REPORT FOR THE COMMISSIONING OF NEW

STEAM BOILERS (H-301 D/E)

ENAR PETROLEUM REFINING FACILITY II

Prepared By FAISAL WAHAB

Checked & Approved By MUHAMMAD WAQAS
 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

ACKNOWLEDGEMENT
I, wish to express our sincere gratitude to EPRF and its competent team, for their continuous
guidance, helpful information and technical prowess that were of tremendous help at all times
during our commissioning of new steam boilers (H-301 D/E).

During the entire course of our services to EPRF our sincere gratitude to several individuals and
organization for supporting us throughout the commissioning period.

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

This document is made according to the agreement between M/s. ENAR Petroleum Refining
Facility (Owner) and M/s. Extreme Engineering (Contractor).

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

Table of Contents
Introduction ............................................................................................................................................ 4
Owner Responsibilities ............................................................................................................................ 4
Contractor scope of work ........................................................................................................................ 4
Cold Commissioning ............................................................................................................................. 4-5
Hot Commissioning ................................................................................................................................. 5
Pre and Post Chemical Treatment of Boiler (H-301 D/E) .......................................................... 5-6

Burner Analyzing and Tuning ……………………………………………………………………………………………………………………6

Observation/Suggestions …………………………………………………………………………………………………………………………6

Observation/Suggestions ……………………………………………………………………………………………………………………7-12

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

INTRODUCTION
To enhance steam production ENAR Petroleum Refining Facility (EPRF) has installed two new
fire tube boilers (H-301D & H-301E). Those boilers supplied by FULTON, are capable to generate
7.5 Ton of steam each. They are equipped with duel firing burner which shall be commissioned
on furnace oil and natural gas (supplied by SSGC).

OWNERS RESPONSIBILITIES
Owner team members that were present with us during our work were responsible in;

 Providing water for the cleaning and hydro testing.

 Will ensure the availability of water source within 75m radius of boiler, with a 2.5 inch
connection.
 Electricity shall be provided by EPRF.

CONTRACTOR SCOPE OF WORK

Contractor scope of work and responsibilities included;

 Checking/verification of logic/control loops of de-aerator and two boilers.

 Commissioning of all axillaries and firing equipment
 Alkali boil out of pressure parts
 Hydro testing of shell and tubes of both boilers

These are the activities that were performed by our team during Cold/Hot commissioning of
FULTON boilers. Commissioning of all auxiliaries/equipment were witnessed and signed by the
Project coordinator present on the field.

COLD COMMISSIONING

During Cold Commissioning, loop wire testing and verification of electrical and automation
control panels was performed as per the technical drawing provided by the Project
Coordinator. Boilers and feed water control panels were made live to perform sequence check.

 De-Aerator control panel was powered up, its water level sensor, temperature sensor
and feed control valve were checked and found in working condition.

 Feed water system was made active to fill the boiler with water (provided by ENAR), to
check the water level system, low level and high level safety.

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

 Boiler blower was made live, rotation and vibration checks were performed. Correction
to the rotation of the boiler blower was performed.

 After checking the necessary controls and checks, Boiler firing was done in the absence
of fuel. The system sequence were found to be in working condition.

 Hydraulic testing of boilers shell and tubes were performed (before and after Alkali Boil
Out) by filling the boiler with water and through external pressure pump, the shell was
pressurized slowly from 0 PSI to 600 PSI. After 10 (ten) minutes, physical inspection was
done and no leakage was found in the whole boiler.

HOT COMMISSIONING
During hot commissioning, gas supply was turned ‘ON’ and power panel was made live. Boiler
was fired on minimum gas pressure. Sequence and safety checks were performed.

 Gas regulator output was adjusted to 70-75 mBar.

 Gas low and high pressure switches were adjusted to 20 mBar & 100 mBar.

After these above mentioned system checks, the boiler was made ready for the next procedure
i.e. Alkali boil out.

PRE AND POST CHEMICAL TREATMENT OF BOILER (H-301 D/E)

Before Starting the Alkali Boil out procedure, following steps were performed as pre-requisite.

 Physically inspection of the boiler through main-hole was performed.

 Boilers were checked for oil and grease traces if present any.
 Visible tubes and boiler shell was inspected and found to be dry.
 A layer of rust was observed inside the boilers.

After the initial inspection, the boilers H-301 D/E was filled with water (pH 7.0, hardness
<10ppm), and was slowly brought to temperature of 65C. A test sample was taken for oil and
grease.

The result was found to show oil and grease traces as ‘NIL’ (Report is shared with EPRF as well).
Point to note: For Alkali Boil-out Procedure, oil and grease traces must be present, since there
was none (as seen in the test report), boilers were drained of water and next step of rust
removal was performed.

