Training -Reforming Section

PT INTI KARYA PERSADA TEKNIK

Ammonia Plant. Reforming & Waste Heat Recovery Section Training material r. basuki 1/3/2012

Training manual for IKPT Engineers on ammonia plant steam reforming and rrocess waste heat recovery section. Jan 2012

Daftar Isi

1.

2.

Introduction To Steam Methane Reforming & Waste Heat Recovery Section 1.1

Objective

4

1.2

Ammonia Plant. KBR Purifier Process vs Conventional SMR

4

1.3 Reforming dan Waste Heat Recovery 1.3.1 Objectives: 1.3.2 101-B Primary Reformer 1.3.3 103-D Secondary Reformer 1.3.4 107-D Effluent Transfer Line 1.3.5 Riser Transition Assembly

7 7 7 10 10 11

1.4

11

Objective

12 12

2.2 101-B Primary Reformer 2.2.1 Radiant Section 2.2.2 101-B Radiant Harps & Other Pressure Part 2.2.3 101-B Primary Reformer Transition Duct & Convection Section

12 12 14 18

2.3

101-BL Combustion Air Preheater

20

2.4

101-BJ Primary Reformer Induced Draft Fan & 101-BJ1 Primary Reformer Forced Draft Fan

20

2.5

107-D Effluent Transfer Line

20

2.6

103-D Secondary Reformer

21

2.7

103-D – 101-C Transfer Line

21

2.8

Pengelasan Heater Tube

21

2.9

Quality Control

22

Construction Plan 3.1

4.

Waste Heat Recovery Section

Construction Highlight 2.1

3.

4

Objective

24 24

3.2 Scope of Work 3.2.1 Instalasi 101-B Primary Reformer dan Peralatan lainnya 3.2.2 Installation of 101-B Associated Equipment 3.2.3 Instalasi 107-D, 103-D, 101-C dan 102-C 3.2.4 Welding Of High Alloy Radiant Harps, Stainless Steel Piping Component And Transfer Lines 3.2.5 Refractory Work for 101-B, 103-D, 107-D and Field Joints between 103-D, 101-C and 102-C 3.2.6 Dry-Out of Castable 103-D 3.2.7 Steel Erection & Refractory Lining of 102-B 3.2.8 Pre-commissioning 3.2.9 Others

24 25 25 25 25 25 26 26 26 26

3.3

27

Schedule of Work

Refractory & Dry-Out Work 103-D 4.1

Objective

27 27

5.

4.2 Refractory work 4.2.1 Penyiapan Material 4.2.2 Penyiapan Peralatan dan Platform Untuk Kerja 4.2.3 Lining Work 4.2.4 Pemasangan Supprot Brick dan Dome Brick

28 29 29 29 29

4.3

29

Drying-Out work

Precommissioning Work

30

1.

INTRODUCTION TO STEAM METHANE REFORMING & WASTE HEAT RECOVERY SECTION

1.1

Objective Memberikan pemahaman dasar sistem proses reforming dan sistem pemanfaatan panas buang dari reformer. Pengenalan singkat kompenen/peralatan yang membentuk sistem tersebut dan istilah/penamaan yang digunakan

1.2

Ammonia Plant. KBR Purifier Process vs Conventional SMR Purifier Process memiliki beberapa perbedaan yang mendasar dibanding proses SMR konvensional. Perbedaan yang utama adalah pada sistem pengaturan jumlah N2 yang dimasukkan dalam sistem proses yang diperlukan bagi pembentukan produk NH3. Pada proses SMR konvensional N2 masuk (sebagai udara) ke Secondary Reformer dengan jumlah yang terukur secara stoikhiometrik sesuai kebutuhan reaksi sintesa NH3 pada reactor Amonia. Pada sistem Purifier, N2 (sebagai udara) masuk ke Secondary Reformer dalam jumlah yang berlebih karena pada dasarnya yang dipentingkan adalah kebutuhan O2 untuk reaksi oksidasi sisa gas alam yang belum terengkah di Primary Reformer. Pengaturan kebutuhan N2 secara stoikhiometrik untuk reaksi sintesa NH3 (dan pengaturan impurities pada synthesis loop) dilakukan pada unit Purifier. Karena adanya keterbatasan jumlah N2 yang bisa dimasukkan ke Secondary Reformer pada sistem konvensional, maka Primary Reformer dirancang untuk merengkah feed gas hingga hanya menyisakan 10-11 % CH4 pada gas proses yang masuk ke Secondary Reformer, dan process gas keluar dari Secondary Reformer hanya menyisakan 0.2~ 0.3% CH4. Sebaliknya dengan sistem Purifier, sisa CH4 (methane slip) dari Primary Reformer dapat mencapai 25%, yang akan dioksidasi di Secondary Reformer hingga mencapai + 3% saja. Karena reaksi perengkahan metana di Primary Reformer bersifat endotermis (membutuhkan panas), berkurangnya reaksi reforming yang terjadi berarti berkurangnya penggunaan fuel gas dan turunnya kondisi operasi/suhu di Primary Reformer bila dibanding dengan teknologi yang konvensional. Penggunaan udara yang berlebih di Secondary Reformer dan tingkat konversi metane yg lebih rendah memberikan kondisi(suhu) operasi yg lebih rendah pada gas proses masuk ke sistem Waste Heat Recovery.

o

T = 800 C

NG Purification

101-B Primary Refomer

N G

Steam Drum

103-D Secondary Reformer

CO2 Removal

Shift Conversion WHB & Superheater

Methanation & Dryer

Steam Generator

o

S t e a m

T = 980 C

Compression Purge Gas NH3 Synthesis

NH3

Ammonia Process (General)

o

T = 715 C P = 40 kg/cm2 g

NG Purification

Steam Drum

101-B Primary Refomer

N G

103-D Secondary Reformer

Shift Conversion WHB Generator & Superheater

CO2 Removal Steam Generator

o

Steam

Methanation & Dryer

T = 898 C

Purifier

P = 39 kg/cm2 g Purge Gas

Compression

NH3 Synthesis

Ammonia Process PKT-5

NH3

1.3

Reforming dan Waste Heat Recovery

1.3.1

Objectives: Pengenalan komponen komponen yang membentuk sistem Primary Reformer, Secondary Reformer dan 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 box dan 2) convection (heat recovery) section dan dilengkapi dengan peralatan lainnya.

1.3.2.1 101-B Radiant Box Sesuai namanya, merupakan bangunan struktur baja berbentuk kotak dimana terjadi proses perpindahan 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, sedangkan proses perengkahan tsb terjadi dalam sejumlah tabung baja paduan Ni tahan panas dengan bantuan katalis 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 kesatuan yang disebut radiant harp. Keempat radiant harp tsb tergantung (suspended) didalam radiant box dengan menggunakan sejumlah spring hanger Gas umpan masuk ke catalyst tube melalui inlet pigtail dibagian atas catalyst tube, mengalir kebawah melewati unggun katalis dan keluar ke header pengumpul yang disebut outlet manifold untuk selanjutkan dialirkan ke luar radiant box melewati riser tube. Burner utamanya ditempatkan dibagian atas radiant box dan mengarah kebawah (arch burner) ditempatkan dalam 5 lajur berselang dengan posisi radiant harp. Udara pembakar yang telah dipanaskan dan bertekanan positif, didistribusikan kemasing-masing burner dengan menggunakan combustion air duct, sedangkan radiant box sendiri beroperasi pada kondisi tekanan negatif (-10 ~ 20 mmH2O). Untuk mencegah struktur baja tersebut dari panas yang terbentuk didalamnya, radiant box dilapis dengan sejumlah refraktori pelindung panas. Refraktori tersebut terdiri atas berbagai jenis dan penggunaan, terutama ceramic fiber, fire brick dan castable.

Gambar. Top Fired Reformer

Hanya 50-60% dari panas yg dihasilkan dari pembakaran fuel gas yg dimanfaatkan di radiant box, sisa panas pada gas buang yang keluar dari radiant box (dengan suhu 800 oC) dimanfaatkan untuk pemanasan 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, komponen pipa fuel dan burner, saluran udara pembakaran, spring hanger, air dampers, control valves, gas detection, 107-D Effluent Transfer Line dan juga akses untuk operator dan maintenance. Untuk mengurangi panas di ruangan tsb ditambahkan exhaust fan di atap bangunan ini

Struktur atap tsb. dirancang untuk menerima beban dari radiant harp dan Effluent Transfer Line disamping beban lainnya.

