Catalyst Handling and Loading

Procedures and Key-points

PT Kilang Pertamina International
RU VI Balongan ARHDM unit
Module 13 Run 17.2 Kick Off Meeting

15 March 2023
Nippon Ketjen Co., Ltd.

NK-OT1-2203-019
 Agenda

1. Time frame and catalysts for ARHDM Module 13

2. Sock loading
3. Catalyst handling
4. Lifting of catalyst bag
5. Communication within 3 parties
6. Loading activity check list

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 Milestone – 2023 M13 R17.2
Tentative Schedule

Meetings
July Kick off meeting

Maintenance shutdown for Module 13

July Catalyst unloading
July Mechanical repair
July Catalyst loading
July Box up

Start up
System press up
Sulfiding
Cut in feed
Full duty

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 1. Pertamina Preparation
Catalyst at Pertamina Warehouse
(2023 Delivery)
NIPPON KETJEN CATALYSTS DELIVERY for M13R17.2
'23 Delivery Bag Drum Extra drum Total, kg Marking
For M13 QTY weight/bag, kg QTY weight/drum, kg QTY weight/drum, kg
KG 542-7R 2 1,160 6 145 3,190
KG 1-5B 2 1,360 8 170 4,080
KFR 22-3Q 8 760 6,080
KFR 22-2Q 6 760 4 95 4,940
KFR 53-1.3Q 20 960 4 120 19,680
KFR 71B-0.9E 32 1,040 2 130 33,540 -
KFR 22-5B 5 1,360 4 170 7,480
Total catalyst 75 28 78,990

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 1. Pertamina Preparation
Leftover Catalysts
(After M12R15.2 Loading)

NIPPON KETJEN REMAINING CATALYSTS from M12R15.2

'22 Left over Bag Drum Extra drum Total, kg Marking
For M12 QTY weight/bag, kg QTY weight/drum, kg QTY weight/drum, kg
KG 542-7R 1 1,160 2 145 1,450
KG 1-5B 1 1,360 4 170 2,040
KFR 71B-0.9E 11 1,040 6 130 12,220 -
Total catalyst 13 12 15,710

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 1. Pertamina Preparation
Catalyst Availability
(2023 Delivery + M12R15.2 Leftover)

NIPPON KETJEN CATALYSTS AVAILABILITY for M13R17.2

'23 Availability Bag Drum Extra drum Total, kg Marking
For M13 QTY weight/bag, kg QTY weight/drum, kg QTY weight/drum, kg
KG 542-7R 3 1,160 8 145 4,640
KG 1-5B 3 1,360 12 170 6,120
KFR 22-3Q 8 760 6,080
KFR 22-2Q 6 760 4 95 4,940
KFR 53-1.3Q 20 960 4 120 19,680
KFR 71B-0.9E 43 1,040 8 130 45,760 -
KFR 22-5B 5 1,360 4 170 7,480
Total catalyst 88 40 94,700

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 1. Pertamina Preparation
Receiving Catalysts

Identification tag

Marker x 4 sites Contains 8 drums vol

and stencil ;1600 liter

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 Catalyst Loading Scheme R-101
M13-R-101 CATALYST LOADING SCHEME R-101
Results NIPPON KETJEN TRAIN
Plan
CATALYST HEIGHT VOL DENSITY
Weight BAG DRUM RE-CALC Loading
TARGET
2,970 mm m3 kg/m 3
kg # # kg Type

3,150 SPACE 180mm VOID 180 2.74

3,230 CB 1/2" 80mm L CB 1/2" 80 1.22 1,134 1,380 5 1,380
3,630 KG 542-7R 400mm L KG 542-7R 400 6.08 763 4,640 3 8 4,640 Sock
3,930 KG 1-5B 300mm L KG 1-5B 300 4.56 1,342 6,120 3 12 6,120 Sock
4,480 KFR 22-3Q 550mm F KFR 22-3Q 550 8.36 454 3,800 5 3,800 Sock
5,180 KFR 22-2Q 700mm F KFR 22-2Q 700 10.64 464 4,940 6 4 4,940 Sock

KFR 53-1.3Q
2,300mm F KFR 53-1.3Q 2,300 34.97 563 19,680 20 4 19,680 Sock
7,480
4,150mm L KFR 71B-0.9E 4,150 63.10 676 42,640 41 42,640 Sock
TL: 10,760 KFR 71B-0.9E *
11,630
11,980 KFR 22-3Q 350mm F KFR 22-3Q 350 5.32 428 2,280 3 2,280 Sock
12,130 KFR 22-5B 150mm F KFR 22-5B Cone + 150 9.12 820 7,480 5 4 7,480 Sock
F CB 1/2" 2 Dump Nozzles 1,400 1,656 6 1,656 Sock

