CHAPTAR
Catalyst loading procedure SECTION
Document Type: System / Sub-system: REV. 1
POM-BOOK 1 STATUS
Contractor Document Number: Page 1 of
Approval
APPROVED FOR ISSUE BY:
TITLE NAME SIGNATURE DATE
Rev. Description Originator Date Reviewed by Date
1
TABLE OF CONTENTS
1 INTRODUCTION :
1.1 System Overview
1.2 Purpose of the Procedure
2 DEFINITIONS AND ABBREVIATION:
3 REFERENCES
4 RESPONSIBILITIES AND SAFETY.
5 SPECIAL TOOLS.
6.1 Hooper
6.2 rake
6 COMMISSIONING SCOPE OF WORK
7.1 Pre-Requisites
7.2 Loading preparation:
7 Execution plan.
8.1 Procedure description.
8.2 Special precautions during loading.
8.3 Loading procedure.
8.4 After loading procedure.
8 RECORDS:
9 ATTACHMENTS:
9.1P&ID
9.2MSDS
9.3Blind list
.. This document is the sole property of SPIE Oil & Gas Services. It cannot be used,
reproduced, transmitted or disclosed without its prior written authorization.
1 Introduction
9.1 System overview
The gas to the De-Ethanizer Unit contains water and this water must be removed in the
Molecular Sieve Unit. This is accomplished by passing the gas over beds of solid-pellets
which will adsorb the water from the gas (called the Drying Cycle). Flowing hot gas over the
bed will remove the adsorbed water (Regen Cycle), and prepare the bed for another drying
cycle
9.2 Purpose of the Procedure:
The aim of is procedure is to give general guidelines for preparatory work prior to loading the
adsorbent material into dehydration molecular sieve V-1442/V-1443.
10 DEFINITIONS AND ABBREVIATION:
Hooper: The hopper is simply a flow-bin that is adapted with a proper valve system
for dumping the Mole sieve catalyst. The hoppers capacity almost (2-3
drums in one time) and the hopper must be resistant to that weight. It
should be equipped with 4 hooks in order to be lifted by a Crane. The
bottom opening should be large enough to prevent clogging problems. The
valve should be guillotine type and should be easy to operate. It should
enable to stop the flowing of Molsieve catalyst quickly if some problem
occurs during the loading phase. It should not crush product by its motion.
Sock loading: using a sock made of rubber or canvas one end is attached to the hooper
discharge pipe and the other travel to within 3ft.
Rake: made out of wood or metal and its length should be 1 meter.
11 REFERENCES:
11.1 Project documentation
Commissioning execution plan
Refer to P&ID
Refer to JRA
Refer to PTW system procedure
Refer to confined space entry procedure
11.2 Vendor procedure
Refer to MSDS: CERAMIC BALLS, 19 MM (3/4”)-F88575.
DENSTONE 5767 1/8" SIZE-F81763.
Refer to vendor procedure
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reproduced, transmitted or disclosed without its prior written authorization.
12 RESPONSIBILITIES
All personnel involved in the execution of this procedure shall adhere to health, safety and
environment.
12.1 Vendor representative
Vendor representative will review and ensure that adsorbent loading method
statement is aligned with vendor loading procedure
12.2 HSE manager
Assist and reviews risk assessments and other safety assessments to support
Health,Safety&Environment management.
12.3 Safety officer
Ensure site safety and health plan is prepared and implemented.
12.4 Commissioning piping supervisor
To confirm the vessel and piping to the project drawing and specification
12.5 Fitters
13 HSE
13.1 General
Following safety rules to be followed up before starting and during adsorbent material
loading operation:
Materials loading Must not carried out at raining weather.
Barricade the area around the dryer and install warning signs boards prior to the
commencement of adsorbent material loading.
Install safety tags on the boundary isolation valves.
Ensure the valid PTW is available along with confined space entry permit.
Hold a tool box talk prior to start of adsorbent material loading operation to review
safety consideration and potential hazards of loading operation.
Temporary safety shower and eye wash arrangement to be made available prior to
start of this operation.
Entire area to be suitably illuminated using proper light.
Lifting plan for activities must be available.
The below equipment’s of dryers to be protected against falling materials (covered
with a plastic sheet )
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reproduced, transmitted or disclosed without its prior written authorization.
13.2 PTW and JRA
Permit to work is reviewed at least 1 day before the planned date for execution of the work.
The permit to work is open on the day of execution and can be renewed for 1 week.
PTW is not open for the night shift/night work.
Job risk assessment is conducted prior opening the permit to work. The JRA is attached to
the permit to work for opening. HSE manager drives the JRA committee.
13.3 PPE
All personnel working on this operation shall have the following minimum PPE:
Safety glasses.
Coveralls
Dust mask or most appropriate respiratory equipment’s as recommended in
respective MSDS.
