INSTALLATION, OPERATING &

MAINTENANCE MANUAL
FLAMAX INCINERATOR

TYPE SLW 90/18 0

CLIENT: CONOCO-PHILLIPS
GRISSIK

GENERAL INDEX
GENERAL

INDEX

..
1
1. INTRODUCTION
.. 4
1.1.

GENERAL

DESCRIPTION

.. 4
1.2.

DESCRIPTION

OF

INCINERATOR

4
1.3.

DESIGN

BASIS

.
1.4.

PARTS OF INCINERATOR . ..
..

2. PROCESS

DESCRIPTION

...

7
2.1.

FIRST

CHAMBER

7
2.1.1.

Solid

Waste

Combustion

7
2.1.2.

Liquid

Waste

Combustion

8
2.2.

SECOND

CHAMBER

.
2.2.1.

Solid

Waste

Combustion

2.2.2.

Liquid

Waste

8
9

BURNER

...

.
2.3.1.

General

068

Description

.
Engineering

Combustion

..
2.3.

.
9
2

2.3.2.

Mounting and Installation Instructions

...

. 11
2.3.3.

Adjustment

of

Gas

Flow

12
2.3.4.

Troubleshooting

Instructions

14
2.4.

POWER

&

UTILITY

REQUIREMENTS

16
3. COMMISSIONING

..

. 17
3.1.

GENERAL

17
3.2.

HEATING

UP

PROCEDURES

17
3.3.

PERFORMANCE

TEST

PROCEDURES

. 18
3.4.

EMISSION

MEASUREMENTS

. 19
3.5.

ASH

MEASUREMENTS

.
4. OPERATING

19

SEQUENCE

.. 19
4.1.

PREPARATION
.. 19

4.2.

PURGING
..
20

4.3.

PREHEATING
. 21

4.4.

BURNING
..
21

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4.5.

COOLING

22

5. OPERATING

CONDITIONS

22
5.1.

OPERATING

SET

POINT

..
5.2.

INSTRUMENTATION

SET

22

POINT

23
6. MAINTENANCE

PROCEDURES

.
6.1.

COMBUSTION

CHAMBER

MAINTENANCE

.
6.1.1.

Combustion

23

23

Chamber

Cleaning

23
6.1.2.

Checking

and

Repairing

Leakage

at

Refractory

23
6.1.3.

Maintenance

of

Shell

. 24
6.2.

MAINTENANCE

OF

FUEL

SYSTEM

25
6.2.1.

Maintenance

of

Piping

..
6.2.2.

Maintenance

of

Fuel

System
25

Paper

Strainer

Filter

25
6.2.3.

Maintenance

of

Burner

.. 25
6.3.

MAINTENANCE

OF

AIR

SYSTEM

.. 26
6.3.1.

Maintenance of Blower

..

26
6.3.2.

Plenum

and

Ducting

Maintenance

.. 26

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6.4.

ELECTRICAL

AND

CONTROL

SYSTEM

MAINTENANCE

. 27
6.4.1.

Electrical

Checking,

Maintenance,

and

Repairing

27
6.4.2.

Control

System

Checking,

Maintenance,

and

Repairing

.. 27
6.5.

MAINTENANCE

AND

REPAIRING

SCHEDULE

28
7. TROUBLESHOOTING
. 30
7.1.

EXCESSIVE

STACK

EMISSIONS

.. 30
7.1.1.

Black

Smoke

30
7.1.2.

White

Smoke

31
7.2.

LEAKAGE

OF

SMOKE

FROM

COMBUSTION

CHAMBER

.. 32
7.3.

EXCESSIVE

AUXILLIARY

FUEL

USAGE

32
7.4.

INCOMPLETE

BURNOUT-POOR

ASH

QUALITY

. 33
8. TECHNICAL

DATA

. 33
8.1.

FIRST

CHAMBER

.. 33
8.2.

SECOND

CHAMBER

. 34
8.3.

EXHAUST

STACK

.. 34
8.4.

PRIMARY

AIR

BLOWER

.. 34
8.5.

SECONDARY

AIR

BLOWER

34
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8.6.

PRIMARY

BURNER

..
8.7.

SECONDARY

34

BURNER

.. 35
8.8.

LIQUID

TRANSFER

PUMP

35
8.9.

BUFFER

TANK

.. 35
9. REFERENCE

DRAWINGS

35
10. ATTACHMENTS
....

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35

1. INTRODUCTION
PT. UNOCAL in Lawe lawe Indonesia has been supplied with a FLAMAX
INCINERATOR. The Equipment provides for fail safe, pyrolysis incineration of
solid waste.
These Installation, operation and maintenance instruction have been compiled
to provide installer and user of FLAMAX INCINERATOR with the information
necessary for the correct operation and maintenance of the unit.
1.1. GENERAL DESCRIPTION
FLAMAX INCINERATOR, when properly designed, operated and maintenance,
will destroy even the most hazardous organic waste in high efficiency and
effective manner. For safe and high efficiency, it is essential that all personnel
involved with the installation, operation and maintenance of the unit are
familiar with these instructions.
1.2. DESCRIPTION OF INCINERATOR
Incineration is a process that destroys organic material by application of heat,
in a controlled and isolated system. The organic material destruction will
produce heat, ash, and flue gas. A simple scheme of incineration process is
illustrated below.
CONTROLLED
ENERGY SUPPLY

WASTE
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CONTROLLED
AIR

INCINERATOR

HEAT

RESIDUES

FLUE GAS

Combustion residues come from incombustible materials (i.e. metal, glass),

ash (mineral) and carbon (as charcoal). Charcoal is organic material which is
not combusted due to lack of oxygen. Charcoal could be minimized with
continuous supply of oxygen during the combustion process. Sorting the feed
waste could minimize the incombustible materials. To achieve high destructive
efficiency and control the flue gas (emission), incinerator consists of two
combustion chambers: first chamber and second chamber .
Incinerator performance can be evaluated easily on its capability to
achieve burning capacity with good emission and the easiness of operation.
Visually, the quality of emission can be detected by opacity percentage,
starting by 0 (clear/smokeless) to 100 (black dense smoke). Qualitatively, the
threshold

of the

emission

has been

formulated

by

Bapedal

into

Kep-

03/Bapedal/09/1995.
1.3. DESIGN BASIS
Following waste and fuel properties have served as design basis for FLAMAX
INCINERATOR designed for PT. Gulf Indonesia Resources (Conoco- Phillips),
Grissik:

WASTE DATA
Componen ts (*)

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Volume
(M3/da y)

Density
(Kg/L)

%Weight
(Approx.
)

NHV dry basis

(Btu/lb)

Approx.
Moisture
Content (%)

DOMESTIC
WASTE
Wet trash
Plastics
Paper
Wood
Metal
Textile
Leather
Rubber
Glass
TOTAL

7.93
1.86
0.985
0.49
0.265
0.212
0.086
0.085
0.085

0.22
0.003
0.003
0.07
0.001
0.001
0.009
0.000
0.005

77.59
4.13
2.98
10.59
0.80
0.80
1.63
0.32
1.15

12

0.3

100

2000
14000
7200
2800
300
7500
7500
10000
60

70
0.2
10.20
20
5
10
10
1.2
2

* Average composition

ULTIMATE ANALYSIS OF WASTE (DRY- BASE)

Componen ts (*)
SOLID WASTE
Wet trash
Plastics
Paper
Wood
Metal
Textile
Leather
Rubber
Glass
TOTAL

C
(%)

H
(%)

O
(%)

37.24
2.48
1.3
5.25
0.04
0.44
0.98
0.25
0.01

4.97
0.3
0.18
0.64
0.00
0.00
0.05
0.13
0.03

29.17
0.94
1.31
4.51
0.03
0.25
0.19
0.00
0.00

47.9 8

6.30

36.4 2

N
(%)
2.09
0.00
0.01
0.02
0.00
0.04
0.16
0.01
0.00
2.33

S
(%)
0.23
0.00
0.01
0.01
0.00
0.00
0.01
0.00
0.00
0.26

Ash
(%)
3.88
0.41
0.18
0.16
0.73
0.02
0.16
0.03
1.14
6.71

Total
(%)
77.59
4.13
2.98
10.59
0.8
0.8
1.63
0.32
1.15
100

* Average composition
FUEL PROPERTIES
Units
Components
:

0.479

Mole %

N2

29.48

Mole %

CO2

69.27

Mole %

C1

0.620

Mole %

C2

0.063

Mole %

C3

0.024

Mole %

IC4

0.016

Mole %

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NC4

0.014

Mole %

IC5

0.002

Mole %

NC5

0.032

Mole %

S.G
M.W

0.846
24.498

Lb/lbm

NHV
GHV
Pressure

644.64
715.65
80

ol
BTU/ft 3
BTU/ft 3
Psig

C6

Totally, The incinerator has capacity of 180 L/hr liquid wastes and 90 kg/hr
solid wastes. The incinerator capacity has safety factor about 30 % from
wastes quantity. For daily operation, the incinerator is operated maximum 12
hours for liquid wastes and 4 hours for solid wastes. For yearly basis, it is
operated for 280 days.
Incinerator can be used for domestic burning too but the capacity will be
different. Its capacity is about 60 -70 kg/hr for domestic waste burning.
1.4. PARTS OF INCINERATOR
The FLAMAX INCINERATOR comprises the following parts:
First Chamber
Second Chamber
Exhaust Stack
Burner
Blower
Feeding system
Control Panel
2. PROCESS DESCRIPTION
2.1.

