BLANK Pre-Commissioning Form

FORM # F-001 (5/09)SHT 1 of 8SAUDI ARAMCO PRE-COMMISSIONING FORMFURNACES AND HEATERS

EQUIPMENT TYPE:USER REFERENCE:

EQUIPMENT TAG NO.:DESCRIPTION:

BI/JO NO.:PLANT NO. / LOCATION:

REF. DRAWINGS & DOCUMENTS:

MANUFACTURER:

MODEL NO.:SERIAL NO.:

COMMISSIONING DATE:

GENERAL

NOTE: The items listed below are generic in nature, and must be supplemented with any specific instructions for commissioning and start-up, that may have been supplied by the manufacturer.

Yes No NA

1- Check that the name plate is installed correctly and that the information on it is correct and legible.

2- Note any modifications or alterations during construction and erection and ensure that they are according to specifications. All deviations should be recorded.

3- Make sure that non-destructive examination has been conducted and the results are recorded on field welds.

4- Make sure that welding procedures are documented and heat treatment and stress relieving are conducted and recorded.

5- Ensure that the safety instruction sheet is completed.

6- Check that hydrotest is conducted in accordance with codes and specifications.

7- Ensure that all exposed surfaces, easily accessible by operators, and with a temperature above 150 deg. F are insulated for personnel protection.

8- Ensure that safe access is provided to all valves and instruments.

Yes No NA

9- Check that all spare parts, if any required, are provided.

HEATER CASING

1- Check for sources of air infiltration. Entry and exit points for all tubes require sealing devices. Packing should be provided around convection section tubes at the end of the tube sheets. Convection section header boxes should be gasketed.

2- Check that large panels are adequately supported. Additional stiffening may be required to prevent bowing.

3- Check that rain water cannot accumulate in arches, angles, or channels.

ACCESS AND OBSERVATION DOORS

1- Check that adequate radiant section observation doors have been provided for the tubes, supports, walls, arch and burner flames.

2- Make sure that convection section observation doors have been installed to view representative tubes, extended surface, and tube sheets.

3- Make sure that all doors fit properly, to minimize air infiltration.

Yes No NA

4- Make sure that any explosion on pressure release doors will not discharge flue gas in a direction where personnel exposure could occur.

BURNERS

1- Installed burners should be protected from mechanical damage and all refractory material kept dry.

2- Make sure there is no serious refractory damage and that burner internals are clear of debris.

3- Check for adequate clearance between burner tiles and floor refractory.

4- Check gun size, position, and alignment.

5- Ensure that suitable ignition equipment has been provided. Check that spares have been provided.

6- Make certain that both ignitor guns and burner assembly can be removed while heater is in operation.

7- Check that burner support is adequate to ensure that burner alignment does not change while in service.

8- Ensure that suitable flame scanners have been provided and that spares are available.

DAMPERSYes No NA

1- Check operability of all dampers. Critical dampers, such as flue gas/combustion air bypass dampers, must be thoroughly checked, both internally and externally. (Tight closure and ease of operation are essential if these dampers are to perform their intended function.) Look for the possibility of thermal growth problems.

2- Check that stack damper indicator corresponds with damper position and that stops have been provided.

3- Make certain that forced draft heaters cannot be over pressured by improper damper operation.

4- Check that mechanical bearings in hot service have been selected for the expected operating conditions. Installing them outboard to reduce their operating temperature is the preferred practice.

5- Check for shaft leakage problems in forced or induced draft systems.

6- Check that individual burner dampers are capable of locking in the "fully open" or "fully closed" position.

BURNER PIPINGYes No NA

1- Review burner fuel valving system to ensure all burner startup, operating and shutdown requirements are met.

2- Review the ignitor fuel and air valving system to ensure all ignitor startup, operating and shutdown requirements are met

3- Ensure that all oil and atomizing steam connections are properly connected (i.e., none are reversed at the burners).

4- Check that the insulation and steam tracing called for on the design drawings has been properly installed.

5- Check that piping flexibility and support is adequate for gun height repositioning, and that only minor thermal growth forces will be imposed at the burner gun to piping junctions.

6- Check that fuel piping has been seal welded.

RADIANT AND CONVECTION SECTION COILS

1- Review support and guide system for freedom of movement. Check that the inlet and outlet piping does not impose excessive forces on the coil assemblies.

2- Check for adequate clearances for thermal movement inside heater, at tube entry and exit points, and crossover piping.

Yes No NA

3- Review the operability of any piping spring or counterweight support systems.

SOOT BLOWERS

1- Check that steam piping is properly sloped and trapped.

2- Ensure that blowers have been properly serviced for start-up, in accordance with the manufacturer's instructions.

3- Conduct blower run-in test, in accordance with the manufacturer's instructions, to ensure that limit switches are positioned properly and that the lance has adequate clearances when in the soot blower cavity. Make sure that all poppet valves are adjusted to provide the required lance steam pressure.

AIR PREHEATERS

1- The items to be checked will depend on the actual type of air preheater used. Follow the instructions of the manufacturer. In all cases, make certain that adequate instrumentation has been installed to study the thermal performance of the air preheater and provide for its safe operation. Also, make sure that adequate cleaning facilities have been provided to maintain thermal performance and that associated air/flue gas dampers will provide for satisfactory operation of the fired heater with the air preheat system bypassed.

FANSYes No NA

1- Ensure that instrumentation in accordance with the design drawings has been installed. In all cases, the instrumentation must provide for the operability and safety requirements for the forced draft systems.

2- Check bearing lubrication and cooling systems.

3- Check operability of forced draft fan inlet guide vane assembly.

4- Make certain that ductwork does not impose loads on fans.

5- Check operability of automatic back-flow check for forced draft fans operating in parallel.

REFRACTORY PLACEMENT & INSULATION

1- Ensure that the installation, curing and drying of refractory has been carried out in accordance with the refractory manufacturer procedures and all the work is done by qualified workers.

Yes No NA

2- Inspect refractory and insulation for quality of workmanship and overall integrity.

3- Check that all expansion joint packing have been installed, and no other thermal expansion problems are evident.

4- Make sure that convection section setting will not impose forces on the arch nose area.

5- Ensure that all required field testing are carried out, for example production, cold crushing and density tests.

DRYOUT

1- Following the hydrotest, ensure that the test water has been removed from the coils, to the maximum extent practical.

2- Ensure that all fuel lines have been steam blown dry, but not through the burner guns.

- Check the performance of all burners during the dryout operation.

3- Monitor the thermal movement of tubes, tube support systems and refractory during dryout for evidence of any problems.

NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approvals adjusted to reflect the needs of the Project Acceptance Committee.APPROVALSSAPMTINSPECTIONOTHER DEPT.OPERATIONS

Signature & Date

CopyrightSaudi Aramco 2009. All rights reserved.