Catalyst Refer

Total Sheet : 38 Sheets
Subcontractor’s Name : NIPPON EXPRESS CO., LTD.
Employer : Nghi Son Refinery and Petrochemical LLC.
Contractor : JGCS Consortium
Zone : JVD COMISSIONING
Project Name : NSRP Complex Project
Subcontract No. : CNT-6495-HVL1-001
Document Title : GENERAL INITIAL CATALYST & MEDIA LOADING

PROCEDURE
Contractor Doc. No. : VV31G0-010-A-100 Revision No. : 0
Issue Purpose to Contractor (FA,FC) : FA
Review Result Sticker (Filled By JGCS)
Result CODE: A, B, R, F ( )
Next Status: FA, FC ( )
Re-submission Date: ( )
Responsible Dept./Person: ( )
JVD JVD QC
Construction HSSE Zone QC Endorsement
Checked By (Name, Sign) ( ) ( ) ( ) ( )
Result Code ( ) ( ) ( ) ( )
Date ( ) ( ) ( ) ( )
Approved By (Name, Sign) ( )
A: Approved without Comment; B: Approved with Comments

R: Not Approved; F: Not Subject to Review
Issue Purpose Sticker
Issue Purpose to Employer: FA, FR, FI, FC ( FA )
Document Class: Z, X, Others ( Z )

NGHI SON REFINERY AND PETROCHEMICAL PROJECT
Title : GENERAL INITIAL CATALYST & MEDIA LOADING Contractor Doc. No:
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PROCEDURE VV31G0-010-A-100
GENERAL INITIAL CATALYST & MEDIA

LOADING PROCEDURE
Document Class: Z
ISSUE PURPOSE FOR APPROVAL
Rev Date Page Description Prep’d Chk’d App’d
0 06-Dec-16 All For Approval Min T. Miyazaki M.Umeda
Operation Centre JOB Code: Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by
NEX Min T.Miyazaki M.Umeda
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CONTENTS
1. INTRODUCTION ................................................................................................................................. 3
2. SCOPE ................................................................................................................................................. 3
3. SCHEDULE .......................................................................................................................................... 3
4. REFERENCE DOCUMENTS ................................................................................................................... 3
5. ABBREVIATION AND DEFINITION ..................................................................................................... 3
6. PURPOSE ............................................................................................................................................ 4
7. RESPONSIBILITIES ............................................................................................................................ 4
8. PRECAUTION ...................................................................................................................................... 6
9. EQUIPMENT & MATERIALS ................................................................................................................ 6
10. SAFETY MEASURES............................................................................................................................. 7
11. CATALYST & MEDIA LOADING PROCEDURE ...................................................................................... 9
11.1. PLANNING WORK .................................................................................................................... 9
11.2. PREPARATION WORK .............................................................................................................. 9
11.3. CATALYST LOADING/ EXECUTION ........................................................................................ 10
12. BOLT TIGHTENING/ TENSIONING PROCEDURE .............................................................................. 11
13. DISPOSAL OF HAZARDOUS/ CHEMICAL WASTE .............................................................................. 11
14. SAMPLE CATALYST LOADING PHOTOS ............................................................................................ 11
15. SAMPLE CATALYST LOADING DRAWINGS ....................................................................................... 11
16. INSPECTION RECORD ...................................................................................................................... 11
17. RESCUE PLAN ................................................................................................................................... 11
18. EMERGENCY PLAN ............................................................................................................................ 12
19. COORDINATION PLAN ..................................................................................................................... 12
20. CONTINGENCY PLAN ........................................................................................................................ 12
21. MANAGEMENT OF CHANGE .............................................................................................................. 13
22. JOB SAFETY ANALYSIS ..................................................................................................................... 14
ATTACHMENTS:
ATTACHMENT-1 EQUIPMENT LIST 1 Page
ATTACHMENT-2 CATALYST AND MEDIA LOADING SCHEDULE 1 Page
ATTACHMENT-3 SAMPLE PHOTOS FOR CATALYST LOADING 6 Pages
ATTACHMENT-4 SAMPLE LOADING DRAWINGS 2 Pages
ATTACHMENT-5 SAMPLE INSPECTION RECORD SHEET 1 Page
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1. INTRODUCTION
This document describes the general procedure and requirements for carrying out Initial Catalyst & Media
Loading Works applied to facilities of the plant constructed in NSRP Project.
This procedure shall serve as part of Method Statement for Initial Catalyst Loading Work (of each
equipment) which shall defines specific procedures individually and get approval from the JGCS/ NSRP prior
to actual works.
2. SCOPE
• To perform Initial Catalyst and Media Loading Works at Nghi Son Refinery and Petrochemical
Complex Project for Listed Equipment in Attachment-1.
3. SCHEDULE
• Please refer to Attachment-2 for Contractor’s Catalyst and Media Loading Schedule.
4. REFERENCE DOCUMENTS
S-000-1654-0100V Job Safety Analysis (JSA) & Safe Work Method Statement Procedure
S-000-1654-0130V Emergency Response Plan
S-000-1654-0200V PTW (Permit to Work) Procedure
MD-04-HSE-HS-PD-003 Permit to Work Procedure
S-000-1654-0210V HSSE & S Training Plan
S-000-1654-0450V Hazardous Materials Management Plan
S-000-1710-0001V Pre-commissioning and Commissioning Execution Plan
5. ABBREVIATION AND DEFINITION
• Employer
Nghi Son Refinery and Petrochemical Limited Liability Company (NSRP)
• Contractor
A Joint Venture formed by JGC Corporation, Chiyoda Corporation, GS Engineering & Construction
Corporation, SK Engineering & Construction Co., Ltd., Technip France and Technip Geoproduction
(M) Sdn. Bhd. (JGCS)
• JVD
Contractor's Joint Venture Directorate
• Licensor
Process licensors: Chevron, Lummus Global, Axens, UOP, Mitsui Chemicals, Foster Wheeler and
Jacobs.
• Speciality Subcontractor
Nippon Express Co., Ltd. (NEX)
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6. PURPOSE
The purpose of this loading procedure is to ensure that the Catalyst/ Media are properly loaded to the
vessels or system before start-up activities:
• Safely
• Free from damage
• In correct kind and quantity with reference to engineering data sheet and Vendor/ Licensor or
Supplier documents
• On schedule and systematic
7. RESPONSIBILITIES
7.1 Construction Manager
The Construction Manager is responsible for the overall management of the Project. Construction team to
ensure that safe and effective operations are established, documented and executed. He shall provide inputs
to the Project Execution Plan to ensure that construction strategies/ philosophy are addressed.
7.2 HSSE & S Manager
HSSE & S Manager is responsible for overall health, safety, social, environment and security of the project.
He shall establish a Safety Management Plan based on the guidelines issued by JGCS/ NSRP and implement
accordingly for the safe completion of the project coordinating with client HSSE & S Manager.
7.3 QA/QC Manager
QA/ QC Manager shall ensure that all loading works are carried out as per vendor drawing, licensor,
contractor and owner specifications. He shall be the one coordinating with Contractor QA/QC Manager and
field supervisors for inspection works. He shall be coordinating with contractor for joint inspections.
7.4 Material Control Manager
Material Control Manager shall coordinate with contractor representatives and its own material control
supervisors. He shall record all the materials received from contractor and handed over to NEX loading crew
for loading works as per requirement. He shall preserve and protect the received materials from potential
damages. Shall be the one sending the materials to site from Material Storage areas.
7.5 Supervisors
Supervisors shall coordinate with contractor/ employer representatives and other subcontractors within the
area, and supervise the activities, along with the work leader, foreman and construction team. Shall provide
the necessary documents (vendor drawings, packing lists, lifting plans, Loading plans, Loading diagrams
etc.) to the teams involved.
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7.6 Gas Tester or Inspector
Gas Tester shall be qualified, licensed and certified by contractor. He shall be the only one performing gas
testing and giving the go signal to the NEX representative that the equipment internal is safe to work. Gas
testers and testing devices shall be provided by the contractor. NEX shall use own gas tester for subsequent
periodic test.
7.7 Safety Supervisors
Safety supervisors shall coordinate with the contractor and other subcontractor safety officers working
around the area. He shall ensure that all the gas tests are done and the oxygen level insidethe equipment is
suitable for working. He shall ensure that all necessary checklist and inspections are done. All tools to be
used are properly colour coded, inspected and certified. Ensures that all personnel assigned for the task has
been briefed and understood the work to be done.
7.8 Confined Space Attendant
Confined space attendant shall be at the equipment entry point or manhole area at all times. He shall re-
ensure that all the workers going inside the equipment has proper PPE and safety tools needed. Shall record
all entry and exit times of the personnel working inside the equipment. Shall record all the tools brought in
and out of the equipment.
7.9 Foreman/ Work Leader
Shall apply and revalidate all the necessary permits, monitor the activities and ensure that the procedure are
observed and assist the supervisor in directing the workforce. Ensure that the latest and updated revision
vendor drawings are at hand prior and during all construction works.
7.10 Mechanical Internal Workers/ Fitters
Only assigned workers shall be the one doing the tasks. Workers shall ensure that they understand the job
and the risks prior to entering the equipment.
7.11 Operators
Only qualified Crane, Forklift, Transporter, etc. operators shall be handling or operating the assigned
machine/s to them. He shall ensure that the machine he operates is in good condition. He shall also be
responsible for completing the checklists prior to every start of work and or every working day.
7.12 Banks man
Banks man shall be the only one to give the signal to operators during construction equipment operations.
7.13 Scaffold Erector
Scaffold Erector shall be the only one to erect the scaffolds to be used in and outside the equipment. He
shall be trained, certified and ensure that the erected scaffold is sound and safe and passed all the
necessary inspections needed prior to use.
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7.14 Emergency Rescue Team (ERT) for Internal Works
Shall be provided, certified & approved by the Contractor. ERT personnel must always be present whenever
a team is working inside the equipment. ERT shall be the only team that will perform rescue works if
necessary.
Note: To be discussed and address detail in “Rescue Plan”.
8. PRECAUTION
8.1 Isolation Certificate to be issued by Employer.