Correct breathing air system: full face mask with permanent air supply,
13.4 Rescue plan
Tripod
Safety shower and eye wash
Oxygen cylinder and first aid kit
13.5 Vessel entry control
Personnel shall enter the vessel only after the vessel entry permit is completed.
Whenever personnel working inside the vessel, stand by person shall be near by the man
way to assist in emergencies
Records of entries and exits are performed.
O2 content is checked before any vessel entries.
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reproduced, transmitted or disclosed without its prior written authorization.
14 Special tools
14.1 Funnels
14.2 Hooper
14.3 Loading socks
14.4 Rope bucket
15 COMMISSIONING SCOPE OF WORK:
15.1 PRE PREREQUISITIES
The vessel need to be cleaned conditions before loading the adsorbent (to be checked by
client and vendor during inspection). Also the adsorbent materials need to be inspected
before loading.
Access platform and ladder shall be free of obstacles. If necessary tarpaulin is placed of the
access platform to avoid catalyst to fall on the ground.
Tested and certified crane and slings should be available. Lifting equipment i.e. forklift, crane
are available for loading.
15.2 Loading preparation
The preparation and installation of the equipment necessary to perform the operation like
funnels, hopper, loading socket and ventilation means are made available.
Box up the bottom man way.
Blind list to be prepared.
16 EXCUTION PLAN
16.1 PROCEDURE DESCRIPTION
The contractor (Petrojet) will prepare the detailed loading method on the basis of Vendor
guidelines.
The adsorbent materials vendor’s representative will review and ensure that the contractor
loading method statement is aligned with vendor loading procedure.
16.2 SPECIAL PRECAUTIONS DURING LOADING
Safety precautions have to be defined and applied as mentioned in MSDS.
It’s important not to forget anything inside the vessel such as helmets, rags.
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reproduced, transmitted or disclosed without its prior written authorization.
Some materials such as thermo well not withstand direct step on, care to be taken not to
step on.
16.3 LOADING PROCEDURE
Enough area is requested around the Mole sieve drier vessels to store full and empty drums
(Empty drums should stay in the loading area until the loading of one vessel is completed).
Enough space is necessary for the loading process namely, filling of hopper, crane and forklift
movements.
The procedure used for the Mole sieve catalyst dumping is by “Sock Loading” method which
prevents the Mole sieve catalyst by being crushed and damaged while loading.
The sleeve prevents Mole sieve from falling from high elevation and avoids crushing of the
Mole sieve by damaging it. This would damage the product and hence create dust and
reduce its performance. The loading technician will crimp the sock to restrict free fall of
material as he spreads the catalyst evenly. As the bed level rises the sock is cut and removed
from the vessel.
The catalyst hopper is lifted by the crane to the platform at the top of the Molsieve vessel.
After the hopper is positioned at the top of the vessel the manual valve is pulled to release
the catalyst through the canvas sleeve.
Each bed of Ceramic balls is levelled after its complete loading. After each level, Operator
should go and inspect the ceramic balls layer (already installed with screen) and after he
gives clearance the next layer of material is loaded. After each layer of material loading,
record is taken which is used as a reference document for future Mole sieve loading.
The Loading Technician will evenly distribute the inert balls/Mole sieve catalyst around the
full diameter of the Mole sieve drier vessel. After loading every 76+ drums of catalyst
(calculated based on UOP), the loading is stopped and the catalyst is evenly levelled by a
Rake to maintain the correct bulk density of the catalyst.
A loading chart is maintained and the ullage is taken after every layer of inert balls and
catalyst loading after every 76+ drums of Mole sieve loading which is used as a reference
document for future Mole sieve loading.
The loading pattern for the Mole sieve Driers is given below:
1/4”&1/8” ceramic support already installed with screen.
UI-94 1/16” pallet layer 6300lb (21.16 drum).
UI-94 1/8” pallet layer 19500lb (65 drum)
SS floating screen
3/4" ceramic support layer is 17ft3(6”hight)
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reproduced, transmitted or disclosed without its prior written authorization.
Loading Pattern of Molecular Sieve Drier
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reproduced, transmitted or disclosed without its prior written authorization.
8.4 AFTER LOADING:
When the loading operation is completed, all the vessel internal if were removed prior to
loading must be installed back (nozzles, distributors).
Before closing the man way top cover, vessel final closure certificate has to be signed off
(kiel&petrojet approved sheet).
The vessel has to be isolated by closing inlet and outlet valves and must be reserved under
nitrogen atmosphere.
The empty drums have to be shipped back to Kiel laydown yard.
17 RECORDS:
Once the vessel is filled with the adsorbent materials the final closure certificate will
be completed and signed off by contractor (petrojet) and client.
18 ATTACHEMENTS:
P&ID#375-222
BLIND LIST
MSDS#89034/8999/F81763/F81764/88575
JRA
PTW
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reproduced, transmitted or disclosed without its prior written authorization.
