OFz-320 boiler Mersin

Dry-Out and Heating-up instructions

For the refractory linings of CFB boiler with accessories

Rev.01

OFz-320 boiler Mersin

Based on
 Dry-out and Heating-up instructions
OFz-320 boiler Mersin

Content

1 Dry-out............................................................................................................................................. 3
1.1 Dry-out..................................................................................................................................... 3
1.2 Boiler readiness ....................................................................................................................... 3
2 Dry-out charts.................................................................................................................................. 4
3 Dry-out during initial Heating–up (option)...................................................................................... 4
4 Breaks .............................................................................................................................................. 5

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 Dry-out and Heating-up instructions
OFz-320 boiler Mersin

1 Dry-out
This document is based on refractory supplier instructions – Calderys.

1.1 Dry-out
The dry-out of the CFB Boiler is to be considered as a separate process prior initial heating-up. The
dry-out process will be executed at ambient or operation pressure. A temporary protection of the
plant unit against inclement weather is required and has to be decided before starting the process.

The Startup burners to be used for the dry-our process has to enable well controlled rise of
temperatures, holding certain temperatures for a certain time period and protection of the
refractory linings for too rapid temperature increases and local overheating.

Before starting the dry-out it must be sure that the setting and hardening of all refractory
components have been completed properly. For this reason the refractory linings have to get an air
curing of at least 24 hours at ambient temperatures to be considered of at least +5°C. The refractory
lining has always to be protected against water penetration such as rain, Demi water etc.

Dry-out will be performed by 6 Start-up burners installed on side walls of the combustion chamber.
The inert material delivered from other CFB boiler will be used for better heat distribution
throughout the boiler (combustion chamber – cyclones – siphons – return tubes etc.).

1.2 Boiler readiness

Is expected that dry-out will continuously pass to blow-out process therefore all necessary systems
for operation must by checked, tested and ready for safe boiler operation.

Fuel (natural gas), Demi water, electricity, ash, instrument air etc. will be provided for continuous
operation without any interruption. Boiler will be filled-up by Demi water and tightness test of boiler
pressure part should be done before ash will be loaded to the combustion chamber. All hangers’
locks will be removed after tightness test.

For the dry-out process the CFB boiler will be ready for operation at least in following requirements:

- Drainage and vents are ready for operation

- Boiler protection were checked and tested
- Start-up burners are ready for operation
- Funs, blowers are ready for operation
- Needed measurements should be in operation (drum level, water-steam and flue-gas
temperatures, air flow measurement, feed water and injection flow measurements, pressure
measurements etc.)
- At least one layer of insulation is installed and hot parts are protected against injury
- External and internal ash system should be ready for ash loading, discharging from the boiler
before and during dry-out. Amount of ash should by according boiler manufacture operation
instructions. Emergency ash discharging should be ready in case leakage on pressure part will
occur during dry-out process.
- Scaffoldings and construction material interfere operation should be removed

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OFz-320 boiler Mersin

2 Dry-out charts
The heating-up and cool down rates as well as hold temperatures should be followed as strictly as
possible. It has to be made sure than on the average the specified heating-up and cool down rates
respective hold temperatures are maintained for several hours.

As reference dry-out temperature is taken temperature measurements at the pass between

combustion chamber and cyclones. During boiler trip the flue gas temperature measurement and
thermal shock for refractory is not as significant as indicated by measuring the temperature of flue
gas.

3 Dry-out during initial Heating–up (option)

In case the refractory lining is to be dried during the initial (First) heating-up of the unit the following
curve should be maintained (according Calderys instructions):

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 Dry-out and Heating-up instructions
OFz-320 boiler Mersin
The holding time at 150 °C for min. 12 hours should enable water vaporization from the refractory.
The holding time at 300 °C for approx. 20 hours should enable complete vaporization of the co called
unbounded water.

The holding time at 600 °C for approx. 7 hours should finalized upper layer of dry-out process.

Produced steam will be vented through temporary pipe to the silencer.

This schedule should also be applied in case of major repairs at the refractory linings.

4 Breaks
Should a break happened during the process before dry-out and heating-up are completed, the
following heating-up needs to be applied:

- Dry-out heating up rate 25°C/h

- First start-up after dry-out is completed – heating up rate 50°C/h
- Normal operating – heating up rate 80°C/h

The above mentioned rates can be applied without any holding periods up to temperature range
monitored before the break. Breaks during holding periods require repetition of that holding period
where the break happened.

In case re-condensation due to interruption of dry-out process for long time will take place the
process has to be re-started again.

NOTES FROM MEETING ON 5.10.2016

Calderys supervisor will be observing the whole dry-out process from beginning to reaching up to
operation temperature of the boiler.

Calderys supervisor may change the dry-out curve.

There are 4 regions in the boiler which have the temperature measurements. Unless the
temperature differences between these regions are too high (to be assessed and decided by Calderys
supervisor) the temperature-time diagram which stated above will be followed based on the
measurement on region 2.

If Calderys supervisor decides that difference between regions are high, then another holding point
(constant temperature inside the furnace chamber for a defined time period) will be added to the
temperature-time diagram.

The temperature may increase in the furnace chamber rapidly up to 50 Celcius degree in the
beginning. After this temperature, the curve must be followed with start-stop of the burners to keep
the average temperature.

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 Dry-out and Heating-up instructions
OFz-320 boiler Mersin
The dry-out will start with the lower capacity burners on the front wall area. Later, according to need
other burners will supplement the firing.

A slower gradient than 20 Celcius per hour may be followed during the first heating period up to 150
Celcius. This is better to eliminate any risk due to sudden heating of surface during start-stop of
burners.

An inspection of the refractory surface area after completion of combined Dry-out and Blow-out
processes together with representatives of Calderys, Efor, Rafako and Soda.

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OFz-320 boiler Mersin

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OFz-320 boiler Mersin

ADDITIONAL NOTES AND LOG DURING DRY-OUT

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OFz-320 boiler Mersin

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