8.2 Weather conditions (wind / rain etc.) shall be monitored before any loading plan is executed on the day of
loading.
8.3 Shall check the labelling of drums or container if it matches with the data sheet. Make sure that the
chemicals which are going to be loaded into the project installed equipment is positively identified and
compared with Datasheet requirements. Equipment, as well, to be positively identified (Nameplate and
marked up, Tag Number).
8.4 Ensure that the vessels for loading are properly checked for cleanliness.
8.5 Disposal of spillage chemicals should not be made indiscriminately. Environmental impact should be a
concern. The material safety data sheet should be read and the disposal is carried-out in accordance with the
instruction written therein.
8.6 Toolbox meeting shall be conducted at site involving all concerned personnel to remind safety measures and
the objective of the activities.
8.7 Shall not overfill or over pressurize any vessel.
9. EQUIPMENT & MATERIALS
9.1 All cranes, hoists, lifting gears, electric powered tools, and hand tools shall undergo JGCS’s inspection and
will comply with JGCS’s safety requirements. Inspection tags shall be pasted on specific tools, equipment. No
equipment will be allowed to be used for work without JGCS’s “Approved” tag.
9.2 The following Tools and Equipment may be used for the work as necessary:
• Fork lift
• Trailers
• Lorry truck
• Cranes
• Hand tools
• Lifting gears
• Winch
• Pulley
• Lighting systems
• Material baskets
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• Hoppers
• Air Compressors
• Ladders
• Scaffolding
• Generators
• Levelling tools
• Exhaust and ventilation systems
• Others (as required.)
Other equipment/ tools might be added depending on the requirement and availability. Contractor shall be
informed with regards the matter prior to usage of the equipment.
10. SAFETY MEASURES
Safety regulations and precautions governing equipment internal installation and chemical handling shall be
complied with at all times by all involved personnel in the working areas.
10.1 Ensure that all workers and supervisors has attended and passed the necessary SIC and other important
trainings such as confined space entry training and working at heights training prior to entering NSRP site
and starting the job. Any unauthorized person caught entering the equipment shall be given disciplinary
actions or termination.
10.2 All Supervisors assigned, shall have on hand the approved Method Statement (MS), Latest Vendor
Drawings & Installation Manual, Job Safety Analysis (JSA) and the Permit to Work (PTW) at all times during
the works.
10.3 All Workers shall be briefed on the MS & JSA daily prior to start of work.
10.4 Prior to commencement of any activities, START (Safety Task Analysis Risk Talk) shall be done on the
project site as well as general safety requirements.
10.5 Site Supervisors shall ensure that the persons being briefed at site are well aware of all safety procedures
including the MS & JSA related to the work to be implemented on site for the activity concerned.
10.6 Only Certified Authorized Gas Tester from the contractor shall perform the gas tests at the equipment and
ensure that the equipment passed the gas tests before issuing PTW for confined space and before anyone
goes into the equipment. Periodic gas testing shall be done by NEX.
10.7 All persons going into the equipment must have proper PPE as required to do the job, and equipped with
the emergency flashlights, communication device and personal gas tester/ monitor.
10.8 Only qualified persons shall operate machinery or cranes. A list of qualified persons shall be developed and
maintained on site for reference and inspection by JGCS as required.
10.9 All tools must be properly colour coded and inspected prior to use.
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10.10 Equipment checklist shall be completed during morning time or prior to any lifting works.
10.11 Only appointed signal man/ banks man can give the signal for the equipment operators. Signal man/ banks
man and operators shall confirm method of communications. Signal man & crane operators shall ensure
that the communication devices are clear on both ends.
10.12 A stand by, competent and knowledgeable, confined space attendant trained in emergency rescue
procedures will be assigned for an entry and exit log. He shall be responsible and shall check who enter
the confined space has a valid identity card for confined space entry. He shall record names of all persons
who entered the confined space and make sure all persons have come out after the task is done. Tools
and materials bring in and out of confined space shall be recorded as well.
10.13 Continuous monitoring and inspection shall be maintained to detect any unsafe acts while performing the
job.
10.14 NEX shall provide proper lighting (Explosion proof) and ventilation inside the equipment.
10.15 Contractor to provide details for rescue operation in case of emergency and ensure that all personnel are
aware and knowledgeable of this rescue plan or operation.
10.16 Contractors Provided Rescue team should be available all the time especially during confined space works
are in progress.
10.17 Good housekeeping practices shall be done after each activity or at the end of every working day.
10.18 Appropriate warning signs and barricades shall be provided to warn and protect personnel working around
and in the area.
10.19 All personnel involved in the catalyst loading shall wear protective clothing, gloves, eye goggles and
Breathing Apparatus (if required). Life-line shall be provided for worker working inside reactor. Grounding
connection for metallic materials used inside equipment shall be provided to prevent static explosion.
Loading area shall be roped-off and warning sign shall be displayed in the area.
10.20 Positive isolation on each vessel during loading activity shall be confirmed, especially if loading personnel
will work inside the vessel.
10.21 Areas under commissioning must be clean and free of loose debris and only authorized personnel shall be
permitted in the loading areas.
10.22 Breathing mist/ fume/ vapour and contact with skin/ eyes shall be minimised when handling catalyst,
chemicals and other liquid bulk materials. Precaution of handling for each chemical and other liquid bulk
material shall refer to Material Safety Data Sheet (MSDS) provided by chemical suppliers.
10.23 Material Safety Data Sheet (MSDS) shall always be referred for the particular materials to be handled. All
the precautions and safety measures mentioned on the data sheet must be respected and implemented.
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10.24 On handling of hazardous chemicals and other liquid bulk materials, an emergency shower and eyewash
facility must be ready for service on unexpected splash of the hazardous materials.
10.25 A confined space entry permit shall be obtained prior to any entry to vessel.
11. CATALYST & MEDIA LOADING PROCEDURE
11.1. PLANNING WORK
11.1.1. Catalyst loading activities shall be carried-out only if the vessels (or systems) have been isolated.
11.1.2. Cleanliness inside vessels shall be verified before start of catalyst loading.
11.1.3. Loading Timing shall be scheduled for daylight loading.
11.1.4. Catalyst loading instruction sheet with marked-up P&ID indicating the isolation valves and blind(s) to
be installed shall be prepared in accordance with relevant procedure. MSDS of the materials shall be
available at all times.
NOTE: All blinds shall be ensured to be on the correct side of the isolation valve.
11.1.5. Transportation route and the parking location shall be marked in the plot plan for delivering Catalyst
Materials.
11.1.6. Pressure testing shall be applied where applicable after the loading activities by Contractor.
11.1.7. Inerting shall be implemented by Contractor, where applicable, after the completion of loading.
11.2. PREPARATION WORK

