Training - Reforming Section

PT INTI KARYA PERSADA TEKNIK
Ammonia Plant.
Reforming & Waste Heat Recovery
Section
Training material
r. basuki
1/3/2012
Training manual for IKPT Engineers on ammonia plant steam reforming and rrocess waste heat recovery
section. Jan 2012
Daftar Isi
1.
2.
Introduction To Steam Methane Reforming & Waste Heat Recovery Section

1.1
Objective
1.2
Ammonia Plant. KBR Purifier Process vs Conventional SMR
1.3
Reforming dan Waste Heat Recovery
1.3.1 Objectives:
1.3.2 101-B Primary Reformer
1.3.3 103-D Secondary Reformer
1.3.4 107-D Effluent Transfer Line
1.3.5 Riser Transition Assembly
7
7
7
10
10
11
1.4
11
Objective
12
12
2.2
101-B Primary Reformer
2.2.1 Radiant Section
2.2.2 101-B Radiant Harps & Other Pressure Part
2.2.3 101-B Primary Reformer Transition Duct & Convection Section
12
12
14
18
2.3
101-BL Combustion Air Preheater
20
2.4
101-BJ Primary Reformer Induced Draft Fan & 101-BJ1 Primary Reformer Forced Draft Fan
20
2.5
107-D Effluent Transfer Line
20
2.6
103-D Secondary Reformer
21
2.7
103-D 101-C Transfer Line
21
2.8
Pengelasan Heater Tube
21
2.9
Quality Control
22
Construction Plan
3.1
4.
Waste Heat Recovery Section
Construction Highlight
2.1
3.
Objective
24
24
3.2
Scope of Work
3.2.1 Instalasi 101-B Primary Reformer dan Peralatan lainnya
3.2.2 Installation of 101-B Associated Equipment
3.2.3 Instalasi 107-D, 103-D, 101-C dan 102-C
3.2.4 Welding Of High Alloy Radiant Harps, Stainless Steel Piping Component And Transfer Lines
3.2.5 Refractory Work for 101-B, 103-D, 107-D and Field Joints between 103-D, 101-C and 102-C
3.2.6 Dry-Out of Castable 103-D
3.2.7 Steel Erection & Refractory Lining of 102-B
3.2.8 Pre-commissioning
3.2.9 Others
24
25
25
25
25
25
26
26
26
26
3.3
27
Schedule of Work
Refractory & Dry-Out Work 103-D

4.1
Objective
27
27
5.
4.2
Refractory work
4.2.1 Penyiapan Material
4.2.2 Penyiapan Peralatan dan Platform Untuk Kerja
4.2.3 Lining Work
4.2.4 Pemasangan Supprot Brick dan Dome Brick
28
29
29
29
29
4.3
29
Drying-Out work
Precommissioning Work
30
1.
INTRODUCTION TO STEAM METHANE REFORMING & WASTE HEAT

RECOVERY SECTION
1.1
Objective
Memberikan pemahaman dasar sistem proses reforming dan sistem pemanfaatan panas buang dari
reformer.
Pengenalan singkat kompenen/peralatan yang membentuk sistem tersebut dan istilah/penamaan
yang digunakan
1.2
Ammonia Plant. KBR Purifier Process vs Conventional SMR

Purifier Process memiliki beberapa perbedaan yang mendasar dibanding proses SMR konvensional.
Perbedaan yang utama adalah pada sistem pengaturan jumlah N2 yang dimasukkan dalam sistem
proses yang diperlukan bagi pembentukan produk NH3.
Pada proses SMR konvensional N2 masuk (sebagai udara) ke Secondary Reformer dengan jumlah
yang terukur secara stoikhiometrik sesuai kebutuhan reaksi sintesa NH3 pada reactor Amonia.
Pada sistem Purifier, N2 (sebagai udara) masuk ke Secondary Reformer dalam jumlah yang berlebih
karena pada dasarnya yang dipentingkan adalah kebutuhan O2 untuk reaksi oksidasi sisa gas alam
yang belum terengkah di Primary Reformer. Pengaturan kebutuhan N2 secara stoikhiometrik untuk
reaksi sintesa NH3 (dan pengaturan impurities pada synthesis loop) dilakukan pada unit Purifier.
Karena adanya keterbatasan jumlah N2 yang bisa dimasukkan ke Secondary Reformer pada sistem
konvensional, maka Primary Reformer dirancang untuk merengkah feed gas hingga hanya
menyisakan 10-11 % CH4 pada gas proses yang masuk ke Secondary Reformer, dan process gas
keluar dari Secondary Reformer hanya menyisakan 0.2~ 0.3% CH4. Sebaliknya dengan sistem
Purifier, sisa CH4 (methane slip) dari Primary Reformer dapat mencapai 25%, yang akan dioksidasi
di Secondary Reformer hingga mencapai + 3% saja.
Karena reaksi perengkahan metana di Primary Reformer bersifat endotermis (membutuhkan panas),
berkurangnya reaksi reforming yang terjadi berarti berkurangnya penggunaan fuel gas dan turunnya
kondisi operasi/suhu di Primary Reformer bila dibanding dengan teknologi yang konvensional.
Penggunaan udara yang berlebih di Secondary Reformer dan tingkat konversi metane yg lebih rendah
memberikan kondisi(suhu) operasi yg lebih rendah pada gas proses masuk ke sistem Waste Heat
Recovery.
T = 800 C
NG
Purification
101-B
Primary
Refomer
N
G
Steam Drum
103-D
Secondary
Reformer
CO2
Removal
Shift
Conversion
WHB &
Superheater
Methanation
& Dryer
Steam Generator
S
t
e
a
m
T = 980 C
Compression
Purge Gas
NH3
Synthesis
NH3
Ammonia Process (General)
T = 715 C
P = 40
kg/cm2 g
NG
Purification
Steam Drum
101-B
Primary
Refomer
N
G
103-D
Secondary
Reformer
Shift
Conversion
WHB Generator
& Superheater
CO2
Removal
Steam Generator
Steam
Methanation
& Dryer
T = 898 C
Purifier
P = 39
kg/cm2 g
Purge Gas
Compression
NH3
Synthesis
Ammonia Process PKT-5
NH3
1.3
Reforming dan Waste Heat Recovery
1.3.1
Objectives:
Pengenalan komponen komponen yang membentuk sistem Primary Reformer, Secondary Reformer
dan Waste Heat Recovery
Pengenalan istilah dan penamaan komponen pada Primary Reformer dan Peralatan lain
1.3.2

Merupakan tungku bakar (fired heater) yang terdiri atas 2 bagian utama, yaitu 1) radiant box dan 2)
convection (heat recovery) section dan dilengkapi dengan peralatan lainnya.
1.3.2.1 101-B Radiant Box

Sesuai namanya, merupakan bangunan struktur baja berbentuk kotak dimana terjadi proses
perpindahan panas secara radiasi, yang diperlukan bagi proses perengkahan gas umpan (gas alam +
steam) menjadi gas proses.
CH4 + H2O CO + 3 H2
dH = 206 kJ/mol
CO + H2O CO2 + H2
dH = -41 kJ/mol
Panas radiasi didapat dari pembakaran fuel gas dengan menggunakan sejumlah burner, sedangkan
proses perengkahan tsb terjadi dalam sejumlah tabung baja paduan Ni tahan panas dengan bantuan
katalis Ni (catalyst tube) pada tekanan + 40 kg/cm2g dan temperature + 725 oC.
Catalyst tubes ini disusun menjadi 4 lajur yang masing-masingnya terangkai menjadi satu kesatuan
yang disebut radiant harp. Keempat radiant harp tsb tergantung (suspended) didalam radiant box
dengan menggunakan sejumlah spring hanger
Gas umpan masuk ke catalyst tube melalui inlet pigtail dibagian atas catalyst tube, mengalir kebawah
melewati unggun katalis dan keluar ke header pengumpul yang disebut outlet manifold untuk
selanjutkan dialirkan ke luar radiant box melewati riser tube.
Burner utamanya ditempatkan dibagian atas radiant box dan
mengarah kebawah (arch burner) ditempatkan dalam 5 lajur
berselang dengan posisi radiant harp.
Udara pembakar yang telah dipanaskan dan bertekanan positif,
didistribusikan kemasing-masing burner dengan menggunakan
combustion air duct, sedangkan radiant box sendiri beroperasi pada
kondisi tekanan negatif (-10 ~ 20 mmH2O).
Untuk mencegah struktur baja tersebut dari panas yang terbentuk
didalamnya, radiant box dilapis dengan sejumlah refraktori
pelindung panas. Refraktori tersebut terdiri atas berbagai jenis dan
penggunaan, terutama ceramic fiber, fire brick dan castable.
Gambar. Top Fired Reformer
Hanya 50-60% dari panas yg dihasilkan dari pembakaran fuel gas yg dimanfaatkan di radiant box, sisa
panas pada gas buang yang keluar dari radiant box (dengan suhu 800 oC) dimanfaatkan untuk
pemanasan berbagai aliran proses pada seksi konveksi (convection section).
Bagian atas radiant box (upper structure) merupakan bangunan baja dengan atap dan penutup dinding
(siding). Didalamnya ditempati oleh beberapa komponen pipa penyaluran gas proses, komponen
pipa fuel dan burner, saluran udara pembakaran, spring hanger, air dampers, control valves, gas
detection, 107-D Effluent Transfer Line dan juga akses untuk operator dan maintenance. Untuk
mengurangi panas di ruangan tsb ditambahkan exhaust fan di atap bangunan ini
Struktur atap tsb. dirancang untuk menerima beban dari radiant harp dan Effluent Transfer Line
disamping beban lainnya.
1.3.2.2 101-B Convection Section

Convection Section terdiri atas 2 bangunan struktur baja yang disebut hot leg dan cold leg .yang
dihubungkan dengan lorong saluran gas buang. Masing-masing bangunan terdiri atas beberapa
convection module yang berfungsi sebagai penukar panas dengan memanfaatkan sisa panas dari gas
buang yang mengalir didalam bangunan tersebut.
Tabel.
101-B Primary Reformer Convection Modules PKT-5
Hot Leg
Cold Leg
1. Mixed Feed Heater
1. Steam Superheater (1)
2. Process Air Heater (2)
2. Feed Preheater
3. Steam Superheater (2)
3. Process Air Heater (1)
Masing-masing heater module merupakan sekumpulan pipa yang diletakkan beraturan pada beberapa
baris (row), disanggah oleh tube supports dibagian tengah dan end tubesheets dikedua
pinggirnya. Tube support dibentuk oleh besi cor (cast steel) tahan panas sedangkan end tubesheet
dibentuk dari plat baja dengan tambahan castable sebagai pelindung panas. Fluida masuk melalui inlet
header dan keluar dari convection module melalui outlet header, mengalir secara countercurrent/cross
dengan aliran flue gas.
Bahan konstruksi untuk pipa maupun tube support /tubesheets terutama ditentukan oleh suhu gas
buang yang melewatinya. Pipa yang terekspos panas radiasi (Mixed Feed) umumnya berupa bare
pipe/tube sedangkan pipa selebihnya dimana konveksi lebih dominan umumnya menggunakan
finned tube untuk meningkatkan efisiensi perpindahan panas. Jenis materialnya bervariasi sesuai
suhu operasi, bisa berupa baja Ni-Cr, logam paduan Cr maupun baja karbon. Material tube support
dan tube support brackets untuk Module terbawah pada hot-leg umumnya menggunakan grade
HK untuk ketahanan terhadap temperature tinggi, dan secara bertahap berkurang hingga besi karbon
pada module terakhir.
Untuk membantu agar aliran flue gas lebih homogen, pada bagian atas hot & cold leg diberi
distributor plates yang biasanya terbuat dari pelat paduan Nickel (high Ni alloy plate-atau Alloy 800
HT ataupun SS 310H).
Panas yang diperlukan untuk seluruh Convection Modules maupun untuk memanaskan udara
pembakaran, tidak seluruhnya dapat dipasok dari sisa panas yang dihasilkan melalui Arch Burner
semata. Karena itu panas juga ditambahkan melalui 101-B Tunnel Burner dan 101-B Steam Superheater
Burner.
1.3.2.3 101-BL Air Preheater

