Job. N. 261 908054 Doc. N.

ffiryr§-:?rygl Customer

Plant:
BAPCO Rev. 0

HTH 2sMWFO/PA NF QCP233O1 B

SERVICE ACTIVITY
REPORT
From 0110312020 to 06/03/2020

2
I
0 Dec. 07, 2006 issue
HEV. Date Description Prepared Checked Approved
 Job. N. 261 908054 Date 06103t2020
f;annnn ffcna
re§ Customer BAPCO PS3 Rev. n
Plant:
HTH25MWiFO/PA Sr.Nr QCP233O1 B
SERVICE ACTIVITY REPORT

) Heater general inspection (internal and external)

Wiring Cable
Wiring cable on Boiler side was damage ftrr time,sun & enviromental condition, all external protection is
done

cable to JB on boiler side QCP23301B

cable connection to CRUDE OIL regulation Valve

 Job. N. 261 908054 Date 06t03t2020

reilf;annun ffi*n* §nersia Customer BAPCO PS3 Rev. 0

I
Plant: I urHzsMWFoiPA Sr.Nr I
I

QCP23301B
I

SERVICE ACTIVITY RE PORT

Burner tip, tube and diffuser inspection and cleaning or replace

Replace pilot gun & cleaning bumer plate.

refractory side is not

actually broken but was at
limit condition for maintaing
safety condition, strongly
suggested to replace with a
netv one.

H
Y
'.tA

Remove all accumulated soot from heater different compartments

Cleaning internal part ofHeater and air preheater.

Refractory condition inspection and repair if needed

Refractory side was at limit should be replaced as soon as possible same for refractory inspection's door
that was seriously damage

Inspection door burned & operation of repair, door should be changed with a new one
 Job. N, 261 908054 Date 06t03t2020

ffiU**nnn ffi*n* §n*rcia I Customer BAPCO PS3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP233O1 B
SERVTCE ACTIVITY REPORT

) Inspection coils condition for leak or damaged

THICKNESS CONTROL

Thickness control show value into admissible range, heater pipe thick is in good condition.

LEAK:

Diathermic Oiì Rupture disk Valve , should be replace.

LEAKINGFROM DIATHERMIC OILPRESSUREGAUGE, TO BE REPLACE

Diathermic Oil Leakage from coil Drain, should remove insolation & repair
 Job. N. 261 908054 Date 06t03t2020

ffiUu'",n*n §sn* *nergia I

Customer BAPCO PS3 Rev. 0
Plant:
HTH25MW/FO/PA Sr.Nr QCP23301 B
SERVICE ACTIVITY REPORT

Combustion Air pressure gauge missing, should be re-install

Crude Oil pressure Gauge, broken.

i:,m I

.l

Leak on Heat exchanger, crude oil side leah on diathelmic oil side
 Job. N. 261908054 i oat" 06t0312020

ffif; ean*un sc*na snersra Customer BAPCO PS3 Rev.

I 0
Plant:
HTH25MW/FO/PA Sr.Nr QCP23301 B
§effi

Leak on diathermic oil valve on heat exchanger E-23001B

FLEXBLE HOSE
High pressure Flexible hose should be replaced
ffi tan*un ffi;srt*trnengim
N

sERVtcE RcnvrrY
) Check, test and calibrate all protection and control devises where applicable

Fire Emergency stop of customer side was Not connected to Terminal, cable are
not present in the cabinet.

visual Level ofExpansion Tank not according ( real level show in pic was at 40%)
ONE of visual level should be replaced

BMS

BMS
@,1":. BMS on heater 233018 was damage , replace with
spare part on site
a new one, need to restore the

UV SENSORCONNECTION
UV sensor connection was modified fiom original drawing, was use a VFC from Kl22 to close
contact on BMS
instead the vFC of FIREYE uv sensor, fireye contact eneigise K122 relay.