11.2.1. Relevant Permit to Work shall be obtained.
11.2.2. Necessary temporary working platforms shall be constructed using scaffolding materials.
11.2.3. Required lifting crane with inspection sticker shall be set up with outrigger fully extended at
designated location.
11.2.4. Required equipment, tools and materials (Fork Lift, Roller Conveyor, Transfer Hopper, Loading
Hopper, etc.) shall be standby. Materials which need to be cleaned shall be done accordingly.
11.2.5. Tool Box Talk (START) shall be conducted to explain to all workers the job/ task steps and the
related Hazards & control measures.
11.2.6. Barricades shall be installed and relevant Warning Signs shall be posted as required.
11.2.7. Fire Extinguishers (dry powder) shall be in place.
11.2.8. MSDS shall be checked before start loading and ensure the MSDS is on site during handling of
chemicals.
11.2.9. Location of nearest Emergency Shower and Eyewash Facility shall be identified and ensure every
personnel involved are notified. Shall check provided facilities are available and ready to use.
11.2.10. Availability of plant air and ready to use shall be checked.
11.2.11. Protective clothing and other safety protections shall be available to personnel as required by MSDS.
11.2.12. Contractor HSSE Department shall be notified prior to start catalyst loading.
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11.3. CATALYST LOADING/ EXECUTION