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

For Rust Removal, the boilers were refilled with fresh treated water. NA-2000C chemical was
added though the main-hole of the boilers. Boilers were brought to 65 C temperature and the
heated water was circulated from blowdown to main-hole through circulation pump
continuously for 5 hours. The pH was maintained at 5.5 till next day. Boilers were drained and
washed thoroughly till water from blowdown appeared clear.

For Neutralization, Boilers were refilled with fresh treated water and NA-101 chemical was
added though the main-hole of the boiler. Boiler was brought to 65 C temperature and the
heated water was circulated from blowdown to main-hole through circulation pump
continuously for 5 hours. The pH was maintained at 9.5 till next day. Boiler was drained and
washed carefully till water from blowdown appeared clear.
The process was declared complete when the draining water pH and the washing water pH
reached equilibrium. Chemical tests were then performed of blowdown water from both the
boilers. The final test reports bearing serial number: 8607 for boiler H-301D and report bearing
serial number: 8639 for boiler H-301E showed ‘NO’ trace of oil and grease.
(Chemical Test Reports are attached)

BURNER ANALYZING AND TUNING

Inspection of boilers H301 D/E burners was performed on manual firing mode. Air and fuel ratio
was set to minimum to hold the flame in combustion chamber. After analyzing the data, the
burner was fine tuned to 0-100% on both furnace and natural gas.
The burner was then set to auto mode, and was fined tuned to work smoothly from 0-100% on
both fuels.

(Chemical and Flue Analysis reports are attached)

OBSERVATIONS/SUGGESTIONS
During the commissioning of both 7.5 Ton FULTON steam boilers, it was observed that the
maximum throughput of steam was 5 Tons per hour on both fuels (Furnace oil and Natural gas)
under current conditions.
Our suggestion is, to get the maximum output of steam from both the boilers on both fuels, few
mechanical alterations are required in burners of both the boilers. This change will increase the
current output from 5 tons per hour to 6.5 Tons per hour.

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

REPORTS

RE-TUNING DATA
BOILER H-301 D

NATURAL GAS
Low-Fire 20% 40% 60% 80% 100%

O2 % 2.8 10.2 11.1 80 6.4 6.8

CO ppm 57 48 46 49 46 67
CO2 % 10.4 6.1 5.6 7.3 8.3 8
Stack Temp °C 213.3 217.5 225.2 233.4 238.4 239
Efficiency 82.6 78.1 76.7 79 79.8 79.5
XAIR % 14.2 95.3 113.2 62 43.1 48.2

REMARKS:
 Tuning performed again on EPRF request.
 Air damper and gas butterfly were opened 100%, for tuning at maximum air and natural gas.
 After tuning all the parameters are ok.
 Boiler Running Low-fire to high-fire smoothly.

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

TUNING DATA
BOILER H-301 D

FURNACE OIL
Low-Fire 20% 40% 60% 80% 100%

O2 % 4 10.6 11.7 9.6 7.6 6.9

CO ppm 13 16 17 19 21 22
CO2 % 9.7 5.8 5.8 6.5 7.5 8
Stack Temp °C 212.3 215.9 215.9 230.3 236.9 240.6
Efficiency 83.8 81.2 80.2 82.4 84.6 83.9
XAIR % 22.2 104.9 104.9 83.3 57.1 50.3

REMARKS
 After tuning all the parameters are ok.

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

RE-TUNING DATA
BOILER H-301 E

NATURAL GAS
Low-Fire 20% 40% 60% 80% 100%

O2 % 2.3 11.6 12.3 10.2 8.6 8.8

CO ppm 40 42 44 47 49 48
CO2 % 10.7 5.3 4.9 6.1 7.1 6.9
Stack Temp °C 211.8 215.6 221.6 229.7 234 234.3
Efficiency 82.8 76.8 75.3 77.4 78.6 78.3
XAIR % 10 124.7 143 95.3 69.9 72.7

REMARKS
 Tuning performed again on EPRF request.
 Air damper and gas butterfly were opened 100%, for tuning at maximum air and natural gas.
 After tuning all the parameters are ok.
 Boiler Running Low-fire to high-fire smoothly.

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 REPORT FOR THE COMMISIOING OF NEW STEAM BOILER (H-301 D/E)

TUNING DATA
BOILER H-301 E

FURNACE OIL

Low-Fire 20% 40% 60% 80% 100%

O2 % 5.3 7.3 7.7 6.6 5.9 3.1

CO ppm 44 46 43 50 56 78
CO2 % 12 10.3 9.9 10.8 11.3 13.4
Stack Temp °C 216.4 216 222.3 230.4 237.1 243.7
Efficiency 84.6 82.4 83.7 83 83.4 84.2
XAIR % 31.4 53.6 58.3 46.1 39.1 17.4

REMARKS
 After tuning all the parameters are ok.

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