TRICHY

PROCEDURE FOR SLOW FIRING (OIL/GAS FIRED BOILERS)

Project : M/s.BASF INDIA LIMITED
DW DATA ACCEPTED FOR
INFORMATION ONLY / WITH COMMENTS
Authorization to proceed does not relieve Contractor/Supplier of its responsibility or liability under the Contract and or Purchase Order.

P%&e # o' (

Bo !er No.: BM"#$

01.

REFRACTORY DRY OUT:

By S.Sasikumar on Dec 27, 2013

After the refractory works are completed, the refractory work must be subjected to proper curing and initial heating. These two procedures must be strictly carried out. Otherwise, cracks may occur on the refractory surface. The procedure is given below. 02. CURING FOR CASTABLE REFRACTORY: All the castable are hydraulic setting type and need the presence of moisture for setting process, so it is necessary to ensure that the castable does not dry out to exposure or due to heat produced within the mass. It should not be allowed to dry during first after it has been placed. "oist condition has to be maintained by covering the castable with wet gunny sacks or by fre#uent sprinkling of fine mist of cold water on all exposed surfaces. $prinkling should be started after the castable has set partially. It is generally advisable to spray water on dense castables every !% minutes for ! hours. 03. INITIAL HEATING FOR REFRACTORY: &roper attention should be given during initial heat up of castables, as they have ! hours

considerable lower permeability when compared to brick. It is more difficult for the water to pass through the castable and escape as the refractory is heated more rapidly. 'apid heating also causes the hot face to dry up and heat up while the rest of castables is still comparatively cool. This will lead to expansion of hot face and hence develops a crack on cold face.

1. During dry out process, the flue gas leaving convection section need to be monitored regularly to ensure that overall flue gas temp inside boiler changes as per thermal cycle indicated in this procedure 2.After dry out process is completed, boiler cooled down, and manhole opened, internal inspection need to be carried out by refractory specialist to inspect the condition of castables ( Castables are supposed to develop cracks but refractory specialist will judge which crack is acceptable and which ones needs repair)

TRICHY
PROCEDURE FOR SLOW FIRING (OIL/GAS FIRED BOILERS)
Project : M/s.BASF INDIA LIMITED P%&e ( o' ( Bo !er No.: BM"#$
04. SLOW FIRING PROCEDURE : (ollowing are to be done before slow firing is started) a* +o fans should be operated for the heating purpose. (iring should be done only by natural draught. (or this all dampers should be kept open. b* $ufficient si,ed fire wood re#uired has to be stocked for the dry out. c* $low firing can be done by burning si,ed wood in the furnace. The si,ed wood can be fed in the furnace through the manhole. The fuel re#uired shall be computed as if the boiler would be operated to generate -. "/' load. The fo o!"#$ he%& %#' ()*"#$ +(he') e "+ *e(o,,e#'e': 0. . 5. 1eat gradually upto 00-2/ and hold at this temperature for 03 hours. Then raise the temperature at rate of 0-2/ to 0%2/ per hour upto temperature for 3 hours. Then raise the temperature at rate of 0-2/ to 0%2/ per hour upto 6%%-2/ 6or* to the maximum possible temperature between 5%-2/ to %%-2/* and hold at this temperature for 0- hours. !. After this the furnace can be cooled naturally. TE-PERATURE 4-2/ and hold at this

TRICHY
PROCEDURE FOR AL)ALI BOILOUT (OIL/GAS FIRED BOILERS)
Project : M/s.BASF INDIA LIMITED P%&e # o' ( Bo !er No.: BM"#$

1.

The boiler shall be ready in all aspects for steaming to the design capacity and steam parameters. 7nsure drum internals including screen boxes are fixed and welding is completed before alkali boilout. /lose all sampling points and instrument tappings at sources. Temporary sampling line for alkali boilout is recommended to avoid choking due to loose mill scale, debris, etc.

8eep ready the following chemicals )9 .0 Trisodium phosphate 6+a5&O!* !--- ppm The #uantity for each boilout shall be estimated ! x water volume of boiler 6:";5 x ! 8gs* . sodium /arbonate 6+a /O5* !---ppm. The #uantity for each boilout shall be estimated ! x water volume of boiler 6:";5 x ! 8gs*

5.

The boilout is to be carried out in three stages and fresh chemicals are to be charged before each stage.

!.

(ill the boiler with <" water 60-- mm below manhole door level*. <issolve chemicals in <" water 6use plastic containers* and pour into the drum through manhole door. 6<o not put solids in drum*.

%.

=ight9up the boiler and raise the steam pressure gradually to % kg>cm? as per standard operating procedure and maintain the pressure for minimum 0 hours.

4. A.

@low down once in two hours for

minutes to be given.

$amples are to be taken for every two hours and analysis is to be carried out to determine the following. 0. p1 . Total alkalinity 5. Oil

TRICHY

PROCEDURE FOR AL)ALI BOILOUT (OIL/GAS FIRED BOILERS)

Project : M/s.BASF INDIA LIMITED P%&e ( o' ( Bo !er No.: BM"#$
3. 7nsure the pressure is maintained in the boiler for each stage of alkali boilout as follows )9 Fo* 20 .$/(,0 1*e++)*e 2o" e*: DURATION I $tage II $tage III $tage DURATION I $tage II $tage III $tage 9 9 9 A 8g>cm? 0- 8g>cm? - 8g>cm? 9 9 9 0 1ours. 0 1ours 0 1ours 9 9 9 % 8g>cm? A 8g>cm? 0- 8g>cm? 9 9 9 0 1ours. 0 1ours 0 1ours

Fo* 44 .$/(,0 &o 34 .$/(,0 "#e 1*e++)*e 2o" e*+

9.

7ach stage of boiling can be terminated when the content of oil in the boiler water maintains a steady value. 1owever final reading of oil should be

%90- ppm. <ecision for termination will be based on re#uirement for specific boiler. 0-. (or each stage, after termination of boilout procedure, shut down the boiler and allow the unit to cool down gradually. 00. <rain the boiler after the drum pressure reaches atmospheric pressure. Bater jet shall be used to clean the headers for each stage. 0 . After complete draining of boiler, clean the complete unit by filling the water and drain it for atleast one time for each stage. 'epeat the fill and drain until free from Alkalies. The handhole pipes of all headers preferably at bottom most point to be cut and inspected for any foreign material and cleaned using water jet. 05. After inspection and cleaning re9weld the end caps and hydro test the boiler to working pressure.

During alkali boil out operation ,important parameters like pressure, feeding rate ,temperature and water analysis etc. are systematically logged.