11.3.1. Canvas sheets shall be standby/ set for rain protection above top manhole.
11.3.2. Removable spool/ manhole cover on the top side of the equipment shall be removed, if any.
11.3.3. Catalyst Dump Nozzle shall be opened at the bottom of equipment and position the blower to blow
air from bottom to top for ventilation inside of reactor. A blower shall be put at the top of the reactor
in reverse position to vacuum the air inside.
11.3.4. The flange of catalyst dump nozzle shall be reinstated.
11.3.5. Ventilation and lighting shall be provided.
11.3.6. Confined space entry permit shall be obtained, oxygen content shall be checked and Safety Tool box
Talk shall be conducted to all personnel’s before going inside the reactor.
11.3.7. Required chemical suit, airline mask with communication cable (or walkie talkie), step board,
explosion proof lighting, etc. shall be provided as required to enter the equipment.
11.3.8. Safety ladder (vertical aluminium ladder or rope ladder) shall be provided for access to enter/ exit
into/ out of equipment.
11.3.9. Manway, Deflection basket, inlet distributor, etc. shall be removed/ open as necessary.
11.3.10. Marking shall be made inside the equipment for every level of catalyst to be loaded. Initial marking
shall be made up to 1m from bottom tangent line. Subsequent levels shall be marked as the catalyst
level getting higher. Photo records shall be taken for future reference.
11.3.11. Stationary loading hopper fitted with slide valve shall be installed on top of equipment.
11.3.12. Type of Catalyst to be loaded shall be checked. Required volume shall be prepared.
For loading works using assisting crane, catalyst to be loaded shall be poured into lifting (transfer)
hopper via loading platform. (Please refer to Attachment-4)
For loading works using provided gantry cranes (e.g. RHDS Reactor), catalyst to be loaded shall be
attached to the loading frame.
11.3.13. Exposure time of catalyst to environment shall be minimized to avoid absorption of moisture.
11.3.14. Plastics sheets, canvas sheets shall be provided to protect transferred catalyst from rain water.
11.3.15. Loading method shall be confirmed and required personal protections shall be prepared.
11.3.16. Catalyst transfer hopper/ container shall be hoisted up by using assisting crane/ provided gantry
crane above stationary loading hopper installed on top of equipment.
11.3.17. Fresh catalyst shall be manually loaded to stationary loading hopper to load into the equipment.
11.3.18. Catalyst shall be loaded into the equipment using the method required by the licensor either by
Dense or Sock loading method depending on the type of catalyst and on its layer.
11.3.19. Loaded Catalyst shall be distributed equally and levelled.
11.3.20. Level of each layer of loaded catalyst shall be confirmed before loading next layer. The inspection
procedure and frequency of inspection shall be specified according to Employer’s instruction.
11.3.21. Catalyst drain pipe, manway of grid tray, deflection basket, etc. shall be reinstated as required
before continue loading for the next layer.
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11.3.22. Loaded catalyst type, level, type of loading, loaded volume, etc. shall be recorded for every layer
using Contractor approved Catalyst Loading Record Sheet. The record sheet shall be signed by
representative of Contractor and Company after completion of the loading.
11.3.23. The Vessel Internal (Upper portion) shall be installed in accordance with vendor drawing and be
inspected by Employer and Contractor. After completion of catalyst and packing loading, the
equipment shall be boxed up. Relevant bolt tightening procedures shall be followed. All temporary
spool pieces, gaskets shall be removed and replaced with permanent items. Final leak test shall be
performed by Contractor as necessary.
11.3.24. After completion of loading activity all leftover material shall be returned immediately back to
Contractor to preserve well in the designated location for future use.
11.3.25. Housekeeping shall be done on and around the equipment.
12. BOLT TIGHTENING/ TENSIONING PROCEDURE
NEX shall engage Lilama Corporation for bolt loosening/ Hydraulic Torqueing and Tensioning of Manholes,
Top Nozzle Flanges, Dumping Nozzles, etc. required for Catalyst Loading Works as per project specifications
and Bolt Tightening Procedure for each equipment issued by Client, if any.
*Please refer to Document Number VV3160-001-A-146 & VV3160-001-A-158 for approved Method
Statements and Job Safety Analysis.
13. DISPOSAL OF HAZARDOUS/ CHEMICAL WASTE
Hazardous/ Chemical waste disposal area shall be provided by Contractor. Necessary permit to disposal shall
be obtained and the waste shall be disposed as per project specifications and procedures.
14. SAMPLE CATALYST LOADING PHOTOS
Please refer to Attachment-3 for Sample Catalyst Loading Photos.
15. SAMPLE CATALYST LOADING DRAWINGS
Please refer to Attachment-4 for Sample Catalyst Loading Drawings.
16. INSPECTION RECORD
Please refer to Attachment-5 for Sample Inspection Record Sheet.
17. RESCUE PLAN
NEX shall follow the Rescue plan provided by contractor. Emergency Rescue Team shall always be present
while internal works are ongoing.
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18. EMERGENCY PLAN
In case of emergency (fire, riot etc.), everybody has to stop work; All Electric powered Devices shall be
turned off and stowed in a safe position, entry supervisor shall instruct all workers within the equipment to
go out and head to the nearest muster points. During lifting by crane, the load will be lowered and made
“Safe as Practical”. Stop equipment engine, remove the key and proceed to safe muster point in cross wind
direction. Do the head count and wait for further instructions from Security Department and JGCS-HSSE
Department. The work shall only be resumed after “All clear” signal and confirmation is obtained from the
Security and JGCS-HSSE Department.
19. COORDINATION PLAN
Lifting Supervisor shall coordinate the lifting operation. The directions shall be given by means of
conventional hand signal and/ or radio communication between signalman and crane operator in an agreed
form of language understandable between the two and the Lifting Supervisor.
Installation supervisor or internal works supervisor shall be the one to coordinate all the installation
procedures to be done. He will ensure that all personnel involved in the task are briefed and has attended
the tool box meeting prior to installation works.
QA/QC representative shall coordinate with the Installation supervisor and ensure that all the works has
complied and have met with the requirements as specified in the vendor drawings. He shall coordinate with
the Contractor's Representative, Employer Representative, Licensor and others when final joint inspection
shall be done.
Safety supervisors shall always be present at site and check if any unsafe work acts are being done and
rectify the situation. He/ she shall be informed of all the activities to be done inside and outside the site and
coordinate to the proper authorities if ever an emergency occurs.
20. CONTINGENCY PLAN
Loading operation shall stop if it is raining and Licensor/ NSRP do not agree to proceed with the loading
work. If raining starts after or during loading works and Licensor/ NSRP instruct to stop the work, confined
space attendant shall inform everybody inside the equipment and let everyone out. Ensure to cover all
manholes to prevent or minimize the accumulation of water inside the equipment. Battery operated torches
or flashlights shall be prepared if ever power failure shall occur.
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21. MANAGEMENT OF CHANGE
If the operation cannot continue in accordance with the agreed procedure, the operation shall stop and the
procedure reassessed to take into consideration the reason for stoppage. If the reassessment is considered
a relatively minor deviation from the agreed procedure, the drawings shall be clearly marked with the
actions considered appropriate and agreed prior to operations recommencing. If the reassessment is
considered a relatively major deviation from the agreed procedure, then the appropriate actions shall be
taken, that as a minimum will require the drawings to be marked and amended in accordance with the
revised proposals agreed and if significant may require production of a drawing revision, calculations or
other information as applicable.
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22. JOB SAFETY ANALYSIS
Company Nippon Express Co., Ltd. JSA no NA

