training -reforming section
TRANSCRIPT
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PT INTI KARYA PERSADA TEKNIK
Ammonia Plant.
Reforming & Waste Heat Recovery
SectionTraining material
r. basuki
1/3/2012
Training manual for IKPT Engineers on ammonia plant steam reforming and rrocess waste heat recoverysection. Jan 2012
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4.2 Refractory work 284.2.1 Penyiapan Material 294.2.2 Penyiapan Peralatan dan Platform Untuk Kerja 294.2.3 Lining Work 294.2.4 Pemasangan Supprot Brick dan Dome Brick 29
4.3 Drying-Out work 29
5. Precommissioning Work 30
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NG
Purification
Methanation
& Dryer
CO2
RemovalShift
Conversion
103-D
Secondary
Reformer
101-B
Primary
Refomer
Compression
NH3
Synthesis
Purge Gas
NH3
Steam Drum
S
T = 800oC
T = 980oC
Ammonia Process (General)
WHB &Superheater
Steam Generator
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NGPurification
Meth& D
CO2Removal
ShiftConversion
103-DSecondary
Reformer
101-BPrimary
Refomer
Comp
N
Syn
Purge Gas
NH
Steam Generator
Steam Drum
Steam PuT = 898
oC
T = 715oC
Ammonia Process PKT-5
WHB Generator
& Superheater
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1.3 Reforming dan Waste Heat Recovery
1.3.1
Objectives:
Pengenalan komponen komponen yang membentuk sistem Primary Reformer, Secondary Reformerdan Waste Heat Recovery
Pengenalan istilah dan penamaan komponen pada Primary Reformer dan Peralatan lain
1.3.2 101-B Primary Reformer
Merupakan tungku bakar (fired heater) yang terdiri atas 2 bagian utama, yaitu 1) radiant boxdan 2)convection(heat recovery) sectiondan dilengkapi dengan peralatan lainnya.
1.3.2.1
101-B Radiant Box
Sesuai namanya, merupakan bangunan struktur baja berbentuk kotak dimana terjadi prosesperpindahan panas secara radiasi, yang diperlukan bagi proses perengkahan gas umpan (gas alam +steam) menjadi gas proses.
CH4 + H2O CO + 3 H2 dH = 206 kJ/mol
CO + H2O CO2 + H2 dH = -41 kJ/mol
Panas radiasi didapat dari pembakaran fuel gas dengan menggunakan sejumlah burner, sedangkanproses perengkahan tsb terjadi dalam sejumlah tabung baja paduan Ni tahan panas dengan bantuankatalis Ni (catalyst tube) pada tekanan + 40 kg/cm2g dan temperature + 725 oC.
Catalyst tubes ini disusun menjadi 4 lajur yang masing-masingnya terangkai menjadi satu kesatuanyang disebut radiant harp. Keempat radiant harp tsb tergantung (suspended) didalam radiant boxdengan menggunakan sejumlah spring hanger
Gas umpan masuk ke catalyst tube melalui inlet pigtaildibagian atas catalyst tube, mengalir kebawahmelewati unggun katalis dan keluar ke header pengumpul yang disebut outlet manifold untukselanjutkan dialirkan ke luar radiant box melewati riser tube.
Burner utamanya ditempatkan dibagian atas radiant box danmengarah kebawah (arch burner) ditempatkan dalam 5 lajurberselang dengan posisi radiant harp.
Udara pembakar yang telah dipanaskan dan bertekanan positif,didistribusikan kemasing-masing burner dengan menggunakancombustion air duct, sedangkan radiant box sendiri beroperasi padakondisi tekanan negatif (-10 ~ 20 mmH2O).
Untuk mencegah struktur baja tersebut dari panas yang terbentukdidalamnya, radiant box dilapis dengan sejumlah refraktoripelindung panas. Refraktori tersebut terdiri atas berbagai jenis danpenggunaan, terutama ceramic fiber, fire brickdan castable.
Hanya 50-60% dari panas yg dihasilkan dari pembakaran fuel gas yg dimanfaatkan di radiant box, sisapanas pada gas buang yang keluar dari radiant box (dengan suhu 800 oC) dimanfaatkan untukpemanasan berbagai aliran proses pada seksi konveksi (convection section).
Bagian atas radiant box (upper structure)merupakan bangunan baja dengan atap dan penutup dinding(siding). Didalamnya ditempati oleh beberapa komponen pipa penyaluran gas proses, komponenpipa fuel dan burner, saluran udara pembakaran, spring hanger, air dampers, control valves, gasdetection, 107-D Effluent Transfer Line dan juga akses untuk operator dan maintenance. Untukmengurangi panas di ruangan tsb ditambahkan exhaust fan di atap bangunan ini
Gambar. Top Fired Reformer
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Struktur atap tsb. dirancang untuk menerima beban dari radiant harp dan Effluent Transfer Linedisamping beban lainnya.
1.3.2.2 101-B Convection Section
Convection Section terdiri atas 2 bangunan struktur baja yang disebut hot legdan cold leg .yangdihubungkan dengan lorong saluran gas buang. Masing-masing bangunan terdiri atas beberapa
convection module yang berfungsi sebagai penukar panas dengan memanfaatkan sisa panas dari gasbuang yang mengalir didalam bangunan tersebut.
Tabel. 101-B Primary Reformer Convection Modules PKT-5
Hot Leg Cold Leg
1. Mixed Feed Heater 1. Steam Superheater (1)
2. Process Air Heater (2) 2. Feed Preheater
3. Steam Superheater (2) 3. Process Air Heater (1)
Masing-masing heater module merupakan sekumpulan pipa yang diletakkan beraturan pada beberapa
baris (row), disanggah oleh tube supports dibagian tengah dan end tubesheets dikeduapinggirnya. Tube support dibentuk oleh besi cor (cast steel) tahan panas sedangkan end tubesheetdibentuk dari plat baja dengan tambahan castable sebagai pelindung panas. Fluida masuk melalui inletheader dan keluar dari convection module melalui outlet header, mengalir secara countercurrent/crossdengan aliran flue gas.
Bahan konstruksi untuk pipa maupun tube support /tubesheets terutama ditentukan oleh suhu gasbuang yang melewatinya. Pipa yang terekspos panas radiasi (Mixed Feed) umumnya berupa bare
pipe/tube sedangkan pipa selebihnya dimana konveksi lebih dominan umumnya menggunakanfinned tube untuk meningkatkan efisiensi perpindahan panas. Jenis materialnya bervariasi sesuaisuhu operasi, bisa berupa baja Ni-Cr, logam paduan Cr maupun baja karbon. Material tube supportdan tube support bracketsuntuk Module terbawah pada hot-leg umumnya menggunakan gradeHK untuk ketahanan terhadap temperature tinggi, dan secara bertahap berkurang hingga besi karbonpada module terakhir.
Untuk membantu agar aliran flue gas lebih homogen, pada bagian atas hot & cold leg diberidistributor platesyang biasanya terbuat dari pelat paduan Nickel (high Ni alloy plate-atau Alloy 800HT ataupun SS 310H).
Panas yang diperlukan untuk seluruh Convection Modules maupun untuk memanaskan udarapembakaran, tidak seluruhnya dapat dipasok dari sisa panas yang dihasilkan melalui Arch Burnersemata. Karena itu panas juga ditambahkan melalui 101-B Tunnel Burner dan 101-B Steam SuperheaterBurner.
1.3.2.3 101-BL Air Preheater
Merupakan alat penukar panas utk memanfaatkan sisa panas gas buang guna menaikkan suhu udara
pembakar. Umumnya yang digunakan adalah type recuperative berupa plate heat exchanger. Gas buangyang masih panas mengalir di salah satu sisi pelat sedangkan udara mengalir disisi lainnya secara crossflow. Pelat-pelat tsb menjadi media perpindahan panas antara kedua aliran gas tersebut.
Plate exchanger ini biasa terdiri dari 2 bagian, yaitu 1) cold section dimana udara yg masih dinginmasuk dan 2) hot section dimana gas buang yg panas masuk. Secara konstruksi kedua seksi tersebuttidak banyak berbeda, kecuali pada cold section dimana struktur baja dan pelat yg bersentuhandengan gas buang dilapis dengan bahan anti korosi (glass enameled) untuk mencegah terjadinya reaksigaram sulfat Fe2(SO4)3 antara besi dengan gas sulfur yg terkondensasi. Pembentukan garam besi
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sulfat tsb tidak hanya menyebabkan kerusakan struktur baja dan plat penghantar panas tetapi jugamenyumbat area aliran gas buang.
1.3.2.4 101-BJ ID Fan & 101-BJ1 FD Fan
Primary Reformer ini beroperasi dengan sistem balanced draftdengan menggunakan 2 fan utama yaitu1) 101-BJ Induced Draft Fan, dan
2) 101-BJ1 Forced Draft Fan
ID Fan mempertahankan kondisi vakum didalam reformer dan menarik gas buang hingga keluar kestack, sedangkan FD Fan berfungsi memasok udara pembakaran melewati Air Preheater hingga kemasing-masing burner.
Pada PKT-5, kedua fan mengunakan sistem penggerak utama berupa steam turbin dengan sistempenggerak cadangan (standby)steam turbin juga. Pada sistem yg lebih umum hanya ID Fan yangmenggunakan pengerak cadangan dan biasanya berupa motor listrik, sedangkan FD Fan biasanyahanya memiliki satu penggerak berupa steam turbin atau motor listrik.Pengerak utama umumnyaberupa steam turbin karean pertimbangan kehandalannya .
1.3.2.5
101- B Burners
Selain 101-BBA Arch Burner yang memasokpanas yang diperlukan untuk prosesperengkahan gas alam, keseluruhan PrimaryReformer juga dilengkapi dengan burnerdengan fungsi yang berbeda:
101-BBT Tunnel Burner, memasoktambahan panas untuk mendapatkan suhucampuran gas alam dan steam (mixed feed)yang dikehendaki sebelum masuk ke catalysttubes maupun kebutuhan panas aliran gasproses di hot-leg
101-BBS Steam Superheater Burner,memasok tambahan panas untukmendapatkn temperature superheated steamyang dikehendaki dan bagi kebutuhan panaskedua aliran proses lainnya di cold leg.
Penggunaan udara pembakaran yg sudahdipanaskan di 101-BL Air Preheatermenyebabkan potensi terbentuknya senyawaNOx atau Sox pada proses pembakaran fuelgas menjadi lebih besar. Karenanya typeburner yg dipakai dirancang untukmengurangi kemungkinan ini. Ada beberapa
pilihan type low NOx burner, tetapi ygumum dipakai di Primary Reformer adalahtype staged fuel, dimana bahan bakar masukke sistem burner secara bertahap.
