ADHI KARYA - JEPOE JOINT OPERATION

COMMISSIONING PROCEDURE
Document No.

Rev. : 0
PLG-100-CP-PS-0028
REFRACTORY DRY OUT PROCEDURE
Page Number

1 of 10







O OW WN NE ER R : :

P PT T. . P PL LN N ( (P Pe er rs se er ro o) )

P PR RO OJ JE EC CT T N NA AM ME E : : P PL LT TU U L LA AM MP PU UN NG G ( (2 2 X X 1 10 00 0 M MW W) )
P PR RO OJ JE EC CT T T TI IT TL LE E : : P PL LG G
J JO OB B N NU UM MB BE ER R : :
0 07 79 90 08 8
L LO OC CA AT TI IO ON N : :
T TA AN NJ JU UN NG G S SE EL LA AK KI I, , L LA AM MP PU UN NG G









0 October 26,2011 Issued for Approval
REV DATE DESCRIPTION
DPI FSB KSN PLN KITSUM II
PREPD VERD CHKD APPD




ADHI KARYA - JEPOE JOINT OPERATION
COMMISSIONING PROCEDURE
Document No.

Rev. : 0
PLG-100-CP-PS-0028
REFRACTORY DRY OUT PROCEDURE
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TABLE OF CONTENT

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCE
4.0 GENERAL DESCRIPTION OF THE SYSTEM
5.0 SAFETY PRECAUTIONS
6.0 IMPLEMENTATION OF METHODE
7.0 COMBUSTION SYSTEM
8.0 TEMPERATURE CONTROL
9.0 THERMOCOUPLES
10.0 TEMPERATURE RECORDING
11.0 THERMAL INSULATION / BULKHEADS
12.0 DRY OUT TEMPERATURE SPECIFICATION
13.0 DOCUMENTATION
14.0 APPENDICES









ADHI KARYA - JEPOE JOINT OPERATION
COMMISSIONING PROCEDURE
Document No.

Rev. : 0
PLG-100-CP-PS-0028
REFRACTORY DRY OUT PROCEDURE
Page Number

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1. PURPOSE
This Commissioning Procedure is provided and guide to supervise, testing and
evaluation for Refractory Dry Out used base on standard and meet contract
specification, and ensure that no water found at the refractory of the Boiler and system
can operate normally and safely.

2. SCOPE OF WORK
This Scope of Work covers all the specific procedure Refractory Dry Out of CFBC Unit
100 MW Wind Box and Start-up Burner Tunnel by high velocity gas firing is valid in
power plant

3. REFERENCE
3.1 RDO Flow Diagram
3.2 Yising Refractory data sheet for low temperature RDO
3.3 Job Safety Analysis

4. GENERAL DESCRIPTION OF THE SYSTEM
This application Combined Low Temperature and High Temperature refractory
dry-out of plant as detailed above, to the client (Refractory Manufacturers) defined
temperature cycle.

5. SAFETY PRECAUTIONS
5.1 Verify all personnel use protective equipment (safety shoes, safety helmet, ear
protector, etc)
5.2 Verify working permit available.
5.3 Prepare and show off safety sign for dangerous area, especially for rotating
equipment



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5.4 Provide fire extinguisher around flammable area.
5.5 Verify working area safe and clean.
5.6 Take safety meeting/job safety analysis to anticipate and avoid accident, if
accident happen use safety rule procedure

6. IMPLEMENTATION OF METHODE
6.1 High velocity gas firing is proposed to effect the dry-out of the component by :
Internal vessel firing.
6.2 It is assumed that the low temperature and high temperature dry-out
operations be undertaken in one stage for the item parts of the site integrated
plant.
6.3 Salient Details for RDO
6.3.1 Wind Box and Start-up Burner Tunnels
6.4 Temperature Profile References
6.4.1 Great Wall Refractories data sheet for low temperature RDO
2.4.2 Owner Engineering Department.

7. COMBUSTION SYSTEM
7.1 The dry-out operation will be undertaken by the introduction of high velocity gas
burners, as appropriate. The burner will operate on LPG, and will be a
maximum thermal release of 2.0 x 10
6
Kcals/hour, and a maximum combustion
air flow of 2200m
3
/hour.





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COMMISSIONING PROCEDURE
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7.2 The burner will be operated with a minimum flame length, and accordingly only
hot combusted gas will enter the compartments, to give effective forced
convection heat transfer to the refractory, and a high degree of temperature
uniformity.
7.3 The burner will be fitted with intermittent spark ignition, and wi l l be
moni t ored cont i nuousl y by a U-V devi ce coupled to safety shut-off valves.
7.4 The burner arrangement to be adopted will be given in Fig. 1

8. TEMPERATURE CONTROL
8.1 The high velocity gas burner will be controlled manually by adjustment of the LPG
and air flow rates to suit the prevailing ci rcumstances. Control will be effected
by continuous inspection of the temperature recording instruments.
8.2 The dry-out cycle will proceed in accordance with the time-temperature
programmed in Section 8. The minimum prescribed t emper at ur es wi l l be
achieved in the gas stream f or t he f ul l height of t he component . It is
recognized that variations in temperature will occur, particularly on long
section lengths, and it may therefore be necessary to exceed the minimum
temperatures prescribed at the burner inlet points.

