Document nNpXEQor31J13JnDRRa5z4bVa

FINAL ARRAN08MENT of rebuilt scclionol-hcoder boiler. Redesigned unit now operates ot ISO psig, uses former lupeiheoter os economizer, hos air heoter [X, ASME Power Boiler Code, field welds on pressure parts. Table I: Progress on Dismantling, Moving, Re-erecting , the Boiler Redesign. Meanwhile, engineers While's Denver office were redesign^] the unit, adapting it to the service* quired. Because of the boiler helgjjrt they had to raise four bays of the exjjjr ing Cast Mill plant. They designed vj1 detailed foundations and structural alterations; CF&I shops gave priori#] to the fabrication. ,S The original, suspended tile settWl could not be salvaged, nor could tile shapes be used because of deliver^ requirements. So White designed a eta? pletely new setting, arranged for alr-j Suitable unit located, esomioed; insurance company's Inipectlen completed Centred everded. Construction equipment loaves Denver Cottsyriile, Ron. Dltmontling netted at Sinclair Refinery, Coffeyville Fleitk refractory-setting design completed, engineering dotign on boiler burners ond font completed, fans locoted oatf purchased, mHcelluneees boiler trim and fittings pur chased Dismantling completed ond fait of five railroad cars shipped Induced-draft foe received on job leitrumeril ond control piping slorted Ja* 7 Frtssure parti computed and toiled, bailies ond ploitic rtfraclory sotting storted Jon 31 Fowor piping storied Fob 13 Insulation itortod on drum, docto ond breeching fob 19 Refractory attlog completed, drylng-out started Mer 9 Unit cot tato full service. Complolo oiccpt for Insulation Mar 7 Platforms, walkways, building Utoratlons complotod Mar I Final adjustment of combustion control complotod *pv * Insulation finished on bailor, auxiliaries and plant piping Mote During obovo operations, CF&I removed three con demned Stirling boilers cooled rear wall and floor instead e|| fe' the. original air-cooled side walls. Th*^ new setting, which uses plastio **j'! castable refractories, is designed Wj full suspension. Where needed, ner channels and angles were welded to th*1 boiler structure for the suspension *& chors end clips. This design penniii1! replacing any section without disturbing the sections above. J IOriginal design of rebuilt holler for 460 psig, 660 F. Cast Mill generator steam at ISO psig. saturated. By anslpij ing the tube surfaco and baffling, tie] engineers found that changing the gsV path and using the superheater surlier' r Cu tn'econorolter would develop desired P ^ta'piciir w'<h proper auxiliaries. They `^rlefrib surface in its original location A^*io'*th'ebot pass (about ISOO F) between S:'ihsifir*t and second boiler posses, but K>iihl It to provide drainage. This design A^hY/perfonned outstandingly well, with . ^Bo^evidence of steam bindlog.ln the i^boflerpcirculation system. Soo Table U '.'to^rformance figures, j'^/gtrmir#. Coke gas, natural gas and ^{fuei oil are uaed at East Mill. Original ^ burners la ibo replacement unit eould v^Wl'rbura these fuels satisfactorily. So required capacity. White personnel located, In Baltimore, Md., an unused - induced-draft fan with correct characleristica. They moved a temporary forced-draft fan from idle mill equip ment. This has now been replaced with another in conjunction with a Riley Stoker Corp air healer to increose the unit's efficiency and capacity until the additional 100,000 Ib-per-hr boiler Is ready for service. Table ill summarizes auxiliary equipment. Construction went on without jnei- dent, and the boiler cut Into the plant natural and coke-oven gas. It was shut down and Inspected- during the recent steel strikes. Pressure parts and re fractories have been troublafree. Conventional boiler design would normally provldo at least 25% more surface to develop capacity shown in Table II. This more efficient use of sur face is largely due to the economizer being in the 1500-F zone, with conse quent high temperature difference end improved heat transfer. This installation shows what can be accomplished with idle equipment. In caobinatlon natural-gas, coke-gos and system on March 5,1952,17 weeks after an emergency. The new boilers, ordered '^fueUil burners, together with new date of contract. This period included in November 1951, could not be sched v.V>wUdbpxes and alructurnl front, were lime for complete dismantling and uled for delivery until October and ?.uiattaU*d. (Photo, p 81) transporting to Pueblo, Colo., some SOO December 1952, moay months after ^s^'Orafl equipment was inadequate to miles drom Coffeyville, Kan. Unit boa March 5, when the rebuilt unit, was cut !:'';hiadle the volumes necessary for the carried over 100,000 lb per hr on both Into full service for the first time. ' mi/v w. r. Table fit Performance of Rebuff! Unit Table III: Cqoipment Daicription FIELD CUTS on straight-tube boiler were rr>ode for easy shipping and roosscmbly. Engineers moved loctionol headers ond connected tubes os units, cut wotorwolls through the heed; eis to meet roilwoy clearances. This saved re-erection *"***) *- Without e>r beater ot two capacities fObitrvorf) With tuturo oh hooter (Predicted) ^Athjgtovaporetloa, Ib/kr tTy-Tiap/goi to economiser (appro*), F VaTiBfC-voler entering economiser, F veto loafing econamlier, f nit gas. % &lJ**ltfboflr oiit goi, F ^'"'P.'.slr-hoottr oilt grn, F ^Tnjp-omWoot olr, f ***ino #,r p is,Pg Hiroogh bailor, In. vC'iS* ,hT,uRh 0,r heater, la. `trough breeching, in. 4*fl, In. IjjJf."W induced-droit .fon, In. les, through olr bt, I*, log* through ducts, lo. :*,'* 1" windbo*, lo. ffyMc PNtt. Ot Li Ian, In. 'Vn!?*** Iiose/hr, Btu/eo ft %^'.ffit|.nCy( % _10,000 199 253 9.4 _380 8] -- _0.00 0.00 0.17 0.17 _ 0,10 0.00 0.10 -- 83.6 100.000 1500 199 272 10.4 _576 81 -- _0.98 0.40 0.12 1.70 _ 0.90 3.60 450 23,000 73.9 100.000 1500 199 272 10.6 595 400 80 335 1.20 1.90 0.50 1.10 3.70 2.50 1.00 5.2$ 8.75 23,000 62J .f* It robullt Wa!ih-Widar loctionol Nooder boiler with woterwalls, Foster-^.hr oitondod surfoeo economiser, ond fature Riley Stoker air boater. Saturated- "U*. h 360 to 171 F, operotlog pressure ISO to 17S psig, feedwater ?N-.f?F**ohire 199 f, Fuel it natural gas ot 98$ Ihj par cu ft. Bailor Wolib-Weldner oectionol header 525 psig Surfaces, Sq ft Boiler Wotervell .EcanomUat (tubular) 6150 1280 630 Total 8060 (Table II data based en this total) Air heoter, sq ft new being laslelted Furnace volume, cu ft 9480 5570 Sailing A F Green Kott-5et side walls, Sapor-PlatHc (root and rear walls. Folly tutponded setting designed by i F White fngrg Corp Burners Feobady Eagrg Carp .Typo A-20 forced-droft borners with coke-oven got ring; center-fired noturol-gos gun end steam-atomiiing oil , burners ` Irff fan Buffalo Forge Co No. 6V4 5SLO indoced-draft (en direct-connected to 1200-rpm 75-bp motor F-d fan laffola Forge `Co No. 8 SCIO forced-draft fan, belt-driven from 900-rpm 7J-bp motor ENOINEEtINO AND MANAGEMENT SECTION POVrtt. 2&!**WlT 1933 ENGINEERING AND MANAGEMENT SECTION