BLACK LIQUOR RECOVERY BOILER ADVISORY COMMITTEE
MINUTES OF MEETING Crowne Plaza Hotel/Atlanta Airport April 10, 11 & 12, 2017
OBJECTIVE BLRBAC’s objective is to promote improved safety of chemical recovery boilers and their auxiliaries through the interchange of technical knowledge, experience, and data on past and any future recovery boiler incidents. Bylaws - 2.1
OFFICERS Chairman: John Gray Tel: 912-277-1388 Rayonier Advanced Materials Cell: 912-321-7582 10 Gum Street [email protected] Fernandina Beach, FL 32035
Vice- Dave Slagel Tel: 912-966-4312 Chairman: International Paper Cell: 912-414-2706 1 Bonnybridge Road [email protected] Port Wentworth, GA 31407
Secretary: Everett Hume Tel: 781-255-4733 FM Global Cell: 413-265-9562 1151 Boston-Providence Turnpike [email protected] Norwood, MA 02062
Treasurer: Len Olavessen Cell: 901-573-8343 LENRO, Inc. [email protected] 1851 N. Virginia Avenue Bartow, FL 33830
REGULAR MEMBERSHIP Organizations operating, manufacturing, or insuring chemical recovery boilers are eligible.
ASSOCIATE MEMBERSHIP Organizations having a direct interest or role in the safety of chemical recovery boilers are eligible.
CORRESPONDING MEMBERSHIP A company residing outside of the United States which finds it impractical to attend meetings on a regular basis because of distance and expenses, but desires to be involved and informed of BLRBAC activities. Bylaws - 3.1
BLRBAC INTERNET ADDRESS: ---- www.blrbac.org IRS Employer ID/Tax ID (IRS E.I.N.T./T.I.N.) ---- #13-366-5137
Meeting Minutes BLRBAC April 12, 2017 EXECUTIVE COMMITTEE
John Gray Dave Slagel BLRBAC Chairman BLRBAC Vice-Chairman Rayonier Advanced Materials International Paper 10 Gum Street 1 Bonnybridge Road Fernandina Beach, FL 32035 Port Wentworth, GA 31407 Tel: 904-277-1388 Tel: 912-9664312 Cell: 912-321-7582 Cell: 912-414-2706 [email protected] [email protected]
Everett Hume Len Olavessen BLRBAC Secretary BLRBAC Treasurer FM Global LENRO, Inc. 1151 Boston-Providence Turnpike 1851 N. Virginia Avenue Norwood, MA 02062 Bartow, FL 33830 Tel: 781-255-4733 Cell: 901-573-8343 Cell: 413.265.9562 [email protected] [email protected]
David von Oepen John Phillips Operator Representative Manufacturing Representative WestRock Andritz 28270 U.S. Highway 80 West 5405 Windward Pkwy, Ste. 100W Demopolis, AL 36732-5152 Alpharetta, GA 30004 Tel: 334-289-6315 Tel: 770-640-2434 [email protected] Cell: 678-427-6899 [email protected]
Jimmy Onstead Insurance Representative FM Global One Cowboys Way, Ste. 600 Frisco, TX 75034 Tel: 972-731-1656 Cell: 903-744-2734 [email protected]
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Secretarial Barbara Holich Frank's Cell: (630) 269-1005 Services 5500 Irish Spring Street Barbara's Cell: (630) 640-1805 Las Vegas, NV 89149 E-Mail: [email protected]
*****************************
Meeting Minutes BLRBAC April 12, 2017 Page 2 of 116 BLRBAC SUBCOMMITTEES
AUXILIARY FUEL BLACK LIQUOR, SAFE FIRING OF Bruce Knowlen, Chairman Vernon Blackard, Chairman International Paper International Paper 32901 Weyerhaeuser Way S., Ste101 2895 79 Trail Rd. Federal Way, WA 98001 Roy MT 59471 Tel: (253) 924-4637 Cell: 251-284-3471 [email protected] [email protected]
EMERGENCY SHUTDOWN PROCEDURES FIRE PROTECTION IN DIRECT John Andrews, Chairman CONTACT EVAPORATORS BSI Craig Cooke, Chairman 2347 MacLaura Hall Avenue FM Global Charleston, SC 29414 815 Byron Drive Tel: 843-509-4926 Oconomowoc, WI 53066 [email protected] Tel: 262-567-7370 [email protected]
INSTRUMENTATION MATERIALS & WELDING David Avery, Chairman Blair, Mike, Chairman Domtar Paper Company International Paper P. O. Box 678 6285 TriRidge Blvd. Bennettsville, SC 29512 Loveland, OH 45140 Tel: 843-454-8937 Tel: 205-260-6359 [email protected] Cell: 205-260-6359 [email protected]
PERSONNEL SAFETY PUBLICITY & NEWS RELEASE Robert Zawistowski, Chairman Matt Paine, Chairman Power Specialists Associates, Inc. FM Global 531 Main Street 1151 Boston-Providence Turnpike Somers, CT 06071 Norwood, MA 02062 Tel: 860-763-3241, Ext. 135 Tel: 781-255-4733 [email protected] [email protected]
WASTE STREAMS WATER TREATMENT Paul Seefeld, Chairman Tom Przybylski, Chairman A.H. Lundberg Associates, Inc. Power Specialists Associates 6174 Kissengen Springs Ct 531 Main Street Jacksonville, FL 32258 Somers, CT 06071 Tel: 904-614-6492 Tel: 860-763-3241 [email protected] [email protected]
Meeting Minutes BLRBAC April 12, 2017 Page 3 of 116 FUTURE BLRBAC MEETINGS Fall October 2, 3 & 4 55th Anniversary 2017 Reduced registration fee of $55.00 for all first-time confirmed attendees from voting member companies Spring April *9, 10 & 11 -- 2018 tentative Fall October *22, 23 & 24 -- 2018 tentative Spring April 8, 9 & 10 -- 2019 tentative Fall October 7, 8 & 9 -- 2019 tentative "Bring Operator(s). Give them a chance to hear first hand!" Past Chairman Lon Schroeder ***************************** * NOTE: For varying reasons, the previously published meeting dates have been changed at the discretion of the Executive Committee. BLRBAC has established its own WEB Site which is: www.blrbac.org
At this WEB site you will find a copy of past Meeting Minutes and the next Meeting Notice. Therefore, each Representative and Associate Representative is asked to inform their people of this WEB site. This is where they can obtain the following BLRBAC documents: BLRBAC MEETING NOTICE COVER LETTER General Information
REGISTRATION FORM Print and mail to Said & Done with appropriate fees before the posted cut-off date.
CROWNE PLAZA HOTEL Blocked room dates, pricing, address, hotel phone numbers
SCHEDULE List of subcommittee activities on Monday and Tuesday
AGENDA Reports given to Joint BLRBAC Meeting on Wednesday
OPERATING PROBLEMS Mail/e-mail completed questionnaires to Barbara Holich. These QUESTIONNAIRE will be given to the Vice Chairman and he will see that your concerns are brought up and discussed during the Operating Problems session at the next meeting.
Mrs. Barbara Holich Frank's Cell Phone: 630-269-1005 BLRBAC Secretarial Services Barbara's Cell Phone: 630-640-1805 5500 Irish Spring Street E-mail: [email protected] Las Vegas, NV 89149
These are available at the BLRBAC INTERNET ADDRESS: www.blrbac.org
Meeting Minutes BLRBAC April 12, 2017 Page 4 of 116
BLRBAC Guidelines & Recommended Practices
LEGAL NOTICE
Emergency Shutdown Procedure (Dated: October 2012)
Safe Firing of Black Liquor in Black Liquor Recovery Boilers (Dated: April 2016)
Materials & Welding Guidelines (Dated: April 2013)
Safe Firing of Auxiliary Fuel in Black Liquor Recovery Boilers (Dated: February 2012)
Fire Protection in Direct Contact Evaporators and Associated Equipment (Dated: February 2012)
Personnel Safety & Training (Dated: February 2012)
Application of Rotork Actuators on Black Liquor Recovery Boilers (Dated: October 2005)
Post ESP Water Level (Dated: January 2005)
Post ESP Guidelines (Dated: October 2002)
Boiler Water Management Guidelines for Black Liquor Recovery Boilers (Dated: April 2016)
Instrumentation Checklist and Classification Guide for Instruments and Control Systems Used in the Operation of Black Liquor Recovery Boilers (Dated: April 2014)
Thermal Oxidation of Waste Streams in Black Liquor Recovery Boilers (Dated: April 2016)
If you have any questions, contact:
Secretary: Everett Hume Tel: 781-255-4733 FM Global Cell: 413-265-9562 1151 Boston-Providence Turnpike [email protected] Norwood, MA 02062
Meeting Minutes BLRBAC April 12, 2017 Page 5 of 116
AUXILIARY FUEL SUBCOMMITTEE
‡Bruce Knowlen – Chairman International Paper 32901 Weyerhaeuser Way S., Ste101 Federal Way, WA 98001 Tel: (253) 924-4637 [email protected]
‡Tom DeBeer – Vice Chairman Allen L. Ray – Secretary ‡Michael Acree AIG Process Barron CCA Combustion Systems 5001 Willow Creek Drive 105 19th Street South 884 Main St. Woodstock, GA 30188 Birmingham, AL 35210 Monroe, CT 06468 Tel:(678) 494-6026 Tel: (205) 956-3441 Tel: (919) 269-0464 Cell:(404) 218-8613
[email protected] [email protected] [email protected]
‡Mike Bruce Chad Harrod ‡Brook M. Holland International Paper Georgia Pacific George H. Bodman, Inc. 104 Putnam Center road Brunswick Cellulose, Inc. 228 Wild Rose Lane Putnam Station, N.Y. 12861 PO Box 1438 Canton, NC 28716 Tel: (518) 586-6954 Brunswick, GA 31520 Cell: (828) 421-0487 Tel: (404) 652-5815 [email protected] [email protected] [email protected]
‡Greg Imig ‡Greg Kornaker ‡Bentley Sherlock Andritz Babcock & Wilcox Company Georgia Pacific 5405 Windward Pkwy, Suite 100W P. O. Box 351 133 Peachtree St. Alpharetta, GA 30004 Barberton, OH 44203-0315 Atlanta, GA Tel: (770) 640-2633 Tel: (330) 860-2009 Tel: (404) 652-4608 Cell: (404) 545-9076 [email protected] [email protected] [email protected]
‡Andrew Young FM Global Property Insurance 34414 NE 101st Ave. La Center, WA 98629. Cell: (360) 904-6884 [email protected]
‡Denotes attendance at the meeting in April of 2017.
Meeting Minutes BLRBAC April 12, 2017 Page 6 of 116
EMERGENCY SHUTDOWN PROCEDURES SUBCOMMITTEE
‡John Andrews – Chairman BSI 2347 MacLaura Hall Avenue Charleston, SC 29414 Tel: 843-509-4926 [email protected]
‡Dean Clay, Secretary ‡Scott Crysel ‡James Franks BSI FM Global XL Catlin 935 Hidden Ridge Drive 5700 Granite Parkway, Suite 700 855 Dogwood Road Milford, OH 45150-5588 Plano, TX 75024 Somerville, TN 38068 Tel: 513-497-9070 Tel: 972-731-1658 Tel: 901-465-0771 [email protected] [email protected] [email protected]
‡Chris Jackson ‡Rinus Jellema ‡John A. Kulig AXA Matrix Risk Consultants Howe Sound Pulp & Paper Babcock & Wilcox Company 1362 11th Court, 3838 Port Mellon Hwy P. O. Box 351, BVSW2B Fox Island, WA 98333 Port Mellon, BC, Barberton, OH 44203-0351 Tel: 253-303-0289 Canada Tel: 330-860-6438 Cell: 503-840-5775 Tel: 604-884-2751 [email protected] [email protected] [email protected]
‡Karl Morency – Vice Chair ‡Scott Moyer ‡Frank Navojosky Georgia-Pacific WestRock International Paper 133 Peachtree Street NE 1660 Prudential Drive, Ste. 202 6283 Tri-Ridge Blvd Atlanta, GA 30303 Jacksonville, FL 32207 Loveland OH 45140-7810 Tel: (404) 652-4629 Cell: 904-437-7149 Cell: 513-334-9999 [email protected] [email protected] [email protected]
‡John Phillips ‡David Slagel ‡John Weikmann Andritz Pulp & Paper International Paper Valmet Inc 5405 Windward Pkwy., Ste. 100W 1 Bonneybridge Road 3440 Toringdon Way, Suite 300 Alpharetta, GA 30004 Port Wentworth, GA 31407 Charlotte, NC 28277 Tel: 770-640-2434 Tel: 912-966-4312 Tel: 704-414-3431 [email protected] Cell: 912-414-2706 [email protected] [email protected]
‡Denotes attendance at meeting April 2017
Meeting Minutes BLRBAC April 12, 2017 Page 7 of 116
FIRE PROTECTION IN DIRECT CONTACT EVAPORATORS AND ASSOCIATED EQUIPMENT SUBCOMMITTEE
‡Craig Cooke - Chairman FM Global 815 Byron Drive Oconomowoc, WI 53066 Tel: 262-567-7370 [email protected]
‡Kevin Huelsbeck - Vice Chair Randy Baker ‡Stephen Cox Buckeye Technologies FM Global Property Insurance International Paper One Buckeye Drive Midwest-Chicago Ops 15532 Harbor Point Lane Perry, FL 32348 N8955 Willow Lane Maumelle, AR 72113 Tel: 850-584-1380 Menasha, WI 54952 Tel: 409-779-7104 [email protected] Tel: 920-205-5529 [email protected] [email protected]
‡Robert Goddard ‡Joseph Lynch Nick Merriman Austrian Energy & Environment XL Group Swiss Re America Holding Corporation Graz, Austria 129 Drive 1143 1150 Sanctuary Parkway, Suite 425 Tel: +43 316 501-2810 Tupelo, MS 38804 Alpharetta, GA 30009 [email protected] Tel: 662 844-5897 Tel: 1770-569-8706 [email protected] [email protected]
Daniel Nesmith Christopher Skorton Alarick Tavares Kapstone Australian Paper Georgia-Pacific P.O. Box 118005 133 Peachtree St. NE Charleston, SC 29423-8003 Tel: 61 0408-722-672 Atlanta, GA 30303 Tel: [email protected] Tel 404-652-4606 [email protected] [email protected]
Jim Taylor ‡Rachakrit Withayaphan Mondi Pine Bluff Siam Cellulose Co. P. O. Box 20700 19 Moo 19Saeng-Xuto Road 1701 Jefferson Parkway Tambol Thapa Pine Bluff, AR 71612 Ban Pong, Ratchaburi 70110 Thailand [email protected] Tel: +66 3221 1388-90
[email protected] ‡Denotes attendance at the April 2017 meeting.
PUBLICITY & NEWS RELEASE SUBCOMMITTEE Matt Paine - Chairman FM Global 1151 Boston-Providence Turnpike Norwood, MA 02062 Tel: 781-255-4733/ Cell: 781-255-4733 [email protected]
‡Denotes attendance at the April 2017 meeting
Meeting Minutes BLRBAC April 12, 2017 Page 8 of 116
INSTRUMENTATION SUBCOMMITTEE ‡David Avery – Chairman Domtar Paper Company PO Box 678 Bennettsville, SC 29512 Tel: 843-454-8937 [email protected]
‡Rick Matarrese – Secretary David T. Boudreau ‡John Browning, Jr SAPPI (S.D. Warren Company) FM Gobal Georgia Pacific 1329 Waterville Road 655 Engineering Dr. #300 133 Peachtree St. NE (30303) Skowhegan, ME 04976 Norcross, GA 30092 Atlanta, GA 30348-5605 Tel: 207-238-7502 Tele: 770-777-3684 Tel: 251-743-8336 [email protected] [email protected] [email protected]
‡Joel Byrd ‡William Camp John Cover John E. Cover Engr., Inc. International Paper Company International Paper Company P.O. Box 35010 12515 Choctan Rd 100 Jensen Rd 5425 Caldweld Mill Road Bogalusa, La 70427 Prattville, AL 36067 Birmingham, AL 35236-6010 Tel:985-516-1110 Tel: 334-361-5620 Tel: 205-991-7106 [email protected] [email protected] [email protected]
‡Chris Dailey Michael Kiper ‡Bruce Knowlen BSI Georgia-Pacific International Paper Company Stapleton, Al 36578 133 Peachtree St. NE (30303) IPGCFIC-1G39 Tel:251-422-4849 Atlanta, GA 30348-5605 Federal Way, WA 98001 [email protected] Tel: 404-652-2838 Tel: 253-924-4637 [email protected] [email protected]
‡Gregory J. Kornaker ‡Eladio Ruiz de Molina Robert Putman Kapstone Paper Babcock & Wilcox CORR System, Inc. 5600 Virginia Ave. Power Generation Group, Inc. 3026 Overhill Road North Charleston, SC 29406 20 South Van Buren Avenue Birmingham, AL 35223 Tel: 843-745-3313 P.O. Box 351 Tel: 205-879-4382
Barbenton, OH 44203-0351 [email protected] [email protected]
Andy Smith Harri Soderlund Jari Sopanen AIG Andritz Jari Consultoria de Automacao Ltda 203 Dunleith Drive 1115 Northmeadow Parkway Rua Amilcare Bientinezi 315 cs 30 Woodstock, GA 30188 Rosewell, GA 30076 Capao Raso, Curitiba Tel: 770-671-2447 Tel: 770-640-2409 Brazil 81150-180 [email protected] Cell: 678-644-9882 Tel: +554199991-3833 [email protected] [email protected]
Gordon L. Vandenburg ‡C.A. Vossberg Liquid Solids Control, Inc. Electron Machine Corp. P.O.Box 259, P.O.Box 2349 Farm St. Umatilla, FL 32784 Upton, MA 01568 Tel: 352-669-3101 Tel: 508-529-3377 [email protected] [email protected]
‡Denotes attendance at the meeting in April of 2017
Meeting Minutes BLRBAC April 12, 2017 Page 9 of 116
MATERIALS & WELDING SUBCOMMITTEE
Michael Blair – Chairman International Paper 6285 TriRidge Blvd. Loveland, OH 45140 Tel: 205-260-6359; Cell: 205-260-6359 [email protected]
‡Jesse Worsham - Co Chair Lynn Barrett ‡Jennings Bird Zampell Refractories Domtar Paper Valmet 6801 Parke East Blvd. Marlboro Mill Tel: 803-235-8091 Tampa, FL 33610 P. O. Box 678 [email protected] Tel: Bennettsville, SC 29512 [email protected] Tel: 843-479-0200, Ext 8879 ‡Alt: Ron Reed [email protected] John Heffernan Tel: 704-281-3073 262 Titus Ave. [email protected] Warrington, PA 18976 Tel: 215-491-9300 [email protected]
‡George Bodman ‡Roger Carpenter Yurij Duda Savcor 13 Kingwood Villas Court PSF Industries
Kingwood. TX 77339 Tel: 206-571-3144 [email protected] Tel: 800-28- 6069 or [email protected] 281-359-4006 Cell: 713-557-2118 Alt: Kevin Flynn [email protected] Tel: 206-641-4983 [email protected]
‡Jeffery Forry ‡Steve Harville ‡Fabian Henriques Glatfelter National Boiler Services PSA Inc. Tel: 717-225-4711 Trenton, GA 531 Main Street Cell: 717-578-2084 Cell: 251-591-7850 Somers, CT 06071 [email protected] sharville @nationalboiler.com Tel: 614-440-4284 fabian.henriques @psaengineering.com Alt: Mike Messamore National Boiler Services Tel: 706-657-1584 mmessamore @nationalboiler.com
Michael Hollern Billy Jones ‡Mark LeBel New Page Kapstone Andritz Pulp and Paper 300 Pratt St Tel: 843-745-3507 Luke, MD 21540 Cell: 843-297-2001 5405 Windward Parkway, Ste. 100W Tel: 301-359-3311, Ext. 3280 william.jones @kapstonepaper.com Alpharetta, GA 30004 Cell: 301-802-2470 Tel (770) 640-2643 [email protected] Cell (678) 577-8613 [email protected]
‡Alternate - Alec Shull ‡Denotes attendance at the meeting in April of 2017.
