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In March turnaround shutdown of the VGH unit was planned.

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During this period the hydrotreating catalyst, which was in operation sincewas replaced. As commonly agreed by contract, prior to loading the fresh catalyst, the reactors have been cleaned and inspected anti aging rutin 20s flapper the catalyst supplier representative. Once approved to be clean, the loading of fresh catalyst was carried out. Sock loading technique was used as in the past.

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After finishing the maintenance works, start-up, drying and successful activation of the catalyst took place all under the assistance of catalyst supplier engineer March Feed rate, delta pressure, temperatures Process technology, production, energy managment about 4 °C to °C.

At this time some first delta pressure across the second reactor can be noticed see Figure 1. The dP level was between to kPa which was considered normal.

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During this period, the guarantee test run was executed. From 30 May the dP was continuously increasing at a pace of about 2 kPa per day at about stable throughput. The dP across the reactor slowly decreased from to kPa. During all this period the feed and products qualities were stable, and all the other unit parameters were kept at normal operation level.

Decisions to The pressure drop in general can be caused by constant and variable factors. The constants are used equipment design, used material, reactor internals, piping, etc.

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The variables are processed material properties viscosity, density, impuritiesprocess severity flow, temperature, pressure, cokeunit upsets equipment failure, etc. Due to above mentioned upset of the unit, some operation and strategy decisions had to be made.

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The intention was to keep the unit running full semi-product tanks and empty product tanks after turnaround in refinery. Such issue was not experienced at this unit in the past.

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Based on the available information, it was really difficult to find out what has been really happening in the unit. There was a plan to stop the unit, take all the catalyst out, reload it back to reactor again and get back the unit to normal operation.

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Delta pressure measurement indicated that there is some problem at the second or third bed. To solve such specific situation and to lower the dP across the main reactor, the lower purity hydrogen from CCR Reforming 5 unit was replaced by high purity hydrogen from the HPP unit thereby decreasing the volumetric flow of the gas through the reactors.

This had positive impact on the dP, the catalyst lifetime, and the unit was able to operate at higher throughput.

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The decision was done that unit will not be stopped and if possible, would run in this operation mode till the TA in May What is the maximum possible and safe dP level across the reactor? This question had to be answered so the unit can be operated on a safe side.

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After analyzing relevant issues from process and mechanical point of view, the common agreed maximum dP was kPa. But even this limit had to be pushed to the limits kPa in to 'survive' the last weeks before the general TA. Besides standard maintenance works, in light of the above, there was high focus on the main reactor.

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At the guard reactor 12R nothing strange or uncommon was noticed. In the main 12R reactor the first bed was vacuumed and unloaded without any problems, nor indication of any catalyst damage.

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After opening the manway between first and second bed, on the bubble cup tray about 50 mm of catalyst was found. After opening also the manway in the bubble cup tray, it was found that about 1. The top layer of the bed was also mixed with different size of inert balls and catalyst. Later, after opening the manway and entering the third bed, high level of catalyst was observed.

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YEP special issue, Fig. Top of 2 nd bed — missing 1. Bended thermocouples that were pulled out of the reactor seem to be the evidence of high pressure forces present in the third bed.

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These bends were present only on the thermocouples from the third bed. Overfilled 3 rd bed — catalyst anti aging rutin 20s flapper to bubble cups tray The conclusion was that the catalyst migrated from the second to the third bed and caused the high delta pressure over the reactor as it has reached the bubble cup trays and was very compact.

A new question arose — how did the catalyst move through the Johnson screens tray? After unloading all the catalyst, passivating and cleaning the reactor, no visible or serious hyaluronic acid anti wrinkle day cream on trays could be observed during the first visits in the reactor.

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After further cleaning and investigation it has been found that the sealing ceramic ropes around the Johnson screen were in bad condition and even fragmented at some places Figure 5.

Also catalyst was found there. There are 5 layers of the rope around all the Johnson screens.

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There were two points determined as possible places through which the catalyst and inert balls could have migrated through by the Johnson screens — such holes at the end of each beam is by design for material dilatation Figure 6. Damaged ceramic rope YEP special issue, Fig. This has caused the increased pressure drop.

Due to more severe conditions in the reactor, the catalyst was compacted and misdistributions of the reaction mass occurred, probably also creating some channelling through the catalyst.

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Even looking back to the operation history, it is hard to judge how fast and how long the large amount of catalyst has travelled.

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