Gambar. Fuel Staged Burner
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Pada tipe burner ini, ada satu primary burner yg terletak ditengah dan beberapa secondary burneryang berada disekelilingnya dan terlindung oleh burner tiles. Seluruh udara untuk pembakaran masukmelalui bukaan ditengah burner tiles yang menyelimuti primary burner. Sebaliknya gas yang masuk keprimary burner hanya sebagian dari seluruh gas pembakaran yang diperlukan. Dengan sistem initemperatur nyala yang terjadi di primary burner mengalami pendinginan karena adanya kelebihanudara tersebut.
Sisa fuel gas didistribusikan ke secondary burner yang terletak lebih menjorok kedepan diwilayahnyala api dengan suhu yang lebih rendah. Pembakaran secara bertahap ini menghasilkan temperaturenyala yang lebih rendah dan mengurangi pembentukan senyawa Sox/NOx.
1.3.3
103-D Secondary Reformer
Merupakan bejana tekan dimana terjadi reaksi pembakaran oksigen dengan gas proses dari primaryreformer. Reaksi pembakaran tsb meningkatkan temperature gas menjadi lebih dari 1200 oC hinggamemungkinkan terjadinya reaksi perengkahan lanjutan sisa metan pada gas proses dengan bantuankatalis.Bagian bawah bejana tekan berisi katalis sedangkan bagian atas yg berbentuk leher botolditempati oleh mixing chamberuntuk pembakaran gas proses dari primary reformer dengan udarayang dimasukkan dari atas bejana.
Untuk melindungi dari suhu yang tinggi, bagiandalam bejana dilapis dengan bahan refraktori(castable) tahan temperature tingi dan bagianluarnya dilengkapi dengan jaket air untukmendinginkan bejana tekan dari gas panas yangmungkin bersinggungan dengan dinding bejanamelalui retakan pada lapisan refraktori.
Unggun katalis ditempatkan diatas tumpukanalumina balls, dilindung dari nyala pembakarandengan lapisan hexagonal tiles yang dipasangmenutupi unggun katalis. Seluruh sistem katalisini bertumpu pada dome brickyang merupakan
struktur bata refraktori berongga untukmengalirkan gas proses keluar dari SecondaryReformer menuju Waste Heat Boiler.
Gambar sketsa disamping mewakili modelsecondary reformer Kellogg tempo dulu.Disain yang diterapkan saat ini merupakanperbaikan dari design awal yang seringbermasalah dengan nyala api yang menyentuhhexa-tile dan unggun katalis.Ruang bakar menjadilebih tinggi, demikian juga dengan lokasi burneryang makin di atas. Tingginya leher botol inimenyebabkan elevasi primary reformer juga naik.
Bagian dasar radiant box berada pada elevasilebih dari 3 m dari ground level agar Effluent
Transfer Line dapat menjangkau posisi gas inletke secondary reformer.
1.3.4 107-D Effluent Transfer Line
Alat ini merupakan saluran pengumpul gas proses dari radiant harps dan mengalirkannya keSecondary Reformer. Merupakan bejana tekan berbentuk selongsong pipa yang diberi lapisanrefraktori pelindung panas dibagian dalam dan jaket air diluarnya.
Gambar. Secondary Reformer
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Disatu ujung Transfer line tersambung las ke Secondary Reformer sementara bagian lainnyatergantung ke struktur Primary Reformer dengan bantuan spring support.
1.3.5 Riser Transition Assembly
Aliran gas proses dari Riser Tube masuk ke 107-D Effluent Transfer Line dengan melalui RiserTransition Assemblyyang merupakan penghubung antara riser tube yang mendapat panas didalam
radiant box dengan effluent transfer line yang relative dingin. Transition assembly dibentuk oleh 2komponen, 1) kerucut dari baja paduan Ni (Incolloy 800 HT) yang disambung dengan 2 ) bejanatekan dari bahan baja karbon berbentuk pipa dengan lapisan dalam refraktori (bubbled alumina castable)dan liner sleeve dibagian dalam dan jaket air dibagian luar.
1.4
Waste Heat Recovery Section
Terdiri atas 3 peralatan utama, yaitu
101-C Secondary Reformer Waste Heat Boiler
102-C Steam Superheater
141-D Steam Drum101-C Secondary Reformer Waste Heat Boiler.
Berbeda dengan disain standar Kellogg, WHB untuk PKT-5 merupakan jenis fire tube dengansirkulasi natural. Boiler ini berbentuk shell & tube heat exchangerdengan aliran gas panas pada sisi tubedan boiler feed waterpada sisi shell.
141-D Steam Drum, duduk diatas boilerdengan ditopang beberapa riser pipesyangsekaligus mengalirkan campuran air dansteam dari boiler ke steam drum. Saturatedsteam yang terbentuk di steam drumdialirkan ke 102-C Steam Superheater
untuk pemanasan lanjutan sedangkan sisaair dan make-up nya mengalir ke boilerdibawahnya melalui beberapa downcomer.Untuk mengatur laju alir/tekanansteam/effisiensi penyerapan panasditempatkan gas by-pass valve yangmengatur aliran gas yang masuk ke firetubes.Bagian gas proses masuk WHBdilindungi dengan refractori (castable)tahan temperature tinggi, demikian jugadengan sisi keluarnya. Sedangkan bagianlainnya termasuk steam drum, riser dan
downcomers diberi lapisan insulasi luaruntuk konservasi panas dan personnelprotection.
102-C Steam Superheater, merupakan vertical heat exchanger dengan gas by-pass valve untukmengatur temperatur superheated steam, dengan memanfaatkan sisa panas gas proses keluar dari
WHB.
Gambar. Fired Tube Waste Heat Boiler dan SteamDrum
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2.2.1.1
Steel structure
Radiant Box
Dipasok dalam bentuk beberapa panel dan komponen yang siap dipasang dengan baut.
Pengelasan diperlukan untuk memasanggusset plateuntuk platform, walkway atau pipe support, danseal weldpanel radiant box agar kedap air/udara.
Beberapa kolom atau beam utama memerlukan pengelasan setelah seluruh radiant box terpasang.Untuk sementara komponen ini dipasang dengan baut.
Brick support (SS) plate (kalau dipakai) dilas dilapangan sesuai dengan gambar instalasi refraktori.
Pemasangan beam dan plat pada radiant arch dan akses operator (burner level) memerlukan kolomsementara hingga roof truss sudah terpasang, termasuk untuk memasang 107-D Transfer Line.
Tambahan kolom ini tidak dipasok supplier dan menjadi lingkup subkontraktor.
Upper structure & roof
Dipasok dalam komponen lepas yang siap dipasang. Tiang-tiang utama dipasang dengan sistembaut dan las, sedangkan untuk truss atap perlu dilakukan pre-assembly dibawah sebelum dipasang.
Sebagian komponen upper structure dan roof akan dipasang setelah radiant harp di masukkandalam radiant box
Tabel. Ringkasan Steel Structure Radiant Section
Supply condition Installation method note
1 Radiant wall Panel Bolting, seal weld
2 Radiant floor Panel + beam Bolting, weld (seal & butt)
3 Platform,stairway,ladder
Pre-fab frame Weld to support beam
Loose component Bolting & weld to column
Gusset plate weld
4 UpperColumn
Prefab. Bolting & weld
5 Roof Truss Loose component bolting Pre-assemblybefore install
6 Radiant Arch Pre-fab beam & archplates
bolting Temp supportrequired
7 Operator way Grate section panel bolting
8 Roof &Siding
Loose pieces bolting
Note:
2.2.1.2Refractory
Tabel. Ringkasan Refraktori Radiant Box
Supply condition Installation method note
1 Radiant wall Ceramic fiberModule
Surface cleaning
stud weld and manually
Power brush
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Tabel. Ringkasan Refraktori Radiant Box
Supply condition Installation method note
& blanket installed
Asphalt coat brush
2 Radiant arch Ceramic fibermodules & blanket
Surface cleaning
stud weld and manual install
Power brush
Asphalt coat brush
Burner tiles manual, with mortar For arch burner
3 Tunnel Wall Calcium silicateboard
manual with mortar
Insulating brick manual with mortar
Support plate weld By Mechanical
Fire brick manual
Tunnel Cover brick manual
Burner tiles For tunnel burner
4 Radiant Floor Calcium silicateboard
manual, with mortar
Insulating brick manual
Fire brick manual
castable Anchor weld + cast
Ceramic fiberblanket
Stud weld and manual For bottom duct
2.2.2
101-B Radiant Harps & Other Pressure Part
2.2.2.1
Presure parts
Pressure part yang dilewati oleh mixed feed gas hingga keluar ke 107-D Effluent transfer lineterdiri atas:
Inlet manifold
Inlet pigtails
Radiant harps
Riser Transition Assembly
Inlet manifold, merupakan pipa header penyaluran mixed feed gas ke masing-masing radiant harp.merupakan pipa nir karat 308H berukuran 8 dengan sejumlah outlet connection (sock-o-let)untuk masing-masing inlet pigtails.
Inlet pigtail, merupakan pipa nir karat (308H) berukuran 1-11/2 yang menyalurkan gas umpandari inlet manifold ke masing-masing catalyst tube. Pigtail dibentuk untuk mengurangi dampakekspansi termal dari catalyst tube maupun inlet manifold. Dipasok dalam bentuk satuan untukdipasang dan dilas di lapangan
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Radiant harps, merupakan rangkaian sejumlah catalyst tube (HP Mod) yang disusun berjajar. Tubeini dilengkapi dengan top pipe (SS 308H) dan grating dibagian bawah untuk menopang unggunkatalis. Gas proses keluar dari tube katalis melalui pipa keluar ( 1, Alloy 800 HT) yangtersambung dengan outlet manifold(Alloy 800 HT). Setiap satu rangkaian radiant harp dilengkapi 1buah Riser Tube(HP Mod) terpasang dibagian tengah untuk menyalurkan gas ke Effluent TransferLine. Setiap radiant harp dipasok menjadi 3 bagian, yaitu end parts(2 ea) dan mid part(1 ea) yang
harus disambung di lapangan dalam posisi sudah tergantung pada spring hanger.
Untuk pengapalan, radiant harp dilapis anti karat yang harus dibersihkan sebelum dipasang.