Meeting Minutes BLRBAC April 12, 2017 Page 10 of 116
MATERIALS & WELDING (Cont.)
Michael Lykins ‡Max D. Moskal ‡Preston Morgan Packaging Corporation M&M Engineering Chicago Tube & Iron 1061 Woodcliff Drive 11020 W. 72nd Street a/k/a CTI Power South Elgin, IL 60177 Indiana Head Park, IL 60525 PO Box 670 Tel: 630-384-5272 Tel: 512-407-3755 421 Browns Hill RD Cell: 630.659.7115 Cell: 708-288-8430 Locust, NC 28097 [email protected] max_moskal @mmengineering.com Tel: 704-781-2067
Cell: 704-533-4217 Alternate - Ronald Lansing [email protected]
Joe Nelson Dan Phillips ‡Chris Rawls Georgia Pacific Wesco Applied Technical Services Brunswick, GA Welding Engineering Services Tel: 757-218-8465 Tel: 205-631-6457 Portland, Oregon 97062 [email protected] Tel: 503-720 - 9270 Cell: 770-330-7924 [email protected] [email protected] Alt: Thomas Kapperman
Tel: 678-231-8025 Alt: Terry Lane [email protected] Georgia Pacific Tel: 412-506-8168 ‡[email protected]
‡Shawn Santo ‡Stacy Power ‡Eric Moberg RAE Engineering AZZ SMS FM Global 4810- 93 Street 1615 118th Ave N. Tel: (815) 385-3946 Edmonton,AB St. Petersburg FL 33716 [email protected] Canda T6E 56M4 Tel: 843-957-2111 Tel: 780-718-2880 [email protected] ‡Dave Lang Cell: 780-718-2880 FM Global [email protected] Alternate-Pedro Almador Box 1567
Little Elm, TX 75068
Tel: 972-731-1882
‡Bob Roy Douglas Singbeil William Smith FPInnovations – Paprican Acuren RMR Mechanical 3800 Wesbrook Mall Tel: 281-716-7012 PO Box 170 Vancouver, BC V6S 2L9 [email protected] Cumming, GA 30028 Tel: 604 222 3254 Tel: 770-205-9646 Cell: 604 839 3254 [email protected] [email protected]
Dick Williams dick.williams @rmrmechanical.com
Doug Keiley KB Engineering and Inspection
‡Denotes attendance at the meeting in April of 2017.
Meeting Minutes BLRBAC April 12, 2017 Page 11 of 116
PERSONNEL SAFETY SUBCOMMITTEE
‡Robert E. Zawistowski - Chairman Power Specialists Assoc., Inc. 531 Main Street Somers, CT 06071 Tel: 860-763-3241, Ext. 135 [email protected]
Sam Dean – Vice Chairman Steve Bogart ‡Gregory Burns Rayonier Advanced Materials Weyerhaeuser Kapstone 4470 Savannah Highway 3401 Industrial Way 5600 Virginia Avenue Jesup, GA 31545 P. O. Box 188 North Charleston, SC 29423 Tel: 912-427-5103 Longview, WA 98632 Tel: 843-745-3481 [email protected] Tel: 360-414-3337 [email protected] [email protected]
‡Brian Fiala Levi Harrington - Alternate ‡John Fredrickson Packaging Corporation Packaging Corporation Sappi Fine Paper NA N. 9090 County Road E. N. 9090 County Road E. 2201 Avenue B Tomahawk, WI 54487 Tomahawk, WI 54487 P.O. Box 511 Tel: 715-453-2131, ext. 298 Tel: 715-453-2131, ext. 551 Cloquet, MN 55720 [email protected] [email protected] Tel: 218-878-4378
‡Sam Hendrix Ron Hess Wes Hill Global Risk Consultants Georgia-Pacific International Paper 110 Cedar Cove Court 349 NW 7th Ave Power Manufacturing Solutions Buckhead, GA 30625 Camas, WA 98607 International Paper Co. Tel: 770-490-4719 Tel: 360-607-4189 1163 Grand Pointe Dr. ronald.hess [email protected] Gulf Breeze, Fl. 32563 @globalriskconsultants.com Tel: 318-658-4591
‡Daryl Hoffman ‡Jennifer Johnston ‡Zack Payne FM Global Georgia-Pacific Andritz Granite Park Two, 133 Peachtree St., NE 5405 Windward Parkway 5700 Granite Parkway, Suite 700 Atlanta, GA 30303 Suite 100W Plano, TX 75024 Tel: 404-652-4632 Alpharetta, GA 30004-3894 Tel: 972-731-1978 [email protected] Tel: 770-640-2420 [email protected] [email protected]
‡Eric Schwartz Chris Suresh ‡David Von Oepen Domtar Paper Babcock & Wilcox WestRock 100 Clinchfield Street 20 S. Van Buren Avenue 28270 U.S. Highway 80 West Kingsport, TN 37660 Barberton, OH 44203-0351 Demopolis, AL 36732-5121 Tel: (423) 247-7111 Tel: (330) 860-1335 Tel: (334) 289-6315 [email protected] [email protected] [email protected]
‡Denotes attendance at the April 2017 meeting
Meeting Minutes BLRBAC April 12, 2017 Page 12 of 116
SAFE FIRING OF BLACK LIQUOR SUBCOMMITTEE ‡Vernon Blackard - Chairman International Paper 2895 79 Trail Rd. Roy MT 59471 Cell: 251-284-3471 [email protected]
Clif Barreca ‡Raymond Burelle Joel Byrd International Paper International Paper 1131 Charest Way, Ottawa ON P. O. Box 1391 12515 Church Street Valmet New Bern, NC 28563 Bogalusa, LA 70427 Tel. 613 618-9172 Tel: 252-633-7696 Tel: 85-516-1110 [email protected] [email protected] [email protected]
Raul Das ‡Mark Donahue ‡Len Erickson Buckeye Technologies Fossil Power Systems, Inc. Power Specialist Assoc. One Buckeye Drive 10 Mosher Drive 7744 West Paloma St. Perry, FL 32348 Dartmouth, NS B3B 1N5, Canada Boise, ID 83704-0701 Tel: 850-584-1514 Tel: 902-468-2743, Ext. 238 Tel: 208-841-4246 Cell: 850-672-2326 Cell: 902-468-2323 [email protected] [email protected] [email protected] [email protected]
‡Daniel Franco Majed Ja’arah ‡Guy Labonte International Paper Smurfit Kappa Columbia FM Global Rome GA Calle 15 #18-109 600 de la Gauchetiere Ouest, 14th [email protected] Yumbo, Valle, Colombia Floor Cel: +57 3113001079 Montreal, Que H3B 4L8 Tel: (57-2) 6914 000 Ext. 2016 Canada [email protected] Tel: 514-876-7412 Cell: 514-942-3651 [email protected]
‡Doug Murch ‡Bob Phelps ‡Mark Sargent WestRock Extra Hand, Plant Support Services George H. Bodman, Inc. 501 South 5th Street 5440 Karma Road 857 Tall Trees Drive Richmond VA 23219 Chester, VA 23831 Cincinnati, OH 45245 Tel: 804-444-5245 Ph. (804) 921-7374 Tel: 514-543-0480 Cell: 804-787-0781 Cell: 804-748-4391 [email protected] [email protected] [email protected]
‡Alvaro Timotheo ‡Thomas Wranosky - Co-chair Andritz Pulp & Paper International Paper 5405 Windward Parkway, Ste.100W 568 Shore Airport Road Alpharetta, GA 30004 Ticonderoga, NY 12883-9699 Tel: 770-640-2642 Tel: 518-585-5305 Cell: 770-630-4577 [email protected] [email protected]
‡Denotes attendance at the meeting in April of 2017.
Meeting Minutes BLRBAC April 12, 2017 Page 13 of 116
WASTE STREAMS SUBCOMMITTEE
‡Paul Seefeld – Chairman Lundberg LLC 9246 Audubon Park Ln S Jacksonville, FL 32257 Cell: 904-614-6492 [email protected]
‡Mark E. Cooper – Vice David Frazier Olli Kujanpaa Chairman International Paper Georgia Pacific FM Global Technology 550 Burrard St., Ste. 1788 6285 Tri-Ridge Blvd Atlanta, GA Bentall 5 Loveland, Ohio 45140 [email protected] Vancouver, BC V6C2B5 Cell: 706-305-5321 Cell: 425-877-9735 [email protected] [email protected]
John Lewis ‡Pasi Miikkulainen ‡Steven L. Osborne Fluor Andritz Babcock & Wilcox 100 Fluor Daniel Drive 5405 Windward Parkway 20 S. Van Buren Avenue Greenville, SC 29607-2762 Alpharetta, GA 30004 Barberton, OH 44203 Tel: 864 517-1683 Tel:770-640-2414 Tel: 330.860.1686 [email protected] Cell: 678-230-1525 [email protected] [email protected]
‡Michael D. Sides ‡Greg Wass XL Catlin Lundberg LLC 1360 Olympia Park Circle 13201 Bel-Red Road Ocoee, FL 34761 Bellevue, Wa 98005 Tel: 203-964-5333 Office: 425-283-5070 Mobile: 407-462-4622 Cell: 425-503-2747 [email protected] [email protected]
‡Denotes attendance at the meeting in April of 2017.
Meeting Minutes BLRBAC April 12, 2017 Page 14 of 116
WATER TREATMENT SUBCOMMITTEE
‡Tom Przybylski Power Specialists Assoc., Inc. 531 Main Street, Somers, CT 06071 Tel: 860.763.3241 [email protected]
‡Craig Aderman Robert Bartholomew, P.E. ‡Kelli Bastarache Sheppard T. Powell Associates, LLC Sappi Fine Paper NA Power Specialists Assoc., Inc. 1915 Aliceanna Street 89 Cumberland Street 531 Main Street Baltimore, MD 21231 P.O. Box 5000 Somers, CT 06071 Voice: 410-327-3500 Westbrook, ME 04098-1597 Tel: 860-763-3241 [email protected] Tel: 207-856-3517 [email protected]
Cell: 207-831-2472 [email protected]
‡Wayne Bucher ‡Fred Call ‡Ray Cassel NORAM Engineering Buckman North America RMIS Birmingham, AL 1256 North McLean Blvd. 8571 Rosemary St # B, Commerce City, Tel: 205-408-1874 Memphis, TN 38108-1241 CO 80022 Cell: 205-368-9396 Tel: 207-214-8357 Tel: 303-789-9307 [email protected] [email protected] [email protected]
‡Susan Childress ‡Frank DeStefano Buck Dunton ChemTreat, Inc. IP Technology Power Mfg. Solutions The Purolite Company 4301 Dominion Blvd. 5870 Anderson Road 500 Locust Grove Glen Allen, VA 23060 Grovetown, GA 30813 Spartanburg, SC 29303 Tel: 804-935-2000 Tel: 706-339-1631 Cell: 864-617-0881 [email protected] [email protected] [email protected]
Don Flach Claude Gauthier, P.E. John Gray Georgia-Pacific Corporation The Purolite Company Rayonier Advanced Materials 133 Peachtree Street P.O. Box 308, Paris, Ontario 10 Gum Street Atlanta, GA 30303 Canada N3L 3G2 Fernandina Beach, FL 32034 Tel: 386-336-5584 Tel: 800-461-1500 Tel: 912-277-1388 [email protected] Tel: 519-448-4512 Cell: 912-321-7582 [email protected] [email protected]
‡Ken Hansen Jeff Fox Norris Johnston Nalco Company Water Wizard Consulting B&W Consultant 1601 W. Diehl Road 37 Hough Road Barberton, OH 44203 Naperville, IL 60563-1198 Lacey's Spring, AL 35754 Tel: 330-256-5955 [email protected] Tel: 256-650-0049 [email protected] Cell: 256-520-1011
Dave Kittel Ben Kupka Sam Lewis Valmet, Inc. RMIS Delta Training Partners, Inc. 3430 Toringdon Way, Ste. 201 6060 Saltsburg Rd 4020 Oleander Drive Charlotte, NC 28277 Murrysville, PA 15668 Wilmington, NC 28403 Tel: 704-414-3434 Tel: (724) 387-2861 Tel: 910-790-1988 Cell: 704-614-0492 [email protected] [email protected]
‡Denotes attendance at the meeting in April 2017.
Meeting Minutes BLRBAC April 12, 2017 Page 15 of 116
WATER TREATMENT SUBCOMMITTEE - (Cont.)
Michael Lykins Tom Madersky ‡Jason Miller Packaging Corporation of America Power Specialists Assoc., Inc. Andritz Inc. 1061 Woodcliff Drive 531 Main Street 1115 Northmeadow Parkway South Elgin, IL 60177 Somers, CT 06071 Roswell, GA 30076-3857 Cell: 630-659-7115 Tel: 860-763-3241 Tel: 770-640-2528 [email protected] [email protected] Cell: 770-335-8529 [email protected]
Rick Morgan Kurt Parks Jim Robinson FM Global Packaging Corporation of America GE (Infra, Water) 5700 Granite Pkwy. 5495 Lake Park-Clyattville Road 4636 Somerton Rd. Plano, TX 75024 Valdosta, GA 31601 Trevose, PA 19053 Tel: 972-731-1869 Tel: 229-559-2257 Tel: 215-942-3381 [email protected] Cell: 229-415-8557 [email protected] [email protected]
‡Denotes attendance at the meeting in April 2017.