FIRST CHAMBER

First Chamber is a place where the organic solid wastes burned . The organic
wastes burn above its flash temperature. Generally, organic waste has a flash
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10

point temperature between 200 500

C. To reach the intended flash point,

the combustion chamber should be heated using the heat supplied by the fuel
from pilot burner.
2.1. 1. Solid Waste Combustion
Burning rate of Solid waste is controlled by pyrolysis process. Pyrolysis is an
endothermic

reaction

that

decomposes

organic

compounds

into

simpler

compounds, such as methane (CH 4 ), ethane (C 2 H 6 ), carbon monoxide (CO),

and other combustible gasses. To achieve pyrolysis reaction condition, first
chamber must be in high temperature (above 500

C) and absence of

oxygen/air supply. Before pyrolysis temperature is reached, first chamber

must be heated by pilot burner until waste flash point temperature achieved.
Above waste flash point temperature, first chamber heating can be helped by
waste burning to accelerate achievement of pyrolysis temperature. After
pyrolysis temperature is achieved, the temperature could be maintained just
by burning some of the waste (no fuel consumption condition/steady state
condition). As much as 30 - 60 percent of stoichiometric oxygen is supplied
into the first chamber at steady state condition.
The air needed in first chamber is supplied by blower through tuyers attached
on the wall of chamber. Tuyere arrangement will determine the distribution of
air supply in all over the waste surface, heat distribution, and temperature
distribution. It is also minimize the turbulence. Air supply is controlled by
control valve and manual damper to achieve optimum pyrolysis rate and
prevent particle carried out by flue gases.
2.2. SECOND CHAMBER
Second Chamber is a place where gasses, from imperfect combustion in first
chamber, are burned. Following two chapters will describe burning process in
second chamber while burning solid waste and liquid waste.
2.2. 1. Solid Waste Combustion
Gasses from the pyrolysis process are a source of air pollution. These gasses
must be combusted completely in the second chamber. With oxygen/air
addition;
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068

methane,

ethane,

carbon

monoxide,

and

other

pyrolysis

is
11

combusted. Oxygen/air quantity, mixing quality between air and pyrolysis

gasses, and retention time influence completeness of combustion. As much as
185 210 percent of oxygen stochiometric is supplied into second chamber to
ensure that all of pyrolysis gasses is burned completely. Air supply in second
chamber is controlled by control valve and manual damper. Mixing quality
between air and pyrolysis gasses is enhanced by cyclic flow and tuyere
arrangement in second chamber. Pyrolysis gasses combustion has retention
time about 1 2 seconds.
2.3. BURNER
2.3. 1. Gener al Description
Flamax Incinerator for PT. UNOCAL in Lawe lawe Indonesia uses RAYGAS PRESSURE BURNERS. These burners are designed for natural gases and
have been approved in accordance with DIN 4788. The dynamically balanced
blower wheel is directly mounted to the motor shaft and has a stable
characteristic over the entire operating range. The supply of the air required
for good combustion is controlled by an adjustable air inlet shutter in the air
inlet housing. The low- air cut- out provided on the burner, assures that the
burner is only ignited in the presence of the necessary supply of combustion
air. The interruption of the supply of combustion air effects a security switch
out on the burner.
The automatic supply of gas to the burner is shut off by means of
automatic gas solenoid valves or hydromotor valves class A. If the required
gas pressure does not come up to the estimated minimum gas pressure the
burner is automatically shut down by means of the automatic low gas switch.
For the purpose of flame stabilization and for assuring best possible
mixing of the gas with the combustion air, a baffle plate with suitable baffles is
provided in front of the burner head. The fuel- air mixture is ignited electrically
by means of a spark supplied by a high- voltage transformer between the
ignition electrode and burner head. The flame is supervised by an ionizationprinciple. By this means the control of the flame stability is guaranteed. The
RAY-gas burner gives fully automatic operation. Burner control is by means of
electronic controls, limit controls, and monitors (operating is a function of
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068

12

temperature or pressure) in conjunction with the automatic gas burner control

unit. The two stage control burners are equipped with a two stage solenoid
valve. The gas amounts are adjustable on the gas solenoid valve. The
servomotor sets the air supply shutter to a position assuring the necessary
supply of combustion air.
A fuel- air compound control unit combined with servomotor is standard
on the burners. This compound control is a coupled combination of control
elements and controls the RAY control- shutter that is mounted to the burner.
The camplate, which is an integral part of the compound control, permits
accurate adjustment of the combustion air required for each firing rate. This
makes it possible to adjust best possible combustion at any load.
The combustion chamber is pre- purged, and for this the air inlet shutter
is fully opened. This allows all existing regulations to be met. The amount of
gas required for the high- fire position are to be adjusted by means of the gas
solenoid valve of hydromotor valve class A required under DIN 4788. The
valves and low- gas switches are to be installed into the gas supply line to the
burner and therefore supplied as separate items.
For service purpose the mixing head can be easily removed from burner
housing, without disconnection of the gas supply line by removing the housing
cover.
The burner

used on the RAY Forced- Draft

Gas burners meet

all

applicable regulations as well as the requirements of safe and trouble- free

operation. Each burner is supplied with a main gas valve (solenoid or motor
valve) with volume control and a low- gas cut- out (minimum pressure).
Two- Stage Control
The two- stage control system is normally used within the range of from 100%
to 50% load. It is in this range that the burner firing rate is controlled in
accordance with the heat required, the burner remaining continuously in
operation. If less heat is required, the burner is automatically switched from
stage 2 (high fire position) to stage 1 (low fire position). As soon as more heat
is needed, burner

operation

is controlled

by automatically

starting

and

stopping the burner as required.

In the burner, the amount of fuel and combustion air is controlled by the RAY
compound control unit. The amount of combustion air required for the gas
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13

volume determined by the gas valve is controlled by the compound control

unit.
When the master switch is turned on or when the control thermostat of stage
1 (control manostat) automatically operates, the control current is released.
The motor operator moves the compound control unit to position stage 2 for
pre- purging the firebox. At the end of the pre- purged period, the motor
operator and compound control unit move the air damper and gas valve to
starting position. After the burner has been started, the compound control unit
moves up to stage 1. Operation remains stage 1 until more heat is required,
causing a drop in temperature or pressure. This is when temperature or
pressure control of stage 2 triggers the burner stage 2, i.e. the compound
control unit moves to stage 2. If at burner stage 1 the temperature or pressure
of the heat generator continues to rise and exceeds the preset temperature or
pressure

limit,

the

temperature

or

pressure

limit

control

of

stage

automatically stops the burner. As soon as the temperature or pressure drops

below the setting temperature or pressure limit control of stage 1, the burner
is automatically started again.
Modulat i ng Control
The modulating control system makes it possible to adjust the firing rate of
the continuously operating burner within the control range to the load demand
of the

heat

receiver.

