INCINERATOR WORK COMMISSIONING REPORT

INCINERATOR WORK COMMISSIONING REPORT

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JOB TITLE DESCRIPTION JOB LOACATION Incinerator, BYGP

STARTED DATE 18th September, 2013

COMPLETION DATE 2nd October,2013

WORK TEAM SUPERVISOR Engineer SAIFUL ISLAM CHOWDHURY

COMPANY MIR TRADING COMPANY

INTRODUCTION

Equipment Information

Name: Therm Industrial Rotary kiln Incinerator

Rotary Kiln Incinerator

Manufacturer: Therm Engineering Co. Ltd

Model: RTN-50

Country of Origin: Thailand

Located in: BYGP, Hobigong

Installation and operation start date: June,

2010

Operator’s name: Mr Choyn

Sizing

50 – 1,000 kg/hr

Characteristic

Rotary kiln incinerator has 2 chambers. The primary chamber is 4 degree incline rotary cylinder for

burning waste under 800C. The ash from burnt waste is at the end of chamber and will be collected in

valves. Combustion gas would flow into secondary chamber for burning. This chamber is vertical cylinder

shape, the gas can combust under 1,100°C with 2-second resident time in this chamber before flowing

into cyclone. The treated gas from cyclone would be discharged or entered to air pollution treatment

system and dioxin-furan treatment machine for the large incinerator system. Fuel both diesel, fuel oil,

and LPG with safety equipment could be selected.

Air supply system is support the complete combustion by feeding primary air to heat exchanger to

provide hot air to flow into smoke controller.

Hydraulic system is used in waste feeder to provide continuous and automatic feeding or it can be

selected to use manual mode.

Inside of rotary kiln is made of firebrick and cast able of which all layer thickness is not less than 150

mm. they can resist at least 1,600°C and the quality of material is compile with ASTM standard. The

second layer of rotary kiln is 10 mm insulation, and the outside kiln is 16 mm steel coated paint to resist

600°C.

Outside chamber covers by steel sieve to protect from heat and danger from rotary. The rotation of the

incinerator is driving by electric motors and round speed is adjusted following the temperature inside

chamber. The 1st layer of smoke chamber is made of fire brick and cast able at least 100 mm. and can


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resist temperature at least 1,600°C. The 2nd layer is an insulation at least 50 mm thickness; the 3rd layer

(outer) is made of steel at least 12 mm. coated with paint to resist temperature at least 600°C.

Burner is imported from Europe, USA, or Japan, which compile with ISO9001 equipped with blower and

air supply system. It uses household electricity, 220V/380 V, 50Hz. Photocell is automatically control the

burner’s operation. Automatic shut off and flame detector is installed to prevent the explosion in the

incinerator.

Thermo couple (type K) is made of stainless steel, covered with ceramic, and jointed with flange. The

probe can resist temperature up to 1,200oC.

Temperature controller would control and display the temperature in both primary and secondary

chamber, air pollution treatment system in digital system. The controller is high precision and easily

used. Electrical equipment’s are compiled with NEC (National Electric Code) standard or the agency

endorsed by the Engineering institute of Thailand. Air quality discharge from incinerator is complied

with Notice of Ministry of Natural Resources and Environment B.E. 2546 or Ministry of Science,

Technology and Environment B.E. 2540.

Option:

Air pollution treatment system

Dioxin-Furan treatment machine

Touch screen and PLC

Burner and sludge waste feeding system

Biogas burner, biogas tank and system

OPERATION OF INCINERATOR

The incineration process

Step 1: Prepare for incineration

Conditions for incinerating waste

Operate the incinerator only when:

• Enough safety boxes and waste have been deposited.

• The wind is not blowing towards the health facility or other buildings near the incinerator.

• No large groups of people are present in the immediate area.

START UP

Prior to start-up:

• Make sure that there is adequate fuel (wood, coconut shells or other combustible agro waste, and

kerosene) available at the incinerator.

• Make sure that the health care waste stored in the incinerator is dry. If it is wet, place it in a well-

ventilated spot inside the WDS to dry.

• Ensure that all tools and equipment are in working order

• Wear personal protective equipment

(gloves, goggles, overalls, and masks).


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Step 2: Clean the incinerator

When cleaning the incinerator

• Remove the ash from the incinerator

• Empty the ash into the ash residue pit. Be sure to

Wipe the ashtray off any residue ash with a brush.

• After cleaning, return the ashtray back into the incinerator.

• Clean the lower inside of the incinerator with a brush and dustpan.

During incinerator cleaning

• Wear gloves and a facemask when removing the ash.

• Rake the ash and other noncombustible waste directly into the ash pit.

• Replace the trap door of the ash pit to avoid accidents.

• From time-to-time, distribute the ash evenly within the pit.

Step 3: Receive the waste

• Inspect the waste and ensure that is properly packaged (i.e., categories of health care waste in

appropriate waste bags).

• Weigh or count the waste bags and count the safety boxes. Record these quantities in the Waste-

Disposal Record.

