RW-WI-001-18-

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CATALYST/ADSORBENT Page No. Page 1 of 11

SUBJECT: WORK PORCEDURE FOR UNLOADING/

LOADING CATALYST/ADSORBENT

CLIENT: PETRONAS CHEMICAL MTBE SDN BHD

PROJECT: ADSORBENT CHANGE OUT FOR V- 1004 A PRE

TA PDH 2018

Prepared by : Approved by:

Signature :

Name : Muhammad Faiz

Position : QC Engineer OE PCMTBE (PDH)
Date : 27/02/2018
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Rev. Description Author Effective Date

0 Initial release Muhammad Faiz 27/02/2018

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TABLE OF CONTENTS

SECTION TITLE

1.0 Purpose and scope

2.0 Objective
3.0 Responsibilities
4.0 Work Instruction
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1.0 PURPOSE AND SCOPE

The purpose of this document is to outline the detail step by step work procedure for
preparation and execution work for unloading and loading of adsorbent and ceramic
ball (adsorbent change out)

2.0 OBJECTIVE
This procedure is written with the intention of being a working instruction for RWNA
personnel by detailing the standard of workmanship and acceptance criteria throughout
each phase of loading and unloading activities.

3.0 RESPONSIBILITIES
3.1 Project Manager
 Shall ensure all works related are following the approved
procedure. He shall also act as the overall client interface
throughout the duration of the project.
 To ensure that the works performed according to quality and HSE
requirements, and within time frame.

3.2 Project Engineer

 Responsible for ensuring that client’s agreed quality
requirements are satisfied.
 To ensure that the operations are performed in a safe manner and
that the product meets the requirements specified herein.
 To ensure that the QC inspector inspect and report on the quality
of the product in accordance with this document and other related
document.
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3.3 Safety Supervisor

 Ensure that all the operations are performed in a safe manner
 Ensure that all workers are well trained before starting to perform
their task in order to avoid accident.
 Ensure that all workers comply with specific safety regulation at
client premise.

3.4 Work Supervisor

 Shall be responsible for all workers, consumable, material, and
equipment necessary for the required operation.
 Assist Safety Supervisor to ensure that all the operations are
performed in a safe manner.
 To ensure that all workers are well trained before starting to
perform their task in order to avoid accident.
 Assist Safety Supervisor to ensure that all workers comply with
specific safety regulation at client premise.
 Assist QC to ensure workers perform their works without
neglecting quality aspect.
 Ensure that all inspection and reporting is performed correctly
and submitted to client on time.

3.5 QA/QC
 Ensure all the works performed is according to the client’s
requirement.
 Perform all required inspection in accordance to the latest
revision of the approved ITP.
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 Submit daily report and inspection report to client every day.

4.0 WORK INSTRUCTIONS

4.1 General
 All workers shall have undergone the required and relevant
safety and security induction course.
 Equipment and electrical tools shall have been inspected
and certified for safe use.
 Prepare and mobilize all the required hand tools and pre-
inspected equipment.
 Preparation of equipment setup at the designated vessel i.e.
hooking up flexible suction hoses to cyclone, dust collector
and vacuum machine and laying of air hose and nitrogen
hose.
 Qualified / competent riggers shall be deputed during the
execution of the job to instruct the lifting activity at site.
 Prior to perform the work, all piping/line that connected to
the vessel shall be isolated or de-blinding works (if
applicable) by specific method as per approved EJIS (spade
blind / blank off / swing spectacle blind / shut off valve).
This activity must be witnessed by PCMTBE / OPN team.
 To ensure that the works performed according to quality
and HSE requirement, and within time frame.

4.2 Catalyst Preparation

 Forklift and lorry will be used as main transportation of new
/ fresh media (adsorbent and ceramic ball) from storage
area to temporary storage close to the vessel. Media
containers must be handled carefully.
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 The containers must never be rolled, to avoid breakage of

adsorbent particles.
 The adsorbent should be placed on pallets and should not
be stored directly on ground.
 To protect from rain, cover the adsorbent and ceramic ball
drums with canvas.

4.3 Opening Top Elbow / Manhole Cover and Lifting

 Stand-by multi-layer heavy duty canvas sheet and plywood
cover for covering top manhole.
 Dismantling of top elbow or cover, lifting by using crane
(crane specification and lifting data) as per approved lifting
plan.
 Prior to carry out lifting works, simulation test must be
carrying on crane to ensure that the crane has the right
boom, length and reach. Load test must be carried out on
the crane 1.25 times the maximum load to be lifted.
 The boom length and the distance center of the crane and
the weight to be lifted shall be confirm and measured so
that it follows approved lifting plan requirement and not
exceeding the crane loading chart limits.
 During lifting, involved area shall be double line barricade
and safety signage installed.
 Crane signaling only by authorized / competent signalman.
Watchman / safety watcher to standby to ensure that the
crane boom does not touch any surrounding structure.
 Tailing rope shall be used to ensure that the equipment to
be lifted does not rotate.
 Flange face is to be protected and sealed by using tape.
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4.4 Un-loading Activities

