CR Asia Group

Work Instruction
Sock Loading of Reformer Tubes
Revision Record
Issue
No

Revision
No

Date

Page
Edition

01

00

25-02-08

All

Established /Revised;

(Peter Cheshire)
Group Catalyst Manager

Description of Revision

Prepared
By

Approved
by

DAR
No.

GCM

Assigned
Mgr.

088/08

First issue

Business Unit Reviewed;

Group Reviewed;

(
)
Business Unit QUENSH
MR

( Nuchanart Lapasanoi )
Group QUENSH MR

Document :

WI-CH-16

Issue Date :

25 February, 2008

PERMIT REQUIRED PRIOR TO COPYING

Accepted / Approved;

(
)
Business unit assigned
Manager

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

1 of 3

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction
Sock Loading of Reformer Tubes

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 Asia Companies.
3. Reference
None
4. Form
F-CH-04
F-CH-05
F-CH-06
F-CH-09
F-CH-16

Blind List Acceptance for Reactors

Gas Test Result
Loading Report
Confined Space Entry Log Sheet
Critical Activities Checkpoint

5. Definition
None
6. Responsibility
6.1 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/Foreman 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 Technician / worker are responsible to follow strictly on each step of this instruction and
perform work that assigned from their supervisor.
7. Procedure
7.1 Job Preparation & Safety
-

Hold JSA briefing prior to job set up.

Ensure valid permits are on hand
Brief all crew on the safety precautions laid out in the permit.
Have appropriate amounts of pre weighed catalyst socks stored in the most accessible
position available on the top platform.

7.2 Pre Loading Checks

- Carry out Video inspection of all empty tubes. Check catalyst supports are installed and
ensure lower flanges have been tightened up on new gaskets.
- Once the lower flanges are bolted up, check that personnel working on the top platform do
not have any loose objects in their pockets, or carry any items which could fall into the
tubes.

Document :

WI-CH-16

Issue Date :

25 February, 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

2 of 3

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction
Sock Loading of Reformer Tubes
-

Conduct empty DP tests on every tube and record results. (Any variances need to be
checked out and rectified.) Ensure a clients representative is witness to all density pressure
testing & recording.

7.3 Loading stage one

- Load first catalyst type into 3 or 4 test tubes. Vibrate tubes after every second sock. Carry
out outage & DP checks to confirm ideal vibration timing.
- Load all of the tubes with the first type of catalyst. Vibrate for the time that was established
during test tube loading. Check outage and DP test. Reject tubes that are outside the range
of +/- 5%.
7.4 Loading Stage Two
- Ensure all rejected tubes are reloaded and re tested.
- Proceed to load the first four tubes with the second catalyst type. Ensure that vibration times
are kept consistent.
- Take outage measurements and DP checks. Top up tubes in order to meet final outage &
DP readings. Load all tubes with the second type of catalyst. Take outages & DP test. Top
up as required.
- Tubes to be within +/- 3% from the average.
- Following adjustments complete one final DP check of a random selection of tubes that has
been agreed to by the client.
7.5 Job Completion
- Ensure all QA/QC documentation is completed and approved by the client.
- Complete an official loading report and submit to client with final QA/QC package. Carry out
general house keeping and remove all equipment from the structure.
- Carry out general house keeping and remove all equipment from the structure.
- Obtain permits for entry into bottom headers & vacuum out dust & debris from catalyst
loading prior to box up.

Document :

WI-CH-16

Issue Date :

25 February, 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

3 of 3

CONTROLLED DOCUMENT