Contract Resources Petrochem Services (India) Pvt. Ltd.

Quality Approve Plan for DHT Internal Replacement

Objective: To describe safe working procedure for Catalyst unload & load with internals installation in confined spaces

under normal atmosphere.

1.0 Scope

This procedure is applicable for CR India Operations – Mechanical Division.

2.0 Job description: Internals installation includes:

2.1.1 New internals shifting, box opening as per B.O.M and its segregation, mock up of tray assembly,

Inspection as per drawings

2.1.2 Internal installation: Provide scaffolding as per requirement, individual tray assembly, welding, NDT

and inspection

3.0 Form

All Safety related forms.

4.0 DEFINITION:

4.1 Confined spaces

Confined space refers to a space that has any of the following characteristics:

1. Limited openings for entry and exit.

2. Unfavorable natural ventilation.

3. Not designed for continuous worker occupancy

It includes, but is not limited to, vessels, reactors, tanks and sewer system.
4.2 Competent person

Competent person refers to a person with sufficient theoretical knowledge and practical experience to make an informal

assessment of the likelihood of a dangerous atmosphere being present or subsequently arising in the confined space.

4.3 Responsibilities

Team Leader/ Supervisor/ Project Manager are responsible for the job with regard to safety, progress, records and

contact with client representatives

4.3.1 One man in charge of emergency rescue team

4.3.2 One man in charge of HSE

4.3.3 One man in charge of QA/QC

4.3.4 Individual in charge of communication for ground and top activities

The above responsibilities can be interchanged since all the personnel are trained and are fit to fulfill all requirements for

any specialized work.

4.4 CHARACTERISTICS OF CONFINED SPACES

4.4.1 The available space usually creates a limited work area

4.4.2 Presence of dangerous or hazardous substances. Small quantities of these substances in a confined space

lead to dangerous concentrations

4.4.3 In most cases, there is little or no natural ventilation. Forced ventilation may be difficult to install

4.4.4 Limited visibility, requiring the usage of artificial lighting

4.4.5 Access to a confined space is often difficult to reach and small. In some cases, these may have to be

doubled as an emergency escape

4.5 General Hazards

Work in confined and enclosed space has a greater likelihood of causing fatalities, severe injuries and illness. The

key hazards associated with confined spaces are;

 4.5.1 Serious risk of fire and explosion

4.5.2 Loss of consciousness from asphyxiation arising from gas, fumes, vapour or lack of oxygen

4.5.3 Loss of consciousness arising from an increase in body temperature

4.5.4 Asphyxiation/suffocation arising from free flowing solid (engulfment) or the inability to reach a

breathable atmosphere due to entrapment

Surveyors will routinely enter confined spaces that are difficult to access due to small and/or narrow openings. There may

be physical constraints within the space which need to be considered, and the space itself may be cramped permitting

only restricted mobility.

Given the usual enclosed and darkened nature of a confined space this activity ideally should not be carried out by

personnel suffering from phobias (e.g. claustrophobia) or who are susceptible to panic or anxiety attacks.

4.6 TOOL BOX-JOB START MEETING

4.6.1 Tool box meeting is conducted by operations dept. All supporting teams are involved in this meeting.

Record of Tool box –job start log is maintained by catalyst division.

4.6.2 Refer form F-WI-CH-01 - Tool box –job start log

4.7 Standby / rescue

4.7.1 Standby: A standby person should be assigned to remain on the outside of the confined space and be in

constant contact (visual or two-way voice communication e.g. walkie-talkie) with the survey team

inside. Routines for communication intervals with the survey team should be established.

4.7.2 The standby person: should not have any other duties than to serve as standby and know who should

be notified in case of emergency; should never leave his post even after help has arrived and is a key

communication link to others onboard; should be able to communicate sufficiently in a relevant

common language. Communication between watch personnel (Bridge, Cargo Control Room or Engine

Control Room) and standby person should be established.

4.7.3 Rescue: Rescuers must be trained in and follow established emergency procedures and use appropriate

equipment and techniques (such as lifelines, respiratory protection, standby persons).Emergency and

evacuation procedures should be agreed and understood by all parties involved in a potential rescue

operation. Steps for safe rescue should be included in all confined space entry procedures. Rescue

should be well planned and evidence should be made available that indicates dALBANNA/Clientls have

been frequently conducted on emergency procedures.

4.8 Personal Protection Equipment (PPE)

4.8.1 PPE is traditionally regarded as the last line of protection with the emphasis being placed on avoidance

and appropriate managerial control methods. However, the potentially hazardous nature and isolated

position of those entering a confined space means that, for the surveyor, PPE may be the first line of

protection.

4.8.2 Each confined space will present different hazards and degrees of risk to health and safety, the final

provision of PPE should therefore be based on an assessment of risk.

