out through the PI is oxygen
free.

7.5.7.13.

7.5.7.14.

Pressure the reactor back up to 0.5 bar g. Check for flange

leaks.
7.5.7.15.

Record all loading data, number of catalyst drums, inert balls,

etc.
Note : The opening, loading and closing procedure of the reactors should be a
continuous operation without break. During this operation a positive nitrogen
pressure should be maintained in the reactor at all times.
7.6 Box up
7.6.1 Reinstate the tray sections and clean.
7.6.2 Request final inspection & clearance for man way box up.
7.6.3 Box up reactor man way elbow using torqueing / tensioning .

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

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CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (Multi Bed) in Inert
Atmosphere
7.7 De-blinding
7.7.1. Procure work permits with RA and blind/de-blind list.
7.7.2. Identify the locations and request for scaffolding if necessary.
7.7.3. Use necessary PPE, loosen bolts and carefully remove the blind or reverse
the blind manually or using chain block or crane.
7.7.4. Remove the old gaskets and box up the flange with new gaskets inspected
by CLIENT.
7.7.5. Bolting initiated by hand-tightening followed by tension/torque tightening
as per the sequence to be followed after alignment of the flanges. The
torque/tension sequence with values are to be recorded.
7.7.6. Ensure all the joints mentioned in the list are de-blinded and tightened.
7.7.7. Tag all flanges after completion for client approval prior to accepting
signatures from all concerned departments on the deblind- list.
7.8

SITE CLEAN UP (Housekeeping)

7.8.1.Housekeeping is always an important part of any project and the object is to

leave any site as clean if not cleaner then when you arrived.
7.8.2.Always clean equipment at work site prior to demobilization. No equipment
should ever leave the site dirty.
7.8.3.
All electrical leads to be rolled up and taped securely. Ensure that there is
no risk of other equipment being loaded or sat on top of leads causing
damage.
7.8.4.All airlines and hoses are to be washed, rolled up and secure these are to be
either placed in hose cages or site container.
7.8.5. If any equipment is damaged this should be clearly identified and taken off
site for repairs.
7.8.6.All areas around the work area that were made dirty or are dirty should be
degreased and cleaned. Any contaminated soil should be placed in
containers for further treatment.
7.8.7.All used gloves, paper overalls, rags and other consumable should be
collected for correct disposal and not left in the work area.
7.8.8. All empty drums should be removed from the area.
7.8.9. Check that all fittings have been removed from temporary pipe work.
7.8.10. All vacuum or pump hose should be washed and stored correctly for
transportation.
7.8.11. Return any equipment that is not required for the next project to local
office/yard for service.
7.8.12. All equipment that is on hire should be cleaned and returned to the
appropriate hire company or collection organized.
7.8.13. Ensure that clients view the site when you have completed demobilization.
Show pride in the fact that we have not left the client with any further
problems.
7.8.14.Have the clients representative sign the completion certificate and
encourage them to make comments on the way the site has been handed
back to him.
Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (Multi Bed) in Inert
Atmosphere

8.0 Process flow chart

Mobile Hopper

Fixed Hopper
to feed
Scaffolding

Dense Machine

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

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