Setiap sepasang catalyst tube digantung dengan menggunakan spring hanger ke struktur atap,sedangkan riser tube disambung las ke Effluent Transfer Line
Riser Transition Assembly, berupa kerucut dari baja paduan Ni (Incoloy 800 H atau setara) denganbagian atas berupa baja karbon dengan refraktori pelindung panas (bubled alumina castable) dan linersleeve Incoloy 800H. Dipasok terpisah untuk dipasang diantara Riser Tube dan Effluent TransferLine di lapangan. Selain pengelasan, baik pressure part dan liner sleeve, diperlukan juga pengisianbubled alumina castablepada area penyambungan las.
Tabel. Ringkasan Radiant Harps + other pressure part
Supply condition Installation method note
1 Radiantharp
Terbagi 3 bagian, 2 endsection + 1 midsection.
Tube Top Cover
Thermowell extension
Thermowell sleeve
Instalasi per bagian setelahradiant upper structure selesaidikerjakan
Pengelasan (buttweld) outletmanifold pada posisi sudahtergantung
Thermo well extension dilassebelum insulasi outletmanifold
Lifting beam
Temporarysupport
Test pieces
Weld rod
2 Inlet Pigtail Satuan Fit-up dengan posisi inletmanifold dan catalyst tubeyang sebenarnya.
Socket weld pada inletmanifold dan cat-tube top pipe
Cut & bevelPaper boardgasket
Test piece
Weld rod
3 Inletmanifold
Terbagi 2 bagian perrow
Dipasang berikut tube guidedan hanger
Test piece
Weld rod
But-weld pada posisi sesuaigambar
4 TransitionAssembly
Transition assemblyset
Metal sleeve (Alloy800HT) + Cardboard
Fit-up setelah riser tube dan107-D pada posisi sesuaigambar
Cut & bevelTemp support
Test piece
Weld rod
Butt-weld to riser tube & to107-D
Test piece
Weld rod
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Tabel. Ringkasan Radiant Harps + other pressure part
Supply condition Installation method note
Install & weld liner sleeve withcardboard
Weld rod
Expansion space
Castable pouring By Refractory
Metal sleeve weld at 107-D Weld rod
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2.2.2.2
Refractory
Pelindung panas dalam berbagai bentuk digunakan pada pressure part, sebagai table berikut:
Tabel. Ringkasan Refractory pada Radiant Harps + other pressure part
Supply condition Installationmethod
note
1 Cat Tube TopPipe
Ceramic fiber blanket
Metal sheet
As per dwg
2 Inlet Pigtail pre-formed mineralwool
Fiber glass cloth
As per dwg
3 Inlet manifold Pre-formed mineralwool
Ceramic fiber bulkMetal sheet
As per dwg
4 Outlet pipe &manifold
Ceramic fiber blanket
Tie-wire
As per dwg
5 TransitionAssembly
Bubbled aluminacastable
cast manually afterliner sleeve in place
as cast homogenity
Insulating can (pre-fab)
Ceramic fiber blanket
Ceramic fiber fabricsewn with blanket
Tie-wire
Insulating Can to beassembled &
welded in place
At top part of risercovering weld jointand transition pieces
Insulating can weldingby Mechanical,ceramic fiber blanketby Refractory
Weld rod 617
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2.2.3 101-B Primary Reformer Transition Duct & Convection Section
Transition Duct, dipasok dalam bentuk section panel (roof, floor dan end panels, header cover)dan fabricated beams. Castable dan silicate board dipasok terpisah untuk di lapis dan cor ditempat
Convection section dipasok dalam beberapa komponen, sebagai Tabel berikut:
Tabel. Komponen Transition Duct dan Convection Section
Komponen M R O
1 steel structure, dalam bentuk side wall dan end wall panels, pre-fabricated beam, header cover, pre-fab platform, ladder,combustion air duct, damper, dll.
2 tube bundles lengkap dengan tube supports; support bracketsdipasok terpisah untuk dipasang menjadi module sebeluminstalasi
*
3 distribution plate (pre-fab) dan supportnya, castable supportplates
*
4 pipe spool pieces, untuk penyambungan antar tube bundle atautube header dan cross-over pipes, hangers, dll.
*
5 refractory material: castable untuk side wall & end tubesheet;ceramic fiber module & blanket untuk roof; external insulationfor ducting and pipe,
*
6 burners & burner tiles * *
Tube bundle, wall panel dan header cover dirakit dahulu berikut castable menjadi satu bagianheater module sebelum dipasang diposisi yang ditentukan.
Castable lining pada roof panel diusahakan dilakukan sebelum instalasi, kecuali material yangtersedia bisa dan cukup untuk diaplikasi dengan sistem gunning.
Tabel. Ringkasan Pekerjaan Mechanical Convection Section & Transition Secti on
Supplycondition
Installationmethod
note
1 Transition Duct section panel
beam
bolting & weld Castable lining diroof panel
sebelum instalasi2 Convection inlet,
outlet , &transition/ burnerduct
section panel
pre-fab column
bolting & weld
3 Heater module section panel
tube bundle
Castable lining onsection panel
Preassembly of
By Refractory
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Tabel. Ringkasan Pekerjaan Mechanical Convection Section & Transition Secti on
Supplycondition
Installationmethod
note
Support bracket module
Module installation Lifting beam4 Cross-over pipes,
etcSpool pieces
Springsupport/hanger
welding Test piece
Weld rod
5 Air duct & damper prefab duct &damper
gasket
bolting
6 Burner & burnertiles
burner tiles insections
burner assembly
burner tilesw/mortar
by refrctory
by mechanical
Tabel. Ringkasan Pekerjaan Refractory Convection Section & Transition Section
Supply condition Installation method note
1 Transition Duct castable
silicate board
anchor
form work
Castable lining di roofpanel sebelum instalasi
2 Convection inlet,outlet , &transition/burner duct
castable & anchor
ceramic fiber module
anchor welding
formwork
castable lining
ceramic fiber installation
3 Heater module Castable
Anchor
Support plate
Anchor welding
Support plate welding
Form work
Castable lining onsection panel
By mechanical
Before module pre-assembly
4 Cross-overpipes, etc
Pipe perform mineralwool
Metal sheet
As per dwg
5 Air duct &damper
mineral wool board +jacket
anchor welding
6 Burner & burnertiles
burner tiles in sections burner tiles w/mortar
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2.3
101-BL Combustion Air Preheater
Dipasok dalam beberapa bagian (boxed) yang harus dipasang diposisi sesuai petunjuk gambarbersama flue gas dan combustion air ducting. Pemasangan dengan sistem baut dan seal weldingpada sisi flue gas.
Insulasi luar dipasang kemudian sesuai gambar.
2.4 101-BJ Primary Reformer Induced Draft Fan & 101-BJ1 Primary Reformer ForcedDraft Fan
Dipasok terpisah antara fan dan penggeraknya, untuk dipasang ditempat.
Sisi inlet & outlet fan dilengkapi dengan expansion joint untuk mencegah beban berlebih pada fan
Material insulasi luar dipasok sebagai bagian dari Primary Reformer tapi pengerjaannya dapat sajadilakukan oleh subkontraktor insulasi.
2.5 107-D Effluent Transfer Line
Dipasok dalam bentuk jadi dipasok lengkap dengan selonsong dalam (metal sleeve), refraktoriyang sudah di cor di shop, water jacket dan kompenen hanger. Beberapa bagian dari pelat waterjacket harus dipasang dilapangan setelah 107-D digantung di struktur atap Primary Reformer dansetelah penyambungan dengan Transition Assembly maupun dengan 103-D Secondary Reformer.
Untuk penyambungan dengan 103-D digunakan tambahan Fit-up section, merupakan bagian dari107-D yang dipasok terpisah untuk fit-up dilapangan dengan inlet stub 103-D Secondary reformer.
Bagian utama 107-D harus dipasang terlebih dahulu dengan temporary support sebelum strukturatap Primary Reformer dapat dipasang.
Pemasangan liner sleeve (dengan lapisan cardboard) dilakukan setelah pengelasan sambungan ke103-D maupun ke transition assembly dan pengecoran bubled alumina castabale.
Tabel. Ringkasan Pekerjaan 107-D Effluent Transfer Line
Supply condition Installation method note
1 Main body Dengan temporary supportsetelah radiant box steelterpasang
Posisi inlet stubs 107-D terhadapposisi radiant harps
Elevasi thdp 103-D inlet stub
2 Fit-up section Fit up at field
weld
107-D pada kondisi tergantung
dan levelled
3 metal sleeves fit-up w cardboard
weld
Setelah bubled alumina & inspeksi
Expansion clearance
4 Bubled aluminacastable
As per dwg Setelah pengelasan pressure part;by refractory subcontractor
5 Brick w/ceramic A sper dwg Flange cover, after final inspection
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Tabel. Ringkasan Pekerjaan 107-D Effluent Transfer Line
Supply condition Installation method note
fiber blanket
Water jacket Fit-up & weld Setelah temporary support dilepas
2.6 103-D Secondary Reformer
Terdiri atas
bejana tekan
mixing chamber, dipasang terakhir setelah inspeksi final sebelum top cover
top & bottom cover w/insulating can + gasket, dipasang setelah inspeksi final
komponen pelat incoloy atau nirkarat yang harus dilas dilapangan setelah selesai atau diantaratahapan pengecoran castable
refractory material, terdiri atas high alumina castable
catalyst support, berupa dome brick dan mortar, alumina ball dan hexagonal tile
steel form untuk pengecoran castable,
wooden form untuk peletakan dome-brick
Pengelasan inlet stub end dengan 107-D maupun outlet stub-end dengan transfer line ke 101-Cdilakukan setelah castable dryingout selesai dilakukan
Castable drying out dilakukan dengan kondisi water jacket telah terpasang karena diperlukan untuksirkulasi air pendinginan dinding reformer.
Refractory work 103-D dan drying out nya dibahas dalam bab tersendiri.
2.7
103-D101-C Transfer Line
Bejana tekan berbentuk selonsong dengan lapisan castable tahan panas dibagian dalam. Mengacupada disain Kellogg standar dilengkapi juga water jacket dibagian luar, sedangkan castable sendiridilindungi dari aliran gas dengan liner sleeve
Selain pekerjaan fit-up dan pengelasan pressure part (baja karbon) dilakukan juga fit-up danpengelasan liner sleeve sebelum dapat diserahkan kepada subkontraktor refraktori untukpengecoran bubbled alumina castable.
Pemasangan liner sleeve (dengan card board) perlu memperhatikan clearance yang diperlukan
untuk expansi pada kondisi suhu operasi.
