CR Asia Group

Work Instruction for

Catalyst Loading by Dense method (SingleBed) 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 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 that all the equipment like Vacuum Unit, Cyclone ,Demountable
Vacuum Pipe, Vacuum Hose, Dust Collector, Inside Lightening ( 24 Volt),dense
loading device other safety equipment set as per requirement, screening
machine, lifting tools tackles, rescue equipment
Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

1 of 5

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (SingleBed) in Inert
Atmosphere
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 Prepare 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.
7.2.12
Before starting to remove final bolts, ensure
that all necessary safety measures are being taken, and correct PPEs.
7.2.13Bolts 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.
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.
.
Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

2 of 5

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (SingleBed) in Inert
Atmosphere
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 % by volume
Temperature: < 50 deg. C
Hydrocarbons: 1% Volume
LEL: <10%
Hydrogen Sulphide: 10ppm
Carbon Monoxide: 50ppm
Benzene: 5ppm
Carbonyls: 0.1ppm
7.5 CATALYST LOADING by Dense Loading Method in Inert Atmosphere.
7.5.1.
The following procedure describes in detail the loading steps
recommended by dense loading .
7.5.2.
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.

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. Fixing of 12 mesh screen on reactor bottom support grid as per the mesh screen
7.5.6.4. Box up of dump nozzle plug & flange with new gaskets
7.5.6.5. Tarpaulins should be available in case of rain or interruption during

loading.
7.5.6.6. One safety harness, portable oxygen analyzer, air packs and dust masks.
7.5.6.7. The oxygen analyzer will be used when reactors are open for catalyst

loading to make sure that no air is entering.

7.5.4.

Catalyst Loading Procedure

7.5.5.

Take initial outage from the reactor inlet flange to top of outlet collector.

7.5.6.

loading of 1 inch HP alumina balls ,loading under normal atmosphere.

7.5.7.

Level the surface and take initial level reading

7.5.8.

loading of 0.5 inch 1 inch HP alumina balls till level is reached

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

3 of 5

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
Catalyst Loading by Dense method (SingleBed) in Inert
Atmosphere
7.5.9.

Level the surface and take final level reading.

7.5.10.

sock loading of 0.25 inch 1 inch HP alumina balls till level is reached

7.5.11.

Level the surface and take final level reading

Box-up the side man-holes using permanent gaskets & start nitrogen purging of theVessel
Set up of Dense loading on Top of reactor manway.
Lifting hopper & loading hoppers to be provided with nitrogen purge
7.5.12.
Start dense loading (UOP CuS based adsorbent) of under inert atmosphere.
7.5.13.

Level the surface and take final level reading

7.5.14.

fix the 12 mesh screen on the CuS based adsorbent as per drawing mesh screen

sock loading of 3/8 inch HP Alumina Balls on mesh screen. Level the surface and
take final level reading

7.5.15.

sock loading of 1 inch HP Alumina Balls till 150 mm level is reached. Level the
7.5.16.
surface and take final level reading.
Box up

Box-up the top Gas Distributor & other nozzles

7.6.1

Request final inspection & clearance for man way box up.
Box up reactor man way elbow using torqueing / tensioning .

7.7 De-blinding
Deblinding of reactor connected lines and torqueing of bolts
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.
8.0 Process flow chart

Mobile Hopper

Fixed Hopper
to feed
Scaffolding
Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

4 of 5

CONTROLLED DOCUMENT

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

Dense Machine

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

5 of 5

CONTROLLED DOCUMENT