• Store the waste temporarily in the designated storage area and always store the safety boxes upright.

• Report any problems to the supervisor.

! DO NOT OPEN THE LINER BAGS OR SORT THROUGH THE WASTE

Step 4: Light and warm up the incinerator

Light the incinerator

• Open the ash door wide, keep the loading door closed.

• Place firewood or other readily combustible materials on the grate.

• Pour a small quantity of kerosene (app ½ liters) over the materials if necessary.

• Light the fire through the ash door (See Fig. 8).

• Avoid looking directly into the grate when lighting the fire in case any explosive or volatile gas remains

in the primary combustion

Chamber.

• Use a taper of burning paper rather than a match or cigarette lighter.

• After steady burn is achieved (approximately 5 minutes), add more combustible material (not health

care waste) to the burning fire through the ash door.

• Repeat this procedure until the temperature gauge displays a temperature of at least 600°C and then

close the ash door.

• Observe the temperature gauge mounted on the chimney until the temperature stabilizes. Lighting the

Incinerator

! NEVER use petrol or diesel to light the fire

TYPES OF WASTE NOT FOR INCINERATION

INCLUDE:

• Mercury thermometers

• Batteries

• X-ray or photographic materials

• Aerosol cans or gas containers, PVC

plastics (this includes blood bags and IV

lines), non-combustible waste

• Glass vials which can explode if uncapped

(they also melt and could block the

incinerator grate)


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Step 5: Load and burn the waste

• Attend to the incinerator at all times during the loading and burning process.

• Open the loading door

• Load the waste – one safety box at a time

• Close the loading door.

• Load safety boxes (or wood, coconut husks, etc.) when the temperature drops below 600°C;

• Load health-care waste when the temperature is above 600°C;

• Do not load very wet safety boxes or bags of waste.

• Place them in a dry, well-ventilated, warm place to dry.

• Burn safety boxes and bags of non-sharps waste alternately if both types of waste are available.

• Ensure complete combustion of the waste by use of a poker to continuously agitate the fire when

necessary.

Visual guide to judging temperature:

• If a good strong flame is visible through the secondary air hole, the temperature should be more than

600°C at this point.

• If the smoke is dense white, grey, or black, poor combustion is occurring because the temperature is

below 600°C.

• If the temperature is too high, the chimney glows red.

• As a rule: Burn safety boxes in order to increase temperatures in the incinerator; burn bags of other

waste in order to reduce temperatures in the incinerator.

Step 6: Burn down/cool down

• To end the burning process, load a safety box and allow it to burn completely.

• After 10 minutes, add wood and allow it to burn completely.

• Do not leave the incinerator until the temperature on the gauge falls below 400°C or the flames have

completely burnt down.

• Let the incinerator cool down overnight after use.

• Remove the ash the next morning.


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DRAWINGS

Fig: Single line diagram of incinerator operation


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WORK PROCEDURE

WORK DONE

DATE JOB DESCRIPTION REMARKS

18-09-2013 Visual inspection and started the 1st step of the job.

19-09-2013 Removing old fire bricks

20-09-2013 Removing old fire bricks and burner cleaning



23-09-2013 Removing old fire bricks

24-09-2013 Cleaning the incinerator

25-09-2013 Angle bar welding

26-09-2013 Angle bar welding

27-09-2013 Burner layering with Aluminum bauxite and fire clay mixer

28-09-2013 Installing fire brick tali

29-09-2013 Installing fire bricks

30-09-2013 Installing fire brick tali and Installing fire bricks

01-10-2013 Finishing the brick laying and cleaning the chimney

02-10-2013 Incinerator layering and chimney fixing with the mixture of fire clay, aluminum bauxite and castable and finishing the job.

03-10-2013 The entire additional job including housekeeping and remaining material calculation.

04-10-2013 Curing process starts As per

05-10-2013 Curing process continued after the initial firing.

06-10-2013 Curing process continued.

07-10-2013 Incinerator Ready for operation.

SL DESCRIPTION MATERIAL USED

1 Removing previous old and distorted fire bricks and it’s supporting elements

HILTI, Mason’s Hammer , chisel

2 Welding angle bar for burner Welding machine

3 Cleaning burner Trowel, Hammer, Brushes, Chisel, Shovel(Belcha)

4 Fire bricks laying Bricks, cast able, fire clay, TATA S90 mixture, light, Graining Machine other hand tools

5 Finishing the layer with cast able and fire clay mixer Castable, fire clay, TATA S90 mixture

6 Cleaning the chamber Trowel, Hammer, Brushes, Chisel, Shovel(Belcha)

7 Finishing the chamber with fire clay and cast able mixer Castable, fire clay, TATA S90 mixture


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CURING AND DRY OUT

MAINTAINANENCE

MAINTENANCE

As with any type of equipment, there is a need to perform regular maintenance to ensure that the

incinerator will continue to work properly and to prolong its life span. Each step of the incineration

process should have an inspection/maintenance checklist.