2.8 Pengelasan Heater Tube
Heater tube dimaksud mencakup inlet manifold, inlet pigtail, outlet manifold, risert transition,cross over tube dan heater tube lain.
Selain kebutuhan akan test piece untuk pengetesan welder dan penyiapan WPS/PQR perludiperhatikan juga pasokan kawat las untuk masing-masing joint/jenis base metalnya.
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Contoh breakdown pengelasan di sistem Reforming ditampilkan dalamAttachment-2
2.9
Quality Control
Kendali kualitas pada pekerjaan konstruksi reformer dibagi dalam beberapa tahapan:
Tahapan Pekerjaan /QC items note
1 Fondasi dan posisi anchor bolt
a posisi masing-masing fondasi terhadap center-lineprimary reformer dan terhadap dinding luar radiantbox atau convection modules
Surveyor/mech
b posisi center-line 107-D/101-B Primary Reformerterhadap center-line 103-D
Surveyor/civil
c jarak titik acuan 107-D/riser tube terhadap center-line 103-D
Surveyor/civil
d Elevasi akhir pad-plate masing-masing fondasi Surveyor/mech
e Lain-lain, sesuai Construction Specification
2 Steel Structure
a Seal welding & butt welding of beam/column Visual/PT
b Plumbness, straightness Y-level,
c HT bolt size and tightening
d Lain-lain sesuai Specification
3 Heater Module
a Posisi inlet/outlet header relatif terhadap dindingdan column splice
b Expansion clearance, posisi finned tube pada endtubesheet setelah pre-assembly
visual
c Pemasangan temporary tie-rod visual
d Metode pemasangan/spreader beam/lifting beam Lifting plan
e Lain-lain sesuai specification
4 Refractory Work, Ceramic Fiber Module/Blanket
a Surface cleaning visual
b Marking for anchor
c Stud anchor welding Bend testd Material checking
e Sequence pemasangan As per dwg
5. Refractory, castable
a Surface preparation visual
b Marking for anchor (pitch dan jenis) As per dwg
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Tahapan Pekerjaan /QC items note
c Anchor welding Bent test
d Form work (sealed, space/castable thickness)
e Material use/mixing water quantity/mixer + tool
cleanliness
As per manual
f Castable check for void/honeycomb/dryness/spalling
Light hammering
6 Burner & burner tiles
a Posisi secondary burner tips
b Burner tip cleanliness,
7 Radiant Harps, installation
a Inside cleanliness/defect Visual/boroscope
b Support grid /grating opening Visual/boroscope/
dP checkc Elevasi dan levelness outlet manifold/top pipe
d Thermal expansion space at outlet manifold
e Spring setting Cold/hot setting
8 Inlet Manifold, installation & welding
a Inside cleaning
b Posisi guide/hanger dan thermal expansionmovement/clearance
c Fit-up & straightness during welding
d Root pass: PT; final pass : PT, RT
8 Outlet manifold welding
a Fit-up
b Level and straightness of tube, interpass tempduring welding
c Root pass PT; Final PT & RT
9 107-D, installation
a Level & centerline terhadap 101-B maupun 103-D
b Posisi inlet stub end terhadap posisi riser tube
c Spring setting (final)
d Castable line
e Liner sleeve installation and clearance
10 Riser Transition Assembly
a Center-line to radiant harps and 107-D inletconnection
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Tahapan Pekerjaan /QC items note
b Fir-up
c Root pass PT; Final PT & RT
d Castable lining
e Root pass PT; final pass PT & RT
11 101-BL Air Preheater
a Surface condition
b Position of each section
c Seal welding
3.
CONSTRUCTION PLAN
3.1
Objective
Membagi seluruh aktifitas konstruksi menjadi paket-paket yang dapat di subkontrakkan
Memberikan gambaran urutan aktifitas konstruksi secara keseluruhan sesuai dengan paketpekerjaan
3.2 Scope of Work
Keseluruhan lingkup kerja konstruksi untuk sistem reforming, waste heat recovery dan firedheaters adalah sebagai berikut
Erection and steel work for 101-B Primary Reformer and its proper
Installation of 101-B associated equipment (Fans, Air preheater, Burners, etc.)
Equipment installation of 107-D, 103-D, 101-C and 102-C and the transferlines
Welding of high alloy radiant harps, stainless steel piping component and transfer linespressure part and incoloy sleeves
Steel erection & refractory lining of 102-B
Refractory work for 101-B, 103-D, 107-D and field joints between 103-D, 101-C and 102-C
Drying-out 103-D
Precommissioning
Catalyst loading
Radiant Harp balancing
Kelima butir pertama biasanya menjadi satu paket pekerjaan kontaktor mekanikal denganpembatasan sesuai penjelasan pada bab sebelumnya.
Urutan pekerjaan untuk area Primary Reformer secara rinci dapat dilihat dalam Attachment-1, dansecara ringkas dijabarkan dibawah ini.
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3.2.1
Instalasi 101-B Primary Reformer dan Peralatan lainnya
Mencakup instalasi struktur baja 101-B radiant box, 101-B Convection Modules dan bangunanbaja, dampers, combustion air duct, stack dan platform/ladder.
Instalasi struktur baja radiant box dilakukan secara sekuensial dengan instalasi107-D and 103-Dmaupun dengan instalasi radiant harps.
Temporary support untuk instalasi combustion air duct and 107-D harus disiapkan olehmechanical subcontractor.
Convection coils, steel panels dan refractory material dipasok terpisah. Perlu dilakukanpreassembly per module dan dilapis dengan castable sebelum dipasang ditempatnya. Subkontraktormekanikal perlu menyiapkan meja kerja untuk fabrikasi module dan menyiapkan lifting frameuntuk instalasi module.
3.2.2 Installation of 101-B Associated Equipment
Peralatan dimaksud mencakup 101-BL Air Preheater, ID and FD Fans (101-BJ1 & 101-BJ2) danpenggeraknya, roof fans, dampers with actuators, dan burners (101-BBA, BBS, BBT), dipasangoleh Mechanical subcontractor, kecuali untuk burner tiles yang dikerjakan oleh refractory
subcontractor,3.2.3
Instalasi 107-D, 103-D, 101-C dan 102-C
Diperlukan heavy cranesuntuk mengangkat ketiga peralatan tersebut.
Jadual instalasi 103-D menentukan bagi penyelesaian pekerjaan di 101-B radiant box karenabanyaknya aktiftas yang terkait maupun karena keterkaitan dengan akses untuk heavy crane.
3.2.4 Welding Of High Alloy Radiant Harps, Stainless Steel Piping Component And TransferLines
Mencakup pengelasan 101-B radiant harps, pengelasan stainless steel inlet manifold, cross-overpipes and pigtails, pengelasan high pressure piping pada convection modules, and pengelasan padatransfer lines antara 107-D, 103-D, 101-C and 102-C - termasuk Incoloy/ Inconel liner sleeves.
LihatAttachment-2danAttachment-8untuk rinciannya.Vendor akan menyiapkan test piece untuk welder test termasuk penyediaan kawat las biladiperlukan.
3.2.5 Refractory Work for 101-B, 103-D, 107-D and Field Joints between 103-D, 101-C and 102-C
Refractory work pada 101-B radiant box dimulai setelah selesainya pengelasan radiant harps dancold setting (balancing).
Castable lining work pada 101-B convection panel dimulai sebelum module pre-assembly dnselanjutnya secara sekuensial dengan instalasi heater module dan coils,
Secondary reformer (103-D) lining work dimulai setelah water jacket selesai dikerjakan. Pekerjaanrefraktori termasuk instalasi dome brick dan alumina ball sebelum catalyst loading, dan
pemasangan circle brick dan hexagonal tiles setelahnya.Rincian pelaksanaan refraktori di 103-D khususnya dijabarkan dalam bab berikut.
Perlu diperhatikan umur high alumina castable yang digunakan pada 103-D. Sebaiknyapenegecoran dilakukan tidak lebih dari 6 bulan sejak tanggal produksi karena sangat berpengaruhpada kualitas castable tsb. (umur castable ini bervariasi antara 69 bulan)
Penyimpanan material refractory (terutama high alumina castable untuk 103-D) sangat pentingterhadap kinerja castable tersebut. Karenanya subkontraktor perlu menyiapkan tempatpenyimpanan yang khusus, terhindar dari kelembaban udara, air hujan dan terik matahari. Air
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steam line to fans drivers, dan lainnya.
Instrument subcontractor melakukan pemasangan instruments dan control valve
Electrical subcontractor untuk sistem penerangan dan power line ke peralatan di reformer(roof fans, actuators, etc.)
Insulation subcontractor, melaksanakan external insulation fuel gas/process gas/steam/airpiping diluar area radiant box dan convection coil headers,
Leak testing untuk fuel piping dan pneumatic testing keseluruhan sistem, dilakukan padaperiode commissioning.
3.3 Schedule of Work
Titik acuan konstruksi primary reformer dan peralatan lainnya adalah pemasangan 103-DSecondary Refomer. Pengelasan radiant harps dan effluent chamber 107-D baru akan dilakukansetelah reactor ini terpasang pada posisinya.
Secara tentative, instalasi 103-D dilakukan paling lambat 3 bulan setelah struktur baja Primary
Reformer dikerjakan, kecuali bilamana diperlukan akses untuk heavy lifting.Refractory work pada 103-D akan dimulai lebih kurang 2 bulan setelah instalasi 103-D.
Convection coil, air preheater and fans sudah harus terpasang sebelum pemasangan danpengelasan cross over pipe dan ducting.
Jadual umum konstruksi ditunjukkan pada gambarhalaman berikut danAttachment-3.
4. REFRACTORY & DRY-OUT WORK 103-D
4.1 Objective
Pekerjaan castable lining dan drying-out 103-D merupakan salah satu pekerjaan yang sangat kritisdan cukup berat. Kegagalan disaat peleksanaan pekerjaan refarktori ini berdampak sangat besarkepada proyek dan kehandalan operasi selanjutnya. Karena itu perencanaan yang rinci sangatdiperlukan dan pengawas maupun kontraktor yang dipilih selain harus berpengalaman utkpekerjaan sejenis juga perlu memahami persyaratan dan kelengkapan kerja yang diperlukan.