Activity Catalyst & Media Loading Works Area NA
Equipment and tool use NA Date NA
Who or What
No. Description of Job Step Potential Hazard/Risk Might Be Control Measures Action By:
Harmed
1. Mobilization: • Space Constrained / People, • Identify existing plant and machinery around Work Supervisor
Manpower, Material and Traffic congestion Property the work area Worker
Equipment • Driver and operator shall be adequately Driver
• Hand Tools advised/ briefed on the routing and site plan
• Trailer requirement. Routing/ map need to be
• Lorry attached with JSA.
• Mobile Crane • Establish space to park/ store equipment and
• Lifting Gears vehicle.
• Fork Lift • Ensure flagman is present to guide vehicle
• Generator movement.
• Ventilation System
• Overload of trailer/ truck People • Ensure that trailer/ truck is not overloaded Work Supervisor
with material and materials are stacked and properly Worker
secured and lashed. Driver
• Load/ material to be transported shall not
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protrude more than one meter from tail

bucket.
• To install flag at the end of protruding
materials.
2. Ground/ Work Area • Trip, Slip and Fall (Bodily People • To remove obstructions Work Supervisor
Preparation (Manual Injuries) Worker
Handling/ sorting
materials)
• Obstruction to walkway People and • To ensure proper access is provided. Work Supervisor
Property • Direction signage to be displayed.
• Back Injury People • To apply Buddy System Work Supervisor
• To ensure correct techniques during manual Worker
lifting.
• Pinch Point People • Wear leather or rubberized, cotton hand Work Supervisor
glove while doing work Worker
• Constant reminder on pinch point area
3. Transfer of catalyst • Drums slip off from the People • Use drum stopper on loading platform. Work Supervisor
manually on loading P/F lashing • Ensure sufficient working space. Worker
• Pinch Point People • Wear leather or rubberized, cotton hand Work Supervisor
glove while doing work. Worker
• Constant reminder on pinch point area
• Apply approved rigging method as described
at the method statement.
• Rigging equipment shall be inspected.
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• Exposure to the dust People • To wear suitable respiratory equipment. Work Supervisor
emission during handling NIOSH N95 (or equivalent) Worker
of materials • Wear safety glasses or goggle
(inhalation, contact to • To provide emergency eyewash
skin) • MSDS must be visible on site for references
4. Lifting Activities • Crane topples People and • Only certified and qualified riggers are Signal man
Property allowed to do the job
• Inadequate ground • Supervision/ control of crane movement with Crane operator
bearing capacity and clear instruction and communication
improper outriggers • To ensure that the load does not exceed the Lifting supervisor
setting SWL of the lifting crane, follow approved
lifting plan and crane manufactures manual Riggers
• Damage to existing • Constant awareness of pinch point areas
equipment • All rigging will be inspected prior to use
• Check the crane’s hoisting wire if
• Load shifts perpendicular to the crane’s boom tip and
the crane’s hook block above the centre of
• Injury/loss of life gravity of the material. Attach tag lines.
• Slowly tension the rigging slings. Stop and
• Failure of crane check tensioning, if satisfied, proceed.
• Monitor weather condition and forecast
• Miscommunication continuously. Follow Crane manufacturer’s
operational specifications with regard to wind
• Adverse weather speeds. In the absence of specific
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conditions, strong wind information from the crane manufacturer,

and heavy downfall crane shall not be operated in wind speeds
more than 10 m/s
• Check all lifting tackles certified, colour
coded, and as described in the rigging study.
• Avoid standing under a suspended load
5. Working in Confined Space • Exposure to the dust People • To wear suitable respiratory equipment. (EN Workers
to perform the following emission during handling 143 class P3 (99.95%) or more high class Supervisors
activities: of materials such as NIOSH N100, R100, P100 (99.97%)
1. Loading of catalyst • Personnel entering a confined space are
2. Levelling of required to have a Confined Space Entry
catalyst Awareness Training
• Wear safety glasses or goggles
• MSDS must be visible on site for reference
• Apply rotation work
• Limitation of workers direct exposure
handling the materials
• Apply continuous ventilation
• Wear chemical suit or a disposable coverall
• Ensure ventilation hose are in place in
accordance to the catalyst dust control plan
• Canvas shielding at loading point
• Oxygen Deficiency People • Use of AIR LINE Supply Mask Workers
• Personnel entering a confined space are Supervisors
Page 17 of 37
REV. 0
required to have a Confined Space Entry

