Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
(HTS) High Temperature Shift Catalyst (VSG-F101) - Comprehensiev OverviewGerard B. Hawkins
The high temperature shift duty introduction and theory
HTS catalyst characteristics
developments over time
Typical HTS operational problems
Improved catalysts
VULCAN Series VSG-F101 Series
Summary
Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
(HTS) High Temperature Shift Catalyst (VSG-F101) - Comprehensiev OverviewGerard B. Hawkins
The high temperature shift duty introduction and theory
HTS catalyst characteristics
developments over time
Typical HTS operational problems
Improved catalysts
VULCAN Series VSG-F101 Series
Summary
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Why have a Secondary Reformer ?
Need nitrogen to make ammonia
Wish to make primary as small as possible
Wish to minimise methane slip since methane is an inert in the ammonia synthesis loop
Other methods of achieving this
Braun Purifier process
Can address all these with an air blown secondary
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Common poisons include
Sulfur
Chlorides and other halides
Metals including arsenic, vanadium, mercury, alkali metals (including potassium)
Phosphates
Organo-metalics
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
The Benefits and Disadvantages of Potash in Steam ReformingGerard B. Hawkins
Why do we include potash ?
What are the benefits ?
What are the disadvantages ?
Catalyst Deactivation
Carbon Deposition : Thermodynamics & Kinetics
Carbon formation margin
Reaction chemistry (Tube inlet)
Hydrocarbons undergo cracking reactions on hot surfaces at the tube inlet
Products of catalytic cracking reactions can form polymeric carbon
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Need to remove poisons prior to entering downstream catalyst beds, including
Pre reformers
Primary reformers
HTS
LTS
Note : no Secondary - poisons do not stick as temperature is too high
Note that methanator is a purification step
Removes CO and CO2 which poisons synthesis catalyst
Steam Reformer Surveys - Techniques for Optimization of Primary Reformer Oper...Gerard B. Hawkins
Introduction
Background Radiation and Temperature Measurement
Reformer Survey Inputs
Other Troubleshooting Tools
Safety
Preparation
Onsite Data Collection
TWT Survey
Observation/Troubleshooting
Modelling and Analysis
Results/Outputs
Case Studies
Conclusions
Case Study 1
Case Study 2
Case Study 3
Conclusions
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Why have a Secondary Reformer ?
Need nitrogen to make ammonia
Wish to make primary as small as possible
Wish to minimise methane slip since methane is an inert in the ammonia synthesis loop
Other methods of achieving this
Braun Purifier process
Can address all these with an air blown secondary
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Common poisons include
Sulfur
Chlorides and other halides
Metals including arsenic, vanadium, mercury, alkali metals (including potassium)
Phosphates
Organo-metalics
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
The Benefits and Disadvantages of Potash in Steam ReformingGerard B. Hawkins
Why do we include potash ?
What are the benefits ?
What are the disadvantages ?
Catalyst Deactivation
Carbon Deposition : Thermodynamics & Kinetics
Carbon formation margin
Reaction chemistry (Tube inlet)
Hydrocarbons undergo cracking reactions on hot surfaces at the tube inlet
Products of catalytic cracking reactions can form polymeric carbon
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Need to remove poisons prior to entering downstream catalyst beds, including
Pre reformers
Primary reformers
HTS
LTS
Note : no Secondary - poisons do not stick as temperature is too high
Note that methanator is a purification step
Removes CO and CO2 which poisons synthesis catalyst
Steam Reformer Surveys - Techniques for Optimization of Primary Reformer Oper...Gerard B. Hawkins
Introduction
Background Radiation and Temperature Measurement
Reformer Survey Inputs
Other Troubleshooting Tools
Safety
Preparation
Onsite Data Collection
TWT Survey
Observation/Troubleshooting
Modelling and Analysis
Results/Outputs
Case Studies
Conclusions
Case Study 1
Case Study 2
Case Study 3
Conclusions
Revamp objectives
Revamp Philosophy
Revamp options
Semi-Regenerative Reforming Unit
Typical Flow Scheme
Continuous Reforming Unit
Typical Flow Scheme
Revamp to Hybrid Operation
What may be achieved?