A temperature

or pressure

sensor

transmits

the

temperature or pressure of the heat generator to a control element and on to

the motor operator. If the temperature or pressure of the heat generator
decreases, the motor operator moves the compound control unit to a position
resulting in a higher firing rate. If the temperature or pressure in the heat
generator increases, the motor operator moves the compound control unit to a
position causing a lower firing rate. If the temperature or pressure continues to
rise in the low fire position, the burner is shut down by the temperature or
pressure limit control (thermostat or manostat). As soon as the temperature or
pressure drops below the limit that has been preset on the limit control, the
burner is automatically restarted.

2.3. 2. Mounti ng and Installation Instructions

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14

Impor t an t : Take care to avoid damage when unpacking or handling the

burner. Do not hold the burner by damper box, by cable inlets or the control
linkage. Remove the burner from packing, hold it at the flange or at the
housing
Mounting: Normally, the burner is flanged directly to plate. Use a gasket to
obtain a good seal and good thermal insulation between the plate and the
burner. For mounting the burner proceed as follows:
a. turn the stud screws into the tapped holes of the plate
b. Attach the gasket
c. Place the burner against the plate, slip the washers on the stud screws, and
secure the burner flange to the plate by means of the cap nuts. Uniformly
tightening the nuts.
The nominal diameter of the gas supply line must be chosen according to the
pipe length and gas pressure. The gas velocity in the inlet should not be too
high as otherwise disturbing flow noises may occur.
Operati ng Cycle and Flame Detection
When heat is required, the fan motor starts and the firebox is pre- purged. The
pre- purge period is present in the automatic gas burner control unit. The
centrifugal switch releases the further operating cycles upon reaching the
necessary number of revolutions of the motor. The ignition transformer is
energized by the automatic gas burner control unit and there will be a spark
between ignition electrode and burner head. The gas solenoid valve opens so
far that the set start gas amount will be released. This is mixed with the
combustion air. The gas- air mixture is ignited by means of the spark. A flamerod made of high heat- resistance material is fixed to the burner head, which is
connected to the control unit and is supplied with alternating voltage. At a
distance of 3

to 5 mm from the flame rod is the ground rod. The air gap

between flame rod and ground rod is ionized by the flame and thus electrically
conducting. A rectifier effect results from the different masses of the ionized
parts (flame rod and ground). There flows a direct current of low intensity (1
10 A)
The flame supervising relay in the control unit is designed to be energized by
direct current only. If an alternating current pulse received (due to a shortcircuit in the ionizing path or a short circuit due to creep currents caused by
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15

moisture, etc) the flame relay is de- energized and the automatic gas control
unit shifts to trouble position. With the ionizing type of flame supervising a
flame cannot be simulated. After the flame supervising relay in the automatic
gas control unit is in operation, the program is continued and the gas valve
opens slowly from the preset start amount of gas to the main gas amount
which is also adjustable on the valve. The burner keeps operating until a
normal shut- off or a manual shut off occurs. When the burner is shut down,
the gas solenoid valve is closed immediately. As soon as the temperature or
pressure drops below the setting of the control thermostat or manostat. The
air damper is closed during shutdown of the burner and is opened by the
compound control for firebox pre- purging. At the end of the pre- purge period
the compound control regulates gas valve and air damper back to ignition
position. The minimum amount of air is assured by a low- air cut- out. The
above mentioned operating cycle is repeated.
2.3. 3. Adjust m en t of Gas Flow
Upon adjustment of the gas pressure regulator and venting of the gas
pipe, the
position of the gas control shutter and of the air damper is to be checked. At
first, check the air damper in the compound control position Closed. In this
position, the cam belt pulleys of the diving element (drive to air damper) are
positioned on the last set screw of the cam belt plate. Adjust the set screw to
close the air damper. The position of the cam belt plate can be readjusted on
the cam Closed in the motor operator.
The gas control shutter has to be slightly opened( approx. 15 o) in the igniting
position (cam belt pulleys are located on the second set screw of the cam belt
plate). The positioning of the valve is shown by the mark of the shaft end. It
can be corrected by changing the length of the drive lever. The air damper is
to be adjusted to an opening gap of 20 25 mm on the corresponding set
screw in the cam- belt.
The gas control shutter and the air damper should be open with the compound
control in position open. The position Open of the compound control can
be adjusted on the corresponding cam in the motor- operator.

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16

Note: Check firm fit of all joints and linkages (for exampl e

after

readjust m e n t ) and tight en, if necessary.

Ignite the burner for the first time with excess air ( open air damper some
more) ad reduced gas flow (make corresponding adjustment on the main shutoff cock or on the gas valve with main load adjustment). By interrupting the
Open pulse for motor- operator, the servo motor remains in the starting load
position. If necessary, the gas pressure has to be readjusted after the flame
has been ignited. Pay intention to the fact that the gas pressure upstream of
the gas control shutter should not exceed 50 mbar.
The gas temperature should not drop below 0 o C and should not exceed 60 oC.
The starting gas amount to be fired can now be found out on the gas flow
meter with correctly adjusted gas pressure. The starting gas amount can be
corrected if necessary by changing the length of the drive lever. The necessary
combustion air amount for the starting gas amount is to be adjusted on the
set- screw in the cam belt. Find out of the right setting by CO and CO2
measurements. By means of briefly connecting the open pulse for the motor
operator, the compound control will be opened until the cam belt pulleys of
the driving elements reach the next set screw. By measuring the CO and CO2
content, adjust the right air amount on the set- screw for every further
position. The full load gas amount is limited by the flow regulator in the main
gas valve. For adjustment, depending on the type of valve.
For burner with two- stage control the position of stage 1 can be freely chosen
in the adjusted range between starting load and full load.
Upon adjustment of the air amount in the different stages a microam meter
has to be connected between the ionizing cable and the connecting terminals
of the ionizing cable in the base of the control unit. By starting the burner
again it can be checked whether the ionizing is sufficient in all load ranges. It
must be at least 1 A.
Adjust m e n t of the low- gas cut- out
The set pressure downstream of the gas pressure regulator is to be reduced by
about 25 % (by turning the gas pressure regulator or slowly closing the annual
shut- off valve). Check whether at this setting by decreasing the gas amount, a
too high CO content (air excess CO) is reached in the flue gas. In case this
should happen, the decreased pressure must be slightly increased, approx. 15
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17

 20 % below the normal pressure, in order to avoid inadmissible CO

production. After that check with the pressure set like this whether the
ionizing current is still sufficient in all load ranges.
The low- gas cut- out is to be adjusted in such a way that it cuts off the burner
at decreasing gas pressure and starts the burner again when the pressure
exceeds the set value. Then, readjust the gas pressure regulator to the
pressure selected when the burner was adjusted.
Upon placing the regulated burner in service make sure that all unions, vents
and test connections of the burner and gas train are closed. All screwed
connections, nipples and linkages must be firmly tightened. The adjusting
devices on the gas pressure regulators and valves have to be locked, if
necessary, in accordance with the descriptions. In case the adjusting device
was protected by a cap against in advertent movement, the cap has to be
replaced after adjustment has been made.
2.3. 4. Troubleshooti ng instructions
2.3. 4. 1 .

Burner fails to start

a. Room thermostat, manostat or time switch have cut off

b. Low- water switch has cut off because the water level has dropped below
the lower limit.
c. The protective motor cut- out has operated
d. The power supply has been interrupted (blown fuse)
e. The safety network of the system is interrupted in some place (thermostat,
manostat, limit- switch or low- water cut- out detective)
f.

The automatic gas burner control unit is defective

g. Ionizing electrode touches frame parts of the burner

h. Main gas solenoid valve does not open, solenoid coil is defective
2.3. 4. 2 .

Burner starts and stops again after a short while

of opera tion
a. No ignition,. Ignition electrode not correctly adjusted. There must exist a
gap of about 3 mm between the electrode tip and the opposite spark
member. Insulation of the electrode is cracked or dirty. Ignition cable or
ignition transformer defective.

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18

b. Gas pressure control defective, low gas pressure. Dirty gas filter and lowgas switch cuts off.
c. Motor overload cut- out maladjusted or defective and switching off the
motor during the starting procedure.
d. Switching contacts in automatic gas burner control unit are scorched (due
to a short- circuit, for instance)
e. Ionizing electrode in contact with burner parts or ground bar. The flame
relay in the automatic gas burner control unit fails to operate.
f.

Cable at the ionizing bar defective of insulation of ionizing bar cracked.

2.3. 4. 3 .