As a general rule the following guidance is offered.

Basic surveyor PPE should include:

− Body protection (hard wearing overalls with suitable pockets for notebook, etc);

− Foot protection (steel toecaps (200 joules), steel midsoles, good grip, oil resistant);

− Head protection (hard hat with chinstraps);

− Hand protection (hard wearing gloves);

− Eye protection (protective glasses, goggles);

− Ear protection (ear defenders or ear plugs – worn subject to communication system);

− Gas meter - multi-gas meter for measuring of HC, H2S, CO, O2 is recommended;

− Lighting (hand held with lanyard and appropriate beam width)

5.0 Work Procedure

5.1 BLINDING OF VESSEL / REACTOR

5.1.1 Ensure that the vessel/reactor has been clearly identified by the relevant operations or maintenance

personnel.

5.1.2 Before starting the blinding process, ensure that the correct blinds list is available.

5.1.3 Identify blinds to be installed and acquire the correct tools (Torquing/ tensioning Tools)
 5.1.4 Ensure that work permits are in place and that the lines are de-pressurized. (This may require operations

check). Check what service the lines have been in and acquire the necessary protection. e.g.

Acid/Nitrogen etc.

5.1.5 In some instances, permission may be granted for the hot bolting or skip bolting to take place. (Removal

of every second or alternate bolt).

5.1.6 Put in place a drip tray (if practical) underneath the flange to be broken to collect any spilt product.

5.1.7 Before starting to remove final bolts, ensure that all necessary safety equipment is worn. E.g. safety

goggles/ Single line mask etc.

5.1.8 Ensure that the bolts farthest away from the personnel are removed first to prevent any trapped product

from spraying.

5.1.9 Do not remove all bolts and ensure that line does not require any additional support when bolts are

loosened.

5.1.10 Insert blind ensuring that a gasket is inserted on both sides of the blind. Should only one gasket be

required, place this on either the pressure side or the vessel side depending on the application.

5.1.11 In the event of only one gasket being used get approval first and determine which side this is to go.

5.1.12 Bolting up should be done in a criss-cross sequence and ensure that flanges are aligned and stud bolts

have even tightness.

5.1.13 At completion of blinding ensure that blinds are checked and that blind list is signed off by all parties.

5.1.14 Clean up any spilt product and leave area in a safe and clean condition.

Top Elbow Removal

Using torquing/ tensioning loosen the bolts in sequence.
Ensure upstream line having adequate support and Remove top elbow using crane of suitable capacity
and transfer to grade level for neutralisation and cleaning.
Install Serration protection for manway flange and blind the I/L as per blinding procedures explained
above.
Carry out necessary gas tests for safe entry.

INITIAL GAS TESTING – REACTORS

 The following is the standard outline of requirements for testing of atmospheres in reactors
prior to entry. These limits are for entry without gas suits.

 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.

Prepared By :- Swapnil Patil ( Quality Control)

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 Quality Approve Plan for DHT Internal Replacement


The following tests are carried out to ensure all personnel are aware or the dangers involved.

Oxygen Content: Normal Entry: 19.5%-21% of Vol.

Temperature: < 45 deg. C

Hydrocarbons: 1% Volume

LEL: < 10%

Hydrogen Sulphide: 10ppm

Carbon Monoxide: 50ppm

Benzene: 5ppm

Carbonyls: 0.1ppm
(NOTE: Parameters may change as per job requirement)

 These limits are subject to change as regulations vary from client. We believe that they are within
acceptable tolerances.
 All tests are carried out using either MSA or Draeger gas testing units (or their
equivalents) for the Oxygen and LEL. Draeger or MSA (or their equivalents) test tubes are
used for recording other substances. These results are to be recorded on the Atmosphere
Analysis Result Form.
 The oxygen and LEL are always monitored continuously when personnel are inside a reactor to
ensure no unforeseen problems arise.
NOTE: There are other substances that from time to time may be present in the
atmospheres that we are to enter. These will be either identified by our clients or
from MSDS (material safety data sheets) supplied by catalyst manufacturer or the
client.
 Refer form, Initial Gas Test Results

 Refer form, Testing of Atmospheres. Check List

 Refer form, Entry Checklist

 Refer form, Reactor Entry Log

7.5 Unloading of Ceramics/ Catalyst

7.5.1. Ensure confined space entry permits( inert entry) are in place.
7.5.2. Inert Entry Technician enters reactor using life support equipment.
7.5.3. Removal of tray sections required for access the bed (if fitted).
7.5.4. Vacuum required amount of inert / ceramics from top of catalyst.
7.5.5. Take samples as directed.
7.5.6. Vacuum catalyst in level layers to required depth.
7.5.7. Catalyst conveyed are stored in the already lined drums and purged with nitrogen lance before drum
liner is sealed.
7.5.8. Transfer drums to designated lay down area.