1.3.2.2 101-B Convection Section Convection Section terdiri atas 2 bangunan struktur baja yang disebut hot leg dan cold leg .yang dihubungkan dengan lorong saluran gas buang. Masing-masing bangunan terdiri atas beberapa convection module yang berfungsi sebagai penukar panas dengan memanfaatkan sisa panas dari gas buang 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 dikedua pinggirnya. Tube support dibentuk oleh besi cor (cast steel) tahan panas sedangkan end tubesheet dibentuk dari plat baja dengan tambahan castable sebagai pelindung panas. Fluida masuk melalui inlet header dan keluar dari convection module melalui outlet header, mengalir secara countercurrent/cross dengan aliran flue gas. Bahan konstruksi untuk pipa maupun tube support /tubesheets terutama ditentukan oleh suhu gas buang yang melewatinya. Pipa yang terekspos panas radiasi (Mixed Feed) umumnya berupa bare pipe/tube sedangkan pipa selebihnya dimana konveksi lebih dominan umumnya menggunakan finned tube untuk meningkatkan efisiensi perpindahan panas. Jenis materialnya bervariasi sesuai suhu operasi, bisa berupa baja Ni-Cr, logam paduan Cr maupun baja karbon. Material tube support dan tube support brackets untuk Module terbawah pada hot-leg umumnya menggunakan grade HK untuk ketahanan terhadap temperature tinggi, dan secara bertahap berkurang hingga besi karbon pada module terakhir. Untuk membantu agar aliran flue gas lebih homogen, pada bagian atas hot & cold leg diberi distributor plates yang biasanya terbuat dari pelat paduan Nickel (high Ni alloy plate-atau Alloy 800 HT ataupun SS 310H). Panas yang diperlukan untuk seluruh Convection Modules maupun untuk memanaskan udara pembakaran, tidak seluruhnya dapat dipasok dari sisa panas yang dihasilkan melalui Arch Burner semata. Karena itu panas juga ditambahkan melalui 101-B Tunnel Burner dan 101-B Steam Superheater Burner.

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 buang yang masih panas mengalir di salah satu sisi pelat sedangkan udara mengalir disisi lainnya secara cross flow. 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 dingin masuk dan 2) hot section dimana gas buang yg panas masuk. Secara konstruksi kedua seksi tersebut tidak banyak berbeda, kecuali pada cold section dimana struktur baja dan pelat yg bersentuhan dengan gas buang dilapis dengan bahan anti korosi (glass enameled) untuk mencegah terjadinya reaksi garam sulfat Fe2(SO4)3 antara besi dengan gas sulfur yg terkondensasi. Pembentukan garam besi

sulfat tsb tidak hanya menyebabkan kerusakan struktur baja dan plat penghantar panas tetapi juga menyumbat area aliran gas buang.

1.3.2.4 101-BJ ID Fan & 101-BJ1 FD Fan Primary Reformer ini beroperasi dengan sistem balanced draft dengan menggunakan 2 fan utama yaitu 1) 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 ke stack, sedangkan FD Fan berfungsi memasok udara pembakaran melewati Air Preheater hingga ke masing-masing burner. Pada PKT-5, kedua fan mengunakan sistem penggerak utama berupa steam turbin dengan sistem penggerak cadangan (standby)steam turbin juga. Pada sistem yg lebih umum hanya ID Fan yang menggunakan pengerak cadangan dan biasanya berupa motor listrik, sedangkan FD Fan biasanya hanya memiliki satu penggerak berupa steam turbin atau motor listrik.Pengerak utama umumnya berupa steam turbin karean pertimbangan kehandalannya .

1.3.2.5 101- B Burners Selain 101-BBA Arch Burner yang memasok panas yang diperlukan untuk proses perengkahan gas alam, keseluruhan Primary Reformer juga dilengkapi dengan burner dengan fungsi yang berbeda: 101-BBT Tunnel Burner, memasok tambahan panas untuk mendapatkan suhu campuran gas alam dan steam (mixed feed) yang dikehendaki sebelum masuk ke catalyst tubes maupun kebutuhan panas aliran gas proses di hot-leg 101-BBS Steam Superheater Burner, memasok tambahan panas untuk mendapatkn temperature superheated steam yang dikehendaki dan bagi kebutuhan panas kedua aliran proses lainnya di cold leg. Penggunaan udara pembakaran yg sudah dipanaskan di 101-BL Air Preheater menyebabkan potensi terbentuknya senyawa NOx atau Sox pada proses pembakaran fuel gas menjadi lebih besar. Karenanya type burner yg dipakai dirancang untuk mengurangi kemungkinan ini. Ada beberapa pilihan type low NOx burner, tetapi yg umum dipakai di Primary Reformer adalah type staged fuel, dimana bahan bakar masuk ke sistem burner secara bertahap.

Gambar. Fuel Staged Burner

Pada tipe burner ini, ada satu primary burner yg terletak ditengah dan beberapa secondary burner yang berada disekelilingnya dan terlindung oleh burner tiles. Seluruh udara untuk pembakaran masuk melalui bukaan ditengah burner tiles yang menyelimuti primary burner. Sebaliknya gas yang masuk ke primary burner hanya sebagian dari seluruh gas pembakaran yang diperlukan. Dengan sistem ini temperatur nyala yang terjadi di primary burner mengalami pendinginan karena adanya kelebihan udara tersebut. Sisa fuel gas didistribusikan ke secondary burner yang terletak lebih menjorok kedepan diwilayah nyala api dengan suhu yang lebih rendah. Pembakaran secara bertahap ini menghasilkan temperature nyala 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 primary reformer. Reaksi pembakaran tsb meningkatkan temperature gas menjadi lebih dari 1200 oC hingga memungkinkan terjadinya reaksi perengkahan lanjutan sisa metan pada gas proses dengan bantuan katalis.Bagian bawah bejana tekan berisi katalis sedangkan bagian atas yg berbentuk leher botol ditempati oleh mixing chamber untuk pembakaran gas proses dari primary reformer dengan udara yang dimasukkan dari atas bejana. Untuk melindungi dari suhu yang tinggi, bagian dalam bejana dilapis dengan bahan refraktori (castable) tahan temperature tingi dan bagian luarnya dilengkapi dengan jaket air untuk mendinginkan bejana tekan dari gas panas yang mungkin bersinggungan dengan dinding bejana melalui retakan pada lapisan refraktori. Unggun katalis ditempatkan diatas tumpukan alumina balls, dilindung dari nyala pembakaran dengan lapisan hexagonal tiles yang dipasang menutupi unggun katalis. Seluruh sistem katalis ini bertumpu pada dome brick yang merupakan struktur bata refraktori berongga untuk mengalirkan gas proses keluar dari Secondary Reformer menuju Waste Heat Boiler.

Gambar. Secondary Reformer

1.3.4

Gambar sketsa disamping mewakili model secondary reformer Kellogg “tempo dulu”. Disain yang diterapkan saat ini merupakan perbaikan dari design awal yang sering bermasalah dengan nyala api yang menyentuh hexa-tile dan unggun katalis.Ruang bakar menjadi lebih tinggi, demikian juga dengan lokasi burner yang makin di atas. Tingginya leher botol ini menyebabkan elevasi primary reformer juga naik. Bagian dasar radiant box berada pada elevasi lebih dari 3 m dari ground level agar Effluent Transfer Line dapat menjangkau posisi gas inlet ke secondary reformer.

107-D Effluent Transfer Line Alat ini merupakan saluran pengumpul gas proses dari radiant harps dan mengalirkannya ke Secondary Reformer. Merupakan bejana tekan berbentuk selongsong pipa yang diberi lapisan refraktori pelindung panas dibagian dalam dan jaket air diluarnya.

Disatu ujung Transfer line tersambung las ke Secondary Reformer sementara bagian lainnya tergantung 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 Riser Transition Assembly yang merupakan penghubung antara riser tube yang mendapat panas didalam radiant box dengan effluent transfer line yang relative dingin. Transition assembly dibentuk oleh 2 komponen, 1) kerucut dari baja paduan Ni (Incolloy 800 HT) yang disambung dengan 2 ) bejana tekan 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 Drum

101-C Secondary Reformer Waste Heat Boiler. Berbeda dengan disain standar Kellogg, WHB untuk PKT-5 merupakan jenis fire tube dengan sirkulasi natural . Boiler ini berbentuk shell & tube heat exchanger dengan aliran gas panas pada sisi tube dan boiler feed water pada sisi shell. 141-D Steam Drum, duduk diatas boiler

Gambar. Fired Tube Waste Heat Boiler dan Steam Drum

dengan ditopang beberapa riser pipes yang sekaligus mengalirkan campuran air dan steam dari boiler ke steam drum. Saturated steam yang terbentuk di steam drum dialirkan ke 102-C Steam Superheater untuk pemanasan lanjutan sedangkan sisa air dan make-up nya mengalir ke boiler dibawahnya melalui beberapa down comer.Untuk mengatur laju alir/tekanan steam/effisiensi penyerapan panas ditempatkan gas by-pass valve yang mengatur aliran gas yang masuk ke fire tubes.Bagian gas proses masuk WHB dilindungi dengan refractori (castable) tahan temperature tinggi, demikian juga dengan sisi keluarnya. Sedangkan bagian lainnya termasuk steam drum, riser dan downcomers diberi lapisan insulasi luar untuk konservasi panas dan personnel protection.

102-C Steam Superheater, merupakan vertical heat exchanger dengan gas by-pass valve untuk

mengatur temperatur superheated steam, dengan memanfaatkan sisa panas gas proses keluar dari WHB.

Transfer Lines

Aliran gas proses dari Secondary Reformer ke WHB dan selanjutnya ke Steam Superheater difasilitasi dengan menggunakan transfer lines

2.