Typical C5+ Yield at Decreasing Pressure
Changes Required for Full Conversion
Typical Benefits of Full Conversion
Revamping of Existing Continuous Reforming Units
Fired Heaters Revamp
Burners
Reactor Options
Regeneration Section
Summary
The petroleum industry uses Reforming as a primary process for quality improvement to meet final fuel specifications as well as hydrogen and LPG production for many intermediate processing units. This course covers the core elements of Reforming technology. Key variables that affect product yields and properties are described and their impact on the optimisation of the unit operation discussed. A framework is presented for troubleshooting operating problems and, throughout this discussion, participants are encouraged to describe their specific challenges.
VULCAN VGP-1000 High Temperature Mn Sulfur Guard TechnologyGerard B. Hawkins
High Temperature Sulfur Removal in the Presence of Chlorides, for Magnaformers
Catalytic Reforming Overview
Commercial Catalytic Reforming Processes
Application for Catalytic Reforming
Sulfur Removal
Magnaforming Overview
A case study of thinning of ng (natural gas) injection line in mp section bef...Prem Baboo
In urea plant Medium pressure Inerts gases recover HRU burner in Captive Power Plant. The inserts containing useful fuel in the form of Hydrogen & Methane about 40-45% volume percentage of total inerts. This inerts also containing Oxygen because the passivation air is given in carbon Dioxide compressor suction line for passivation of Reactor vessel and all downstream Stainless Steel vessel. In the presence of Oxygen there are chances of explosive mixture of Hydrogen and Oxygen in exit of MP section final vent line, to overcome this dangerous situation natural gases are added in the MP section before MP condenser so that the range of explosive can be avoided. These gases Hydrogen & Methane come with carbon Dioxide gas from Ammonia plant, carbon Dioxide about 0.5-0.7 % and Methane about 0.08 to0.1%. But we have seen after implementation of this scheme, frequent leakage was observed from inlet flange as well as heavy erosion was noticed in the inside surface of vapour inlet line and flange. Erosion was noticed from NG injection point and extended downstream up to nozzle flange in elliptical pattern. Material of construction of the process piping is A312 TP -316 L (Cr-18%, Ni-12%, Mo-2.0%, N-0.2%, and C-0.03%) which is compliable as per basic licenser. Hence frequent thinning of the pipe wall nearing injection point is due to sudden expansion of natural gas. In order to minimize pipe wall erosion phenomenon near NG injection point an alternative arrangement of NG injection extending the 1” NG line up to center of the vapour inlet line has been implemented and location of injection also changed as fig.-3.
This is presentation given by PG&E representatives about a large Liquified Natural Gas (LNG) project being developed in Felton, CA. This project is one of the largest ever developed in the industry.
RV Thuwal - Refit project overview by Maritime Survey AustraliaMichaelUberti
KAUST engaged Maritime Survey Australia to act as a project manager to oversee a major refit of the vessel, RV Thuwal which involved wiring upgrades, installation of new navigational equipment, a new galley, a scientific survey room and a vessel upgrade of the hydraulics, heating, ventilation and cooling systems.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
TECHNICAL TRAINING MANUAL GENERAL FAMILIARIZATION COURSEDuvanRamosGarzon1
AIRCRAFT GENERAL
The Single Aisle is the most advanced family aircraft in service today, with fly-by-wire flight controls.
The A318, A319, A320 and A321 are twin-engine subsonic medium range aircraft.
The family offers a choice of engines
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
1. ANNUAL TURNAROUND JUNE 2015 Page | 1
REPORT ON PRIMARY
REFORMER
CATALYST
UNLOADING AND
LOADING
2. ANNUAL TURNAROUND JUNE 2015 Page | 2
PRIMARY REFORMER CATALYST REPLACEMENT PLANNED JOB FOR
ANNUAL TURNAROUND 2015 AT MANGALORE CHEMICALS AND
FERTILIZERS LIMITED, PANAMBUR, MANGALORE, KARNATAKA- 575010.