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Gambar. Sekuen Pelaksanaan Pekerjaan Reforming Section
4.2
Refractory work
Cakupan aktifitas pekerjaan ini dimulai dengan proses:
penyiapan material
penyiapan peralatan dan platform untuk kerja
pembersihan permukaan steel dan anchor, dilanjutkan dengan pemasangan drop form
sample test castable utk memastikan jumlah air pencampur
lining work, dalam 3 tahap diselingi pekerjaan pemotongan/pengelasan pelat
pelepasan drop form dan inspeksi
pemasangan support brick
drying-out
dome brick dan catalyst loading
Secara lebih rinci, sekuen aktifitas refraktori dan pekerjaan mekanikal yang terkait dijabarkan dalamAttachment-4.1.
61-101-B Primary Reformer & 61-103-D Secondary Reformer
Welding
Refractory
Vessel
Installation
103-D installation
61-101-B RadiantPanel installation
Platform up toelev. 13.000
Panel welding
Anchor welding ofConvection panel
Castable liningwork. Convection
Section Panel
Radiant box upperstructure/roof
trusses
ConvectionModule Installation
Water jacket
61-107-D EffluentChamber
Combustion AirDuct
Radiant Harps
Radiant Harpwelding
Burner tiles & radbox refractory
work103-D Lining 103-D Dryout
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4.2.1
Penyiapan Material
Penyimpanan material castable harus sudah ditangani dengan benar sejak kedatangan di site.Diperlukan gudang yang bebas air dan udara lembab, serta cukup dingin dan tidak terkena panaslangsung matahari. Praktisnya adalah dengan memanfaatkan container pengiriman yang ditempatkandibawah atap dengan penopang balok kayu (agar tidaklangsung kontak dengan tanah)serta diberipendingin udara (AC). Udara panas pada material castable dalam waktu lama dapat berakibat rusaknyacastable.
4.2.2
Penyiapan Peralatan dan Platform Untuk Kerja
Daftar peralatan untuk casting maupun drying-out dijabarkan dalamAttachment 4-3
Platform kerja diperlukan baik didalam didalam bejana tekan maupun pada elevasi top opening.
Platform didalam reactor harus dapat memuat minimal 8 orang dengan 3 vibrator dan tool. Platformjuga harus mudah dibongkar dan dipindah mengikuti ketinggian pengecoran
Platform di top opening harus cukup lebar dan kuat untuk memuat 2 mixer, 3 drum air, 3-4 palet berisicastable, ruang kerja untuk 12-16 orang
4.2.3 Lining Work
Dilakukan dalam 3 tahapan, 1) dibawah posisi dome-brick, 2) diatas dome brick hingga posisi mixingchamber, dan 3) diatas mixing chamber hingga top opening.
Tahap 2 relatif memakan waktu lama karena jumlah yang harus di cor cukup besar.
Rincian pekerjaan ditampilkan dalamAttachment 4-2.
4.2.4
Pemasangan Supprot Brick dan Dome Brick
Sebelum pemasangan, disiapkan brick sesuai nomor row dan ututan pemasangan. Penyediaan brickdiatur sesuai dengan kebutuhan (sesuai row yang dikerjakan)
Dry setting (pemasangan sementara tanpa mortar) perlu dilakukan untuk memastikan posisi setiapbrick sebelum dipasang ulang secara permanen dengan mortar.
Untuk pemasangan dome-brick (setelah drying-out castable), dilakukan dengan menggunakan domebrick wooden form yang disiapkan oleh supplier. Sebelum pemasangan ditempat, sebaiknya dilakukandry setting diluar untuk memastikan space antar brick yang nantinya diisi dengan mortar. Key brick(brick paling atas) harus terpasang dengan benar untuk memastikan kekokohan struktur dome dalammenanggung beban alumina ballast dan catalyst diatasnya.
4.3 Drying-Out work
Pengeringan castable dilakukan dengan cara menghembuskan udara panas kedalam 103-D melaluibottom opening. Udara panas dihasilkan dari pembakaran gas alam pada furnace yang ditempatkandiluar vessel dan disalurkan dengan menggunakan ducting. Skedul pemanasan dan pengukuran suhu(flue gas dan vessel skin) diatur dalam prosedur Kellogg.
Prosedur diatas tidak selalu dapat dilakukan tergantung dengan bentuk bejana tekan tsb maupunfurnace yang tersedia sehingga perlu dilakukan penyesuaian dilapangan. LihatAttachment-6
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5.
PRECOMMISSIONING WORK
Pekerjaan pre-commissionin dan commissioning di area reforming mencakup:
Catalyst loading pada 101-B. Lihat Attachment-7
Catalyst loading 103-D
Radiant harp balancing (cold setting)
Chemical cleaning 101-C dan 141-D
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing
Remarks/ Inspection Requirement
A. Preparation
A.1 Foundation hand over from civil, reconfirmdimensional and position of anchors
Grease anchors bolts and nuts
Check and record foundation andanchor position
A.2 Liner plate installation Liner plate, non-shrink mortar.Check and record for elevation
A.3 Prepare work bench for pre assembly of radiant
panels and platform
Steel beams, temporary platform
support and wooden plank. Thebench should be sized enough for 2panels
B. Radiant Box Pre Assembly & Installation
Panels of wall #2 & #4 require pre assembly on ground prior toerection/installation. At same time platform support can beinstalled to the extent feasible
Sequence of pre assembly and installation:
Wedges required for adjusting panelplumbness
Pre assembly on steel bench
B.1 Wall panels (start from wall #4 & wall #3) andfloor walls, in sequential order:
Pre assembled panels to be highstrength bolted
B.2 Plumbness and diagonal dimensional check Bolts at splice to be manuallytightened before plumbness check.Gap at splice should be max. 3 mm.;
B.3 Bolt tightening and seal welding High strength bolting before sealwelding
B.4 Liner plate tack welding and grouting Non-shrink mortar required
C. Combustion Air Duct & Arch Plate Installation
Ducts panels and arch platesarepre assembled on ground prior toinstallation. Each row is pre assembled into 2 pieces without sealplates
C.1 Install temporary support for ducts and 107-D Support are supplied bysubcontractor based on designsfurnished by TEC
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
C.2 Install ducts: Cover openings with plank orplywood for personnel protection
C.3 Install seal plates for duct connection (sealingcompound & sealing gasket Weld duct endopenings to wall structure
Align duct according to dwg.,
Maintain expansion clearance as per
C.4 Arch grating
C.5 Install ends cover, After castable lining work
D. 107-D Pre-installation
D.1 Temporary support installation on top of ducts Dwg. NA Check alignment to inlet of 103-Dand centerline to the reformer.
Plumb line from center of 107-Dinlet stub is + 12 mm from centerof drain opening on the floor
D.2 Pre-installation of 107-D, at its designatedelevation and position
407-D series
E. Roof trusses
Requires pre assembly on ground to complete set of trusses beforeinstallation
E.1 Pre assembly of End-trusses & Sub-trusses Dimensional check against actualcolumn position on radiant walls
Column bevel ends are prepared onground
E.2 Install:
Upper column
End trusses, Sub trusses, Vertical bracing
Bracing & post
Tie bracing & effluent chamber support, roofbracing
E.4 Complete roof construction before H.3, includinginstallation of exhaust fans
F. 107- D Setting and Adjustment
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
F.1 Install 107-D spring support, in locked conditionaccording to dwg.
Install hanger to spring support and weld the pin
Check spring no. and its locationwhich is align with transfer linesupport points
Check that the 107-D is positionedcenter line to reformer for its entirelength and align to 103-D inlet stub
F.2 Roof trusses are completely installed, bolt tightenedand welded
Suspend 107-D by tightening spring turnbuckles,
F.3 Remove 107-D temporary support after positionand level of the vessel is inspected.
F.4 Measure distance from 107-D end to 103-D inletstub.
Cut 107-D field piece to the required length plusallowance for end preparation.
Bevel end according to WPS
Fit-up and tack weld field piece
F.5 Welding pressure shell of 107-D field piece to startfrom 103-D side
Check vessel centerline to furnaceand adjust weld sequence if required
F.6 Installation of water jacket
G. Duct Hanger & Manifold Installation
G.1 Install duct hanger and set level of duct byadjusting bolts
Adjust duct to center of 107-D inlet stub
Check level of duct, checkexpansion allowance on ductconnection
Plumb line from center 107-D inletstub, was within + 12 mm frommidpoint of adjacent duct wall
G.2 Install inlet manifold support & guide
Install inlet manifold and support hangers. Use turn
buckles of intermediate support to maintain slopeof manifolds
G.2 & G.3 can be done after radiantharps installation (H)
Maintain slope of (- 25 mm) + (3mm) towards cross over pipe
Check clearance as per drawingG.3 Weld Grinnell pipe covering protection saddle,followed by guide roller and
G.4 Remove duct temporary support
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
K.1 Suspend harps on hand tightened springs andremove temporary support
Install bottom header boxes to maximum extent,leave access for jigs and welding work
Drop plumb line from riser transition to flooropening. Centering riser tube was within + 12 mmfrom top of riser to connection point with outletmanifold,
Check if drain nozzle and thermowell connections
are correctly centered over floor openings. Flooropening should be adjusted accordingly ifconflicted.
See KBRs balancing procedure
Do not weld cover plates at thisstage.
Plumb hanger was within + 3 mm
Measure and record distant of topflange from datum line beforesupport is removed
K.2 Leveling center harps outlet manifold was within +10 mm for 3 m length by using hangers threadedrod
Adjust elevation and level of end harps was aligningwith center harp.
Fit up for welding.
210-D103 Level to within +10 mm per 2500mm length.
Measure and record distant of topflange from datum line before
welding
Measure and record elevation ofmanifold above floor at three pointsfor each third
K.3 Weld manifold according to the approvedprocedure
Use jig to fix position of manifoldduring welding
K.4 Record position of tube assemblies after welding Measure and record distant of topflange from datum line
Measure and record elevation ofmanifold above floor at three pointsfor each third
K.5 Adjust the hanger based on final record of distantof top flange from datum line
Release or tightened the threadedrod by the difference in recordbefore and after welding
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
K.6 Raise riser to correct position for field welding byadjusting spring turnbuckles.
107-D to remain as per F.6.
Before welding:
Check for correct weld gap
Measure and record distant of topflange from datum line & elevationof manifold above floor at threepoints for each section
After welding finished:
Measure and record distant of top
flange from datum line & elevationof manifold above floor at threepoints for each third
Adjust spring turn-bucklesaccording to differences in recordmeasurement
K.7 Install drain and thermowell connection and sleeves
Welds as per approved procedure
210-D102
K.8 Riser insulating cans was installed after pneumatic
test of radiant coil (step P.)