Merupakan alat penukar panas utk memanfaatkan sisa panas gas buang guna menaikkan suhu udara
pembakar. Umumnya yang digunakan adalah type recuperative berupa plate heat exchanger. Gas buang
yang masih panas mengalir di salah satu sisi pelat sedangkan udara mengalir disisi lainnya secara cross
flow. Pelat-pelat tsb menjadi media perpindahan panas antara kedua aliran gas tersebut.
Plate exchanger ini biasa terdiri dari 2 bagian, yaitu 1) cold section dimana udara yg masih dingin
masuk dan 2) hot section dimana gas buang yg panas masuk. Secara konstruksi kedua seksi tersebut
tidak banyak berbeda, kecuali pada cold section dimana struktur baja dan pelat yg bersentuhan
dengan gas buang dilapis dengan bahan anti korosi (glass enameled) untuk mencegah terjadinya reaksi
garam sulfat Fe2(SO4)3 antara besi dengan gas sulfur yg terkondensasi. Pembentukan garam besi
sulfat tsb tidak hanya menyebabkan kerusakan struktur baja dan plat penghantar panas tetapi juga
menyumbat area aliran gas buang.
1.3.2.4 101-BJ ID Fan & 101-BJ1 FD Fan

Primary Reformer ini beroperasi dengan sistem balanced draft dengan menggunakan 2 fan utama yaitu
1) 101-BJ Induced Draft Fan, dan
2) 101-BJ1 Forced Draft Fan
ID Fan mempertahankan kondisi vakum didalam reformer dan menarik gas buang hingga keluar ke
stack, sedangkan FD Fan berfungsi memasok udara pembakaran melewati Air Preheater hingga ke
masing-masing burner.
Pada PKT-5, kedua fan mengunakan sistem penggerak utama berupa steam turbin dengan sistem
penggerak cadangan (standby)steam turbin juga. Pada sistem yg lebih umum hanya ID Fan yang
menggunakan pengerak cadangan dan biasanya berupa motor listrik, sedangkan FD Fan biasanya
hanya memiliki satu penggerak berupa steam turbin atau motor listrik.Pengerak utama umumnya
berupa steam turbin karean pertimbangan kehandalannya .
1.3.2.5 101- B Burners

Selain 101-BBA Arch Burner yang memasok
panas yang diperlukan untuk proses
perengkahan gas alam, keseluruhan Primary
Reformer juga dilengkapi dengan burner
dengan fungsi yang berbeda:
101-BBT
Tunnel
Burner,
memasok
tambahan panas untuk mendapatkan suhu
campuran gas alam dan steam (mixed feed)
yang dikehendaki sebelum masuk ke catalyst
tubes maupun kebutuhan panas aliran gas
proses di hot-leg
101-BBS Steam Superheater Burner,
memasok
tambahan
panas
untuk
mendapatkn temperature superheated steam
yang dikehendaki dan bagi kebutuhan panas
kedua aliran proses lainnya di cold leg.
Penggunaan udara pembakaran yg sudah
dipanaskan di 101-BL Air Preheater
menyebabkan potensi terbentuknya senyawa
NOx atau Sox pada proses pembakaran fuel
gas menjadi lebih besar. Karenanya type
burner yg dipakai dirancang untuk
mengurangi kemungkinan ini. Ada beberapa
pilihan type low NOx burner, tetapi yg
umum dipakai di Primary Reformer adalah
type staged fuel, dimana bahan bakar masuk
ke sistem burner secara bertahap.
Gambar. Fuel Staged Burner
Pada tipe burner ini, ada satu primary burner yg terletak ditengah dan beberapa secondary burner
yang berada disekelilingnya dan terlindung oleh burner tiles. Seluruh udara untuk pembakaran masuk
melalui bukaan ditengah burner tiles yang menyelimuti primary burner. Sebaliknya gas yang masuk ke
primary burner hanya sebagian dari seluruh gas pembakaran yang diperlukan. Dengan sistem ini
temperatur nyala yang terjadi di primary burner mengalami pendinginan karena adanya kelebihan
udara tersebut.
Sisa fuel gas didistribusikan ke secondary burner yang terletak lebih menjorok kedepan diwilayah
nyala api dengan suhu yang lebih rendah. Pembakaran secara bertahap ini menghasilkan temperature
nyala yang lebih rendah dan mengurangi pembentukan senyawa Sox/NOx.
1.3.3

Merupakan bejana tekan dimana terjadi reaksi pembakaran oksigen dengan gas proses dari primary
reformer. Reaksi pembakaran tsb meningkatkan temperature gas menjadi lebih dari 1200 oC hingga
memungkinkan terjadinya reaksi perengkahan lanjutan sisa metan pada gas proses dengan bantuan
katalis.Bagian bawah bejana tekan berisi katalis sedangkan bagian atas yg berbentuk leher botol
ditempati oleh mixing chamber untuk pembakaran gas proses dari primary reformer dengan udara
yang dimasukkan dari atas bejana.
Untuk melindungi dari suhu yang tinggi, bagian
dalam bejana dilapis dengan bahan refraktori
(castable) tahan temperature tingi dan bagian
luarnya dilengkapi dengan jaket air untuk
mendinginkan bejana tekan dari gas panas yang
mungkin bersinggungan dengan dinding bejana
melalui retakan pada lapisan refraktori.
Unggun katalis ditempatkan diatas tumpukan
alumina balls, dilindung dari nyala pembakaran
dengan lapisan hexagonal tiles yang dipasang
menutupi unggun katalis. Seluruh sistem katalis
ini bertumpu pada dome brick yang merupakan
struktur bata refraktori berongga untuk
mengalirkan gas proses keluar dari Secondary
Reformer menuju Waste Heat Boiler.
Gambar. Secondary Reformer
1.3.4
Gambar sketsa disamping mewakili model

secondary reformer Kellogg tempo dulu.
Disain yang diterapkan saat ini merupakan
perbaikan dari design awal yang sering
bermasalah dengan nyala api yang menyentuh
hexa-tile dan unggun katalis.Ruang bakar menjadi
lebih tinggi, demikian juga dengan lokasi burner
yang makin di atas. Tingginya leher botol ini
menyebabkan elevasi primary reformer juga naik.
Bagian dasar radiant box berada pada elevasi
lebih dari 3 m dari ground level agar Effluent
Transfer Line dapat menjangkau posisi gas inlet
ke secondary reformer.

Alat ini merupakan saluran pengumpul gas proses dari radiant harps dan mengalirkannya ke
Secondary Reformer. Merupakan bejana tekan berbentuk selongsong pipa yang diberi lapisan
refraktori pelindung panas dibagian dalam dan jaket air diluarnya.
Disatu ujung Transfer line tersambung las ke Secondary Reformer sementara bagian lainnya
tergantung ke struktur Primary Reformer dengan bantuan spring support.
1.3.5
Riser Transition Assembly

Aliran gas proses dari Riser Tube masuk ke 107-D Effluent Transfer Line dengan melalui Riser
Transition Assembly yang merupakan penghubung antara riser tube yang mendapat panas didalam
radiant box dengan effluent transfer line yang relative dingin. Transition assembly dibentuk oleh 2
komponen, 1) kerucut dari baja paduan Ni (Incolloy 800 HT) yang disambung dengan 2 ) bejana
tekan dari bahan baja karbon berbentuk pipa dengan lapisan dalam refraktori (bubbled alumina castable)
dan liner sleeve dibagian dalam dan jaket air dibagian luar.
1.4
Waste Heat Recovery Section

Terdiri atas 3 peralatan utama, yaitu
101-C Secondary Reformer Waste Heat Boiler
102-C Steam Superheater
141-D Steam Drum
101-C Secondary Reformer Waste Heat Boiler.

Berbeda dengan disain standar Kellogg, WHB untuk PKT-5 merupakan jenis fire tube dengan
sirkulasi natural . Boiler ini berbentuk shell & tube heat exchanger dengan aliran gas panas pada sisi tube
dan boiler feed water pada sisi shell.
141-D Steam Drum, duduk diatas boiler
Gambar. Fired Tube Waste Heat Boiler dan Steam

Drum
dengan ditopang beberapa riser pipes yang

sekaligus mengalirkan campuran air dan
steam dari boiler ke steam drum. Saturated
steam yang terbentuk di steam drum
dialirkan ke 102-C Steam Superheater
untuk pemanasan lanjutan sedangkan sisa
air dan make-up nya mengalir ke boiler
dibawahnya melalui beberapa down
comer.Untuk mengatur laju alir/tekanan
steam/effisiensi
penyerapan
panas
ditempatkan gas by-pass valve yang
mengatur aliran gas yang masuk ke fire
tubes.Bagian gas proses masuk WHB
dilindungi dengan refractori (castable)
tahan temperature tinggi, demikian juga
dengan sisi keluarnya. Sedangkan bagian
lainnya termasuk steam drum, riser dan
downcomers diberi lapisan insulasi luar
untuk konservasi panas dan personnel
protection.
102-C Steam Superheater, merupakan vertical heat exchanger dengan gas by-pass valve untuk
mengatur temperatur superheated steam, dengan memanfaatkan sisa panas gas proses keluar dari
WHB.
Transfer Lines
Aliran gas proses dari Secondary Reformer ke WHB dan selanjutnya ke Steam Superheater
difasilitasi dengan menggunakan transfer lines
2.
CONSTRUCTION HIGHLIGHT
2.1
Objective
Memberikan gambaran teknis peralatan yang membentuk sistem reforming dan sistem
pemanfaatan panas di sistem reforming, khususnya yang terkait dengan pelaksanaan konstruksi
dilapangan:
Kondisi terkirim peralatan
Cakupan pekerjaan konstruksi
Pembagian kerja dan tanggungjawab diantara kontraktor pelaksana
Kendali kualitas konstruksi
2.2
2.2.1
Radiant Section
Komponen yang membentuk Radiant Section terdiri atas beberapa bagian yang dapat dibagi dalam
beberapa paket pekerjaan konstruksi:
Tabel. Komponen Radiant Box dan Split of Work
Komponen
bangunan baja, untuk radiant box maupun struktur penutup

diatasnya, termasuk akses operator, platform, stairway & ladder,
roofing & siding
komponen gas proses, berupa radiant harps (termasuk catalyst tube

top cover, thermowell sleeve/extention), inlet pigtails, inlet
manifolds & cross-over pipe
refraktori, berupa ceramic fiber (module & blanket), refractory brick

(fire brick, insulating brick, tunnel cover brick), castables, material
insulasi luar, semuanya beserta attachment (anchor clip, pin dll) dan
bahan pendukung lainnya (mortar, asphalt coating, dll).
burners (arch burners, tunnel burners), burner tiles, combustion air

ducts, air dampers
fuel lines dan control valves
asesoris seperti spring hangers/spring support, peep holes. ruler
Insulasi pipa, termasuk cross-over pipe, inlet manifold, fuel line
Note: M : mekanikal; R: refraktori/insulasi; O: other (piping, listrik, instrument, insulasi pipa)
2.2.1.1 Steel structure