Meeting Minutes BLRBAC April 12, 2017 Page 16 of 116
Registered for the meeting were:
3S Team Boiler Services and Inspection (BSI), Fudge, Joey, Skiatook, OK Andrews, John, Charleston, SC Pyszynski, George, Skiatook, OK Clay, Dean, Simsboro, LA
A.H. Lundberg Buckman Laboratories Seefeld, Paul, Jacksonville, FL Call, Fred, Newry, ME
AirTek Construction ChemTreat Greenstreet, Milton, Baltimore, MD Graham, Jim, Collierville, TN Shanahan, Dennis, Troy, AL Chicago Tube and Iron (CTI Power) American Forest & Paper Assn. (AF&PA) Morgan, Preston, Locust, NC Grilliot, Wayne, Springboro, OH Clearwater Paper American International Group (AIG) Beck, Justin, Lewiston, ID DeBeer, Thomas, Woodstock, GA Wallace, Jeff, Lewiston, ID Smith, Andy, Atlanta, GA Clyde Bergemann, Andritz, Jameel, Ishaq, Atlanta, GA Bunner, Ben, Alpharetta, GA Miller, Mark, Atlanta, GA Gazsi, Andrew, Alpharetta, GA Herchuck, Josiane, Alpharetta, GA CORR Systems, Imig, Greg, Alpharetta, GA Ruiz de Molina, Eliadio, Birmingham, AL Johnson, David, Alpharetta, GA LeBel, Mark, Alpharetta, GA Day & Zimmermann, Miikkulainen, Pasi, Alpharetta, GA Wasson, Eric, Charlote, NC Miller, Jason, Alpharetta, GA Payne, Zack, Alpharetta, GA Domtar Phillips, John, Alpharetta, GA Avery, David, Bennettsville, SC Schull, Alec, Alpharetta, GA Worsham, Jesse, Bennettsville, SC Timotheo, Alvaro, Alpharetta, GA E and E Tech, Applied Technical Services (ATS) Locke, Jaye, Atlanta, GA Castle, Bill, Marietta, GA Kapperman, Thomas, Marietta, GA Electron Machine Rawls, Christopher, Marietta, GA Osborne, Brad, Umatilla, FL Vossberg, C. A., Umatilla, FL AXA Matrix Risk Jackson, Christopher, Fox Island, WA Expera Specialty Solutions, Barzyk, David, Mosinee, WI AZZ Basler, Dan, Kaukauna, WI Power, Stacy, St. Petersburg, FL Markrof, Scott, Mosinee, WI McCarty, Matt, Kaukauna, WI Babcock & Wilcox Schmitt, Jennifer, Kaukauna, WI Coley, Lance, Calera, AL Hansen, Kenneth, Barberton, OH Extra Hand Plant Support Services Kornaker, Greg, Barberton, OH Phelps, Robert, Chester, VA Krekeler, Daniel, Barberton, OH Kulig, John, Barberton, OH FITNIR Analyzers, Leibel, Greg, Charlette, NC Trung, Thanh, Vancouver, BC, Canada Oliveira, Paulo, Overland Park, KS Osborne, Steve, Barberton, OH Sallee, Greg, Atlanta, GA Schwartz, Eric, Barberton, OH Stonecipher, Greg, Chattanooga, TN
Meeting Minutes BLRBAC April 12, 2017 Page 17 of 116
Registered for the meeting were:
FM Global Glatfelter Beaulieū, André, Montreal, Que, Canada Anders, Aaron, Chillicothe, OH Britt, Francisco, Plano, TX Curry, Christopher Ryan, Chillicothe, OH Cooke, Craig, Plano, TX Forry, Jeffrey, Spring Grove, PA Cooper, Mark, Woodinville, WA Free, Roger, Chillicothe, OH Crysel, Scott, Plano, TX Montgomery, Ryan, Chillicothe, OH Hoffman, Daryl, Oak Harbor, WA Huelsbeck, Kevin, Sherwood, WI Global Risk Consultants Hume, Everett, Norwood, MA Garfield, Michael, Lowell, ME Jackson, Larry, Macon, GA Labonté, Guy, Montreal, Que. Graphic Packaging International, Lang, David, Plano, TX Baker, Kenneth, Macon, GA Leonessa, Raphael, Sao Paulo, Brazil Matarrese, Rick, Alpharetta, GA Greif, Meehan, Tom, Johnston, RI Casey, David, Amherst, VA Merchant, Brent, Plano, TX Haskins, Bill, Amherst, VA Moberg, Eric, Plano, TX Smith, Mike, Amherst, VA Murphy, Tim, Clermont, GA Onstead, Jimmy, Frisco, TX Houghton Cascade, Rust, Mark, Murfreesboro, TN Leary, William R., Auburn, WA Young, Andrew, La Center, WA Howe Sound Pulp & Paper, Fossil Power Systems (FPS) Jellema, Marinus (Rinus), Port Mellon, BC, Canada Donahue, Mark, Dartmouth, NS, Canada Integrated Test & Measurement (ITM), Fuel Tech Carlier, Tim, Milford, OH Bohlen, Scott, Warrenville, IL Weber, Jack, Jacksonville, FL International Paper Adams, Wayne, Clinton, NC Gecko Robotics, Alex, Leni, Redwood, MS Demmer, Troy, Pittsburgh, PA Bruce, Mike, Loveland, OH Loosararian, Jake, Pittsburgh, PA Blackard, Vernon, Loveland, OH Bryan, Greg, Redwood, MS General Electric, Byrd, Joel, Loveland, OH Kistka, Gerry, Jacksonville, FL Camp, William, Prattville, AL Childress, Susan, Loveland, OH George H. Bodman, Inc. Cox, Stephen, Loveland, OH Bayse, Michael, Kingwood, TX Craft, Matthew, Columbus, MS Bodman, George, Kingwood, TX Fuhrmann, Dave, Loveland, OH Holland, Brook, Kingwood, TX Hendrix, Sam, Loveland, OH Sargent, Mark, Kingwood, TX Knowlen, Bruce, Federal Way, WA McGloster, Davon, Redwood, MS Georgia-Pacific, Navojosky, Frank, Loveland, OH Bettilyon. William, Perdue Hill, AL Slagel, David, Port Wentworth, GA Browning, John, Atlanta, GA Weinberg, Marla, Loveland, OH Hill, Wes, Camas, WA Wilson, Ken, Columbus, MS Johnston, Jennifer, Atlanta, GA Wranosky, Tom, Ticonderoga, NY Lane, Terry, Brunswick, GA Meadows John, Brunswick, GA Interstate Paper Miller, William K., Brunswick, GA Edwards, Brian, Riceboro, GA Morency, Karl, Atlanta, GA Stapleton, David, Riceboro, GA Selner, Dale, Atlanta, GA Sherlock, Bentley, Atlanta, GA Jansen Combustion Wilhite, John, Atlanta, GA Campbell, Steve, Kirkland, WA La Fond, John, Kirkland, WA
Meeting Minutes BLRBAC April 12, 2017 Page 18 of 116
Registered for the meeting were:
Kadant Black Clawson, Peerless Manufacturing Patel, Jean-Claude, Mason, OH (a/k/a CCA Combustion Systems) Smith, Jason, Mason, OH Acree, Michael, Monroe, CT
KapStone Paper Power Specialists Associates (PSA), Burns, Gregory, North Charleston, SC Bastarache, Kelli, Somers, CT Deweese, Kenneth, North Charleston, SC Erickson, Leonard, Somers, CT Green, Aric, North Charleston, SC Henriques, Fabian, Somers, CT Underwood, Ellen, Charleston, SC Przybylski, Tom, Somers, CT Zawistowski, Bob, Somers, CT K-Patents Betts, Herb, Naperville, IL PSF Industries, Hamalainen, Arto, Naperville, IL Carpenter, Roger, Seattle, WA Pyörälä, Keijo, Naperville, IL Wagner, Phil, Naperville, IL Purolite Burinsky, Frank, Bala Cynwyd, PA LENRO, Inc., DeStefano, Frank, Bala Cynwyd, PA Olavessen, Len, Bartow, FL Friesan, Chris, Bala Cynwyd, PA
Liquid Solids Control RAE Engineering & Inspection, Sweeney, Michael, Upton, MA Santo, Shawn, Edmonton, Alberta, Canada
Lundberg, LLC Rayonier Advanced Materials, Wass, Greg, Bellevue, WA Gray, John, Fernandina Beach, FL
M&M Engineering, Riceboro, GA, Moskal, Max, Indiana Head Park, IL Stroud, Douglas, Riceboro, GA
Marlon Garcia, Inc., Rick Spangler, Inc. Garcia, Marlon, Woburn, MA Spangler, Rick, St. Simons Island, GA
Marsh & McLennan, RMR Mechanical Weisenberg, Dale, Calgary, Alberta, Canada Roy, Bob, Cumming, GA
MPW Industrial Services, Rockwell Automation, Chandler, Nathan, Hebron, OH Hunter, Marc, Burr Ridge, IL Houck, Carey, Hebron, OH Landis, William, Hebron, OH Rocky Mt Ind Services (RMIS), Marchant, Rick, Hebron, OH Cassel, Raymond, Denver, CO McGraw, Robert, Hebron, OH Kupka, Benjamin, Denver, CO
Nalco, Sandvik, Fox, Jeffrey Springboro, OH Day, Katie, Houston, TX Moffett, Danny, Naperville, IL Picker, Karen, Houston, TX Ribeiro, Claudemir, Houston, TX National Boiler Service Harville, Steve, Trenton, GA Sappi Fine Paper Mesamore, Mike, Trenton, GA Aderman, Craig, Westbrook, ME Bolduc, Lance, Skowhegan, ME NORAM Engineering and Constructors Boudreau, David, Skowhegan, ME Bucher, Wayne, Birmingham, AL Naidoo, Derrick, Ngodwana, South Africa Willemse, Christo, Mbombela, South Africa Packaging Corp. of America Fiala, Brian, Tomahawk, WI Siam Cellulose, Rossiter, Casey, Tomahawk, WI Withayaphan, Rachakrit, Bangpong, Thailand
Meeting Minutes BLRBAC April 12, 2017 Page 19 of 116
Registered for the meeting were:
Smurfit Kappa, Verso Paper Franco, Daniel, Cali, Columbia Jirschele, Dale, Wisconsin Rapids, WI Lewis, Jason, Bangor, ME Solenis, Mcozck, Jeff, Wisconsin Rapids, WI Holloway, Scott, Fayetteville, AR Schmidt, Timothy, Wisconsin Rapids, WI Meredeth, James, Gulf Breeze, FL W. L. Gore & Associates, Southern Environmental Ellis, Jim, Elkton, MD Hendrix, Angela, Pensacola, FL Kiernon, Paul, Elkton, MD Lawton, Roger, Pensacola, FL Water Wizard Consulting, Swiss Re, Johnston, Norris, Lacey's Spring, AL Lynch, Joe, Alpharetta, GA Moran, Jose, Vancouver, BC, Canada WestRock, Davedson, Jeff, Demopolis, AL Thompson Construction Group, Fullington, Scott, Tacoma, WA Halbig, John, Sumter, SC Hewitt, Mike, Demopolis, AL Moyer, Scott, Jacksonville, FL Thompson Industrial Services Murch, Douglas, Chesterfield, VA Gorosh, Sam, Sumter, SC Sanders, Doug, Cottonton, AL Gray, Steven, Sumter, SC Sargent, Caleb, Covington, VA Harry, Todd, Sumter, SC Shirley, Wade, Cottonton, AL Jackson, Dwayne, Sumter, SC von Oepen, David, Meridian, MS Wood, Jason, Covington, VA United Water Consultants, Kelly, John, West Chicago, IL Woodland Pulp, Provencher, James, Baileyville, ME Valmet Bird, Jennings, Charlotte, NC XL Catlin Burelle, Raymond, Charlotte, NC Goddard, Robert, Tupelo, MS Daigle, Chad, Charlotte, NC Franks, James, Somerville, TN Martin, James, Charlotte, NC Sides, Michael, Ocoee, FL Osborne, David, Charlotte, NC Reed, Ron, Charlotte, NC Zeeco, Trivett, Michael, Charlotte, NC Langstine, Bob, Broken Arrow, OK Weikmann, John, Charlotte, NC
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MAIN COMMITTEE MEETING
INTRODUCTION – John Gray - Chairman: Good morning! Welcome everybody to the Spring 2017 Main Committee Meeting! The Main Committee Meeting is now open. This meeting, as are all BLRBAC meetings, is being held in strict compliance with BLRBAC’s Anti-Trust Policy. You have seen this policy several times throughout the course of this session. It essentially states that we do not talk about pricing, pricing competition and there are no restrictions on competition.
We will begin with some introductions: John Gray - BLRBAC Chairman – Rayonier Advanced Materials Dave Slagel - BLRBAC Vice-Chairman - International Paper Everett Hume - BLRBAC Secretary - FM Global Len Olavessen - BLRBAC Treasurer – Lenro, Inc. John Phillips – Boiler OEM Representative - Andritz Jim Onstead – Insurance Representative – FM Global David VonOepen - Operating Representative - WestRock
OLD BUSINESS 1. ACCEPTANCE OF THE SPRING 2016 MEETING MINUTES – John Gray
Acceptance of Minutes from the Fall 2017 Session. Those Meeting Minutes have been posted on the BLRBAC web site for review now for several months. Do we have any corrections to those minutes as posted? If not, can I get a motion to accept those Minutes? (Accepted.) Can I get a second? (Seconded!) All in favor? All opposed? Thank you. The Fall 2016 Meeting Minutes have been unanimously approved.
NEW BUSINESS 1. NEW MEMBERS/REPRESENTTIVE CHANGES REPORT – Everett Hume
NEW REGULAR MEMBERSHIP - None Reported
NEW ASSOCIATE MEMBERSHIPS
Sandvik – Houston, TX Katie Day has been designated as the Associate Representative Claudemir Ribeiro has been designated as the Alternate Representative
NEW CORRESPONDING MEMBERSHIPS – None Reported
REGULAR REPRESENTATIVE CHANGES
Glatfelter Doug Moir replaced William Gentzler as the designated Representative Jeff Forry replaced William Plappert as the designated Alternate Representative
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1. NEW MEMBERS/REPRESENTTIVE CHANGES REPORT – (Cont.)
REGULAR REPRESENTATIVE CHANGES – (Cont.)
International Paper Frankl Navojosky remains as the designated Representative David Frazier replaced David Fuhmann as the designated Alternate Representative
ASSOCIATE REPRESENTATIVE CHANGES – None Reported
CORRESPONDING MEMBERSHIP CHANGES - None Reported
MEMBERSHIP COMPANY NAME CHANGES
Envirosystems USA, Inc., (d/b/a RMIS) or VISTEC Previously known as Rocky Mountain Industrial Services Ernest Wigglesworth remains as the designated Associate Representative Charles Wigglesworth remains as the designated Alternate Associate Representative
MEMBERSHIP COMPANY STATUS CHANGES - None Reported {Secretary’s Note: The Company Membership List posted on the BLRBAC website may be out of date and not reflecting all the mergers, acquisitions, and name changes that have occurred. Anyone who sees something that needs changing should bring it to the attention of the BLRBAC Secretary via [email protected]}
2. EXECUTIVE COMMITTEE REPORT – John Gray
The Executive Committee met Tuesday afternoon in closed session with 6 of 7 members present. Some of the highlights from those discussions:
Credit Cards for Advanced Registration: On the issue of using credit cards for Advanced Registration, unfortunately bank regulations have recently changed, and this has made it more difficult and costly for us to offer credit card Advanced Registration through our bank. We are attempting to work with the bank, but are also exploring other avenues such as PayPal. So, at this time, we are not at a point where we can accept credit card payments for Advanced Registrations. Use of a credit card for at door registration is already in place and working well.
55 Year Anniversary: As a reminder, the October 2017 (10/2,3,4) session will mark the 55 Year Anniversary of BLRBAC. For that session, we are offering a reduced Advanced Registration fee of $55.00 for all 1st time attendees from a voting member company. This is for Advanced Registration only. At door registration will remain unchanged at $200.00. All operating companies are encouraged to bring your operators!
Lastly, the EC is considering the creation of a new Educational Subcommittee. We believe a committee such as this could add significant value. We will be working on establishing guidelines to govern the deliverables from this committee, and setting up clear boundaries between this SC and all others.
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3. TREASURER’S REPORT – Len Olavessen
Good morning again! As of this morning our checking account balance is $88,042.88. After the expenses for the meeting, which includes the Crowne Plaza and some office expenses, etc., we have a balance of $60,852.47. Our beginning balance on the first of January was $60,483.60; therefore, our registration revenue is somewhat balancing our expenses. We are financially in good shape. Any question about that? Basically, I’m telling you that we are in good financial shape.
The meeting statistics were 189 Advance Registrations; 57 At Door Registrations; for a total of 246 paid registrations. We had 19 paper companies; five insurance companies; three boiler manufacturers; 31 Associate companies and ten guests of member companies. We had four off-shore attendees; one from Columbia; one from Thailand; and two from South Africa. Any questions or comments?
4. SECRETARY’S REPORT – Everett Hume
Very briefly, it seems like every meeting I probably repeat this, so I’ll repeat it again. When registering, please remember to include your check along with your registration form. Barbara can’t process anything without a check and a clearly printed registration form. Every meeting we seem to get a lot of checks with no names attached or we get a lot of registration forms but no check enclosed. She can’t do anything with those. The second part of that process is that if you think you are registered and you have not received an e-mail verification from her within a maximum of two weeks after you have sent in your registration request, you are not registered. So please get in touch with her to figure out where you are a t. She has been very good at getting back to most of you and I’m sure that most of you that have advance registered have received an e-mail which has your registration number right there. Every year we get probably about 30 or so people who have said, “….well, I thought I was registered!” We ask, “…did you get a verification e-mail?” “No.” Keep that in mind when you are registering this year for the fall meeting. Make sure that you go through that process and then you will have no problems when you show up for the BLRBAC meeting.
Again, as John said about the fall meeting, with the $55.00 rate for first time attendees of a voting member company, it is an excellent opportunity for the mills to bring some of the operators for the first time and expose them to what we are doing here. I will be putting a splash up on the home page of the BLRBAC WEB site to remind people to bring your operators and let them participate in our 55th Anniversary.
It is required that each regular member company (boiler insurers, boiler operators and boiler manufacturers – voting members) keep me advised of names and e-mail addresses of their designated Representative and designated Alternate Representative. Preferably they will be someone who regularly attends BLRBAC. It is the member company’s responsibility to keep me informed of any changes in representation by e-mailing me. A “Representative Change Form” is posted on the BLRBAC website to make it easier for management to submit the changes in responsibility and/or any e-mail address changes.
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4. SECRETARY’S REPORT – (Cont.) SECRETARIAL SERVICES REPORT – (Cont.)
Anyone who wishes to be added or deleted from the BLRBAC e-mail list, must e-mail me ([email protected]) your intentions. Include your name, company and your e-mail address. Someone is needed to take the initiative (in the best case scenario, this should be the designated Representative or Associate Representative) to keep me advised of any member company name changes, mergers, etc., so that the BLRBAC database can be properly maintained.
Be sure that I have your current working e-mail address. BLRBAC's Meeting Notice and posting on- line of Meeting Minutes will only be sent via e-mail. If an e-mailed address notice is returned to me as “undeliverable,” that e-mail address will be deleted from the BLRBAC database after a second attempt has been made.
If you are a designated Representative or Alternate Representative for your organization and something happens wherein you will no longer be functioning in this capacity, such as, retirement, occupational change, downsizing, etc., please let me know ([email protected]) and supply me with the name and e-mail address of whomever will fill your vacated position within BLRBAC.
Per BLRBAC’s policy, BLRBAC’s Secretarial Services will verify receipt of meeting registrations and checks via e-mail when appropriate e-mail addresses are given on the registration form. Sometimes e-mails pop back as "undeliverable." This may be due to the fact that the e-mail box is full, incorrectly typed due to not being able to decipher attendee handwriting, etc. I will do my best to see that all e-mails are properly received at the posted e-mail address. The BLRBAC database is always updated and corrected according to what information is given on the most recent Registration Form.
All Advance Registration attendees are recorded, given a registration number and sent a confirmation e-mail usually on the same day checks are received. This notification is sent to the e-mail address listed on the Registration Form. If you have not received a confirmation notification from me, you are not registered for BLRBAC! I am again requesting that all Meeting Registration Forms be completed in their entirety. This form is the only way I can confirm the accuracy of the BLRBAC database and e-mail address book.
Finally, if you know from past experience that your Accounting Department takes weeks to issue a requested check for registration purposes, just send me your completed Registration Form and a personal check before the posted cut-off date. Then you can get reimbursed from your company at a later date. This will guarantee you are registered at the Advance registration fee. Per BLRBAC policy, there are no exceptions when paying after the cut-off date given on the Registration Form. Your organization will be required to pay the higher At Door fee for all registrations posted after the cut-off date.
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5. SUBCOMMITTEE REPORTS
5.1 AUXILIARY FUEL REPORT – Bruce Knowlen
The SFAF meeting was called to order with a reminder of the BLRBAC Anti-Trust Statement. The minutes of the last meeting were read and approved.
Introductions were made of all attending. There were 9 of 11 members and 7 guests present. Of these, we had 4 members replaced: Kevin Huelsbeck of FM Global was replaced by Andrew Young, Dan Krekeler formerly of International Paper was replaced by Mike Bruce, Nick Merriman formerly of Andritz was replaced by Greg Imig, and Nathan Schindler of CCA Combustion Systems was replaced by Michael Acree. We extended a welcome to these new members and appreciate their companies providing our subcommittee with this talent.
A call was made for any new business. Two topics were raised from the group:
Q - What changes are recommended by BLRBAC when converting from No. 6 oil to No. 2 oil or what advice can be offered? A - No specific changes come from the SFAF document. However, several suggestions were provided including: Consider the atomization – steam or air is possible; Air-to-fuel ratio may need adjustment; The oil heater may not be needed but location and weather could impact this; Pump seals and other gaskets could begin to leak as the light oil replaces the heavy oil – these should be checked for compatibility; Temperature and pressure interlocks can be adjusted to more appropriate settings; and Flame detection may require adjustment and re-aiming.
Q - What experience and options can be given for Auxiliary Fuel Flame Scanners to discriminate the flame from the smelt bed or furnace background radiation? A - Angle of the flame detector (aiming) is critical for performance of the scanner. There are different scanner technologies that are selected based on fuel - UV for Natural Gas typically and IR with Oil. Continuous gas ignitors can be used in place of main burner scanners.
A flame scanner presentation was made several years back and if interest indicates we may be able to find an authority to present on this topic at a future meeting.
Old Business –
We recognized that modifications to the SFAF document have been delayed and not published yet. Some changes of logic in the figures are needed but these have been unavailable in an editable form. The BLRBAC Secretary was recognized for delivering new modifiable figures of our subcommittee’s document. Thanks Everett!
Two subjects were carried over from the last meeting – Superheater Clearing, and edits to Chapter 5 tables. Due to circumstances, the task teams assigned to work on these after last October were not able to contribute. We resumed work during this session.
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.1 AUXILIARY FUEL REPORT – (Cont.)
The text previously passed by the subcommittee on superheater clearing is as follows:
Prior to the recovery boiler coming on line and producing steam, flue gas temperatures entering the superheater must not exceed OEM recommended levels (typically < 900°F) regardless of fuel being fired. Operators should ensure that all superheater tubes have been cleared of condensate allowing cooling steam flow through all superheater tubes prior to allowing flue gas temperatures to exceed the manufacturer’s recommended level. Most recovery boilers are equipped with superheater outlet tube thermocouples. These thermocouple readings will tell the operator when the individual platen clears of condensate with a characteristic “pop” or jump of approx. 50-75°F in the metal temperature. Operating procedures and practices should be developed and operators trained to recognize that the boiler should not be placed in the header until all superheater tubes are cleared of condensate.
After reviewing this text, we set on inserting this alert into the flow of logic. Various locations and methods were discussed. A proposal was generally agreed on and will be presented in a modified figure at the Fall meeting.
The Tables of Chapter 5, Other Audible Alarms and Visual Indications was again postponed to the Fall.
The subcommittee is planning to meet again in the Fall Meeting of 2017. We adjourned at 3:25 PM.
CHAIRMAN: As you may have noticed, Bruce had some turnover in his subcommittee. As a reminder to all Subcommittee Chairs, please keep us updated with your current membership list with company names and e-mail addresses of everyone on your subcommittee. That current list needs to go either directly to Barbara or you can send it to any of us as it will be forwarded to Barbara.
