Refractory Dry Out Procedures

Refractory Dry Out ProceduresPage: 1 of 11 TAM/GPOS - 02

Document Class 1

PT TRUBA ALAM MANUNGGAL ENGINEERING CHINA SFECO

PT.GLOBAL POWER SERVICES

B Revised as comments

A For approval

Rev. Description Date Prepared Checked Reviewed Approved

PT. PLN (PERSERO)PEMBANGKIT SUMATERA II

OWNERSNO.

PT. PLN (PERSERO)JASA SERTIFIKASI (LMK)

ClientPLTU 3 BANGKA BELITUNG

Bangka, Bangka-Belitung, Republic of IndonesiaDOC. NO. TAM01-NW0095-BB-0001

Electronic File Name: Date of Issue: Revision No.

Refractory Dry Out Procedures

Page 2 of 11

1.0 SCOPE

This procedure covers the general requirements for boiler refractory dry out.

2.0 PURPOSE

During the installation of refractory, its humidity and size is relevantly larger than the size after it

is dried up. So that it shall be driying up before it is put into high temperature during boiler

normal operation to eliminate natural water and crystal water.The remained water evaporation

will cause cracks, protrusion, displacement or even worse falling off. In order to lengthen

refractory lifespan and prevent boiler part abrasion, the curing process is necessary.

3.0 REFERENCE

3.1 VENDOR REFRACTORY DATA SHEET

4.0 GENERAL DESCRIPTION OF THE SYSTEM

4.1 Data of the boiler

Type of the boiler : CFB

Max steam capacity : 130t/hr

Steam outlet temperature : 540 C

Steam outlet pressure : 9.81 MPa

5.0 IMPLEMENTATION OF METHODE

5.1 High velocity gas firing is proposed to effect the dry-out of the component by : Internal

vessel firing. The thermal input will be supplemented with the use of 1 or 2 Under Bed

Burners for the High Temperature segment of the process (*if wood firing not reach the

temp.)

5.2 It is assumed that the low temperature a n d high temperature dry-out operations will be

undertaken in one stage for the item parts of the site integrated plant.

5.3 Salient Details for RDO

5.3.1 Furnace5.3.2 Cyclone Inlet Duct / Crossover5.3.3 Cyclone5.3.4 Cyclone Outlet Duct5.3.5 Seal Pot5.3.6 Ash Return Duct


Page 3 of 11

5.4 Temperature Profile References

5.4.1 Great Wall Refractory data sheet for low temperature RDO5.4.2 Owner Engineering Department.

6.0 SAFETY PRECAUTION

6.1 All staff shall wear helmet correctly before entering the site.

6.2 All staff shall well familiar with Electric Power Construction Safe Working Regulation.

6.3 Field apparatus and valve shall have nameplate. Work yard shall have security facilities

and warning logo. Holes, channels and cavities shall be covered with board parallel with

the ground or the reliable fence and red lamp shall be set in the dangerous place at night.

6.4 Refractory devices are put in to use with abundant equipments.

6.5 Sufficient lighting and emergency lighting can be used at any time.

6.6 Complete footpath, crawling ladder and fence with unimpeded passageway, fire goods

and trash shall be totally cleaned.

6.7 Warning board of No Open Flames shall be hanging out in the operating region of fuel

equipment. Tinder taking is strictly forbidden for entering this region and special person

shall be arranged to take good care of that.

6.8 Oil box and running pipe shall be kept strictness without oil leaking. If there has oil leak,

it shall be repaired in time and clean up the oil in time.

6.9 Making good protection to avoid scald and burn in the site.

7.0 REFRACTORY DRY OUT PREPARATIONS

7.1 According to various boiler construction materials, fabricate 3 groups of relevant

standard test blocks (160 40 40mm). Put them into relevant positions during

curing: furnace lower part, cyclone separator and Wind box, for the convenience

of calculating material water content. The water content shall be lower than 0.5%

after the curing.

7.2 Finish the installation work of boiler proper, loop sealing system and flue gas system.

Air leakage and air pressure tests shall be qualified.

7.3 Check and clean the inside of furnace, flue/air duct, cyclone separator, loop seal, air

pre-heater and dust remover.