5.2 LINE UP INTERNALS FOR REACTOR

 5.2.1 The following are the general procedures for lining up equipment for internal installation in reactors.

5.2.2 The general procedures for preparation for this work include:

5.2.2.1 Ensure that all permits are in place

5.2.2.2 Set up site office, containers etc

5.2.2.3 Establish communications and cordon off area in agreement with client

5.2.2.4 Scaffolding shed for internal inspection near reactor area

5.2.2.5 Shifting of internals from ware-house to scaffolding shed

5.2.2.6 Opening of wooden boxes and segregation of job subjects

5.2.2.7 Mock-up internals as per installation inside the reactor

5.2.2.8 CLIENT Inspection and clearance for installation

5.2.2.9 Ensure QA/QC is being followed

5.2.2.10 Keep the work area clean and safe

5.2.2.11 Inert Atmosphere to Normal Atmosphere after doing Passivation.

5.2.2.12 Final Cleaning of Recator.

6.0 Installation Activities

6.6.1 Internal Support Skirt:-

Install skirt sections onto existing support ring.
Verify dimension between skirt ring flange & reactor wall at support ring & verify
orientation & fit up of skirt sections.
Loosely bolt section together.
Level Skirt sections to acceptable tolerance ± 6 mm ( ± ¼ inch)
Tighten all bolts around the Skirt.
HPCL Inspection.
6.6.2 Lower Vapour Distribution Tray:-
Install match-marked support beam into reactor.
Level Support Beam to acceptable tolerance ± 6 mm ( ± ¼ inch)
Install J Clips around outer tray sections as required.
Install Match mark tray sections on Top of support beam according to drawings.
When installing the tray section it is best practice to install trays first with flange.
Verify the orientation & fit up of tray sections on support beam.
Level tray sections to acceptable tolerance ± 6 mm ( ± ¼ inch) using the same method
of levelling as used previously for the Beams.
Tighten the J Clip to support ring around outer tray sections.
Bolt up Centre man way to verify suitable fit prior to seal welding of tray Section
(Remove after Verification complete.)
Tack Weld the tray sections to be welded in place so that required gaps
between component will be maintain throughout seal welding of tray sections.
Prepared By :- Swapnil Patil ( Quality Control)
 Contract Resources Petrochem Services (India) Pvt. Ltd.

Quality Approve Plan for DHT Internal Replacement

HPCL Inspection for fit-up ( Dimension & Orientation)

Begin stich welding the trays by welding 150 mm (6 Inches) along the seam to be welded
in an alternating fashion down the length of seam. This is to prevent tray deformation caused
by excessive heat built up. Not performing this procedure will result in deformed trays &
potentially affect the performance of the internals as designed. CR site supervisor to ensure
that same procedure follow.
HPCL Inspection (Visual. DP Testing).
6.6.3 Rough Liquid Distribution tray:-
Install the seal blanket on top of middle flange of support Beams.
Install Match- marked tray sections of top of middle flange of support beams.
Verify the orientation & fit up of tray sections on support beams
Note:- Inserting a nut between the tray ends as shown may help expedite this process.
Also Verify that panel numbers match installation drawings & that the sieves holes line
up correctly between Ultramix cap.
Install support rods between lower vapour / Liquid distribution tray & rough liquid
distribution tray.
Tack weld Support rod Nuts to lower vapour/ liquid distribution tray.
Level the tray Section to acceptable tolerance ± 6 mm ( ± ¼ inch).
Remove the outer most tray sections & tackweld support rods.
Replace outermost tray section.
Install centre manwaysection to verify suitable fit prior to sealing ( remove after verification
is complete)
Install rope packing between adjacent tray section banding plates.
Install & tighten bolts to secure rope packing in place .
Fix the tray sections to support beam by tightening the nuts of J clip.
Verify bevel on J clip bolts are oriented correctly.
Fix the Outermost tray section to support the rod by tightening the nuts.
Clear the debris from installed tray.
HPCL Inspection.
6.6.4 Mixing Chamber:-
Install required gasketing between sections & begin arranging pieces of the mixing
chamber/ gasketing/ bolt inside the vessel working on section at time. Take special care to not
lose access to the bolting flanges on the bottom side of the mixing chamber.
As a pieces become more arranged it will necessary to support the tray sections on
wood blocks from beneath the mixing chamber.
Continue installing bolts while tray is suspended on wood blocks until all bolts/ gaskets
are installed.
Use Hydraulic Jack or similar method to lift the assembled mixing chamber & allow
the removal of the wood blocks from beneath the mixing chamber.
Bolt up centre man way to verify suitable fit.

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 Contract Resources Petrochem Services (India) Pvt. Ltd.

