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Loading of Reactors

This work instruction outlines the procedure for safely loading hydrocracking unit (HCU) reactors. It details responsibilities, pre-loading requirements such as checking reactor internals and installing equipment, the loading process of inert balls and catalyst using socks or dense loading, checks between beds, and job completion steps like installing filters and obtaining permits. The objective is to perform the task safely without impacts to personnel or the environment.

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Vishal Bailur
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
147 views

Loading of Reactors

This work instruction outlines the procedure for safely loading hydrocracking unit (HCU) reactors. It details responsibilities, pre-loading requirements such as checking reactor internals and installing equipment, the loading process of inert balls and catalyst using socks or dense loading, checks between beds, and job completion steps like installing filters and obtaining permits. The objective is to perform the task safely without impacts to personnel or the environment.

Uploaded by

Vishal Bailur
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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CR Asia Group

Work Instruction
Loading of HCU Reactors
Revision Record
Issue
No

Revision
No

Date

Page
Edition

01

00

25-02-08

All

Established /Revised;

(Peter Cheshire)
Group Catalyst Manager

Description of Revision

(
)
Business Unit QUENSH
MR

WI-CH-20

Issue Date :

25 February, 2008

Approved
by

DAR
No.

GCM

Assigned
Mgr.

092/08

First issue

Business Unit Reviewed;

Document :

Prepared
By

PERMIT REQUIRED PRIOR TO COPYING

Group Reviewed;

( Nuchanart Lapasanoi )
Group QUENSH MR

Accepted / Approved;

)
Business unit assigned
Manager

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

1 of 3

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction
Loading of HCU Reactors

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 is applies to all CR Asia Companies.
3. Reference
None
4. Form
F-CH-04
F-CH-05
F-CH-06
F-CH-09
F-CH-10
F-CH-16
F-CH-19

Blind List Acceptance for Reactors


Gas Test Result
Loading Report
Confined Space Entry Log Sheet
Acceptance of Quench Zone Box up
Critical Activities Checkpoint
Change of Atmosphere

5. Definition
None
6. Responsibility
6.1 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/Foreman 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 Technician / worker are responsible to follow strictly on each step of this instruction and
perform work that assigned from their supervisor.
7. Procedure
7.1 Job Preparation & Safety
-

Hold JSA briefing prior to job set up.


Ensure valid permits are on hand
Brief all crew on the safety precautions laid out on the permit.
Have final loading diagram signed off by client and pass on to necessary personnel.
Hold tool box talk and emphasis safety and critical activity check points (CACP). Safety Supervisor & Rx Top Supervisor to sign off all Critical Activity Check Points prior to
commencing activity.

7.2 Pre Loading Requirements


- Check the reactor internals for cleanliness and conduct a final vacuum of any dust & debris
if necessary.

Document :

WI-CH-20

Issue Date :

25 February, 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

2 of 3

CONTROLLED DOCUMENT

CR Asia Group
Work Instruction
Loading of HCU Reactors
-

Ensure that ceramic rope is installed in the dump nozzle. Install dump nozzle key and box
up dump nozzle. Check that the outlet collector and reactor internals are installed as per
reactor design.
Re set dump chains if fitted.
Mark up bed heights for the inert balls and catalyst as per loading diagram.
Install loading hoppers, safety, breathing, and dust collection equipment. Install loading pipe
& sock attachment.

7.3 Loading
- Sock load lower inert balls to required height and ensure that the bed is level and that
outage measurements are correct. Record all measurements at every change of layer.
- Sock load or (dense load if required see CR-SP-010) catalyst ensuring that there is an even
distribution of catalyst.
- Once the required height of catalyst is achieved, level the bed, load any upper inert balls or
rings.
- Take outage measurements.
7.4 Between Beds
Once catalyst & inert material loading is complete, have client operations inspect and authorise
box up of quench zone & distribution tray levels at the top of the bottom bed. Repeat all above
steps for subsequent beds until final box up status is achieved.
7.5 Job Completion
- Obtain all permits necessary for box up.
- Install top filter deck trays & Install filters (see CR-SP-016)
- Vacuum/clean the area around reactor top to remove all dust & debris.
- Carry out general house keeping and equipment removal from reactor top.
- Sign off all QA/QC and have client operations witness.

Document :

WI-CH-20

Issue Date :

25 February, 2008

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

01

Page :

3 of 3

CONTROLLED DOCUMENT

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