CR Asia Group

Work Instruction for

Unloading & Catalyst Loading by Dense 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

Preparation & Safety

Ensure that all confined space entries are supervised by certified persons.
Tool Box Talk must be given to the workers involved before starting the job.
Confirm all PTW conditions are met. Location of blinds/ isolations is identified and
recorded
and available with the permit.
Risk assessment and SOP are readily available and discussed with line supervisors
identified for the job
Ensure that check list has been filled and signed off.
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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CR Asia Group
Work Instruction for
Unloading & Catalyst Loading by Dense method (Multi Bed)
in Inert Atmosphere
Team Leader shall ensure that the contractor meets all mandatory requirements as
per standards.
A method for controlling identity & head count in the confined space shall be
established and displayed and is to be ensured.
Ensure availability of current rescue plan and it is understood by all.
Ensure all the records and documentation is kept as per audit requirement.
All the contractor persons must have undergone Plant specific training.
Safe Access and Exit (No obstructions on escape route).

LINING UP EQUIPMENTS IN REACTOR

Set up & Validation of mechanical & Electrical tools,Vaccum units,cyclone hopper,dust
bag collector,Breathing air equipments,Mock drill,Rescue plan,HIRA & RA.
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 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 Single line mask to be as a precautionary measure while removing bolts.
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.
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
Inert Confined Space Entry Requirements
Persons involved in the job should be skilled & adequately trained (with valid training
certificate) for

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

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CR Asia Group
Work Instruction for
Unloading & Catalyst Loading by Dense method (Multi Bed)
in Inert Atmosphere
entry into confined spaces with oxygen deficient, inert or contaminated atmosphere.
The training
should include
1) Use of online BA with lockable helmet.
2) Use of 2way communication systems, safety harness and personnel hoists.
3) Use of air monitoring instruments/stretcher.
4) Use of emergency action plan, first aid and CPR.
5) Rescue of person from inert atmosphere
6) Medical fitness validation by Client doctor.
Breathing Air and Communication Systems Requirement
The following lists the minimum requirements:
A positive pressure double demand valve type breathing apparatus with full face
lockable helmet with camera on the front side shall be used by entrant and
rescuer.
For attendant sitting outside for monitoring, use of air supplied fullface mask is
mandatory. The communicator sitting at Life support system panel away from
the manhole may not require breathing protection.
Two completely independent air supplies for each person who will enter the confined
space, and for the
rescuer; Separate life support panel shall be provided for each entrant and rescuer,
each panel shall have
separate Rota meters for monitoring of breathing of both entrant and rescuer.
Analysis of breathing air used shall be readily available (certificate from the vendor
filling the cylinder).
The breathing air quality shall meet the requirement as mentioned in D Grade
Standards.
Banks of air cylinders that are manifolded in such a manner that the two independent
air supply lines
are provided for primary and secondary use. The secondary air supply should be
sufficient to allow
persons to evacuate the confined space. Each person who will enter the space should
have an escape air
bottle attached as close as possible to their mask/helmet, i.e. totally independent of
the primary and
secondary air supplies;
Sufficient number of BA cylinders (minimum inventory considering for next 24 hrs.
consumption) shall be
made available at job location. Accordingly refilling is to be planned considering lead
time at BA filling.
Life support control station to be set up as close to the entry point as practicable to
continuously
monitor the supply air pressure to individual masks/helmets. Each breathing apparatus
should be
provided with an alarm (audio & visual) indicating low supply pressure and an
automatic switch over for

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

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CR Asia Group
Work Instruction for
Unloading & Catalyst Loading by Dense method (Multi Bed)
in Inert Atmosphere
the secondary air supply. However in case of secondary fails to supply breathing air,
Primary needs to act as a breathing air should be available for maintaining air flow for
the entrant and rescuer. First time check of the system is to be performed by OEM
personnel, later on OEM certified person for maintenance of life Support system/BA
mask/helmet shall be made available at job location during the activity.
BA Panel setup should be provided with a battery power back up, automatically
cutting in on failure
of electricity supply. The battery supply should keep communication systems alive as
well as providing
emergency lighting at least for the time needed to evacuate persons from the confined
space;
(minimum 60 min backup)
Extended speaker arrangement to be made available at platform deck for monitoring
the communication
between the groups of people.
Common communication system between BA panel operator (monitoring breathing &
voice of entrant),
entrant & rescuer must be ensured. Thus all three persons can talk to each other.
Reinforced umbilical cords linking each person in the confined space with the
monitoring station and
carrying primary and secondary air supplies and communication cables;
Safety harness double lanyard and lifeline shall be used along with the fall protection.
The same shall be
checked and validated by Maintenance team.
A hoisting device (pneumatic winch) capable of assisting in rescuing persons from
the confined space;
the same shall be checked and validated by Maintenance team for its certification.
A supply of emergency air cylinders (escape bottle) capable of providing minimum 07
minutes back up.
7.5.1.
7.5.2.
7.5.3.
7.5.4.
7.5.5.
7.5.6.

Unloading of Ceramic balls / Catalyst in Inert Atmosphere.

Ensure confined space entry permits( inert entry) are in place.
Inert Entry Technician enters reactor using life support equipment.
Removal of tray sections required for access the bed (if fitted).
Vacuum required amount of inert / ceramics from top of catalyst.
Take samples as directed.
Vacuum catalyst in level layers to required depth.

7.5 CATALYST LOADING by Dense Method in Inert Atmosphere.

7.5.1.
The following procedure describes in detail the loading steps
recommended by dense loading
7.5.2.
Dense loading procedure to be done as per Specified loading
diagram & adhere to Client specifications.
7.5.3.

Catalyst Loading Procedure

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
Unloading & Catalyst Loading by Dense method (Multi Bed)
in Inert Atmosphere
7.5.7.1. The following instructions must be strictly adhered to throughout the

entire catalyst loading for the reactors. An loading specialist will be

present during the loading to advise and monitor the loading method.
Dense loading procedure to be done as per Specified loading
diagram & adhere to Client specification.
7.6 Box up
7.6.1 Reinstate the tray sections and clean.
7.6.2 Request final inspection & clearance for man way box up.
7.6.3 Box up reactor man way elbow using torqueing / tensioning .
7.7 De-blinding
7.7.1. Procure work permits with RA and blind/de-blind list.
7.7.2. Identify the locations and request for scaffolding if necessary.
7.7.3. Use necessary PPE, loosen bolts and carefully remove the blind or reverse
the blind manually or using chain block or crane.
7.7.4. Remove the old gaskets and box up the flange with new gaskets inspected
by CLIENT.
7.7.5. Bolting initiated by hand-tightening followed by tension/torque tightening
as per the sequence to be followed after alignment of the flanges. The
torque/tension sequence with values are to be recorded.
7.7.6. Ensure all the joints mentioned in the list are de-blinded and tightened.
7.7.7. Tag all flanges after completion for client approval prior to accepting
signatures from all concerned departments on the deblind- list.
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.
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.
7.8.4.All airlines and hoses are to be washed, rolled up and secure these are to be
either placed in hose cages or site container.
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
Unloading & Catalyst Loading by Dense 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 :

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CONTROLLED DOCUMENT

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

Mobile Hopper

Fixed Hopper
to feed
Scaffolding

Dense Machine

Document :

CRAI-SD-CH-03

Issue Date :

November 28 , 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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Copy Number :

Issue Number :

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