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Refractory Dry Out Procedures

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) OWNERS

PEMBANGKIT SUMATERA II NO.

PT. PLN (PERSERO)

JASA SERTIFIKASI (LMK)
Client
PLTU 3 BANGKA BELITUNG DOC. NO. TAM01-NW0095-BB-0001
Bangka, Bangka-Belitung, Republic of Indonesia
Electronic File Name: Date of Issue: Revision No.
 Refractory Dry Out Procedures

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 Furnace
5.3.2 Cyclone Inlet Duct / Crossover
5.3.3 Cyclone
5.3.4 Cyclone Outlet Duct
5.3.5 Seal Pot
5.3.6 Ash Return Duct

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 Refractory Dry Out Procedures

5.4 Temperature Profile References

5.4.1 Great Wall Refractory data sheet for low temperature RDO
5.4.2 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.

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 Refractory Dry Out Procedures

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.

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 Refractory Dry Out Procedures

8.0 REFRACTORY CURING PROGRAM

8.1 Low-temperature curing program
Temperature Temperature rising Time
Remarks
(C) speed C /h (hr)

Normal temperature 150 5 17 Remove free water

150 C maintain 32
150 - 250 C 5 16
Remove structure water
250 C maintain 32
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
Time (hr) Remarks
(C) speed C /h
Normal temperature - 150 10 20 5 - 10
maintain temp. 10 Remove free water
150
150 - 250 10 20 16
250 Maintain temp. 16
Remove structure water and
250 350 15 25 16
Heat Balance Stage
350 Maintain temp. 48

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

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 Refractory Dry Out Procedures

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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 Refractory Dry Out Procedures

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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 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 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.

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 Refractory Dry Out Procedures

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

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 Refractory Dry Out Procedures

APPENDIX 1

TO FLUE DUCT

Firewood Combustion

Temporary Line ( drain wind

box to drain seal pot)

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 Refractory Dry Out Procedures

APPENDIX 2

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 FIELD INSPECTION AND TESTING REPORT

Form No. : Page No.

REFRACTORY DRY OUT
Drawing No. :

CHECK LIST

No Subject Yes No N/A Remarks

Check and clean the inside of furnace, flue/air duct,
1 cyclone separator, loop seal, air preheater
preheater, wind box,
burner and dust remover
Complete the installation of boiler expansion
2
indicator and adjust the needle to zero
3 Completion of fuel oil system and burner
Completion of Combustion system and Feed Water
4
System
5 Drum water level shall be clear and accurate
Install and pre-commission
commission boiler relevant
6 thermal instruments and electrical instruments.
Put into operation after colligation.
Supply demineralized water until normal water
7
level.Clean the water level gauge
Make sure manhole at back opening on open
8
position
9 Availability of fire
ire woods and other material as fuel
Interconnection temporary line between drain
10
windbox and drain sealpot
Tool, Instrumentation, and communication
11
equipment related to the test shall be furnished.
12 Fire fighting equipment should be ready on area

Tested by Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN PLN COMM.
Signature
Print name
Date
 FIELD INSPECTION AND TESTING REPORT

Form No. : Page No.

REFRACTORY DRY OUT
Drawing No. :

RDO Process Report

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

Parameter
Remarks
No Area Time
Temp Temp Rising

Tested by Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN PLN COMM.
Signature
Print name
Date
 FIELD INSPECTION AND TESTING REPORT

Form No. : Page No.

REFRACTORY DRY OUT
Drawing No. :

RDO Process Report

Area :
Temperature Temperature Time Result Remarks
(C) Rising Speed (Duration)
OK NO
(C) hr
1. Low Temperature (at Burner and Windbox)
Normal temperature 150 5 17
150 C maintain 32
150 - 250 C 5 10
250 C maintain 36

2. Low Temperature (at Furnace Dense)

Normal temperature 150 5 17
150 C maintain 32
150 - 250 C 5 10
250 C maintain 36

3. High Temperature
250 350 15 25 10
350 Maintain temp. 56

4. Natural Cooling Down -

Note

Tested by Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN PLN COMM.
Signature
Print name
Date
 FIELD INSPECTION AND TESTING REPORT

Form No. : Page No.

REFRACTORY DRY OUT
Drawing No. :

Date :

Activity : Visual Inspection after Refractory Dry Out Completed

Equipment : Refractory

Condition
No Subject Remarks
Good Bad
1 REFRACTORY FURNACE

2 REFRACTORY WINDBOX

3 REFRACTORY LEFT CYCLONE

4 REFRACTORY RIGHT CYCLONE

See attachment visual inspection report

Note :

Tested by Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN PLN COMM.
Signature
Print name
Date
 FIELD INSPECTION AND TESTING REPORT

Form No. : Page No.

REFRACTORY DRY OUT
Drawing No. :

ATTACHMENT JOINT INSPECTION

FURNACE

PICTURE PICTURE

BEFORE RDO BEFORE RDO

PICTURE PICTURE

AFTER RDO AFTER RDO

Remarks :

Tested by Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN PLN COMM.
Signature
Print name
Date
 FIELD INSPECTION AND TESTING REPORT

Form No. : Page No.

REFRACTORY DRY OUT
Drawing No. :

ATTACHMENT JOINT INSPECTION

WIND BOX

PICTURE PICTURE

BEFORE RDO BEFORE RDO

PICTURE PICTURE

AFTER RDO AFTER RDO

Remarks :

Tested by Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN PLN COMM.
Signature
Print name
Date
 FIELD INSPECTION AND TESTING REPORT

Form No. : Page No.

REFRACTORY DRY OUT
Drawing No. :

ATTACHMENT JOINT INSPECTION

CYCLONE L/R

PICTURE PICTURE

BEFORE RDO BEFORE RDO

PICTURE PICTURE

AFTER RDO AFTER RDO

Remarks :

Tested by Responsible by Witness and Approved by

TAME - SFECO CONSULTANT PLN PLN COMM.
Signature
Print name
Date