Quality Approve Plan for DHT Internal Replacement

HPCL Inspection
Loosely attached cover plate to mixing chamber by bolting.Cover Plates attached will
be fully attached after liquid collection tray beam is installed.
Clean installation debris from installed
tray. HPCL Inspection.

6.6.5 Liquid Collection Tray.

Install match marked support beam on top of the support Beam.
Verify the beam spacing & dimensions between beam ends & reactor wall. This is easily
done by the checking interbeam spacing & triangular of the beam( Cross Dimension)
Tighten the cover plate bolting on mixing chamber.
Cover the mixing chamber flange with appropriate gasketing.
Install the tray section on top of supporting beams, employing necessary
dimensional adjustments
Verify orientation & fit up of tray sections on support beams & mixing chamber flange.
Level tray acceptable limit ± 6 mm (± ¼ inches).
Bolt up the centre manway to verify suitable fit.
HPCL Inspection
Fix the tray section to support ring & support beams by tightening the nuts of J clip.
Fix mixing chamber flange to liquid collection tray panels using required gasketing & bolts.
Verify bevel on J clip bolts are oriented correctly.
Clean the installation debris from tray.
HPCL Inspection.
6.6.6 Quench Distributor.
Install the quench pipe from outside the reactor through quench nozzle.
Screw in the flange to the Quench pipe & tack weld the flange to the pipe taking special care to
ensure correct orientation of the flanges with respect to final quench distribution device.
HPCL Inspection.
6.6.7 Catalyst Support Grid.
Put the filler plate & rope packing in support beam groove, if not already installed prior
to shipping.
Install match marked support beam onto reactor.
Level the support beam to acceptable tolerance limit ± 6 mm (± ¼ inches).
Check the Gap between filler plate & support ring. Arrange the filler plate & rope packing
to minimize the gap.
HPCL Inspection.
Seal weld the filler plate to support ring.
Place the Grid section on the beams & support ring.

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 CR Petrochem Services (India) Pvt. Ltd.

Quality Approve Plan for DHT Internal Replacement

Install the ceramic rope.

Clean the installation debris from installed Grid.
HPCL Inspection.
6.6.8 Thermocouple installation:-
Thermocouple installation as per Installation Procedure or as per client
requirement.

CATALYST LOADING by Sock Loading

The following is a broad procedure for the loading of Reactor. As reactors vary in design it may be
necessary to develop on site methods after considering specific drawings.
Mark up for reloading as required and measure bed depth to get a datum point.
Install loading hopper positioned over man way to allow access for personnel entry.
Note: Loading hopper may require scaffold support.

Install loading pipes and secure safely. Add a length of sock at the end for control.
Ensure that the bottom of the bed is clean and dry.
Install plugs in dump nozzles as required or in beds with dump chains. Secure in position and tie
up with rope.
Decant catalyst from drums into transfer hoppers at grade level.
Technician enters reactor using life support equipment and prepares for reload.
Transfer the content of transfer hopper using crane to loading hopper placed at reactor man way
platform.
Load as required as per loading diagram and repeat the above steps for different types of catalysts.

Box up all 4th bed Manway trays

Loading of catalyst for 3rd bed by sock method.

Box up all 3rd bed Manway Trays.

Box up Main manway.

Installation of Elbow with Inlet Diffuser.

Document CRIN-WI-HSE-01 Revision Number 00 Copy Number

Issue Date 09.11.2011 Issue Number 01 Page 10
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 CR Petrochem Services (India) Pvt. Ltd.

De-Blinding of Vessels/Reactors:

Ensure isolation all work-related lines with mechanical/maintenance dept

Procure blinds list

Working platform is to be fully secure and safe for work

Procure work permits with RA and blinds list

Accumulate all serviced bolts and nuts around the work area

Brief all crew on the safety precautions laid out on the permit. Establish what service the

lines have been in and have the correct personnel protective equipment in-place

Bolting is to be performed using tensioning/Torquing tools as directed by client

Bolting by the usage of hammer (extreme cases like non-assembly of

torquing/tensioning tools with the nuts/bolts) is to be done only after acquiring

permission from client.

Before assembly of the bolts, ensure that all holding points on the line are adequately supported

Proper gaskets are to be installed after being inspected by client.

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.

Tag all flanges after completion for client approval prior to accepting signatures from all

concerned departments on the de-blinds-list

Final house-keeping of the entire work area

Document CRIN-WI-HSE-01 Revision Number 00 Copy Number

Issue Date 09.11.2011 Issue Number 01 Page 11
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 CR Petrochem Services (India) Pvt. Ltd.

6.1.1 Work permits to be closed.

Document CRIN-WI-HSE-01 Revision Number 00 Copy Number

Issue Date 09.11.2011 Issue Number 01 Page 12
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