Refractory Dry Out Procedures

Refractory Dry Out Procedures

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TAM/GPOS TAM/GPOS - 02

Document Class

1

PT TRUBA ALAM ALAM MANUN MANUNGGA GGAL L ENGINEER ENGINEERING ING – CHINA CHINA SFECO SFECO PT.GLOBAL PT.GLOBAL POWER SERVICES

B

Revised as comments

A

For approval

Rev. Description

Date

PT. PLN (PERSERO) PEMBANGKIT PEMBANGKIT SUMATERA SUMATERA II

Prepared Checked Reviewed Approved

OWNER’S NO.

PT. PLN (PERSERO) JASA SERTIFIKA SERTIFIKASI SI (LMK) (LMK) Client

PLTU PLTU 3 BANGKA BELITUNG BELITUNG

DOC. NO.

TAM01-NW0095-BB-0001

Bangka, Bangka-Belitung, Republic of Indonesia

Electronic File Name:

Date of Issue:

Revision No.


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

5.3

Salient Details for RDO 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

Furnace Cyclone Inlet Duct / Crossover Cyclone Cyclone Outlet Duct Seal Pot Ash Return Duct

Refractory Dry Out Procedures 5.4

Temperature Profile References 5.4.1 5.4.2

Great Wall Refractory data sheet for low temperature RDO 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 equipment’s.

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.


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 150°C and 250°C 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 precommissioning. 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.


8.0 REFRACTORY CURING PROGRAM

8.1

Low-temperature curing program Temperature

Temperature rising

Time

(°C)

speed °C /h

(hr)

≤5

17

maintain

32

≤5

16

maintain

32

Normal temperature – 150 150 ˚ C

150 - 250 ˚ C 250 ˚ C

Remarks

Remove free water

Remove structure water

Total minimum curing time Shutdown the boiler and check low temperature curing condition

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

Temperature rising

(°C)

speed °C /h

Time (hr)

Normal temperature - 150

10 – 20

5 - 10

150

maintain temp.

10

150 - 250

10 – 20

16

250

Maintain temp.

16

250 – 350

15 – 25

16

350

Maintain temp.

48

Cooling Down Total minimum curing time After finish, natural cooling down

Remarks

Remove free water

Remove structure water and Heat Balance Stage


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 outlet flue ductID 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.


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 - 350°C periods and ±10°C tolerance is permitted in other temperature period. According to the actual craft condition, partial short time over-heating is permitted with ±30°Ctolerance, 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 m 2 intervals at least.

Refractory Dry Out Procedures 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 50°C 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.


12.0 APPENDIX 12.1 General Arrangement of High Velocity Gas Flow 12.2 Temperature Rise Curve


APPENDIX 1

TO FLUE DUCT

Firewood Combustion

Temporary Line ( drain wind box to drain seal pot)


APPENDIX 2

FIELD INSPECTION AND TESTING REPORT

Form No. :

Page No. REFRACTORY DRY OUT

Drawing No. :

CHECK LIST No

1 2 3 4 5 6 7 8 9 10 11 12

Su ject Check and clean the insid e of furnace, flue/air duct, cyclone separator, loop se al, air preheater, wind box, burner and dust remover

Yes

No

N/A

Remarks

Complete the installation of boiler expansion indicator and adjust the n eedle to zero Completion of fuel oil sy tem and burner Completion of Combusti n system and Feed Water System Drum water level shall be clear and accurate Install and pre-commission boiler relevant thermal instruments and electrical instruments. Put into operation after co lligation. Supply demineralized w ter until normal water level.Clean the water leve l gauge Make sure manhole at ack opening on open position Availability of fire woods and other material as fuel Interconnection temporar line between drain windbox and drain sealpo t Tool, Instrumentation, and communication equipment related to the est shall be furnished. Fire fighting equipment should be ready on area

Tested by

Responsible by TAME - SFECO

Signature Print name Date

Witness and Ap roved by CONSULTANT

PLN

PLN COMM.


Form No. :


Drawing No. :

RDO Process Report Area : Furnace / Wind Box / C yclone (L/R)

Date : ....................

Parameter No

Area

Time

Tested by

Remarks Temp



Temp Rising


PLN

PLN COMM.


Form No. :


Drawing No. :

RDO Process Report

Area : Temperature

Temperature Rising Speed

(˚C)

1.

150 ˚ C 150 - 250 ˚ C 250 ˚ C

150 ˚ C 150 - 250 ˚ C 250 ˚ C

maintain

32

≤5

10

maintain

36

≤5

17

maintain

32

≤5

10

maintain

36

15 – 25

10

Maintain temp.

56

NO

High Temperature

250 – 350 350

4.

17

OK

Remarks

Low Temperature (at Furnace D nse)

Normal temperature – 150

3.

≤5

Result

Low Temperature (at Burner and Windbox)

Normal temperature – 150

2.

(˚C)

Time (Duration) hr

Natural Cooling Down

-

Note

Tested by




PLN

PLN COMM.


Form No. :


Drawing No. :

Date

:

Activity

:

Visual In pection after Refractory Dry Out Complete

Equipment

:

Refractor y

No

Condition Good Bad

Subject

1

REFRACTORY FURNACE

2

REFRACTORY WINDBOX

3

REFRACTORY LEFT CYCL NE

4

REFRACTORY RIGHT CYCLONE

emarks

See attachment visual inspection report Note :

Tested by




PLN

PLN COMM.


Form No. :


Drawing No. :

ATTACHMENT JOINT INSPECTION

FURNACE

PICTURE

PICTUR

BEFORE RDO

BEFORE R O

PICTURE

PICTUR

AFTER RDO

AFTER R O

Remarks :

Tested by




PLN

PLN COMM.


Form No. :


Drawing No. :


WIND BOX

PICTURE

PICTUR

BEFORE RDO

BEFORE R O

PICTURE

PICTUR

AFTER RDO

AFTER R O

Remarks :

Tested by




PLN

PLN COMM.


Form No. :


Drawing No. :


CYCLONE L/R

PICTURE

PICTUR

BEFORE RDO

BEFORE R O

PICTURE

PICTUR

AFTER RDO

AFTER R O

Remarks :

Tested by




PLN

PLN COMM.

Refractory Dry Out Procedures

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