Documente Academic
Documente Profesional
Documente Cultură
Objective
This work instruction covers the Fresh Catalyst Loading in PSA Reactor.
Scope
This Procedure applicable to the CR Petrochem India Operations at CLIENT
Reference Documents
Form
Blinding List
Flange Tightening
Initial Gas Testing
Entry Log
Continuous Gas Testing
Catalyst Loading Report
Job Completion Certificate
Customer Satisfaction Questionnaire
Definition
Responsibilities
Operation Department is responsible for the job execution & inspection.
Procedure
TOOL BOX-JOB START MEETING
Tool box meeting is conducted by operations dept. all supporting teams involved in this meeting.
acquire the
all
parties.
Document :
CRAI-SD-CH-08
Issue Date :
September 01,2015
Revision Number :
00
Copy Number :
Issue Number :
01
Page :
1 of 5
CONTROLLED DOCUMENT
CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
7.2.14 Clean up any spilt product and leave area in a safe and clean condition.
7.3 Lining of Equipment at PSA Reactor Area
7.3.1The following are the general procedures for lining up equipment for catalyst Loading for PSA
7.3.2The general procedure for preparation for this work includes.
7.3.2.1 Ensure that all permits are in place.
7.3.2.2 Set up the Containers.
7.3.2.3 Establish communications and cordon off area in agreement with client.
7.3.2.4 Line up and secure vacuum equipment and associated pipe work.
7.3.2.5 Set up dust collection equipment and ducting Also setup BA Apparatus on the top of the reactor.
7.3.2.6 Ensure the scaffolding used is having green tag with remark Fit for use
7.3.2.7 Ensure all PPE is being worn and is suitable.
7.3.2.8 Ensure QA/QC is being followed.
7.3.2.9 Keep area clean and SAFE.
7.3.2.10 Drum liners & ties to be used.
7.4 Initial Gas Testing of PSA Reactor.
7.4.1
The following is the standard outline of requirements for testing of atmospheres in PSA prior to
7.4.2
7.4.3
personnel entry. These limits are for entry without gas suits.
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.
The following tests are carried out to ensure all personnel are aware or the dangers involved.
Oxygen Content: Normal Entry: 19.5%-21%
Temperature: < 45 deg. C
Hydrocarbons: 1% Volume
LEL: <5%
Hydrogen Sulphide: 10ppm
The following is a broad procedure for the loading in a PSA. As reactors vary in design it may be
necessary to develop on site methods after considering specific drawings.
7.5.2
Mark up for Loading as required and measure bed depth to get a datum point.
Document :
CRAI-SD-CH-08
Issue Date :
September 01,2015
Revision Number :
00
Copy Number :
Issue Number :
01
Page :
2 of 5
CONTROLLED DOCUMENT
CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
7.5.3
Install loading hopper positioned over man way to allow access for personnel entry.
7.5.4
While opening the Drums please depressurised the drum by removing the vent screw.
7.5.5
7.5.6
Carry out Inspection for Cleaning & internal by video camera or as per client instruction.
7.5.7
7.5.8
Install the client provided loading device at the Top of the Manway as per Drawing S803
( Provided By UOP). It is sole property of the UOP. After completion of the job return back the
same to UOP.
7.5.8.1
Loading device consist of Loading Funnel, Hold down pipe, loading device (4 rings)
7.5.8.2
Special attention shall be paid to careful installation & alignment of the loading device as this
will affect the loading density.
7.5.8.3
All the rings of the loading device have to be installed horizontally and in the centre of the
vessels. For distance & set up kindly refer drg. S804
7.5.8.4
In order to respect the distance indicated between rings i.e. 40mm,75 mm & 150mm, it is
important that the required no. of the nuts per bar as per drawing.
7.5.8.5
This requires One lock nut at top end of the bar & one nut plus one lock nut at lower end.
Note that Locknuts are nuts inside the O ring.
7.5.8.6
Distance between top of the ring no. 1 and bottom of the Hold pipe or orifice plate, whichever
is lower to be calculated 200 mm. It is recommended to have the lower ring attached by a
small wire to one of the flats of the holddown pipes. This avoids problems in the unlikely
event that the loading device should slip off end of the hold down pipe during loading.
7.5.8.7
In order to ensure equal loading distribution the hold down pipe should be rotated over 90
on regular basis. For each layer the should make at least two full turns.
7.5.9
If the absorber stored in the drums , it is recommended to have the content of 200 lbs, drums
transfer into larger hopper in order to speed up the loading.
7.5.10 Start the Loading of the Catalyst & Inerts as per the loading diagram
7.5.11 Ensure that all the catalyst evenly distributed in the PSA Reactor.
7.5.12 Loading densities will be checked during loading in order to predict layer height. If the loading
height indicated on the data sheet cannot be met contact UOP PSA process department
immediately to discuss further action.
7.5.13 If after loading a sieve, the bed height is lower than the expected height and there are spare
sieves available on site, these should be loaded.
7.5.14 The total height shall not exceed the overall height as given in the data sheet. For proper flow
distribution a minimum space between the top of the bed and the bottom of the nozzles screen
is required as indicated on the absorbent loading data sheet.
Document :
CRAI-SD-CH-08
Issue Date :
September 01,2015
Revision Number :
00
Copy Number :
Issue Number :
01
Page :
3 of 5
CONTROLLED DOCUMENT
CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
7.5.15 When loading interrupted all the vessels shall be properly covered to avoid any contamination
by humidity or rain.
7.5.16 Levelling & Inspection using Video Camera
7.5.17 At the end of loading submit the loading report for exact loading quantities, densities & height of
the each layer.
7.5.18 Ensure all QA/QC is being completed.
7.5.19 Take samples during loading as requested.
7.6
Deblinding & box up of PSA Reactor
7.6.1
Take a permit for Deblinding & box up.
7.6.2
Refer Blinding form for Deblinding.
7.6.3
Install nozzle screen in top manhole with one gasket.
7.6.4
Install manhole flange with the correct bolting & bolting torques.
7.6.5
Install interconnecting pipes.
7.6.6
Put the DIP tray (If possible) underneath to avoid the spillage of Debris.
7.6.7
Use proper tools for the De Blinding as per Permit Requirement
7.6.8
Ensure the required PPE wear by the operator.
7.6.9
Remove the alternate bolts.
7.6.10
Remove the blinds from Flanges.
7.6.11
Do alternate bolting as per instruction.
7.6.12
Inspection & Signoff on the Blinding form by all parties.
7.6.13
Close the permit.
7.7 SITE CLEAN UP (Housekeeping)
7.7.1 Housekeeping is always an important part of any project and the object is to leave any site as
7.7.2
7.7.3
site dirty.
All electrical leads to be rolled up and taped securely. Ensure that there is no risk of other
7.7.4
7.7.5
7.7.6
7.7.7
cleaned. Any contaminated soil should be placed in containers for further treatment.
All used gloves, paper overalls, rags and other consumable should be collected for correct
7.7.8
7.7.9
7.7.10
7.7.11
7.7.12
collection organised.
7.7.13 Ensure that clients view the site when you have completed demobilisation. Show pride in the fact
that we have not left the client with any further problems.
Document :
CRAI-SD-CH-08
Issue Date :
September 01,2015
Revision Number :
00
Copy Number :
Issue Number :
01
Page :
4 of 5
CONTROLLED DOCUMENT
CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
7.7.14 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-08
Issue Date :
September 01,2015
Revision Number :
00
Copy Number :
Issue Number :
01
Page :
5 of 5
CONTROLLED DOCUMENT