TRACE HEATER
The Trace heater on crude oil Line are not working actually, NEED To BE REPLACED
ASAP.
Customer request is improve an upgrade in order to permii starting with diesel oil,
swap to crude oil and betbre stop
heater swap again to diesel in automatic, to flush the tine.
 Job. N. 261 908054 Date 06t03t2020

§annnn §on* §ner,6ia

ffiil I
Customer
Plant:
BAPCO PS3 Rev. 0

HTH25MW/FO/PA Sr.Nr QCP233O1 B

SERVICE ACTIVITY REPORT

SETTINCS OF FIEATER:

I
I

r-l,l r rl l,llli
lIti llxt,tlil

lrl _0 0
 Job. N. 261 908054 Date 06103t2020
§annnn ffir:n* §nergia
ffi§ I
Gustomer BAPCO PS3 Rev. 0
Plant:
HTH2SMW/FO/PA Sr.Nr QCP23301 B
SERVICE ACTIVITY ìT
SAFETY CHECK

All safety device installed was tested, attached doc form.

tsono Energia §.p.4.

1\lrtr!3r 6tLt{. iùrr;tt lr.':r,llnirrcM ciwrxiiwori
. .,.§\ ,1('"" :? . .u-ì,3,1,- .(,r:-il-,r,',
ri . J | (-.:. ,,.6-, ir,.;1 pr5r:rrr;
[1 fi,.-, - tL, .

e.nlit: brrù i.iìiìilxjnrr. r lyeb *ì*r.rùo! *. B1fu.....aaiif tl,n

ts*hts r§r*§§&
\), \v

Cliente: §i),?* ?3§

Collaudo Oispositivi di Sicurezza Generatore BONO

a _ rl./
Tipo 'r I;1 1 ?l"ll,1 Numero di fabbrica yt;1,'gii./! 6 _-

tllell:ilcl
i F:L{ar6g ,
rTzLa&$'8.
t,. '-.,/
.ì. '--
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.{Ulr,lr "',.,Jì I'\-,-',rJ
l:,jrllitlt .t,;:!
I :rr uti"4' i.; 1'>§r'r/1!,
. -Ld**Li:-ri ,
x!; tt i i, rr , tr, iJ ,'/
il
::ì
;!,L'fi)t
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l

iJtì§r!J;vJ
r'ì .»c (,. rr'

"i3: tvti

clìe tulti I drspositrv; o; sicurezza sopra

;,;:r.rir, u3n 1i; J... l[l .r;. ,;. -r:.,

 Job. N. 261 908054 Date 06t0312020

ffi §anrlsr-r ffirn* Hnergim

I
Customer
Plant:
BAPCO PS3 Rev. 0

HTH25MW/FO/PA Sr.Nr QCP23301 B

SERVICE ACTIVITY REPORT

OXYGEN PROBE
Oxygen probe on QCP2330lB not working, in stand by condition show 0.0% of 02 ,should be replaced
witha new one.

Blower compartment inspection and cleaning

Check Damper movement , remove internal impediment due for a construction of negative sample of DPT
combustion air, check movement & cleaning damper . Movement part was grease from customer.

Check /grease or replace the bearing of compassion air motor.

Check- Also motor of oil purnp & Fan was grease from customer regularly.

Doing hydro jet cleaning.

Job not possible ON SITE no hydro cleaning available

10
 Job. N. 261 908054 Date 06t03t2020

ffi§ f;annun H*nrl §naroia I Customer BAPCO PS3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301 B
SERVICE ACTIVITY REPORT

Perform chemical cleaning

Job not possible ON SITE

Perform Hydro test.

Job not possible ON SIT

Functional Check.

AIR FAN MOTOR

Air Fan Motor only running in LOCAL mode from JB on Heater side, switch to move from LOCAL to REMOTE
control was not used from a long time and now is out ofservice.
Switch should be replace ASAP in order to retum in normal working condition

IGNITION SEQTIENCE
During ignition sequence pilot time is not enough to ensure all the time correct working of boiler, often we had a
shutdown for lack of flame in main valve position.
Customer usually is use to by-pass the UV sensor signal ( really dangerous)
To fix situation properly we increase pilot time on I(130 up to maximum ( 30 sec). Solve it.