CONSTRUCTION HIGHLIGHT

2.1

Objective Memberikan gambaran teknis peralatan yang membentuk sistem reforming dan sistem pemanfaatan panas di sistem reforming, khususnya yang terkait dengan pelaksanaan konstruksi dilapangan: •

Kondisi terkirim peralatan

•

Cakupan pekerjaan konstruksi

•

Pembagian kerja dan tanggungjawab diantara kontraktor pelaksana

•

Kendali kualitas konstruksi

2.2

101-B Primary Reformer

2.2.1

Radiant Section Komponen yang membentuk Radiant Section terdiri atas beberapa bagian yang dapat dibagi dalam beberapa paket pekerjaan konstruksi: Tabel. Komponen Radiant Box dan Split of Work Komponen

M

1

bangunan baja, untuk radiant box maupun struktur penutup diatasnya, termasuk akses operator, platform, stairway & ladder, roofing & siding



2

komponen gas proses, berupa radiant harps (termasuk catalyst tube top cover, thermowell sleeve/extention), inlet pigtails, inlet manifolds & cross-over pipe



3

refraktori, berupa ceramic fiber (module & blanket), refractory brick (fire brick, insulating brick, tunnel cover brick), castables, material insulasi luar, semuanya beserta attachment (anchor clip, pin dll) dan bahan pendukung lainnya (mortar, asphalt coating, dll).

4

burners (arch burners, tunnel burners), burner tiles, combustion air ducts, air dampers

5

fuel lines dan control valves

6

asesoris seperti spring hangers/spring support, peep holes. ruler

7

Insulasi pipa, termasuk cross-over pipe, inlet manifold, fuel line

R

O





 

 



Note: M : mekanikal; R: refraktori/insulasi; O: other (piping, listrik, instrument, insulasi pipa)

2.2.1.1 Steel structure Radiant Box

Dipasok dalam bentuk beberapa panel dan komponen yang siap dipasang dengan baut. Pengelasan diperlukan untuk memasang gusset plate untuk platform, walkway atau pipe support, dan seal weld panel 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 kolom sementara 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 sistem baut 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 masukkan dalam 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

Upper Column

Prefab.

Bolting & weld

5

Roof Truss

Loose component

bolting

Pre-assembly before install

6

Radiant Arch

Pre-fab beam & arch plates

bolting

Temp support required

7

Operator way

Grate section panel

bolting

8

Roof & Siding

Loose pieces

bolting

Note:

2.2.1.2 Refractory Tabel. Ringkasan Refraktori Radiant Box 1

Radiant wall

Supply condition

Installation method

note

Ceramic fiber Module

Surface cleaning

Power brush

stud weld and manually

Tabel. Ringkasan Refraktori Radiant Box

2

3

Radiant arch

Tunnel Wall

Supply condition

Installation method

& blanket

installed

Asphalt coat

brush

Ceramic fiber modules & blanket

Surface cleaning

Asphalt coat

brush

Burner tiles

manual, with mortar

Calcium silicate board

manual with mortar

Insulating brick

manual with mortar

Support plate

weld

Fire brick

manual

Tunnel Cover brick

manual

2.2.2

Radiant Floor

Power brush

stud weld and manual install

Burner tiles 4

note

For arch burner

By Mechanical

For tunnel burner

Calcium silicate board

manual, with mortar

Insulating brick

manual

Fire brick

manual

castable

Anchor weld + cast

Ceramic fiber blanket

Stud weld and manual

For bottom duct

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 line terdiri 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 umpan

dari inlet manifold ke masing-masing catalyst tube. Pigtail dibentuk untuk mengurangi dampak ekspansi termal dari catalyst tube maupun inlet manifold. Dipasok dalam bentuk satuan untuk dipasang dan dilas di lapangan

Radiant harps, merupakan rangkaian sejumlah catalyst tube (HP Mod) yang disusun berjajar. Tube

ini dilengkapi dengan top pipe (SS 308H) dan grating dibagian bawah untuk menopang unggun katalis. Gas proses keluar dari tube katalis melalui pipa keluar ( 1”, Alloy 800 HT) yang tersambung dengan outlet manifold (Alloy 800 HT). Setiap satu rangkaian radiant harp dilengkapi 1 buah Riser Tube (HP Mod) terpasang dibagian tengah untuk menyalurkan gas ke Effluent Transfer Line. 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) dengan

bagian atas berupa baja karbon dengan refraktori pelindung panas (bubled alumina castable) dan liner sleeve Incoloy 800H. Dipasok terpisah untuk dipasang diantara Riser Tube dan Effluent Transfer Line di lapangan. Selain pengelasan, baik pressure part dan liner sleeve, diperlukan juga pengisian bubled alumina castable pada area penyambungan las. Tabel. Ringkasan Radiant Harps + other pressure part 1

Radiant harp

Supply condition

Installation method

note

Terbagi 3 bagian, 2 end section + 1 mid section.

Instalasi per bagian setelah radiant upper structure selesai dikerjakan

Lifting beam

Tube Top Cover

Pengelasan (buttweld) outlet manifold pada posisi sudah tergantung

Thermowell extension Thermowell sleeve

2

Inlet Pigtail

Satuan

Inlet manifold

Terbagi 2 bagian per row

Test pieces Weld rod

Thermo well extension dilas sebelum insulasi outlet manifold Fit-up dengan posisi inlet manifold dan catalyst tube yang sebenarnya. Socket weld pada inlet manifold dan cat-tube top pipe

3

Temporary support

Dipasang berikut tube guide dan hanger

Cut & bevel Paper board gasket Test piece Weld rod Test piece Weld rod

But-weld pada posisi sesuai gambar 4

Transition Assembly

Transition assembly set Metal sleeve (Alloy 800HT) + Cardboard

Fit-up setelah riser tube dan 107-D pada posisi sesuai gambar

Cut & bevel Temp support Test piece Weld rod

Butt-weld to riser tube & to 107-D

Test piece Weld rod

Tabel. Ringkasan Radiant Harps + other pressure part Supply condition

Installation method

note

Install & weld liner sleeve with cardboard

Weld rod

Castable pouring

By Refractory

Metal sleeve weld at 107-D

Weld rod

Expansion space

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

1 2

Supply condition

Installation method

Cat Tube Top Pipe

Ceramic fiber blanket

As per dwg

Inlet Pigtail

pre-formed mineral wool

note

Metal sheet As per dwg

Fiber glass cloth 3

Inlet manifold

Pre-formed mineral wool

As per dwg

Ceramic fiber bulk Metal sheet 4 5

Outlet pipe & manifold

Ceramic fiber blanket

As per dwg

Transition Assembly

Bubbled alumina castable

cast manually after liner sleeve in place

as cast homogenity

Insulating can (prefab)

Insulating Can to be assembled & welded in place

At top part of riser covering weld joint and transition pieces

Tie-wire

Ceramic fiber blanket Ceramic fiber fabric sewn with blanket Tie-wire

Insulating can welding by Mechanical, ceramic fiber blanket by Refractory Weld rod 617

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

1

steel structure, dalam bentuk side wall dan end wall panels, prefabricated beam, header cover, pre-fab platform, ladder, combustion air duct, damper, dll.

2

tube bundles lengkap dengan tube supports; support brackets dipasok terpisah untuk dipasang menjadi module sebelum instalasi

*

3

distribution plate (pre-fab) dan supportnya, castable support plates

*

4

pipe spool pieces, untuk penyambungan antar tube bundle atau tube header dan cross-over pipes, hangers, dll.

*

5

refractory material: castable untuk side wall & end tubesheet; ceramic fiber module & blanket untuk roof; external insulation for ducting and pipe,

6

burners & burner tiles

R

O

*

*

*

Tube bundle, wall panel dan header cover dirakit dahulu berikut castable menjadi satu bagian heater module sebelum dipasang diposisi yang ditentukan. Castable lining pada roof panel diusahakan dilakukan sebelum instalasi, kecuali material yang tersedia bisa dan cukup untuk diaplikasi dengan sistem gunning. Tabel. Ringkasan Pekerjaan Mechanical Convection Section & Transition Secti on

1

Transition Duct

Supply condition

Installation method

note

section panel

bolting & weld

Castable lining di roof panel sebelum instalasi

beam 2

3

Convection inlet, outlet , & transition/ burner duct

section panel

Heater module

section panel

bolting & weld

pre-fab column

tube bundle

Castable lining on section panel Preassembly of

By Refractory

Tabel. Ringkasan Pekerjaan Mechanical Convection Section & Transition Secti on

4

5

Supply condition

Installation method

Support bracket

module

Cross-over pipes, etc

Spool pieces

Air duct & damper

prefab duct & damper

note

Module installation

Lifting beam

welding

Test piece

Spring support/hanger

Weld rod bolting

gasket 6

Burner & burner tiles

burner tiles in sections

burner tiles w/mortar

burner assembly

by refrctory by mechanical

Tabel. Ringkasan Pekerjaan Refractory Convection Section & Transition Section

1

Transition Duct

Supply condition

Installation method

castable

form work

silicate board

Castable lining di roof panel sebelum instalasi

anchor 2

Convection inlet, outlet , & transition/ burner duct

castable & anchor

anchor welding

ceramic fiber module

formwork

note

castable lining ceramic fiber installation

3

Heater module

Castable

Anchor welding

Anchor

Support plate welding

Support plate

Form work Castable lining on section panel

4

Cross-over pipes, etc

Pipe perform mineral wool

As per dwg

Metal sheet 5

Air duct & damper

mineral wool board + jacket

anchor welding

6

Burner & burner tiles

burner tiles in sections

burner tiles w/mortar

By mechanical Before module preassembly

2.3

101-BL Combustion Air Preheater Dipasok dalam beberapa bagian (boxed) yang harus dipasang diposisi sesuai petunjuk gambar bersama flue gas dan combustion air ducting. Pemasangan dengan sistem baut dan seal welding pada sisi flue gas. Insulasi luar dipasang kemudian sesuai gambar.

