CR Asia Group

Work Instruction for

Catalyst Loading by Sock 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 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), other
Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

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CR Asia Group
Work Instruction for
Catalyst Loading by Sock method (Multi Bed) in Inert
Atmosphere
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 Prepare 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.
7.3 LINING UP EQUIPMENTS IN REACTOR
7.3.1. 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 BA equipments on reactor top
Set up dust collection equipment and ducting.
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

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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Issue Number :

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CR Asia Group
Work Instruction for
Catalyst Loading by Sock method (Multi Bed) in Inert
Atmosphere
7.5 CATALYST LOADING OF MULTI BED by Sock Loading
7.5.1
Bed 2 Loading
7.5.1.1. Take initial outage from the reactor inlet flange to top of outlet collector.
7.5.1.2. Start loading of 25 mm ceramic balls on the sides of outlet collector. Level
the surface and take initial level reading
7.5.1.3. Load 25 mm ceramic balls till level is reached above outlet collector by
vacuuming. Level the surface and take final level reading.
7.5.1.4. Box-up dump nozzles at the bottom bed. Fill dump nozzles with 12 mm
Ceramic balls.
7.5.1.5. sock loading of 12 mm ceramic balls till level is reached. Level the surface
and take final level reading.
7.5.1.6. sock loading of 6 mm ceramic balls till level is reached. Level the surface
and take final level reading.
7.5.1.7. Convert the reactor atmosphere from normal atmosphere to inert for
catalyst loading.
7.5.1.8. Prior to loading Pre-sulfided catalyst lifting hopper & loading hopper to be
provided with nitrogen purge provision.
7.5.1.9. sock loading (Pre-sulfided KF851) of 1.55 mm DIOS Catalyst under inert
atmosphere. Level the surface and take final level reading.
7.5.1.10. sock loading of 6 mm ceramic balls till level is reached. Level the surface
and take final level reading.
7.5.1.11. sock loading of 25 mm ceramic balls till level is reached. Level the
surface and take final level reading.
7.5.1.12. Report the void space of bed 2.
7.5.1.13. Box-up Vapor Liquid Distribution Tray Manway after getting clearance for
Cleanliness
7.5.1.14. Box-up Support Grid Manway after getting clearance for cleanliness.

7.5.2 Bed 1 Inert loading

7.5.2.1. Take initial outage from the reactor inlet flange to top of bed 1 catalyst
support grid.
7.5.2.2. Box-up dump nozzles at the bottom bed. Fill dump nozzles with 6 mm
Ceramic balls.
7.5.2.3. loading 25 mm of ceramic balls by sock till level is reached. Level the
surface and take level reading after loading.
7.5.2.4. sock loading of 6 mm ceramic balls till level is reached. Level the surface
and take final level reading.
7.5.2.5. sock loading 1.55 mm of Catalyst (Pre-sulfided KF 851) till level is reached
Leveling of catalyst to be done at pre-determined frequency.
7.5.2.6. Sock Loading of catalyst (TK 30) till 450 mm level is reached. Level the
surface and take final level reading.
7.5.2.7. Leveling of catalyst at pre-determined frequency loading CatTrap-50 till
level is reached. Level the surface and take final level reading
7.5.2.8. loading CatTrap-30 till level is reached. Level the surface and take final
level reading loading CatTrap-10 till level is reached. Level the surface and
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 Sock method (Multi Bed) in Inert
Atmosphere
take final level reading sock loading 25 mm of ceramic balls till level is
reached. Level the surface and take level reading after loading.
7.5.2.9. Report final bed 1 void.
7.6 Box up
7.6.1. Boxup Top Liquid Distribution Tray Manway
7.6.2. Installation of top elbow
7.6.3. Request final inspection & clearance for man way box up.
7.6.4. Box up reactor man way elbow using torqueing / tensioning.
7.7 De-blinding
7.7.1. Deblinding of reactor connected lines and torqueing of bolts.
7.7.2. Leak test of all deblinded flanges will be carried out
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

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

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CONTROLLED DOCUMENT

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

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