LOAD CATALYST

Maintain the dry instrument air purges established following the reactor section and the Regeneration Section dryouts.

5.1 LOAD PLATFORMING REACTORS

Load catalyst into each Platforming reactor in the reactor stack according to the procedures in the General Operating Manual for the UOP CCR Platforming Process Unit.

NOTE: The Spent catalyst L-Valve Assembly will not be filled with catalyst at this time. The manual V-ball and B-valve below the catalyst collector should remain closed throughout the loading. The blind above the upper, V-ball valve must be open before loading. The blind below the lower, B-ball valve can be closed until after catalyst loading is complete.

5.2 LOAD REDUCTION ZONE

Load catalyst into the Reduction Zone at the top of the Platforming reactors through the catalyst inlet nozzle in the top head or through the manway of the Reduction Zone.

The quantity of catalyst loaded above the Reduction Zone low-level alarm instrument should at least be sufficient to satisfy the net thermal and mechanical slump of the catalyst in the Platforming reactor stack.

NOTE: percent of the catalyst loaded into all of the Platforming reactors is normally provided for net thermal and mechanical slump requirements.

However, for the purpose of checking the response and linearity of the Reduction Zone's level controller, the quantity of catalyst loaded in the Reduction Zone should be up to near the top (around 80-90%) of the level controller.

During loading of the Reduction Zone, gauge the level in the Reduction Zone using a measuring tape as it is being filled and compare it with the level indication of the Zone's level controller. Gauge the level after loading, say, each 2 or 3 drums of catalyst or at each 5 or 10% change in the level indication, in order to check the response and the linearity of the level instrument.

5.3 LOAD DISENGAGING HOPPER AND REGENERATION TOWER

Load the Disengaging Hopper D-1353 and Regeneration Tower T-1351 through the top nozzle of the Disengaging Hopper.

During the loading of the Disengaging Hopper, the response and linearity of Disengaging Hopper's level recorder will be checked. Close the manual V-port ball valve above the Nitrogen Seal Drum. Load catalyst into the Disengaging Hopper through the top nozzle. The Regeneration Tower will fill first and then the Disengaging Hopper.

Perform the calibration of the level instrument as per the manufacturer's procedure. This usually requires gauging the level in the Hopper using a measuring tape on a plumb-bob as it is being filled. For each 5^–10% of the range of the level indication, check the response and the linearity of the level instrument. Load catalyst up to the top (100%) of the level recorder.

Some level instruments can be calibrated before the vessel is loaded. In this case, the calibration should be checked during loading of the vessel in a similar manner to that outlined above.

NOTE: The Regenerated Catalyst L-Valve Assembly will not be filled with catalyst at this time. The manual V-ball and B-valve below the Lock Hopper should remain closed throughout the loading of the Disengaging Hopper.

5.4 CAUTIONS

a. For record purposes, keep complete and accurate records of the number of catalyst drums loaded into each of the Platforming reactors and the Regeneration Section.

b. Be careful to avoid spilling any of the catalyst during loading because platinum reforming catalyst is relatively expensive. If any catalyst does spill, sweep it up and return it with catalyst fines for metals recovery.

c. Do not discard empty catalyst drums. Store them with their lids and clamp rings in a dry location. Normal practice is to use the empty catalyst drums for return of catalyst fines or spent catalyst and for handling catalyst during unloading.

6. LOAD AND CALIBRATE THE LOCK HOPPER'S SURGE ZONE

The Lock Hopper Surge Zone level instrument must be calibrated so that the Lock Hopper load size (i.e., the amount of catalyst transferred during each cycle of the Lock Hopper) can be determined during initial operation. The initial positions of the (point) sources and detectors for the high-level and low-level nuclear level instruments in the Lock Hopper Zone of the Lock Hopper should have been set at their design positions, according to the UOP Project Specifications. The position of the low-level source and detector will be adjusted to give the required Lock Hopper load size during initial operation. Accurate measurement of the Lock Hopper load size is important because it is the basis for determining the catalyst circulation rate during normal operation.

a. Remove the spoolpiece below the two manual ball valves below the Lock Hopper. Install a canvas sock (as required) below the valves leading to a convenient location to collect catalyst. Open the lower ball valve keeping the upper (V-ball) valve closed.

b. Open the observation port nozzle of the Lock Hopper Surge Zone that is located close to the bottom of the standpipe from the Lock Hopper Zone. This port is used for observing the catalyst level and measuring the outage with a plumb-bob.

c. Place an empty, tared drum under the sock attached to the manual ball valve.

d. Open the manual V-port ball valve above the Nitrogen Seal Drum D-1357 and allow catalyst to flow from the Disengaging Hopper and Regeneration Tower through the Nitrogen Seal Drum and into the Lock Hopper.

NOTE: As the Disengaging Hopper catalyst level decreases, re-check the calibration of the level instrument against the readings taken during the filling.

e. Carefully observe the rate of filling of the Lock Hopper Surge Zone such that the catalyst level can be stopped at the bottom (0%) of the Surge Zone level instrument.

f. Proceed with the calibration of the Surge Zone level instrument, filling the Surge Zone from the Disengaging Hopper D-1353 controlling the rate with the manual V-port ball valve above the Nitrogen Seal Drum. Use the same method as was employed during the calibration of the Disengaging Hopper level instrument.

g. When the calibration is complete and the catalyst level is at 100% of the level instrument, continue to fill the Surge Zone until the tip of the cone (catalyst bed surface) reaches the bottom of the standpipe from the Lock Hopper Zone. Close the manual V-port ball valve above the Nitrogen Seal Drum D-1357.

h. Open the manual V-port ball valve below the Lock Hopper and empty the catalyst from the Surge Zone into catalyst drums. Carefully weigh all catalyst removed from the Surge Zone. As the catalyst level decreases in the Surge Zone, re-check the calibration of the level instrument against the readings taken during the filling.

i. When the Surge Zone is empty, close the manual V-port ball valve below the Lock Hopper. Re-install the piping at the outlet of the manual valves.

j. Carefully record the total mass of catalyst removed from the Surge Zone. Set this catalyst aside for the first catalyst addition to the system. Take a sample of this catalyst for LOI analysis. This information is needed to calculate the dry mass of the catalyst in the Surge Zone.

k. Open the manual V-port ball valve above the Nitrogen Seal Drum and allow catalyst to fill the Nitrogen Seal Drum and the entire Lock Hopper.

NOTE: The level in the Disengaging Hopper D-1353 should now be at a reasonable working level for initial operation and allow for catalyst "fluff' (decrease in catalyst density when it is flowing versus initial, loaded density) during initial circulation of catalyst. Detailed calculations for the individual unit should be performed to determine

whether this is the case or whether more catalyst will be required to make-up inventory into the Disengaging Hopper.