PROCESS CREW MEMBERS
K. SELVAN
DHARMARAJ. D. D
K. P. DEVADIGA
PRASHANT. A
SHARATH. A
SILAMBARASAN
PRASHANTH. K
VINAYA
ABHAY
ABDUL
ROHIT
BHARATH
JEEVAN
YASHWANTH
SACHIN
3. ANNUAL TURNAROUND JUNE 2015 Page | 3
SUMMARY
After the successful operational period for the year 2014-2015, inspection of
primary reformer tubes and replacement of primary reformer catalyst was planned to
provide solution for the high reformer tube skin temperatures.
Sud Chemie (Catalyst Supplying Firm) took the initiative of supplying the two
layered catalyst for the primary reformer. Catalyst was made available as per our
requirement with bottom layer having 42% of Ni Catalyst (Reformax 330 G90 LDP- 10
hole- 19*16mm) and 58% of NiK Catalyst (Reformax 250- 5 hole- 16*16mm).
Bottom layer catalyst:
REFORMAX 330 G90 LDP (10 hole) - 19*16mm
49 drums of new catalyst and 1 drum of old catalyst were available.
Drum info- Net weight- 156 kgs/Gross weight- 176 kgs/Volume- 200 liters.
Density- 780 kg/m3.
4. ANNUAL TURNAROUND JUNE 2015 Page | 4
Top layer catalyst:
REFORMAX 250 (5 hole)- 16*16mm
68 drums of new catalyst were available.
Drum info- Net weight- 216 kgs/Gross weight- 236 kgs/Volume- 200 liters.
Density- 1080 kg/m3.
CR- Asia was given the contract for unloading and uniform loading of primary
reformer catalysts. Services included reformer tubes counter weight adjustment, tube
flanges bolt loosening/tightening (without hammer- pneumatic torque allowed), shifting of
spent/new catalyst drums, visual display of individual reformer tube internal surface with
video cam assembly, for spent catalyst sampling, empty/loaded catalyst dip and differential
pressure (DP) checking, catalyst unloading by BIVAC pump and loading by UNIDENSE
method.
5. ANNUAL TURNAROUND JUNE 2015 Page | 5
DETAILED REPORT
After planned ammonia plant shutdown, reformer cooling using inert gas (Nitrogen)
was prolonged for LTCO convertor bed cooling (@1000 hours on 10th June, 2015).
Depressurization of front end was done at HT guard inlet vent point after isolating HTCO
convertor inlet isolation valve. After depressurizing, following jobs were done in the
mentioned order (Jobs completed in approximately 8 hours)-
Reformer feed spaded (FRRC-203 d/s)
Make gas boiler(H201) outlet spaded
Reformer furnace man way covers opened
Reformer outlet T-plug removed
All reformer burner guns removed
Demineralized water flushing done for fuel naphtha header towards raw naphtha
storage tank
Reformer fuel naphtha strainer spaded (SM1 u/s)
Reformer tube counter weight locked
Reformer tube and pigtail flanges insulation removed
All 224 tube flanges bolt removal initiated. Long pigtail to short pigtail flange
removed and respective orifices positions were marked and tied to the same flanges (Jobs
completed in approximately 24 hours).
Unloading of primary reformer was started at 1825 hours on 10th June, 2015. CR-
Asia BIVAC with a single hose was used for unloading with vacuum reading of -350 mm
Hg/-0.135 inch Hg. Dust sample was collected from bottom T- plug and handed over to Q/C
& Lab for analyzing. With completion of catalyst unloading for “A” & “B” row, rigs for
measuring differential pressure across tubes were being made ready for MCFL rig. [Note: A
second vacuum hose was made ready and utilized to accelerate the catalyst unloading
process. A metal tip nozzle was being used in case of compacted spent catalyst unloading. A
mark with tape was made on each hose being inserted into tubes to make sure the catalyst
support grid was not being damaged for every tube.]