5.2 SAFE FIRING OF BLACK LIQUOR REPORT – Vernon Blackard and Tom Wranosky
SFBL Subcommittee Meetings – Monday 8:30 AM (CLOSED) and 01:00 PM (OPEN). Sub- Chair meeting on Monday 4 pm. Main meeting report out Wednesday 8:00 AM.
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.2 SAFE FIRING OF BLACK LIQUOR REPORT – (Cont.)
Agenda:
Open the meetings. Closed and Open.
Reviewed BLRBAC Anti-Trust statement. Both closed and open meeting.
Introduced members and guests. 13 of 18 members present and 58 guests in open meeting.
Reviewed and approved the Fall 2016 meeting minutes.
Reviewed working draft document for next revisions. Items discussed below:
Chapter 5 page 35 – Figure 2 Add start DT agitators as black liquor fuel permissive in logic. • Dissolving Tank agitator • In the logic explanation chart referring to Figure 2 • Logic Diagram Block: “Prove Dissolving Tanks Agitators in Operations” • Purpose: Prevent dissolving tank green liquor from reaching a high density and solidifying • Hazard: Uncontrolled green liquor density leading to possible shutdown to physically remove solidify green liquor with jack hammer
Chapter 9.1.6 Spout inspection interval (Page 67).
Inspect the smelt spouts during every scheduled major outage. If a spout fails an inspection, replace it. All spouts should be replaced at least once every major maintenance outage with a new spout.
Replacement spouts should be field hydro tested to manufacturer's specifications prior to use. NEVER REBUILD, REPAIR OR MODIFY A SMELT SPOUT!
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.2 SAFE FIRING OF BLACK LIQUOR REPORT – (Cont.)
At each major outage, cut up at least one removed smelt spout. Thoroughly inspect the cooling water jacket internals, cooling water supply lines, valves and instrument devices, to ensure adequacy of the cooling water quality and the corrosion/deposition control program. Furthermore, a periodic inspection of sections of the cooling water piping should be made to ensure the absence of internal buildup or scale that could restrict cooling water flow. Sections of piping with scale or buildup should be replaced or cleaned.
Both smelt spout cooling water head tanks and collection tanks should be inspected and cleaned at each major outage.
Spout cooling water piping, valves and instrument devices should be check for leaks prior to start up. Boiler expansion should be monitored to allow proper movement of any steam or water hoses connected to the spouts.
A condition based decision should be used to determine the proper service run period for smelt spouts beyond the traditional one-year service run. The conditions to extend establish the service run period beyond the traditional one-year service run should include but not limited to; spout failures, operational upsets or. operational changes that can impact spout integrity, significant liquor cycle chemistry changes, past issues with spout cracking, no manufacturing defects, waterside deposits, loss of spout cooling water episodes, or material wastage.
• Additional information for Chapter 9. Smelt spout operating period extending beyond one year. I put together a list of additional inspection and verification that could be included in our document to help better define what could be seen as a smelt spout prolonged life extension program. The program could include the following verifications: Scan the thickness of the surface of the spouts exposed to the smelt, including the inner and outer lips and underside of the spouts Visual inspection of the exposed surface, looking for dents and scratches. Using liquid penetrant in suspected zone for positive indication. This assessment should be conducted by a qualified NDE inspector and a boiler manufacturer service engineer. Review the spout cooling water daily log sheets for chemical residual data. A corrosion coupon placed in the cooling water return tank is analyzed Review the boiler liquor firing rate. Review of historical alarm for the spout cooling water low flow and high temperature and compare with baseline data Annual hydrostatic test of the spout system Internal inspection of the spout system, water side, head tank and receiver Spout opening contour tubes are checked with liquid penetrant and elcometer for clad thickness
MOC? TOM TO WORK ON
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.2 SAFE FIRING OF BLACK LIQUOR REPORT – (Cont.)
Consider adding “Major Maintenance Outage” to our definition section. Doug Murch will work on this.
Chapter 10.1 Plugged Spouts (Page 70).
There have been documented cases on recovery boiler master fuel trip situations that sootblowers have continued to run for long periods of time. This practice can lead to removing large amounts of slag from superheater and generating bank tubes and depositing this slag into the lower furnace which can lead to plugged spouts and difficulty in opening spouts on subsequent start-up. For this reason, it is recommended that the sootblower sequence be stopped and sootblowers be retracted on any boiler master fuel trip condition.
Revise figure 4. for MFT to add this logic. Vernon check with Everett to see how to revise figures and work on this one.
Sootblower MFT retract and Shutdown
It should be noted that the Instrumentation Checklist and Classification Guide in APPENDIX A, Section E “Boiler Cleaning System” has the “Automatic soot blower blowing sequence control” listed as Class 1 instruments for tripping the steam and retracting the soot blower on MFT.
They have as comment:
Free operator from other duties. • We can add: “prevent from worsening a bad situation by dropping more salt cake onto the bed” Sootblower MFT retract and Shutdown
It should be noted that the Instrumentation Checklist and Classification Guide in APPENDIX A, Section E “Boiler Cleaning System” has the “Automatic soot blower blowing sequence control” listed as Class 1 instruments for tripping the steam and retracting the soot blower on MFT.
They have as comment: . Free operator from other duties. . We can add: “prevent from worsening a bad situation by dropping more salt cake onto the bed”
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.2 SAFE FIRING OF BLACK LIQUOR REPORT – (Cont.)
Chapter 10.2 Design Item 8. Explosion Relief (Page 72)
The following should be considered when designing dissolving tank explosion relief: • Dissolving tank vent scrubber bypass damper size and capacity. • Dissolving tank explosion damper size and capacity. • Dissolving tank overflow capacity as compared to green liquor pumps and tank water/weak wash make up flows. • Dissolving tank overflow elevation as compared to tank roof elevation to allow proper explosion venting from tank during heavy smelt runs. Not enough “open area” above tank level will severely limit tank venting capacity and allow more damage and less ability to for spout shatter jets to reduce work properly. • Advanced controls on dissolving tank density controls to mitigate possible damage from heavy smelt runs. Possible but not limited to using green liquor flow, weak wash make- up flow, green liquor density, tank level, green liquor temperature, vent temperature. Usually provide a high ramp rate for pumping capacity increase and weak wash capacity increase during heavy smelt runs. • Operation guidelines to assist with controlling heavy smelt run periods. • Maintenance guidelines to assist with keeping the systems in good working condition. Check devices/explosion relief equipment for proper cleaning and operation at every major maintenance outage.
CHECK FIGURES AND ALARMS FOR THIS INFO LEN AND TOM
CHAPTER 14 AUDIBLE ALARM AND INDICATING SYSTEM (Page 86)
Updated alarm list for items 39 through 49.
Open item discussion from members and guests. Reviewed Figure 5 as it relates to starting black liquor pumps after email question from Rudy Haraga of PSA. Mark Donahue explained how the logic is supposed to work and will revise the explanation part of our document to clarify how the logic is to work.
External BLRBAC Black Liquor Pump Start Permissives - Clarification.msg
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MARK D TO WORK ON KEY LIQUOR WASH LOGIC. PROPOSED CHANGES TO LOWER FURNACE WASH LOGIC.
Reviewed again the dissolving tank incident report for GP Purdue Hill Alabama. Both dissolving tank incidents were caused by smelt pools behind plugged spout causing heavy runoff when spout was opened. Corrective actions seem insufficient for both reports unless more details are provided. Would want to see hot restart procedure with sufficient details on how to deal with all spout plugs and decision process to allow shut down of unit if large inventory of smelt is observed in unit with all spouts plugged.
Continue review to document as related to AFPA documents on Dissolving Tank explosions. Received document from Wayne of AFPA on Smelt water explosions for review.
Wayne Grilliot Consultant, Recovery Boiler Program American Forest & Paper Association C/O: APEC, LLC 204 Hiawatha Trail Springboro, Ohio 45066
Mobile: (937) 602-1892 (Preferred) Fax: (937) 746-5569 Main Office: (937) 746-4600
We continued discussion on items working at AFPA and our possible ways to assist with our document. Mark Sargent reported that University of Toronto has many items working and he needs their results to provide information for BLRBAC SFBL to work on.
NEW ITEMS:
LARGE TUBE LEAK = ADD TO FIGURES/TABLES, ANY ADDITIONS TO VERBAGE FOR OPERATOR FOLLOW UP? MARK D.
START LOGIC FIGURE 2 = FIRST FUEL CHECK O2/COMBUSTIBLES….DO FOR EACH FUEL ADDED AFTER?? TOM NOTE TO DAVE
REVISE FOR GUIDEANCE FOR ALL SPOUTS PLUGGED DURING OPERATION. CHAPTER 10 PG 74
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.2 SAFE FIRING OF BLACK LIQUOR REPORT – (Cont.)
DO NOT fire black liquor if all smelt spouts are plugged! Firing rate should be dependent on bed and spout conditions, with production pressures having minimal impact on the decision-making process. Should a large molten smelt inventory accumulate that cannot be safely removed from the furnace for fear of excessive smelt runoff, operating procedures should exist that instruct operating personnel to shut down the boiler, cool the bed and water wash the material out of the furnace.
CHAIRMAN: It is just a permissive and we want to have it as both a control room check your amps; make sure you have your normal amps and also an operator observation to go with that.
5.3 ESP SUBCOMMITTEE REPORT – Karl Morency for John Andrews (See Appendix I – Incident List)
The ESP Subcommittee met in closed session on Monday April 10th, 2017 with 13 members represented. The Subcommittee met in open session on Tuesday morning April 11th, 2017 with 13 members represented and about 200 guests. The Subcommittee gives thanks to John Harmon of GE Power for his service with the committee. GE Power had decided not to continue support for the Subcommittee.
During the open session, the Subcommittee reviewed 28 incident reports from North America and 1 International Incident. Of the 28 incidents, there were no Smelt Water Explosions reported and one Dissolving Tank Explosion. Seven (7) of the reported leaks were classified as critical incidents and 18 were non-critical incidents. There were two ESP with no leak reported. An ESP was performed in 8 of the incidents including 4 of the critical incidents representing 67% of the critical incidents that should have been ESP’d. This percentage is lower than we have seen historically.
The basic definitions of Explosions, Critical Incidents and Non-Critical Incidents were revised by the Executive Committee in September 1999. They are summarized as follows:
Explosions: Only if discernible damage has occurred. This does not include incidents where there is only evidence of puffs or blowback alone. With the new emphasis on damage, more attention will be given to the extent of damage and the amount of downtime for the damage repair (as opposed to total downtime that includes other activities).
Critical Incidents: All cases where water in any amount entered the recovery unit forward of isolating baffles (and therefore would be a similar criterion to the need to perform an ESP). This includes leaks of pressure parts of all sizes. Since small leaks often wash adjacent tubes to failure, this category is important to our learnings.
Non-Critical Incidents: Those cases that did not admit water to the boiler cavity defined above.
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.3 ESP SUBCOMMITTEE REPORT – (Cont.)
Appendix A contains a summary of the incidents reviewed during the meeting.
Incident Locations
The incident locations are summarized as follows:
• 12 – Economizer • 1 – Furnace Screen • 3 - Superheater • 3 – Upper Furnace • 2 – Lower Furnace • 2 - ESP No Leak • 4 – Lower Vestibule • 1 – Dissolving Tank Explosion
The general locations of the leaks for boilers in North America are shown in Figure 1, which displays a typical boiler, not representing any particular style or model. The yellow circles are the non-critical incidents and the red circles indicate the location of the critical incidents. The two blue dots represent the ESP with no leak.
The attached bar graphs (Figures 2 – 7) show the number of leaks reported by boiler location over the past 13 years to see if there is a trend in leaks occurring in a specific area. There does not appear to be any significant trend from any area during that time.
Incidents by Boiler Type
The incidents by the number of drums and the back-end arrangement were reviewed. There were 7 incidents reported in a single drum unit and 21 incidents reported in two drum units.
Four (4) of the reported incidents were in boilers with Cascade Evaporators and 2 of the units had a Cyclone Evaporator. Twenty-three (22) of the incidents involved units with extended economizers.
Leak Cause
The determination of the cause of the leak is somewhat of a subjective determination by the Subcommittee based on information in the reports. The breakdown is listed below:
• 4 –Fatigue • 2 - Weld Failure • 8- Erosion or Corrosion Thinning • 3 – Mechanical Damage • 8 - Stress Assisted Corrosion
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.3 ESP SUBCOMMITTEE REPORT – (Cont.)
How Discovered
Operator observations during boiler walk downs continue to be the prevalent method of detecting leaks and accounted for identification of 25 of the leaks (89%). This is a higher percentage than in the past and shows that operators are continuing to be diligent in looking for leaks. One leak was detected by Control Room Instrumentation observations and two leaks were identified by hydrostatic testing. None of the leaks were initially identified by a Leak Detection System. and one of the incidents reported that the leak detection system confirmed the presence of the leak during continued investigation.
Leak detection systems were reported to be installed on units in 13 of the incidents (46%).
Incident Review
Figure 8 shows the critical incidents reported each year. There were 7 reported this meeting and only represents half the year so it should continue close to the recent average by the end of the year. Figure 9 shows the history of Recovery Boiler Explosions showing the recent smelt water explosions in 2012 and 2013 so hopefully we can continue the string of no explosions.
Figure 10 shows the history of reported dissolving tank explosions with the one reported last year and one this year so we are continuing to see these incidents. Following the recommendations from Section 10 of the Safe Firing of Black Liquor document would prevent many of the reported dissolving tank incidents that have occurred in the past.
Figure 11 the five-year rolling average which is now at 0.2 indicating only one reported explosion in that five-year period. Hopefully with another year of no reported explosions we can get back down to zero but it does appear that we have reached a plateau of one to two boiler explosions in a five-year period.
Figure 12 is a plot of explosion history per 100-boiler operating years. This is a statistical summary of the experience across the industry. The smelt water explosion experience has dropped slightly to 0.477 explosions per 100 boiler operating years due to the explosions in the last couple of years, but the total explosions, which includes all boiler explosions and dissolving tank explosions, decreased slightly to .867 explosions per 100 boiler years. The factor is calculated by a summation of all reported explosions since 1948 divided by a summation of the number of boilers reported in service each year during the same period. We have accumulated over 18,463 total recovery boiler operating years in the BLRBAC database for North America and have recorded 88 smelt water explosions. We all need to continue to get those trends going down.
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.3 ESP SUBCOMMITTEE REPORT – (Cont.)
List of Operating Boilers
The BLRBAC Boilers in Service Database currently has 188 active recovery boilers listed, 148 in the US and 40 in Canada with a decrease on one boiler in the US and one in Canada. In the US, the average age is 39.7 years and the oldest is 65 years. The average age in Canada is 39.6 years and the oldest boiler is 70 years which is a 1947 Alstom unit at Three Rivers, PQ.
The list is available on the BLRBAC web site. We urge you to look over the list and if there are any changes or corrections, contact Dean Clay
Learnings
There are several learnings that come from review of the incident reports that may be of value for the industry. This is not a complete list but a few items that stood out during the incident review. • Inspect and maintain vibration restraints in Economizer to prevent fatigue failures at the tube to header connections. • Check slip joint for feedwater line as it goes through the lower ash hopper wall to confirm the freedom of movement in order to prevent cracking of the feeder tubes. • Include the location of economizer and generating bank baffles in operator training so that operators are aware of the potential for leaks to enter the furnace cavity. Normally two drum units will allow water to enter the furnace from a leak in the upper hot economizer but in single drum units with a baffled generating bank, leaks in the upper economizer cannot get to the furnace. • When repairing leaks at superheater clips, replace clip at a different spot away from repair weld to eliminate the possibility for additional stress on the repair from the clip. • Implement inspection plan for SAC on older boilers (>15 years). TAPPI TIP 0402-38 Guidelines for detecting and mitigating waterside cracking (SAC) provides a good reference document for inspection methods and locations to inspect. • Inspect lower header under spouts for weak wash corrosion that may occur due to leaks in spout enclosure skirts and baffles. • Maintain integrity of skirts in spout hoods to prevent weak wash from getting on lower headers. • Develop procedures for operating with plugged spouts and in accordance with Chap 10 SFBL to include minimum spouts open to fire black liquor and when to stop all firing. Follow the procedure in spite of production pressures. • Spout torches are good tool for opening plugged spouts.
ESP Guideline Changes
The Subcommittee has approved the revision of the ESP Guidelines that combines the Post ESP Guidelines that covers the actions that should take place after the ESP has been initiated with the ESP Recommended Good Practice Document. The draft was submitted to the Executive Committee for their review and comment.
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5. SUBCOMMITTEE REPORTS – (Cont.) 5.3 ESP SUBCOMMITTEE REPORT – (Cont.)
Additional updates include the DCE Fire Suppression Medium as a specific exclusion to the “Stop All Water and Steam Supplies” in Section 3.8 and wording to clarify that all motor protection interlocks such as motor heater and overloads should be bypassed on the Rapid Drain Valves with the initiation of the ESP. Protection should be utilized in the close circuit to keep from burning up the motor unnecessarily. There is a guide on the BLRBAC web site for how Rotork Actuators should be set up for Rapid Drain Valves.
Incident Questionnaires
The Incident questionnaires are key to the operation of the ESP Subcommittee. We appreciate the good job that the mills have done in filling them out for their incidents. The current questionnaire has been updated with the contact information to send the file to Dean Clay at [email protected]. Anytime you have an incident that needs to be reported, I know it is very tempting to just go back in the file and pull out the report from a couple of years ago and just fill in the new information, but we really urge you to go and get the most recent version of that off the WEB site and use that for the report.
Again, a reminder that when you are adding pictures into the questionnaire document, it is best that you import the picture as .JPG files rather than cut and paste to minimize the resulting file size.
Dean will send out an e-mail confirmation to the mill any time he receives a questionnaire. If the mill does not receive that confirmation within a couple of weeks of submitting the form, please contact Dean to see if there is a problem.
Dean is working on a revision to the Questionnaire that should make it easier to fill out and it is now in trial mode. The new Questionnaire should be available by the next meeting.
Any questions?
John Gray: I noticed that nearly 50% of the boilers has a leak detection system with no leaks detected by those systems. How does that correlate to cycles past? What is the typical percentage off the cuff?
Karl Morancy: Historically there have been about 50% of the incidents reporting that they have some form of leak detection installed. On average, it has been reported that leak detection systems have identified two leaks and confirmed an additional three.
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Figure 1
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Figure 2 (Critical Exposure Classification Began in 1965, Changed to Critical Incident in 1999)
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Figure 2
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Figure 3
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Figure 4
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Figure 5
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Figure 6
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Figure 7
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(Critical Exposure Classification Began in 1965, Changed to Critical Incident in 1999)
Figure 8
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Figure 9 8
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Figure 109
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Figure 110
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chc
Figure 121
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5. SUBCOMMITTEE REPORTS - (Cont.)
5.4 FIRE PROTECTION IN DIRECT CONTACT EVAPORATORS REPORT – Craig Cooke
The Fire Protection in Direct Contact Evaporators Subcommittee met in Open session Monday morning. We had three members, three new members and one guest in attendance (7 total attendees). We reviewed the BLRBAC Anti-trust policy. We also reviewed and approved the April 2016 minutes.
Our document was completely rewritten in October 2002. Since that time, there have been mainly minor revisions over the years. Most recently there were revisions voted on and accepted during the April 2016 meeting. Those changes focused on ways to help prevent fires, especially during upset conditions.
