CR Asia Group

Work Instruction for

PSA Loading in Inert Atmosphere
1.0

Objective
This work instruction covers the Fresh Catalyst Loading in PSA Reactor.

2.0

Scope
This Procedure applicable to the CR Petrochem India Operations at CLIENT

3.0

Reference Documents

4.0

Form

4.1

Blinding List

4.2

Flange Tightening

4.3

Initial Gas Testing

4.4

Entry Log

4.5

Continuous Gas Testing

4.6

Catalyst Loading Report

4.7

Job Completion Certificate

4.8

Customer Satisfaction Questionnaire

5.0

Definition

NA
6.0

Responsibilities
Operation Department is responsible for the job execution & inspection.

7.0

Procedure

7.1

TOOL BOX-JOB START MEETING

Tool box meeting is conducted by operations dept. all supporting teams involved in this meeting.
Record of Tool box job start log is maintained by catalyst division.

7.2

Blinding of PSA Reactor.

7.2.1 Ensure that the reactor has been clearly identified by the relevant operations or maintenance
personnel.
7.2.2 Before starting the blinding process ensure that the correct blinds list is available.
7.2.3 Identify blinds to be installed and acquire the correct tools e.g. (slogging spanners, ring-open end
spanners, flange spreaders, chain block, podger bars etc.)
7.2.4 Ensure that work permits are in place and that the lines are de pressurized. (This may require
operations check). You should also check what service the lines have been in and

acquire the

necessary protection. E.g. Acid/Nitrogen etc.

7.2.5 In some instances permission may be granted for the hot bolting or skip bolting to take place.
(Removal of every second or alternate bolt).
7.2.6 Put in place a drip tray (if practical) underneath the flange to be broken to try and collect any spilt
product.
7.2.7 Before starting to remove final bolts ensure that all necessary safety equipment is worn.
Document :

CRAI-SD-CH-08

Issue Date :

September 01,2015

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
7.2.8 When the time comes to finally remove remaining bolts ensure that the bolts are removed the
furthest away from you first. This could prevent trapped product from spraying in your direction.
7.2.9 Do not remove all bolts and ensure that line does not require any additional support when bolts are
loosened.
7.2.10 Insert blind ensuring that a gasket is inserted on both sides of the blind. Should only one gasket is
required place this on either the pressure side or the vessel side depending on the application.
7.2.11 In the event of only one gasket being used get approval first and determine which side this is to go.
7.2.12 Bolting up should be done in a criss-cross sequence and ensure that flanges are aligned and stud
bolts have even tightness.
7.2.13 At completion of blinding ensure that blinds are checked and that blind list is signed off by

all

parties.
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

7.3.1

The following are the general procedures for lining up equipment for catalyst Loading for PSA

7.3.2

The 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
7.4.1

Initial Gas Testing of PSA Reactor.

The following is the standard outline of requirements for testing of atmospheres in PSA 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%
Temperature: < 45 deg. C
Hydrocarbons: 1% Volume

Document :

CRAI-SD-CH-08

Issue Date :

September 01,2015

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
LEL: <5%
Hydrogen Sulphide: 10ppm
Carbon Monoxide: 50ppm
(NOTE: Parameters may change as per job requirement)
These limits are subject to change as regulations vary from country to country. We believe that they are
within acceptable tolerances.
All tests are carried out using either Honeywell or Dragger gas testing units (or their equivalents) for the
Oxygen and LEL.These results are to be recorded on the Initial Gas testing form.
The oxygen and LEL are always monitored continuously when personnel are inside a confined space to
ensure no unforeseen problems arise.
NOTE: There are other substances that from time to time may be present in the atmospheres that we
are to enter. These will be either identified by our clients or from MSDS (material safety data sheets)
supplied the client.
7.5

Catalyst Loading in PSA (in Inert Atmosphere.)

7.5.1 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.
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 Ensure that the bottom of the bed is clean and dry.
7.5.6 Carry out Inspection for Cleaning & internal by video camera or as per client instruction.
7.5.7 No loading process carried out in raining
7.5.8 Loading will be done as per DOR mentioned
7.5.8.1 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 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.

Document :

CRAI-SD-CH-08

Issue Date :

September 01,2015

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

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CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
7.5.13 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.
7.5.14 When loading interrupted all the vessels shall be properly covered to avoid any contamination by
humidity or rain.
7.5.15 Levelling has to be done & Inspection using Video Camera
7.5.16 At the end of loading submit the loading report for exact loading quantities, densities & height of the
each layer.
7.5.17 Ensure all QA/QC is being completed.
7.5.18 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
7.7.1

SITE CLEAN UP (Housekeeping)

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.

7.7.2

Always clean equipment at work site prior to demobilization. No equipment should ever leave the
site dirty.

7.7.3

All electrical leads to be rolled up and taped securely. Ensure that there is no risk of other
equipment being loaded or sat on top of leads causing damage.

7.7.4

All airlines and hoses are to be washed, rolled up and secure these are to be either placed in
hose cages or site container.

7.7.5

If any equipment is damaged this should be clearly identified and taken off site for repairs.

Document :

CRAI-SD-CH-08

Issue Date :

September 01,2015

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

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CONTROLLED DOCUMENT

CR Asia Group
Work Instruction for
PSA Loading in Inert Atmosphere
7.7.6

All areas around the work area that were made dirty or are dirty should be degreased and
cleaned. Any contaminated soil should be placed in containers for further treatment.

7.7.7

All used gloves, paper overalls, rags and other consumable should be collected for correct
disposal and not left in the work area.

7.7.8

All empty drums should be removed from the area.

7.7.9

Check that all fittings have been removed from temporary pipe work.

7.7.10 All vacuum or pump hose should be washed and stored correctly for transportation.
7.7.11 Return any equipment that is not required for the next project to local office/yard for service.
7.7.12 All equipment that is on hire should be cleaned and returned to the appropriate hire company or
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.
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.

8.0 Process flow chart

Document :

CRAI-SD-CH-08

Issue Date :

September 01,2015

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

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