 Before resume the unloading activity, PCMTBE AGT
personnel need to carry out LEL gas checking to ensure that
safe work condition inside the vessel.
 PCMTBE Operation to ensure and confirm that sufficient
of N2 flow through hoses that are connected to the vessel,
cyclone, dust collector and drum, in order to provide
sufficient N2 blanket for the pyrophoric media inside the
vessel, vacuum, cyclone, dust collector and drum.
 Before unloading the top insert balls, PCMTBE shall do
initial inspection, external visual & UT inspection and
sampling.
 Top insert balls would be vacuumed out through outside top
manhole, (no man-entry is required). Ceramic ball would
flow through the suction hose to the cyclone collector, then
would be discharged into plastic bag inside the drums,
purge with N2 and seal by using cable ties followed by
closing the drums by drum covers.
 The drums are then will be labelled with the scheduled
waste label stickers provided by PCMTBE / HSE.
 Top wire mesh shall be removed and (to be replaced new if
required).
 Unloading activity continues by vacuuming from outside
top manhole until reachable level.
 To continue unloading activity by vacuuming or manually.
 Adsorbent and Ceramic Ball would be discharged on
continuous basis until completion subject only to bad
weather condition
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 Confined Space Entry (CSE) will be done to remove the

balance / remaining of the absorbent and bottom ceramic
balls by vacuuming.
 Drums must be strapped and wrapped properly before being
transported to the storage / shelter area to avoid drum
topple. Putting extra care to prevent spillage during
handling.

4.5 Removal of Internal Bottom Grating (if required for cleaning)

 The bottom grating with mesh also to be removed (if
required) and to be inspected by PCMTBE Operation.
 Inspection carried out by PCMTBE before proceeds for
internal cleaning by power brushing method or as per
approved PCMTBE SOE.
 Take samples for scheduled waste analysis during
unloading. Chemical analysis and report to be done by
PCMTBE.

4.6 Loading Activities

 After cleaning and inspection completed, preparation for
loading balls and catalyst shall be done on dry weather
condition basis.
 Marking the level of each layer of loading material
internally. Line out crane and the loading equipment at
proper location as close as possible to the vessel (as per
approved Lifting Plan).
 Re-instate the bottom grating with mesh (if any).
 Remove ventilator and box up the side manhole / manway
after loading the 19mm, 6mm and 3mm ceramic balls.
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 Install the receiving hopper on top of the vessel equipped

with flexible hose to allow the minimum height of media
free falling during loading into the vessel.
 Begin de-canting the bottom ceramic balls into the loading
hopper with accordance to the required volume and level.
 Lifting the loading hopper using crane to the receiving
hopper at the Top Manhole and slight open loading hopper
discharge valve.
 Leveling of the layer surface to be measured and recorded
until reaching the desired level by the confined space entry
personnel.
 De-canting the Adsorbent into the loading hopper with
accordance to the required volume and level.
 Lifting the loading hopper using crane to the receiving
hopper at the Top Manhole and slight open loading hopper
discharge valve.
 Leveling of the Adsorbent layer surface to be measured and
recorded until reaching the desired final level by the
confined space entry personnel.
 Install the top floating screen of mesh; followed by
inspection from PCMTBE Operation.
 Fill the top ceramic balls into the loading hopper with
accordance to the required volume and level.
 Lifting the loading hopper using crane to the receiving
hopper at the Top Manhole and slight open loading hopper
discharge valve.
 Leveling of the top ceramic balls layer surface to be
measured and recorded until reaching the desired final level
by the confined space entry personnel.
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 Keep record of each media loaded into the vessel and to

handover the original copy to client.
 Final inspection by PCMTBE OPN prior to Box Up after
loading activity completion.
 Install the inlet distributor and top elbow. Box up activity
and Control Bolting at top elbow / manway.
 De-blinding activity as per approved EJIS and Control
Bolting at EJIS point.

4.7 Control Bolting

 Refer Control Bolting Procedure

4.8 Safety
 Contractor shall use proper and fit to use equipment.
 Use of personnel protective equipment (PPE) as per JHA
requirement shall be mandatory to avoid any incident /
accident during the change out activities. Contractor shall
ensure that all works are performed with due regard to the
safety of personnel.

4.9 Housekeeping
 Disconnect suction hose, air hose, electrical cable and
others and prepare for de-mobilization.
 All the unwanted materials / items shall be removed from
the site.
 Proper housekeeping at work area after de-mobilization as
per existing site condition.