Radiant Box
Dipasok dalam bentuk beberapa panel dan komponen yang siap dipasang dengan baut.
Pengelasan diperlukan untuk memasang gusset plate untuk platform, walkway atau pipe support, dan
seal weld panel radiant box agar kedap air/udara.
Beberapa kolom atau beam utama memerlukan pengelasan setelah seluruh radiant box terpasang.
Untuk sementara komponen ini dipasang dengan baut.
Brick support (SS) plate (kalau dipakai) dilas dilapangan sesuai dengan gambar instalasi refraktori.
Pemasangan beam dan plat pada radiant arch dan akses operator (burner level) memerlukan kolom
sementara hingga roof truss sudah terpasang, termasuk untuk memasang 107-D Transfer Line.
Tambahan kolom ini tidak dipasok supplier dan menjadi lingkup subkontraktor.
Upper structure & roof
Dipasok dalam komponen lepas yang siap dipasang. Tiang-tiang utama dipasang dengan sistem
baut dan las, sedangkan untuk truss atap perlu dilakukan pre-assembly dibawah sebelum dipasang.
Sebagian komponen upper structure dan roof akan dipasang setelah radiant harp di masukkan
dalam radiant box
Tabel. Ringkasan Steel Structure Radiant Section
Supply condition
Installation method
note
Radiant wall
Panel
Bolting, seal weld
Radiant floor
Panel + beam
Bolting, weld (seal & butt)
Platform,
stairway,
ladder
Pre-fab frame
Weld to support beam
Loose component
Bolting & weld to column
Gusset plate
weld
Upper
Column
Prefab.
Bolting & weld
Roof Truss
Loose component
bolting
Pre-assembly
before install
Radiant Arch
Pre-fab beam & arch

plates
bolting
Temp support
required
Operator way
Grate section panel
bolting
Roof &
Siding
Loose pieces
bolting
Note:
2.2.1.2 Refractory
Tabel. Ringkasan Refraktori Radiant Box
1
Radiant wall
Supply condition
Installation method
note
Ceramic fiber
Module
Surface cleaning
Power brush
stud weld and manually
Tabel. Ringkasan Refraktori Radiant Box
Radiant arch
Tunnel Wall
Supply condition
Installation method
& blanket
installed
Asphalt coat
brush
Ceramic fiber
modules & blanket
Surface cleaning
Asphalt coat
brush
Burner tiles
manual, with mortar
Calcium silicate
board
manual with mortar
Insulating brick
manual with mortar
Support plate
weld
Fire brick
manual
Tunnel Cover brick
manual
2.2.2
Radiant Floor
Power brush
stud weld and manual install
Burner tiles
4
note
For arch burner
By Mechanical
For tunnel burner
Calcium silicate
board
manual, with mortar
Insulating brick
manual
Fire brick
manual
castable
Anchor weld + cast
Ceramic fiber
blanket
Stud weld and manual
For bottom duct
101-B Radiant Harps & Other Pressure Part
2.2.2.1 Presure parts

Pressure part yang dilewati oleh mixed feed gas hingga keluar ke 107-D Effluent transfer line
terdiri atas:
Inlet manifold
Inlet pigtails
Radiant harps
Inlet manifold, merupakan pipa header penyaluran mixed feed gas ke masing-masing radiant harp.
merupakan pipa nir karat 308H berukuran 8 dengan sejumlah outlet connection (sock-o-let)
untuk masing-masing inlet pigtails.
Inlet pigtail, merupakan pipa nir karat (308H) berukuran 1-11/2 yang menyalurkan gas umpan
dari inlet manifold ke masing-masing catalyst tube. Pigtail dibentuk untuk mengurangi dampak
ekspansi termal dari catalyst tube maupun inlet manifold. Dipasok dalam bentuk satuan untuk
dipasang dan dilas di lapangan
Radiant harps, merupakan rangkaian sejumlah catalyst tube (HP Mod) yang disusun berjajar. Tube
ini dilengkapi dengan top pipe (SS 308H) dan grating dibagian bawah untuk menopang unggun
katalis. Gas proses keluar dari tube katalis melalui pipa keluar ( 1, Alloy 800 HT) yang
tersambung dengan outlet manifold (Alloy 800 HT). Setiap satu rangkaian radiant harp dilengkapi 1
buah Riser Tube (HP Mod) terpasang dibagian tengah untuk menyalurkan gas ke Effluent Transfer
Line. Setiap radiant harp dipasok menjadi 3 bagian, yaitu end parts (2 ea) dan mid part (1 ea) yang
harus disambung di lapangan dalam posisi sudah tergantung pada spring hanger.
Untuk pengapalan, radiant harp dilapis anti karat yang harus dibersihkan sebelum dipasang.
Setiap sepasang catalyst tube digantung dengan menggunakan spring hanger ke struktur atap,
sedangkan riser tube disambung las ke Effluent Transfer Line
Riser Transition Assembly, berupa kerucut dari baja paduan Ni (Incoloy 800 H atau setara) dengan
bagian atas berupa baja karbon dengan refraktori pelindung panas (bubled alumina castable) dan liner
sleeve Incoloy 800H. Dipasok terpisah untuk dipasang diantara Riser Tube dan Effluent Transfer
Line di lapangan. Selain pengelasan, baik pressure part dan liner sleeve, diperlukan juga pengisian
bubled alumina castable pada area penyambungan las.
Tabel. Ringkasan Radiant Harps + other pressure part
1
Radiant
harp
Supply condition
Installation method
note
Terbagi 3 bagian, 2 end

section + 1 mid
section.
Instalasi per bagian setelah

radiant upper structure selesai
dikerjakan
Lifting beam
Tube Top Cover
Pengelasan (buttweld) outlet

manifold pada posisi sudah
tergantung
Thermowell extension
Thermowell sleeve
Inlet Pigtail
Satuan
Inlet
manifold
Terbagi 2 bagian per

row
Test pieces
Weld rod
Thermo well extension dilas

sebelum insulasi outlet
manifold
Fit-up dengan posisi inlet
manifold dan catalyst tube
yang sebenarnya.
Socket weld pada inlet
manifold dan cat-tube top pipe
Temporary
support
Dipasang berikut tube guide

dan hanger
Cut & bevel

Paper board
gasket
Test piece
Weld rod
Test piece
Weld rod
But-weld pada posisi sesuai

gambar
4
Transition
Assembly
Transition assembly
set
Metal sleeve (Alloy
800HT) + Cardboard
Fit-up setelah riser tube dan

107-D pada posisi sesuai
gambar
Cut & bevel

Temp support
Test piece
Weld rod
Butt-weld to riser tube & to

107-D
Test piece
Weld rod
Tabel. Ringkasan Radiant Harps + other pressure part

Supply condition
Installation method
note
Install & weld liner sleeve with

cardboard
Weld rod
Castable pouring
By Refractory
Metal sleeve weld at 107-D
Weld rod
Expansion space
2.2.2.2 Refractory
Pelindung panas dalam berbagai bentuk digunakan pada pressure part, sebagai table berikut:
Tabel. Ringkasan Refractory pada Radiant Harps + other pressure part
1
2
Supply condition
Installation
method
Cat Tube Top

Pipe
Ceramic fiber blanket
As per dwg
Inlet Pigtail
pre-formed mineral
wool
note
Metal sheet
As per dwg
Fiber glass cloth

3
Inlet manifold
Pre-formed mineral
wool
As per dwg
Ceramic fiber bulk

Metal sheet
4
5
Outlet pipe &

manifold
As per dwg
Transition
Assembly
Bubbled alumina
castable
cast manually after

liner sleeve in place
as cast homogenity
Insulating can (prefab)
Insulating Can to be
assembled &
welded in place
At top part of riser

covering weld joint
and transition pieces
Tie-wire

Ceramic fiber fabric
sewn with blanket
Tie-wire
Insulating can welding

by Mechanical,
ceramic fiber blanket
by Refractory
Weld rod 617
2.2.3
101-B Primary Reformer Transition Duct & Convection Section

Transition Duct, dipasok dalam bentuk section panel (roof, floor dan end panels, header cover)
dan fabricated beams. Castable dan silicate board dipasok terpisah untuk di lapis dan cor ditempat
Convection section dipasok dalam beberapa komponen, sebagai Tabel berikut:
Tabel. Komponen Transition Duct dan Convection Section
Komponen
steel structure, dalam bentuk side wall dan end wall panels, prefabricated beam, header cover, pre-fab platform, ladder,
combustion air duct, damper, dll.
tube bundles lengkap dengan tube supports; support brackets

dipasok terpisah untuk dipasang menjadi module sebelum
instalasi
distribution plate (pre-fab) dan supportnya, castable support

plates
pipe spool pieces, untuk penyambungan antar tube bundle atau

tube header dan cross-over pipes, hangers, dll.
refractory material: castable untuk side wall & end tubesheet;

ceramic fiber module & blanket untuk roof; external insulation
for ducting and pipe,
burners & burner tiles
Tube bundle, wall panel dan header cover dirakit dahulu berikut castable menjadi satu bagian
heater module sebelum dipasang diposisi yang ditentukan.
Castable lining pada roof panel diusahakan dilakukan sebelum instalasi, kecuali material yang
tersedia bisa dan cukup untuk diaplikasi dengan sistem gunning.
Tabel. Ringkasan Pekerjaan Mechanical Convection Section & Transition Secti on
Transition Duct
Supply
condition
Installation
method
note
section panel
bolting & weld
Castable lining di
roof panel
sebelum instalasi
beam
2
Convection inlet,
outlet , &
transition/ burner
duct
section panel
Heater module
section panel
bolting & weld
pre-fab column
tube bundle
Castable lining on
section panel
Preassembly of
By Refractory
Tabel. Ringkasan Pekerjaan Mechanical Convection Section & Transition Secti on
Supply
condition
Installation
method
Support bracket
module
Cross-over pipes,
etc
Spool pieces
Air duct & damper
prefab duct &

damper
note
Module installation
Lifting beam
welding
Test piece
Spring
support/hanger
Weld rod
bolting
gasket
6
Burner & burner

tiles
burner tiles in
sections
burner tiles
w/mortar
burner assembly
by refrctory
by mechanical
Tabel. Ringkasan Pekerjaan Refractory Convection Section & Transition Section
Transition Duct
Supply condition
Installation method
castable
form work
silicate board
Castable lining di roof

panel sebelum instalasi
anchor
2
Convection inlet,
outlet , &
transition/
burner duct
castable & anchor
anchor welding
ceramic fiber module
formwork
note
castable lining
ceramic fiber installation
Heater module
Castable
Anchor welding
Anchor
Support plate welding
Support plate
Form work
Castable lining on
section panel
Cross-over
pipes, etc
Pipe perform mineral

wool
As per dwg
Metal sheet
5
Air duct &

damper
mineral wool board +

jacket
anchor welding
Burner & burner

tiles
burner tiles in sections
burner tiles w/mortar
By mechanical
Before module preassembly
2.3
101-BL Combustion Air Preheater

Dipasok dalam beberapa bagian (boxed) yang harus dipasang diposisi sesuai petunjuk gambar
bersama flue gas dan combustion air ducting. Pemasangan dengan sistem baut dan seal welding
pada sisi flue gas.
Insulasi luar dipasang kemudian sesuai gambar.
2.4
101-BJ Primary Reformer Induced Draft Fan & 101-BJ1 Primary Reformer Forced
Draft Fan
Dipasok terpisah antara fan dan penggeraknya, untuk dipasang ditempat.
Sisi inlet & outlet fan dilengkapi dengan expansion joint untuk mencegah beban berlebih pada fan
Material insulasi luar dipasok sebagai bagian dari Primary Reformer tapi pengerjaannya dapat saja
dilakukan oleh subkontraktor insulasi.
2.5

Dipasok dalam bentuk jadi dipasok lengkap dengan selonsong dalam (metal sleeve), refraktori
yang sudah di cor di shop, water jacket dan kompenen hanger. Beberapa bagian dari pelat water
jacket harus dipasang dilapangan setelah 107-D digantung di struktur atap Primary Reformer dan
setelah penyambungan dengan Transition Assembly maupun dengan 103-D Secondary Reformer.
Untuk penyambungan dengan 103-D digunakan tambahan Fit-up section, merupakan bagian dari
107-D yang dipasok terpisah untuk fit-up dilapangan dengan inlet stub 103-D Secondary reformer.
Bagian utama 107-D harus dipasang terlebih dahulu dengan temporary support sebelum struktur
atap Primary Reformer dapat dipasang.
Pemasangan liner sleeve (dengan lapisan cardboard) dilakukan setelah pengelasan sambungan ke
103-D maupun ke transition assembly dan pengecoran bubled alumina castabale.
Tabel. Ringkasan Pekerjaan 107-D Effluent Transfer Line
Supply condition
Installation method
note
Main body
Dengan temporary support

setelah radiant box steel
terpasang
Posisi inlet stubs 107-D terhadap

posisi radiant harps
Fit up at field
107-D pada kondisi tergantung

dan levelled
Fit-up section
weld
3
metal sleeves
Elevasi thdp 103-D inlet stub
fit-up w cardboard
Setelah bubled alumina & inspeksi
weld
Expansion clearance
Bubled alumina
castable
As per dwg
Setelah pengelasan pressure part;

by refractory subcontractor
Brick w/ceramic
A sper dwg
Flange cover, after final inspection
Tabel. Ringkasan Pekerjaan 107-D Effluent Transfer Line
Supply condition
Installation method
note
Fit-up & weld
Setelah temporary support dilepas
fiber blanket
Water jacket
2.6