I initially thought our meeting Monday morning would be…. Boring! However, our small group and especially our new members infused us with ENTHUSIASM and new perspectives. Good questions were raised and valuable clarifications were generated. There was nothing that changes the overall intent of our guidelines. We did generate a list of enhancements and clarifications. Those will be submitted to the Executive Committee. They will review those suggested changes and decide if they can be incorporated with or without a membership vote.
There were no DCE fire incidents reported. We urge reporting of all fire incidents; minor and severe. Valuable lessons can be learned from both minor incidents that are quickly and easily dealt with as well as the larger and more severe fires.
Our next meeting will be April 2018, always an Open Session in the morning. We encourage attendance and always welcome new members.
5.5 INSTRUMENTATION REPORT - Dave Avery
The Instrumentation Subcommittee met in open session on Monday morning with 10 members and 13 guests. Our session began with reading the antitrust statement continuing with introductions of members and guest.
We reviewed minutes from our October meeting and approved them as presented. Reaching out to our guest we requested topics of interest from them, topics requested were none.
Under Old Business:
The group followed up on discussion on what makes a qualified I&E technician. Using a brainstorming technique, we developed the minimal knowledge and task list proposal presented below:
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.5 INSTRUMENTATION REPORT - (Cont.)
Proposed BLRBAC E&I Qualifications Statement
Qualified electrical and instrumentation technicians should be readily available to cover issues with the recovery boiler at all times. Qualified shall be defined as a technician that…..
• Understands the recommended good practices of BLRBAC • Understands the basics of recovery boiler process, operation, control and safety interlocking • Understands the individual unique and specialized control equipment and systems associated with the recovery boiler such as the solids control, burner management, drum level control, etc. • Has a working knowledge of all instruments associated with recovery boilersboilers. • Can quickly identify where all instrument/devices and supporting documents are.
The following may be considered when determining the above qualifications
Understands proper calibration and testing procedures for these instruments Has a working knowledge of electrical circuits and relay systems. Has a working knowledge of microelectronic control systems (DCS, PLCs, etc.) Has received basic E&I system “trade school’ type training. Has received training on specialized systems as developed by the vendor. Has participated in an in-house type apprenticeship program. Has a level of experience that is commensurate with the importance of recovery operations. Receives continuous and ongoing refresher training on existing systems as needed Receives immediate update training on any new devices or systems.
This E&I Qualifications statement is being submitted to the Executive Committee for their review and posting on the website for membership review. This statement will be incorporated into Recommended Good Practices definition section if accepted by the membership.
New Business:
American Forest & Paper Association (AF&PA) has developed “Recovery Boiler Functional Checks AF&PA Example Document Rev4” based on Instrumentation Recommended Good Practice - BLRBAC 3.13 Functional Testing described below BLRBAC 3.13 Functional testing of Recovery Boiler Safety Systems (RBSS). This Functional test documentation includes the function description being tested, the test method, the trip point or setting, test results including as found and as left and date tested.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.5 INSTRUMENTATION REPORT - (Cont.)
John Browning presented an update on the progress AF&PA has made in the development a formal written testing and checking program. The document they developed took into consideration:
-Mills to pre-determine maximum acceptable tolerance from trip point settings. -Field verifications should occur for each trip -ESP tests to be conducted as well as per mill Standard Operating Procedures. -All auxiliary fuel systems should be included (for example oil systems and gas systems) -The following is an example and not limited to the trips and permissive listed. Each facility should customize to their system. -Calibrations should also be conducted on major outages to ensure accuracy of instrumentation.
The “Functional Trip Checks” form they developed is a tool that we can all use to help improve our Recovery Boiler Safety programs. The tool incorporates the spirit of what the instrumentation document 3.13 is looking for. AF&PA has done a good job in follow-up on a BLRBAC Recommended Good Practice.
The executive committee has requested that the Instrumented Subcommittee review our Recommend Good Practices with NFPA85 as it applies to Boiler Purge, Precipitator Fire and Explosion Prevention. The review excluded parts of NFPA85 that do not apply to recovery boilers; i.e. pulverized coal, fluidized bed, single burner boilers, heat recovery steam generators and combustion turbine exhaust systems.
The evaluation looked at the scope of NFPA85 and even the recognized Recovery Boiler exclusion statement 1.1.3.” This code does not cover process heaters used in chemical and petroleum manufacture in which steam generation is incidental to the operation of a processing system.”
BLRBAC – recognizes – “The black liquor recovery boiler presents problems of operation and safety that far exceed those of the conventional power boiler. It is primarily a chemical recovery process unit in which the organic materials in the black liquor are burned while the sodium salt is reduced and drained as molten smelt from the furnace bottom. At the same time the heat released is used for steam generation. While most of the heat for this process is provided from burning the black liquor, additional heat from gas or oil-fired auxiliary fuel burners is needed to start up the unit, regulate the char bed, avoid blackouts, and to furnish additional steam. “
Working past that statement we looked at what it takes to properly use fossil fuels auxiliary burners verses the way BLRBAC Recommended Good Practices handle the burning of fossil fuels.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.5 INSTRUMENTATION REPORT - (Cont.)
BLRBAC established a Recommended Good Practice for “Safe Firing of Auxiliary Fuel in Black Liquor Recover Boilers”; this practice extensively covers the policies NFPA 85 as it applies to Aux Fossil Fuels in a Recovery Boiler. The Other Good Practices “Safe Firing of Black Liquor” “Waste Streams” along with “Fire Protection for DCE” cover the recognized basics of: Recovery boiler explosions which fall into four categories -- smelt water explosions, auxiliary fuel explosions, explosions from ignition of unburned gases from pyrolyzed black liquor, and dissolving tank explosions. These Items other than Aux Fuel are not covered by NFPA85, but are extensively by BLRBAC.
The BLRBAC “Good Practices” have help reduce the boiler explosions from Auxiliary Fuels with 1960’s (had10) through 1990’s (down to zero).
Conclusion: BLRBAC Recommended Good Practices are adequately covering and making changes to address issues as they are presented. At this time, we find no changes are needed to our documents as it applies to Boiler Purge, Precipitator Fire and Explosion Prevention.
The afternoon session had six members and five guests. Drum Level Measurement and protection is our next topic of discussion. This topic will be developed over the next few sessions the topic will include: Calibration, installation, defining different types of measurement devices used and the supporting calibration equations.
One final note: Rick Matarrese Subcommittee secretary is being replaced by Kevin Huelsbeck, Rick has been with a quite a few years doing a great job and providing insight to our many discussions we will miss him. But we are happy for him he is retiring looking for the “Good Life” we wish him well in his new adventures.
5.6 MATERIAL & WELDING REPORT - Mike Blair
The Materials and Welding Subcommittee met in Open Session on Monday morning, April 10, 2017.
The meeting was opened with a review of the BLRBAC Anti-Trust Statement.
Attendance 17 members and 14 guests attended the morning session.
New Business
Membership Changes:
Eric Moberg will become the FM Global Primary representative replacing Dave Lang.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.6 MATERIAL & WELDING REPORT - (Cont.)
New Members: Jeffery Forry from Glatfelter Chris Rawls (Primary) and Thomas Kapperman (Secondary) from Applied Technical Services Roger Carpenter (Primary), Kevin Flynn(Secondary) from PSF Industries
Document Development The subcommittee continued to review and edit Section 2.5 Plugging Tubes in Drums and Headers.
AFTERNOON SESSION The afternoon session of the Materials and Welding Subcommittee was open and was attended by 17 members and 15 guests.
The meeting was opened with a review of the BLRBAC Anti-Trust Statement
Old Business The meeting minutes from the Fall 2016 Subcommittee meeting were reviewed and accepted.
Presentation of Experience Chris Rawls of Applied Technical Service provided a presentation titled “Phase Array Ultrasonic vs. Computed Radiograph
Next Meeting Agenda Continue development of the document Section covering Plugging Tubes in Drums and Headers.
5.7 PERSONNEL SAFETY REPORT – Robert Zawistowski
The Personnel Safety Sub-committee met in an "open” session on Monday, April 10, 2017. There were 10 members (out of 16) plus 41 guests in attendance during the meeting.
Representation at our meeting by regular members and guests included original equipment manufacturer Andritz and Babcock & Wilcox. Equipment suppliers K-Patents, W.L. Gore & Associates. Representation from insurance and insurance service companies included FM-Global and Swiss Re. Operating company representation was present at this meeting with representatives from Expera, Georgia-Pacific, Glatfelter, Graphic Packaging, Grief, International Paper, SAPPI, International Paper, Packaging Corporation of America, Kapstone, Verso and WestRock. Consultant representation included George H. Bodman, 3S Team, Power Specialists Assoc., Inc, and RSI.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.7 PERSONNEL SAFETY REPORT - (Cont.)
The BLRBAC anti-trust statement was read.
The minutes of the last meeting were read.
The “Common Practices” document was discussed and edited. Photos that we received "permission to use" have been inserted into the document and we turned over the files to the Executive Committee for review and comment.
Section 2.10 in our main document with information pertaining to plugged hoppers was reviewed and edited. Changes were made to the language, based on good discussion points by the group. This document was turned over to the Executive Committee for review and comment.
A presentation, on development of a more smelt resistant material and protective garment design, specifically for spout decks was made by Jim Ellis and Paul Kiernan of W.L. Gore & Associates. This presentation contained excellent information and supporting data. As chairman of this subcommittee I am recommending a repeat of this presentation be made at a future BLRBAC meeting following the general meeting held on Wednesday morning.
John Stelling, PCA Tomahawk has stepped down from the subcommittee and Brian Filia of PCA Tomahawk who was the alternate representative is now the primary representative. Levi Harrington of PCA Tomahawk will be the new alternate representative from PCA Tomahawk. We thank John for his years of service. Joining the subcommittee, we welcome Zack Payne of Andritz and Gregory Burns of Kapstone.
In closing, we are always welcome to new committee members who can participate in any capacity even if you can only attend meeting intermittently. Simply let me know via e-mail at the address below you are interested and provide me with your contact information.
Bob Zawistowski Chairman – Personnel Safety Subcommittee [email protected]
5.8 PUBLICITY & NEWS REPORT – Matt Paine
No report was given at this time.
5.9 WASTE STREAMS REPORT – Paul Seefeld
On April 10, 2017, the Waste Streams Subcommittee met in a closed session at 9:00 AM. There were six of nine members present. In the afternoon session, there were six members and three guests present. At the start of both the morning and afternoon sessions the BLRBAC antitrust statement was reviewed. The October 2016 meeting’s minutes were reviewed and unanimously accepted.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.9 WASTE STREAMS REPORT - (Cont.)
Morning (Closed) Session: The subcommittee discussed the possibility of addressing the ESP testing procedure. We felt that if the ESP test simulates an MFT, then the waste streams systems will be verified under the MFT. Table 5, in chapter 5, shows the system operating and fail status.
Each section of the liquid waste streams document (Chapter 6) was reviewed and modified for clarity. This is part of our ongoing effort to review and update every chapter in the document. Most of the changes were for clarification. We did modify a paragraph in both the methanol and turpentine sections to address the safe venting of the waste gases.
If methanol is fed to a system that partially recirculates to an atmospheric tank, that tank should either be vented to the atmosphere at a safe elevation outside of the boiler building, or collected into an NCG system. An alternative is to use a pressurized storage tank that flashes back to the evaporators.
In addition, we did modify the ratio limit statement on both the methanol and turpentine streams to clarify the intent of the guidance. The change in the methanol verbiage is important as it allows the mills flexibility to run a higher flow of diluted methanol. The paragraph follows.
Methanol flow rate must be measured to maintain a safe black liquor to methanol ratio. A safe upper limit is 1% by volume of pure methanol due to its volatile nature and potential instability.
We reviewed the latest Finnish waste streams document and compared the liquid streams portion of the documents. Their version only addresses methanol and turpentine and does not specify a % feed ratio. They reference turpentine, but it is clear they meant red oil (a by-product of the stripping process).
Afternoon (Open) Session: In the afternoon, we reviewed our discussions regarding ESP testing and the modifications of the liquid waste sections with the guests. There were no concerns with the clarity or intent of the changes.
The afternoon subcommittee meeting adjourned at 1:28 PM.
MISC: Again, the subcommittee is down to nine members. We would like to get two more members, preferably from companies operating waste stream systems.
Any questions?
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.9 WASTE STREAMS REPORT - (Cont.)
JOHN GRAY: You have a previous change which we are ready to vote on. So yesterday Paul went over Section 4.2.3 and the changes there. Do we need to review those again? If you don’t mind, Paul…..
PAUL SEEFELD: So the dissolving tank then gas section is within the weak gas section, if you were here yesterday to hear the exciting presentation that I gave, we talked about this. Again, what we did was a lot of the information was found in little pieces and parts all over the section of the whole chapter. What we did was to take it all off in one little section of the chapter. The changes that we made were that we made it so that not only was the indirect contact, but also direct contact scrubbers, and then there was no change to the NCR interlocks. The big change is that we made were additions right on the bottom. The money slides were on the bottom. The biggest addition is this last bullet point here where it says the final low point fail safe designs prevent condensate from reaching the boiler. The design should include an interlock to divert the dissolving tank cast source out of the boiler and what that really is basically a low point loop that has something on the bottom of the loop or an indication on the loop that will drain at that bottom of the loop before it goes to the boiler. It is not a control valve. It will do it. It is like a dead-man switch. We wanted to get away from a control valve reliance on some sort of control valve at that point. But other than that, everything that is up there is already in the document, just not written quite as well.
JOHN GRAY: So these changes have been posted on the WEB site for over two months ahead of this meeting. Paul reviewed them yesterday in the Operation Problems Solving Session. Now he has reviewed them again. Everyone should be familiar at this point with the change. It would encourage membership to go out when you get the notification that there is something to review to review it and take advantage of the fact that it is sitting there and you can look at it at your leisure. We will continue to do these overviews of changes prior to voting, but it would streamline the process if you had already looked at it on the website. Can I get a motion and a second to accept these changes? Motion made and seconded and approved.
5.10 WATER TREATMENT REPORT – Tom Przybylski
Agenda - Morning BLRBAC Antitrust Statement/Review Action Item List
Review & Approve October Minutes
Membership Changes
Review Edits of the Condensate & Deaerator Sections
Resume Production of Chemical Cleaning Section
Agenda - Afternoon Continue Production of Chemical Cleaning Section
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
Item 1: BLRBAC Antitrust Policies/ Review Action Item List • Tom Przybylski called the meeting to order around 8:30 am and reviewed the BLRBAC Antitrust Policies with attendees. Tom Przybylski quickly reviewed the agenda. Item 2: Review Minutes from October Meeting • Tom Przybylski noted that the minutes from the fall were sent out for review; albeit last minute. A hard copy was distributed to the group in the morning session for their review. Jason Miller motioned to accept the minutes as written. Motion seconded by Ben Kupka and Jeff Fox and carried. Item 3: Membership Changes • Tom Przybylski went through the current membership list and with the group’s help modified the list to reflect changes in representation for current participating companies.
Item 4: Review Changes to Condensate & DA System Documents • Tom Przybylski started the proceedings by reviewing the deaerator systems with minor edits that he made to the document. I&C comment to be removed from section and then section to be submitted to Executive Committee. Norris inquired as to if all notes were incorporated into document from the previous meeting. Przybylski said they were. Jack Kelly asked question about weld inspection frequency. Przybylski said already included in ASME docs. Motion to submit to Executive Committee by Jeff Fox. Seconded by Norris and Jason Miller. Motion carried. • Condensate section up for review next. Przybylski made additional edits (definitions) to the edits made in the fall meeting which he reviewed with the group. Replaced drawing with a bypass loop with insertion into that particular loop. Condensate receiver definition updated. Expanded on definition for vacuum receivers. Norris questioned whether part of the definition should be separated pertaining to the vent portion of the definition. Przybylski went through the entire definition and Norris Johnston withdrew his question. • Dryer drainage systems definition added. • Condensate pump seals definition expanded upon. Group suggested modifying to include seal water heat exchanger to the existing definition for clarification. Przybylski suggested adding wording to include packing material to this definition. "Systems with pump packing can contaminate condensate from deterioration of the packing" sentence was added and approved by the group. • Przybylski asked if committee is good with changes to definitions and if drawing changes were acceptable. Changes were acceptable to all; Norris Johnston made a motion to accept. Seconded by Jeff Fox.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
• Craig Aderman brought up the lack of criteria in WTS documents for using "must". Believes that using must should be used for anything with RB safety. Przybylski went over group's definition for criteria for using "must" or "shall". Craig Aderman suggested that once documents are approved and posted we should go through all and make sure "musts" and "shalls" meet criteria. Item 5: Resume Production of Chemical Cleaning Section • Kelli Bastarache to go through and make current documents being edited for formatting consistency with all docs already submitted and published.
Introduction & Definitions - Cleaning Purpose • Norris Johnston questioned whether we should use "chemical solvent systems" in the cleaning purpose section. Group decided to change to "chemical solvent formulations". Caleb Sargent made statement that chemical cleaning does not minimize tube damage but is to remove deposits which will then, in turn, minimize tube wastage. Group decided to reword paragraph and state purpose of chemical cleaning (to remove deposits) and then the benefits of chemical cleaning. Norris Johnston made motion to accept purpose wording. Jason Miller seconded and motion carried.
Typical RB Cleaning Focus Areas • Norris Johnston made motion to accept purpose wording. Jason Miller seconded and motion carried. Superheater and composite tube circuity should come out of drawing and economizer added. Also, suggest making drawing a two-drum illustration. Ray Cassel suggested that simpler is better; all configurations cannot be covered. Jason Miller suggested adding (s) to any circuits where there could be more (i.e., drum(s)). • Mike Bayes asked whether illustration is necessary for this particular section. Norris Johnston made motion to delete diagram to avoid confusion to end users. Jason Miller and Jeff Fox seconded. Illustration deleted. Text part of "focus area" revised to "are the wetted surfaces of a boiler, including drums, tubes, and headers. Motion made by Ben Kupka to approve focus areas. Seconded by Norris Johnston and motion carried.
Definitions • Alkaline Boilout - On review nobody like the wording from the prior meeting. Changed definition to remove organics wording and add "residue (rolling compounds, preservatives, and cutting oils) and debris from wetted surfaces following new construction or refurbishment". Motion to approve made by Jason Miller and seconded by Susan Childress. Motion carried. • Passivation - good.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
• Neutralization - Some discussion on prior definition. Some confusion as to whether neutralization applies to boiler but should it include waste streams as well. Group decided to add a second sentence to include chemical cleaning waste streams to the definition. • DWD - changed "means of measuring" to "A measure of the amount of deposit removed from the wetted surface of a tube sample over a given area (usually . . .)."