6. ANNUAL TURNAROUND JUNE 2015 Page | 6
Spent catalyst sampling was done for the following tubes A24, A44, A48, B16 and
D16. As decided, samples were collected at heights of 3m, 6m and 9m for all the 5 tubes.
Reformer catalyst unloading for all 224 tubes was completed on 12th June, 2015 (Job
completed in approximately 48 hours). The spent catalyst was being collected in the
provided Mangala Urea bags and shifted to the reformer bottom shed. All 224 tubes empty
dip readings were noted down. Later that night at 2230 hours, all reformer tubes inner
surface cleaning by stainless steel wire mesh was initiated. To extract the excess scale
formation inside the reformer tubes, arrangement was made with a buffing plate (Diameter
100mm) having connected rods (threaded with nut and bolt) for extension as the plate
moves inside the tube. As the assembly was not much efficient and the potential risk of it
getting clogged was more, the arrangement was rejected.
Simultaneously bottom layer Ni catalyst drums were being shifted from the storage
area to shed (reformer bottom area) and top layer NiK catalyst to shed (stores area). [Note:
Catalyst drums were being shifted in absence of rain. Drum rolling to be avoided. Keep the
drums on wooden pallets, avoid stacking them up. Protect from rain and stagnant water by
providing tarpaulin cover. Keep the lids on, avoid catalyst exposure and do not damage the
drums.]
DP measurement details:
CR-ASIA DP apparatus orifice diameter: 8mm.
MCF DP rig orifice downstream hose length/diameter: 6.00mts/ 0.75”.
Orifice u/s instrument air maintained pressure: 4.00 kg/cm2. (Transmitter range: 0-10
kg/cm2.g).
Orifice d/s pressure indicates DP. (Transmitter range: 0-4 kg/cm2.g).
7. ANNUAL TURNAROUND JUNE 2015 Page | 7
Inner deposits collected from some of
the reformer tubes.
Composition:
Nickel 33.91%
Iron 18.65%
Chromium 05.16%
Aluminum 0.42%
Calcium 0.12%
Magnesium 0.062%
Copper 0.08%
Potash 0.062%
Vanadium 0.035%
Lead ND
Sulfides as S <10ppm
Chloride <1ppm
Sulfate <1ppm
Phosphate <1ppm
After the cleaning of tubes, visual inspection was done using the video cam and
remote display. D31 reformer tube catalyst grid support was found damaged (On 16th
June, 2015). At the same time dip readings and DP checking across empty tube (with MCFL
rig) was initiated and completed. It was replaced with a new grid support and was cross
checked with the old dip and DP readings. CR-Asia rig connections were made ready and
DP checking for each reformer tube was initiated.
At reformer top; arrangement were being made for catalyst weighing, catalyst dust
blowing, protection from rain and provision of breeze free surroundings. Some reformer
tubes (49 in nos.) having DP values (with CR-Asia rig) more than 0.04kg/cm2.g were
decided to be cleaned again by removal of catalyst grid support. After tube cleaning and
checking the improved DP readings for the respective tubes, catalyst grid supports were
boxed up and clearance was given for catalyst loading (On 1600 hrs on 19th June, 2015).
8. ANNUAL TURNAROUND JUNE 2015 Page | 8
Test loading of first layer (Ni) catalyst was done for the first tube of each row i.e. A1,
B1, C1 and D1 in presence of Sud Chemie representative. Dip and DP readings were noted
down as a reference value for rest of the tubes. It was decided to go ahead with 5 buckets of
catalyst for each tube weighing 7kgs. Supervision was deputed to employees to follow up
the catalyst weighing, catalyst drum being utilized and correctional weight for each tube.
[Note- Weighing machine was deployed from ABC plant to weigh catalyst for loading.
Instrument air connection was provided from PICV-2211 tapping for checking reformer tube
DP and catalyst dust blowing. A separate instrument air connection was provided from F-
4210 area for air wench to lift catalyst drums.]
