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BOILER CFB 1 ENGINEERED BY TERMORAK HASLE MATERIALS SUPERVISED BY TERMORAK PRICE 100 %

BOILER CFB 1 ENGINEERED BY TERMORAK HASLE MATERIALS SUPERVISED BY TERMORAK PRICE 100 % BOILER CFB 2 ENGINEERED BY BOILER MANUFACTURER UNKNOWN MATERIALS SUPERVISED BY LOCAL REFRACTORY COMPANY PRICE 70 % BOTH BOILERS SAME SIZE, REFRACTORY MATERIAL NEEDED 200 T

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BOILER CFB 1 ENGINEERED BY TERMORAK HASLE MATERIALS SUPERVISED BY TERMORAK PRICE 100 %

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  1. BOILER CFB 1 • ENGINEERED BY TERMORAK • HASLE MATERIALS • SUPERVISED BY TERMORAK • PRICE 100 % BOILER CFB 2 • ENGINEERED BY BOILER MANUFACTURER • UNKNOWN MATERIALS • SUPERVISED BY LOCAL REFRACTORY COMPANY • PRICE 70 % BOTH BOILERS SAME SIZE, REFRACTORY MATERIAL NEEDED 200 T • ONE OPERATION DAY 250 000 EURO • OPERATION START 2006

  2. 2007 REFRACTORIES CFB 1: INSPECTION SHOWS NOTHING WRONG, EXPECTATION YEAR 2008 SITUATION SAME. SHUT DOWN TIME 10 DAYS CFB 2 : FIRST SHUT DOWN AFTER 6 MONTHS. PROBLEMS AT LOOP SEALS, TARGET AREA AND EROSION VERY HIGH IN MANY RISK AREAS. SHUT DOWN 10 DAYS, TEMPORARY REPAIRINGS. EXPECTATION AFTER NEXT 6 MONTH PERIOD MAINTANANCE TIME SHOULD BE 20 DAYS. AFTER NEXT SIX MONTH PERIOD NEED TO REPAIR ALL KICK-OUTS, BOTH CYCLONES TARGET AREAS, AT LOOP SEAL AREA CONTINUE WITH TEMPORARY REPAIRINGS, TWO SB AND TWO FF. SHUT DOWN TIME 28 DAYS.

  3. 2008 REFRACTORIES CFB 1: INSPECTION SHOWS NOTHING WRONG, EXPECTATION YEAR 2009 SOME MINOR REPAIRINGS. SHUT DOWN TIME 15 DAYS BECAUSE OF OTHER ISSUES. CFB 2 : BOILER OWNER DECIDE TO CHANGE SUPERVISING. TERMORAK`S SUPERVISOR COMES TO MAKE INSPECTION AFTER 18 MONTHS OPERATION. THIS TIME ONLY TEMPORARY REPAIRINGS, 10 D TERMORAK`S RECOMMENTATION IS TO START RENEWING AREAS SO THAT IN EVERY ANNUAL SHUT DOWN SHALL BE REPAIRED ONE ENTIRETY. AFTER 24 MONTH SHUTDOWN TIME 18 DAYS.

  4. AFTER THIS IN NORMAL CASES MAINTANENCE TIMES IN BOTH BOILERS WOULD BE THE SAME 15 – 30DAYS ANNUALLY. ONLY IN BOILER 2 THERE WAS LARGER AMOUNT OF LABOR IN TWO SHIFTS DURING NEXT THREE YEARS. HOWEVER DURING FIRST TWO YERS BOILER 1 HAD 25 NON-OPERATING DAYS AND BOILER 2 66. THAT MEANS 41 DAYS DIFFERENCE AND 10 250 000 EURO PRODUCT LOSE. THAT IS APPROXIMATELY 9 TIMES BOILER 1 REFRACTORY PRICE. IN THIS CASE BOILER 1 IS RARE CASE BECOUSE LAST YEAR I MADE INSPECTION THERE AFTER 54 MONTH RUNNING AND STILL THERE WAS NO NEED TO MAKE ANY REPAIRINGS FOR THE REFRACTORIES.

  5. MISTAKES IN CASE BOILER 2: • BOILER MANUFACTURER HAD NO EXPERIENCE OF REFRACTORY, NO PROBER PLANNING • MATERIALS IMPROBER AND WRONG CHOSEN. ALSO NOT WITH EQUAL QUALITY • SUPERVISING NOT PROFESSIONAL • BECOUSE OF UNPROFESSIONAL SUPERVISING INSTALLATION WAS NOT UNDER CONTROL. • FIRST REPAIRINGS WITH SAME MATERIALS AND SAME METHODS. BECOUSE OF IMPROBER REPAIRINGS EROSION WENT HIGHER DUE TO BIG AMOUNT OF LOOSE REFRACTORY MATERIAL INSIDE THE BOILER.

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