CR3 India completed a catalyst replacement project on two reactors during a planned shutdown for a refinery in India. The scope covered spent catalyst unloading, reactor internal inspection, replacement of damaged internals, fresh catalyst loading, reactor closure, and commissioning support.
The team loaded 648 m³ of fresh catalyst and replaced 32 spillways and 5 mixing chambers across the two reactors, alongside internal tray and grid replacements. A catalyst support grid repair was carried out using an engineered method, agreed with the client and verified through quality checks before proceeding.
The work was performed in confined spaces with restricted access, under strict HSE and quality requirements, with continuous gas monitoring. The project encountered inspection-related delays and other operational challenges, but close coordination between CR3, the client, and the project’s quality, safety and execution teams kept the shutdown on schedule.
The project was completed with zero rework on reactor internal replacement and catalyst loading activities.
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