210-D104
K.9 Install arch cover plates according to drawings Check bolt position/clearance forarch plate movement, adjust platesif required (ditto N.2)
K.1 Weld cover plate as per drawing Check expansion clearances
L. Refractory Lining & Burner tiles (Radiant Box)
L.1 Install sidewall brick lining. Including tunnel burnerside bricks and burner tiles
Ensure that dimension of brick on burner wall sideis correct to ensure straightness of tunnel wall
215-D series
Suppliersdwgs.
Test for anchor stud weld strength
Maintain and check for expansionclearance on brick wall as perdrawing
L.2 Install arch burner tiles Check for correct position for eachtype of arch burners
Check for tiles projection
L.3 Install arch module lining except area around risertransition assembly (if step P.1 is not yet perfrmed)
Supplierdwgs.
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
L.4 Install tunnel wall bricks, floor brick and bull-nosecastable lining
L.5 Outlet manifold lining after catalyst loading. StepM.1, and system pneumatic test, step P.4
M. Catalyst Loading
M.1
Catalyst loading will start if radiant harps weldingand upper structure is completed
Catalyst loading to proceed in accordance withprocedure
Detailed procedure was developedusing KBRs loading procedure. Bed
density of catalyst was confirmedprior to loading
M.2
Replace gasket with permanent material and bolttightened as per instruction, after final inspectionof catalyst bed
Bolt torque controlled
N. 107-D & Radiant Tubes Spring Adjustment (Cold Setting)
N.1 Fill in water to 107-D jacket to operating level.
Remove spring locks and adjust spring to theoperating load (cold)
N.2 Release radiant tubes spring locks Check for any obstruction, adjustarch plates if required
Check bolt position (on slotedholes) for duct movement
N.3 Adjust spring to Final Cold Operating load settings Record final spring setting
Measure and record distance of topflange from datum line
N.4 Set 107-D spring limit stop 15 mm. upward and 3mm downward.
O. Installation of Arch and Tunnel Burners
O.1 Install burners as per drawing/instruction Check orientation and record burnertip projection
Check for easiness of operation ofburner air damper
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
P. Refractory and External insulation (Radiant Box)
Step P1, P2 & P5 was completed after system pneumatic test
P.1 Install & welding riser cans with ceramic fiberblanket
210-D104
P.2 Install ceramic cloth (Nextel BS-40) w/cardboardbelow riser cans
Install flexible boot on riser openings
Suppliersdwgs.
P.3 Complete ceramic fiber lining on arch plates Suppliersdwgs.
P.4 External insulation on air ducts
P.5 Complete refractory work on outlet manifold andheader boxes, and castable on air ducts
Install tunnel slabs.
Provide protection on slabs by usingplywood
Q. Inlet pigtail and external pipe welding and insulation
To be performed before system pneumatic test, before or aftercatalyst loading, but after cross-over piping (step S1 to S5)
Q.1 Fit up inlet pigtail by trimming excess length. Donot cold spring.
Q.2 Insert 1.5t cardboard spacer to sockolet on inletmanifold and on radiant tubes before insertingpigtail into sockolet.
Perform visual check for the gasketbefore pigtail installation
Q.3 Socket weld inlet pigtails to radiant tubes and toinlet manifold
PT
Q.4 External insulation except at weld joints (wascompleted after pneumatic test)
Q.5 Adjust spring to Final Cold Operating load settings Record final spring setting
Measure and record distance of topflange from datum line
R. Convection & Transition Section Installation and Castable lining
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
Convection coil are supplied separately from its casing (convectionpanels). Thus to complete the module, the convection panels,castable lining on the panels and installation of convection coilsshould be done in sequential order on steel bench before finalinstallation.
Mechanical subcontractor to prepare lifting frame suitable forerection of heaviest module.
R.1 Install hot/cold legs convection box up to elev. +6050. Dimensional check and bolt tightening and
seal weld splicesInstall transition floor and roof
Weld columns to cap plate before installation ofupper module
Plumb and square check
Check for type and position / levelof tubesheet supports and guides
Strength bolted and seal welded
R.2 Castable lining work on convection box.
As alterntive, lining may be applied on horizontalposisiton before panel assembly
Check for anchor welds
Check for castable homogenity byhammer test
R.3 pre-assembly and install lowest convectionmodules, both legs
Install tie-beam between hot and cold leg, if any
Full-weld column to pad plate before installation ofnext upper module
Ceramic fiber was place on top castable surface atmodule splice.
Install convection next modules in sequencebetween hot and cold leg. Follow step 2 to 4 foreach module
Bolt and seal weld splices
install and weld distributor supports
Additional temporary tie-plate/rodmay be necessary to hold firm the
modules during erectionPosition of tie-plate/rod are atcolumn D & H, lower part. To beremoved after column welding.
R.4 Install roof structure, including duct support
Install platform on convection section
Install end walls on transition section
R.5 Install distribution plates
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
R.6 Ceramic fiber modules and castable lining.
Install burner tiles
R.7 Install superheater burners Check for position and projectionof burner tips
S. Cross Over Pipes And Convection Module Jump-Over Pipe Installation And Welding
S.1 Plumb and install /weld strut hanger (FS01) as perdrawing, 610 mm from center line of inlet manifold
210-D401 Plumb was + 3 mm
Total length of strut = 2872 mmfrom inlet manifold center
S.2 Install horizontal pieces (C001) with hangers and -25 mm slope down to coil header
Weld to coil header after fit-up and elev. check
210-D401
S.3 From field weld end of (C001) measure actualelevation of field weld joints of cross over pipe
S.3 Cut (C007) to actual length
Plumb and install /weld (C007) to Barco strut
Weld to inlet manifold after fit-up,
S.4 Cut (C003) to actual length
Fit-up and weld (C002)
S.5 Measure and cut (C006), (C005), (C004) to actuallength. Same as S.3
S.6 Fit-up and weld steam superheater jump-over pipes Convection tubes are cold spring forfit-up, as per drawing. RT & PT
S.7 External insulation except at field weld joint (wascompleted after system pneumatic test)
T. Combustion Air Duct & Stack
T.1 Completely install ducts after the Fans and AirPreheater is ready
T.2 Install stack and connecting flue gas duct to ID Fan Stack is castable lined on the groundbefore erection.(step U.2)
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ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE(TYPICAL)
No ActivitiesReferencedrawing Remarks/ Inspection Requirement
U. Castable lining / External Insulation on Convection Duct and Other Equipment
U.1 Castable and or ceramic fiber lining on transitionduct, convection duct
U.2 Castable lining on stack (if required)
V. Accessories
V.1 Install dampers, actuator, flexible joint, manholes,peep doors, etc.
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ATTACHMENT-2
FIELD WELDS FOR REFORMER SYSTEM (TYPICAL)
No. Base Material
Filler metal
(Brand name orequal)
QTY
1 101-B Radiant Coil (For 1 set of coil)
1.1 Outlet manifold:
RP3 (KHR32C) to RP4 (KHR32C)
ERNiCrCoMo-1
(Inco 617)
2 butt welds @
8 NPS x 32 mm.thick
See E99C-108-7
1.2 Riser transition
RF9 (SB408-UNS NO8811) toRF12 (SB564-UNS8811)
Inconel 617 1 butt weld@
6NPS x 16.2 mm.
Dwg. 210- D105
1.3 Outlet Manifold. Drain connectionRP 12 (SB407)
ERNiCrCoMo-1
(Inco 617)
1 butt-weld
1 NPS Sch. XXS
1.4 Outlet manifold. Thermowell,RP13 (SB407-NO8811)
ERNiCrCoMo-1
(Inco 617)
2 butt welds
NPS Sch. 80
1.5 Outlet manifold. thermowell/drain pipe sleeve,
RP4/RF2 (KHR32C) to TP 310
ERNiCrCoMo-1
(Inco 617)
3 welds
4 NPS Sch.XXS
1.6 Inlet nozzle to inlet pigtail
TP 304H to TP 304H
ER308H Socket weld
1 NPS Sch. 40S
Cardboard gasket1.5t, alloy verified,PT
1.5 Pipe saddle to inlet manifold
304H to 304H
E308H 1 joint
1.6 Outlet manifold drain
TP 310 to piping
By piping
2 Riser Transition Assembly
(for 1 set)
2.1 Riser transition to 107-D TransferLine SA 106 Gr. B
16 NPS Sch.40 See dwg. 407-D6/210- D105
2.1.1 Step #2 , Riser internal sleeve(RA3) Incoloy 800 HT to Incoloy800 HT
ERNiCr-3
(Inco 82)
1 fillet joint
141.3 x 6.55 t.
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ATTACHMENT-2
FIELD WELDS FOR REFORMER SYSTEM (TYPICAL)
No. Base Material
Filler metal
(Brand name orequal)
QTY
2.1.2 Step#3 detail A
Effluent Chamber stub to Riser,SA 105 to RP14 (SA106 Gr B)
ER 70S-2, E-7018
1 butt-joint
141.3 x 6.55 t
2.1.3 Step #5 part 3
Incoloy800HT to Incoloy 800HT
ERNiCr-3
(Inco 82)
2.2 Non-pressure part
Riser Transition water jacket to
nozzle, RA6A (A283 Gr. C) toRA11 (STPT410)
ER 70S-2
(TGS-50)
1 fillet joint
2.3 Riser Transition Insulation Can
Incoloy 800HT / Inconel 601
Inconel 617 1 lot Dwg. KBR
210D104
3 101-B Inlet Manifold
3.1 Inlet Manifold to Cross Over Pipe,304H to 304H
ER308H, E308H 4 Butt welds, 8NPS Sch. 80S
Alloy verified, RT,PT
3.2 Inlet Manifold to inlet pigtail
304H to 304H
ER308H Socket weld
1 NPS Sch.40S
1.5 mm thickcardboard gasket,alloy verified, RT,PT
3.3 Cross Over Pipe, horizontal
XP1 (304H) to XF1 (304H)
ER308H, E308H 2 @ 14 NPS, Butt-weld
Alloy verified, RT,PT
3.4 Cross Over pipe, vertical
XF3 (A 182-F304H) to XP2(A312-TP304H)
ER308H, E308H 4 @ 8NPS,Butt-weld
Field fit-up
Alloy verified, RT,PT
3.5 Cross Over to Mixed Feed Coiloutlet header, A 403 Gr. WP304H
to 304H
ER308H, E308H 4 @ 14 NPS, Butt-weld
3.6 Strut, A 312 TP304H 4 @ 3 NPS Sch. 80
4 107-D Effluent Chamber
4.1 107-D to 107--D pressure shell
Joint #1
E-7018 or
ER70S-2 & E 762 OD x 16 t.