During Ignition sequence find problem with pilot valves, was neaessary
replace pilot line with new line initially designated to eCp2330lA .
The pilot valves also ifenergized didn't open, so it's necessary provide to
ship spare part ( 2 new pilot valves) and replace it.
On site at the moment there is NO spare for pilot valve available.

cleaning UV sensor lens , cleaning burner nozzle & flushing line with diesel oil.

IGNITION SEQUENCE
Ignition sequence become difficult with crude oil maintain a correct pressure drop due a problem on feedline not
,
traced( not working). so customer usually start with diesel oil then change to crude oil.
This operation is doing manually, sometimes they forgot diesel valve opin and fill the tank with return
of crude oil
(there isn't a check valve) so customer want to upgrade to an automatiCswitch from diesel into
crude oil.

11
 Job. N. 261 908054 Date 06t03t2020

fimn*nr: §*n* §nangia I Customer BAPCO PS3 Rev. I

Plant: Sr.Nr QCP23301 B
HTH2SMW/FO/PA
SERVICE ACTIVITY REPORT

REGULATION VALVE
Due to a problem with main flame ( was unstable) after cleaning crude oi1 line it was necessary reset & calibrate
FV005B (crude oil regulation valve ) and PDV009B ( atomizing air regulation valve).
Customer requires is to replace with new one all this valve on this heaters inciuding TV007B.
This heaters had for a long time problem due a valve regulation '

ry%-
k

REGT]LATION CHECK
Control modulation set with Heater in production, customer switch OFF Heater A for next service, so movement
between different point ofcombustion curve is subject to the consumption from the plant.

t2
 Job. N. 261 908054 Date 06t03t2020

ffiil f,annnn B*nei sners[a

I
Customer
Plant:
BAPCO PS3 Rev. 0

HTH25MW/FO/PA Sr.Nr QCP23301 B

SERVICE ACT]VITY REPORT

> COMBUSTION CHECK

flow from regulation valve & nozzle,to ensure stable flame at ignition point we move light off
Due a not correct
valve position to 40Yo instead of 22%. All follow position until point 7 was changed, was necessa-ry decrease air
position & increase crude oil valve opening to ensure an acceptable Oz level , original value was 2,7%o of C,2, but the
result still remain a low O2 value.
To complete regulation must replace valve regulation and bumer nozzle.
Combustion check not show a significate difference between 02 value checked before & after air preheater.
Attached the complete combustion analysis, here a table with value.

Crude Crude Air Air Oz CO, CO 02 CO, CO

oil oil damper damper LEVEL % mg/m' LEVEL % mg/m3
valve valyeYo o/
/o o/ o/
/o /o @3%O2 % @3%O,
o/ NEW
/o OLD NEW NEW NEW OLD OLD
OLD
Light ))o 40,0 6,5 6,5
off
P1 ))o 44,0 6.5 6,5 02 value in this point was around 2,5o/owas not possible
P2 26,0 47,0 5 8.5 adjust combustion curve due acritical condition ofcrude oil
P3 34,0 49,0 n5 0.5 system
P4 43,5 5 1,0 2"0 )o
P5 48,0 s1 0 4.5 3,0 7,0 10 838 7,2 )'t 5298
P6 54,0 57,0 7,0 4,0 o,J 27 6,9 10 I 533
P7 58,0 60,0 20,s 6,0 1,0 7,4 18 5.9 3,8 98
P8 59,0 63,0 24,0 24,0 0,1 8.1 29 §§ 0
P9 6s,0 65,0 35,0 35,0 0,3 8,0 40 4.4 4,9 48
P 0 68,0 68,0 41,0 4l,0 0,1 8.1 58
P I 71,0 71.0 47,0 47 "0 9,9 8,2 82
P 2 74,0 7 4,0 52,0 §?n 9,9 8.3 91
P 3 78,0 78.0 575 57.5 Was not possible test point above P 12 due a low
P 4 79,0 79,0 s9 59,0 consumption from plant and consequence high temp of
P 5 80,0 80,0 60 60,0 diathermic oil outlet that cause a frequent stop for stand-by

) Conclusion
Main problem on this site is a relaxing manage in heaters maintenance, flame stability'problem is
almost appears two months ago, pipe tracer was broken from 6 months, BMS was damage( and heater
stop) from January 2020.
Seems that persomel didn't take care of problem & don't explain about historical of problem,
So we have notice of all problem after 2 days ofinvestigation .

