SUATU BEKAS YANG TERTUTUP YANG DIGUNAKAN UNTUK MENJANAKAN STIM PADA TEKANAN YANG MELEBIHI TEKANAN ATMOSFERA TERMASUK PERALATAN SUPERHEATER & ECONOMIZER SERTA KELENGKAPAN LAIN YANG ADA DIPASANG KEPADANYA.
BBB / SHMS
AKTA = Undang-undang
PERBEZAAN ISTILAH
- Akta dibincang diperingkat Parlimen
- Terhasil dari akta & dibuat oleh JKJ Rules = Hukuman / Penalti
-Undang-undang melibatkan misconduct
OSHA 94
1. What is OSHA 94 - New act - Occupational Safety & Health Act 1994
OBJEKTIF OSHA 94
1. Memberi / Melindungi Keselamatan pekerja
- Kesihatan pekerja
- Kebajikan pekerja 2. Melindungi orang luar kpd Hazard di workplace 3. Suasana pekerjaan yg diperlukan dari segi psychology pekerja & kehendak psychology 4. Mempunyai sistem keselamatan & kesihatan pekerjaan yang berasaskan undang2 & kod industri yang praktik dimana ianya berkombinasi dengan data.
BBB / SHMS
1. Nama
4. Tempoh
5. Jenis Boiler 6. HS
- Heating B/Minyak
- K/plant - Press
BBB / SHMS
-BST
HS ? Perlukan ?
1. Visit 2 x /bulan
TUGAS VE
2. Report & submit to JKKP sblm end of each month 3. Accompany during any JKKP inspection
4. Inspection
Initial Ins. Plant / unit baru - Regular / annual Ins. 15 or 12 bln
- Commissioning SB
- Boiler Failure - Further Ins. Datang dgn notis utk periksa samaada
BBB / SHMS
3. No. pendaftaran
4. Nama Pembuat 5. S/N 6. Nama boiler & Jenis WTB / FTB 7. HS = m3 & ft2
8. Nama Insp.
* Tempoh 15bln + 3bln + 3bln * Permohonan lanjutan 1 bulan sblm tamat
BBB / SHMS
- (Surat, CF asal, lap opr, lap main, lap W threatment, NDT & aktiviti kslmtn)
Conversion Table
Kpa = Psi x 6.895 m2 = ft2 x 0.093 lb = kg x 2.205
OC
BBB / SHMS
= I.8(OC) + 32
Jenis Boiler
1. WTB Air bergerak dalam tube manakala flue gas dari furnance ke bhg luar yang bersebelahannya 2. FTB - Flue gas dari furnance mengalir dalam
baru FTB.
4. Electrode boiler Heating guna elektrod
BBB / SHMS
- Chemical Reaction
3. Jenis Pembakaran Direct - Waste Heat boiler
BBB / SHMS
3. Superheater Tube
- Material High Carbon Steel
BBB / SHMS
1. Flaring (expand)
Pemasangan Tube
2. Welding
3. Forging
BBB / SHMS
Steam Theory
N = Sifat2 stim & air sama terjadi pada P = 3200psi T1 = T2 = Evaporatif temp. (300oC dalam sawit) T3 > T1 = T2 Degree of fraction = 1 / (1-x) where x = wet steam
Wet steam =Wap air yg masih bersentuh dgn air pada T sama
Dry steam = Wap yg tidak mengandungi cairan & susah
BBB / SHMS
dipanaskan
Heat Transfer
3 Kaedah
1. Sinaran
2.Konduksi 3.Olahan
BBB / SHMS
SB Water Circulation
OBJEKTIF 1. Better Heat Transfer 2. Cooling system for SB 3. Better chemical reaction
BBB / SHMS
4. Better BD
BBB / SHMS
Essential Fittings
4V 2 SV (HS < 100ft2,1)
- MSV - BDV
2G PG
- Insp. Test att.
- FCV
5W 2 Feed Pump (HS < 150ft2,1) - Fusi Plug - 2 WG (Eva < 300 lb/hr,1)
2P Name Plate
- Regis. Plate
- LW Alarm
SV
Punca-punca SV Blow 1. 2. During Steam test Setting SV
3.
4. SET SV 5.
1.
2. 3.