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ATTACHMENT-2
FIELD WELDS FOR REFORMER SYSTEM (TYPICAL)
No. Base Material
Filler metal
(Brand name orequal)
QTY
SA 516-70 to SA 516-70 7018
4.2 107-D internal sleeves
Incoloy 800HT to Incoloy 800HT
ERNiCr-3
(Inco 82)
(= 816oC)
4.3 107-D internal sleeve to 103-D
Incoloy 800HT to Incoloy 800HT
ERNiCr-3
(Inco 82)
(= 816oC)
4.4 Joint #2
SA 516-70 to SA 516-70
E-7018 or
ER70S-2 & E
7018
762 OD x 16t
4.5 Cap weld, seal weld plug ER70S-2/E-7018
4.6 107-D water jacket E-7018
5 101-B Convection Coils
5.1 Mixed Feed gas outlet header toCross Over pipe
304H to 304H
ER308H, E308H 14NPS, butt-weld Item 3.5
5.2 Hot Steam superheater coil. Jump-Over pipes SA 335 Gr P91 to SA234 Gr WP 91
ER80S-B8/E8018-B8
28 butt-weld @114.3 OD x 11.1 AW
Field fit up. Argonbacking. PWHTmachine reqd
5.3 Cold Steam Superheater. Jumpover pipes. SA 335 Gr. P91 to SA234 Gr. WP91
ER80S-B8/E8018-B8
28 butt-weld @114.3 OD x 11.1 AW
Field fit up. Argonbacking. PWHTmachine reqd
5.4 Coil headers connections in/out By piping
6 103-D Secondary Reformer
6.1 103-D transfer line to 101-C
A 516-70 to A 516-70
ER70S-2 & E
7018
6.2 Process Air Inlet By piping
6.3 103-D transfer line to 101-Cinternal sleeve
Incoloy 800HT to Incoloy 800HT
Inconel 617 orInconel 117
6.4 103-D top liner cover ERNiCr-3
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ATTACHMENT-2
FIELD WELDS FOR REFORMER SYSTEM (TYPICAL)
No. Base Material
Filler metal
(Brand name orequal)
QTY
(Incoloy 800 HT plate) (Inco 82)
6.5 103-D Dome support cutouts
Incoloy 800HT
ERNiCrMo-1
(Inconel 617)
6.6 Pouring port patch plate
Incoloy 800HT
ERNiCr-3
(Inco 82)
6.7 Water Jacket & Platform
CS
ER70S-2 or 6/E7018
7 101-C & 102-C 301-D01/D05
302D01/D05
7.1 101C to 102-C, press. shell.
A516-70 to A516-70
ER70S-2 & E7018
813 OD
7.2 101C to 102-C, liner sleeve
6t Inconel 601 plate
Inconel 617 orInconel 117
546 OD x 6t Parts of sleeve areship loose, to besite fab.
7.3 101-C gas outlet, cold bypass
SA 335 P11
By piping
7.4 102-C gas outlet, hot by-pass
SA 335 P11
By piping
7.5 102-C Gas outlet, main
SA 336 F11
By piping
7.6 Cap weld and plug
SA 105 / SA 234 WPB
After refractoryfilled
7.7 Water Jacket 102-C
SA-283-C
ER70S-2 or 6/E-
7018
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ATTACHMENT-3
PRIMARY REFORMER SCHEDULE
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ATTACHMENT-4
SECONDARY REFORMER FIELD WORK (TYPICAL)
4.1 Sequence of Work
Work description Reference Responsible party
1 103-D, vessel installation and weld ofwasher
403-D3, DetailL
Heavy lift and mechanical contractor
2 Platform and Water jacket 403-D7 Mechanical
3 Opening of top head (MH#1) andbottom cover
403-D1;
D4 Detail I
Mechanical
4 107-D installation and welding, shelland sleeves
403-D5 Mechanical, in sequential order withrefractory work
5 Water piping to/from 103-D WaterJacket Piping
6 Ring plate (Incoloy 800HT) weld at gasoutlet to 101-C
403-D, Detail B Mechanical, tack weld prior pouring,finish weld after dry-out
7 Refractory lining, 1st & 2nd batch 403-D1; D8 Refractory contractor
8 Welding of pouring patches 403- D6 DetailA
Mechanical, before lining of topsection
9 Refractory lining top section 403-D1; D6 DetailA; D8
10 Remove CS shroud
Cut-outs weld (dome support), Incoloy800HT plates
403-D4, Detail
F
Mechanical, after lining
11 Support brick installation, 403-D8 Refractory contractor, before dry-out
12 Dry-out Refractory contractor
13 Top liner cover (MH#1) weld, Incoloy800HT plate
403-D4, DetailA
Mechanical, after dry-out
14 Dome brick installation, 403-D8 Refractory contractor, using Woodentemplate supplied by vendor
15 103-D gas outlet transfer line (pressure
shell and liner sleeve) to 101-C
403-D5, Detail
B
Mechanical, in sequential order with
refractory work16 Air Piping welding Piping contractor
17 Air inlet insulation, with high tempwater proof caulk
403-D5, detailD
Insulation contractor,
18 Alumina ball 50#, 25# 403-D8 Refractory, after lining and domeinspection,
19 Catalyst loading 403-D8 Mechanical
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20 Circle brick and hexagonal tiles 403-D8 Refractory
21 Mixing chamber & top cover install 403-D8 Mechanical contractor, after lining thecover with ceramic fiber by refractorysubcontractor
22. Install bottom opening
4.2. Refractory Work
Work Description Remarks
A. Preparation
Store castable in cool & dry air As soon as the material arrives at site, they are tobe unloaded from container and place in thewarehouse with good ventilation and dry. Ifrequired an air conditioned warehouse to beprovided to store this material
Check and remove damaged bags and lumpymaterial
Check if spare is enough
B Surface Preparation
Provide working platform and necessary supportinside vessel
Steel frame with wooden plank
Sand blasting/power brush & internal cleaning Seal all thermowell openings with wooden plug
Sleeves to be covered with cardboard, cover allanchor tip with plastic coat as per drawing
C. Drop forms installation
Paint/coat form steel with form coating (Nox-Crete)
Steel forms to be applied by refractorysubcontractor based on Supplier drawing
Check if thermowell and liner sleeves are coveredwith cardboard as per drawing and anchor alreadywith cellulose acetate coat/shellac varnish
Install & tack weld sleeve/ring plate (#6) By mechanical contractor
Install forms as per drawings
Forms can be tack welded to CS shroud (403-D4,F)
Check for required space between forms and theshell (the required thickness of castable lining)using gauge
Check and adjust level/height of forms on eachrow and compare against drawing. Use woodenshim to adjust level or height of forms
Check if Pouring ports can be closed easily
Check for any foreign object left inside the form
D. Perform trial run, after all equipments are ready
Prepare and dry run equip. and tools See list of equipment & tools required
All equipment was set as per approved planning
Perform sample test Mix castable with 3 different water content,measure flow ability using timer. Select whichwater content to be applied.
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4.2. Refractory Work
Work Description Remarks
Perform trial operation Measure time required from start of castablemixing until castable is in drum*) and hopper iswashed ready to receive castable mix (1 cycle)
E. Lining Work
Lining will be done in 3 stages:
Below the dome support
Above dome (catalyst chamber) to mixingchamber, approx. 100 Tons
Above mixing chamber, after patch weldingand sleeve installation (by mechanical)
Target is 500 kg. in place within 5 minutes1) orless. With 100 tons of castable to pour, therequired time will be 17 hours continuousoperation
The above time is estimated by assuming thatmixers will be located on ground and castable mixis lifted by crane. Less time (13 hours) may beachieved if mixers are set directly above the vesseltop opening, reducing time required for lifting by1 minute or 500kg in-place in 4 minutes.
Vibration must be applied during castable pouringwork to remove air trapped in the castable butcare not to cause excessive segregation of castabledue to prolonged vibration. As much as possibleuse all openings provided on steel form to insertvibrators.
1) This target is subject to changed based on
actual flow test as per para 4.5.4. of KBRsspecification D11-1TS-7943
See Supplier lining procedure for details.Subcontractor to prepare detailed planning forContractor approval
Check items before each batch:
Water cooling is available and circulatinginside water jacket
Blower is running and temperature insidevessel is normal/cool
Steel cone feeder is easily operated anddismantled
Castable are placed in shade and in coolcondition and the packing is in goodcondition
Back up power for mixer, vibrator, lighting isavailable and tested
Vibrators are working properly
Tools are available within arm reach
Clean water for the mix is acceptable, sourceis secured.
Ice is available and acceptable
Enough skilled manpower for 3 shifts
4.3 Equipment For Lining Work
Lining work shall proceed continuously until it is completed. No cold joint is permitted. Therefore it is mandatory forinstaller to provide back ups to avoid interruption due to mechanical or power failure. All equipment shall be in goodworking condition for 24 hour continuous operation
Mixing & Lining
1 Mixer, 2 ea. Paddle type, 16-30 rpm min. withmotor 20 KW, bottom opening, cap.250 kg castable ( 1250 od x 440 h)min.
Need power supply and temporaryelec. panel
4 Pouring hopper ; Pouring hopper size to fit vessel topopening, its outlet to fit cone-shape
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4.3 Equipment For Lining Work
cone shape steel funnel,20 m length min. or vinylchloride 175 od x 20 mflrxible hose;
chute for pouring port(for flex. Hose) and
deflection chutes
funnel,
Cone-shape funnel are hold togetherby bolt but should be easily dis-asssy to adjust height of pouringposition
5 Steel form 3 sections: upper, catalyst bed andbottom section
Supplied by Vendor
6 Pneumatic needle vibrator,40 mm OD
2 ea. with long enough hose to aircompressor, 12 000 rpm min.
Need source of compressed air
7 Electric Vibrator, (optional) 2 ea, form vibrator, 12 000 rpm min. Need power supply and temporarybreaker
8 Shovel, trowel As required
9 a. DC Lamps; Flash light;
b. Emergency lamps
3 @ 12 watt; 3 sets
2 sets, portable
Minimum requirement
10 DC battery operatedintercom
For coordination between s/v in theoutside with s/v in the inside ofvessel
11 Working platform formixing with steel roof
covered with waterprooftarpaulin
To accommodate two mixers,working in tandem. for 16 people
and 4 crate of castable (3200 kg)
At top opening level
12 Temporary storage at filed To accommodate 20 crates or morecastable, with waterproof cover
13 Water bucket 6 @ 30 liter
14 Ice container 1 m3, made from plywood withinsulator
15 Water pump 2 ea, cap. 10 liter/minutes
16 Drums for icy water 2 @ 100 liters for icy water,
1 @ 100 liters on top of vessel for
cleaning the chute and funnel17 1 water hose As required
18 Exhaust fan, heavy duty 2 sets with Inside of vessel
19 Electric cable withreceptacles
For lamps, vibrators, blowers; 200m.