Awareness Training
• Gas and Oxygen level check before entering
a confined space (Oxygen level must be
between 19.5% to 23.5%)
• Continuous gas test monitoring to ensure the
atmosphere is maintained at a safe level.
• Continuous ventilation inside the confined
space
• Stress and/or physical People • Continuous ventilation inside the confined People
exhaustion space
• Rest Breaks (at agreed intervals), Job
rotation
• Apply “Buddy System”
• Unauthorized Entry People • Ensure personnel involved has authorization Supervisor
from direct supervisor (Name Lists of
personnel must be displayed at site)
• Place signage and warning labels on
manholes
• Fall from height / Falling People and • 100% tie-off at all time when working above Workers
Object Property 1.8 meter Supervisor
• Installation of life line and checked by
competent person before use
• Use proper access and make sure that there
Page 18 of 37
REV. 0
is no obstruction along the walkway and on

the working platform that could compromise
the height of the guard rails.
• Barricade the area below work at height
• Do not carry any material during use of
ladder
• Secure hand tools with rope
• Materials or tools should be tied off on
secured area when not in use
• Secure safety helmet with chin strap
• Use hoist bags/ tool bags to contain material
and tools.
• Protruding material and People • Place material and tool away from access Workers
sharp object way
• Barricade around work and material storage
area
• Wear suitable hand gloves
• Use of correct tools for the activity
• Protect sharp objects
6. Usage of rope ladders for • Wrongly installed People • Rope ladder must be installed on a Workers
entry and exit scaffolding structure or to an existing Supervisors
structure and inspected by a competent Inspectors
person prior to use
• Rope ladder must be installed as per
Page 19 of 37
REV. 0
manufacturer’s recommendation.
• Pre-check all ladder condition prior to use
• The usage of rope ladder must be equipped
with self-retracting devices for vertical life
line. This shall be installed separately
• Only trained and competent person shall use
the self-retracting devices
• Checklist to be provided for every inspection
on the rope ladder and self-retracting
devices.
• Defective equipment People • Rope ladders shall be stored at a designated Supervisor
container or tool box when not in use Appointed custodian
• Appointed custodian for safe keeping and
issuance of rope ladder
• Keep rope ladders from contact with
chemical or paint or substances that might
compromise the condition of the rope access
• Unfamiliar on using rope People • User must be physically fit Supervisor
ladder • User must undergo simulated training prior Worker
to assign on the use of rope ladder
7. Bolt tightening of manhole • Pinch Point People • Wear correct hand gloves for the work Supervisor
cover • Constant reminder for pinch point areas Workers
8. Operating of diesel or • Ignition source People and • Provide fire extinguisher near equipment Worker
petrol-driven machines property • To carry out pre-use checking of machine Supervisor
Page 20 of 37
REV. 0
and equipment Operator

• No refuelling of fuel on running machines
• Do not operate equipment should there be
presence of fuel trace
• Oil spill Environment • Use of hand pump on refuelling Operator
• To completely drain the hose pump before Supervisor
retrieving the hose
• To use proper and acceptable condition drip
tray/ pan during refuelling
• Oil spill kit shall be readily available in case
of oil spill
• Refuel only when all machines are turned-of
• Wear appropriate PPE for the job
• Carbon Monoxide (CO) People • Place equipment at a safe distance and away Supervisor
Emission from confine space activities Worker
• Equipment to be maintained as and when
required
• Work leader to monitor the wind direction on
the need to change position of engine driven
equipment
9. Housekeeping • Trip, slip and fall People • Identify sharp edges/ object and remove
where possible
• Ensure work area is barricaded
Page 21 of 37
ATTACHMENT-1
EQUIPMENT LSIT
Page 22 of 37
EQUIPMENT LIST
No. of Reactor dimention Approx. Volume Loading Method Number of

NO. Package FWBS Unit System Description Licensor OC Reactor/Adsorber Tag Purpose Type of media Remarks
Reactors (IDmmxT/Tmm) (m3) (D- Dense, S-Sock) Beds
1 GD10-01 028 Indirect Alkylation UOP JGC 028-R-041 SHP Reactor 1 1400 x 11100 15.05 Catalyst, Inert balls S 1
2 GD10-02 028 Indirect Alkylation UOP JGC 028-R-101/102 Poly Reactor-1/2 2 4600 x 13000 92.52 x 2 Catalyst, Inert balls S 3
3 GD10-03 028 Indirect Alkylation UOP JGC 028-R-201 Hydrotreater Reactor 1 4600 x 11200 165.34 Catalyst, Inert balls D 2
4 GD10 GD10-04 084 Amine Regeneration Unit NA JGC 084-F-002 Activated Carbon Filter 1 2800 x 6000 9.7 ton Activated Carbon S 1
5 GD10-05 087/088/089 Sulfur Recovery Jacobs JGC 087/088/089-R-001 1st Clause Reactor 3 3600 x 7150 ( 21 + 13.6 ) ton x 3 Catalyst, Inert balls S 1
6 GD10-06 087/088/090 Sulfur Recovery Jacobs JGC 087/088/089-R-002 2nd Clause Reactor 3 3600 x 7150 27.3 ton x 3 Catalyst, Inert balls S 1
Tail Gas Treating and TGTU Tail