Page 4 of 11

7.4 Complete the installation of boiler expansion indicator and adjust the needle to

zero.

7.5 Complete the installation of fuel oil system. After water pressure test, clean it and put

into pre-commissioning and then supply oil to the boiler formally.

7.6 Install and pre-commission boiler relevant thermal instruments and electrical

instruments. Put into operation after colligation.

7.7 Finish the installation of boiler inside. Drum water level shall be clear and accurate.

Lighting condition shall be good.

7.8 Make sure the availability of woods or other material as fuel media for low

temperature curing program

7.9 Make sure all the supporting system for RDO must be ready, such as : Drain Pump,

Boiler Fans, and Cooling System

7.10 Supply softened water or chemical demineralized water until normal water level.

Water temperature shall follow design requirement. Clean the water level gauge.

7.11 Set a certain amount of bed materials in boiler air distribution grid and open back

opening man hole for the convenience of hot flue gas flowing through air distribution

device evenly.

7.12 Reserve humidity exhausting hole at the proper position of furnace wall to make sure

that the steam can be exhausted freely during curing.

7.13 Install temporary thermocouple for burner area ( burner 1 and 2 )

7.14 Install temporary line from drain wind box to drain seal pot

7.15 Temperature rising rate, insulation temperature and insulation duration shall be in

consistent with possible dehydration and other physical variation and deformation.

Curing process can be divided into the following two classes:

The first stage (Phase 1) : carry out mid-low temperature curing at approximately

150C and 250C stages according to water discharge law. The main purpose of this

stage is to discharge free water in the castables. There is a large amount of free water

in the castables that using cement as combining agent. So that the insulation time for

this stage shall be long enough to eliminate free water completely.

The second stage (phase 2) : high temperature curing combining with boiler pre-

commissioning. The main purpose for this stage is to discharge structural water in

the refractory materials. Structural water refers to H-O-H. Eliminate H- and -O-H to

increase refractory intensity.


Page 5 of 11

8.0 REFRACTORY CURING PROGRAM

8.1 Low-temperature curing program

Temperature

(C)

Temperature rising

speed C /h

Time

(hr)Remarks

Normal temperature 150 5 17 Remove free water150 C maintain 32

150 - 250 C 5 16Remove structure water

250 C maintain 32

Total minimum curing timeShutdown the boiler and check low temperature curing condition

7.2 High temperature curing program (combine with pre-commissioning)

Temperature

(C)

Temperature rising

speed C /hTime (hr) Remarks

Normal temperature - 150 10 20 5 - 10Remove free water150 maintain temp. 10

150 - 250 10 20 16

250 Maintain temp. 16Remove structure water and

Heat Balance Stage250 350 15 25 16

350 Maintain temp. 48

Cooling Down

Total minimum curing time

After finish, natural cooling down


Page 6 of 11

9.0 REFRACTORY DRY OUT OPERATION METHOD

9.1 Low temperature

1) Startup Burner and Hot Primary Air :

Gas flow:

Hot Primary Air Start up Burner Seal Pot and Separator Separator Outlet

Flue Duct ID fan

Operation method:

In the initial stage, remove start up oil gun, open ID fan inlet and Outlet dumper. Open

man hole, set the fire wood, cover the primary air nozzle at bed furnace with rockwoll

and Supervise burner wall and wind box temperature during baked period. The

temperature rising rate shall strictly follow the requirement in the curve.

In order to make hot flue gas reach the loop seal connect the temporary thin pipe of

drain wind box to drain of seal pot for flue emission.

When baked for period, then the natural cooling to ambient temperature install the

start up burner back for the high temperature curing period.

2) Furnace Dense-Phase Zone

Gas flow:

Furnace dense-phase zone Loop seal and cyclone separator outletflue ductID fan

Loop seal

Operation method:

In the initial period, bake the furnace from thermal firewood and the temperature

rising rate shall follow the curve. If the firewood heat quantity cannot meet

temperature rising requirement, input burner into service to continue heating up.

Closely supervise wall temperature metering point until the first stage of curing is

finished.


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9.2 High-temperature Refractory Dry Out (*if wood firing methode not reach temp.)

After the first stage of Refractory Dry Out remove all temporary facilities, recover

formal system and start the second stage of curing, that is, high temperature curing stage.