20 Electrical Panel completewith switches and breakers
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4.3 Equipment For Lining Work
21 Cover sheet, tarpaulin 1 lot
22 Flow Test table, ASTMC230 1 ea For checking consistency,
ASTM sample forms 3 sets For production samples
23 Test hammer 1 ea min.
24 Measuring glass 1 ea, 5 liter
25 Steel ruler 2 @ 2.5 meter
26 Timer 1 ea
27 Thermometer 1 ea
28 Coating material Nox-Crete, 1 can
29 Poly ethylene film 0.2 mm x 1.8 mm. x 25 m
30 tapes As required
Material Handling and Back-up
1 Forklift, 1.5 ton 1 ea. for material handling, 1 ea. forcastable mixing operation
2 Crane 70 T, with beam able to lift material tothe top of vessel (30 m)
Include. 1 standby
3 Light truck 1 for material handling
4 Air compressor 2 sets, for vibrators, cap. ? Include. 1 standby5 Diesel Generator 2 cap.400A Ac/DC, for power and
for weldingInclude. 1 standby
7 Water truck 1
Others
2 Disk Grinder with enoughcup wheel
Min. 2 sets,
3 Wrenches Min. 2 set, For steel forms bolting
4 Winches 1 set For steel form assy6 Diamond cup wheel Min. 4 blades, 6 /8 dia. For brick cutting
7 Jig saw, complete withblade
1 ea jig saw, 10 blades
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ATTACHMENT-5. CERAMICFIBER MODULE (TYPICALEXAMPLE)
The module is an accordion-foldedblanket module that uses either 304SSor 310SS hardware and anchoringsystems. Two grades of ceramic fiberblanket: HP (high purity) grade andHZ (zirconia) grade are normally usedin reformer, in standard thicknessesfrom 6 inches to 12 inches and in 128kg/m3and 160 kg/m3(8 and 10 pcf)densities.
Spun Ceramic Fiber Module Physical Properties
Ceramic Fiber Module SpecsHigh-Purity Grade
Blanket
ZirconiaGrade
Blanket
Color White White
Maximum Use Limit 1260C (2300F)1426C(2600F)
Continuous Use Limit 1100C (2012F)1350C(2461F)
Standard Density, pcf (kg/m3)8, 10 (128, 160)
8, 10 (128,160)
Standard Sizes, inch (mm)12 x 12 (305 x 305)
12 x 12 (305 x305)
Standard Thickness, inch (mm) 6 - 12 (152 - 305)6 - 12 (152 -
305)
Spun Ceramic Fiber Module Chemical Composition
Chemical Contents High-Purity GradeZirconia
Grade
Al2O3 47% - 49% 39% - 40%
SiO2 50-52% 38-45%
ZrO2 - 15-17%
Fe2O3 0.2% 0.2%
K2O + Na2O 0.2% 0.2%
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ATTACHMENT-6
DRYING-OUT 103-D SECONDARY REFORMER
Drying Out Equipment:
Maker: Mannings Thermal & Environmental Engineers, UK
Burner type: nozzle mix high velocity gas burner, with turndown ratio 50:1; with separateburner control module
Burner capacity: 30 MM Btu/hr
Blower type: 11 KW Air Fan, fixed speed, 6 flexible duct, ref no: 99928
Blower capacity: 310,000 SCFH max.
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Burner Set Up(dimension in cm)
Note:
T1 : skin temperature of bottom manhole liner sleeveT2 : gas temperature at bottom sectionT3 : gas temperature at outlet stackT4 : surface refractory temperature below domeAT, BT: gas temperature at main area of vesselMT: metal temperature at top (MT1,2) and bottom (MT3,4)
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ATTACHMENT -7.
101-B CATALYST LOADING
Preparation
Tube opening to be covered with plywood at all times, except during loading, to prevent foreignobject from entering the tube
Temporary shelter will be prepared to accommodate catalyst screening, weighing and bagging.
Tube Inspection before Loading Work
Inside cleanliness, particularly bottom grating.
Pressure drop of empty catalyst tubes
Dimensional check of empty tubes (height from bottom to top flange)
Catalyst Charge
1000 mm long, 100 mm ID of pipe is used as measuring bucket. Fill the measuring bucket with catalyst
up to top of pipe and record weight of each measurement.Catalyst charge will be as the following:
Upper portion, Synetic 25-4
Lower portion, Synetic 57-4G
Target height is as shown in Attachment-1
Preliminary result of measurement indicates weight of catalyst is 6.5 kgs (0.83 kgs/ltr) and 7.2 kgs(0.92 kgs/ltr) for lower (Synetic 57-4G) and upper portion (Synetic 25-4) respectively.
Total charge of catalyst for effective height of each radiant tube will be as follow:
Synetic 25-4 Synetic 57-4G
Weight (kgs) 33.0 44.5
Height (mm) 4567 6851
Volume(ltr) 35.9 53.9
Effective catalyst volume of total tube is 20.1 m3 (0.0897 m3/tube) with additional Synetic 25-4 ofapprox. 1.2 m3 to top level.
Catalyst Loading Plan
Lower portion will be loaded in 6 incremental charges each equal to 7.4 kgs
Upper portion will be loaded in 4 incremental charges each equal to 8.2 kgs
However actual weight of catalyst loaded to last section of each portion will be adjusted to therequired height.
Weighed catalyst for each incremental loading section will be filled into loading sock; record actualweight of the catalyst on each sock.
Loaded socks will be put inside drum and properly protected from direct sun and rain water, readyfor loading work
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Catalyst Loading Sample
Two (2) tubes will be loaded fully (after measuring dP and height of empty tubes) in order to get valuesof:
time to vibrate the catalyst,
actual load density,
target and variation on bed pressure dropThese figures are used as reference during the loading work of the remaining tubes.
Inspection & Measurement During Catalyst Loading
Each measurement will be recorded in format as shown in Attachment-2 Actual weight of catalyst for each incremental charge and total of each portion Outage of catalyst before and after vibration
Pressure drop measurement after each sectionloading.Acceptance
Catalyst bed height: aver. Ht + 100 mm Ht = total bed height
Pressure drop: aver. Pt + 5% P t = total press drop
Primary Reformer Loading
Tube ID 100,1 mm ID = 85,4 mm Note 3
Msw 12,0 mm
Tube length (eff) 11.418 mm
Tube Length (ovearl l 11.531 mm
Tube per row 56 KATALCO 25-4
Number of rows 4 600 mm
Total tube nos. 224
KATALCO 25-4
4567 mm ID = 100,1 mm(40%)
KATALCO 57-4G
6851 mm
(60%)
Notes:
Effective catalyst volume = 20,1 m3. Total catalyst volume 21,3 m3
Dimensions given on this sketch are for catalyst loading purpose only.
Maximum Weld portrusion = 3,0 mm. Therefore, maximum OD for catalyst "socks" is 79,4 mm
OVERALLCATALYSTTUBE
LENGTH
11531mm
12,9
63mm
6112mm
944 mm
100 mm
EFFECTIVECATALYSTTUBE
LENGTH
11418mm
UNDERSIDE ARCH EL. 114863
Catalyst
Retainer
TOP OF CATALYST
FACE OF FLANGE EL. 116408
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ATTACHMENT-8.
PENGELASAN CAT. TUBE OUTLET MANIFOLD
Timing
Welding was performed after the following works were completed:
61-101-B Radiant Box roofing is completed
61-107-D Effluent Chamber was installed with springs and levelled
Catalyst tube springs already installed and levelled
Welding of 61-107-D extension piece with 61-103-D gas inlet nozzle
Sequence
Welding on radiant harps was progressing in the following order:
Riser transition assemblies were set and welded to 61-107-D Effluent Chamber gas inlet stub
Welding of outlet manifold between inner and out harps section.
Welding of risers to riser transition assemblies
Welding of thermowell and drain sleeves
Welding of inlet pigtails to catalyst tubes and Inlet Manifold
Procedure
Riser Transition Assembly to Effluent Chamber, pressure part
Check position of Effluent Chamber stub end, should be within tolerance set on drawing
Insert Incoloy sleeve to Riser Transition Assembly and weld
Fit up the Transition Assembly to Effluent Chamber stub end and weld
Outlet Manifold, outer to inner harp
Springs position must be on centreline
Outlet manifold must be levelled, adjusted by spring
All temporary attachment must be removed, except for riser which must be hold to keep centered
Insert soluble paper into outlet header for argon blanket
Perform PT on bevelled end to ensure no crack and other irregularities
Fit up outlet manifold and keep the pipes straight during welding by jig
Argon gas was introduced from catalyst tube top flange
Perform root pass welding followed by penetrant test. Welding must be performed intermittent indifferent place so as to maintain steel temperature and straightness of the manifold.
Final pass must be penetrant and radiographic tested
See attached pictures.
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Riser to Riser Transition
Both ends must be penetrant test to ensure no surface defect
Radiant harps must be position to the required height by adjusting springs turnbuckle until bothends are within fit up tolerance
Keep outlet header in level position
Fit up and maintain by jig
Introduced argon gas from Effluent Chamber
Weld intermittently such as to keep plumbness of the riser
Root pass is penetrant tested.
Final pass is penetrant and radiographic tested
Inlet Pigtail to Catalyst Tubes and Inlet Manifold
After inlet manifold and radiant harps welding is completed
Trial fit up to ensure position is match
Provide space of 1.5 mm inside sockolet for tube thermal expansion. Check carefully that thespace is maintained before pigtail can be tackwelded. Preferred way to do is by using 3 mmcardboard gasket placed inside the sockolet before pushing the pigtail in.
check weld contour and penetrant test the weldment
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ATTACHMENT-10.
PICTURES
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Gambar-1. Instalasi Convection Coil
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Gambar-2. 101-BL Air Preheater
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Gambar-3 Riser & Insulating Can
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Gambar 4. Sekuen pekerjaan mekanikal & refraktori di seksiReforming
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Gambar-5. 103-D Dome Brick
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