Poor Combustion

a. The air shutter is closed too much. CO-content of flue gas exceeds 100
mg/m3. Make absolutely sure to open the air shutter to an extent where
the CO-content of the flue gas is below 100 mg/NM3. Examine mixing
assembly to see whether changes have occurred. For example by normal
wear.
b. The CO2-content is too low. The gas flow is insufficient, compared with the
volume of air. The gas pressure has decreased or the combustion air
shutter has been opened too far. If the gas flow rate is still all right,
readjust the volume of combustion air by closing the shutter as required.
Take care to see that the CO-content is not allowed to rise above 100
mg/m3.
c. Mixing assembly dirty on air or gas side and disrupting the preset gas- air
ratio.
2.3. 4. 4 .

Burner starts and stops at short inter vals

a. The heat consumption is too low or the burner operates at high rate gas.
b. The inlet line thermostat, steam pressure regulator or room thermostat
setting is too low or these units are operating with too narrow switching
difference. Readjust.
c. The automatic gas burner control units has a poor contact in the plug base
or is defective.
d. Low gas switch is set at too high cut- off pressure. Upon opening the gas
solenoid or moor valve, the gas pressure drops for a short while. Adjust
low- gas switch to low- west cut- off pressure.
2.3. 4. 5 .
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Burner fails to cut out autom a t ically

19

a. Inlet line thermostat, or room thermostat are set too high. Correct the
adjustment
b. Stick contacts in one of the control elements.
2.3.4.6. Flame goes out during operation
a. Gas pressure has decreased. Low gas cut- out has stopped to operate.
b. Gas filter upstream of gas pressure regulator is dirty.
c. Ionizing rod has come loose and touches burner parts
2.3. 4. 7 .

Fuses have blow n

a. Gas pressure has decreased. Low- gas cut- out has stopped to operate.
b. Fuses have not been firmly screwed in.
c. Motor bearings are defective or motor winding has burnt out.
d. Fuses have blown or automatic circuit breaker has operated, for example
due to a short circuit in the electric installation.
2.3. 4. 8 .

Noisy operations

a. Motor bearings are worn out.

b. Blow wheel has turned loose on shaft
c. Excessive flame noise can be corrected by changing the burner setting.
2.4. POWER & UTILITY REQUIREMENTS
Electrical Power
3 Phase/ 460 VAC/ 60 Hz : 5 kW
1 Phase/ 240 VAC/ 60 Hz : 1 kW
1 Phase/ 120 VAC/ 60 Hz : 1 kW
Instrument Air
-

Header pressure : 80 psig

Temperature : 85 oF

Fuel Gas
-

Pressure: 80 psig

Flow rate: max. 60 Nm3/hr

3. COMMISSIONI NG
3.1.

Gener al

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This section defines the recommended commissioning activities and

procedures to be used for the FLAMAX INCINERATOR in the Project. The
section

consists

of heating

up procedure,

performance

test

procedure,

emission measurements and ash measurements.

3.2.

Heati ng up procedur es

Before the incinerator can be used, heating up process must be done to

prevent cracking of the new refractory layer caused by sudden extensibility.
This Procedure is executed in three phases procedure:
Drying Phase : This is done to dry up of castable material. It is done at

ambient temperature of 40 OC to 400 OC during 22 hours.

Heating Phase : This process prevents cracking of the refractory layer

caused by sudden

extensibility

and to stabilize

burning

chamber

temperature. Heating up takes 19 hours with a temperature of 400 OC to

1000 OC.
Cooling Phase : This process is executed with a purpose to prevent the

sudden temperature decreasing which can caused refractory layer to be

cracking. Decreasing of temperature should be done gradually to reach
ambient temperature during 19 hours.
Total time for heating up process requires 60 hours.
3.3.

Perfor m a nce test procedur es

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21

This test is to know performance of the incinerator unit concerning

capacity and emission result. The process should be done with care to obtain
the quality and efficiency of the waste burning with careful burning quality of
emission and guided burning capacity can prolong the machine lifetime.
Each kind of waste has it own characteristic with different burning
process. Therefore handling of each types of waste is different. Generally, this
test required some factor to be observed concerning the function of incinerator
unit.

Waste Feeding System.

The waste feeding must be in balance with the incinerator unit capacity
and the waste specification requirement.

1. Solid Waste
The waste feeding is regulated by a certain time interval. The time interval is
between 10 to 15 minutes. If we made a time interval for 15 minutes, the
waste feeding required is 75 kg for each interval. This strategy should be
done to obtain the optimal burning result.
3.4.

Emission measur e m e n t s
Incinerator performance can be evaluated easily on its capability to

achieve burning capacity with good emission and the easiness of operation.
Emission is one of indicator aspect of a complete incinerator process. Visually,
the quality of emission can be detected by opacity percentage, starting by 0
(clear/smokeless) to 100 (black dense smoke). Qualitatively, the threshold of
the emission has been formulated by Bapedal

Regulation

into Kep-03

/Bapedal/09/1995.
Bapedal Regulation ( Kep 03 / Bapedal / 09 / 1995 )
1. Particle
50 mg/Nm 3
2. Sulfur dioxide (SO 2 )

250 mg/Nm 3

3. Nitrogen dioxide (NO 2 )

300 mg/Nm 3

4. Hydrogen fluoride (HF)

10

5. Carbon monoxide (CO)

100 mg/Nm 3

mg/Nm 3

6. Hydrogen Chloride (HCl) 70

mg/Nm 3

7. Hydrocarbon ( as CH 4 ) 35

mg/Nm 3

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8. Arson (As)

mg/Nm 3

9. Cadmium (Cd)

0,2

mg/Nm 3

10. Chromium (Cr)

mg/Nm 3

11. Lead (Pb)

mg/Nm 3

12. Mercury (Hg)

0,2

mg/Nm 3

13. Talium (Tl)

0,2

14. Opacity

mg/Nm 3

10

Measurement of the 14 parameters is done with three condition of testing :

empty condition, normal condition and overload condition.

3.5.

Ash measure m e n t s

Quantity of ash from the remnant of the burning depends on the type of waste
impact. If the input of waste contains inorganic material substance, like heavy
metal, calcium, etc. The percentage of ash produced will increase. The
percentage of ash weight of the correspond with the weight of the waste
feeding.
4. OPERATING SEQUENCE
4.1.

PREPARATION

1. Check the condition of chamber. Remove the ash from the combustion
chamber.
2. Closed and lock Charging Door and 2 nd Chamber Ash Door .
3. Check the condition of 1 st Chamber
Chamber

Ther mocouple

thermocouples

are

broken.

Therm ocoupl e

(TE 2) . Report
Incinerator

can

to your

(TE 1) and 2 nd
supervisor

if the

not

be

operated

if

the

Selector,

All

Burner- Control

thermocouples are broken.

4. Check feeding system ( bucket ) condition.
5. Make

sure

to

set

Mode

Operation

Selectors Lever at OFF position. It prevents all equipments in the

incinerator work prematurely.
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23

6. Connect to power supply to activate main control panel and all equipment
controlled. Lift Pow er Supply lever and all MCB to ON position.
7. Ensure AC POWER ON upside control panel illuminate. If they do not
illuminate, stop the process and report to your supervisor.
8. Activate main control panel by pressing [MAIN SWITCH START] .
9. Ensure

PRIMARY

TEMPERATURE

CONTROLLER

and

SECONDARY

TEMPERATURE CONTROLLER active. If they do not active, stop the

process and report to your supervisor.

Set

PRIMARY

TEMPERATURE

CONTROLLER

to

650

and

SECONDARY TEMPERATURE CONTROLLER These values depend on

wastes burned and quality of emission. Setting of PRIMARY CHAMBER
TEMPERATURE CONTROLLER could be raised for wastes that take
time to burn.
10. Turn

Mode

Operation

Selector

to

[AUTOMATIC

OPERATION]

or

[MANUAL OPERATION]
a. If [MANUAL OPERATION] is selected, do Purging

operation then.

Purging operation will be explained in the following chapter.

b. If

[AUTO MATIC

OPERATION]

is

selected,

Press

[AUTO MATIC

OPERATION START] button to begin incinerator operation. Then, PLC

system will work. Operating procedure between PLC system and manual
operation are the same but PLC system do it automatically. Operator
should supervise working control panel until [READY TO LOAD] Lamp
illuminate.
Note:

Automatic operation is the default methode for operating UNOCAL

incinerator.
-

Manual operation can only be done for inproperly operation or for

burner system manual check .

