Boiler refractory dry out

procedure
Boiler Refractory dry out is to ensure proper drying, curing
of refractory applied on furnace and other components. The
refractory usually undergoes considerable chemical changes,
during initial heating. Controlled heating, through these
reactions ensures maximum strength. While heating, there
must be free air flow over the system to ensure removal of
moisture.

In order to commence refractory dry out, the following pre-

requisites and inputs have to be ensured.

Prior to carrying out this test, all the pre-commissioning

checks should have been completed.

Ensure tlie availability of adequate feed water as per

recommendation of the boiler supplier, adequate wooden logs
to the required sizes, Draft system and instruments required
for the Boiler firing.

Ensure the availability of adequate qualified boiler

operating staff and operators.

Keep open all the vent lines ( 100% open) on the boiler
drum, top super heater header throughout the refractory dry
out period.
Procedure for Boiler Refractory Dry out

Refractory baking and dry out cycle requires very slow and
controlled heating of refractory as recommended by the
refractory manufacturers. Thermal stresses will be produced
if heating rate is too rapid. Longer period of low
temperature drying causes more even heat distribution
resulting better refractory dry out.

Fill the drum with the specified quality feed water 50mm
below the normal water level since the water level in gauge
will raise as heat is absorbed. Maintain normal water level
in the drum throughout the period. Place the dry fire wood
(2inch diameter and 2 feet length), free from nails and
packing metal strips, on the grate. Start ID and FD fan at
minimum load to light up the boiler. Ensure that rate of
heating is maintained at the rate of 25°C per hour. Raise
the temperature of flue gas at boiler outlet to 100°C and

hold the temperature to up to l0 hours at 100°C for soaking

refractory castables. If the temperature falls, increase the
firing rate and maintain the required temperature. Then
raise the flue gas temperature at boiler outlet to 250°C and
hold it 6hours for soaking the refractory castables. Again
raise flue gas temperature at boiler outlet to 350°C and
hold it for 10 hours for soaking the refractory castables.
Once the above heating schedule is over, the fire is
extinguished and the boiler may be allowed to cool down
naturally keeping FD, ID & SA fans off. Fan auxiliary
dampers should be in fully closed condition. A thorough
examination is to be made to check refractory condition
after boiler is cooled down. Minor cracks (up to 3mm) are to
be filled with castable refractory.

Refractory dry out should be carried out as per the curve

given by Refractory manufacturer.