As catalyst available was close to the amount needed after loading “A” and “B” row
tubes, it was decided to load remaining tubes with maximum of 36kgs till all tubes are
covered. Dip readings were noted of all reformer tubes filled with Ni catalyst. Later dip
corrections were done by additional top up for selective tubes to get the dip reading closer
to 7.2m (Completed by 0700hrs on 21st June, 2015). DP readings for all tubes with Ni
catalyst were noted down with CR-Asia rig and later with MCFL rig. As for the Ni catalyst
loading, all new catalyst was utilized and 1 drum old catalyst weighing 112.8kg/141liters
was unutilized which was shifted to DAP plant storage.
After getting approval of DP and dip readings, clearance was given for loading of
second layer (NiK) catalyst. Test loading was done for first tube of each row i.e. A1, B1, C1
and D1. Dip and DP readings were noted down as a reference value for the rest of the tubes.
It was decided to go ahead with 7 buckets for each tube weighing 10kgs. After loading of
NiK catalyst for all tubes, dip readings were noted down and correction were done by
additional top up for selective tubes to get the dip reading closer to 0.8m (Completed by
0600hrs on 23rd June, 2015). DP readings for NiK catalyst were noted down using CR-Asia
and later with MCFL rig. DP correction was done for B1 and B49 tubes as the respective DP
readings were on the lower side. For NiK catalyst, 3 full drums of catalyst and a partly filled
drum was shifted to catalyst storage (725 liters in total).
9. ANNUAL TURNAROUND JUNE 2015 Page | 9
After getting of approval of DP and dip readings, it was decided to box up all
reformer tube flanges. Later orifices and long pigtail to short pigtail flanges were boxed up.
Reformer tubes counter weights were released properly. Housekeeping was done at
reformer top and insulation job was kept pending as high pressure leak test and flange
bolts hot tightening had to be done. Instrument air connections were normalized for TICV-
211 and TI-231. Empty drums were filled with spent catalyst and content displaying
hazardous sticker was pasted on each drum.
DIP HEIGHTS FIXED FOR LOADING
Empty dip height from tube top flange to the catalyst support grid- 11.83 meters.
Empty dip height from tube top flange to the top surface of Reformax330 (G90 LDP-
10 holed) catalyst- 7.20 meters.
Empty dip height from tube top flange to the top surface of Reformax250 (5 holed)
catalyst- 0.80 meters.
Allowable DP variation from average DP of 224 tubes- +3% to -3%.
AVERAGE TUBE DP AFTER EACH LAYER OF CATALYST LOADING WITH CR-ASIA RIG
Average tube DP after loading Reformax 330-G90 LDP catalyst- 0.1837 bar.g
Average tube DP after loading Reformax 250 catalyst- 0.5462 bar.g
CATALYST CONSUMPTION FOR ALL 224 TUBES
Total Reformax 330-G90 LDP catalyst utilized- 8138.156 kilograms.
Total Reformax 250 catalyst utilized- 15160.843 kilograms.
Hence, total catalyst utilized- 23298.999 kilograms.
10. ANNUAL TURNAROUND JUNE 2015 Page | 10
APPROXIMATE TIME REQUIREMENT:
Time required for T plug dropping. : 05 hrs
Time required for reformer tube to : 25.50 hrs
short pigtail flange & short pigtail.
to long pigtail flange disconnection.
Time required for catalyst unloading. : 52.50 hrs
Time require for tube inner surface cleaning
and tube visual inspection. : 88 hrs.
Dead time due to reformer tube inspection : 06 hrs.
Time required for catalyst support grid
removal, cleaning and box up. Empty tube
DP measurement was done simultaneously. : 56 hrs.
Time required for Reformax-330-G90 LDP
catalyst loading. : 30 hrs
Dead time due to power failure. : 01 hrs.
Time required for 1st layer catalyst
dip and DP measurement/adjustment. : 08 hrs.
Time required for Reformax-250 catalyst
loading. : 48.50hrs
Time required for 2nd layer catalyst
dip and DP measurement/adjustment. : 12 hrs.
Time required for tubes boxing up. : 36 hrs
Time required for t plug boxing up. : 05hrs
Dead time due to radiography. : 08 hrs
Total time required. : 381.50 hrs