In order to guarantee efficiency & safety condition for heater ALL SPARE PARTS IN THE LIST
SHOULD BE REPLACE .
Especially Crude oil pipe line need a strong upgrade: trace heater, nozzle,crude oil 3 way
valve(BV0O4B) & crude oil regulation valve should be replace.

) spARE PART LIST FOR HEATER QCP23301B

MANDATORY

. OXIGENPROBE
. PILOT VALVE (NR2)
. 3 WAY VALVE TCV 008B at EXCHANGER E-23001B

13
 Job. N. 261 908054 Date 06to3t2020

ffir*ns"ron §cno trnergia I Customer BAPCO PS3 Rev. 0

Plant:
HTH25MWFO/PA Sr.Nr QCP23301 B
SERVIGE ACTIVITY REPORT

. BURNERREFRACTORY
. REFRACTORYDOOR
. BMS ( HONEYWELL 7850 Or new type in case on cabinet upgrade)
. COMBUSTION AIR GAUGE
. VISUAL LEVEL OF EXPANSION TANK ( COLIMA)
. RUPTURE DISK FORDIATHERMIC OIPLANT.
. SPARE NOZZLE FOR CRUDE OIL
. CRUDE OIL PIPE HEATER TRACING ( available on site)
. FLEXIBLE HOSE FOR CRUDE OIL BURNER LINE.
. PSV FOR CRUDE OIL LINE
. PSV FOR DIATHERMIC OIL LINE
. CRUDEOILPRESSUREGAUGE
. FV005B ( crude oil regulation valve)
. PDV009B ( atomizing air regulation valve)
. crude oil 3 way valve(BV004B)
. TV007B ( crude oil heating skid valve)
SUGGESTED
. PLC SIEMENS S73OO , CPU315-2DP . SPARE PARTS MAYBE NOT YET AVAILABLE
. ELECTRICALPANELUPGRADE(HMD
. FUEL SYSTEM UPGRADE FOR WORKING IN AUTOMATIC MODE IN ORDER TO
SWITCH FROM HFO TO DIESEL & VICE VERSA.

) REMARKS FROM CUSTOMER:

Gliente/Customer.

14
 Job. N. 261908054 Doc. N.

Customer BAPCO PS4 Rev. 0

Plant:
HTH 25MW/FO/PA NF QCP23401B

SERVICE ACTIVITY
REPORT
From 08/03/2020 to 11/03/2020

2
1
0 Dec. 07, 2006 issue
Rev. Date Description Prepared Checked Approved
 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

 Heater general inspection (internal and external)

Wiring Cable
Wiring cable on Boiler side was damage for time,sun & enviromental condition, all external protection is
done

cable to JB on boiler side QCP23401B

cable connection to UV SENSOR TE cable connection CRUDE OIL VALVE cable connection

Cleaning of UV sensor lens & Burner Nozzle

 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

 Burner tip, tube and diffuser inspection and cleaning or replace

Replace pilot gun & cleaning burner plate.

 Remove all accumulated soot from heater different compartments

Cleaning & prepare combustion chamber pipe for tickness control, all pipe present a consistent dust on surface.
Recommended to organize an a hydro jet cleaning next stop.

Cleaning of air preheater.

 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

 Refractory condition inspection and repair if needed

Refractory door damage on QCP23401B

Need to be replaced

Refractory condition on BURNER side:

Refractory is not broken but is at lifetime limit , strongly
suggest to provide to had a spare part available on site.

 Inspection coils condition for leak or damaged

THICKNESS CONTROL Thickness control show value into admissible range, heater pipe thick is in good
condition.

LEAK:

Diathermic oil differential pressure switch Leak

 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

Diathermic oil rupture disk leak

TV008 diathermic oil regulation valve inlet at all heat exchanger leakages or damage . SHOULD BE REPLACE Nr
3 valve.