Break • Deposit Elemental Analysis - Discussion as to what to include in definition. Bob Bartholomew suggested via email SEM/EDS and XRD language be added into definition. Group agreed to not include the methods of performing elemental analysis into this definition; then decided to define deposits separately. Group decided to take elemental out of the definition title and just call it "deposit analysis" and add inorganic and organic components as opposed to "elements" in the definition itself. Group also decided to add LOI (loss on ignition) definition to this section. Ken Hansen asked as to why the methods of elemental analysis were removed . . . all agreed that the definition section is not the place for the methods to be stated. Motion by Tom Przybylski to accept deposit analysis as written and seconded by Mike Bayse. • Loss on Ignition (LOI) - Definition added to section (Bob Bartholomew suggested definition removed as methods are not going to be included in document) and approved by the group. • Solvent Efficacy Test (Dissolution Test) - Accepted as written. • Chelant Cleaning - Minor changes of definition as written . . . added "metallic components" of a deposit to the definition. Group also decided to change "sequestering" to "solubilizing". Definition then accepted as written. • Acid Cleaning - Accepted as written. • Magnetite - Modified definition so to avoid confusion for the end user when talking about the magnetite film and the importance of it. Questions were brought up as to if "iron oxides" should be used instead of having a standalone definition of magnetite. Group agreed to change the magnetite to "iron oxide" and then state the two primary iron oxide forms in boiler deposits (magnetite and hematite). Definition then accepted as written. • Water Block - Accepted as written. • Air Bladders - Accepted as written. • Backfilling/Forward Filling - Changed definition to say, "Filling a boiler component" as opposed to "Filling an area" and added "properly treated" water instead of stating just water and to "establish a water block". Group then discussed the various scenarios used for backfilling/forward filling the boiler; added backfilling and forward filling statement. Definition then accepted as written.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
• Circulation - Made minor change to add "boiler circuits to be cleaned". Definition then accepted as written. • Operational & Preoperational Chemical Cleaning - Discussion as to whether these two definitions needed to be included seeing as how they are not used anywhere else in the document. Group decided to leave definitions in document and made minor edits to preoperational chemical cleaning definition; which the led to adding mill scale definition to this section. • Mill Scale - Definition added and accepted as written. • Inhibitor - Accepted as written.
Guidelines & Monitoring Tools • Opening paragraph - Section will need to be shifted to make it consistent with documents already submitted (monitoring, inspection). Kelli Bastarache to do over break so this section can be reviewed after lunch.
2.0 Cleaning Determination Protocols • Changed 2.0 heading to "Determining When to Chemically Clean". • Opening paragraph - Accepted as written. • Much discussion ensued to placement of subsections and whether there was a lot of redundancy in the subsequent sections.
2.1.1 Time Intervals Previous History of Cleaning • Evaluate history of cleaning -
2.1.2 Review Major Rebuilds Modifications • Minor edits made to opening paragraph which was then accepted as written. Group decided to go back to the outline and see the layout of this particular section; which is not consistent with other sections.
Lunch Break - Tom Przybylski adjourned the meeting for a lunch break, to reconvene at 1:00 p.m. • Jack Kelly reviewed a paper submitted to NACE by Catherine Noble (which was also distributed to the subcommittee for their review). Jack Kelly discussed economizer pitting and has proposed to the Executive Committee that a co-committee be formed to discuss economizer corrosion, FAC, and deposit corrosion. Email to be sent out to subcommittee to see if there is interest in any WTSC members joining such a committee.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
• Tom Przybylski reviewed the BLRBAC anti-trust statement again when meeting reconvened at 1:00 p.m.
Item 6: Continue Production of Chemical Cleaning Section 2.0 Determining When to Chemically Clean • Kelli Bastarache moved guidelines and monitoring tools to end of Section 2.0 during the lunch break. • Przybylski brought up the original outline for review. Also, discussed that this section will not follow sections that have already been produced and published as it is a totally different animal and does not fit into the same structure.
2.1.1 Time Intervals Previous History of Cleaning • Evaluate Previous Cleanings - statement accepted as written. • When Done/Frequency History - Przybylski asked if this subheading is necessary . . . struggling as to how this fits into section (should it be included in another section??). Jason Miller suggested adding it in some form to the "Evaluate Previous Cleanings" subheadings. Group decided to just add making a note of how often the unit has been cleaned under the "When Done" subheading. • What Removed/Recent & Trends - Accepted as written with minor change (changed recipes to formulations). Title of subheading also changed to "What Removed". Group then decided to change text to reference reviewing the history of composite drain sample analysis from past cleanings. A definition of composite drain sample analysis was then added to the definition section after much discussion. Discussion then turned to suspended solids . . . oy vey, which is not part of the definition. Definition of composite drain sample accepted. Jack Kelly asked how you handle heavy deposits in the steam drum and floor tubes. Several from the group stated these deposits are vacuumed, high pressure water used to wash, etc. RMIS stated these deposits are cleared out before chemical cleaning starts as these are not adhered and are a waste of solvent if not taken out beforehand. • Quantitative & Qualitative Data - Minor edits made and paragraph accepted as written. • Water Quality Changes & Upsets - Group edited paragraph to make it less specific as to condensate polishers or magnetic filter. Norris Johnston suggested "water chemistry changes" be changed to "feedwater chemistry changes" . . . Susan Childress then suggested that it be changed to "feedwater quality changes" so as to avoid confusion for the end users. Paragraph then accepted as written.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
2.1.2 Review Major Rebuilds/Modifications • Przybylski asked if this section should be moved to another location in document. It was decided by the group that some of paragraphs apply to this particular section. Przybylski determined text existed later on in the document and it was removed from here. The remainder of the subsection was accepted as written.
2.1.3 Operating History Since the Last Cleaning • Question again raised if this is redundant information. Group decided to 86 this section and relocate bullet points to "Water Quality Changes & Upsets" section.
2.1.4 Tube Condition History • Same question . . . is this section redundant??? Bullet points moved up into "Quantitative & Qualitative Data" subheading, along with lead in paragraphs prior to bullets. This entire document to be formatted by Kelli Bastarache prior to the fall session and the next edit. This remaining portion of this paragraph were then deleted. • Fred Call asked if there should be something in here about if the underlying condition of the tube is considered when deciding whether it should be cleaned or not based on that should be in this document. RMIS says a risk assessment should be done prior to. This statement was then added to Section 2.2 to be discussed during the next session. • "Phosphate hideout" bullet point added to "Water Quality Changes & Upsets" in Section 2.1.1 after suggestion from Ken Hansen. Definition of phosphate hideout was then added to the document. Definition accepted as written.
2.2 Determine Current Conditions
2.2.1 Ability of Tubes to Withstand a Chemical Cleaning • Discussion as to what to include for current tube criteria to determine when to replace tubes vs. chemical cleaning. Group decided to add bullet points 1st and go back and add lead in paragraph.
2.2.2 Confirm Pressure-Part Replacement Plans • Most of initial paragraph relocated to other sections in the document. Remaining paragraph accepted as written.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
2.3 Cleaning Criteria • Przybylski suggested this section be moved to guidelines and monitoring tools section. Group agreed. Przybylski suggested we revisit this section during the next session. Reviewed "Time-Based Criteria" in Section 2.3.1. This part of Section 2.3.1 accepted as written. Much of the narrative included in this section under the "Data-Based Criteria" removed and bullet points left (DWD, excursions, tube failures, etc.) since they already are defined in the definitions section.
2.5.1 Risk Assessment & Chemical Cleaning Types • Group agreed to remove the chemistry information from this section and just leave info contained in the table. • Group agreed that effectiveness table included in the existing doc is good information. RMIS and Susan Childress suggested that a disclaimer statement be included that this information is theoretical only and should NOT be used in place of a solvent efficacy test. Lead in statement added to the paragraph stating such.
Guideline(s) & Monitoring Tools • Guideline #1 - Minor changes made to existing wording. Guideline then accepted as written. • Guideline #2 - Guideline accepted as written. • Guideline #3 - Guideline accepted as written • Guideline #4 - Minor changes made to existing wording to include consulting appropriate SMEs to determine when an economizer should be chemically cleaned. Guideline then accepted as written. • Guideline #5 - Minor changes to state metallurgy of sweetwater condensers should be reviewed to ensure compatibility with proposed cleaning solvents. Guideline accepted as written. • Monitoring Tool #1 - Discussion on DWD values to determine when to chemically clean. Minor edits made so it reflects that the planning stages of a chemical clean should be put into place when your DWD hits certain limits. Do we want to include B&W #'s in here . . . do we need permission?? . . . B&W #'s based on scrape method . . . what about glass bead blasting??? Need to add disclaimer to document from B&W. We will revisit monitoring tools during the fall session.
Adjournment • There being no further new business, Norris Johnston motioned to adjourn the meeting. Jason Miller seconded and motion passed unanimously. Meeting adjourned at 3:25 p.m.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
• Action Items Updated April 10, 2017 Action Owner Due Date Confirm final changes to condensate section and send Team Done out to committee members for a final review. Confirm final changes to deaerator section and send out Team Done to committee members for a final review. Remove superheater circuitry from chemical cleaning Sam Done drawing and make other changes Check to see if the term steam blows is defined in the Team superheater section. If not, put it in. Confirm consistency of DWD definition across all documents Research preferred method for determining DWD. Tom or designee Share results with committee at next meeting, and try to select a recommended method Contact metallurgists regarding trends in finding copper Buck Dunton Before 2017 Fall in DWD analysis and its importance (in pulp and paper meeting industry) Group to decide if feedwater heater deployment should Team Discuss as addendum be added to the scope of work of the documents under section is being development. Large variation in design, location, use of developed live steam vs. recovered heat, etc. Add “pretreatment” and “external treatment” for TBD To be done towards glossary for drum tube circuitry section end of development cycle Add definition of “critical” condensate stream to TBD To be done towards glossary (stream that contains a contaminant that could end of development shut down the recovery boiler). Possibly define “major cycle condensate stream” in glossary depending upon further discussion Include diagram and narrative definition for “double Team To be done towards block and bleed” in glossary to be developed end of development cycle Review finished drafts of documentation to identify any Team To be done towards conflict with TAPPI Tip data. Bring any such instances end of development to subcommittee for discussion/action. cycle Address dryer drainage oxygen profiling as Team Tabled until fall 2017 troubleshooting tool. Some data added--will be reconsidered via reviews etc.
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5. SUBCOMMITTEE REPORTS - (Cont.) 5.10 WATER TREATMENT REPORT - (Cont.)
• Retired Items Create deaerator circuitry showing basic Tom and Sam DONE configuration Add drawing to deaerator section and submit what Tom and Sam DONE has been assembled to date to subcommittee members for review and comment Revise Drawing of Condensate Sampling System per Tom and Sam DONE comments from team. Add sample cooler and valve in drain leg. Also, add dump and divert valve “system,” and caption “recommended configuration for condensate sampling of a condensate stream with the potential for liquor contamination. Add drawing to this section to illustrate the configurations that are recommended Investigate whether there are mentions of soluble vs. DONE particulate iron testing in any other of the completed documents, and consider discussion of the subject in the condensate section. Finish revisions for condensate section confirmed in Tom and Kelli DONE this meeting, and send out entire section to subcommittee for review before next meeting Show block valve in advance of sample cooler in Sam & Michael DONE “open” position. Move block valve to discharge side W. of sample cooler. Contact members that have missed meetings to see if Tom and Kelli Before 2017 Fall meeting they are still wanting to continue: Claude Gauthier/no longer active Tom will check on others
6. AMERICAN FOREST & PAPER ASOCIATION RECOVERY BOILER REPORT – Wayne Grilliot (See Appendix II – Slide Presentation)
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7. TAPPI STEAM & POWER/ENERGY MANAGEMENT REPORT – Danny Tentra
Good morning! My name is Danny Tandra. I’m the new chairperson for TAPPI Energy Recovery Recourse Committee replacing Chris Jackson following his two-year term which ended last year. This TAPPI Committee previously known as the Steam & Power Energy Management Committee, but last year we changed it to Energy Recovery Recourse Committee. This committee is supported by TAPPI Engineering Division. Our main purpose is to collect this meeting information useful to pulp and paper industry practitioner that is not available elsewhere and our primary interest, of course, is in recovery power island and recourse area.
There is a change in the committee officer; myself versus chairperson Stan Tandra for Power Group. Technical Program Chair, Peter Tantrum with Pfitnier Analyzer and our Membership Chair is Justin Beck. He is with Clearwater.
There are four subcommittees within this committee first is Recovery and Power Boilers led by Bently Sherlock and Energy Management led by Ben Bender. Water Treatment led by Jim Graham and this is a relatively new subcommittee, Lime Kilns led by Peter Gerawk.
There is a new TAPPI TIP. TIP is technically an information paper being proposed from EFNPA Recovery Boiler or in the subcommittee meeting last February. That was a soot blower upgrade project guidelines to avoid excessive movement and damage to the boiler tubes. We are going to talk about forming a working group right after this BLRBAC meeting.
We also updated the draft for new committee guidelines that was released. This is to replace and update the old guidelines for the committee.
We are going to have a sitting committee meeting this morning and main committee starting at 1:30 p.m. in Lombard I which is the room just across this room. We are going to have a Technical Presentation by Tantrum and the title is “Reducing Risk of Smelt Dissolving Tank Explosion of Dissolving Tank TTA Control.” I am inviting everybody to participate in that Main Committee meeting. No report was given at this meeting.
8. WESTERN CANADA BLRBAC REPORT – Rinus Jellema
No report was given at this meeting.
9. ACTIVITIES OUTSIDE NORTH AMERICA REPORTS
No report was given at this meeting.
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10. OPERATING PROBLEMS SESSION REPORT – David Slagel
The operating problem session was held the afternoon of April 11th with large membership attendance.
Eight submitted questionnaires were reviewed during the session. A wide variety of topics were covered with good audience participation. Safe operation for dissolving tanks was a focus topic with specific interest in prevention of dissolving tank explosions. Functional testing was also a highly-discussed topic.
This concludes the operating problem session report.
I would like to remind everyone before we close the main committee meeting that we have two Technical presentations immediately following this meeting. The first is a presentation by Troy Demmer of Gecko Robotics entitled “Safer, Faster, and Cost-efficient Boiler Inspections” followed by a presentation by Tim Carlier of Integrated Test & Measurement entitled “Superheater Overheat Protection (SHOP) – Avoiding Short Term Overheat Failures of Recovery Boiler Superheater Tubes”.
CHAIRMAN: That concludes our Main Committee Meeting this morning. Thank you all for your attendance and your time away from home. Just a reminder as Dave mentioned, we do have two Technical Presentations which will immediately follow the close of this meeting. We hope you will stick around for a few minutes for those. Our next meeting will be October 2, 3 & 4, 2017. I'll now entertain a motion to close the Main Committee business meeting. Second? All in favor? The Main Committee Meeting is now closed. Safe travel everyone!
NEXT MEETING:
BLRBAC’S 55th Anniversary Crowne Plaza Hotel, Atlanta, GA October 2, 3 & 4, 2017
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APPENDIX I INCIDENT LIST
NO LEAK SPRING 2017-01 Classification: No Leak Location: WestRock, Fernandina Beach, FL Unit: RB4, 1970, B&W, PR-126, 2 Drum, Large Economizer Unit Size: 3MM lb ds/day; 492,000 lb/hr steam at 900 psig, 825°F, 875 psig design Incident Date: February 27, 2017 Downtime hrs, leak/total 75 hrs liq to liq ESP? Yes Leak/Incident Loc: No Leak Found How discovered: Operator round Wash adjacent tube: N/A Root cause: N/A Leak detection: Yes – No leak identified Bed cooling enhance: Yes Last full inspection: November 2016 Sequence of events: While making his final boiler round, the Recovery Boiler Operator noticed a change in the salt cake in the boiler bank hopper under the mud drum. The operator saw something that appeared to be liquid on the hopper wall. He called the shift supervisor to aid in the investigation. The shift supervisor heard rumbling on the 6 1/2th floor (bottom of boiler bank hopper elevation). Both employees evacuated the boiler and called for an emergency shutdown to be performed. Isolated the boiler building for 12 hours. Moderate size bed was cooled by Southland. Thermal probe reading of less than 400 F on bed before waterwash was started. Hydro showed no leaks. Repair procedure: N/A Future prevention: N/A
NO LEAK Spring 2017-02 Classification: No Leak Location: International Paper, Riegelwood, NC Unit: RB4, Originally CE in 1974, Modified by Tampella in 1991, Contract #23771, 2 Drum, Cascade type DCE Unit Size: 2.4 MM lb ds/day; 326,000 lb/hr steam at 600 psig, 800°F, 1000 psig design (MAWP) Incident Date: January 9, 2017 1:29 pm Downtime hrs, leak/total: 39 hours 50 minutes ESP? YES Leak/Incident Loc: No Leak How discovered: Indications on DCS Wash adjacent tube: NA Root cause: Cascade fire deluge system going off, sending firewater to nozzles in Cascade ductwork up to PPT. The diaphragm on the PSOV valve for the firewater deluge system had developed a rupture and allowed firewater to go out through the nozzles on the Fire suppression system on the Cascade. Leak detection: Mass Balance System Bed cooling enhance: None Needed Last full inspection: Jan/Feb 2016 Sequence of events: Recovery Operator noticed changes on the DCS indicating a possible Generator and/or Economizer leak. Opacity went up and ID fan speed maxed out between 12:45 and 1:00 Meeting Minutes BLRBAC April 12, 2017 Page 70 of 116
pm. Firing solids started to drop and both stacks had a large plume of water vapor coming out. When they started to put oil in and take liquor out there was some feedwater steam flow separation that indicated a possible tube leak. Unit was ESP’d at 1:29 pm. Repair procedure: NA Future prevention: Replace this PSOV valve annually.
ECONOMIZER SPRING 2017– 03 Classification: Noncritical Location: Georgia Pacific ARC, Purdue Hill, AL Unit: #8 RB, 1991, B&W, PR-216, 1-drum, large economizer (mini-header design) Unit Size: 6.2 MM lb ds/day; 796,200 lb/hr steam at 1225 psig, 900°F, 1500 psig design (MAWP) Incident Date: April 22, 2015 Downtime hrs, leak/total ESP? No Leak/Incident Loc: #73 supply pipe to header weld, Econ II (cold) @190’ 3” elev., 105’ 3” above floor How discovered: Operator making rounds found damp ash in the hopper Wash adjacent tube: Yes, washed a hole in #74 supply pipe Root cause: Stress/fatigue cracking. Missing side-to-side restraints and expansion interference at header penetration through the hopper. Leak detection: Yes Bed cooling enhance: N/A Last full inspection: Sept., 2014 Sequence of events: Operator detected damp ash in econ hopper on 4/22/15. Another boiler annual outage was in progress so this boiler remained on line until 5/18/15. Repair procedure: Ground out crack and weld repaired Future prevention: The feedwater header penetrations through the casing will be replaced with an OEM designed slip joint to provide the vertical, horizontal, and axial movement. Hand cuffs are planned to be installed between the bottle headers in groups of 4 to 5.