Catalyst weight 91,580

16" 8" dia meter 4,400 mm Height 100mm = 1.5205 m3
4,400 mm xsa 15.205 m2 Vol 1.0 m3= 66 mm

Level check for KFR 71B-0.9E : Bag # 10, 30 and final

F Load planned catalyst quantities. Level check for KFR 53-1.3Q : Bag # 10 and final
L Adjust catalsyt quantities by height. Level check for other grade : Initial and final
* Based on M12R15.1 loading results only 40 bags were loaded
* Based on M13R17 loading results only 41 bags were loaded 8
NK-OT1-2203-019
* Base on M12R15.2 loading only result only 41 bags and 2 drums were loaded
 Role of NK during Site Assistance
Sock Loading

NK will provide technical assistances during catalyst loading;

NK to advice to Pertamina related to the issue catalyst loading and

handling

But not directly to catalyst loading contractor

➔ We may need an agreement of Pertamina before our advice to contractor

Need to establish 24 hours contact among the 3 parties for smooth

communication

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 2. Sock Loading Preparations

Sock loading with “plate sole” would brake catalyst particles >> Use snow
show shoes
Sock tube: 6 inch diameter is recommended
Height of free fall : < 1 meter
<1m

show shoes

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 2. Sock Loading - Method

Loading direction (Reactor top view)

1: X direction 2: Y direction 3: X direction 4: Y direction

11

Constant height increase (Reactor front view)

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 2. Sock Loading - Levelling

Use wooden rake (No metal)

Proper loading way gives good leveling and
time saving

X
Rake
Recommendation Improper way
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 2. Sock Loading – Height Measurement

Rx top flange
Man-way
a

d b
2,970
180mm c
80mm L
KG 542-7R 400mm L
Rector front view L Rector top view

Measure from Rx top flange

4-point (a,b,c,d) measurement is required
Loading worker must be inside reactor during loading
including measurement activity
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 2. Sock Loading
Loading and Maldistribution -1

Directionally Angled Loading Causes Mal-Distribution

Feed Gas Feed Gas

X

Uniform oil flow Deflected liquid flow

Uniform gas flow Uniform gas flow
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 2. Sock Loading
Loading and Maldistribution -2

Varying Loading Density Causes Mal-Distribution

Feed Gas Feed Gas X

Uniform oil flow Uniform oil flow

Uniform gas flow Non-uniform gas flow
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 2. Sock Loading
Maldistribution due to poor catalyst loading

Inclined catalyst Not Fully

angle of repose due Wetted
to uneven loading Catalyst
causes liquid to flow
to center of reactor.

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 3. Catalyst Handling
Distinguish Catalyst Grades & Size

KFR 22 has 3 different sizes of 5B/3Q/2Q

KFR 71B has different sizes of 1.3Q/0.9E

Catalysts grade on bag

Weight (kg or lbs) on ID
card

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 3. Catalyst Handling
Remove of Plastic Cover

Precautions: Experiences:

Think how to use your Cut carelessly

cutter for opening outer causing damage on
covers and strength. the super suck in ’04
Do not damage catalyst load
bag

Remove the plastic cover No need to cut the

from the top bag.
Caused damage on
super suck

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NK-OT1-2203-019
 3. Catalyst Handling
Catalyst loading scheme 1

May require 2 bags lift up for

continuous supply

Support mesh screen on the top

will help easy opening of the bag
and prevent inner bag dropping,
but small object falling …
For workers on top of hopper,
Use longer land-yard for escaping to a safe
19
space
NK-OT1-2203-019
 3. Catalyst Handling
Catalyst loading scheme 2

Precautions: Experiences:

Open the bottom window See next page!!

of the outer bag. No need
to open fully, otherwise
inner bag will drop out
Do not untie a knot on top.
Keep it remain
Hold the knot with a hand, Used cutter knife,
and cut just over the knot saw…
. in one slice, using bended
knife (“sabit or alit”) then
remove it.

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 3. Catalyst Handling
No Contamination 1

Dropping of a piece of plastic or whole may stop the loading activity over
30 min, if it stacked inside hopper nozzle

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 3. Catalyst Handling
No Contamination 2

Do not use cutter knife !!

