CR Asia Group

Work Instruction for

Catalyst Skimming
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 Petrochem, however does not apply when standard entry
conditions are exceeded where additional PPE is required.
3. Reference document
4. Form
5. Definition
6. Responsibilities
6.1 Project / 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 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 Foreman / Technician / Workers are responsible to follow strictly each step of this instruction and
perform work that is assigned by their supervisor.

7. Procedure Steps
7.1 Preparation & Safety
7.1.1 Hold the JSA prior to Job set up
7.1.2 Hold the tool box talk immediately prior to starting the entries & before every shift. Record the
data in Safety Tool Box Form.
7.1.3 Take a valid permit for execution of job.
7.1.4 Brief all the crew on the safety precaution
7.1.5 Ensure the respirator is suitable for Job Execution.
7.1.6 Ensure that all the equipment like Vacuum Unit, Cyclone ,Demountable Vacuum Pipe, Vacuum
Hose, Dust Collector, Inside Lightening ( 24 Volt), other safety equipment set as per requirement,
screening machine, lifting tools tackles, rescue equipment
7.2 Pre Entry Checklists
7.2.1 Test the inside atmosphere of Tank and ensure it is within limit as per CR Petrochem & Client
safety Procedures
7.2.2 Entrant should be suited in following
Cotton Coverall
Disposable Coverall with Hood
Gloves providing suitable protection against contaminate.
Well aware about the Rescue Plan.
Well aware about the Rescue Plan.
Suitable Respirator as per inert entry.

Document :

CRAI-WI-CH-07

Issue Date :

18-12-2013

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

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CR Asia Group
Work Instruction for
Catalyst Skimming
7.2.3 Stand By Entrant Should be suited in following
Cotton Coverall
Disposable Coverall with Hood
Hard Hat
Shoes with the disposable coverall sealed Against them
Gloves providing suitable protection against contaminate.
Well aware about the Rescue Plan.
7.2.5

Manhole Watcher should be suited in following.

Cotton Coverall
Disposable Coverall with Hood
Rigger Shoes with the disposable coverall sealed Against them
Gloves providing suitable protection against contaminate.
Well aware about the Rescue Plan.

7.2.6

7.2.7
7.2.8

Person at the cyclone hopper should be suited in following.

Cotton Coverall
Disposable Coverall with Hood
Rigger Shoes with the disposable coverall sealed Against them
Gloves providing suitable protection against contaminate.
Well aware about the Rescue Plan.
Communication will be either by radio or by Hand signaling and viaual
Ensure that the inside atmosphere & temperature check during the entry with the Gas meters.
CR Gas Testing Limits
Inert Entry
Oxygen <3%
LEL <10%
Hydrogen Sulphide<10ppm
Carbon Monoxide<35ppm
Nickel Carbonyl<0.001 ppm
Temperature <40C
(Note: The limits are subjected to change as per job requirement)
7.3 Diesel Vacuum Unit Basic Operation Instruction
7.3.1 Pre start Up
a) Complete daily check list and retain copy
b) Ensure vacuum hosed clear of product
c) Check purge in bag house is functioning
d) Check drive belt pulley alignment (belt drive model)
e) Ensure all pipes and hoses are assembled correctly
7.3.2 Start Up
a) Open by-pass valve (if fitted)
b) Set engine throttle control to start position
c) Turn key on control panel to start position
d) Crank engine until running and release key to run position
e) Check for vacuum leaks while warming up motor
f) Adjust throttle control to required rpm
g) Check gauges & warning lights are functioning & set by-pass
7.3.3 Operation
a) Constantly monitor engine temperature
b) Constantly monitor engine oil pressure
Document :

CRAI-WI-CH-07

Issue Date :

