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ISGEC John Thompson

ER/ 0734 / Ref-Alkali


Rev 02 00/ 30.06.09

PROCEDURE FOR REFRACTORY DRYOUT


ALONGWITH ALKALI BOIL OUT

GENERAL
A newly erected boiler, or one on which
extensive furnace refractory repairs have
been carried out will require to be dried
out thoroughly before commissioning the
boiler. The procedure is to allow control
drying out of wet brickwork and refractory
to the lowest rate of heating possible for
avoiding the separation or cracking.
Thermal stresses will be produced if
heating rate is too rapid.
From this it follows that LONGER PERIOD
OF LOW TEMPERATURE DRYING CAUSES
MORE
EVEN
HEAT
DISTRIBUTION
RESULTING IN BETTER REFRACTORY
DRY OUT.
In deciding initial heating temperature and
its duration the following factors should be
considered:
Estimated moisture content of walls
and refractory.
Thickness of walls and refractory.
The distance from heat source.

The efficiency of a boiler is dependent on


the heat transfer capacity of the heating
surfaces, and this is seriously impaired by
the internal surfaces of tubes if they get
coated with deposits, as occurs naturally
in the course of normal running.
Also, a newly erected boiler, or one on
which extensive repairs to pressure parts
have been carried out, may have an oil or
grease film on internal areas which is
1 x 190 TPH CFBC Boiler
M/s Arasmeta Captaive Power Co. Ltd., C.G.

impossible to wholly remove by manual


cleaning. Since oil and grease have a very
low
rate
of
heat
transfer,
tubes
contaminated by them can become
overheated when subjected to high
temperatures. This will lead to blistering or
burning of the tube metal with consequent
risk of rupture. Chemical cleaning of boiler
pressure parts is carried out to overcome
the above problems.

Initial Preparation
Ensure the availability / completeness of
the following:Maintain minimum 48 hours time lag
for natural curing (air drying) of the
applied
refractory
at
ambient
temperature between boiler light up for
the refractory dry out activity and
refractory application job completion.
All type of refractory sample test piece
will be taken separately.
Ensure boiler erection completed,
refractory
and
insulation
works
completed, Expansion indicators in
position with zero setting, and all
temporary supports removed.
Boiler hydraulic test is complete.
Mechanical
completion
of
boiler
including auxiliaries and piping.
Ensure all permanent supports for
pipelines, valves and ducts are
provided.
Temporary piping for chemical boil out
activity is completed if any as agreed
mutually.
1

ER/ 0734 / Ref-Alkali


Rev 02 00/ 30.06.09

ISGEC John Thompson


Ensure that all steam line valves
(excluding line drain valves) connected
to deaerator is closed.
Close Main Steam Stop Valve (MSSV)
including Bypass fully and ensure that
alkaline solution does not enter
turbine,
gland
steam
condenser,
ejectors & PRDS. Chemicals are added
directly to boiler drum so there are no
chances of chemical entry to HP
Heaters.
Ensure the availability of Boiler feed
pumps, Deaerator, transfer water
pump.
Quantity of fuel required to be
estimated as per the capacity and type
of boiler. (IJT has already intimated the
required quantity of fuel for this
activity)
Availability
of
Electrical
&
Instrumentation controls & Power
supply to run the drives.
Water at correct pressure & quality as
per Technical data sheet.
Availability of Chemicals
Fuel should be free from foreign
materials such as metal, any other
scrap items to avoid damage to the
boiler components.
Boilers
filling
complete.
Ensure
system.

the

arrangements

readiness

of

are

draught

Ensure the availability of required


instrumentation for boiler firing.
ACPCPL to ensure the availability of
skilled
operation
engineers
and
supervisory staffs during the activity
and also availability of communication
facilities such as walky- talky with
chargers and the Public announcement
system. Ensure proper illumination of

1 x 190 TPH CFBC Boiler


M/s Arasmeta Captaive Power Co. Ltd., C.G.

all the floors


deaerator area.

of

Boiler,

TG

and

Boiler drum pressure gauge & Furnace


pressure gauge
Availability of Drum & Deaerator Water
level control system and associated
alarms, protection & interlocks.
Drum level gauge glass with illuminator
assembly.
Availability of CBD, IBD and all drain
valves in good working conditions.
Ensure that during chemical boil out,
Transmitters connected to water side
are isolated to avoid any damages to
transmitter due to alkali. However one
drum level transmitter may be taken in
line after filling the impulse lines with
D M Water & must be thoroughly
flushed after completion of the activity.
Ensure that temperature measurement
instruments
such
as
calibrated
temperature recorders for different
locations temperature measurement,
wherever measurement is necessary
during the dry out process is installed.
The steam pressure gauges should be
checked as soon as sufficient pressure
is available.
ACPCPL-II to arrange for testing facility
at their laboratory.