X
X

Use of any saw is not recommended,

it will produce piece of plastic that
will fall into the hopper 22
NK-OT1-2203-019
 3. Catalyst Handling
Do not ignore small pieces

More than 1 m of catalyst

mountain in the ’04 loading at
Balongan just because of the
cutter knife pieces drop in

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NK-OT1-2203-019
 3. Catalyst Handling
Do not drop bags

Catalyst is heavy and expensive

➢ Use proper belt or tools when lift
➢ Never make a ring between 2 bags

Strong wind may loose

balance of the bag and may
result in a breakage of the bag
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NK-OT1-2203-019
 3. Catalyst Handling
Sock Tube
Precautions:
Proper connections are
requested No dropping of
tubes
Bottom connection at the
hopper must be
disconnected when
loading is idle/shift change
Can be apply ridged pipe
at the section below
hopper. Hold and close the
sock outlet.
NK-OT1-2203-019
Experiences:
Caused crashing of
CB in ’02 loading
Unexpected catalyst
wet and disposal by
rain inside into reactor
in ’06 loading
Sock emptied often,
and static closed tube.
Slow catalyst flow
in ’06 load
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 3. Catalyst Handling
Hopper
Precautions: Experiences:

Hopper shutter is Rain water into the

NK-OT1-2203-019
designed for catalyst stop, catalyst bed in ’06
not for stopping water load
leakage
Fix the shutter slider Catalyst leakage is
more than normal
Cover materials that Rain water along the
have enough size to outer surface of
cover all hopper body hopper drained into
Install water prevention reactor in ’06 load
guide along the catalyst
hopper outside
For top hopper area,
cover must be high on
center to prevent water
pooling 26
 3. Catalyst Handling
Protecting catalyst from rainwater

1. Cover entire of Hopper with

2
waterproof canvas (w/o
holes)
2. Use an object so that cover
must be high on center
1 3. Close shutter of hopper after
confirming no catalyst inside
4. Cover reactor top with the
canvas

3 In case of rainy day,

5. Remove sock tube and then
4/6 close reactor top with a plate
5 6. Cover reactor top with the
canvas
NK-OT1-2203-019 Reactor 27
 3. Catalyst Handling
NO SMOKING

Smoking kills you instantly in

case you ignore the rules

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 4. Lifting of Catalyst Bag

X X X

Use Proper belts or tools when lift

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 4. Lifting of Catalyst Bag
Inadequate Lifting Method and Results

X X

Non-uniform tension increases fracture risks for lifting belts

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 4. Lifting of Catalyst Bag
Proper Angles

X
NK-OT1-2203-019 < 60o angle should be maintained 31
 4. Lifting of Catalyst Bag
NK Recommendation

Control angles below 60o using slings

Chain Slings (length: > 1 m)
Wire Rope Slings (length: > 1 m)

X 2 sets X 4 sets
(Same length) (Same length)
NK recommendation

Do NOT hook two bags with one sling

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 4. Lifting of Catalyst Bag
NK Recommendation

Proper bag position

Front view

X X
Top view

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 4. Lifting of Catalyst Bag
Recommended Lifting Method

Lifting to Rx top
at constant speed

DO NOT STAY IN
CRANE WORK AREA

X
Hooking Centering Confirmation
Centering
NK-OT1-2203-019 before lifting up 34
 4. Lifting of Catalyst Bag
Actual Operation

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 4. Lifting of Catalyst Bag
How to Open Catalyst Bag
1 2

1.Open bottom window of

catalyst bag 2. Cut inner plastic bag to open

3 4

3. Untie a string
NK-OT1-2203-019 4. Load catalyst to Hopper
 5. Communication within 3 parties
To be updated during KOM

Parties Name Contact numbers Local numbers,

HP
Local HP# to be provided
Pertamina,
Process
engineer
Local HP# to be provided
Pertamina,
Operation

Local HP# to be provided

Pertamina,
Maintenance

Local HP# to be provided

Pertamina
Laboratory
Local HP# to be provided
Pertamina
Plan & Econ 37
NK-OT1-2203-019
 5. Communication Line within 3 parties

Parties Name Contact numbers

NK Supervisor Syahrial 0822 1095 6002

(day shift)
NK Supervisor To be updated
(night shift)
Ground worker To be updated
(day shift)
Ground worker To be update
(night shift)
Remote Yamada +65 9678 8518
(day/night)

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 650mm F
KFR 22-2Q 700mm F
6. Loading activity check
KFR 53-1.3Q
list (R-101)
2,300mm F

1
Step
4,085mm L Responsible parties P L N
7 Bottom layer catalyst marking : y y y
0,760 KFR 71B-0.9E
Reactor wall :
6 - General cleanliness y y n
- Ceramic ball holder/ gasket
7 KFR 22-3Q 220mm
Thermowell
F :
5 - General cleanliness/bent y y n
KFR 22-5B
3 6 150mm F condition
- Holder
5 Dump nozzle :
2 4 F cleanliness
- General y y n
- Ceramic ball holder/ gasket
4 Elephant stool / Grid support :
16" 8" 3 - General cleanliness y y n
- Damage/Mesh/Sealing
Responsible parties Reactor bottom shell :
2 - General cleanliness y y n
P Pertamina - Damage