Terdiri atas
bejana tekan
mixing chamber, dipasang terakhir setelah inspeksi final sebelum top cover
top & bottom cover w/insulating can + gasket, dipasang setelah inspeksi final
komponen pelat incoloy atau nirkarat yang harus dilas dilapangan setelah selesai atau diantara
tahapan pengecoran castable
refractory material, terdiri atas high alumina castable
catalyst support, berupa dome brick dan mortar, alumina ball dan hexagonal tile
steel form untuk pengecoran castable,
wooden form untuk peletakan dome-brick
Pengelasan inlet stub end dengan 107-D maupun outlet stub-end dengan transfer line ke 101-C
dilakukan setelah castable drying out selesai dilakukan
Castable drying out dilakukan dengan kondisi water jacket telah terpasang karena diperlukan untuk
sirkulasi air pendinginan dinding reformer.
Refractory work 103-D dan drying out nya dibahas dalam bab tersendiri.
2.7
103-D 101-C Transfer Line

Bejana tekan berbentuk selonsong dengan lapisan castable tahan panas dibagian dalam. Mengacu
pada disain Kellogg standar dilengkapi juga water jacket dibagian luar, sedangkan castable sendiri
dilindungi dari aliran gas dengan liner sleeve
Selain pekerjaan fit-up dan pengelasan pressure part (baja karbon) dilakukan juga fit-up dan
pengelasan liner sleeve sebelum dapat diserahkan kepada subkontraktor refraktori untuk
pengecoran bubbled alumina castable.
Pemasangan liner sleeve (dengan card board) perlu memperhatikan clearance yang diperlukan
untuk expansi pada kondisi suhu operasi.
2.8
Pengelasan Heater Tube

Heater tube dimaksud mencakup inlet manifold, inlet pigtail, outlet manifold, risert transition,
cross over tube dan heater tube lain.
Selain kebutuhan akan test piece untuk pengetesan welder dan penyiapan WPS/PQR perlu
diperhatikan juga pasokan kawat las untuk masing-masing joint/jenis base metalnya.
Contoh breakdown pengelasan di sistem Reforming ditampilkan dalam Attachment-2
2.9
Quality Control
Kendali kualitas pada pekerjaan konstruksi reformer dibagi dalam beberapa tahapan:
Tahapan Pekerjaan /QC items
1
5.
note
Fondasi dan posisi anchor bolt
posisi masing-masing fondasi terhadap center-line

primary reformer dan terhadap dinding luar radiant
box atau convection modules
Surveyor/mech
posisi center-line 107-D/101-B Primary Reformer

terhadap center-line 103-D
Surveyor/civil
jarak titik acuan 107-D/riser tube terhadap centerline 103-D
Surveyor/civil
Elevasi akhir pad-plate masing-masing fondasi
Surveyor/mech
Lain-lain, sesuai Construction Specification
Steel Structure
Seal welding & butt welding of beam/column
Visual/PT
Plumbness, straightness
Y-level,
HT bolt size and tightening
Lain-lain sesuai Specification
Heater Module
Posisi inlet/outlet header relatif terhadap dinding

dan column splice
Expansion clearance, posisi finned tube pada end

tubesheet setelah pre-assembly
visual
Pemasangan temporary tie-rod
visual
Metode pemasangan/spreader beam/lifting beam
Lifting plan
Lain-lain sesuai specification
Refractory Work, Ceramic Fiber Module/Blanket
Surface cleaning
Marking for anchor
Stud anchor welding
Material checking
Sequence pemasangan
visual
Bend test
As per dwg
Refractory, castable
Surface preparation
visual
Marking for anchor (pitch dan jenis)
As per dwg
note
Anchor welding
Bent test
Form work (sealed, space/castable thickness)
Material use/mixing water quantity/mixer + tool

cleanliness
As per manual
Castable check for void

/honeycomb/dryness/spalling
Light hammering
Burner & burner tiles
Posisi secondary burner tips
Burner tip cleanliness,
Radiant Harps, installation
Inside cleanliness/defect
Visual/boroscope
Support grid /grating opening
Visual/boroscope/
dP check
10
Elevasi dan levelness outlet manifold/top pipe
Thermal expansion space at outlet manifold
Spring setting
Inlet Manifold, installation & welding
Inside cleaning
Posisi guide/hanger dan thermal expansion

movement/clearance
Fit-up & straightness during welding
Root pass: PT; final pass : PT, RT
Outlet manifold welding
Fit-up
Level and straightness of tube, interpass temp

during welding
Root pass PT; Final PT & RT
107-D, installation
Level & centerline terhadap 101-B maupun 103-D
Posisi inlet stub end terhadap posisi riser tube
Spring setting (final)
Castable line
Liner sleeve installation and clearance
Center-line to radiant harps and 107-D inlet

connection
Cold/hot setting
11
Fir-up
Root pass PT; Final PT & RT
Castable lining
Root pass PT; final pass PT & RT
101-BL Air Preheater
Surface condition
Position of each section
Seal welding
3.
CONSTRUCTION PLAN
3.1
Objective
3.2
note
Membagi seluruh aktifitas konstruksi menjadi paket-paket yang dapat di subkontrakkan
Memberikan gambaran urutan aktifitas konstruksi secara keseluruhan sesuai dengan paket
pekerjaan
Scope of Work
Keseluruhan lingkup kerja konstruksi untuk sistem reforming, waste heat recovery dan fired
heaters adalah sebagai berikut
Erection and steel work for 101-B Primary Reformer and its proper
Installation of 101-B associated equipment (Fans, Air preheater, Burners, etc.)
Equipment installation of 107-D, 103-D, 101-C and 102-C and the transferlines
Welding of high alloy radiant harps, stainless steel piping component and transfer lines
pressure part and incoloy sleeves
Steel erection & refractory lining of 102-B
Refractory work for 101-B, 103-D, 107-D and field joints between 103-D, 101-C and 102-C
Drying-out 103-D
Precommissioning
Catalyst loading
Radiant Harp balancing
Kelima butir pertama biasanya menjadi satu paket pekerjaan kontaktor mekanikal dengan
pembatasan sesuai penjelasan pada bab sebelumnya.
Urutan pekerjaan untuk area Primary Reformer secara rinci dapat dilihat dalam Attachment-1, dan
secara ringkas dijabarkan dibawah ini.
3.2.1
Instalasi 101-B Primary Reformer dan Peralatan lainnya

Mencakup instalasi struktur baja 101-B radiant box, 101-B Convection Modules dan bangunan
baja, dampers, combustion air duct, stack dan platform/ladder.
Instalasi struktur baja radiant box dilakukan secara sekuensial dengan instalasi107-D and 103-D
maupun dengan instalasi radiant harps.
Temporary support untuk instalasi combustion air duct and 107-D harus disiapkan oleh
mechanical subcontractor.
Convection coils, steel panels dan refractory material dipasok terpisah. Perlu dilakukan
preassembly per module dan dilapis dengan castable sebelum dipasang ditempatnya. Subkontraktor
mekanikal perlu menyiapkan meja kerja untuk fabrikasi module dan menyiapkan lifting frame
untuk instalasi module.
3.2.2
Installation of 101-B Associated Equipment

Peralatan dimaksud mencakup 101-BL Air Preheater, ID and FD Fans (101-BJ1 & 101-BJ2) dan
penggeraknya, roof fans, dampers with actuators, dan burners (101-BBA, BBS, BBT), dipasang
oleh Mechanical subcontractor, kecuali untuk burner tiles yang dikerjakan oleh refractory
subcontractor,
3.2.3
Instalasi 107-D, 103-D, 101-C dan 102-C

Diperlukan heavy cranes untuk mengangkat ketiga peralatan tersebut.
Jadual instalasi 103-D menentukan bagi penyelesaian pekerjaan di 101-B radiant box karena
banyaknya aktiftas yang terkait maupun karena keterkaitan dengan akses untuk heavy crane.
3.2.4
Welding Of High Alloy Radiant Harps, Stainless Steel Piping Component And Transfer
Lines
Mencakup pengelasan 101-B radiant harps, pengelasan stainless steel inlet manifold, cross-over
pipes and pigtails, pengelasan high pressure piping pada convection modules, and pengelasan pada
transfer lines antara 107-D, 103-D, 101-C and 102-C - termasuk Incoloy/ Inconel liner sleeves.
Lihat Attachment-2 dan Attachment-8 untuk rinciannya.
Vendor akan menyiapkan test piece untuk welder test termasuk penyediaan kawat las bila
diperlukan.
3.2.5
Refractory Work for 101-B, 103-D, 107-D and Field Joints between 103-D, 101-C and 102-C
Refractory work pada 101-B radiant box dimulai setelah selesainya pengelasan radiant harps dan
cold setting (balancing).
Castable lining work pada 101-B convection panel dimulai sebelum module pre-assembly dn
selanjutnya secara sekuensial dengan instalasi heater module dan coils,
Secondary reformer (103-D) lining work dimulai setelah water jacket selesai dikerjakan. Pekerjaan
refraktori termasuk instalasi dome brick dan alumina ball sebelum catalyst loading, dan
pemasangan circle brick dan hexagonal tiles setelahnya.
Rincian pelaksanaan refraktori di 103-D khususnya dijabarkan dalam bab berikut.
Perlu diperhatikan umur high alumina castable yang digunakan pada 103-D. Sebaiknya
penegecoran dilakukan tidak lebih dari 6 bulan sejak tanggal produksi karena sangat berpengaruh
pada kualitas castable tsb. (umur castable ini bervariasi antara 6 9 bulan)
Penyimpanan material refractory (terutama high alumina castable untuk 103-D) sangat penting
terhadap kinerja castable tersebut. Karenanya subkontraktor perlu menyiapkan tempat
penyimpanan yang khusus, terhindar dari kelembaban udara, air hujan dan terik matahari. Air
conditioning (AC) diperlukan untuk mencegah panas yang berlebihan pada material castable yang
akan berpengaruh pada curing time dan lifetime castable.
Material supplier menyiapkan gambar kerja dan menyediakan steel form untuk pengecoran.
Subkontraktor pelaksana harus menyiapkan platform kerja untuk
Castable work pada
sleeves-nya
3.2.6
transfer lines field joints dilakukan bergantian dengan pengelasan liner
Dry-Out of Castable 103-D

Dry-out operation pada 103-D Secondary Reformer lining dilakukan tanpa dome brick (kecuali
bottom support brick) oleh spesialis dry-out meski lingkupnya bisa menadi satu paket dengan
pekerjaan refraktori.
Jenis dan kelengkapan peralatan maupun pengalaman calon pelaksana harus menjadi perhatian
khusus pada saat pemilihan subkontraktor.
Dry-out operation untuk 101-B Primary Reformer and 102-B Start Up Heater dilakukan pada
tahap commissioning.
3.2.7
Steel Erection & Refractory Lining of 102-B

Dipasok dalam bentuk 2 modules, radiant box dan stack. Radiant box sudah difabrikasi jadi berikut
heating coil dan lining work kecuali untuk floor. Bagian stack dikirim dalam 2 bagian yang sudah di
beri lapisan refractorys with shop refractory lined.
Mechanical subcontractor bertanggungjawab memasang peralatan termasuk platform & ladder dan
asesoris lainnya. Refractory subcontractor bertanggungjawab melaksanakan floor lining, stack
lining (bila diperlukan), pemasangan burner tiles dan lainnya.
3.2.8
Pre-commissioning
3.2.8.1 Catalyst Loading

Catalyst loading 101-B biasanya melibatkan operator klien karena umumnya lebih berpengalaman.
sedangkan untuk 103-D dilaksanakan oleh Mechanical subcontractor dengan supervisi langsung
kontraktor.
Secara keseluruhan peralatan kerja, safety equipment, consumables dll disiapkan oleh
subkontraktor mekanikal.
Yang perlu disiapkan oleh kontraktor utama adalah 1) alat pengukur beda tekanan tabung katalis, 2)
vibrator berikut attachment ke tabung katalis dan 3) alat untuk mengeluarkan katalis dari tabung
bilamana loading dianggap gagal.
Untuk pekerjaan catalyst loading didalam bejana tekan seperti 103-D diperlukan coverall berikut
alat bantu pernafasan dan blower + saluran untuk mengeluarkan debu katalis. Peralatan ini semua
dapat menjadi lingkup subkontraktor dan perlu dirinci lebih detail dalam dokumen lelang.
3.2.8.2 Radiant Harps Balancing