Pic 1 pic 2 FLEX HOSE pic 3 PUMP INLET VALVE

PICTURE 1 - Crude oil line flange on HEAT EXCHANGER present a massive leakage, should replace gasket
PICTURE 2- HIGH PRESSURE FLEXIBLE HOSE burner side was damage and old, SHOUL BE REPLACE.
for safety reason.
PICTURE 3- Manual valve inlet line of diathermic oil pump leakage and disconnect the wheel. Should be checked
or replace.
 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

TV007 crude oil heater

regulation
valve leakage,
should change gasket
crude oil pump
l leakage

 Check, test and calibrate all protection and control devises where applicable

SETTINGS OF HEATER:
 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

SAFETY CHECK

All new safety device installed was tested, was not possible test in working condition all safety
because diathermic oil pump working for booth heater and had to share the oil flow.
One boiler should be in running mode always for production.
ATTACHED SAFETY TEST DOC

OXYGEN PROBE
Oxygen probe on QCP23401B not working, in stand by condition show 0.0% of O2 should be replaced with a
new one.

CRUDE OIL PRESSURE GAUGE

Crude oil pressure gauge broken, should be replace.

 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

 Blower compartment inspection and cleaning

Check Damper movement was regular and without impediment . Movement part was grease from customer.

 Check /grease or replace the bearing of compassion air motor.

Check- Also motor of oil pump & Fan was grease from customer regularly.

 Doing hydro jet cleaning.

Job not possible ON SITE no hydro cleaning available

 Perform chemical cleaning

Job not possible ON SITE

 Perform Hydro test.

Job not possible ON SITE

 Functional Check.

IGNITION SEQUENCE
During ignition sequence pilot time is not enough to ensure all the time correct working of boiler, often we had a
shutdown for lack of flame in main valve position.
To fix situation properly we increase pilot time on K130 up to maximum ( 40 sec). Solve
Crude oil pressure in main line should be @ 10 bar to ensure a correct working of discharge valve and regulation
valve.
 Job. N. 261908054 Date

Customer BAPCO PS4 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP24301B
SERVICE ACTIVITY REPORT

REGULATION CHECK
Control modulation set with Heater in production, customer switch OFF Heater A .

 COMBUSTION REGULATION

Crude oil Air damper % DP atomiz air Atomiz Crude O2 CO2 CO O2 % CO2 CO
valve % pressure oil line % % mg/m3 % mg/m3
press. NEW NEW @3%O2 @3%O2
NEW OLD OLD OLD
OLD NEW OLD NEW % bar bar bar
Light 16,0 34,5 6,0 6,0 24,5 1,8 8,0
off
P1 18,0 39,0 7,0 7,0 45%-1,2 2,6 8,0 11,9 6,8 170
P2 22,0 44,0 8,0 8,0 45%-1,2 2,6 8,0 14,3 5,3 683
P3 31,0 47,0 10,5 10,5 44%-1,0 2,6 8,0 12,1 6,7 169
P4 36,0 49,0 12,0 12,0 44%-1,0 2,5 8,0 11,4 7,2 60
P5 40,0 51,0 15,0 14,0 2,8 8,0 12,3 6,6 154
P6 45,0 53,0 18,0 18,0 8,0 10,8 7,5 22
P7 50,0 55,0 22,0 22,0 8,0 10,7 7,7 26
P8 55,0 57,0 26,0 24,0 56%-1,0 3,8 8,0 6,8 10,7 53
P9 60,0 60,0 30,0 30,0 58%-1,0 3,9 8,0 8,7 9,1 38
P10 66,5 66,5 36,5 36,5 58%-0,4 4,6 8,0 8,3 9,5 30
P11 69,0 69,0 41,0 41,0 58%-0,4 4,6 8,0
P12 74,0 74,0 45,0 45,0
P13 78,0 78,0 50,0 50,0 WAS NOT POSSIBLE TEST OVER P11 COMBUSTION DUE TO A LOW CONSUMPTION
P14 80,0 80,0 55,0 55,0 FROM THE PLANT, SO CRUDE OIL TEMP REACH IN 2 min THE MAXIMUM TRIP
TEMPERATURE OF 80°C.
P15 82,0 82,0 60,0 60,0