2.4

101-BJ Primary Reformer Induced Draft Fan & 101-BJ1 Primary Reformer Forced Draft 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 saja dilakukan oleh subkontraktor insulasi.

2.5

107-D Effluent Transfer Line Dipasok dalam bentuk jadi dipasok lengkap dengan selonsong dalam (metal sleeve), refraktori yang sudah di cor di shop, water jacket dan kompenen hanger. Beberapa bagian dari pelat water jacket harus dipasang dilapangan setelah 107-D digantung di struktur atap Primary Reformer dan setelah penyambungan dengan Transition Assembly maupun dengan 103-D Secondary Reformer. Untuk penyambungan dengan 103-D digunakan tambahan Fit-up section, merupakan bagian dari 107-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 struktur atap Primary Reformer dapat dipasang. Pemasangan liner sleeve (dengan lapisan cardboard) dilakukan setelah pengelasan sambungan ke 103-D maupun ke transition assembly dan pengecoran bubled alumina castabale. Tabel. Ringkasan Pekerjaan 107-D Effluent Transfer Line

1

2

Supply condition

Installation method

note

Main body

Dengan temporary support setelah radiant box steel terpasang

Posisi inlet stubs 107-D terhadap posisi radiant harps

Fit up at field

107-D pada kondisi tergantung dan levelled

Fit-up section

weld 3

metal sleeves

Elevasi thdp 103-D inlet stub

fit-up w cardboard

Setelah bubled alumina & inspeksi

weld

Expansion clearance

4

Bubled alumina castable

As per dwg

Setelah pengelasan pressure part; by refractory subcontractor

5

Brick w/ceramic

A sper dwg

Flange cover, after final inspection

Tabel. Ringkasan Pekerjaan 107-D Effluent Transfer Line

Supply condition

Installation method

note

Fit-up & weld

Setelah temporary support dilepas

fiber blanket Water jacket

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 diantara tahapan 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-C dilakukan setelah castable drying –out selesai dilakukan Castable drying out dilakukan dengan kondisi water jacket telah terpasang karena diperlukan untuk sirkulasi air pendinginan dinding reformer. Refractory work 103-D dan drying out nya dibahas dalam bab tersendiri.

2.7

103-D – 101-C Transfer Line Bejana tekan berbentuk selonsong dengan lapisan castable tahan panas dibagian dalam. Mengacu pada disain Kellogg standar dilengkapi juga water jacket dibagian luar, sedangkan castable sendiri dilindungi dari aliran gas dengan liner sleeve Selain pekerjaan fit-up dan pengelasan pressure part (baja karbon) dilakukan juga fit-up dan pengelasan liner sleeve sebelum dapat diserahkan kepada subkontraktor refraktori untuk pengecoran 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 perlu diperhatikan juga pasokan kawat las untuk masing-masing joint/jenis base metalnya.

Contoh breakdown pengelasan di sistem Reforming ditampilkan dalam Attachment-2

2.9

Quality Control Kendali kualitas pada pekerjaan konstruksi reformer dibagi dalam beberapa tahapan: Tahapan Pekerjaan /QC items 1

2

3

4

5.

note

Fondasi dan posisi anchor bolt

a

posisi masing-masing fondasi terhadap center-line primary reformer dan terhadap dinding luar radiant box atau convection modules

Surveyor/mech

b

posisi center-line 107-D/101-B Primary Reformer terhadap center-line 103-D

Surveyor/civil

c

jarak titik acuan 107-D/riser tube terhadap centerline 103-D

Surveyor/civil

d

Elevasi akhir pad-plate masing-masing fondasi

Surveyor/mech

e

Lain-lain, sesuai Construction Specification

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

Heater Module

a

Posisi inlet/outlet header relatif terhadap dinding dan column splice

b

Expansion clearance, posisi finned tube pada end tubesheet setelah pre-assembly

visual

c

Pemasangan temporary tie-rod

visual

d

Metode pemasangan/spreader beam/lifting beam

Lifting plan

e

Lain-lain sesuai specification

Refractory Work, Ceramic Fiber Module/Blanket

a

Surface cleaning

b

Marking for anchor

c

Stud anchor welding

d

Material checking

e

Sequence pemasangan

visual Bend test As per dwg

Refractory, castable

a

Surface preparation

visual

b

Marking for anchor (pitch dan jenis)

As per dwg

6

7

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

Burner & burner tiles

a

Posisi secondary burner tips

b

Burner tip cleanliness,

Radiant Harps, installation

a

Inside cleanliness/defect

Visual/boroscope

b

Support grid /grating opening

Visual/boroscope/ dP check

8

8

9

10

c

Elevasi dan levelness outlet manifold/top pipe

d

Thermal expansion space at outlet manifold

e

Spring setting

Inlet Manifold, installation & welding

a

Inside cleaning

b

Posisi guide/hanger dan thermal expansion movement/clearance

c

Fit-up & straightness during welding

d

Root pass: PT; final pass : PT, RT

Outlet manifold welding

a

Fit-up

b

Level and straightness of tube, interpass temp during welding

c

Root pass PT; Final PT & RT

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

Riser Transition Assembly

a

Center-line to radiant harps and 107-D inlet connection

Cold/hot setting

Tahapan Pekerjaan /QC items

11

b

Fir-up

c

Root pass PT; Final PT & RT

d

Castable lining

e

Root pass PT; final pass PT & RT

101-BL Air Preheater

a

Surface condition

b

Position of each section

c

Seal welding

3.

CONSTRUCTION PLAN

3.1

Objective

3.2

note

•

Membagi seluruh aktifitas konstruksi menjadi paket-paket yang dapat di subkontrakkan

•

Memberikan gambaran urutan aktifitas konstruksi secara keseluruhan sesuai dengan paket pekerjaan

Scope of Work Keseluruhan lingkup kerja konstruksi untuk sistem reforming, waste heat recovery dan fired heaters 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 lines pressure 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 dengan pembatasan sesuai penjelasan pada bab sebelumnya. Urutan pekerjaan untuk area Primary Reformer secara rinci dapat dilihat dalam Attachment-1, dan secara ringkas dijabarkan dibawah ini.

3.2.1

Instalasi 101-B Primary Reformer dan Peralatan lainnya Mencakup instalasi struktur baja 101-B radiant box, 101-B Convection Modules dan bangunan baja, dampers, combustion air duct, stack dan platform/ladder. Instalasi struktur baja radiant box dilakukan secara sekuensial dengan instalasi107-D and 103-D maupun dengan instalasi radiant harps. Temporary support untuk instalasi combustion air duct and 107-D harus disiapkan oleh mechanical subcontractor. Convection coils, steel panels dan refractory material dipasok terpisah. Perlu dilakukan preassembly per module dan dilapis dengan castable sebelum dipasang ditempatnya. Subkontraktor mekanikal perlu menyiapkan meja kerja untuk fabrikasi module dan menyiapkan lifting frame untuk 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) dan penggeraknya, roof fans, dampers with actuators, dan burners (101-BBA, BBS, BBT), dipasang oleh 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 cranes untuk mengangkat ketiga peralatan tersebut. Jadual instalasi 103-D menentukan bagi penyelesaian pekerjaan di 101-B radiant box karena banyaknya 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 Transfer Lines Mencakup pengelasan 101-B radiant harps, pengelasan stainless steel inlet manifold, cross-over pipes and pigtails, pengelasan high pressure piping pada convection modules, and pengelasan pada transfer lines antara 107-D, 103-D, 101-C and 102-C - termasuk Incoloy/ Inconel liner sleeves. Lihat Attachment-2 dan Attachment-8 untuk rinciannya. Vendor akan menyiapkan test piece untuk welder test termasuk penyediaan kawat las bila diperlukan.

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 dan cold setting (balancing). Castable lining work pada 101-B convection panel dimulai sebelum module pre-assembly dn selanjutnya secara sekuensial dengan instalasi heater module dan coils, Secondary reformer (103-D) lining work dimulai setelah water jacket selesai dikerjakan. Pekerjaan refraktori 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. Sebaiknya penegecoran dilakukan tidak lebih dari 6 bulan sejak tanggal produksi karena sangat berpengaruh pada kualitas castable tsb. (umur castable ini bervariasi antara 6 – 9 bulan) Penyimpanan material refractory (terutama high alumina castable untuk 103-D) sangat penting terhadap kinerja castable tersebut. Karenanya subkontraktor perlu menyiapkan tempat penyimpanan yang khusus, terhindar dari kelembaban udara, air hujan dan terik matahari. Air

conditioning (AC) diperlukan untuk mencegah panas yang berlebihan pada material castable yang akan berpengaruh pada curing time dan lifetime castable. Material supplier menyiapkan gambar kerja dan menyediakan steel form untuk pengecoran. Subkontraktor pelaksana harus menyiapkan platform kerja untuk Castable work pada sleeves-nya 3.2.6

transfer lines field joints dilakukan bergantian dengan pengelasan liner

Dry-Out of Castable 103-D Dry-out operation pada 103-D Secondary Reformer lining dilakukan tanpa dome brick (kecuali bottom support brick) oleh spesialis dry-out meski lingkupnya bisa menadi satu paket dengan pekerjaan refraktori. Jenis dan kelengkapan peralatan maupun pengalaman calon pelaksana harus menjadi perhatian khusus pada saat pemilihan subkontraktor. Dry-out operation untuk 101-B Primary Reformer and 102-B Start Up Heater dilakukan pada tahap commissioning.