High-temperature curing stage is boiler formal operation stage. Start up ID fan and

primary fan. Ignite under burner and Control air room temperature rising rate with

primary air flow rate and oil flow rate. At this time all the systems are in normal

operation status. Control Burner and primary air flow rate to meet temperature rising

curve requirement.

As the steam parameter is very high at the later stage of phrase 2 curing, so this time

boiler blow pipe shall be kept on executed through Boiler Blow Pipe Measures. Carry out

the moisture content test of presetting model after its natural cooling.

10.0 REFRACTORY DRY OUT CAUTIONS

10.1 Curing shall be executed before activate combustion furnace and the curing of hearth,

separator and return value shall be carried out thereupon after that and the curing of

activate combustion furnace shall finished before the phase 2 curing. Detection point

and temperature rising rate in any region shall not exceed the requirement of heating

curve rate and thermal insulation of curing. Temperature rising rate and boiler

temperature shall not over the standard when the curing temperature is in 110 - 350C

periods and 10C tolerance is permitted in other temperature period. According to the

actual craft condition, partial short time over-heating is permitted with 30Ctolerance,

but it would be better if the temperature can be controlled well in accordance with the

standard.

10.2 Because the warming regions are connected during the curing period, which will

interfere temperature and the heating curve in different regions at the same time, so

adding temperature-keeping time of heating curves in different regions during the

curing process is permitted to secure the temperature-keeping time in all parts of boiler.

10.3 Interruption during the curing process caused by the craft, the speed of temperature

rising and dropping shall in accordance with the related standard.

10.4 Air bleeder shall be preset on furnace wall and combustor, etc, which covered the

castables and one air bleeder, shall be made on the fender apron of separator for 5 m2

intervals at least.


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10.5 Steam that produced during the curing process will eject from the exhaust gate. The

temperature tolerance of steam pocket wall shall be no more than 50C during warming

and boosting process. In order to control the temperature, the wall temperature of super

heater shall be closely monitored at the later stage of curing process. The water level

tolerance shall be opened occasionally to feed water for the boiler.

10.6 After low-temperature curing, the moisture content test will be carried out in the related

region of anti-friction and refractory matter; the high-temperature curing will be

conducted once the test is qualified.

10.7 Temperature rising shall be stable during the curing process, and the furnace wall

situation shall be always checked to avoid flow and transformation.

10.8 Open vent properly in order to eject moisture during curing process.

10.9 Flame must be small at the beginning of curing, or else partial temperature rising speed

too fast will cause the negative effects.

10.10 Sewerage under boiler circuit shall be kept totally open to avoid thermal shock and

water attack.

10.11 Set exhausting system shall be connected to keep smooth water in order to avoid the

water attack that caused by water trapped.

10.12 Expansion indicators in all parts of boiler shall be calibrated zero.

10.13 During curing process, blow-off pipe shall be always checked and dealt with the blow

down valve if there has something abnormal.

10.14 All connected drain valve of header can be adjusted according to the curing situation.

11.0 INSPECTION METHOD

11.1 At the beginning of curing, the wall temperature in all points of steam pocket shall be

monitored at any time and record every 1 hour and every 2 hours after the completely

preheat with record other monitoring points every 1 hour.

11.2 At initial stage every 1 hour and then every 2 hours checking the expansion indicator

and make records. If there has any abnormal situation, report shall be made at once,

decrease the temperature and checking then curing again after the problem found and

solved.


Page 9 of 11

12.0 APPENDIX12.1 General Arrangement of High Velocity Gas Flow12.2 Temperature Rise Curve


Page 10 of 11

APPENDIX 1

TO FLUE DUCT

Firewood Combustion

Temporary Line ( drain windbox to drain seal pot)


Page 11 of 11

APPENDIX 2

FIELD INSPECTION AND TESTING REPORT

Form No. :

Drawing No. :

Tested by

SignaturePrint nameDate

No Subject

1Check and clean the inside of furnace, flue/air duct,cyclone separator, loop seal, air preheaterburner and dust remover

2 Complete the installation of boiler expansionindicator and adjust the needle to zero3 Completion of fuel oil system

4 Completion of Combustion system and Feed WaterSystem5 Drum water level shall be clear and accurate

6Install and pre-commission boiler relevantthermal instruments and electrical instruments.Put into operation after colligation

