REFINING INDIA 2025

refining india 2025

Rethinking safety in reactor maintenance: innovations to reduce confined space entry

kevin chase johnson screens

In the petrochemical industry, safety is not just a priority – it is a necessity that under- pins every aspect of plant maintenance and turnaround operations. The confined spaces inside fixed-bed downflow reac- tors, often rendered inert to mitigate the risk of explosions, present particularly dangerous environments for workers. Hazards such as oxygen deficiency, toxic atmospheres, and shifting internal condi- tions make entering these spaces inher- ently risky, even after following extensive safety protocols mandated by regulatory frameworks such as OSHA 1910.146 and NFPA 350 (see Figure 1 ). Despite the rigorous safety measures – ranging from atmospheric testing and con- tinuous monitoring to the use of personal protective equipment (PPE) and emer- gency retrieval systems – confined space entry remains a complex, costly, and dan- gerous 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 compa- nies strive to meet aggressive turnaround schedules while maintaining strict safety compliance, they are increasingly ques- tioning whether these traditional proce- dures 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 extrac- tion can begin. In response to this concern, industry leaders have begun to mandate that workers no longer enter vessels for such preliminary tasks, prompting a search for safer, more efficient solutions. Johnson Screens’S StaySafe Hold-Down Screens Innovation Johnson Screens has responded to this industry-wide challenge with the launch of its StaySafe TM product family of hold-down screens. This line of innovative reactor inter- nals is specifically designed to eliminate the need for confined space entry during criti- cal stages of media bed replacement. The StaySafe platform features two dis- tinct hold-down screen designs: the ‘float- ing’ and the ‘supported’ screen systems, both engineered with the guiding princi- ple of ‘no-entry’ disassembly (see Figures 2 and 3 ). These solutions address the core chal- lenge of safely removing internal reactor

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 methana- tor vessel without exposing workers to the hazardous inert atmosphere traditionally associated 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 comprised 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 turn- around process. Ultimately, this improve- ment 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 prod- uct line stands as a testament to what is possible when safety and innovation go hand in hand. It reinforces the idea that effective main- tenance does not have to come at the cost of worker safety. By eliminating unneces- sary vessel entry and simplifying turnaround operations, Johnson Screens is setting a new standard for confined space safety in the refining and petrochemical sectors. Contact: kevin.chase@johnsonscreens.com DID YOU KNOW? These solutions address the core challenge of safely removing internal reactor components without requiring personnel to enter the vessel

Figure 1 There is a safer, more efficient removal method than entering the vessel

Figure 2 Floating Hold-Down Screen

Figure 3 Manway Hold-Down Screen

entry permits and reducing the risks asso- ciated with confined space operations. The supported hold-down screen vari- ant sits on structural beams and includes a uniquely engineered manway. This man- way can be detached from the screen from outside 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 reposi- tioned and locked back into place exter- nally. Both systems enable faster, safer turnarounds while upholding the highest standards of safety and performance.

components without requiring personnel to enter the vessel, thereby simplifying com- pliance with confined space regulations. The floating hold-down screen is a leap forward in operational safety and effi- ciency. It rests directly on top of the media bed and comprises interlocking compo- nents that are assembled without tools. A central locking hub secures the system, which can then be disassembled from out- side the vessel using special tools. This design allows the screen to be entirely removed without a single worker stepping inside, eliminating the need for

SAVE THE DATE! Join us on 21-22 September 2026