WP + 5psi
Between 1 & 3 ASWP BBP
STARVATION SV drum blow dulu sehinggakan stim tak supply ke SH Overheating pada SH tube
PG
BBB / SHMS
PG Accessories
Tester use for checking PG accuracy
Siphon
(Utk elak kerosakan PG dgn keadaan air dlm sifon / Tiada direct stim ke PG)
BBB / SHMS
5. DC elak
Thermal shock
6. Follow diagram
Test WC keluar steam Emergency Shutdown
BBB / SHMS
WHEN
Sblm Start
Pertukaran shift
Selepas shutdown (normal / emergency)
BBB / SHMS
BDV
1. Tujuan Tomaintain boiler water Quality 2. P.O.M TDS / hareness, Petro Si 3. Type Continuous BD (Auto) - Intermitent BD (Manual ikut spec W)
Fusible Plug
1. OBJ Early protection utk elak SB part out 2. Letaknya WTB, 3in bwh LWL - FTB, 3in atas tube teratas 3. < 2 thn tukar sbb regulation
MSV
1. Letak Top upper drum / SH Header
2. Direct & sudut tegak 3. OPR Time Selepas SV blow & drop kpd WP - Cara buka Manual, Buka sikit dulu + 50psi utk ada hair crack
pipe
- S/H drain
1. Purging (10-15min) utk discharge explosive / flamable gas by start stop ID fan (-ve P) 2. Masuk Feul + Start firing 3. Tutup Furnance door 4. Pasang FD, FJ & SSB Fan 5. Buka damper ID Fan & Ash pit door (Create natural draft & then assign by FD Fan)
6. A/p steam keluar dari air vent, tutup air cock & rise P Follow 0-50psi 45min 50-200psi 7. Buka MSV pada WP 45min 200 300psi 20min
BBB / SHMS
1. Close MSV
Normal Shutdown
1. Close MSV
- Test WG satu lagi kalau LWL Emergency Shut down - Test WG satu lagi kalau OK
a. Close SC & WC
b. Open DC c. Normal stop boiler 2. Over Pressure - Close MSV bila pressure drop 3. SV tak blow a. Continue guna steam
Steam Test
- Upgrade / downgrade biler 3. Cara - Naikkan stim pada setting P - Tutup MSV
- Tutup FCV
- Tutup FP - Tutup BDV - Continuous Firing * Biarkan test 10min, P raise mesti < 10% opr 4. Safety Solid Feul SB W WL sbb SV blow WL drop
- Disconnect Alarm
HT
1. Time Commisioning - Setiap < 7 thn - Lepas repair yang libatkan strength - Permintaan Insp. pada SB yang dia tak dapat masuk 2. HT Pressure - HS < 100psi, 2ASWP - HS > 100psi, 1.5ASWP - Fitting, 2ASWP - Welded joint, 2ASWP 3. Holding time 20min dgn Zero P drop 4. HT tak berjaya, ASWP turun 5. Medium Air
BBB / SHMS
Simpan Boiler
1. Few Days Wet method Maintain SB Water Threatment - Maintain normal WL 2. <1bln Wet method Fully fooded with water - Keluarkan angin - Threated water with catalized NaS04 - Tujuan utk beri Alkali access 150ppm
Water Threatment
BBB / SHMS
PH = 6.8 7.5
Posfate = 30 50ppm
TDS = 1800 2000ppm Caustic Alk = 250 400ppm Silica = 100 200ppm Tot Hardness < 5ppm Cloride < 150ppm Fe ion < 2ppm
BOILER
BBB / SHMS
Boiler Operation
Feed water FEED WATER Corrosion Scaling
Over Heating
Furnance Explosion External loading Thermal Fatigue Faulty Equipment
Erosion
Pitting Caustic cracking
BBB / SHMS
Supervision fault
Pump Failure
No water supply Feed Water line failure
Flame Impigment
By pass Flue gas Restriction Flue Gas
THERMAL FATIGUE
Sudden start / stop To high fluctuation T
BBB / SHMS
Heavy shoot
Water hammer
Corrosion
Crack Buldging
Distortion
Cracking Pitting
Erosion
BBB / SHMS
DETAIL FAILURE
BULDGING 1. Hanya berlaku kepada - Boiler tube - Furnance Chamber
DETAIL FAILURE
CRACKING 1. Caustic Cracking Punca dari high caustic - Pecah antara boundry material - Pecah antara composition - Pecah antara mersentile / perlite
SAGGING & DISTORTION LWL Air kering, panas tetiba sejuk Scalling Overloading
DETAIL FAILURE
Improper set SV
Improper BD FURNANCE COLLAPS
BBB / SHMS
Furnance explosion
Sudden start / stop External / Internal loading
TYPES OF SCALE
- Si - CaSO4 - MgSO4
- FeCO3
- FeO2 3. Permanent hardness 4. Temp hardness
BBB / SHMS
- CA2+
SO42-
Mg2+
- CA2+ Mg2+
Cl2CO2-
Hardness
pH > 7 O2
Boiler Repair
TYPE Retubing Welding Patching Fitting replacement METHOD 1. Hantar report ke JKKP Date, Failure, Cause, sketching, CF & Proposal for repair. 2. Preparation for Inspection B/wall repair
1.
- Follow regulation 78, 76 & 79 FMA 67 2. Carry out hardness test (Brinell) pada buldging area & determine weakend point to cut.
Eclips
NDT
NDT Dye penetherant - Ultrasonic - Magnetic Particle Inspection - Radiography (X-ray) - Eddy Current
DYE PENETHERANT 1. Cuci surface dgn cleaner 2. Apply penetherant liquid & biarkan 3-10min (Merah) 3. Cuci penetherant di surface 4. Apply developer (Putih)
BBB / SHMS
Kelemahan Dye Penetherant Hanya surface crack Surface kena bersih & licin
5. Wait 15-20min
X Ray
Punca Cesium 137 - Cobalt 60 - Iridium 192 - Gamma ray
BBB / SHMS
1. WG
2. BDV
BBB / SHMS
3in atas
highest tube hala furnance
BBB / SHMS
2. Flue gas
3. Water circulation 4. Fusi. Plug
Fitting
1. FCV 6. Dearator 2. SV 3. SV 7. Air kok 8. PG
5.Auxillary line