Installation Procedure for Replacing an Existing Steam Boiler with an ATTSU HH-8000/16

Fire Tube Steam Boiler at AZZAWIYA OIL REFINING COMPANY, Benghazi Asphalt
Plant

1. Introduction:

This report outlines the comprehensive installation procedure for replacing an existing steam boiler with
a new ATTSU HH-8000/16 fire tube steam boiler at the AZZAWIYA OIL REFINING COMPANY's asphalt
plant in Benghazi. The project is managed by the contracting company AL-ITKAN. The detailed process
ensures the seamless integration of the new boiler, complying with safety standards and optimizing
performance, while simultaneously dismantling the old boiler.

2. Project Background:

The AZZAWIYA OIL REFINING COMPANY aims to enhance its operational efficiency by replacing an
existing steam boiler with the ATTSU HH-8000/16 fire tube steam boiler. AL-ITKAN, an experienced
industrial project management firm, is entrusted with executing the installation and dismantling process.

3. Pre-Installation Preparation:

AL-ITKAN initiates the project by reviewing the manufacturer's installation manual for the ATTSU HH-
8000/16 fire tube steam boiler. This manual provides specific guidelines for the installation process,
ensuring a clear understanding of requirements and procedures. Necessary permits and approvals are
secured from local authorities in Benghazi to adhere to regulatory requirements. Since the installation
and dismantling are taking place at the same location, thorough planning is essential to minimize
downtime and disruptions.

4. Site Preparation:

The site preparation phase involves careful assessment of the existing steam boiler's location. AL-ITKAN
ensures that the chosen installation site is suitable for the new ATTSU HH-8000/16 boiler and takes into
consideration the removal of the old boiler. Structural integrity, ventilation, clearance, and safety
measures are evaluated to ensure a seamless transition.

5. Boiler Dismantling:

The existing steam boiler is dismantled following strict safety protocols. AL-ITKAN disconnects all utilities,
including water, steam, fuel, and electricity, and carefully removes the boiler and associated
components. This phase requires coordination and expertise to minimize any potential impact on
ongoing operations.
6. Boiler Unpacking and Inspection:

Upon receiving the new ATTSU HH-8000/16 fire tube steam boiler at the Benghazi asphalt plant, AL-
ITKAN conducts an exhaustive unpacking process. This involves a comprehensive inspection of all
components, including valves, safety devices, fittings, and labels, to ensure they are in optimal condition
for installation.

7. Boiler Mounting:
Following ATTSU's manufacturer guidelines, the new boiler is securely mounted at the designated
installation site. Proper alignment and recommended clearances are adhered to, ensuring efficient and
safe operation.

8. Piping Installation:
The installation of water, steam, and fuel supply lines is executed meticulously, adhering to ATTSU's
specifications and local codes. AL-ITKAN ensures proper incorporation of expansion and contraction
loops to accommodate temperature fluctuations and prevent stress on the system.

9. Ventilation and Combustion Air:

Adequate ventilation and combustion air supply are essential for the safe operation of the fire tube
steam boiler.

10. Electrical Connections:

AL-ITKAN manages electrical connections, including control panels, pumps, fans, and safety devices, in
accordance with ATTSU's specifications. They follow provided wiring diagrams to ensure accurate and
safe connections.

11. Water Treatment and Plumbing:

ATTSU Deaerator works to stop corrosion and scale formation in order to ensure the steam boiler's
lifespan. To facilitate system maintenance and effective operation, plumbing components including
valves, gauges, and drain lines are precisely installed.
12. Safety Devices and Controls:
AL-ITKAN ensures the installation of essential safety devices, including pressure relief valves,
temperature controls, and flame safeguards, as per ATTSU's specifications. These devices are calibrated
for accurate performance and enhanced overall safety.

13. Testing and Commissioning:

The installation process transitions to testing and commissioning. AL-ITKAN conducts a hydrostatic test
to verify the new boiler's integrity, filling it with water to identify any leaks. Successful completion of this
test is followed by comprehensive operational testing to ensure that the ATTSU HH-8000/16 fire tube
steam boiler functions optimally. Calibrating controls, safety devices, and performance indicators fine-
tunes the boiler's efficiency.

14. Final Documentation:

Throughout the installation process, AL-ITKAN maintains meticulous records, including diagrams,
photographs, and test results. Documentation serves as a comprehensive reference for future
maintenance and auditing. AZZAWIYA OIL REFINING COMPANY receives essential documentation,
including the ATTSU manufacturer's manual, maintenance instructions, and warranty details.

Conclusion:
The replacement of the existing steam boiler with the ATTSU HH-8000/16 fire tube steam boiler at
AZZAWIYA OIL REFINING COMPANY's Benghazi asphalt plant reflects AL-ITKAN's meticulous approach,
commitment to guidelines, and prioritization of safety. This project optimizes the asphalt plant's
operations while adhering to safety, efficiency, and long-term performance standards, both for ATTSU's
equipment and local regulations.