7 GD10-07 090/091/093 Jacobs JGC 090/091-R-001 SCOT Reactor 2 3800 x 13100 78.1 ton Catalyst, Inert balls S 1
Gas Incinerator
8 GD20-01 020 Residue Hydrodesulphuriser Chevron- Lummus Global CYD 020-R-111/112/113 HDS Reactor 3 4400 x 16900 (120.9+125.1) x 3 Catalyst, Inert balls D+S 2 - Permanent Hoist and Elevator equipted
GD20
24 GD50-01 023 RFCC UNSAT GAS Plant Axens JGC 023-R-301A/B/C PP Polymer Reactor 3 2600 x 11350 130.5+11 (18.4 ton) Catalyst, Inert balls S 1
25 GD50-02 023 RFCC UNSAT GAS Plant Axens JGC 023-R-302A/B Arsine Guard Bed 2 2100 x 6950 22+7.4 (18.4 ton) Catalyst, Inert balls S 1
26 GD50-03 023 RFCC UNSAT GAS Plant NA JGC 023-F-203 Lean Amine Carbon Filter 1 1400 x 4550 5.1+0.94 Activated Carbon, Inert balls S 1
27 GD50-04 040 Naphtha Hydrotreating UOP TPM 040-R-101 Reactor 1 3700 x 3900 58.142 Catalyst, inert balls S 1
- Sand Blasting to be applied

28 GD50-05 041 PENEX UOP TPM 041-R-101A/B Reactor 2 2500 x 12200 113.45 Catalyst, Inert balls D 1
- to be loaded under N2
29 GD50-06 042 CCR Platforming UOP TPM 042-R-101 Platforming Reactor-1 1 2500 x 10150 190.1 ton (*9) Catalyst, Inert balls S 1
30 GD50-07 042 CCR Platforming UOP TPM 042-R-102 Platforming Reactor-2 1 2500 x 11550 (*9) Catalyst, Inert balls S 1
31 GD50-08 042 CCR Platforming UOP TPM 042-R-103 Platforming Reactor-3 1 2550 x 12950 (*9) Catalyst, Inert balls S 1
32 GD50 GD50-09 042 CCR Platforming UOP TPM 042-R-104 Platforming Reactor-4 1 2550 x 13800 (*9) Catalyst, Inert balls S 1
Spent Catalyst Disengaging 3100 x 5100

33 GD50-10 043 CCR Platforming - Regeneration UOP TPM 043-V-103 1 (*9) Catalyst S 1
Hopper 1400 x 1050
34 GD50-11 043 CCR Platforming - Regeneration UOP TPM 043-V-105 Chloride Adsorber 1 2000 x 3625 (*9) Catalyst S 1
2750 x 6475
35 GD50-12 043 CCR Platforming - Regeneration UOP TPM 043-R-101 Regeneration Tower 1 (*9) Catalyst S 1
1980 x 14015
Regenerated Catalyst
36 GD50-13 043 CCR Platforming - Regeneration UOP TPM 043-V-106 1 1600 x 1710 (*9) Catalyst S 1
Disengaging Hopper
Lock Hopper Disengaging
37 GD50-14 043 CCR Platforming - Regeneration UOP TPM 043-V-108 1 650 x 1275 (*9) Catalyst S 1
Drum
38 GD50-15 043 CCR Platforming - Regeneration UOP TPM 043-V-109 Lock Hopper 1 650 x 1275 (*9) Catalyst S 1
39 GD50-16 043 CCR Platforming - Regeneration UOP TPM 043-V-110 Lock Hopper Surge Drum 1 1050 x 2050 (*9) Catalyst S 1
40 GD50-17 042 CCR Platforming UOP TPM 042-A-501-V101 to 110 PSA Unit 10 2100 x 4400 106.65 ton Mol Sieve D 1
NOTE:
(*9) Total for 042-R-101/2/3/4, 043-V-103/105/106/108/109/110, 043-R-101
Page 23 of 37
ATTACHMENT-2
CATALYST AND MEDIA LOADING SCHEDULE
Page 24 of 37
CATALYST AND MEDIA LOADING SCHEDULE REV-5 AS OF 17-NOV-2016
NO. OF 2017
PACKAGE SYSTEM
NO. UNIT FWBS SYSTEM DESCRIPTION REACTOR JANUARY FEBRUARY MARCH APRIL MAY JUNE
NO. DESCRIPTION
S 1 2 3 4 5 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1 028 GD10-01 Indirect Alkylation 028-R-041 1 3 Days from 10-Feb-2017
2 028 GD10-02 Indirect Alkylation 028-R-101/102 2 18 Days from 27-Feb-2017
3 028 GD10-03 Indirect Alkylation 028-R-201 1 3 Days from 10-Feb-2017
4 084 GD10 GD10-04 Amine Regeneration Unit 084-F-002 1 3 Days from 10-Mar-2017
5 087/088/089 GD10-05 Sulfur Recovery 087/088/089-R-001 3 20 Days Completed by 7-Apr-2017
6 087/088/090 GD10-06 Sulfur Recovery 087/088/089-R-002 3 20 Days Completed by 7-Apr-2017

Tail Gas Treating and TGTU Tail
7 090/091/093 GD10-07 090/091-R-001 2 5 Days Completed by 7-Apr-2017
Gas Incinerator
8 020 GD20-01 Residue Hydrodesulphuriser 020-R-111/112/113 3 15 Days from 12-Mar-2017
9 020 GD20-02 Residue Hydrodesulphuriser 020-R-211/212/213 3 12 Days ftom 27-Mar-2017

