PTQ Q3 2025 Issue

Technology in Action

The supported hold-down screen variant sits on struc - tural beams and includes a uniquely engineered manway. This manway can be detached from the screen from out - side the reactor using an integrated seal and a removable panel, allowing for partial or full removal without vessel entry. After the media change, the manway is repositioned and locked back into place externally. Both systems enable faster, safer turnarounds while upholding the highest stan - dards of safety and performance. Field validation and industry recognition The real-world impact of the StaySafe platform is already evident. At a recent industry conference, CP Chemical was recognised for its search for a solution that enabled the unloading of a methanator vessel without exposing work - ers to the hazardous inert atmosphere traditionally associ - ated with catalyst changes. CP Chemical’s new approach was made possible through the incorporation of StaySafe hold-down screens outlined in some of our past entries. The StaySafe screen used in this solution featured a floating hold-down screen com - prised of interlocking wedges, a locking bar, and a central locking hub – all designed to be removed externally. Once disassembled, the catalyst could be vacuumed out from the top manway as usual. This design not only mitigated the risk of fatal incidents related to confined space entry but also streamlined the turnaround process and ultimately led to the company receiving the AFPM Innovation Award for Occupational Safety this past May. In a field where the motto ‘work safely or don’t do the work’ is increasingly becoming a corporate mandate, the StaySafe product line stands as a testament to what is pos - sible when safety and innovation go hand in hand. It rein - forces the idea that effective maintenance does not have to come at the cost of worker safety. Johnson Screens Kevin Chase Product Manager, Energy and Processing Technologies Email: kevin.chase@johnsonscreens.com The challenge Refineries must bring hydrotreating units online quickly after catalyst changes to minimise downtime, ensure prod - uct quality, and maintain continuous production and profit - ability. While several methods exist for catalyst activation, each comes with its own limitations. In-situ sulphiding is complex, can slow down unit start- up, and pose environmental concerns. The process, which involves injecting a sulphur compound into the reactors after Bringing hydrotreating units online after catalyst change-out

Rethinking safety in reactor maintenance

Innovations to reduce confined space entry In the petrochemical industry, safety is not just a priority – it is a necessity that underpins every aspect of plant main- tenance and turnaround operations. The confined spaces inside fixed-bed downflow reactors, often rendered inert to mitigate the risk of explosions, present particularly dan - gerous environments for workers. Hazards such as oxygen deficiency, toxic atmospheres, and shifting internal condi - tions make entering these spaces inherently risky, even after following extensive safety protocols mandated by regulatory frameworks such as OSHA 1910.146 and NFPA 350. Despite the rigorous safety measures – ranging from atmospheric testing and continuous monitoring to the use of PPE and emergency retrieval systems – confined space entry remains a complex, costly, and dangerous process. The challenge is further compounded during media bed replacements, where the removal of internal components such as hold-down screens typically necessitates worker entry into the reactor. As companies strive to meet aggres - sive turnaround schedules while maintaining strict safety compliance, they are increasingly questioning whether these traditional procedures are still the best approach. One central issue is the requirement to enter a vessel solely to dismantle or remove the hold-down screen before media extraction can begin. In response to this concern, industry leaders have begun to mandate that workers must no longer enter vessels for such preliminary tasks, prompt- ing a search for safer, more efficient solutions. Avoiding confined space entry Johnson Screens has responded to this industry-wide confined space vessel entry challenge with the launch of its StaySafe product family, a line of reactor internals spe - cifically designed to eliminate the need for confined space entry during critical stages of media bed replacement. The StaySafe platform features two distinct hold-down screen designs: the ‘floating’ and the ‘supported’ screen systems, both engineered with the guiding principle of ‘no-entry’ disassembly. These solutions address the core challenge of safely removing internal reactor components without requiring personnel to enter the vessel, thereby simplifying compliance with confined space regulations. The floating hold-down screen is a leap forward in opera - tional safety and efficiency. It rests directly on top of the media bed and comprises interlocking components that are assembled without tools. A central locking hub secures the system, which can then be disassembled from outside the vessel using special tools. This design allows the screen to be entirely removed without a single worker stepping inside, eliminating the need for entry permits and reducing risks associated with confined space operations.

106

PTQ Q3 2025