3.2.7

Steel Erection & Refractory Lining of 102-B Dipasok dalam bentuk 2 modules, radiant box dan stack. Radiant box sudah difabrikasi jadi berikut heating coil dan lining work kecuali untuk floor. Bagian stack dikirim dalam 2 bagian yang sudah di beri lapisan refractorys with shop refractory lined. Mechanical subcontractor bertanggungjawab memasang peralatan termasuk platform & ladder dan asesoris lainnya. Refractory subcontractor bertanggungjawab melaksanakan floor lining, stack lining (bila diperlukan), pemasangan burner tiles dan lainnya.

3.2.8

Pre-commissioning

3.2.8.1 Catalyst Loading Catalyst loading 101-B biasanya melibatkan operator klien karena umumnya lebih berpengalaman. sedangkan untuk 103-D dilaksanakan oleh Mechanical subcontractor dengan supervisi langsung kontraktor. Secara keseluruhan peralatan kerja, safety equipment, consumables dll disiapkan oleh subkontraktor mekanikal. Yang perlu disiapkan oleh kontraktor utama adalah 1) alat pengukur beda tekanan tabung katalis, 2) vibrator berikut attachment ke tabung katalis dan 3) alat untuk mengeluarkan katalis dari tabung bilamana loading dianggap gagal. Untuk pekerjaan catalyst loading didalam bejana tekan seperti 103-D diperlukan coverall berikut alat bantu pernafasan dan blower + saluran untuk mengeluarkan debu katalis. Peralatan ini semua dapat menjadi lingkup subkontraktor dan perlu dirinci lebih detail dalam dokumen lelang.

3.2.8.2 Radiant Harps Balancing Balancing of harps dilakukan sebelum dan sesudah catalyst loading (pada kondisi dingin) dan juga pada kondisi panas setelah suhu flue sesuai dengan kondisi normal.. Kontraktor mekanikal meyiapkan tenaga kerja dan tools untuk membantu melakukan balancing 3.2.9

Others Pekerjaan lain pada area reformer: •

Piping subcontractor untuk pemasangan sistem pemipaan pada burners dan fuel gas, steam snuffing, drain line dari radiant outlet manifold, process gas piping keconvection coil headers,

steam line to fans’ drivers, dan lainnya.

3.3

•

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/air piping diluar area radiant box dan convection coil headers,

•

Leak testing untuk fuel piping dan pneumatic testing keseluruhan sistem, dilakukan pada periode commissioning.

Schedule of Work Titik acuan konstruksi primary reformer dan peralatan lainnya adalah pemasangan 103-D Secondary Refomer. Pengelasan radiant harps dan effluent chamber 107-D baru akan dilakukan setelah 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 dan pengelasan cross over pipe dan ducting. Jadual umum konstruksi ditunjukkan pada gambar halaman berikut dan Attachment-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 kritis dan cukup berat. Kegagalan disaat peleksanaan pekerjaan refarktori ini berdampak sangat besar kepada proyek dan kehandalan operasi selanjutnya. Karena itu perencanaan yang rinci sangat diperlukan dan pengawas maupun kontraktor yang dipilih selain harus berpengalaman utk pekerjaan sejenis juga perlu memahami persyaratan dan kelengkapan kerja yang diperlukan.

Gambar. Sekuen Pelaksanaan Pekerjaan Reforming Section 61-101-B Primary Reformer & 61-103-D Secondary Reformer

Installation

61-101-B Radiant Panel installation

Platform up to elev. 13.000

Radiant box upper structure/roof trusses

Combustion Air Duct

Radiant Harps

Welding

Convection Module Installation

Radiant Harp welding

Refractory

Panel welding

Anchor welding of Convection panel

Castable lining work. Convection Section Panel

103-D Lining

103-D Dryout

Burner tiles & rad box refractory work

61-107-D Effluent Chamber

Vessel

103-D installation

Water jacket

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 dalam Attachment-4.1.

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 panas langsung matahari. Praktisnya adalah dengan memanfaatkan container pengiriman yang ditempatkan dibawah atap dengan penopang balok kayu (agar tidaklangsung kontak dengan tanah)serta diberi pendingin udara (AC). Udara panas pada material castable dalam waktu lama dapat berakibat rusaknya castable.

4.2.2

Penyiapan Peralatan dan Platform Untuk Kerja Daftar peralatan untuk casting maupun drying-out dijabarkan dalam Attachment 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. Platform juga 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 berisi castable, 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 mixing chamber, 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 dalam Attachment 4-2.

4.2.4

Pemasangan Supprot Brick dan Dome Brick Sebelum pemasangan, disiapkan brick sesuai nomor row dan ututan pemasangan. Penyediaan brick diatur sesuai dengan kebutuhan (sesuai row yang dikerjakan) Dry setting (pemasangan sementara tanpa mortar) perlu dilakukan untuk memastikan posisi setiap brick sebelum dipasang ulang secara permanen dengan mortar. Untuk pemasangan dome-brick (setelah drying-out castable), dilakukan dengan menggunakan dome brick wooden form yang disiapkan oleh supplier. Sebelum pemasangan ditempat, sebaiknya dilakukan dry 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 dalam menanggung beban alumina ballast dan catalyst diatasnya.

4.3

Drying-Out work Pengeringan castable dilakukan dengan cara menghembuskan udara panas kedalam 103-D melalui bottom opening. Udara panas dihasilkan dari pembakaran gas alam pada furnace yang ditempatkan diluar 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 maupun furnace yang tersedia sehingga perlu dilakukan penyesuaian dilapangan. Lihat Attachment-6

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

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No

Activities

Reference drawing

Remarks/ Inspection Requirement

A. Preparation A.1

Foundation hand over from civil, reconfirm dimensional and position of anchors

Check and record foundation and anchor position

Grease anchors bolts and nuts 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. The bench should be sized enough for 2 panels

B. Radiant Box Pre Assembly & Installation Panels of wall #2 & #4 require pre assembly on ground prior to erection/installation. At same time platform support can be installed to the extent feasible Sequence of pre assembly and installation:

Wedges required for adjusting panel plumbness Pre assembly on steel bench

B.1

Wall panels (start from wall #4 & wall #3) and floor walls, in sequential order:

Pre assembled panels to be high strength bolted

B.2

Plumbness and diagonal dimensional check

Bolts at splice to be manually tightened before plumbness check. Gap at splice should be max. 3 mm.;

B.3

Bolt tightening and seal welding

High strength bolting before seal welding

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 to installation. Each row is pre assembled into 2 pieces without seal plates C.1

Install temporary support for ducts and 107-D

Support are supplied by subcontractor based on designs furnished by TEC

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) Reference drawing

No

Activities

C.2

Install ducts:

Cover openings with plank or plywood for personnel protection

C.3

Install seal plates for duct connection (sealing compound & sealing gasket Weld duct end openings to wall structure

Align duct according to dwg.,

C.4

Arch grating

C.5

Install ends cover,

Remarks/ Inspection Requirement

Maintain expansion clearance as per

After castable lining work

D. 107-D Pre-installation D.1

Temporary support installation on top of ducts

Dwg. NA

D.2

Pre-installation of 107-D, at its designated elevation and position

407-D series

Check alignment to inlet of 103-D and centerline to the reformer. Plumb line from center of 107-D inlet stub is + 12 mm from center of drain opening on the floor

E. Roof trusses Requires pre assembly on ground to complete set of trusses before installation E.1

Pre assembly of End-trusses & Sub-trusses

Dimensional check against actual column position on radiant walls Column bevel ends are prepared on ground

E.2

Install: Upper column End trusses, Sub trusses, Vertical bracing Bracing & post Tie bracing & effluent chamber support, roof bracing

E.4

Complete roof construction before H.3, including installation of exhaust fans F. 107- D Setting and Adjustment

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No F.1

Activities Install 107-D spring support, in locked condition according to dwg. Install hanger to spring support and weld the pin

F.2

Roof trusses are completely installed, bolt tightened and welded

Reference drawing

Remarks/ Inspection Requirement Check spring no. and its location which is align with transfer line support points Check that the 107-D is positioned center line to reformer for its entire length and align to 103-D inlet stub

Suspend 107-D by tightening spring turnbuckles, F.3

Remove 107-D temporary support after position and level of the vessel is inspected.