Balancing of harps dilakukan sebelum dan sesudah catalyst loading (pada kondisi dingin) dan juga
pada kondisi panas setelah suhu flue sesuai dengan kondisi normal.. Kontraktor mekanikal
meyiapkan tenaga kerja dan tools untuk membantu melakukan balancing
3.2.9
Others
Pekerjaan lain pada area reformer:
Piping subcontractor untuk pemasangan sistem pemipaan pada burners dan fuel gas, steam
snuffing, drain line dari radiant outlet manifold, process gas piping keconvection coil headers,
steam line to fans drivers, dan lainnya.
3.3
Instrument subcontractor melakukan pemasangan instruments dan control valve
Electrical subcontractor untuk sistem penerangan dan power line ke peralatan di reformer
(roof fans, actuators, etc.)
Insulation subcontractor, melaksanakan external insulation fuel gas/process gas/steam/air

piping diluar area radiant box dan convection coil headers,
Leak testing untuk fuel piping dan pneumatic testing keseluruhan sistem, dilakukan pada
periode commissioning.
Schedule of Work
Titik acuan konstruksi primary reformer dan peralatan lainnya adalah pemasangan 103-D
Secondary Refomer. Pengelasan radiant harps dan effluent chamber 107-D baru akan dilakukan
setelah reactor ini terpasang pada posisinya.
Secara tentative, instalasi 103-D dilakukan paling lambat 3 bulan setelah struktur baja Primary
Reformer dikerjakan, kecuali bilamana diperlukan akses untuk heavy lifting.
Refractory work pada 103-D akan dimulai lebih kurang 2 bulan setelah instalasi 103-D.
Convection coil, air preheater and fans sudah harus terpasang sebelum pemasangan dan
pengelasan cross over pipe dan ducting.
Jadual umum konstruksi ditunjukkan pada gambar halaman berikut dan Attachment-3.
4.
REFRACTORY & DRY-OUT WORK 103-D
4.1
Objective
Pekerjaan castable lining dan drying-out 103-D merupakan salah satu pekerjaan yang sangat kritis
dan cukup berat. Kegagalan disaat peleksanaan pekerjaan refarktori ini berdampak sangat besar
kepada proyek dan kehandalan operasi selanjutnya. Karena itu perencanaan yang rinci sangat
diperlukan dan pengawas maupun kontraktor yang dipilih selain harus berpengalaman utk
pekerjaan sejenis juga perlu memahami persyaratan dan kelengkapan kerja yang diperlukan.
Gambar. Sekuen Pelaksanaan Pekerjaan Reforming Section

61-101-B Primary Reformer & 61-103-D Secondary Reformer
Installation
61-101-B Radiant
Panel installation
Platform up to
elev. 13.000
Radiant box upper

structure/roof
trusses
Combustion Air
Duct
Radiant Harps
Welding
Convection
Module Installation
Radiant Harp
welding
Refractory
Panel welding
Anchor welding of
Convection panel
Castable lining
work. Convection
Section Panel
103-D Lining
103-D Dryout
Burner tiles & rad

box refractory
work
61-107-D Effluent
Chamber
Vessel
103-D installation
Water jacket
4.2
Refractory work
Cakupan aktifitas pekerjaan ini dimulai dengan proses:
penyiapan material
penyiapan peralatan dan platform untuk kerja
pembersihan permukaan steel dan anchor, dilanjutkan dengan pemasangan drop form
sample test castable utk memastikan jumlah air pencampur
lining work, dalam 3 tahap diselingi pekerjaan pemotongan/pengelasan pelat
pelepasan drop form dan inspeksi
pemasangan support brick
drying-out
dome brick dan catalyst loading
Secara lebih rinci, sekuen aktifitas refraktori dan pekerjaan mekanikal yang terkait dijabarkan dalam
Attachment-4.1.
4.2.1
Penyiapan Material
Penyimpanan material castable harus sudah ditangani dengan benar sejak kedatangan di site.
Diperlukan gudang yang bebas air dan udara lembab, serta cukup dingin dan tidak terkena panas
langsung matahari. Praktisnya adalah dengan memanfaatkan container pengiriman yang ditempatkan
dibawah atap dengan penopang balok kayu (agar tidaklangsung kontak dengan tanah)serta diberi
pendingin udara (AC). Udara panas pada material castable dalam waktu lama dapat berakibat rusaknya
castable.
4.2.2
Penyiapan Peralatan dan Platform Untuk Kerja

Daftar peralatan untuk casting maupun drying-out dijabarkan dalam Attachment 4-3
Platform kerja diperlukan baik didalam didalam bejana tekan maupun pada elevasi top opening.
Platform didalam reactor harus dapat memuat minimal 8 orang dengan 3 vibrator dan tool. Platform
juga harus mudah dibongkar dan dipindah mengikuti ketinggian pengecoran
Platform di top opening harus cukup lebar dan kuat untuk memuat 2 mixer, 3 drum air, 3-4 palet berisi
castable, ruang kerja untuk 12-16 orang
4.2.3
Lining Work
Dilakukan dalam 3 tahapan, 1) dibawah posisi dome-brick, 2) diatas dome brick hingga posisi mixing
chamber, dan 3) diatas mixing chamber hingga top opening.
Tahap 2 relatif memakan waktu lama karena jumlah yang harus di cor cukup besar.
Rincian pekerjaan ditampilkan dalam Attachment 4-2.
4.2.4
Pemasangan Supprot Brick dan Dome Brick

Sebelum pemasangan, disiapkan brick sesuai nomor row dan ututan pemasangan. Penyediaan brick
diatur sesuai dengan kebutuhan (sesuai row yang dikerjakan)
Dry setting (pemasangan sementara tanpa mortar) perlu dilakukan untuk memastikan posisi setiap
brick sebelum dipasang ulang secara permanen dengan mortar.
Untuk pemasangan dome-brick (setelah drying-out castable), dilakukan dengan menggunakan dome
brick wooden form yang disiapkan oleh supplier. Sebelum pemasangan ditempat, sebaiknya dilakukan
dry setting diluar untuk memastikan space antar brick yang nantinya diisi dengan mortar. Key brick
(brick paling atas) harus terpasang dengan benar untuk memastikan kekokohan struktur dome dalam
menanggung beban alumina ballast dan catalyst diatasnya.
4.3
Drying-Out work
Pengeringan castable dilakukan dengan cara menghembuskan udara panas kedalam 103-D melalui
bottom opening. Udara panas dihasilkan dari pembakaran gas alam pada furnace yang ditempatkan
diluar vessel dan disalurkan dengan menggunakan ducting. Skedul pemanasan dan pengukuran suhu
(flue gas dan vessel skin) diatur dalam prosedur Kellogg.
Prosedur diatas tidak selalu dapat dilakukan tergantung dengan bentuk bejana tekan tsb maupun
furnace yang tersedia sehingga perlu dilakukan penyesuaian dilapangan. Lihat Attachment-6
5.
PRECOMMISSIONING WORK
Pekerjaan pre-commissionin dan commissioning di area reforming mencakup:
Catalyst loading pada 101-B. Lihat Attachment-7
Catalyst loading 103-D
Radiant harp balancing (cold setting)
Chemical cleaning 101-C dan 141-D
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE
(TYPICAL)
No
Activities
Reference
drawing
Remarks/ Inspection Requirement
A. Preparation
A.1
Foundation hand over from civil, reconfirm

dimensional and position of anchors
Check and record foundation and

anchor position
Grease anchors bolts and nuts

A.2
Liner plate installation
Liner plate, non-shrink mortar.

Check and record for elevation
A.3
Prepare work bench for pre assembly of radiant

panels and platform
Steel beams, temporary platform

support and wooden plank. The
bench should be sized enough for 2
panels
B. Radiant Box Pre Assembly & Installation

Panels of wall #2 & #4 require pre assembly on ground prior to
erection/installation. At same time platform support can be
installed to the extent feasible
Sequence of pre assembly and installation:
Wedges required for adjusting panel

plumbness
Pre assembly on steel bench
B.1
Wall panels (start from wall #4 & wall #3) and

floor walls, in sequential order:
Pre assembled panels to be high

strength bolted
B.2
Plumbness and diagonal dimensional check
Bolts at splice to be manually

tightened before plumbness check.
Gap at splice should be max. 3 mm.;
B.3
Bolt tightening and seal welding
High strength bolting before seal

welding
B.4
Liner plate tack welding and grouting
Non-shrink mortar required
C. Combustion Air Duct & Arch Plate Installation

Ducts panels and arch platesarepre assembled on ground prior to
installation. Each row is pre assembled into 2 pieces without seal
plates
C.1
Install temporary support for ducts and 107-D
Support are supplied by

subcontractor based on designs
furnished by TEC
ATTACHMENT-1.
(TYPICAL)
Reference
drawing
No
Activities
C.2
Install ducts:
Cover openings with plank or

plywood for personnel protection
C.3
Install seal plates for duct connection (sealing

compound & sealing gasket Weld duct end
openings to wall structure
Align duct according to dwg.,
C.4
Arch grating
C.5
Install ends cover,
Maintain expansion clearance as per
After castable lining work
D. 107-D Pre-installation
D.1
Temporary support installation on top of ducts
Dwg. NA
D.2
Pre-installation of 107-D, at its designated

elevation and position
407-D series
Check alignment to inlet of 103-D

and centerline to the reformer.
Plumb line from center of 107-D
inlet stub is + 12 mm from center
of drain opening on the floor
E. Roof trusses
Requires pre assembly on ground to complete set of trusses before
installation
E.1
Pre assembly of End-trusses & Sub-trusses
Dimensional check against actual

column position on radiant walls
Column bevel ends are prepared on
ground
E.2
Install:
Upper column
End trusses, Sub trusses, Vertical bracing
Bracing & post
Tie bracing & effluent chamber support, roof
bracing
E.4
Complete roof construction before H.3, including

installation of exhaust fans
F. 107- D Setting and Adjustment
ATTACHMENT-1.
(TYPICAL)
No
F.1
Activities
Install 107-D spring support, in locked condition
according to dwg.
Install hanger to spring support and weld the pin
F.2
Roof trusses are completely installed, bolt tightened

and welded
Reference
drawing

Check spring no. and its location
which is align with transfer line
support points
Check that the 107-D is positioned
center line to reformer for its entire
length and align to 103-D inlet stub
Suspend 107-D by tightening spring turnbuckles,

F.3
Remove 107-D temporary support after position

and level of the vessel is inspected.
F.4
Measure distance from 107-D end to 103-D inlet

stub.
Cut 107-D field piece to the required length plus
allowance for end preparation.
Bevel end according to WPS
Fit-up and tack weld field piece
F.5
Welding pressure shell of 107-D field piece to start

from 103-D side
F.6
Installation of water jacket
Check vessel centerline to furnace

and adjust weld sequence if required
G. Duct Hanger & Manifold Installation

G.1
Install duct hanger and set level of duct by

adjusting bolts
Adjust duct to center of 107-D inlet stub
G.2
Install inlet manifold support & guide

Install inlet manifold and support hangers. Use turn
buckles of intermediate support to maintain slope
of manifolds
G.3
Weld Grinnell pipe covering protection saddle,

followed by guide roller and
G.4
Remove duct temporary support
Check level of duct, check

expansion allowance on duct
connection
Plumb line from center 107-D inlet
stub, was within + 12 mm from
midpoint of adjacent duct wall
G.2 & G.3 can be done after radiant
harps installation (H)
Maintain slope of (- 25 mm) + (3
mm) towards cross over pipe
Check clearance as per drawing
ATTACHMENT-1.
(TYPICAL)
No
Activities
Reference
drawing
H. 101-B Radiant Harps installation

Each harp section will be erected using spreader beam. These harp sections was temporary seated on steel
support below floor level.
H.1
Remove shipping bracing from radiant harps except

for erection purpose
H.2
Install the harp through opening on the roof

structure, start with center harp. Temporary steel
support was positioned so that the outlet manifold
is rested 20 mm below its intended elevation
210-D103
H.3
Install spring hanger assembly and beam, tighten

spring assy by turning threaded rod
212-D101
Plumb hanger was within + 3 mm
Check and record length of upper

and lower attachment and over all
spring assembly
J. 101-B Radiant Riser Transition Assembly welding