9. THERMOCOUPLES
9.1 Thermocoupl es wi l l be manuf act ur ed f rom Ni -Cr/Ni-Al conductor wires,
conforming to BS1401, Part IV Type K. The thermocouples shall be of
sheathed type (mineral insulated). Certification shall be made available
to demonstrate conformance of each thermocouple utilized and shall indicate
a tolerance of 0.75% over the temperature range 400C to 700C.




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9.2 The t hermocoupl es shall be located at several stations along the length of
the components such that they will measure t h e temperature o f t h e g a s
s t r e a m a s i t progresses. The positions of the thermocouples are also
shown in the referenced Figures.
9.3 In the event that thermocouples are required at the refractory surface,
these may be either located at pre- drilled holes and suitably protected by
a refractory cement, or by insertion of metal tags at the refractory surface,
and the thermocouples fixed by the direct wire capacitance discharge method.
9.4 Compensating lead type shall be utilized for extension of the thermocouples to
the recording instrument. Junctions will be polarized to ensure correction, and
made clear of the hot gas stream.
9.5 All thermocouples will be checked for correct polarity, short circuit and open
circuit before commencement of the dry-out cycle.
9.6 Position of thermocouples to be adopted will be given in Fig. 2

10. TEMPERATURE RECORDING
10.1 Temperat ure recorders shall be of the potentiometric self compensating type,
calibrated in degrees Celsius with respect to a nickel-chromium/nickel-
aluminum thermo- couple, Type K.
10.2 All temperature recorders used shall have been calibrated immediately
before use. The calibrations shall be recorded, and evidence to this effect
kept with the instrument. The calibration certificate must show the as found
and as left conditions of the instrument. The instrument(s) utilized for the
calibration shall have certification traceable to a National Standard, and shall
them be calibrated at an interval not exceeding 12 months.




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10.3 The recorders will be potentiometric instruments, self- compensating for
ambient temperature. The chart speed will be set at 50mm/hour unless
otherwise approved and shall be checked during calibration. No artificial
restriction on pen travel will be used. A clear print-out of data will be
demonstrated before commencement of the dry-out cycle.
10.4 A spare recorder will be made available.

11. THERMAL INSULATION / BULKHEADS
11.1 Thermally i n s u l a t e d b u l k h e a d s wi l l b e f i t t e d a t t h e locations of
manhole and inlet / out connections.
11.2 The insulated bulkheads will be constructed from a steel angle framework or
plate, as appropriate. Each bulkhead will be insulated with 25mm of ceramic
fiber insulation, of density 128kg/m
3
, or equivalent.

12. DRY OUT TEMPERATURE SPECIFICATION
12.1 Limitations on the rate of heating and dwell conditions are given in the
manufacturers dry out cycle data table. The rates of heating indicated shall be
regarded as maximum permissible values.
12.2 All i nt er nal t her mocoupl es wi l l achi eve t he mi ni mum specified dwell
temperature for the prescribed period of time.
12.3 Temperature
12.3.1 Ambient temperature to 110C at heating rate 5C/Hr
12.3.2 Hold at 110C for 24 hours
12.3.3 Raise to 150C at rate 5C/Hr
12.3.4 Hold at 150C for 36 hours



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12.3.5 Raise to 250C at heating rate 10C/Hr
12.3.6 Hold at 250C for 12 hours
12.3.7 Raise to 350C at heating rate 10C/Hr
12.3.8 Hold at 350C for 24 hours
12.3.9 Raise to 550C at heating rate 20C/Hr
12.3.10 Hold at 550C for 12 hours followed by natural cool
12.4 Time / Temperature Graphic for RDO given in Figure 4.

13. DOCUMENTATION
13.1 The following documentation will be compiled, on completion of the dry-out
operation:
13.1.1 Time-temperature chart fully identified and referenced with respect to
the thermocouple/trace arrangement. The name(s) of t he t echni ci ans
wi l l accompany t he char t together with details of the client,
component identities and drawing numbers/issues, where known.
Any di screpanci es wi l l be r epor t ed t o t he cl i ent and referenced
on the time-temperature chart.
13.1.2 The working procedure - to be compiled when method is clarified.
13.1.3 Recorder Calibration Certificate(s) Copies
13.1.4 Thermocouple Conformance Certification.

14. APPENDIX
14.1 RDO PROCESS REPORT
14.2 RDO FLOW DIAGRAM
14.3 JOB SAFETY ANALYSIS



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APPENDIX = 1
RDO PROCESS REPORT

Temperature (deg C)
Temperature Rising
Speed (deg C/H)
Time ( H )
Result
Remark
OK NO
Normal Temperature - 110 5 20 (Around)
110 (Max) Maintain 24
110 150 5 8 (Around)
150 (Max) Maintain 36
150 250 10 10 (Around)
250 (Max) Maintain 12
250 350 10 10 (Around)
350 (Max) Maintain 24
350 - 550 15 25 Max 8 14
(Around)

Total minimum baking time
(H)





TESTED BY RESPONSIBLE BY WITNESSED BY SUPERVISED BY DATE

ADHI-JEPOE JO PLN KITSUM II CONSULTANT PLN COMM. TEAM





ADHI KARYA - JEPOE JOINT OPERATION
COMMISSIONING PROCEDURE
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