F.4

Measure distance from 107-D end to 103-D inlet stub. Cut 107-D field piece to the required length plus allowance 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 start from 103-D side

F.6

Installation of water jacket

Check vessel centerline to furnace and adjust weld sequence if required

G. Duct Hanger & Manifold Installation G.1

Install duct hanger and set level of duct by adjusting bolts Adjust duct to center of 107-D inlet stub

G.2

Install inlet manifold support & guide Install inlet manifold and support hangers. Use turn buckles of intermediate support to maintain slope of manifolds

G.3

Weld Grinnell pipe covering protection saddle, followed by guide roller and

G.4

Remove duct temporary support

Check level of duct, check expansion allowance on duct connection Plumb line from center 107-D inlet stub, was within + 12 mm from midpoint of adjacent duct wall G.2 & G.3 can be done after radiant harps installation (H) Maintain slope of (- 25 mm) + (3 mm) towards cross over pipe Check clearance as per drawing

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No

Activities

Reference drawing

Remarks/ Inspection Requirement

H. 101-B Radiant Harps installation Each harp section will be erected using spreader beam. These harp sections was temporary seated on steel support below floor level. H.1

Remove shipping bracing from radiant harps except for erection purpose

H.2

Install the harp through opening on the roof structure, start with center harp. Temporary steel support was positioned so that the outlet manifold is rested 20 mm below its intended elevation

210-D103

H.3

Install spring hanger assembly and beam, tighten spring ass’y by turning threaded rod

212-D101

Plumb hanger was within + 3 mm

Check and record length of upper and lower attachment and over all spring assembly

J. 101-B Radiant Riser Transition Assembly welding J.1

Center and fit-up riser transition assembly to 107-D inlet stub using support

210 - D105,

J.2

Perform welding in sequential order (together with refractory work) as per drawing

407 – D6

J.3

Re-check with plumb line from riser transition inlet stub as per F.2

J.4

Continue with water jacket installation K. Radiant Harps Adjustment and Welding

407 – D6 Perform inspection as per dwg.

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No K.1

Activities

Reference drawing

Suspend harps on hand tightened springs and remove temporary support

See KBR’s balancing procedure

Install bottom header boxes to maximum extent, leave access for jigs and welding work

Do not weld cover plates at this stage.

Drop plumb line from riser transition to floor opening. Centering riser tube was within + 12 mm from top of riser to connection point with outlet manifold,

Plumb hanger was within + 3 mm Measure and record distant of top flange from datum line before support is removed

Check if drain nozzle and thermowell connections are correctly centered over floor openings. Floor opening should be adjusted accordingly if conflicted. K.2

Leveling center harp’s outlet manifold was within + 10 mm for 3 m length by using hanger’s threaded rod Adjust elevation and level of end harps was aligning with center harp.

Remarks/ Inspection Requirement

210-D103

Level to within +10 mm per 2500 mm length. Measure and record distant of top flange from datum line before welding

Fit up for welding.

Measure and record elevation of manifold above floor at three points for each third

K.3

Weld manifold according to the approved procedure

Use jig to fix position of manifold during welding

K.4

Record position of tube assemblies after welding

Measure and record distant of top flange from datum line Measure and record elevation of manifold above floor at three points for each third

K.5

Adjust the hanger based on final record of distant of top flange from datum line

Release or tightened the threaded rod by the difference in record before and after welding

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No K.6

Activities

Reference drawing

Raise riser to correct position for field welding by adjusting spring turnbuckles.

Remarks/ Inspection Requirement Before welding: Check for correct weld gap

107-D to remain as per F.6.

Measure and record distant of top flange from datum line & elevation of manifold above floor at three points for each section After welding finished: Measure and record distant of top flange from datum line & elevation of manifold above floor at three points for each third Adjust spring turn-buckles according to differences in record measurement

K.7

Install drain and thermowell connection and sleeves

210-D102

Welds as per approved procedure 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 for arch plate movement, adjust plates if 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 burner side bricks and burner tiles Ensure that dimension of brick on burner wall side is correct to ensure straightness of tunnel wall

L.2

215-D series

Test for anchor stud weld strength

Supplier’s dwgs.

Maintain and check for expansion clearance on brick wall as per drawing

Install arch burner tiles

Check for correct position for each type of arch burners Check for tiles projection

L.3

Install arch module lining except area around riser transition assembly (if step P.1 is not yet perfrmed)

Supplier dwgs.

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No

Activities

L.4

Install tunnel wall bricks, floor brick and bull-nose castable lining

L.5

Outlet manifold lining after catalyst loading. Step M.1, and system pneumatic test, step P.4

Reference drawing

Remarks/ Inspection Requirement

M. Catalyst Loading M. 1

Catalyst loading will start if radiant harps welding and upper structure is completed Catalyst loading to proceed in accordance with procedure

M. 2

Replace gasket with permanent material and bolt tightened as per instruction, after final inspection of catalyst bed

Detailed procedure was developed using KBR’s loading procedure. Bed density of catalyst was confirmed prior to loading

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 the operating load (cold)

N.2

Release radiant tubes spring locks

Check for any obstruction, adjust arch plates if required Check bolt position (on sloted holes) for duct movement

N.3

Adjust spring to Final Cold Operating load settings

Record final spring setting Measure and record distance of top flange from datum line

N.4

Set 107-D spring limit stop 15 mm. upward and 3 mm downward. O. Installation of Arch and Tunnel Burners

O.1

Install burners as per drawing/instruction

Check orientation and record burner tip projection Check for easiness of operation of burner air damper

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No

Activities

Reference drawing

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 fiber blanket

210-D104

P.2

Install ceramic cloth (Nextel BS-40) w/cardboard below riser cans

Supplier’s dwgs.

Install flexible boot on riser openings P.3

Complete ceramic fiber lining on arch plates

P.4

External insulation on air ducts

P.5

Complete refractory work on outlet manifold and header boxes, and castable on air ducts

Supplier’s dwgs. Provide protection on slabs by using plywood

Install tunnel slabs. Q. Inlet pigtail and external pipe welding and insulation To be performed before system pneumatic test, before or after catalyst loading, but after cross-over piping (step S1 to S5) Q.1

Fit up inlet pigtail by trimming excess length. Do not “cold spring”.

Q.2

Insert 1.5t cardboard spacer to sockolet on inlet manifold and on radiant tubes before inserting pigtail into sockolet.

Perform visual check for the gasket before pigtail installation

Q.3

Socket weld inlet pigtails to radiant tubes and to inlet manifold

PT

Q.4

External insulation except at weld joints (was completed after pneumatic test)

Q.5

Adjust spring to Final Cold Operating load settings

Record final spring setting Measure and record distance of top flange from datum line

R. Convection & Transition Section Installation and Castable lining

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No

Activities

Reference drawing

Remarks/ Inspection Requirement

Convection coil are supplied separately from its casing (convection panels). Thus to complete the module, the convection panels, castable lining on the panels and installation of convection coils should be done in sequential order on steel bench before final installation. Mechanical subcontractor to prepare lifting frame suitable for erection of heaviest module. R.1

R.2

R.3

Install hot/cold leg’s convection box up to elev. + 6050. Dimensional check and bolt tightening and seal weld splices Install transition floor and roof

Check for type and position / level of tubesheet supports and guides

Weld columns to cap plate before installation of upper module

Strength bolted and seal welded

Castable lining work on convection box.

Check for anchor welds

As alterntive, lining may be applied on horizontal posisiton before panel assembly

Check for castable homogenity by hammer test

pre-assembly and install lowest convection modules, both legs

Additional temporary tie-plate/rod may be necessary to hold firm the modules during erection

Install tie-beam between hot and cold leg, if any Full-weld column to pad plate before installation of next upper module Ceramic fiber was place on top castable surface at module splice. Install convection next modules in sequence between hot and cold leg. Follow step 2 to 4 for each module Bolt and seal weld splices install and weld distributor supports R.4

Install roof structure, including duct support Install platform on convection section Install end walls on transition section

R.5

Plumb and square check

Install distribution plates

Position of tie-plate/rod are at column D & H, lower part. To be removed after column welding.

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No R.6

Activities

Reference drawing

Remarks/ Inspection Requirement

Ceramic fiber modules and castable lining. Install burner tiles

R.7

Install superheater burners

Check for position and projection of burner tips

S. Cross Over Pipes And Convection Module Jump-Over Pipe Installation And Welding S.1

S.2

Plumb and install /weld strut hanger (FS01) as per drawing, 610 mm from center line of inlet manifold

210-D401

Install horizontal pieces (C001) with hangers and 25 mm slope down to coil header

210-D401

Plumb was + 3 mm Total length of strut = 2872 mm from inlet manifold center

Weld to coil header after fit-up and elev. check S.3

From field weld end of (C001) measure actual elevation 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 actual length. Same as S.3

S.6

Fit-up and weld steam superheater jump-over pipes

S.7

External insulation except at field weld joint (was completed after system pneumatic test)

Convection tubes are cold spring for fit-up, as per drawing. RT & PT

T. Combustion Air Duct & Stack T.1

Completely install ducts after the Fans and Air Preheater is ready

T.2

Install stack and connecting flue gas duct to ID Fan

Stack is castable lined on the ground before erection.(step U.2)

ATTACHMENT-1. PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL) No

Activities

Reference drawing

Remarks/ Inspection Requirement

U. Castable lining / External Insulation on Convection Duct and Other Equipment U.1

Castable and or ceramic fiber lining on transition duct, convection duct

U.2

Castable lining on stack (if required)

V. Accessories V.1

Install dampers, actuator, flexible joint, manholes, peep doors, etc.