NOTE:
It is essential to have spare gaskets
for Boiler drums as drum inspection
has to be carried out after alkali boil
and after chemical cleaning to
ensure effectiveness of the alkali
boil out and chemical cleaning.
Welded parts of drum internals are
installed. The internal piping of drum
like feed water distribution header and
2

ER/ 0734 / Ref-Alkali


Rev 02 00/ 30.06.09

ISGEC John Thompson


CBD header must be installed before
Alkali boil out. The bolted parts
Cyclones/ Baffles etc. are also to be
installed during the Alkali boil out to
ensure proper cleaning of these parts.
Before lighting a fire, the operator
should check the water level in the
boiler by blowing down the water
column and gauge glass.
Ensure thermal expansion indicator
installed as per drawing
Mark the cold position of pressure
parts with a reference point to check
thermal expansion as per drawing.
Shuttering
material
should
be
completely removed from the refractory
surface.
Furnace Bed surface should
completely cleaned before light up.

be

Install temperarory burners as per


prefixed location.
One operator with communication
facility
to
be
deployed
for
communicating with others to ensure
that the drum level is maintained
healthy during the activity.

PROCEDURE
A liberal blow down may serve to clear
the drain valve seats of any foreign
matter that may be present.
Shut all drain and blow-down valves
except super heater drain valve, which
must be OPEN.
Open all air release valves.
Fill boiler with properly treated
demineralised water up to first port of
drum level gauge glass.
Prepare the boil out chemical solution
in hot demineralised water in the
chemical mixing tank. The solution is
formulated by dissolving the following
1 x 190 TPH CFBC Boiler
M/s Arasmeta Captaive Power Co. Ltd., C.G.

proportionate quantities of chemicals,


depending on the volume of the system
to be cleaned.
- 0.05% Na 2PO4.7H2O
Disodium phosphate)
- 0.1% Na3PO4.12H2O
Trisodium phosphate)

(500

PPM

(1000

PPM

- Surfactant (Washing Powder)- 150 ppm


Mix dissolved chemicals and introduces
solution into drum while at the same
time slowly feeding water to effect a
more even distribution along the drum
length.
Close manhole door and secure tightly.
Then raise the drum level 50 mm below
the normal water level by viewing the
direct level gauges. Fill the drum
through
normal
feed
water
connections.
Shut main steam stop valve.
Spray attemperator valves are closed.
Start required drives for combustion
and draught control.
Light up the burners. After fire is
established, set air to maintain draft &
combustion.
Increase slowly the heat input to boiler
to raise the pressure.
During this period of gradual pressure
raising the plant should be under
constant observation, and the following
inspections are to be made:
- Check all bolted flanges, manhole
doors and inspection caps for leaks
and tightness.
- Check & Record amount of movement
due to thermal expansion against
zero expansion markings. Restriction
to free movement of pressure parts
can result in over-stressing and
rupture and any such restriction
3

ISGEC John Thompson


observed must be investigated and
corrected for free movement.
Increase the firing rate in such a way
that the raise in temperature to be
maintained as pre refractory dry out
curve. Soaking is to be given as per the
heating curve.
Check Water level gauges & if
necessary flush the gauge as procedure
given below:
a. Open drain cock slowly to steam
and water to blow through drain pipe.
b. Shut steam cock and allow water to
blow to drain.
c. Open steam cock and shut water
cock, allowing steams to blow to drain.
d. Shut the drain cock and open water
cock slowly.
The steam pressure gauges should be
checked as soon as sufficient pressure
is available.
Control the fires & gradually raise
furnace temperature up to first stage
soaking at 110 Deg C. Soaking is to be
given as per the heating curve.
Water level in gauge will rise as heat is
absorbed. Maintain normal drum level
i.e.50 % of gauge glass.
On attaining approximately 2kg/cm2
(g) drum pressure, quickly Operate IBD
and all bottom header drains for 10
seconds to flush deposits and settled
sludge. Restore the drum level to
normal.
At a pressure of approximately 30 psig
(2.1 Kg /cm2. g) a good flow of steam
from air release valves will be noticed.
Upon seeing this, the air release valves
are to be shut.
Continue increasing boiler pressure &
leave the CBD valve slightly open to
prevent the choking of sample line and
sample cooler.
1 x 190 TPH CFBC Boiler
M/s Arasmeta Captaive Power Co. Ltd., C.G.