Daily maintenance

The incinerator operator should inspect the incinerator daily and do the following:

• Check for evidence of cracks on the brickwork.

• Perform simple repairs but avoid makeshift solutions.

• Keep the area clean and disinfected.

• Carefully sweep the area around the incinerator to ensure that all the needles and noncombustible

waste are placed in the ash pit.

• Clean tools and equipment.

• Store safety boxes and other health care waste in an orderly manner in the incinerator waste store.

• Maintain fuel stock levels for the incinerator (kerosene, wood etc.).

DURATION FOR TEMP.

DATE START TIME STEPS OF WORK RAISE/FALL HOLD ON

PHASE-1: THERMAL EQUILIBRIUM

04-10-2013

6:00 AM a)Curing 24 hours before the initial firing 24Hrs

PHASE-2: HEATING UP

05-10-2013

6:00 AM Firing (calcining) will take place b) Raise the temp, to 125°C @ 25°C/Hr.

Hold at 125°C c) Raise the temp, to 225°C @ 25°C/Hr. Hold at

225°C

4 hrs 4 hrs

8 hrs 8 hrs

06-10-2013

6:00 AM d) Raise the temp, to 400°C @ 45°C/Hr. Hold at 400°C

e) Raise the temp, to 500°C @ 25°C/Hr.

Hold at 500°C

4 hrs 4 hrs

8 hrs 8 hrs

07-10-2013

6:00 AM f) Cool from 500°C to 150@30°C/Hr 12 hrs

PHASE-3: COOLING DOWN

07-10-2013

6:00 PM g) Below 150°C cooling naturally with sealing of all openings

4 hrs 8 hrs (or more)

PHASE-4: SYSTEM REINSTATE

08-10-2013

6:00 AM The Unit Is Ready For Use


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• Keep tools, records, and protective clothing in the storage room or box provided at the WDS.

• Immediately report to the waste-management supervisor any damage to the incinerator that affects

operation or performance.

Weekly maintenance

• Clean the chimney and remove the soot.

• Remove lumps of melted glass/plastics and clean grates (to improve aeration).

• Clean the filters/jets (for diesel operated incinerators).

• Properly install the grates.

• Maintain good housekeeping of the WDS by clearing the grass around the incinerator.

Monthly maintenance

• Ensure the fence of the WDS site is intact.

• Check the vertical fixings of the chimney and the support plate for corrosion and reset or repair any

holes or weak points.

• Check the top sand seals and top up with fresh sand.

• Check the external brickwork for evidence of thermal damage to the bricks.

• Check the cement seal to brickwork. If there is missing cement, reseal with refractory cement.

• Check the ash door for corrosion, damaged hinges, and latch blockage in the doorframe and repair and

clean as necessary.

• Take an inventory of the condition of tools and equipment and replace or repair as necessary.

Monthly maintenance does not indicate maintenance the end of each month but rather signifies the

issue requires attention at least once during the month.

Yearly maintenance

• Inspect and replace metal parts, bricks and consumable parts where necessary.

• Inspect and replace stay wire/guy ropes to anchor the chimney where necessary.

• Overhaul the incinerator or its components where necessary.

• Check the status of the ash pit. Empty it when full or decommission it.

• Perform annual audit/inspection of all the components and equipment.

• Report when incinerator is no longer effective and/or the ash pit(s) is (are) full, and take appropriate

action.

CONCLUSION

Since this is completely new for MIR we had some challenges during planning phase. We had to identify

scope of work, Brick and material estimation after doing a walkthrough of the incinerator. Without

breaking the old brick and Insulation we had to order the bricks based on Incinerator diameter, length

and thickness. We have order all type of bricks (IB 1”,1.5”, 2” 2.5” both tapered and arch ) to minimize

the work time as we had to finish the complete work in 12 Days. We had completed the work as planned

and within estimated time frame without any incident. Our full time HES and Safety Watch has been

assigned for this work to ensure safe work practice. At the beginning we tried to break the old Fire bricks

by manual chisel and hammer and took us long time to do small area and delayed the process. Later as

per advice we use the jack hammer to break the brick layer in 2 days. We would like to thank Chevron

Mechanical team for their support and help us to complete the job on time. Hope incinerator will run


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smoothly without any major breakdown in in next 5 years. But proper preventive maintenance needs to

be carried out as per manufacturer guideline.

PHOTO GALLERY

Brick Laying procedure with Wooden Frame

After all old brick ripped off and cleaning


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Both IB and Fire bricks laying progress

Insulation bricks and Fire Brick laying in progress


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All IB and FB Brick has been laying completed

Picture of the Burner after reparing


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Incinerator after initial layering

Incinerator ready for curing process


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Chimney and the Incinerator the reparing process

COMMENTS ____________________________________________________________________________________ ____________________________________________________________________________________

MIR SUPERVISOR MECHANICAL SUPERVISOR

___________________ _______________________

Documents

INCINERATOR WORK COMMISSIONING REPORT