ATTACHMENT-2 FIELD WELDS FOR REFORMER SYSTEM (TYPICAL) Filler metal No.

Base Material

1

101-B Radiant Coil

1.1

Outlet manifold:

ERNiCrCoMo-1

2 butt welds @

RP3 (KHR32C) to RP4 (KHR32C)

(Inco 617)

8” NPS x 32 mm. thick

Riser transition

Inconel 617

1 butt weld@

1.2

(Brand name or equal)

(For 1 set of coil)

RF9 (SB408-UNS NO8811) to RF12 (SB564-UNS8811) 1.3 1.4 1.5

ERNiCrCoMo-1

1 butt-weld

(Inco 617)

1” NPS Sch. XXS

Outlet manifold. Thermowell, RP13 (SB407-NO8811)

ERNiCrCoMo-1

2 butt welds

(Inco 617)

½” NPS Sch. 80

Outlet manifold. thermowell/ drain pipe sleeve,

ERNiCrCoMo-1

3 welds

(Inco 617)

4” NPS Sch.XXS

ER308H

Socket weld

Inlet nozzle to inlet pigtail TP 304H to TP 304H

1.5

Pipe saddle to inlet manifold

See E99C-108-7

Dwg. 210- D105

6”NPS x 16.2 mm.

Outlet Manifold. Drain connection RP 12 (SB407)

RP4/RF2 (KHR32C) to TP 310 1.6

QTY

1” NPS Sch. 40S E308H

Cardboard gasket 1.5t, alloy verified, PT

1 joint

304H to 304H 1.6

Outlet manifold drain

By piping

TP 310 to piping 2

Riser Transition Assembly (for 1 set)

2.1

Riser transition to 107-D Transfer Line SA 106 Gr. B

2.1.1

Step #2 , Riser internal sleeve (RA3) Incoloy 800 HT to Incoloy 800 HT

16” NPS Sch.40 ERNiCr-3

1 fillet joint

(Inco 82)

141.3 x 6.55 t.

See dwg. 407D6/210- D105

ATTACHMENT-2 FIELD WELDS FOR REFORMER SYSTEM (TYPICAL) Filler metal No.

Base Material

2.1.2

Step#3

2.1.3 2.2

2.3

(Brand name or equal)

detail A

QTY 1 butt-joint

Effluent Chamber stub to Riser, SA 105 to RP14 (SA106 Gr B)

ER 70S-2, E7018

Step #5 part 3

ERNiCr-3

Incoloy800HT to Incoloy 800HT

(Inco 82)

141.3 x 6.55 t

Non-pressure part Riser Transition water jacket to nozzle, RA6A (A283 Gr. C) to RA11 (STPT410)

ER 70S-2

Riser Transition Insulation Can

Inconel 617

1 fillet joint

(TGS-50) 1 lot

Incoloy 800HT / Inconel 601

Dwg. KBR 210 – D104

3

101-B Inlet Manifold

3.1

Inlet Manifold to Cross Over Pipe, 304H to 304H

ER308H, E308H

4 Butt welds, 8” NPS Sch. 80S

Alloy verified, RT, PT

3.2

Inlet Manifold to inlet pigtail

ER308H

Socket weld 1” NPS Sch.40S

1.5 mm thick cardboard gasket, alloy verified, RT, PT

ER308H, E308H

2 @ 14” NPS, Buttweld

Alloy verified, RT, PT

ER308H, E308H

4 @ 8”NPS,Buttweld

Field fit-up

304H to 304H 3.3

Cross Over Pipe, horizontal XP1 (304H) to XF1 (304H)

3.4

Cross Over pipe, vertical XF3 (A 182-F304H) to XP2 (A312-TP304H)

3.5

Cross Over to Mixed Feed Coil outlet header, A 403 Gr. WP304H to 304H

ER308H, E308H

3.6

Strut, A 312 TP304H

4

107-D Effluent Chamber

4.1

107-D to 107--D pressure shell

E-7018 or

Joint #1

ER70S-2 & E

4 @ 14” NPS, Buttweld 4 @ 3” NPS Sch. 80

762 OD x 16 t.

Alloy verified, RT, PT

ATTACHMENT-2 FIELD WELDS FOR REFORMER SYSTEM (TYPICAL) Filler metal No.

Base Material

(Brand name or equal)

SA 516-70 to SA 516-70

7018

107-D internal sleeves

ERNiCr-3

Incoloy 800HT to Incoloy 800HT

(Inco 82)

107-D internal sleeve to 103-D

ERNiCr-3

Incoloy 800HT to Incoloy 800HT

(Inco 82)

Joint #2

E-7018 or

SA 516-70 to SA 516-70

ER70S-2 & E 7018

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 to Cross Over pipe

4.2 4.3 4.4

QTY

(= 816oC) (= 816oC)

762 OD x 16t

ER308H, E308H

14”NPS, butt-weld

Item 3.5

304H to 304H 5.2

Hot Steam superheater coil. JumpOver pipes SA 335 Gr P91 to SA 234 Gr WP 91

ER80SB8/E8018-B8

28 butt-weld @ 114.3 OD x 11.1 AW

Field fit up. Argon backing. PWHT machine req’d

5.3

Cold Steam Superheater. Jump over pipes. SA 335 Gr. P91 to SA 234 Gr. WP91

ER80SB8/E8018-B8

28 butt-weld @ 114.3 OD x 11.1 AW

Field fit up. Argon backing. PWHT machine req’d

5.4

Coil headers connections in/out

6

103-D Secondary Reformer

6.1

103-D transfer line to 101-C A 516-70 to A 516-70

6.2

Process Air Inlet

6.3

103-D transfer line to 101-C internal sleeve

By piping

ER70S-2 & E 7018 By piping Inconel 617 or Inconel 117

Incoloy 800HT to Incoloy 800HT 6.4

103-D top liner cover

ERNiCr-3

ATTACHMENT-2 FIELD WELDS FOR REFORMER SYSTEM (TYPICAL) Filler metal No.

6.5 6.6 6.7

Base Material

(Brand name or equal)

(Incoloy 800 HT plate)

(Inco 82)

103-D Dome support cutouts

ERNiCrMo-1

Incoloy 800HT

(Inconel 617)

Pouring port patch plate

ERNiCr-3

Incoloy 800HT

(Inco 82)

Water Jacket & Platform

ER70S-2 or 6/E 7018

CS 7

QTY

101-C & 102-C

301-D01/D05 302 – D01/D05

7.1

101C to 102-C, press. shell. A516-70 to A516-70

7.2

101C to 102-C, liner sleeve 6t Inconel 601 plate

7.3

ER70S-2 & E 7018

813 OD

Inconel 617 or Inconel 117

546 OD x 6t

101-C gas outlet, cold bypass

Parts of sleeve are ship loose, to be site fab. By piping

SA 335 P11 7.4

102-C gas outlet, hot by-pass

By piping

SA 335 P11 7.5

102-C Gas outlet, main

By piping

SA 336 F11 7.6

Cap weld and plug

After refractory filled

SA 105 / SA 234 WPB 7.7

Water Jacket 102-C SA-283-C

ER70S-2 or 6/E7018

ATTACHMENT-3 PRIMARY REFORMER SCHEDULE

ATTACHMENT-4 SECONDARY REFORMER FIELD WORK (TYPICAL) 4.1 Sequence of Work

Work description

Reference

Responsible party

1

103-D, vessel installation and weld of washer

403-D3, Detail “L”

Heavy lift and mechanical contractor

2

Platform and Water jacket

403-D7

Mechanical

3

Opening of top head (MH#1) and bottom cover

403-D1;

Mechanical

4

107-D installation and welding, shell and sleeves

403-D5

5

Water piping to/from 103-D Water Jacket

6

Ring plate (Incoloy 800HT) weld at gas outlet 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 Detail “A”

Mechanical, before lining of top section

9

Refractory lining top section

403-D1; D6 Detail “A”; D8

10

Remove CS shroud

403-D4, Detail “F”

Mechanical, after lining

403-D8

Refractory contractor, before dry-out

Cut-outs weld (dome support), Incoloy 800HT plates

D4 Detail “I” Mechanical, in sequential order with refractory work Piping

11

Support brick installation,

12

Dry-out

13

Top liner cover (MH#1) weld, Incoloy 800HT plate

403-D4, Detail “A”

Mechanical, after dry-out

14

Dome brick installation,

403-D8

Refractory contractor, using Wooden template 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 work

16

Air Piping welding

17

Air inlet insulation, with high temp water proof caulk

403-D5, detail “D”

Insulation contractor,

18

Alumina ball 50#, 25#

403-D8

Refractory, after lining and dome inspection,

19

Catalyst loading

403-D8

Mechanical

Refractory contractor

Piping contractor

20

Circle brick and hexagonal tiles

403-D8

Refractory

21

Mixing chamber & top cover install

403-D8

22.