4.2.

PURGING
Purging means activity to discharge combustible gasses that may still

remain in combustion chamber. These combustible gasses may cause an

exploding while the burners are turned on. Purging is done by pressing
[PRIMARY AIR BLOWER (B- 100) ] , [SECONDARY AIR BLOWER (B- 101) ] ,
[AIR BLOWER BURNER START (B- 101A) ] , [AIR BLOWER BURNER START
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24

(B- 101B)] , [AIR BLOWER BURNER START (B- 103A) ] , and [AIR BLOWER
BURNER START (B- 103A) ] push button to ON position. Lakukan hal tersebut
selama kurang lebih 5 minut es .
Note: For Automatic operation, PLC will lock out all burners while it is purging
4.3.

PREHEATING
Preheating is an activity that heat refractory slowly in order to prevent

cracking

at refractory

combustion

chamber

because of suddenly
temperature

to

expansion, and conditioning

achieve

ignition

point

of

wastes.

Preheating should be done in this ways:

1. Ensure AIR BLOWER BURNER B- 103A and AIR BLOWER BURNER B103A at ON position.
2. Activate

Burner

(C- 101A)

[BURNER CONTROL 3]

and

Burner

(C- 101B)

and [BURNER CONTROL 4]

by

turning

switch to ON

position. Aktifnya kedua burner ini diawali dengan menyalanya lampu

[PURGING BURNER 3] dan [PURGING BURNER 4] beberapa saat (+ 15
detik) dan ditandai dengan menyalanya lampu pada [BURNER CONTROL
3] dan [BURNER CONTROL 4] .
3. Preheating 2 nd Chamber is done for about 15 - 30 minut es or until 2 nd
Chamber temperature achieve + 300

C.

4. After 2 nd Chamber temperature has achieved about 300

C, Preheat 1 st

Chamber dengan melakukan hal- hal berikut.

5. Ensure [AIR BLOWER BURNER START (B- 101A) ] and [AIR BLOWER
BURNER START (B- 101B)] at ON position.
6. Activate Burner 1 (C- 100A) & Burner 2 (C- 100B) by turning [BURNER
CONTROL 1] and [BURNER CONTROL 2] switch to ON position. Aktifnya
kedua burner ini diawali dengan menyalanya lampu [PURGING BURNER
1] dan [PURGING BURNER 2] beberapa saat (+ 15 detik) dan ditandai
dengan menyalanya lampu pada [BURNER CONTROL 1] dan [BURNER
CONTROL 2] .
7. Preheat 1 st Chamber until about 500 C for 1 st Chamber tem per a t u r e
and/ 350

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068

C for 2 nd Chamber tem per a t u r e .

25

Note: Pelaksanaan preheating dapat dipercepat dengan memperkecil laju alir

udara pada Pimary Air Blow er (B- 100) dan SECONDARY AIR BLOWER (B101) . Laju alir udara diatur melalui damper- damper yang terdapat di jaringan
pipa kedua blower tersebut.
4.4.

BURNING
After preheating mode done, Setelah dilakukan Preheating, limbah baru

bisa diumpankan.

Pada tahap

ini, prosedur

pengperasian

mode

operasi

manual dan otomatis adalah sama. Tahap operasi Burning ditandai dengan
menyalanya lampu [READY TO LOAD] . Setelah lampu tersebut menyala,
putar Wast e Type Selector ke arah jenis limbah yang akan dibakar. Begitu
ditentukan jenis limbah yang akan dibakar, lampu [READY TO LOAD] akan
padam sedangkan [BURNING OPERATION] akan menyala.
4.4. 1. LIQUID WASTE COMBUSTION
1. Make sure that Charging Door is closed. If Charging Door is open, limit
switch will shut Primar y Air Blow er , 1 st Burner , and 2 nd Burner off .
2. Jika Waste Type Selector diarahkan ke arah [LIQUID WASTE TYPE] ,
Liquid Transfer

Pump akan aktif yang ditandai dengan menyalanya

lampu [LIQUID WASTE]

3. Pembakaran liquid waste hanya dapat dilakukan jika temperature primary
chamber di atas 500 oC. Setting ini bisa diubah sesuai dengan karakteristik
limbah dan hasil emisi. Perubahan setting temperature untuk atomizer
dilakukan di [ATOMIZI NG TEMPERATURE CONTROLLER (TIC- 3).
4. Laju debit limbah cair yang akan dibakar diatur secara proporsional oleh
Temper a t u r e Control Valve berdasarkan fungsi temperature.
4.4. 2.

SOLID WASTE COMBUSTION

1. Make sure that Charging Door is closed. If Charging Door is open, limit
switch will shut Primar y Air Blow er , 1 st Burner , and 2 nd Burner off .
2. Jika Waste Type Selector diarahkan ke arah [SOLID WASTE WASTE
TYPE] , lampu [SOLID WASTE] akan menyala.
3. Open Charging Door and throw limbah padat ke dalam incinerator.
4. Waste

entering

the

incinerator

chamber

must

be met

the

capacity

requirement by incinerator and the quantity of the loading should consider

the type of waste that will be burned. Loading of waste is + 15 22,5 kg
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26

per 10 - 15 minut es dengan komposisi kurang lebih 98.84%- w solid filter,

0.29 %-w oily rags, 0.29 %-w paper, 0.29 %-w plastic and 0.29 %-w clinical
waste.
5. After the waste entered to 1 st Chamber, observe any change that occurred
at combustion process, whether the temperature rise either emission
visually. Adjust the Primar y and Secondar y Air Blow er Damper position
to get optimum combustion condition.
6. Practically, 1 st and 2 nd Burner turned on only at the first operation time
and at a condition that rapid combustion rate was needed (for burning kind
of waste that really hard to burn).
7. Perhatikan operasi incinerator sampai tiba saat limbah padat diumpankan
kembali.
Notes: -

Dont burn the waste beyond design capacity of incinerator.

Dont burn the unusual waste besides the recommended waste.

Dont ever put explosives waste inside the incinerator, such as

pressurize tin, metals, glass or any waste that could be dangerous.

Pelemparan limbah padat harus dilakukan hati- hati sehingga abu di

dalam incinerator tidak beterbangan.

4.5.

COOLING
Waktu untuk tahap pendinginan ini telah diatur dalam PLC. Default

waktu yang telah ditetapkan sekitar 8 jam. Cooling process follows this
procedure:
1. Tekan [COOLING START] Push Button untuk memulai tahap operasi
Cooling .
2. Make sure that lampu di push buttons of [AIR BLOWER BURNER START
(B- 101A) ] , [AIR BLOWER BURNER START (B- 101B) ] , [AIR BLOWER
BURNER START (B- 103A) ] , and [AIR BLOWER BURNER START (B103B)] menyala.
3. Make

sure

that

lampu

[PRIMARY

AIR

BLOWER

(B- 100) ]

and

[SECONDARY AIR BLOWER (B- 101) ] menyala.

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27

4. Turn

[BURNER

CONTROL

1],

[ BURNER

CONTROL

2 ],

[ BURNER

CONTROL 3 ] and [BURNER CONTROL 4] lever at STOP position.

If the time for cooling reaches the setting time (8 hour), system will shut
Control

Panel,

All

Air

Blow er

Burners,

Primar y

Air

Blow er,

and

Secondar y Air Blow er automatically.

5. OPERATING CONDITIONS
5.1.

OPERATING SET POINT

1 st Chamber Temperature : 650 oC

2 nd Chamber Temperature : 1100 oC

5.2.