 CONCLUSION
In order to guarantee efficiency & safety condition for heater ALL SPARE PARTS IN THE LIST
SHOULD BE REPLACE .
Especially Crude oil pipe line need a strong maintenance: replace nozzle , crude oil pump replace gasket
( at least) , crude oil 3 way valve(BV004B) atomizing regulation valve & crude oil regulation valve
should be replace .
Crude oil main line supply should be fix , customer find water in crude oil sample from crude oil pump.
In this heater was find big problem in burner & combustion regulation, due to a low pressure on main crude
oil line ( 8 bar) the consequence was that, to increase a little combustion value ( in order to reduce CO
value) was necessary increment opening crude oil valve position up to 20% ( from 22% to 34,5% in light
off position)in all combustion point until point 7 . customer organize to re-calibrate atomizing regulation
valve & crude oil regulation valve.
 Job. N. 261908054 Doc. N.

Customer BAPCO PS3 Rev. 0

Plant:
HTH 25MW/FO/PA NF QCP23301A

SERVICE ACTIVITY
REPORT
From 13/03/2020 to 16/03/2020

2
1
0 issue
Rev. Date Description Prepared Checked Approved
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

1. Heater general inspection (internal and external)

Wiring Cable
Wiring cable on Boiler side was damage for time, sun & environmental condition, all external protection
is done. Cleaning of UV sensor lens & Burner Nozzle
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

2. Burner tip, tube and diffuser inspection and cleaning or replace

Replace pilot gun & cleaning burner plate.

3. Remove all accumulated soot from heater different compartments

Cleaning & prepare combustion chamber pipe for thickness control, all pipe presents a consistent dust on
surface. Recommended to organize a hydro jet cleaning next stop.

Cleaning of air preheater.

 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

4. Refractory condition inspection and repair if needed

Refractory door damage on QCP23301A Need to be replaced

Refractory condition on BURNER side:

5. Inspection condition for leak or damaged

Circulation pump
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

OXYGEN PROBE
Oxygen probe on QCP23301A not working, in stand by condition show 0.0% of O2 should be replaced with a
new setup.

Main oil storage tank electric heater damage and No oil filtration. Need duplex filter for good circulation.
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

6. Check, test and calibrate all protection and control devises where applicable

Setting of Heater
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

SAFETY CHECK

All new safety device installed was tested, was not possible test in working condition all safety
because diathermic oil pump working for booth heater and had to share the oil flow.
One boiler should be in running mode always for production.
ATTACHED SAFETY TEST DOC
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

7. Blower compartment inspection and cleaning

Check Damper movement was regular and without impediment . Movement part was grease from customer.

8. Check /Grease or replace the bearing of compassion air motor.

Check- Also motor of oil pump & Fan was grease from customer regularly.

9. Doing hydro jet cleaning.

Job not possible ON SITE no hydro cleaning available

10. Perform chemical cleaning

Job not possible ON SITE

11. Perform Hydro test.

Job not possible ON SITE

12. Functional Check.

IGNITION SEQUENCE
During ignition sequence pilot time is not enough to ensure all the time correct working of boiler, often we had a
shutdown for lack of flame in main valve position.
To fix situation properly we increase pilot time on K130 up to maximum (30 sec).
valve.
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT

REGULATION CHECK

Control modulation set with Heater in production.