ER/ 0734 / Ref-Alkali


Rev 02 00/ 30.06.09
Control the fires & gradually raise
furnace temperature at the prescribed
rate up to second stage soaking at 250
Deg C. Soaking is to be given as per the
heating curve.
On attaining approximately 5Kg /cm2
(g) Drum pressure; quickly operate the
intermediate blow down for 10 seconds.
Restore the drum level to normal. Give
blow down thru all bottom header
drains for 10 seconds each to flush
deposits and settled sludge. Restore the
drum level to normal.
Control the fires & gradually raise
furnace temperature at the prescribed
rate up to third stage soaking at 500
Deg C. Soaking is to be given as per the
heating curve.
Continue increasing boiler pressure to
10.1 bar (a) (15 % of normal working
pressure). Leave the CBD valve slightly
open to prevent the choking of sample
line and sample cooler. Operate IBD
and all bottom header drains for 10
seconds every one hour.
Water level in gauge will rise as heat is
absorbed. Maintain normal drum level
i.e. 50 % of gauge glass. This level is to
be maintained through out the dry out
procedure
by
draining
through
continuous blow down/ Intermittent
blow down & if required water can be
taken to maintain drum level.
Maintain 10.1 bar (a) (15 % of normal
working pressure) for a period
of 12
hours. By controlling fuel feed and
adjusting vent. This will ensure a rapid
circulation of water through boiler.
Give blow down at every 2 hrs interval
from water wall and evaporator drains
for one minute each.
Record amount of movement due to
thermal
expansion
against
zero
expansion markings.
4

ISGEC John Thompson


Ensure free movement of pressure
parts during thermal expansion.
While filling drum level care should be
taken that water should not be taken
too fast, as this will drop the furnace
temperature suddenly during dry-out
process.
Now
gradually
reduce
furnace
temperature at the prescribed rate for
controlled cooling from 500 deg C to
180 deg C. Cooling is to be given as per
the heating curve.
Ensure that Burners may be switched
of after attaining around 200 deg C
during the cooling cycle
Stop burner and blow down boiler
manifolds individually by giving blow
down for a period of 2 to 3 minutes
each.
After completion of controlled cooling
cycle i.e. completion of dry out activity,
stop firing fuel & all fans. Allow boiler
to cool down naturally.
When the drum pressure comes down
to 2.5 kg / cm2, open all air vent valves
& drain the boiler by opening all drain
valves.
Following this the entire
boiler can be blown down as quickly as
possible, using all manifold and drum
blow down and drains, at the Engineers
discretion. Ensure that there is no fire
inside
the
furnace
&
furnace
temperature has dropped below 200
degree C.

NOTE:
When blowing down through all
drains
and
blow
downs
simultaneously, due regard must
be exercised for the capacity of
the blow down system.

1 x 190 TPH CFBC Boiler


M/s Arasmeta Captaive Power Co. Ltd., C.G.

ER/ 0734 / Ref-Alkali


Rev 02 00/ 30.06.09
This way evacuate the water before any
dirt or oil has time to settle down. With
blow down and drain valves still open,
wash through drums. Manifolds and
tubes, with high pressure clean water
to wash out any remaining sediment.
After completion of activity and boiler is
cooled down the Boiler should be
flushed with DM water having a pH
value 8.5 10.5 and Hydrazine 1025
ppm and flushing should continue till
pH value of inlet water and effluent
(outlet water from boiler) becomes
same.

Never allow the temperature of


gases entering the Super heater
zone to rise above the normal
working steam temperature of the
super heater until a positive flow of
steam is established through the
super heater drains and vents.

Close all blow down and drain valves


except super heater drain valve, which
must be left open.
A through 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
Close all manhole doors, using new
joints as necessary. If chemicals for
pressure boil out are to be introduced
through Steam Drum manhole, one of
these must be left open.
The boiler is now ready for the pressure
boil out.

ISGEC John Thompson

1 x 190 TPH CFBC Boiler


M/s Arasmeta Captaive Power Co. Ltd., C.G.

ER/ 0734 / Ref-Alkali


Rev 02 00/ 30.06.09

ISGEC John Thompson

1 x 190 TPH CFBC Boiler


M/s Arasmeta Captaive Power Co. Ltd., C.G.

ER/ 0734 / Ref-Alkali


Rev 02 00/ 30.06.09

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