ECONOMIZER SPRING 2017-04 Classification: Noncritical Location: Georgia Pacific, Alabama River Cellulose, Perdue Hill, AL Unit: RB7, 1978, B&W, PR-0192, 2 drum, Large Economizer, Sloped floor to rear Unit Size: 5.4 MM lb ds/day; 697,100 lb/hr steam at 1250 psig, 900°F, 1425 psig design (MAWP) Incident Date: January 1, 2016 Downtime hrs, leak/total 48 ESP? No Leak/Incident Loc: Economizer outlet facing outlet duct on 13th tube from the right wall, 1” circular crack on the bend of an internal loop How discovered: Operator Rounds Wash adjacent tube: No Root cause: Economizer is at end of life Leak detection: No Bed cooling enhance: No Last full inspection: April 2015 Sequence of events: During a walk down an operator heard a noise. He and the crew leader inserted a board into the economizer hopper, and removed it to check for moisture. The board seemed to have some moisture. The decision was made to run with the leak. The #2 precipitator drag chain bogged down, and quit running. While trying to isolate the precipitator the furnace master fuel Meeting Minutes BLRBAC April 12, 2017 Page 71 of 116
tripped on 1/1/16 10:50 AM. While the furnace was down the leak was inspected, and was worse than expected. The furnace was brought back online to allow the mill to take an orderly shutdown to repair the leak. Repair procedure: Pad Weld Future prevention: Inspected similar locations during the next outage. Capital plan to replace the economizer in the future
ECONOMIZER Spring 2017-05 Classification: Noncritical Location: Georgia Pacific, Cedar Springs, GA Unit: RB2, 1990, B&W, PR-214, sloped floor, single drum, large econ Unit Size: 2.5 MM lb ds/day; 397,000 lb/hr steam at 850 psig, 880°F, 1070 MAWP Incident Date: January 4, 2017 Downtime hrs,leak/total 66 hours total ESP? No Leak/Incident Loc: Tube-to-header weld in economizer, the weld was cracked ½ way around the tube. The leak was located on 9th floor, north wall on the 1st economizer pendant tube #7 adjacent to IK 35/36 lane. Upper bottle header tube-to-header fillet weld. How discovered: Operator walkdown Wash adjacent tube: No Root cause: SAC, Stress/fatigue possibly from side to side movement or swaying of the pendant Leak detection: RBLI Bed cooling enhanc No Last full inspection: April 2015 Sequence of events: Operator performing routine walk-down identified water in the economizer hopper. Operator immediately communicated observations to the recovery boiler operator and crew leader. The RBLI data also indicated a leak in the boiler. Because of the location of the leak the decision was made to perform a controlled shutdown of the boiler. The unit was locked out and contractor installed a Dutchman. Similar tube-to-header welds in the IK lane where the leak occurred were thoroughly inspected, both visually and using a dye penetrant test prior to bringing the boiler back to operation. No other issues were found as a result of this testing. Repair procedure: Installed dutchman Future prevention:
ECONOMIZER SPRING 2017-06 Classification: Critical #874 Location: WestRock La Tuque, Quebec, Canada Unit: RB#4, 1966, Combustion Engineering, CA 64134, 2drum, cascade Unit Size: 1.6 MM lb ds/day; 178,000 lb/hr steam at 320 psig, 800°F, 725 psig design (MAWP) Incident Date: October 6, 2016, Downtime hrs, leak/total 12hrs 41hrs ESP? Yes Leak/Incident Loc: Economizer bend top collector How discovered: Assistant operator walkdown Wash adjacent tube: no Root cause: Tube thinned from entry of cold air through leak in casing.
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Leak detection: no Bed cooling enhance: no Last full inspection: November 2015 Sequence of events: 8:30 Assistant operator saw water coming from top right side of economizer casing accumulated on buck stay. Advised team leader and operator. 8:45 Team leader verified if there was leak called operator to confirm operator actuated the ESP. Repair procedure: Replaced thinned bend Future prevention: Economized planned for replacement
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ECONOMIZER SPRING 2017-07 Classification: Noncritical Location: Paper Excellence, Skookumchuck BC Unit: CE/ABB, CA91105, 1993, Single drum, 2 large economizers Unit Size: 3.4 MM lb ds/day; 463,000 lb/hr steam at 630 psig, 750°F, 900 psig design (MAWP) Incident Date: June 26, 2016 Downtime hrs, leak/total: 34hr 15min total ESP? No Leak/Incident Loc: 12ft up from the bottom of the 1st economizer on 74th row from LH side on tube #3 How discovered: During walk down of the boiler Wash adjacent tube: No Root cause: Internal pitting and scale deposits from years of operation during which we had occasional feed water excursions during startups. Economizer is 23 years old. With pitting that we have going on, and off liquor and changing rates is also contributing. Leak detection: No found on walk down and low boiler PO4 Bed cooling enhanc No Last full inspection: June 2016 Sequence of events: On June 23/16 at 1:00pm it was reported that water was coming from the Recovery Boiler 1st economizer hopper. Plan was developed to take the mill down and do planned maintenance while making the Recovery Boiler tube leak repair on June 26/16
- June 26/16 at 5:45pm Recovery Boiler off liquor and burning the bed out. Note: we did not have much bed in the boiler so tripped the boiler on low steam flow with no auxiliary fuel, liquor tripped out when it should have at less than 30% MCR - June 27 11:00am boiler entered to locate the leak. Leak was found to be about 12ft up from the bottom of the economizer and was on the 74th tube counting from the left side on tube row 3 of the rear bank of tubes. The leak was difficult to reach as it was on the back side of the tube so it was decided that we would just plug this tube off. - 5:30 pm repairs complete - 6:30pm filling the boiler - 7:15pm started the hydro test. - 7:45 pm boiler to 600psig inspecting tube plug welds. - 7:50 pm hydro complete. Removing CSE and gas blinds. - 9:30 pm fire in RB following start up curve. - June 28/16 1:30am boiler up to pressure and on line. - 4:00 am Recovery Boiler on liquor.
This outage was 34hrs 15min from liquor off to liquor on. Repair procedure: Since no access to leak tube section was removed at the top and bottom of the tube with the leak. Tube stub cleaned and certified plug installed, 3 passes of 7018 weld electrode applied. Final welds penetrate tested and found good. Future prevention: We know the cause and we have had inline oxygen analyzer on line from deaerator to feed water pumps for 10 years and do manual O2 tests to verify. We moved the inline O2 analyzer in 2015 to after the feed water pumps. We have also been doing Millipore tests on the water coming out of the 1st economizer to get a feel of tube wastage but this has been looking good. We are looking at the cost of replacing the 1st economizer. Plan is to replace 1st economizer in 2017.
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ECONOMIZER SPRING 2017– 08 Classification: Noncritical Location: Paper Excellence, Skookumchuck BC Unit: CE/ABB, CA91105, 1993, Single drum, 2 large economizers Unit Size: 3.4 MM lb ds/day; 463,000 lb/hr steam at 630 psig, 750°F, 900 psig design (MAWP) Incident Date: July 25, 2016 Downtime hrs, leak/total: 34HRS/ total 37hrs ESP? No Leak/Incident Loc: Internal pitting, pinhole leak. The original leak was on the 1st economizer row 83 from the east side on tube #8 about 3.5ft up from bottom economizer header. Second leak was found during hydro test and was on row 34 from east side on tube #1 about 11ft up from bottom header. How discovered: No found on walk down Wash adjacent tube: No Root cause: Internal pitting. After tube sample was taken during the June 2015 mill shut down the root cause was found to be internal pitting. Contributing factors that cause the leaks now are fast rate changes when boiler has to slow down for mill issues. This cycles the economizer temperature. Leak detection: No Bed cooling enhanc No Last full inspection: June 2016 Sequence of events: On July 20/16 it was reported that water was coming from the Recovery Boiler 1st economizer hopper. At the time the Recovery Boiler was at 105% firing rate. Decision was made to operate the RB and limit the steam flow to 463Klb/hr (MCR) and do extra rounds to observe the hopper for any excess water and do extra PO4 tests and organize for a mill outage for July 25/16 July 25/16 at 6:30pm liquor out of the boiler and burning the bed down. - July 25/16 at 9:45pm gas out of Recovery Boiler and boiler now cooling. While cooling leak could be noticed on the east side. - July 26/16 at 10:00am boiler entered to locate the leak. Leak was found to be coming from east side which was 83 rows in from the left hand side on tube #8 about 3.5ft up from the bottom header. Tube #8 is the closest to the boiler outlet ducting so to make repairs we entered the flue gas outlet manway and used rope ladder to get to where leak was then built staging so boiler makers could safely get to the leak and have a work platform. - 4:300pm leak repair complete unlocking water side to do hydro test. - 6:10pm started hydro test to 630psig - 8:50pm hydro complete. Weld repair was found to be tight but while doing the hydro test another leak was found on row 34 from left hand side on tube #1 about 11ft up from bottom inlet header. Staging had to be put up via the bottom of the 2nd economizer hopper up to the leak. Leak was marked but boiler makers were timing out so went home. - July 27/16 6:00am repairs started on 2nd leak. - 8:00am repair complete filling boiler for hydro test. - 10:30am hydro test to 630psig and repair found to be tight, no other leaks found. - 11:00am removing staging and fire side CSE (confined space entry) and water side multipoint. - 3:15pm fire in RB following start up curve. - 10:30pm boiler on line - July 28/16 2:00am on liquor Note: was late getting liquor in due to 1st economizer hopper being plugged. This outage was 55.5hrs from liquor off to liquor on. Repair procedure: Thickness tests were done on the tubes around the leak site for any thinning, none were detected. Pin hole leaks were ground clean and 7018 used for fill and cap. Future prevention: During boiler startups we are ensuring we have added oxygen scavenger for the startup/ hydro water. We are ensuring that we have a water flow through the economizer during startups and when making boiler firing rate changes we are doing them in small increments 5klb/hr solids fired every 15min. We will be replacing the economizer in 2017 during major mill shut down
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ECONOMIZER SPRING 2017– 09 Classification: Noncritical Location: Paper Excellence, Skookumchuck BC Unit: CE/ABB, CA91105, 1993, Single drum, 2 large economizers Unit Size: 3.4 MM lb ds/day; 463,000 lb/hr steam at 630 psig, 750°F, 900 psig design (MAWP) Incident Date: October 4, 2016 Downtime hrs, leak/total: 34HRS/ total 37hrs ESP? No Leak/Incident Loc: The leaks were found on the bottom of 1st economizer 12th row in from east side on tube #1 approx 1.5ft up from header and 18th row in from east side tube #8 approx 14ft up from header How discovered: During walk down of the boiler when RB was at reduced rate then off liquor Evaporator issue Wash adjacent tube: No Root cause: Internal pitting Leak detection: No found on walk down Bed cooling enhanc No Last full inspection: June 2016 Sequence of events: On September 25/16 it was reported that water was coming from the Recovery Boiler 1st economizer hopper. This was found when the Recovery Boiler went off liquor as the Evaporators were having issues with making product solids and having problems getting full liquor flow through the 1st effect. Plan was already in place for a white side area shut down on Oct 5th so decision was made to operate the RB and limit the steam flow to 463Klb/hr (MCR) and do extra rounds to observe the hopper for any excess water and do extra PO4 tests and if out of line then boiler would be taken down earlier. -Oct 4/16 at 5:30pm started taking liquor out of the boiler and burning the bed down. - Oct 4/16 at 9:00pm RB off liquor at 9:30pm gas out of Recovery Boiler and boiler now cooling. While cooling two leaks could be noticed both on the east side. - Oct 5/16 at 9:00am boiler entered to locate the second leak as the first leak could be seen from the manway door and was 12 tubes in from the east side on tube #1. Went into east side bottom north manway and could see water running down the casing at around the teepee baffle area. Went to next manway up on next floor west side and walked across the teepee baffle and found the leak at 71st tube from the west side (18) in from the east side just at the bottom of the teepee baffle which was just under the buckstay. - 10:00am setting up to remove the gladding from the rear casing to get at the 2nd leak as leak could be repaired from outside the boiler once casing was removed at the tube leak location. Repairs started with removing boiler casing. Draining the boiler and locking out the water side for tube leak repairs. - 5:40pm leak repairs complete unlocking water side to do hydro test. Maintenance welding casing back in place. - 6:30pm filling the boiler - 7:00pm boiler full. - 7:20pm started the hydro test. - 8:00pm hydro complete. Weld repairs good and no other leaks found. Waiting for casing to be finished welded back in place. - 11:30pm casing welded back in place removing fire side CSE - Oct 6 12:30am fire in RB following start up curve. - 6:00am boiler up to pressure and on line. - 10:00am Recovery Boiler on liquor. Note: This took a little longer as the 1st economizer hopper had to be washed out to free up the conveyor and the east nozzle pump suction valve was frozen up with solid liquor. At 9:00am the 1st economizer conveyor was freed up and we went to use the west nozzle pump but need electrician to reset the VFD. This outage was 37hrs from liquor off to liquor on. Repair procedure: Thickness tests were done on the tubes around the leak site for any thinning, none were detected. Pin hole leaks were ground clean and 7018 used for fill and cap. Future prevention: During boiler startups we are ensuring we have added oxygen scavenger for the startup/ hydro water. We are ensuring that we have a water flow through the economizer during startups and when making boiler firing rate changes we are doing them in small increments 5klb/hr solids fired every 15min. We will be replacing the economizer in 2017 during major mill shut down. Meeting Minutes BLRBAC April 12, 2017 Page 76 of 116
ECONOMIZER SPRING 2017-10 Classification: Critical #875 Location: International Paper, Eastover, SC Unit: RB1, 1983, CE, 31381 V2RE, 2 Drum, Long Flow Economizer Unit Size: 2.3 MM lb ds/day; 348,000 lb/hr steam at 1500 psig, 900°F, 1670 psig design (MAWP) Incident Date: September 11, 2016 Downtime hrs, leak/total 79 hrs shutdown to liquor ESP? NO Leak/Incident Loc: Economizer tube to upper header weld crack How discovered: Operator walkdowns Wash adjacent tube: Yes, one Root cause: Fatigue bending, undersized weld Leak detection: Yes Bed cooling enhance: No Last full inspection: April 2016 Sequence of events: During the morning 9/11/16 walkdown, operator noticed water droplets at a SB opening. The operator did not hear any loud noises, hissing or see vapor or steam in the area. At this time, the leak detection system was not in alarm. (Note: After further review, the leak detection system had indicated a problem.) The operator thought the SB steam valve was leaking by so he closed the SB manual steam isolation valve. Later that afternoon, the operators went back to the SB opening and saw more water droplets. A sample of the water was obtained to check for boiler chemicals and some observation doors were opened. At this time the operators could see steam and vapor in the top of the front economizer section. At approximately 20:00 9/11/16, a controlled shutdown of #1 RB was initiated to further inspect the boiler. At approximately 01:00 on 9/12/16 all liquor was out of the boiler and the boiler was off line at approximately 02:00 9/12/16. Repair procedure: Plugged tubes Future prevention: Increased NDT inspections, For earlier detection: Leak Detection System Refresher training
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ECONOMIZER SPRING 2017-11 Classification: Noncritical Location: WestRock Mahrt, Cottonton, AL Unit: RB2, 1990, Tampella, Contr #337, single drum, large econ, no DCE Unit Size: 3.75 MM lb ds/day; 561,800 lb/hr steam at 890 psig, 825°F, 1,100 psig design (MAWP) Incident Date: October 10, 2016 Downtime hrs, leak/total Approx. 32 hours / 332 (going into maintenance outage) ESP? Yes Leak/Incident Loc: Economizer, crack How discovered: Routine operator rounds Wash adjacent tube: No Root cause: Design of tube/fin fabrication, SAC. Economizer tubes have fins on the front and back that run from the bend at the bottom to about 1” from the top bottle header. The design of the fins has square corners, creating a stress riser at the ends of the fin. The tube that leaked this time was the second tube from the sootblower pass and the first tube had been removed previously. As the sootblower passes movement is induced on the tube, creating more stress at the end of the tube/fin. Leak detection: Mass balance Bed cooling enhance: No Last full inspection: March 2015 Sequence of events: Operator found leak on routine walk down of boiler at 5pm. Water was coming out of generating bank and economizer salt conveyors. Operator contacted shift supervisor. Shift supervisor confirmed water in generating bank and could not identify exact location of leak. Decision was made to rapid drain ASAP with water in generating bank and unable to determine if leak was spraying to firebox. All maintenance and operations personnel were contact to leave boiler house. Rapid drain EOP initiated at 5:31pm. Rapid drain operated successfully. Boiler house evacuated for 8 hours. Repair procedure: Ground crack, weld repair, and PT Future prevention: A row of economizer tubes was removed previously to allow access to PT and MT this area during shutdowns and make repairs when problem is near sootblower lane. Removing “square fin” design.
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ECONOMIZER SPRING 2017-12 Classification: Noncritical Location: Domtar, Hawesville, KY Unit: #4 Recovery, 1997, Ahlstrom, contract # 59072, 1 drum, large econ. Unit Size: 2.7 MM lb ds/day; 415,880 lb/hr steam at 1250 psig, 860°F, 1550 psig design (MAWP) Incident Date: October 16, 2016 Downtime hrs, leak/total 34:45 ESP? No Leak/Incident Loc: Economizer, ¼” stress crack at toe of membrane. Lower #1 Economizer at bottom of the membrane How discovered: Walkdown Wash adjacent tube: No Root cause: Stress, SAC Leak detection: No Bed cooling enhance: No Last full inspection: September 2015 Sequence of events: On Sunday October 16th operator was doing shift walkdown at 13:45 and notice water in both #1 and #2 economizer conveyors. Mostly #1 Conveyor. We took off liquor at 15:19 10/16/16 and made repairs and fire back in 2:04 AM 10/18/16. Repair procedure: The leak was ground out re-welded. Future prevention: N/A
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ECONOMIZER SPRING 2017-13 Classification: Noncritical Location: Georgia-Pacific, Leaf River Cellulose, New Augusta, MS Unit: 4142, 1983, Gotaverken, Single Drum, Sloped Floor, 5 Spouts Unit Size: 6.435 MM lb ds/day; 983,900 lb/hr steam at 1250 psig, 900°F, 1491 psig design (MAWP) Incident Date: November 21, 2016 Downtime hrs, leak/total 43.3 hrs. ESP? No Leak/Incident Loc: #2 Economizer tube on a butt weld to the top header stub, ½” circumferential crack ~4” from the top of the bottle header How discovered: Utilities operator noted water from the roof of the economizer Wash adjacent tube: No Root cause: Weld exhibited porosity Leak detection: Recovery Boiler Advisor – Mass Balance Bed cooling enhance: No Last full inspection: May 2016 Sequence of events: After 8 PM on 11/21/16 while making a round on the recovery boiler, an operator noted water coming out of the economizer above IK 46 in the #2 economizer. It was obvious that there was a tube leak in the economizer. At that point, operations began to take the liquor out of the recovery boiler to begin to burn out the bed. A normal shutdown was performed rather than an ESP because the location of the leak would not be able to make it to the furnace. The bed burnout took place until 12:30 PM on 11/22/16. After the pressure had been lowered on the boiler, the checkerboard plate on top of the economizer roof was cut out in the location of the leak which revealed the leak in the small dead air space between the flue gas roof and the walking roof. A photograph of the leak can be seen in the appendix. Due to the location of the leak, the leak could be repaired without entering inside the boiler. During the cool down period before a water wash could begin, contractors could repair the leak from the roof and inspected surrounding tubes for damage. There were no other tubes found damaged during the leak. Applied Technical Services performed PT following the repair to the leak.
After the repairs were made and the 12 hour waiting period, the bed was checked for hot spots the hydro was completed on the boiler in the morning on 11/23/16. An 8-hour water wash was done to make sure that the superheater section was clear before starting the boiler back up. At 5:20 PM on 11/23/16 the first gas burner was put in the recovery boiler and the first liquor gun was put in at 3:12 AM 11/24/16.
Repair procedure: Weld repaired in place Future prevention: This row of tubes was replaced in 1992 to change the flue gas to a tube fin baffle design in the economizers. It could not be determined if the crack was in the joint of the weld or in the heat affected zone but it did appear as if there was porosity in the weld. Due to the modification, this was a field weld rather than a shop weld like the rest of the economizer tubes. Due to the location/difficulty of the location, there may not have been RT or 100% testing when these tubes were installed to catch the initial weld defect. Normal procedures now is to have 100% testing on all butt welds.