J.1
Center and fit-up riser transition assembly to 107-D

inlet stub using support
210 - D105,
J.2
Perform welding in sequential order (together with

refractory work) as per drawing
407 D6
J.3
Re-check with plumb line from riser transition inlet

stub as per F.2
J.4
Continue with water jacket installation

K. Radiant Harps Adjustment and Welding
407 D6
Perform inspection as per dwg.
ATTACHMENT-1.
(TYPICAL)
No
K.1
Activities
Reference
drawing
Suspend harps on hand tightened springs and

remove temporary support
See KBRs balancing procedure
Install bottom header boxes to maximum extent,

leave access for jigs and welding work
Do not weld cover plates at this

stage.
Drop plumb line from riser transition to floor

opening. Centering riser tube was within + 12 mm
from top of riser to connection point with outlet
manifold,
Plumb hanger was within + 3 mm

Measure and record distant of top
flange from datum line before
support is removed
Check if drain nozzle and thermowell connections

are correctly centered over floor openings. Floor
opening should be adjusted accordingly if
conflicted.
K.2
Leveling center harps outlet manifold was within +

10 mm for 3 m length by using hangers threaded
rod
Adjust elevation and level of end harps was aligning
with center harp.
210-D103
Level to within +10 mm per 2500

mm length.
flange from datum line before
welding
Fit up for welding.
Measure and record elevation of

manifold above floor at three points
for each third
K.3
Weld manifold according to the approved

procedure
Use jig to fix position of manifold

during welding
K.4
Record position of tube assemblies after welding

flange from datum line
Measure and record elevation of
manifold above floor at three points
for each third
K.5
Adjust the hanger based on final record of distant

of top flange from datum line
Release or tightened the threaded

rod by the difference in record
before and after welding
ATTACHMENT-1.
(TYPICAL)
No
K.6
Activities
Reference
drawing
Raise riser to correct position for field welding by

adjusting spring turnbuckles.

Before welding:
Check for correct weld gap
107-D to remain as per F.6.

flange from datum line & elevation
of manifold above floor at three
points for each section
After welding finished:
flange from datum line & elevation
of manifold above floor at three
points for each third
Adjust spring turn-buckles
according to differences in record
measurement
K.7
Install drain and thermowell connection and sleeves
210-D102
Welds as per approved procedure

K.8
Riser insulating cans was installed after pneumatic

test of radiant coil (step P.)
210-D104
K.9
Install arch cover plates according to drawings
Check bolt position/clearance for

arch plate movement, adjust plates
if required (ditto N.2)
K.1
Weld cover plate as per drawing
Check expansion clearances
L. Refractory Lining & Burner tiles (Radiant Box)

L.1
Install sidewall brick lining. Including tunnel burner

side bricks and burner tiles
Ensure that dimension of brick on burner wall side
is correct to ensure straightness of tunnel wall
L.2
215-D series
Test for anchor stud weld strength
Suppliers
dwgs.
Maintain and check for expansion

clearance on brick wall as per
drawing
Install arch burner tiles
Check for correct position for each

type of arch burners
Check for tiles projection
L.3
Install arch module lining except area around riser

transition assembly (if step P.1 is not yet perfrmed)
Supplier
dwgs.
ATTACHMENT-1.
(TYPICAL)
No
Activities
L.4
Install tunnel wall bricks, floor brick and bull-nose

castable lining
L.5
Outlet manifold lining after catalyst loading. Step

M.1, and system pneumatic test, step P.4
Reference
drawing
M. Catalyst Loading
M.
1
Catalyst loading will start if radiant harps welding

and upper structure is completed
Catalyst loading to proceed in accordance with
procedure
M.
2
Replace gasket with permanent material and bolt

tightened as per instruction, after final inspection
of catalyst bed
Detailed procedure was developed

using KBRs loading procedure. Bed
density of catalyst was confirmed
prior to loading
Bolt torque controlled
N. 107-D & Radiant Tubes Spring Adjustment (Cold Setting)

N.1
Fill in water to 107-D jacket to operating level.

Remove spring locks and adjust spring to the
operating load (cold)
N.2
Release radiant tubes spring locks
Check for any obstruction, adjust

arch plates if required
Check bolt position (on sloted
holes) for duct movement
N.3
Adjust spring to Final Cold Operating load settings
Record final spring setting

Measure and record distance of top
N.4
Set 107-D spring limit stop 15 mm. upward and 3

mm downward.
O. Installation of Arch and Tunnel Burners
O.1
Install burners as per drawing/instruction
Check orientation and record burner

tip projection
Check for easiness of operation of
burner air damper
ATTACHMENT-1.
(TYPICAL)
No
Activities
Reference
drawing
P. Refractory and External insulation (Radiant Box)

Step P1, P2 & P5 was completed after system pneumatic test
P.1
Install & welding riser cans with ceramic fiber

blanket
210-D104
P.2
Install ceramic cloth (Nextel BS-40) w/cardboard

below riser cans
Suppliers
dwgs.
Install flexible boot on riser openings

P.3
Complete ceramic fiber lining on arch plates
P.4
External insulation on air ducts
P.5
Complete refractory work on outlet manifold and

header boxes, and castable on air ducts
Suppliers
dwgs.
Provide protection on slabs by using
plywood
Install tunnel slabs.

Q. Inlet pigtail and external pipe welding and insulation
To be performed before system pneumatic test, before or after
catalyst loading, but after cross-over piping (step S1 to S5)
Q.1
Fit up inlet pigtail by trimming excess length. Do

not cold spring.
Q.2
Insert 1.5t cardboard spacer to sockolet on inlet

manifold and on radiant tubes before inserting
pigtail into sockolet.
Perform visual check for the gasket

before pigtail installation
Q.3
Socket weld inlet pigtails to radiant tubes and to

inlet manifold
PT
Q.4
External insulation except at weld joints (was

completed after pneumatic test)
Q.5
Adjust spring to Final Cold Operating load settings
Record final spring setting

Measure and record distance of top
R. Convection & Transition Section Installation and Castable lining
ATTACHMENT-1.
(TYPICAL)
No
Activities
Reference
drawing
Convection coil are supplied separately from its casing (convection

panels). Thus to complete the module, the convection panels,
castable lining on the panels and installation of convection coils
should be done in sequential order on steel bench before final
installation.
Mechanical subcontractor to prepare lifting frame suitable for
erection of heaviest module.
R.1
R.2
R.3
Install hot/cold legs convection box up to elev. +

6050. Dimensional check and bolt tightening and
seal weld splices
Install transition floor and roof
Check for type and position / level

of tubesheet supports and guides
Weld columns to cap plate before installation of

upper module
Strength bolted and seal welded
Castable lining work on convection box.
Check for anchor welds
As alterntive, lining may be applied on horizontal

posisiton before panel assembly
Check for castable homogenity by

hammer test
pre-assembly and install lowest convection

modules, both legs
Additional temporary tie-plate/rod

may be necessary to hold firm the
modules during erection
Install tie-beam between hot and cold leg, if any

Full-weld column to pad plate before installation of
next upper module
Ceramic fiber was place on top castable surface at
module splice.
Install convection next modules in sequence
between hot and cold leg. Follow step 2 to 4 for
each module
Bolt and seal weld splices
install and weld distributor supports
R.4
Install roof structure, including duct support

Install platform on convection section
Install end walls on transition section
R.5
Plumb and square check
Install distribution plates
Position of tie-plate/rod are at

column D & H, lower part. To be
removed after column welding.
ATTACHMENT-1.
(TYPICAL)
No
R.6
Activities
Reference
drawing
Ceramic fiber modules and castable lining.

Install burner tiles
R.7
Install superheater burners
Check for position and projection

of burner tips
S. Cross Over Pipes And Convection Module Jump-Over Pipe Installation And Welding
S.1
S.2
Plumb and install /weld strut hanger (FS01) as per

drawing, 610 mm from center line of inlet manifold
210-D401
Install horizontal pieces (C001) with hangers and 25 mm slope down to coil header
210-D401
Plumb was + 3 mm
Total length of strut = 2872 mm
from inlet manifold center
Weld to coil header after fit-up and elev. check

S.3
From field weld end of (C001) measure actual

elevation of field weld joints of cross over pipe
S.3
Cut (C007) to actual length

Plumb and install /weld (C007) to Barco strut
Weld to inlet manifold after fit-up,
S.4
Cut (C003) to actual length

Fit-up and weld (C002)
S.5
Measure and cut (C006), (C005), (C004) to actual

length. Same as S.3
S.6
Fit-up and weld steam superheater jump-over pipes
S.7
External insulation except at field weld joint (was

completed after system pneumatic test)
Convection tubes are cold spring for

fit-up, as per drawing. RT & PT
T. Combustion Air Duct & Stack

T.1
Completely install ducts after the Fans and Air

Preheater is ready
T.2
Install stack and connecting flue gas duct to ID Fan
Stack is castable lined on the ground

before erection.(step U.2)
ATTACHMENT-1.
(TYPICAL)
No
Activities
Reference
drawing
U. Castable lining / External Insulation on Convection Duct and Other Equipment

U.1
Castable and or ceramic fiber lining on transition

duct, convection duct
U.2
Castable lining on stack (if required)
V. Accessories
V.1
Install dampers, actuator, flexible joint, manholes,

peep doors, etc.
ATTACHMENT-2
FIELD WELDS FOR REFORMER SYSTEM (TYPICAL)
Filler metal
No.
Base Material
101-B Radiant Coil
1.1
Outlet manifold:
ERNiCrCoMo-1
2 butt welds @
RP3 (KHR32C) to RP4 (KHR32C)
(Inco 617)
8 NPS x 32 mm.
thick
Riser transition
Inconel 617
1 butt weld@
1.2
(Brand name or
equal)
(For 1 set of coil)
RF9 (SB408-UNS NO8811) to

RF12 (SB564-UNS8811)
1.3
1.4
1.5
ERNiCrCoMo-1
1 butt-weld
(Inco 617)
1 NPS Sch. XXS
Outlet manifold. Thermowell,

RP13 (SB407-NO8811)
ERNiCrCoMo-1
2 butt welds
(Inco 617)
NPS Sch. 80
Outlet manifold. thermowell/

drain pipe sleeve,
ERNiCrCoMo-1
3 welds
(Inco 617)
4 NPS Sch.XXS
ER308H
Socket weld
Inlet nozzle to inlet pigtail

TP 304H to TP 304H
1.5
Pipe saddle to inlet manifold
See E99C-108-7
Dwg. 210- D105
6NPS x 16.2 mm.
Outlet Manifold. Drain connection

RP 12 (SB407)
RP4/RF2 (KHR32C) to TP 310

1.6
QTY
1 NPS Sch. 40S

E308H
Cardboard gasket
1.5t, alloy verified,
PT
1 joint
304H to 304H
1.6
Outlet manifold drain
By piping
TP 310 to piping
2

(for 1 set)
2.1
Riser transition to 107-D Transfer

Line SA 106 Gr. B
2.1.1
Step #2 , Riser internal sleeve

(RA3) Incoloy 800 HT to Incoloy
800 HT
16 NPS Sch.40
ERNiCr-3
1 fillet joint
(Inco 82)
141.3 x 6.55 t.
See dwg. 407D6/210- D105
ATTACHMENT-2
Filler metal
No.
Base Material
2.1.2
Step#3
2.1.3
2.2
2.3
(Brand name or
equal)
detail A
QTY
1 butt-joint
Effluent Chamber stub to Riser,

SA 105 to RP14 (SA106 Gr B)
ER 70S-2, E7018
Step #5 part 3
ERNiCr-3
Incoloy800HT to Incoloy 800HT
(Inco 82)
141.3 x 6.55 t
Non-pressure part
Riser Transition water jacket to
nozzle, RA6A (A283 Gr. C) to
RA11 (STPT410)
ER 70S-2
Riser Transition Insulation Can
Inconel 617
1 fillet joint
(TGS-50)
1 lot
Incoloy 800HT / Inconel 601
Dwg. KBR
210 D104
101-B Inlet Manifold
3.1
Inlet Manifold to Cross Over Pipe,