COMBUSTION REGULATION

Date Crude Air damper DP Atomize Atomize Crude O2 CO2 CO O2 % CO2 CO

16.03.20 oil % air pressure oil line % % mg/m3 % mg/m
valve % press. NEW NEW @3%O 3
2
@3%
Time OLD NEW OLD NEW % bar bar bar NEW OLD OL O2 TEMP
D OLD
Light 16,0 34,5 6,0 6,0 24,5 1,8 8,0
off
P1 22.0 6.5 18.5% -1.3 2.7 1.4
12.18 P2 26.0 8.5 19.5 % -1.3 2.8 1.5 12.74 4.60 25 125
12.16 P3 34.0 10,5 21.5 % -1.2 2.9 1.7 10.44 5.88 1 131
12.14 P4 43.5 12,0 22.5 % -1.0 3.2 1.8 8.94 6.72 1.0 134
12.10 P5 48.0 14.5 24.5 % -1.0 3.3 2.1 5.22 8.79 0.0 144
12.08 P6 54.0 17.0 26.0 % -1.0 3.6 2.5 4.71 9.08 0.0 127
12.22 P7 58.0 20.5 30.0 % -0.9 4.2 3.3 4.32 9.29 2 134
12.24 P8 59.0 24.0 31.5 % -1.0 4.6 3.5 4.74 9.06 2 151
12.27 P9 65.0 35.0 40.0 % -1.0 4.9 3.8 3.72 9.63 1 152
12.30 P10 68.0 36,5 45.0 % -0.9 5.3 4.4 3.45 9.72 1 157
12.35 P11 71.0 41,0 49.1 %- 0.9 5.7 4.8 3.21 9.8 1 162
P12 74.0 47.0
P13 78.0 52.0 was not possible test over p11 combustion due to a low consumption from the plant,
P14 79.0 57.5 so crude oil temp reach in 2 min the maximum trip temperature of 80°c.
P15 80.0 60.0

CONCLUSION
In order to guarantee efficiency & safety condition for heater ALL SPARE PARTS IN THE LIST
SHOULD BE REPLACE.
Especially Crude oil pipe line need maintenance: Replace nozzle,
Crude oil pump Tag# P 23302 (A & B) should replace. (Booster pumps) pumps B seal leakage.
Crude oil 3-way valve (BV004B) atomizing regulation valve & crude oil regulation valve should be
replaced.
Both thermal oil pumps condition not good should be replace ASAP.
Circulation pump Tag # P23301 A not running because of motor defected customer remarks
Circulation pump Tag # P23301 B pump running on load, found leakage in gland area.
 Job. N. 261908054 Date

Customer BAPCO PS-3 Rev. 0

Plant:
HTH25MW/FO/PA Sr.Nr QCP23301A
SERVICE ACTIVITY REPORT
Refractory door was damage and will be replace.
Oxygen control was disable & disconnect, should be replace oxygen probe sensor & enable the oxygen
control.
All safety valve, in crude oil & diathermic oil line, factory set was expired. For safety reason should be
replace ASAP.

13. SPARE PART LIST FOR HEATER

QCP23301A MANDATORY

 OXIGEN PROBE
 PILOT VALVE (NR 2)
 REFRACTORY DOOR
 COMBUSTION AIR GAUGES
 RUPTURE DISK FOR DIATHERMIC OIL PLANT.
 SPARE NOZZLE FOR CRUDE OIL
 FLEXIBLE HOSE FOR CRUDE OIL BURNER LINE.
 PSV FOR CRUDE OIL LINE
 PSV FOR DIATHERMIC OIL LINE
 REGULATION VALVE FOR CRUDE OIL FV005B
 REGULATION VALVE ATOMIZING
 CRUDE OIL PRESSURE GAUGES.
 CRUDE OIL PUMP FOR BOTH HEATERS.
 TV007 CRUDE OIL HEATER CONTROL VALVE.
 BURNER CONTROLL UNIT HONYWELL
 UV SENSOR
 PILOT IGNATION TRANSFORMER.
 D.P TRANSMITTER (oil& air)

SUGGESTED

 PLC siemens S7300 , CPU 315-2DP . Spare parts maybe not yet available
 electrical panel upgrade (HMI)
 burner refractory
 Fuel system upgrade for working in automatic mode in order to switch from Crude oil to
diesel & vice versa.

New Work details

 Install new pilot system with new gas and air regulation system along
with high pressure hose pipes.
 Install new air pressure transmitter with connecting piping.
 Install oil line purge valve with feedback cable.
 In electric cabinet change some wiring and add relays & signal converter.
 Upgrade software as per new installation.
 Four Nos of cables direct from electric cabinet (2 cables for gas pilot
valve 1 cable for air pilot valve 1 cable for purge valve.)
 After changes start heater.
 Check combustion valves.
 Check soot blower working