7 Supply demineralized water until normal waterlevel.Clean the water level gauge

8 Make sure manhole at backposition9 Availability of fire woods and other material as fuel

10 Interconnection temporary line between drainwindbox and drain sealpot

11 Tool, Instrumentation, and communicationequipment related to the test shall be12 Fire fighting equipment should be ready on area


REFRACTORY DRY OUT

Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN

Subject Yes No N/ACheck and clean the inside of furnace, flue/air duct,cyclone separator, loop seal, air preheater, wind box,

Complete the installation of boiler expansionindicator and adjust the needle to zero

fuel oil system and burnerCompletion of Combustion system and Feed Water

Drum water level shall be clear and accuratecommission boiler relevant

thermal instruments and electrical instruments.Put into operation after colligation.Supply demineralized water until normal waterlevel.Clean the water level gauge

manhole at back opening on open

ire woods and other material as fuelInterconnection temporary line between drainwindbox and drain sealpotTool, Instrumentation, and communicationequipment related to the test shall be furnished.Fire fighting equipment should be ready on area

CHECK LIST

Page No.

Witness and Approved by

PLN COMM.

Remarks


Form No. :

Drawing No. :

Tested by


Area : Furnace / Wind Box / Cyclone

No Area Time


REFRACTORY DRY OUT



RDO Process Report

Area : Furnace / Wind Box / Cyclone (L/R) Date : ....................

Parameter

Temp Temp Rising

Page No.


PLN COMM.

Remarks


Form No. :

Drawing No. :

Tested by


Area :Temperature

(C)

1. Low Temperature (at Burner and Windbox)

Normal temperature 150

150 C

150 - 250 C

250 C

2. Low Temperature (at Furnace Dense)

Normal temperature 150

150 C

150 - 250 C

250 C

3. High Temperature250 350

350

4. Natural Cooling DownNote


REFRACTORY DRY OUT



RDO Process Report

TemperatureRising Speed

(C)

Time(Duration)

hr

Result

OK

(at Burner and Windbox)

5 17

maintain 32

5 10

maintain 36

Furnace Dense)

5 17

maintain 32

5 10

maintain 36

15 25 10

Maintain temp. 56

-

Page No.


PLN COMM.

Result Remarks

NO


Form No. :

Drawing No. :

Tested by


Date :

Activity : Visual Inspection after Refractory Dry Out

Equipment : Refractory

No Subject

1 REFRACTORY FURNACE

2 REFRACTORY WINDBOX

3 REFRACTORY LEFT CYCLONE

4 REFRACTORY RIGHT CYCLONE

See attachment visual inspection

Note :


REFRACTORY DRY OUT



Visual Inspection after Refractory Dry Out Completed

Refractory

ConditionRemarksGood Bad

REFRACTORY LEFT CYCLONE

REFRACTORY RIGHT CYCLONE

See attachment visual inspection report

Page No.


PLN COMM.

Completed

Remarks


Form No. :

Drawing No. :

Tested by


Remarks :

PICTURE

BEFORE RDO

PICTURE

AFTER RDO


REFRACTORY DRY OUT



ATTACHMENT JOINT INSPECTION

FURNACE

PICTURE

BEFORE RDO

PICTURE

AFTER RDO

Page No.


PLN COMM.

PICTURE

BEFORE RDO

PICTURE

RDO


Form No. :

Drawing No. :

Tested by


Remarks :

PICTURE

BEFORE RDO

PICTURE

AFTER RDO


REFRACTORY DRY OUT




WIND BOX

PICTURE

BEFORE RDO

PICTURE

AFTER RDO

Page No.


PLN COMM.

PICTURE

BEFORE RDO

PICTURE

RDO


Form No. :

Drawing No. :

Tested by


Remarks :

PICTURE

BEFORE RDO

PICTURE

AFTER RDO


REFRACTORY DRY OUT




CYCLONE L/R

PICTURE

BEFORE RDO

PICTURE

AFTER RDO

Page No.


PLN COMM.

PICTURE

BEFORE RDO

PICTURE

RDO

Refractory Dry Out Procedures

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