INSTRUMENTATION SET POINT

DESCRIPTION
Local Panel ESDV
Tank (T-100) HI HI Level
Tank (T-100) LO Level
Tank (T-100) LO LO Level
Primary Fuel LO Pressure A
Primary Fuel LO Pressure B
Primary Fuel HI Pressure A
Primary Fuel HI Pressure B
Burner Air LO Pressure A
Burner Air LO Pressure B
Primary Flame Fail A
Primary Flame Fail A
Primary LO Temperature
Primary HI Temperature
Atomizer Liquid LO Pressure
Solid Waste Door Open
Secondary Fuel LO Pressure

TAG NO.
ESDV-100
LSHH-100
LSL-100
LSLL-100
PSL-100A
PSL-100B
PSH-100A
PSH-100B
PSL-101A
PSL-101A
BE-100A
BE-100B
TAL-100
TSH-100
PSL-102
ZSO-100
PSL-103A

A
Secondary Fuel LO Pressure

PSL-103B

B
Secondary Fuel HI Pressure

PSH-103A

A
Secondary Fuel HI Pressure

PSH-103B

SET POINTS
None
None
None
None

UNIT

B
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Burner Air
Burner Air
Secondary
Secondary
Secondary
Secondary
Atomizing

LO Pressure A
LO Pressure B
Flame Fail A
Flame Fail B
LO Temperature
HI Temperature
Control

PSL-104A
PSL-104B
BE-101A
BE-101B
TAL-101
TSH-101
TIC-3

Temperature
Instrument Air LO Pressure

PSL-105

6. MAINTENANCE PROCEDURES
6.1.

COMBUSTION CHAMBER MAINTENANCE

6.1. 1. Combustion Chamber Cleaning

Material that can not burn will become ash and sometimes slag. These
materials

must

be cleaned

from

combustion

chamber . Ash can

cause

decreasing combustion chamber capacity and slag can disturb air flow and
auxiliary energy supply from burner. This cleaning should be done periodically
or when refractory will be repaired.
Suggested cleaning Method can use following procedure:
a. Decrease Combustion Chamber temperature until ambient temperature
before Special cleaning (when repairing refractory will be done), or until its
temperature below 100

C when periodically cleaning will be done (ash

cleaning).
b. Open Main Charging Door , Ashes Door , and Peephole so air circulation
get proper.
c. Wear proper personal safety equipment such as: safety glasses, dust mask,
helm, gloves, hard- soled rubber shoes, cloth that protects from direct
contact with ash, and other safety equipment that ensure work safety.
Be careful to toxic materi al that may contain in the ash .
d. Get the ash out from combustion chamber carefully and put it in safety
place (like metal barrel). Dont spill it in anywhere.
e. If the ash is still hot; before throw it away, cold the ash by little water to
prevent fire hazard possibility.

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f.

Clean the slag that is shaped at burner hole, air channel (tuyere), main
charging door, and ashes door.

Do not clean slag on refractor y surface ruggedly.

6.1. 2. Checking and Repairing Leakage at Refractor y
Leakage at refractory can be caused by refractory age, improper waste
feeding, colliding or scrapping with hard material, and preheating is not done.
Repairing leakage at refractory should be done to prevent the worst thing,
except

the

leakage

at

refractory

does

not

endanger

operator

or

the

incinerator. Following procedures can be done to repair the leakage at

refractory:
a. Check the possibility to repair it by self. If it is impossible, report it to your
supervisor. If it is possibly to repair by self, you can follow next procedures.
b. Clean combustion chamber from ash first to ensure this working safety.
c. Clean the leakage from slag, ash, and lampblack carefully.
d. Patch the leakage with proper castable .
e. Let the castable dry perfectly and naturally (min. 24 hours).
Do Heating Up to the patch by recommended procedures.

6.1. 3. Maint e n a nce of Shell

Shell wall used in the incinerator is made from mild steel coated with
epoxy coating or heat resistant coating. Shell construction designed, has fulfill
safety pre- requirement, and lifetime to incinerator user.
The following items must be considered in shell maintenance:
a. Checking Incinerator physically
Checking

incinerator

physically

includes

overall

shell

condition,

completeness of equipment (burner, blower, valve thermocouple, etc) and

at

the

original

place,

coat

condition,

Support

structure

condition

(straightness) even shell frame.

b. Shell Condition
Operational condition and the atmosphere of surrounding environment
can influence incinerator condition. Cleanness of the incinerator influence
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30

user convertible and incinerator lifetime.

Thats why, the incinerator need

to be cleaned periodically from lampblack, fuel, dust etc. Shell is cleaned

by dry washing or wet washing. The incinerator can be washed by solution
that is not poison, not corrosive, and does not damage shell coating.
c. Coating
In the months, the effectiveness of coating to protect the incinerator
decreases. Thats why, the incinerator need to be coated again periodically.
Suggested kind of coating is the coating that has service temperature min.
150 o C.
Wear personal safet y equipm e n t properl y while you are coating
the inciner a t o r (helm, safet y glasses, masker, hard- soled rubber
shoes, and safet y belt for a job at more than 2 met ers height ) .
d. Greasing
The incinerator has moving parts (bearing, hinge, etc) that need periodically
maintenance. The maintenance is greasing to the moving parts in order to
work properly. Suggested kinds of greasing are paste ( grease ) or lubricating
oil .
6.2.

MAINTENANCE OF FUEL SYSTEM

6.2. 1. Maint e n a nce of Piping System

Even piping system designed has considered safety aspect, maintenance
must be done to keep fuel system works properly. Maintenance that must be
considered at piping system includes:
a. Physical condition of piping must be in good condition, avoid heat contact
directly, no deformation, and no rust.
b. Valve function must be at good condition.
c. No any leakage.
d. No slugging that block fuel flow.
e. Connection between pipes must be at condition.
6.2. 2. Maint e n a nce of Fuel Paper Strainer Filter
Fuel paper strainer filter will filter solid impurity in fuel. In order to optimize
the fuel paper strainer filter function, fuel purity and periodically checking is
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absolutely needed. Periodically checking of fuel paper strainer filter can be

worked through these following way:
a. Look indications while burner is turning on. If the burner works unstable, It
must be caused fuel flow blocking.
b. Look directly at glass indicator outside fuel strainer if there is any impurity
in paper strainer.
c. Replace fuel paper strainer filter regularly.
Note: Do not detach fuel paper strainer filter when burner will be operated.
6.2. 3. Maint e n a nce of Burner
The system must be maintained at regular intervals, checking all facilities,
especially the safety facilities, flame supervision (ionizing effect), low air cutout, low- water cut- out, thermostats or stream pressure regulators for proper
operations.
The gas firing installation must be checked or serviced once a year to
ensure reliable operation, functional safety and economy. This should be done
by a specialist of the manufacturing company or a specialist authorized by
manufacturers.
The

solenoid

or

motor

valves

have

to

be

checked

for

tightness.

Furthermore, a test log or record has to be made from which the following
values can be taken:
a. The amount of gas being fired (Nm3/h)
b. Gas flow pressure upstream of pressure regulator (mbar, bar)
c. Gas flow pressure upstream downstream of pressure regulator (mbar)
d. CO2 -content of the flue gas (%)
e. CO-content of the flue gasses (mg/m 3 respired, ppm)
f.

Flue gas temperature ( o C).

g. Positive or negative firebox pressure (mbar)

6.3.

MAINTENANCE OF AIR SYSTEM

6.3. 1. Maint e n a nce of Blow er

Blower supplies O2 needed in primary chamber and secondary chamber in
order to produce perfect combustion. Blower maintenance is easy, even
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32

blower should be operated carefully. The following items can become a guide
to operate blower safely:
a. Ensure air supply in combustion chamber produce perfect combustion.
b. The air should be clean from dust, oil, and other dirt.
c. Avoid the blower of heat expose directly that can damage the blower.
d. Check every connection and sealing to avoid the possibility of leakage that
will produce inefficiency from blower itself.
e. Check every connection and terminal to ensure movement of blower blade
correct compared with cycle flow direction sign.
Give a report to your supervisor if blower acted in abnormal performance
condition.
6.3. 2. Plenum and Ducting Maint e n a nce
Plenum

and Ducting

that

will used have been designed to specific

capacity. In order to make Plenum and Ducting works in optimum condition, it

has to made a routine check. Generally, the maintenance needed is very easy
in accordance with some careful points such as:
a. The coating is not cracking
b. There is no rust
c. There is no leakage
The seal should do its function well
6.4.