GD20
12 023 GD50-01 RFCC UNSAT GAS Plant 023-R-301A/B/C 3 14 Days from 16-Mar-2017
13 023 GD50-02 RFCC UNSAT GAS Plant 023-R-302A/B 2 14 Days from 16-Mar-2017
14 023 GD50-03 RFCC UNSAT GAS Plant 023-F-203 1 2 Days from 10-Mar-2017
15 040 GD50-04 Naphtha Hydrotreating 040-R-101 1 10 Days from 29-Mar-2017
16 041 GD50-05 PENEX 041-R-101A/B 2 3 Days from 4-Jun-2017
17 042 GD50-06 CCR Platforming 042-R-101 1 11 Days from 21-Apr-2017
20 042 GD50 GD50-09 CCR Platforming 042-R-104 1 11 Days from 21-Apr-2017
21 043 GD50-10 CCR Platforming - Regeneration 043-V-103 1 11 Days from 21-Apr-2017
23 043 GD50-12 CCR Platforming - Regeneration 043-R-101 1 11 Days from 21-Apr-2017

042-A-501-V101 to
28 042 GD50-17 CCR Platforming 10 12 Days from 10-Feb-2017
110
Page 25 of 37
ATTACHMENT-3
SAMPLE PHOTOS FOR CATALYST LOADING
Page 26 of 37
1. Loading Hopper
2. Setting of Pulley and Hoist on top of Equipment
Page 27 of 37
3. Airline Mask
4. Loading into Stationary Hopper by Assisting Crane and Loading Hopper
Page 28 of 37
5. Rope Ladder
6. Anti-Slip Surface on Rope Ladder Step
Page 29 of 37
7. Catalyst Level Marking on the Vessel Wall
8. Sock Loading
Page 30 of 37
9. Dense Loader
10. Checking for Bolt Tightening of Manway Closing
Page 31 of 37
11. Bolt Tightening of Flange
12. Bolt Tightening of Flange
Page 32 of 37
ATTACHMENT-4
SAMPLE LOADING DRAWINGS
Page 33 of 37
Page 34 of 37
Page 35 of 37
ATTACHMENT-5
SAMPLE INSPECTION RECORD SHEET
Page 36 of 37
QC-COM-920
COMMISSIONING
CATALYST LOADING
INSPECTION RECORD SHEET
SYSTEM No : 020-P-03G / 03I LOCATION : RHDS
SYSTEM Name : RHDS Reactors

ITEM No. :
Bottom Support grid installed : Yes No N/A
Vessel checked for cleanliness before loading : Yes No N/A
Hold down grid installed : Yes No N/A
Final box up of vessel with proper gasket : Yes No N/A
Type of Loading Material :
Inert Material / Catalyst / Resins / Packing / Desiccant / Adsorbent
ATTACHMENTS: Catalyst diagram / table to be attached.
TEST RESULTS AND COMMENTS:
INSPECTORS Sub-Contractor Contractor Employer

NAME
SIGNATURE
DATE
Page 37 of 37

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Total Sheet : 38 Sheets

Subcontractor’s Name : NIPPON EXPRESS CO., LTD.

Employer : Nghi Son Refinery and Petrochemical LLC.

Contractor : JGCS Consortium

Zone : JVD COMISSIONING

Project Name : NSRP Complex Project

Subcontract No. : CNT-6495-HVL1-001

Document Title : GENERAL INITIAL CATALYST & MEDIA LOADING

Contractor Doc. No. : VV31G0-010-A-100 Revision No. : 0

Issue Purpose to Contractor (FA,FC) : FA

Review Result Sticker (Filled By JGCS)

Next Status: FA, FC ( )

Checked By (Name, Sign) ( ) ( ) ( ) ( )

Approved By (Name, Sign) ( )

A: Approved without Comment; B: Approved with Comments

Issue Purpose Sticker

Issue Purpose to Employer: FA, FR, FI, FC ( FA )

Document Class: Z, X, Others ( Z )

GENERAL INITIAL CATALYST & MEDIA

ISSUE PURPOSE FOR APPROVAL

Rev Date Page Description Prep’d Chk’d App’d

0 06-Dec-16 All For Approval Min T. Miyazaki M.Umeda

Operation Centre JOB Code: Operation Centre Doc. No.:

ATTACHMENT-1 EQUIPMENT LIST 1 Page

ATTACHMENT-2 CATALYST AND MEDIA LOADING SCHEDULE 1 Page

ATTACHMENT-3 SAMPLE PHOTOS FOR CATALYST LOADING 6 Pages

ATTACHMENT-4 SAMPLE LOADING DRAWINGS 2 Pages

ATTACHMENT-5 SAMPLE INSPECTION RECORD SHEET 1 Page

5. ABBREVIATION AND DEFINITION

7.1 Construction Manager

7.2 HSSE & S Manager

7.3 QA/QC Manager

7.4 Material Control Manager

7.6 Gas Tester or Inspector

7.7 Safety Supervisors

7.8 Confined Space Attendant

7.9 Foreman/ Work Leader

7.10 Mechanical Internal Workers/ Fitters

7.12 Banks man

7.13 Scaffold Erector

7.14 Emergency Rescue Team (ERT) for Internal Works

Note: To be discussed and address detail in “Rescue Plan”.

8.1 Isolation Certificate to be issued by Employer.

9. EQUIPMENT & MATERIALS

10. SAFETY MEASURES

11. CATALYST & MEDIA LOADING PROCEDURE

11.1. PLANNING WORK

11.2. PREPARATION WORK

11.3. CATALYST LOADING/ EXECUTION

12. BOLT TIGHTENING/ TENSIONING PROCEDURE

13. DISPOSAL OF HAZARDOUS/ CHEMICAL WASTE

14. SAMPLE CATALYST LOADING PHOTOS

Please refer to Attachment-3 for Sample Catalyst Loading Photos.

15. SAMPLE CATALYST LOADING DRAWINGS

Please refer to Attachment-4 for Sample Catalyst Loading Drawings.

16. INSPECTION RECORD

Please refer to Attachment-5 for Sample Inspection Record Sheet.

17. RESCUE PLAN

18. EMERGENCY PLAN

19. COORDINATION PLAN

20. CONTINGENCY PLAN

21. MANAGEMENT OF CHANGE

22. JOB SAFETY ANALYSIS