Loading services Reactor inside air quality :

L
1 - O2 y y n
N Nippon Ketjen
- Hydrocarbon
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 KG 1-5B 350mm L
KFR 22-3Q
6. Loading 650mm
activity check F
list (R-101)
KFR 22-2Q 700mm F
KFR 53-1.3Q
2,300mm F
Step Responsible parties P L N
Catalyst loading KFR 71B-0.9E :
- Time/LSize/ Quality
4,085mm
11 - Quantity y y y
11
60 KFR 71B-0.9E - Initial and final levels
- Loading density
10 Leveling :
10 y y y
9 KFR 22-3Q 220mm
- BaseFlevels of catalyst layer
Catalyst loading KFR 22-3Q :
8 KFR 22-5B 150mm
- Time/FSize/ Quality
9 - Quantity (3bags) y y y
- InitialFand final levels
- Loading density
CB ½” Loading at 2 dump nozzles (6 bags)
16" 8" Catalyst loading KFR 22-5B :
- Time/ Size/ Quality
8 y y y
- Quantity (5bags & 4drums)
- Initial and final levels
- Loading density
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 M12-R-101

6. Loading activity check list (R-101)

2,980
,160 SPACE 180mm
Step Responsible parties P L N
0 CB 1/2" 70mm L
Catalyst loading KFR 22-2Q :
KG 542-7R 400mm - LTime/ Size/ Quality
KG 1-5B 350mm
15 - LQuantity (6 bags& 4 drums) y y y
KFR 22-3Q 650mm - FInitial and final levels
15 - Loading density
KFR 22-2Q 700mm F
Catalyst loading KFR 53-1.3Q :
14 2,300mm F
KFR 53-1.3Q - Time/ Size/ Quality
14 - Quantity (20 bags & 4 drums) y y y
13
4,085mm - LInitial, #10 bag and final levels
10,760 12 KFR 71B-0.9E - Loading density
13 Leveling : y y y
Catalyst loading KFR 71B-0.9E :
KFR 22-3Q 220mm F
- Time/ Size/ Quality
KFR 22-5B 150mm F
12 - Quantity (40-44 bags) y y y
- FInitial, #10 bag, #30 bag and final levels
- Loading density
16" 8"
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 6. Loading activity check list (R-101)
M12-R-101

Responsible parties P L N
Top layer ceramic ball 1/2’’ :
- Time/ Size/ Quality
2,980 20 - Quantity (Adjustment) y y y
- Initial and final levels
3,160 SPACE 180mm
- Loading density
30 20 CB 1/2" 70mm LCatalyst loading KF542-7R :
19 KG 542-7R 400mm L- Time/ Size/ Quality
17
18 KG 1-5B 350mm
19 L- Quantity (4 bags, adjustment) y y y
16 - Initial and final levels
KFR 22-3Q 650mm F
- Loading density
KFR 22-2Q 700mm F
Catalyst loading KG 1-5B :
KFR 53-1.3Q
2,300mm F- Time/ Size/ Quality
18 - Quantity (3 bags & 8 drums, adjustment) y y y
4,085mm L - Initial and final levels
- Loading density
: 10,760 KFR 71B-0.9E
Top layer marking: for KG-1 5B, KF 542-7R, CB
17 ½” y y y
KFR 22-3Q 220mm FCatalyst loading KFR 22-3Q :
KFR 22-5B 150mm F- Time/ Size/ Quality
NK-OT1-2203-019
16 F- Quantity (5 bags) 42 y y y42
- Initial and final levels
 6. Loading activity check list (R-101)
M12-R-101
22 Responsible parties P L N
Baffle tray :
- Underneath condition/ Cleanliness
2,980
21 - Hole/ Cleanliness
20 22 y y n
- Horizontalness
160 SPACE 180mm - Nuts & bolt
0 CB 1/2" 70mm - LGasket & sealing
KG 542-7R 400mm Splash
L tray :
KG 1-5B 350mm - LUnderneath condition/ Cleanliness
- Hole/ Cleanliness
KFR 22-3Q 650mm
21 F y y n
- Horizontalness
KFR 22-2Q 700mm - FNuts & bolt

KFR 53-1.3Q
2,300mm - FGasket & sealing
Distributor tray :
- Underneath condition/ Cleanliness
4,085mm L
- Chimney condition/ Cleanliness
0,760 KFR 71B-0.9E
- Chimney hole/ Cleanliness
20 y y n
- Horizontalness
KFR 22-3Q 220mm - FNuts & bolt
- Gasket & sealing
KFR 22-5B 150mm F
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NK-OT1-2203-019 F