Install bottom opening

Mechanical contractor, after lining the cover with ceramic fiber by refractory subcontractor

4.2. Refractory Work

Work Description

Remarks

A. Preparation

B

Store castable in cool & dry air

As soon as the material arrives at site, they are to be unloaded from container and place in the warehouse with good ventilation and dry. If required an air conditioned warehouse to be provided to store this material

Check and remove damaged bags and lumpy material

Check if spare is enough

Surface Preparation Provide working platform and necessary support inside 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 all anchor tip with plastic coat as per drawing C. Drop forms installation Paint/coat form steel with form coating (NoxCrete)

Steel forms to be applied by refractory subcontractor based on Supplier drawing

Check if thermowell and liner sleeves are covered with cardboard as per drawing and anchor already with 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 the shell (the required thickness of castable lining) using gauge Check and adjust level/height of forms on each row and compare against drawing. Use wooden shim 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 which water content to be applied.

4.2. Refractory Work

Work Description

Remarks

Perform trial operation

Measure time required from start of castable mixing until castable is in drum*) and hopper is washed 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 mixing chamber, approx. 100 Tons



Above mixing chamber, after patch welding and sleeve installation (by mechanical) Target is 500 kg. in place within 5 minutes1) or less. With 100 tons of castable to pour, the required time will be 17 hours continuous operation The above time is estimated by assuming that mixers will be located on ground and castable mix is lifted by crane. Less time (13 hours) may be achieved if mixers are set directly above the vessel top opening, reducing time required for lifting by 1 minute or 500kg in-place in 4 minutes. Vibration must be applied during castable pouring work to remove air trapped in the castable but care not to cause excessive segregation of castable due to prolonged vibration. As much as possible use all openings provided on steel form to insert vibrators. 1) This target is subject to changed based on actual flow test as per para 4.5.4. of KBR’s specification D11-1TS-7943

See Supplier lining procedure for details. Subcontractor to prepare detailed planning for Contractor approval Check items before each batch: 

Water cooling is available and circulating inside water jacket



Blower is running and temperature inside vessel is normal/cool



Steel cone feeder is easily operated and dismantled



Castable are placed in shade and in cool condition and the packing is in good condition



Back up power for mixer, vibrator, lighting is available and tested



Vibrators are working properly



Tools are available within arm reach



Clean water for the mix is acceptable, source is 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 for installer to provide back ups to avoid interruption due to mechanical or power failure. All equipment shall be in good working condition for 24 hour continuous operation

Mixing & Lining 1

4

Mixer, 2 ea.

 Pouring hopper ;

Paddle type, 16-30 rpm min. with motor 20 KW, bottom opening, cap. 250 kg castable ( 1250 od x 440 h) min. Pouring hopper size to fit vessel top opening, its outlet to fit cone-shape

Need power supply and temporary elec. panel

4.3 Equipment For Lining Work funnel,  cone shape steel funnel, 20 m length min. or vinyl chloride 175 od x 20 m flrxible hose;

Cone-shape funnel are hold together by bolt but should be easily disasss’y to adjust height of pouring position

 chute for pouring port (for flex. Hose) and  deflection chutes 5

Steel form

3 sections: upper, catalyst bed and bottom section

Supplied by Vendor

6

Pneumatic needle vibrator, 40 mm OD

2 ea. with long enough hose to air compressor, 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 temporary breaker

8

Shovel, trowel

As required

9

a. DC Lamps; Flash light;

3 @ 12 watt; 3 sets

b. Emergency lamps

2 sets, portable

10

DC battery intercom

operated

For coordination between s/v in the outside with s/v in the inside of vessel

11

Working platform for mixing with steel roof covered with waterproof tarpaulin

To accommodate two mixers, working in tandem. for 16 people and 4 crate of castable (3200 kg)

12

Temporary storage at filed

To accommodate 20 crates or more castable, with waterproof cover

13

Water bucket

6 @ 30 liter

14

Ice container

1 m3, made from plywood with insulator

15

Water pump

2 ea, cap. 10 liter/minutes

16

Drums for icy water

2 @ 100 liters for icy water,

Minimum requirement

At top opening level

1 @ 100 liters on top of vessel for cleaning the chute and funnel 17

1” water hose

As required

18

Exhaust fan, heavy duty

2 sets with

19

Electric cable receptacles

For lamps, vibrators, blowers; 200 m.

20

Electrical Panel complete with switches and breakers

with

Inside of vessel

4.3 Equipment For Lining Work 21

Cover sheet, tarpaulin

1 lot

22

Flow Test table, ASTM C230

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. for castable mixing operation

2

Crane 70 T,

with beam able to lift material to the top of vessel (30 m)

3

Light truck

1 for material handling

4

Air compressor

2 sets, for vibrators, cap. ?

Include. 1 standby

5

Diesel Generator

2 cap.400A Ac/DC, for power and for welding

Include. 1 standby

7

Water truck

1

Include. 1 standby

Others 2

Disk Grinder with enough cup wheel

Min. 2 sets,

3

Wrenches

Min. 2 set,

For steel forms bolting

4

Winches

1 set

For steel form ass’y

6

Diamond cup wheel

Min. 4 blades, 6 “/8” dia.

For brick cutting

7

Jig saw, complete with blade

1 ea jig saw, 10 blades

ATTACHMENT-5. CERAMIC FIBER MODULE (TYPICAL EXAMPLE)

The module is an accordion-folded blanket module that uses either 304SS or 310SS hardware and anchoring systems. Two grades of ceramic fiber blanket: HP (high purity) grade and HZ (zirconia) grade are normally used in reformer, in standard thicknesses from 6 inches to 12 inches and in 128 kg/m3 and 160 kg/m3 (8 and 10 pcf) densities.

Spun Ceramic Fiber Module Physical Properties Ceramic Fiber Module Specs

High-Purity Grade Blanket

Zirconia Grade Blanket

Color

White

White

Maximum Use Limit

1260°C (2300°F)

1426°C (2600°F)

Continuous Use Limit

1100°C (2012°F)

1350°C (2461°F)

Standard Density, pcf (kg/m3) Standard Sizes, inch (mm)

8, 10 (128, 160)

8, 10 (128, 160)

12 x 12 (305 x 305)

12 x 12 (305 x 305)

6 - 12 (152 - 305)

6 - 12 (152 305)

Chemical Contents

High-Purity Grade

Zirconia 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%

Standard Thickness, inch (mm) Spun Ceramic Fiber Module Chemical Composition

ATTACHMENT-6 DRYING-OUT 103-D SECONDARY REFORMER

Drying Out Equipment:

Maker:

Mannings Thermal & Environmental Engineers, UK

Burner type: burner

nozzle mix high velocity gas burner, with turndown ratio 50:1; with separate 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.

Burner Set Up (dimension

in cm)

Note: T1 : skin temperature of bottom manhole liner sleeve T2 : gas temperature at bottom section T3 : gas temperature at outlet stack T4 : surface refractory temperature below dome AT, BT: gas temperature at main area of vessel MT: metal temperature at top (MT1,2) and bottom (MT3,4)

ATTACHMENT -7. 101-B CATALYST LOADING Preparation

•

Tube opening to be covered with plywood at all times, except during loading, to prevent foreign object 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 of approx. 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 the required height.

•

Weighed catalyst for each incremental loading section will be filled into loading sock; record actual weight of the catalyst on each sock.

•

Loaded socks will be put inside drum and properly protected from direct sun and rain water, ready for loading work

Catalyst Loading Sample

Two (2) tubes will be loaded fully (after measuring dP and height of empty tubes) in order to get values of: • time to vibrate the catalyst, • actual load density, • target and variation on bed pressure drop These 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 section loading.

Acceptance

Catalyst bed height:

aver. Ht + 100 mm

Pressure drop:

aver. Pt + 5%

EL. 116408

944 mm

TOP OF CATALYST

ID = 85,4 mm Note 3

KATALCO 25-4 600 mm

UNDERSIDE ARCH INSULATION KATALCO 25-4 4567 mm (40%)

KATALCO 57-4G 6851 mm (60%)

ID = 100,1 mm

100 mm

EL. 114863

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 Catalyst Retainer

OVERALL CATALYST TUBE LENGTH 11531 mm

mm mm mm mm 6112 mm

100,1 12,0 11.418 11.531 56 4 224

FACE OF FLANGE

12,963 mm

Tube ID Msw Tube length (eff) Tube Length (ovearll) Tube per row Number of rows Total tube nos.

P t = total press drop

EFFECTIVE CATALYST TUBE LENGTH 11418 mm

Primary Reformer Loading

H t = total bed height

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 in different place so as to maintain steel temperature and straightness of the manifold.

•

Final pass must be penetrant and radiographic tested

See attached pictures.

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 spring’s turnbuckle until both ends 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 the space is maintained before pigtail can be tackwelded. Preferred way to do is by using 3 mm cardboard gasket placed inside the sockolet before pushing the pigtail in.

•

check weld contour and penetrant test the weldment

ATTACHMENT-10. PICTURES

Gambar-1. Instalasi Convection Coil

Gambar-2. 101-BL Air Preheater

Gambar-3 Riser & Insulating Can

Gambar 4. Sekuen pekerjaan mekanikal & refraktori di seksi Reforming

Gambar-5. 103-D Dome Brick

Gambar-7. Pemasangan 103-D Hexa-Tiles

Gambar-8. 103-D Mixing Chamber Installation & Final Closing