304H to 304H
ER308H, E308H
4 Butt welds, 8
NPS Sch. 80S
Alloy verified, RT,

PT
3.2
Inlet Manifold to inlet pigtail
ER308H
Socket weld
1 NPS Sch.40S
1.5 mm thick
cardboard gasket,
alloy verified, RT,
PT
ER308H, E308H
2 @ 14 NPS, Buttweld
Alloy verified, RT,

PT
ER308H, E308H
4 @ 8NPS,Buttweld
Field fit-up
304H to 304H
3.3
Cross Over Pipe, horizontal

XP1 (304H) to XF1 (304H)
3.4
Cross Over pipe, vertical

XF3 (A 182-F304H) to XP2
(A312-TP304H)
3.5
Cross Over to Mixed Feed Coil

outlet header, A 403 Gr. WP304H
to 304H
ER308H, E308H
3.6
Strut, A 312 TP304H
107-D Effluent Chamber
4.1
107-D to 107--D pressure shell
E-7018 or
Joint #1
ER70S-2 & E
4 @ 14 NPS, Buttweld
4 @ 3 NPS Sch. 80
762 OD x 16 t.
Alloy verified, RT,

PT
ATTACHMENT-2
Filler metal
No.
Base Material
(Brand name or
equal)
SA 516-70 to SA 516-70
7018
107-D internal sleeves
ERNiCr-3
Incoloy 800HT to Incoloy 800HT
(Inco 82)
107-D internal sleeve to 103-D
ERNiCr-3
(Inco 82)
Joint #2
E-7018 or
SA 516-70 to SA 516-70
ER70S-2 & E
7018
4.5
Cap weld, seal weld plug
ER70S-2/E-7018
4.6
107-D water jacket
E-7018
101-B Convection Coils
5.1
Mixed Feed gas outlet header to

Cross Over pipe
4.2
4.3
4.4
QTY
(= 816oC)
(= 816oC)
762 OD x 16t
ER308H, E308H
14NPS, butt-weld
Item 3.5
304H to 304H
5.2
Hot Steam superheater coil. JumpOver pipes SA 335 Gr P91 to SA

234 Gr WP 91
ER80SB8/E8018-B8
28 butt-weld @
114.3 OD x 11.1 AW
Field fit up. Argon

backing. PWHT
machine reqd
5.3
Cold Steam Superheater. Jump

over pipes. SA 335 Gr. P91 to SA
234 Gr. WP91
ER80SB8/E8018-B8
28 butt-weld @
114.3 OD x 11.1 AW
Field fit up. Argon

backing. PWHT
machine reqd
5.4
Coil headers connections in/out
6.1
103-D transfer line to 101-C

A 516-70 to A 516-70
6.2
Process Air Inlet
6.3
103-D transfer line to 101-C

internal sleeve
By piping
ER70S-2 & E
7018
By piping
Inconel 617 or
Inconel 117

6.4
103-D top liner cover
ERNiCr-3
ATTACHMENT-2
Filler metal
No.
6.5
6.6
6.7
Base Material
(Brand name or
equal)
(Incoloy 800 HT plate)
(Inco 82)
103-D Dome support cutouts
ERNiCrMo-1
Incoloy 800HT
(Inconel 617)
Pouring port patch plate
ERNiCr-3
Incoloy 800HT
(Inco 82)
Water Jacket & Platform
ER70S-2 or 6/E
7018
CS
7
QTY
101-C & 102-C
301-D01/D05
302 D01/D05
7.1
101C to 102-C, press. shell.

A516-70 to A516-70
7.2
101C to 102-C, liner sleeve

6t Inconel 601 plate
7.3
ER70S-2 & E
7018
813 OD
Inconel 617 or
Inconel 117
546 OD x 6t
101-C gas outlet, cold bypass
Parts of sleeve are

ship loose, to be
site fab.
By piping
SA 335 P11
7.4
102-C gas outlet, hot by-pass
By piping
SA 335 P11
7.5
102-C Gas outlet, main
By piping
SA 336 F11
7.6
Cap weld and plug
After refractory
filled
SA 105 / SA 234 WPB

7.7
Water Jacket 102-C

SA-283-C
ER70S-2 or 6/E7018
ATTACHMENT-3
PRIMARY REFORMER SCHEDULE
ATTACHMENT-4
SECONDARY REFORMER FIELD WORK (TYPICAL)
4.1 Sequence of Work
Work description
Reference
Responsible party
103-D, vessel installation and weld of

washer
403-D3, Detail
L
Heavy lift and mechanical contractor
Platform and Water jacket
403-D7
Mechanical
Opening of top head (MH#1) and

bottom cover
403-D1;
Mechanical
107-D installation and welding, shell

and sleeves
403-D5
Water piping to/from 103-D Water

Jacket
Ring plate (Incoloy 800HT) weld at gas

outlet to 101-C
403-D, Detail B
Mechanical, tack weld prior pouring,

finish weld after dry-out
Refractory lining, 1st & 2nd batch
403-D1; D8
Refractory contractor
Welding of pouring patches
403- D6 Detail
A
Mechanical, before lining of top

section
Refractory lining top section
403-D1; D6 Detail
A; D8
10
Remove CS shroud
403-D4, Detail
F
Mechanical, after lining
403-D8
Refractory contractor, before dry-out
Cut-outs weld (dome support), Incoloy

800HT plates
D4 Detail I
Mechanical, in sequential order with
refractory work
Piping
11
Support brick installation,
12
Dry-out
13
Top liner cover (MH#1) weld, Incoloy

800HT plate
403-D4, Detail
A
Mechanical, after dry-out
14
Dome brick installation,
403-D8
Refractory contractor, using Wooden

template supplied by vendor
15
103-D gas outlet transfer line (pressure

shell and liner sleeve) to 101-C
403-D5, Detail
B
Mechanical, in sequential order with

refractory work
16
Air Piping welding
17
Air inlet insulation, with high temp

water proof caulk
403-D5, detail
D
Insulation contractor,
18
Alumina ball 50#, 25#
403-D8
Refractory, after lining and dome

inspection,
19
Catalyst loading
403-D8
Mechanical
Refractory contractor
Piping contractor
20
Circle brick and hexagonal tiles
403-D8
Refractory
21
Mixing chamber & top cover install
403-D8
22.
Install bottom opening
Mechanical contractor, after lining the

cover with ceramic fiber by refractory
subcontractor
4.2. Refractory Work
Work Description
Remarks
A. Preparation
Store castable in cool & dry air
As soon as the material arrives at site, they are to

be unloaded from container and place in the
warehouse with good ventilation and dry. If
required an air conditioned warehouse to be
provided to store this material
Check and remove damaged bags and lumpy

material
Check if spare is enough
Surface Preparation
Provide working platform and necessary support
inside vessel
Steel frame with wooden plank
Sand blasting/power brush & internal cleaning
Seal all thermowell openings with wooden plug
Sleeves to be covered with cardboard, cover all

anchor tip with plastic coat as per drawing
C. Drop forms installation
Paint/coat form steel with form coating (NoxCrete)
Steel forms to be applied by refractory

subcontractor based on Supplier drawing
Check if thermowell and liner sleeves are covered

with cardboard as per drawing and anchor already
with cellulose acetate coat/shellac varnish
Install & tack weld sleeve/ring plate (#6)
By mechanical contractor
Install forms as per drawings

Forms can be tack welded to CS shroud (403-D4,
F)
Check for required space between forms and the

shell (the required thickness of castable lining)
using gauge
Check and adjust level/height of forms on each
row and compare against drawing. Use wooden
shim to adjust level or height of forms
Check if Pouring ports can be closed easily
Check for any foreign object left inside the form
D. Perform trial run, after all equipments are ready

Prepare and dry run equip. and tools
See list of equipment & tools required

All equipment was set as per approved planning
Perform sample test
Mix castable with 3 different water content,

measure flow ability using timer. Select which
water content to be applied.
4.2. Refractory Work
Work Description
Remarks
Perform trial operation
Measure time required from start of castable

mixing until castable is in drum*) and hopper is
washed ready to receive castable mix (1 cycle)
E. Lining Work
Lining will be done in 3 stages:
Below the dome support
Above dome (catalyst chamber) to mixing

chamber, approx. 100 Tons
Above mixing chamber, after patch welding

and sleeve installation (by mechanical)
Target is 500 kg. in place within 5 minutes1) or
less. With 100 tons of castable to pour, the
required time will be 17 hours continuous
operation
The above time is estimated by assuming that
mixers will be located on ground and castable mix
is lifted by crane. Less time (13 hours) may be
achieved if mixers are set directly above the vessel
top opening, reducing time required for lifting by
1 minute or 500kg in-place in 4 minutes.
Vibration must be applied during castable pouring
work to remove air trapped in the castable but
care not to cause excessive segregation of castable
due to prolonged vibration. As much as possible
use all openings provided on steel form to insert
vibrators.
1) This target is subject to changed based on
actual flow test as per para 4.5.4. of KBRs
specification D11-1TS-7943
See Supplier lining procedure for details.

Subcontractor to prepare detailed planning for
Contractor approval
Check items before each batch:
Water cooling is available and circulating

inside water jacket
Blower is running and temperature inside

vessel is normal/cool
Steel cone feeder is easily operated and

dismantled
Castable are placed in shade and in cool

condition and the packing is in good
condition
Back up power for mixer, vibrator, lighting is

available and tested
Vibrators are working properly
Tools are available within arm reach
Clean water for the mix is acceptable, source

is secured.
Ice is available and acceptable
Enough skilled manpower for 3 shifts
4.3 Equipment For Lining Work

Lining work shall proceed continuously until it is completed. No cold joint is permitted. Therefore it is mandatory for
installer to provide back ups to avoid interruption due to mechanical or power failure. All equipment shall be in good
working condition for 24 hour continuous operation
Mixing & Lining

1
Mixer, 2 ea.
Pouring hopper ;
Paddle type, 16-30 rpm min. with

motor 20 KW, bottom opening, cap.
250 kg castable ( 1250 od x 440 h)
min.
Pouring hopper size to fit vessel top
opening, its outlet to fit cone-shape
Need power supply and temporary

elec. panel

funnel,
cone shape steel funnel,
20 m length min. or vinyl
chloride 175 od x 20 m
flrxible hose;
Cone-shape funnel are hold together

by bolt but should be easily disasssy to adjust height of pouring
position
chute for pouring port

(for flex. Hose) and
deflection chutes
5
Steel form
3 sections: upper, catalyst bed and

bottom section
Supplied by Vendor
Pneumatic needle vibrator,

40 mm OD
2 ea. with long enough hose to air

compressor, 12 000 rpm min.
Need source of compressed air
Electric Vibrator, (optional)
2 ea, form vibrator, 12 000 rpm min.
Need power supply and temporary

breaker
Shovel, trowel
As required
a. DC Lamps; Flash light;
3 @ 12 watt; 3 sets
b. Emergency lamps
2 sets, portable
10
DC
battery
intercom
operated
For coordination between s/v in the

outside with s/v in the inside of
vessel
11
Working platform for

mixing with steel roof
covered with waterproof
tarpaulin
To accommodate two mixers,

working in tandem. for 16 people
and 4 crate of castable (3200 kg)
12
Temporary storage at filed
To accommodate 20 crates or more

castable, with waterproof cover
13
Water bucket
6 @ 30 liter
14
Ice container
1 m3, made from plywood with

insulator
15
Water pump
2 ea, cap. 10 liter/minutes
16
Drums for icy water
2 @ 100 liters for icy water,
Minimum requirement
At top opening level
1 @ 100 liters on top of vessel for

cleaning the chute and funnel
17
1 water hose
As required
18
Exhaust fan, heavy duty
2 sets with
19
Electric
cable
receptacles
For lamps, vibrators, blowers; 200

m.
20
Electrical Panel complete

with switches and breakers
with
Inside of vessel

21
Cover sheet, tarpaulin
1 lot
22
Flow Test table, ASTM

C230
1 ea
For checking consistency,
ASTM sample forms
3 sets
For production samples
23
Test hammer
1 ea min.
24
Measuring glass
1 ea, 5 liter
25
Steel ruler
2 @ 2.5 meter
26
Timer
1 ea
27
Thermometer
1 ea
28
Coating material
Nox-Crete, 1 can
29
Poly ethylene film
0.2 mm x 1.8 mm. x 25 m
30
tapes
As required
Material Handling and Back-up