ELECTRICAL AND CONTROL SYSTEM MAINTENANCE

6.4. 1. Electrical Checking, Maint e n a nce, and Repairing

Incinerator units at PT. Gulf Resources Indonesia (Conoco- Phillips) using
electrical energy as energy to move some of it parts, indicator, and control for
incinerator unit system. Electrical equipment at this incinerator using 3 phase
and 1 phase power supply depends of equipment specification. Equipment
used in this unit has adjusted to fulfill consumers needs and also taking care
to safety factor aspects to expect the unexpected condition. But in order to
ensure the incinerator in good condition and safe to operate by operator,
incinerator itself, and for the environment; the checking, maintenance and
repairing procedure always needed to be done.
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Some points that has to be take care of from electrical view, includes:
a. Power supply is sufficient to operate the incinerator unit.
b. Main cables and the insulation have to be in good condition.
c. Avoid main cables from heat exposure.
d. Main cable position has to be safe, not pressed and should not hinder
peoples way.
e. There is no cables insulation that gets peeled off.
f.

Terminal and joints condition should in good condition.

g. Check carefully the electrical parts before operating the incinerator unit.
h. Periodically, check the electrical system.
i.

Every time the electrical check set up, incinerator should in SHUT DOWN
position and the repairing procedure has to be done by the expert that
coordinated by supervisor.

j.

Stop the operation of incinerator if there is any suspicious abnormal

function of electrical system and report to supervisor.

Attent ion:
This inciner a t o r
therefor e the

is using high voltage

and electrical curren t ,

and

carefulness every time this unit operat e d should be

emphasized.
6.4. 2. Control System Checking, Maint en a nce, and Repairing
Unit Incinerator at PT. Gulf Resources Indonesia (Conoco Phillips) is
provided by adequate control system to monitoring condition at the time
incineration and cooling process proceed. Temperature, as an important
parameter in incinerator process, controlled by digital thermo- control that
monitoring temperature in combustion chamber when incinerator operated.
Burner as heat source, will automatically stop when working temperature
reached to protect burner from over heating that could be dangerous or
destroy the installed incinerator. As the heat receiver sensor, thermocouple
installed knock down compatible to make the checking, maintenance, and
replacing could be easier.
As guidance, below will be describing some important points that should be
done to control temperature efficiently and effectively. Avoid temperature
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34

combustion

chamber

that

exceeding

1200 oC

to

protect

thermocouple

destruction.
a. Give attention to every temperature drastic rise or drop to anticipate to
wrong waste feeding possibility, quantity of waste or false response from
thermocouple and thermo- control.
b. Checking

and

routine

maintenance

done

by

means

cleaning

up

thermocouple from soot and replacing if there is any damage.

c. Isolation, joints, and cable terminal should be in well and good condition.
Make sure that ther m ocoupl e sleeve (ceramic) condition in good
condition, no cracking or broken.
Checking at control panel includes physical condition, function of every
component inside and make sure that all components in good condition.
Attent ion:
Every

checking,

maint en a nce,

and

repar a t i on

to

control

system

should use proper tools, such as multi tester, test pen, clamp meter ,
etc., and done by exper t technicians that have know - how experi ence
and know ledg e about electricity and control systems.
6.5.

MAINTENANCE AND REPAIRING SCHEDULE

No.

ITEMS

PERIODE

Chamber cleaning up
1
2
3

First chamber ash discharging

Second chamber ash discharging
Cleaning for repairing

1 day (solid waste)

1 week
Depend on necessity

Cracking repair
1

Checking for cracking on refractory

2 months

Shell Maintenance
1
2
3
4

Physical check
Shell Cleaning
Re-paint the incinerator ( Epoxy Coat )
Bearing lubrication, hinge (grease, liquid lubricant)

1
3
6
2

day
days
months
months

1
1
1
6

week
year
month
months

Fuel System Maintenance

1
2
3
4

Fuel
Fuel
Fuel
Fuel

tank physical check

tank re- paint (Epoxy Coat)
System functional check
tank drain

Piping Maintenance
1
2
3

Manual valve function checking

Joints checking
Pipe re- paint

Engineering
068

1 month
1 day
1 year
35

Fuel Paper Strainer Filter Maintenance

1
2
3

Checking paper strainer quality

Replacing 1 st Burner Paper Strainer
Replacing 2 nd Burner Paper Strainer

1 day
6 months
6 months

Burner Maintenance
1
2
3
4

Photocell cleaning up
Joints checking
Total Burner checking and cleaning
Solenoid Valve Burner cleaning up

1
1
3
3

month
day
months
months

1
1
1
6

day
month
month
months

1
6
1
1

month
months
month
month

Blower Maintenance
1
2
3
4

Blower physical check

Joints checking
Tighten Blowers screw
Blower total checking

Electrical Maintenance and Checking

1
2
3
4

Joints, terminal and components checking

Power cable condition checking
Thermocouple checking
Control panel components checking

7. TROUBLESHOOTING
At this chapter, we would describe operational problems that potentially
occurred to incinerator, the source of the problems, and how to handle those
problems. The operational problems such as formation of black and white
smoke,

leakage

smoke

from

combustion

chamber

or

other

openings,

excessive auxiliary fuel usage, and incomplete burnout (poor ash quality).
These operational problems can be minimized through proper operation of the
incinerator together with an effective preventive maintenance.
7.1.

EXCESSIVE STACK EMMISIONS

The proper

operation

of the incinerator

results in relatively

low

emission rates. Excessive emissions form white or black smoke. Excessive

emission rates can usually be attributed to one of the following causes:
a

Set point for the secondary chamber temperature is not high enough.

Excessive negative draft in the primary chamber.

Excessive air supplies in the primary chamber.

Inadequate air supplies to secondary chamber.

Operating at too high primary chamber temperature.

Overcharging.
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36

Problem wastes (composition of wastes).

7.1. 1. Black Smoke

The appearance of black smoke indicates the presence of unburned
carbonaceous material. Dense black smoke is caused incomplete combustion
is occurring.

Incomplete

combustion

is due

to

insufficient

amounts

of

combustion air in second chamber and is usually the results of overcharging,

charging of a highly volatile material, or operating the primary chamber at too
high temperature. The following steps may assist in eliminating black smoke:
1. Check/increase secondary chamber combustion air;
2. Check/decrease primary chamber combustion air.
3. Check/increase secondary chamber temperature.
4. Check/decrease primary chamber temperature.
5. Decrease wastes weight each time loading.
Should these steps fail to eliminate the black smoke, evaluate the
composition of the material remaining to be charged. Highly combustible
materials (i.e., rubber, plastics, etc) that are charged in too great a proportion
to other refuse will results in a combustion rate, which is too rapid. These
materials may be charged in relatively small quantity compare to other
wastes.
If such materials must be burned frequently, experimentation as to the
quantity that may be charged along with other materials may be necessary.
Generally, highly combustible materials must be charged at less than 10
percent by weight of the total charged. If the wastes contain a significant
amount of plastics, Decreasing primary chamber temperature may assist in
reducing emissions. Operating the primary chamber at too high temperature
can cause the plastics to rapidly volatilize.
7.1. 2. Whit e Smoke
The appearance of white smoke from the exhaust stack indicates the
presence of small aerosol in the effluent gas. White smoke may usually be
attributed to following causes:

Excess air that is entering the incinerator, cause entrapment of micron

sized particles.
Engineering
068

37

Secondary chamber is operating at too low temperature causing premature

cooling of the effluent gas.

Following steps may assist in eliminating white smoke:

1. Check or increase operating temperature of secondary chamber;
2. Check/decrease combustion air that is entering primary chamber;
3. Decrease combustion air that is entering secondary chamber.
If these adjustment of the combustion parameters fail to stop the
issuance of white smoke, examine the material to be charged. Possibly the
white smoke is the result of finely divided noncombustible mineral material
present in the waste which is being carried out the stack. Paper sacks that
contain pigment or other metallic oxides, and minerals such as calcium
chloride, generate fine inorganic particulate, which causes white smoke.
The appearance of a white plume (other than a condensing water vapor
plume) a short distance away from the stack probably indicates that Hydrogen
Chloride is condensing. Unfortunately, there is no incinerator adjustment that
will solve this problem. One solution is to reduce the amount of chlorinated
plastics to be charged.
7.2.

Leakage of Smoke from Combustion Chamber

The leakage of smoke through combustion chamber indicates that

positive pressure differential exists in the combustion chamber. Positive

pressure can be caused by excessive combustion air, by excessive charging of
a

highly

volatile

material,

by

too

high

primary

chamber

operating

temperature. The following steps may help eliminate leakage of smoke:

a

Decrease primary chamber operating temperature.

Decrease wastes weight each charging.

Adjust air regulator or damper set points.