18-12-2013

PERMIT REQUIRED PRIOR TO COPYING

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CR Asia Group
Work Instruction for
Catalyst Skimming
c) Watch drive coupling/ belts for wear
d) Shut down if engine is laboring excessively
e) Shut down in the event of unusual bearing/belt noise
7.3.4 Shut Down
a) Ensure vacuum hose is clear of product & open by-pass valve
b) Adjust throttle back to start position and allow to cool down
c) Turn ignition key to off position
d) Check bag house for carry over & filter condition
7.4 Blinding of reactor
7.3.1 Ensure de-pressurization of all work-related lines with mechanical/maintenance dept. of
client.
7.3.2 Procure blinds list and physically identify blinds to be installed under CLIENT presence
7.3.3 Working platform is to be fully secure and safe for work
7.3.4 Request for scaffolding if required at any locations.
7.3.5 Procure work permits with RA and blind list.
7.3.6 Brief all crew on the safety precautions laid out on the permit.
7.3.7 Establish what service the lines have been in and have the correct personnel protective
equipment in-place.
7.3.8 Un-bolting is to be performed using the tensioning/torqueing tools as directed by CLIENT.
7.3.9 Usage of hammer (extreme cases like non-assembly of torqueing/tensioning tools with the
nuts/bolts) is to be done only after acquiring permission from CLIENT.
7.3.10 Bolts and nuts removed are to be placed in trays.
7.3.11 Spilt product from flanges to be collected by trays placed underneath the flange and
adequately disposed.
7.3.12 Before starting to remove final bolts, ensure that all necessary safety measures are being
taken, and correct PPEs.
7.3.13 Single line BA mask to be used depending on the Conditions.
7.3.14 Bolts farthest from manpower are to be removed initially such that no harm arises from exit
of materials, if any.
7.3.15 Before removing all bolts, ensure that all points on the flange are adequately supported.
7.3.16 Proper gaskets to be installed alongside the blinds.
7.3.17 Bolting performed as per the sequence to be followed after alignment of the flanges.
7.3.18 Check all blinds after completion for client approval prior to accepting signatures from all
concerned departments on the blinds-list.
7.3.19 House-keeping of the particular work area
7.4 Top Elbow Removal
7.4.1. Using torquing/ tensioning loosen the bolts in sequence.
7.4.2. Ensure upstream line having adequate support and Remove top elbow using crane of
suitable capacity and transfer to grade level for neutralisation and cleaning.
7.4.3. Install Serration protection for manway flange and blind the I/L as per blinding procedures
explained above.
7.4.4. Carry out necessary gas tests for safe entry.
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.

Document :

CRAI-WI-CH-07

Issue Date :

18-12-2013

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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Copy Number :

Issue Number :

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CR Asia Group
Work Instruction for
Catalyst Skimming
7.5.7.
7.5.8.

Catalyst conveyed are stored in the already lined drums and purged with nitrogen lance
before drum liner is sealed.
Transfer drums to designated lay down area.

7.6 Loading of Catalyst/ Ceramics

7.6.1. Set up loading hopper at reactor top and fit loading sock through slide valve.
a.
Note: Loading hopper may require scaffold support.
7.6.2. Decant catalyst from drums into transfer hoppers at grade level.
7.6.3. Technician enters reactor using life support equipment and prepares for reload.
7.6.4. Transfer the content of transfer hopper using crane to loading hopper placed at reactor
manway platform.
7.6.5. Load as required as per loading diagram and repeat the above steps for different types of
catalyst/ ceramics.

*All the inert entry works will be carried out as per Client & CR standards
7.7Box
7.7.1.
7.7.2.
7.7.3.

up
Reinstate the tray sections and clean.
Request final inspection & clearance for manway box up.
Box up reactor manway elbow using torquing / tensioning.

7.8 De-blinding
7.8.1. Procure work permits with RA and blind/de-blind list.
7.8.2. Identify the locations and request for scaffolding if necessary.
7.8.3. Use necessary PPE, loosen bolts and Carefully remove the blind or reverse the blind
manually or using chain block or crane.
7.8.4. Remove the old gaskets and box up the flange with new gaskets inspected by CLIENT.
7.8.5. 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.
7.8.6. Ensure all the joints mentioned in the list are de-blinded and tightened.
7.8.7. Tag all flanges after completion for client approval prior to accepting signatures from all
concerned departments on the deblind- list.
7.9 SITE CLEAN UP (Housekeeping)
7.9.1.Housekeeping is always an important part of any project and the object is to leave any site as
clean if not cleaner then when you arrived.
7.9.2.Always clean equipment at work site prior to demobilization. No equipment should ever leave
the site dirty.
7.9.3.All electrical leads to be rolled up and taped securely. Ensure that there is no risk of other
equipment being loaded or sat on top of leads causing damage.
7.9.4.All airlines and hoses are to be washed, rolled up and secure these are to be either placed in
hose cages or site container.
7.9.5. If any equipment is damaged this should be clearly identified and taken off site for repairs.
7.9.6.All areas around the work area that were made dirty or are dirty should be degreased and
cleaned. Any contaminated soil should be placed in containers for further treatment.
7.9.7.All used gloves, paper overalls, rags and other consumable should be collected for correct
disposal and not left in the work area.
7.9.8. All empty drums should be removed from the area.
7.9.9. Check that all fittings have been removed from temporary pipe work.
7.9.10. All vacuum or pump hose should be washed and stored correctly for transportation.
7.9.11. Return any equipment that is not required for the next project to local office/yard for service.
Document :

CRAI-WI-CH-07

Issue Date :

18-12-2013

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

00

Copy Number :

Issue Number :

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CR Asia Group
Work Instruction for
Catalyst Skimming
7.9.12. All equipment that is on hire should be cleaned and returned to the appropriate hire company
or collection organised.
7.9.13. Ensure that clients view the site when you have completed demobilisation. Show pride in the
fact that we have not left the client with any further problems.
7.9.14.Have the clients representative sign the completion certificate and encourage them to make
comments on the way the site has been handed back to him.
8.0 Process flow chart

Document :

CRAI-WI-CH-07

Issue Date :

18-12-2013

PERMIT REQUIRED PRIOR TO COPYING

Revision Number :

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Copy Number :

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