1
Forklift, 1.5 ton
1 ea. for material handling, 1 ea. for

castable mixing operation
Crane 70 T,
with beam able to lift material to

the top of vessel (30 m)
Light truck
1 for material handling
Air compressor
2 sets, for vibrators, cap. ?
Include. 1 standby
Diesel Generator
2 cap.400A Ac/DC, for power and

for welding
Include. 1 standby
Water truck
Include. 1 standby
Others
2
Disk Grinder with enough

cup wheel
Min. 2 sets,
Wrenches
Min. 2 set,
For steel forms bolting
Winches
1 set
For steel form assy
Diamond cup wheel
Min. 4 blades, 6 /8 dia.
For brick cutting
Jig saw, complete with

blade
1 ea jig saw, 10 blades
ATTACHMENT-5. CERAMIC
FIBER MODULE (TYPICAL
EXAMPLE)
The module is an accordion-folded

blanket module that uses either 304SS
or 310SS hardware and anchoring
systems. Two grades of ceramic fiber
blanket: HP (high purity) grade and
HZ (zirconia) grade are normally used
in reformer, in standard thicknesses
from 6 inches to 12 inches and in 128
kg/m3 and 160 kg/m3 (8 and 10 pcf)
densities.
Spun Ceramic Fiber Module Physical Properties

Ceramic Fiber Module Specs
High-Purity Grade
Blanket
Zirconia
Grade
Blanket
Color
White
White
Maximum Use Limit
1260C (2300F)
1426C
(2600F)
Continuous Use Limit
1100C (2012F)
1350C
(2461F)
Standard Density, pcf (kg/m3)

Standard Sizes, inch (mm)
8, 10 (128, 160)
8, 10 (128,
160)
12 x 12 (305 x 305)
12 x 12 (305 x
305)
6 - 12 (152 - 305)
6 - 12 (152 305)
Chemical Contents
High-Purity Grade
Zirconia
Grade
Al2O3
47% - 49%
39% - 40%
SiO2
50-52%
38-45%
ZrO2
15-17%
Fe2O3
0.2%
0.2%
K2O + Na2O
0.2%
0.2%
Standard Thickness, inch (mm)

Spun Ceramic Fiber Module Chemical Composition
ATTACHMENT-6
DRYING-OUT 103-D SECONDARY REFORMER
Drying Out Equipment:
Maker:
Mannings Thermal & Environmental Engineers, UK
Burner type:
burner
nozzle mix high velocity gas burner, with turndown ratio 50:1; with separate
control module
Burner capacity:
30 MM Btu/hr
Blower type:
11 KW Air Fan, fixed speed, 6 flexible duct, ref no: 99928
Blower capacity:
310,000 SCFH max.
Burner Set Up (dimension
in cm)
Note:
T1
:
skin temperature of bottom manhole liner sleeve
T2
:
gas temperature at bottom section
T3
:
gas temperature at outlet stack
T4
:
surface refractory temperature below dome
AT, BT: gas temperature at main area of vessel
MT:
metal temperature at top (MT1,2) and bottom (MT3,4)
ATTACHMENT -7.
101-B CATALYST LOADING
Preparation
Tube opening to be covered with plywood at all times, except during loading, to prevent foreign
object from entering the tube
Temporary shelter will be prepared to accommodate catalyst screening, weighing and bagging.
Tube Inspection before Loading Work
Inside cleanliness, particularly bottom grating.
Pressure drop of empty catalyst tubes
Dimensional check of empty tubes (height from bottom to top flange)
Catalyst Charge
1000 mm long, 100 mm ID of pipe is used as measuring bucket. Fill the measuring bucket with catalyst
up to top of pipe and record weight of each measurement.
Catalyst charge will be as the following:
Upper portion,
Synetic 25-4
Lower portion,
Synetic 57-4G
Target height is as shown in Attachment-1

Preliminary result of measurement indicates weight of catalyst is 6.5 kgs (0.83 kgs/ltr) and 7.2 kgs
(0.92 kgs/ltr) for lower (Synetic 57-4G) and upper portion (Synetic 25-4) respectively.
Total charge of catalyst for effective height of each radiant tube will be as follow:
Synetic 25-4
Synetic 57-4G
Weight (kgs)
33.0
44.5
Height (mm)
4567
6851
Volume(ltr)
35.9
53.9
Effective catalyst volume of total tube is 20.1 m3 (0.0897 m3/tube) with additional Synetic 25-4 of
approx. 1.2 m3 to top level.
Catalyst Loading Plan
Lower portion will be loaded in 6 incremental charges each equal to 7.4 kgs
Upper portion will be loaded in 4 incremental charges each equal to 8.2 kgs
However actual weight of catalyst loaded to last section of each portion will be adjusted to the
required height.
Weighed catalyst for each incremental loading section will be filled into loading sock; record actual
weight of the catalyst on each sock.
Loaded socks will be put inside drum and properly protected from direct sun and rain water, ready
for loading work
Catalyst Loading Sample
Two (2) tubes will be loaded fully (after measuring dP and height of empty tubes) in order to get values
of:
time to vibrate the catalyst,
actual load density,
target and variation on bed pressure drop
These figures are used as reference during the loading work of the remaining tubes.
Inspection & Measurement During Catalyst Loading
Each measurement will be recorded in format as shown in Attachment-2

Actual weight of catalyst for each incremental charge and total of each portion
Outage of catalyst before and after vibration
Pressure drop measurement after each section loading.
Acceptance
Catalyst bed height:
aver. Ht + 100 mm
Pressure drop:
aver. Pt + 5%
EL. 116408
944 mm
TOP OF CATALYST
ID = 85,4 mm Note 3
KATALCO 25-4
600 mm
UNDERSIDE ARCH
INSULATION
KATALCO 25-4
4567 mm
(40%)
KATALCO 57-4G
6851 mm
(60%)
ID = 100,1 mm
100 mm
EL. 114863
Notes:
Effective catalyst volume = 20,1 m3. Total catalyst volume 21,3 m3
Dimensions given on this sketch are for catalyst loading purpose only.
Maximum Weld portrusion = 3,0 mm. Therefore, maximum OD for catalyst "socks" is 79,4 mm
Catalyst
Retainer
OVERALL CATALYST TUBE

LENGTH 11531 mm
mm
mm
mm
mm
6112 mm
100,1
12,0
11.418
11.531
56
4
224
FACE OF FLANGE
12,963 mm
Tube ID
Msw
Tube length (eff)
Tube Length (ovearll)
Tube per row
Number of rows
Total tube nos.
P t = total press drop
EFFECTIVE CATALYST TUBE

LENGTH 11418 mm
Primary Reformer Loading
H t = total bed height
ATTACHMENT-8.
PENGELASAN CAT. TUBE OUTLET MANIFOLD
Timing
Welding was performed after the following works were completed:
61-101-B Radiant Box roofing is completed
61-107-D Effluent Chamber was installed with springs and levelled
Catalyst tube springs already installed and levelled
Welding of 61-107-D extension piece with 61-103-D gas inlet nozzle
Sequence
Welding on radiant harps was progressing in the following order:
Riser transition assemblies were set and welded to 61-107-D Effluent Chamber gas inlet stub
Welding of outlet manifold between inner and out harps section.
Welding of risers to riser transition assemblies
Welding of thermowell and drain sleeves
Welding of inlet pigtails to catalyst tubes and Inlet Manifold
Procedure
Riser Transition Assembly to Effluent Chamber, pressure part
Check position of Effluent Chamber stub end, should be within tolerance set on drawing
Insert Incoloy sleeve to Riser Transition Assembly and weld
Fit up the Transition Assembly to Effluent Chamber stub end and weld
Outlet Manifold, outer to inner harp
Springs position must be on centreline
Outlet manifold must be levelled, adjusted by spring
All temporary attachment must be removed, except for riser which must be hold to keep centered
Insert soluble paper into outlet header for argon blanket
Perform PT on bevelled end to ensure no crack and other irregularities
Fit up outlet manifold and keep the pipes straight during welding by jig
Argon gas was introduced from catalyst tube top flange
Perform root pass welding followed by penetrant test. Welding must be performed intermittent in
different place so as to maintain steel temperature and straightness of the manifold.
Final pass must be penetrant and radiographic tested
See attached pictures.
Riser to Riser Transition
Both ends must be penetrant test to ensure no surface defect
Radiant harps must be position to the required height by adjusting springs turnbuckle until both
ends are within fit up tolerance
Keep outlet header in level position
Fit up and maintain by jig
Introduced argon gas from Effluent Chamber
Weld intermittently such as to keep plumbness of the riser
Root pass is penetrant tested.
Final pass is penetrant and radiographic tested
Inlet Pigtail to Catalyst Tubes and Inlet Manifold
After inlet manifold and radiant harps welding is completed
Trial fit up to ensure position is match
Provide space of 1.5 mm inside sockolet for tube thermal expansion. Check carefully that the
space is maintained before pigtail can be tackwelded. Preferred way to do is by using 3 mm
cardboard gasket placed inside the sockolet before pushing the pigtail in.
check weld contour and penetrant test the weldment
ATTACHMENT-10.
PICTURES
Gambar-1. Instalasi Convection Coil
Gambar-2. 101-BL Air Preheater
Gambar-3 Riser & Insulating Can
Gambar 4. Sekuen pekerjaan mekanikal & refraktori di seksi

Reforming
Gambar-5. 103-D Dome Brick
Gambar-7. Pemasangan 103-D Hexa-Tiles
Gambar-8. 103-D Mixing Chamber Installation & Final Closing

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PT INTI KARYA PERSADA TEKNIK

Introduction To Steam Methane Reforming & Waste Heat Recovery Section

Ammonia Plant. KBR Purifier Process vs Conventional SMR

101-BL Combustion Air Preheater

107-D Effluent Transfer Line

103-D Secondary Reformer

103-D 101-C Transfer Line

Pengelasan Heater Tube

Waste Heat Recovery Section

Refractory & Dry-Out Work 103-D

INTRODUCTION TO STEAM METHANE REFORMING & WASTE HEAT

Ammonia Plant. KBR Purifier Process vs Conventional SMR

Ammonia Process (General)

Ammonia Process PKT-5

Reforming dan Waste Heat Recovery

101-B Primary Reformer

1.3.2.1 101-B Radiant Box

Gambar. Top Fired Reformer

1.3.2.2 101-B Convection Section

101-B Primary Reformer Convection Modules PKT-5

1. Mixed Feed Heater

1. Steam Superheater (1)

2. Process Air Heater (2)

3. Steam Superheater (2)

3. Process Air Heater (1)

1.3.2.3 101-BL Air Preheater

1.3.2.4 101-BJ ID Fan & 101-BJ1 FD Fan

1.3.2.5 101- B Burners

Gambar. Fuel Staged Burner

103-D Secondary Reformer

Gambar. Secondary Reformer

Gambar sketsa disamping mewakili model

107-D Effluent Transfer Line

Riser Transition Assembly

Waste Heat Recovery Section

101-C Secondary Reformer Waste Heat Boiler

102-C Steam Superheater

141-D Steam Drum

101-C Secondary Reformer Waste Heat Boiler.

Gambar. Fired Tube Waste Heat Boiler dan Steam

dengan ditopang beberapa riser pipes yang

Kondisi terkirim peralatan

Cakupan pekerjaan konstruksi

Pembagian kerja dan tanggungjawab diantara kontraktor pelaksana

Kendali kualitas konstruksi

101-B Primary Reformer

bangunan baja, untuk radiant box maupun struktur penutup

komponen gas proses, berupa radiant harps (termasuk catalyst tube

refraktori, berupa ceramic fiber (module & blanket), refractory brick

burners (arch burners, tunnel burners), burner tiles, combustion air

fuel lines dan control valves

asesoris seperti spring hangers/spring support, peep holes. ruler

Insulasi pipa, termasuk cross-over pipe, inlet manifold, fuel line

Note: M : mekanikal; R: refraktori/insulasi; O: other (piping, listrik, instrument, insulasi pipa)

2.2.1.1 Steel structure

Bolting, seal weld

Bolting, weld (seal & butt)