7.3.

Excessive auxiliary Fuel Usage

Improper combustion air distribution entering combustion

chamber,

improper air regulator or damper set points, charging a lot of wet wastes, and
wastes that are inconsistently charged can result in excessive fuel usage. If
the combustion air in primary chamber is incorrect or if there is excessive
combustion air, the waste bed will completely burn in some area and not burn
Engineering
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38

at all in other areas. The gasses conveyed to secondary chamber will already
be fully oxidized, and auxiliary

fuel will be necessary to maintain

the

secondary chamber temperature.

If the incinerator is not receiving enough heat input in the form waste
burning to maintain its temperature set points, then the unit will supply its
own heat in the form of auxiliary fuel. Consistent charging of waste at regular
time intervals at a rate 100 % from design capacity, will reduce the amount of
auxiliary fuel required and will enhance the incinerators performance.
The following actions may assist in reducing auxiliary fuel usage:
1. Charge waste at regularly timed intervals at a rate consistent with 100
percent of the design (thermal input) capacity;
2. Check/reduce combustion air level in secondary chamber;
3. Check combustion air level and distribution in primary chamber;
4. Reduce wet waste charged into incinerator;
5. Check sealing system for air leakage;
6. Check the fuel trains and burners for fuel leakage.
7.4.

Incompl et e Burnout- Poor ash quality

Wastes that have not become ash yet sign incomplete burnout. This

problem may be attributed to following causes:

1. 1 st Burner and 2 nd Burner are not properly function so its flame is not
enough to burn wastes and to keep wastes burning.
2. Poor combustion air distribution in primary chamber.
3. Overcharging and charging too much wet waste.
Burner malfunction may arise due to burner power loss, clogged nozzle
burner, failure of the flame safeguard, or leaking fuel trains. Following step
can eliminate these problems:
1. Check power supply to burners.
2. Check burners for clogged nozzle and clean as required.
3. Check the operation of the burner safeguard system as outlined in the
owners manual.
4. Check fuel trains and burner assembly for fuel leakage and repair as
required.
Engineering
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39

5. Perform preventive maintenance on regular basis.

Poor combustion air distribution in primary chamber can be caused
improper combustion air setting, clinker buildup around tuyeres, and tuyeres
clogged with ash or slag from previous charges. These following items can be
done to repair combustion air system:
1. Check each tuyere in primary chamber for ash clogged and rod out as
required.
2. Clean ash inside primary chamber.
Check for combustion air required and adjust to the proper setting as required.
8. TECHNICAL DATA
8.1.

FIRST CHAMBER

Size (outer dimension) : 2600 mm (L) x 1750 mm (W) x 1950 mm (H)

Heat Area : 1,85 m2

Duty : 1.81 MMBTU/HR (Normal condition)

2.36 MMBTU/HR (Maximum condition)

8.2.

SECOND CHAMBER

Size (Outer Dimension) : 1750 mm (D) x 2600 mm (H)

Duty : 0.96 MMBTU/HR (Normal Condition)

1.24 MMBTU/HR (Maximum Condition)

8.3.

EXHAUST STACK

SIZE (Inner Dimension) : 420 mm (D) x 10 m (H)

8.4.

PRIMARY AIR BLOWER

Code : B-100

Type : Centrifugal Fan

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40

Capacity : Max. 14 m3/min.

Static Pressure : 12 mm H2O

Power : 0.375 kW

Brand : Taiko Kikai

8.5.

SECONDARY AIR BLOWER

Code : B-101

Type : Centrifugal Fan

Capacity : max. 14 m3/min

Static Pressure : 12 mm H2O

Power : 0.375 kW

Brand : Taiko Kikai

8.6.

PRIMARY BURNER

Code : C-100 A/B

Quantity : 2

Capacity : 30 Nm3/hr (= 240 000 kcal/hr)

Type : PGN 0

Brand : RAY

8.7.

SECONDARY BURNER

Code : C-101 A/B

Quantity : 2

Capacity : 30 Nm3/hr (= 240 000 kcal/hr)

Type : PGN 0

Brand : RAY

8.8.

LIQUID TRANSFER PUMP

Code : P-100

Capacity : 24 L/min
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41

Type : 20 GPE Gear Pump

Power : 0.75 kW

Brand : EBARA

8.9.

BUFFER TANK

Code : T-100

Size : 1200 mm (D) x 1900 mm (L)

Capacity : 13.5 BBL

9. REFERENCE DRAWINGS

No
.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Ass'y / Sub- Ass'y

Ass'y / Sub- Ass'y Name
No.
P&ID (Solid & Liquid Waste Incinera tor
Central Gas Plant)
PY-01- 068- 00- 00
Incinera to r
PY-01- 068- 01- 01
Primary Chambe r Shell
01- 01Skid for Primary & Secondary Chambe r
02
01- 02Primary Chamber Door
00
01- 03Peephole Cover & Sight Glass
01
01- 03Cover & Swing Burner
02
01- 04
Primary Chambe r Refractory
PY-01- 068- 02- 00
Secondary Chambe r (General
Assembling)
02- 01
Secondary Chambe r Shell
02- 02
Manhole Door
02- 03Secondary Chambe r Accessories
00
02- 03Peephole
01
02- 03Cover & Swing Burner
02
02- 05
Secondary Chambe r Refractory
PY-01- 068- 03- 00
Exhaust Stack
03- 01Shell
00
03- 01Main Shell
01
03- 01Conus
02
03- 02
Sampling Platform

Engineering
068

Draw ing
No.
-

Doc.
Status
DWG.Doc

A-068- 01
B-068- 02
B-06802/02
B-068- 03

DWG.Doc
DWG.Doc
DWG.Doc

B-06804/02
B-06804/03
B-068- 05
C-068- 01

DWG.Doc

C-068- 02
C-068- 03
C-06804/01
C-06804/02
C-06804/03
C-068- 06
D-068- 01
D-06802/01
D-06802/02
D-06802/03
D-068-

DWG.Doc
DWG.Doc
DWG.Doc

DWG.Doc

DWG.Doc
DWG.Doc
DWG.Doc

DWG.Doc
DWG.Doc
DWG.Doc
DWG.Doc
DWG.Doc
DWG.Doc
DWG.Doc
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Exhaust Stack Refractory

Atomize r

03/01
D-06803/02
D-06803/03
D-068- 04
E-068- 02/02

Atomizer Piping Syste m

E-068- 02/03 DWG.Doc

Liquid Waste Tank

E-068- 02/04 DWG.Doc

Fuel Supply Syste m

Gas Burner for Primary Chamber
Gas Burner for Secondary Chamber
Air Supply System
Blower for Primary Chamber
Blower for Secondary Chamber
Plenum & Ducting for Primary Chamber

DWG.Doc
Tex Doc
Tex Doc
DWG.Doc
Tex Doc
Tex Doc
DWG.Doc

Control & Electrical System

Controller & Instrument
Sensor
Box Panel
Compone n t
Wiring

F-068- 02
G-068- 01
G-06802/01
G-06802/02
H-068- 01
H-068- 02
-

Wiring Diagra m

H-068- 03

DWG.Doc

21

03- 02

Cage

22

03- 02

Ladder

23
03- 05
24 PY-01- 068- 04- 0601
25
04- 0602
26
04- 0603
27 PY-01- 068- 06- 04
28
06- 01
29
06- 02
30 PY-01- 068- 07- 00
31
07- 01
32
07- 02
33
07- 0301
34
07- 0302
35 PY-01- 068- 08- 00
36
08- 01
37
08- 02
38
08- 03
39
08- 04
40
08- 0500
41
08- 0501
42
08- 0502
43
08- 0503
45 PY-01- 068- 09- 00
46 PY-01- 068- 10- 00
47
10- 01

10.

Plenum & Ducting for Secondary Chamber

Wiring Mate rial

DWG.Doc
DWG.Doc
DWG.Doc
DWG.Doc

DWG.Doc
DWG.Doc
Tex Doc
Tex Doc
DWG.Doc
Tex Doc
-

Tex Doc

Cable Distribution

H-068- 04

DWG.Doc

Rain Shelter
Air Pressure
Air Pressure Piping

I-068- 01
DWG.Doc
P-068- 01/01 DWG.Doc
P-068- 01/02 DWG.Doc

ATTACHMENTS

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43