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ECONOMIZER SPRING 2017-14 Classification: Noncritical Location: Georgia Pacific, Palatka, Florida Unit: #4 Recovery Boiler, 1977, CE, Contract #22974, 2-drum, long flow economizer Unit Size: 5.0 MM lb ds/day; 850,000 lb/hr steam at 1250 psig, 900°F, 1501 psig design Incident Date: February 8, 2017 Downtime hrs, leak/total 50 hours ESP? No Leak/Incident Loc: Economizer, leak was from a 1/16” pinhole in the weld of a repair window used to access the plugged tube. The window was installed as a repair for economizer tube following the Andritz repair procedure and material. The window is located on the top economizer header and was installed for tube 33-2. How discovered: Operator – normal round Wash adjacent tube: No Root cause: Weld porosity – repaired weld Leak detection: Yes Bed cooling enhance: No Last full inspection: June 2016 Sequence of events: The operator was performing his normal round and saw a wet area in the rear Economizer ash hopper. The operator opened additional doors on the economizer hopper and on the side of the economizer. The operator determined the leak was in the top of the economizer and there was no possibility of spraying back to the generating bank. The boiler was taken down in an orderly manner Repair procedure: The operator was performing his normal round and saw a wet area in the rear Economizer ash hopper. The operator opened additional doors on the economizer hopper and on the side of the economizer. The operator determined the leak was in the top of the economizer and there was no possibility of spraying back to the generating bank. The boiler was taken down in an orderly manner Future prevention: The mill is developing a plan for economizer replacement
SUPERHEATER SPRING 2017-15 Classification: Noncritical Location: Evergreen Packaging, Pine Bluff, AR Unit: RB3, 1959, B&W, PR-60, 2 Drum, Cyclone DCE, Small Economizer Unit Size: 1.4 MM lb ds/day; 202,000 lb/hr steam at 1250 psig, 900°F, 1475 psig design (MAWP) Incident Date: September 23, 2016 Downtime hrs, leak/total 51 Hrs, 39 Min ESP? YES Leak/Incident Loc: 1” hole How discovered: Operator walk down Wash adjacent tube: No Root cause: Sootblower rubbing tube Leak detection: No Bed cooling enhance: Yes Last full inspection: Sequence of events: Repair procedure: Future prevention:
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SUPERHEATER SPRING 2017-16 Classification: Noncritical Location: Westrock Mahrt, Cottonton, AL Unit: RB1, 1966, Babcock & Wilcox, Contr #BW-21974, 2 drum, econ, no DCE Unit Size: 2.9 MM lb ds/day; 440,000 lb/hr steam at 890 psig, 825°F, 1000 psig design (MAWP) Incident Date: November 2, 2016 Downtime hrs, leak/total 28.9 ESP? No Leak/Incident Loc: Superheater tube crack, North side superheater platen 15 tube 7 How discovered: Operator rounds / Leak through refractories Wash adjacent tube: Root cause: Crack caused by tube attachment weld. Leak detection: No Bed cooling enhanc No Last full inspection: February 2015 Sequence of events: Operator was doing his round, and found steam leak on 8th floor through the refractories at 12:00 noon; performed orderly shutdown, took liquor out at 14:30. After the repair of first leak, we found a second leak in the same area on the hydro; performed the same repair as the first leak; performed dye penetrant test and passed. Repair procedure: We ground the crack out, performed dye penetrant test, welded the pair. After the repair, we performed dye penetrant test again to ensure the integrity of the weld. We found a second leak on the hydro; performed the same repair on the second leak. Future prevention: We will perform increased testing on the superheater tubes
SUPERHEATER Spring 2017-17 Classification: Noncritical Location: International Paper, Georgetown, South Carolina Unit: RB2, Babcock and Wilcox, PR-114, 2 Drum, LTV econ, Direct Contact Cyclones Unit Size: 3.9 MM lb ds/day; 500,000 lb/hr steam at 1000 psig, 950°F, 1020 psig design Incident Date: November 26, 2016 Downtime hrs, leak/total: 67.5 ESP? No Leak/Incident Loc: Approximately Elevation 115’, No. 1 platen of the secondary superheat near the left wall How discovered: Operator Basic Care Round Wash adjacent tube: No Root cause: Clinker formation pushed SH platen into the sootblower lane allowing for tube/ sootblower lance friction thinning. Leak detection: Operator heard audible noise during Basic Care walkdown Bed cooling enhance: No Last full inspection: March 2016 Sequence of events: At ~0930hrs. on 11/26/16, a Power Area SO2 was performing Basic Care rounds on the upper floors of #2RB and heard a distinctly different sound coming from the North(Left) superheat section. • It is standard operating procedure to stop sootblowing while performing said walk downs to look and listen for signs of tube leaks. • The operator notified the Control Room and notification was made to the FLL and On call manager. • The only signs of the leak were the noise coming from the superheat section of the boiler. • There were no signs of water smelt contact, no drastic changes in feedwater to steaming rate ratio, no change in boiler chemistry Phosphate ratio and no visible signs (steam or vapor) of a tube leak in the suspected leak location.
The call was made to take the boiler off of liquor at ~1000hrs and all liquor was out for char Meeting Minutes BLRBAC April 12, 2017 Page 82 of 116
bed burn out by 1107hrs. The sootblower system was isolated and shut down to rule out a leaking poppet valve on an IK sootblower in the location. The attemperator was valved out to prevent desuperheater water from making bed contact.
National Boiler (repair contractor), BSI (inspection service contractor), Acuren(NDE) and Sunbelt (Scaffold) were notified of the need for repair and plans were made to bring in the needed help to repair the leak.
Once on site at 1330hrs the AM confirmed the initial assessment that the suspect audible noise was believed to be a superheater tube leak. IP Technology representative was notified and the identification steps were gone over with him by phone.
The char bed was burned out and the boiler was taken off line and all fuel sources were locked out. The boiler was cooled and the small remaining portions of char bed material was tested with a thermal couple(lance) prior to performing a water wash to remove clinkers and salt cake build-up. Thermocouple probe test resulted in all readings 187deg.F or less.
As the boiler cooled the visual inspection of the suspect zone revealed only one failure was absolutely present as expected in the number one platen where IK-1(sootblower) had rubbed the tube until thinned and it failed.
The boiler was water washed and inspected for overhead hazards. Sunbelt made entry into the furnace from the 7th floor manway above IK-1 and erected scaffolding building from the nose arch in the tube leak location. On 11/28/16 at 0400hrs. BSI and NBS made entry and confirmed the visual assessment of the leak and laid out the Dutchman cut lines for a 20” Dutchman.
National Boiler was released to go to work at 0600hrs on 11/28/16, they moved material to the floor and were in the process of repairing after permits were given. As of 0700hrs the repair work had started.
Inspection of the secondary superheater u-straps at the rear wall finds that none are missing and the first three to four platens are in good condition. They were not free swinging. No signs of washing or erosion of adjacent tubes was evident. UT was performed around the holes and the next six platens as well, the lowest reading at the hole was .174 and just outside the rub thickness was back to .210.
Inspection of the number one IK finds the lance in good straight condition with no bowing or bent conditions present. The lance does have severe drag and scrape marks from hitting the seal plate during operations and this appears to start after insertion of 3 feet or in front just past the number one platen.
The unit repair was completed at – 1000hrs. on 11/28/16 and Acuren was released to perform the radiograph inspection. Welds were released for X-Ray at 1130hrs, completed X-Ray at 1240hrs and called good at 1330hrs.
As a precautionary measure, shields were installed on platen one, three and five in the secondary as they were found slightly out of alignment
The unit was released for filling after completing the shields at 1425hrs. Hydro test was completed at 1735hrs. All scaffold was removed by 1900hrs.
The boiler was released to operations to unlock and line up for prestart check list completion and start-up. The boiler was back on liquor by 0715hrs. on 11/29/16.
Repair procedure: Damaged portion of the tube removed and a 20 inch Dutchman was installed, x-rayed and hydrostatic tested. Future prevention: Investigation of causes and preventative measure to stop or minimize clinker formation.
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BOILER BANK SCREEN SPRING 2017-18 Classification: Critical #876 Location: Hood Container of Louisiana, St. Francisville, LA Unit: RB1, 1965, B&W, PR85, Two-Drum, Economizer, Long-Flow Economizer Low Odor Unit Size: 3.0 MM lb ds/day; 481,000 lb/hr steam at 600 psig, 750°F, 675 psig design (MAWP) Incident Date: 12/19/16 Downtime hrs, leak/total 138 ESP? Yes Leak/Incident Loc: Generating bank screen tube How discovered: Operator Rounds Wash adjacent tube: Yes Root cause: Cracking due to cyclic stresses from sootblowing Leak detection: No Bed cooling enhanc Yes Last full inspection: 06/09/16 Sequence of events: 14:20 – Operator noticed water dripping from #6 sootblower opening. Initially thought it was condensate from a leaking poppet valve. Ran #6 IK for two cycles with remainder of blowers turned off but drip continued. 14:25 – Removed lagging from area around #6 IK and found that water was coming from floor above and pooling up on the casing outside #6 IK. 14:30 – Removed lagging from area above #6 IK and on the hot side of steam drum. Water was noted seeping out of the casing. Then verified that water wasn’t dripping from a leaking safety relief valve. 14:45 – Utilities Superintendent notified area manager and asked him to help verify that the leak was coming from inside boiler. 15:20 – Reduced liquor firing rate and increased auxiliary firing. 15:35 – Area manager notified Utilities Manager with findings and agreed and ESP was in order. 15:40 – Operator initiated an ESP. All systems performed as designed. Repair procedure: Tube replacement, Replaced five tubes in the affected area Future prevention: Future Replacement of Components
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UPPER FURNACE Spring 2017-19 Classification: Critical #877 Location: Expera Specialty Solutions, Thilmany Mill, Kaukauna, WI Unit: RB10, 1962, B&W, PR-63, 2-drum, sloped to front floor, large econ Unit Size: 1.17 MMlbds/day, 187,000 lb/hr steam, 630 psig, 700F, 700 MAWP Incident Date: August 28, 2016 Downtime hrs, leak/total 79.4 hrs total ESP? No Leak/Incident Loc: Pin hole leak on attachment weld on door opening tube appears to be from a faulty weld. Super heater tube clip also appears to be from a faulty weld. How discovered: Operator walkdown Wash adjacent tube: No Root cause: SAC Leak detection: No Bed cooling enhance: No Last full inspection: April 2016 Sequence of events: On the morning of August 28th. 2016 at 11:00 am. the assistant boiler operator noticed water running out of the dead air space/nose arch header area, water was also noticed coming out around the screen tube inspection doors. Weekend duty person was summoned to open up the doors on the boiler and inspect for any leaks, noticed some condensate dripping down from the generating bank soot blowers. Water continued to leak out of the dead air space.
At this time the boiler was firing at 40KPPH. The entire mill had been shut down just previous to this on account of a breaker trip at the Water Treatment Plant, we were not firing liquor, we were bringing the boiler up to fire liquor.
Area manager was called in, opened up the dead air space manway door and could visually see water running down inside of the nose arch and running out of the south west corner of the boiler. We then opened up the manway door on the 6th. floor directly across from the suspected leak area and could see a small spot where salt cake was missing.
Verified that no water was running into the furnace section. At 2:00 pm pulled the fire out of the boiler and began the cool down curve. Opened up the man way door on the lower furnace section to again verify no water was entering the furnace.
3:00 pm. Opened up the man way door on the 6th. floor where we suspected the leak, could visually see leak spraying out water onto the lagging and running down the nose arch and trickling down into the dead air space.
On 8/29 at 1:00 pm. While putting a hydro on the boiler noticed another leak in the super heater section. 1st secondary super heater tube 4 rows in from the south side of the boiler and 4 tubes in was leaking on a clip attachment. Repair procedure: Manway opening tube: Upon finding the general location of this indication, we needed to remove part of the boiler lagging to reveal the suspected failure area. Once this was exposed, the small pin-hole indication was found near the top right attached weld of the man way attachment to the wall tube. This small indication was ground out and pad welded, dye penetrated and hydro was good. Super heater tube clip: Removed the tie clip, grounded down the area, dye penetrated the area, welded up the crack, dye penetrated the area again and then re-attached the clip, then performed a hydro and area was good. Possible cause could be lack of penetration on clip weld. Large buildup of salt cake in the primary super heater section, may have caused stress on the attachment clips when shutting the boiler down or starting up. Future prevention: This does stress the importance of doing hydros on the boilers during our 6-month outage periods.
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UPPER FURNACE SPRING 2017-20 Classification: Critical #878 Location: Expera Specialty Solutions, Thilmany Mill, Kaukauna, WI Unit: RB10, 1962, B&W, PR-63, 2-drum, sloped to front floor, large econ Unit Size: 1.17 MMlbds/day, 187,000 lb/hr steam, 630 psig, 700F, 700 MAWP Incident Date: October 14, 2016 Downtime hrs, leak/total 48 hrs added to planned outage ESP? No Leak/Incident Loc: Small pin-hole indication was found near the top left attached weld of the IK5 soot blower wall box to the wall tube How discovered: Annual outage final hydro Wash adjacent tube: No Root cause: SAC at an attachment welded to the left hand side of the tube opening Leak detection: No Bed cooling enhance: No Last full inspection: April 2016 Sequence of events: On the morning of October 14th. at 10:00am while performing the final hydro on the boiler after its annual outage noticed a very small leak coming from the IK5 soot blower tube opening. Took pressure off the boiler, removed the lagging and refractory and spotted a small pin hole leak coming out of an attachment weld. Repair procedure: Upon finding the general location of the indication, we needed to remove part of the boiler lagging to reveal the suspected failure area. Once this was exposed, the small pin-hole indication was found near the top left attached weld of the soot blower wall box to the wall tube. This small indication was ground out and pad welded (Keeping under our allowed limit). After fixing the indication, we decided that we should x-ray the area of failure, and remaining attachment welds on that tube opening. This was only supposed to be for informational purposes to understand if our boiler was experiencing the SAC phenomenon. When the radiography revealed water-side cracking near external attachment welds and outer radii of tube openings – we decided to replace the two-tube opening. The tubes were replaced to a length approximately 2’ above and below the opening. X-ray was performed on final welds to ensure a proper repair. The two tubes removed from service were sent in to PSA for analysis, which solidified our intuitions that the failure was due to SAC. Future prevention: Moving forward, we plan to systematically x-ray and replace as necessary any areas that might have been affected over the years. Overcoming the issue is something that will take time, as the cost for replacement is high (asbestos abatement, refractory repair, insulation replacement, and tube replacement). We know our consequence of failure on a Recovery boiler - This is why it is an important item for us to identify and evaluate our probability of failure when it comes to SAC in No. 10 RB. The product of those two items will help us quantify risk to set priorities.
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UPPER FURNACE SPRING 2017-21 Classification: Noncritical Location: Westrock, Tacoma, WA Unit: 4 RB, 1973, CE, 21971,, Drums - 2, DCE - NO, Floor - Decanting Unit Size: 3.7MMlb DS/day,554,000lb/hr, 875PSIG, 825oF, 1000PSIG Design Incident Date: March 1, 2017, 10:04 Downtime hrs, leak/total 21hr. ESP? NO Leak/Incident Loc: Upper Furnace, above air entry , small crack 6th floor right front water wall How discovered: Walkdown Wash adjacent tube: NO Root cause: Stress Assisted Corrosion (SAC) Leak detection: NO Bed cooling enhance NO Last full inspection: Jan-17 Sequence of events: While the helper was making a walk down with the IK’s on hold he noticed a wet spot on the 6th floor buck stay near the furnace corner, there were no additional indications of a tube leak, manager was called at 4:30am, and came into the mill, at 5:30am we starting removing the boiler insulation and found a small crack on an attachment weld from the buck stay to the water wall tube, there was no indication that any water was entering the furnace, at approximately 7:30am the decision was made to take the boiler down in an orderly fashion, the boiler was off line at 10:04am. Repair procedure: Pad weld, followed by a boiler hydro to 1000psi Future prevention: Inspect all other like attachment welds. We have had previous attachment weld leaks, we made repairs then sectioned out the repaired tubes during the next available outages
LOWER FURNACE SPRING 2017-22 Classification: Critical #879 Location: Verso Luke Mill, Luke MD Unit: #3 Recovery Boiler, 1972, CE 23069, two drums, cascade evaporator, 6 spouts decanting bottom Unit Size: 4.2 MM lb ds/day; 540,000 lb/hr steam at 600 psig, 720°F, 750 psig design (MAWP) Incident Date: August 31, 2016 Downtime hrs, leak/total: 73.5 hrs off-line, 76.5 hrs off-liquor ESP? Yes Leak/Incident Loc: Leak at Rear Wall BL gun port lower left side of crotch plate How discovered: Boiler walk down / Fireman performing scheduled rounds Wash adjacent tube: No Root cause: Failure of tube weld, corrosion and stress / all original tubes. The failure occurred at the toe of the original crotch plate’s tube weld, on the 70th tube of the rear wall at the 3rd liquor gun port opening. The defect indicated a crack at the weld. This tube is 2”, SA-178A, 0.210” nominal wall, 0.086” ASME Min. Leak detection: Yes Bed cooling enhanc No Last full inspection: August 2015 of this particular tube and exact location Sequence of events: On 8/30/16, 3rd shift the Recovery Boiler Fireman was conducting his second round of cleaning Air Pots and BL Gun Ports. At 12:15 AM, the FM found indications of steam vapor wisping and wetting the black liquor deposit on the bottom side of #10 BL Gun Port. This condition was not found on his first round at 10:45 PM. The boiler was operating normally with 14 BL guns, 320 GPM, 69.0% solids and a steam flow of 418,000 lb/hr. The shift foreman and the CR Operator verified that this was not from an external source. The CR Operator confirmed that a small amount of water was entering the furnace from the wall box and then preceded to ESP the boiler at 12:28 AM. The operating crew followed posted procedures and confirmed all ESP functions occurred. Security was notified and boiler access was restricted for 8 hours. Meeting Minutes BLRBAC April 12, 2017 Page 87 of 116
The boiler was allowed to cool naturally for 8 hours before removing the air heater from service and placing the FD Fan back on-line to continue cooling the bed. The boiler has a decanting hearth that has shallow height that freezes quickly. After 12 hours the bed temperature was probed for hot spots, with nothing over 200 F. A boiler fill began at 3 PM with a 540 psig check at 9 PM. No other leaks were found. The fireside was washed with Sootblowers beginning at 11 PM. Scaffolding was installed at 5 AM on 9/1/16. Ten of the remaining 15 wall boxes were exposed for inspection. The failed bent tube was removed and sent out as a template. Several indications were noted on other ports, but were only surface flaws. The bent tube was replaced, x-rayed and a second hydrostatic test was run. The boiler was brought back on-line at 2 AM on 9/3 and returned to liquor firing at 5 AM on 9/3. Repair procedure: Removed tube and replaced it. Future prevention: The remaining liquor gun ports were exposed on the exterior of the boiler. The ports were dye penetrant checked with indications noted on several of the exposed ports. These crotch plates were cut at the leading edge as an attempt to alleviate stress. These ports were retested with no further indications. Remaining wall thickness was checked at all locations. Reinspect this area during next planned shutdown September 2017. Evaluate replacements.
LOWER FURNACE SPRING 2017-23 Classification: Critical #880 Location: Northwood Pulp, Prince George, British Columbia Unit: RB5, CRN# F 0809.1, 1982, CE, CA-79120, 2 Drums, Cross Flow Large Economizer, Unit Size: 3.60 MM lb ds/day; 480,000 lb/hr steam at 652 psig, 752°F, 800 psig design (MAWP) Incident Date: October 4, 2016 Downtime hrs, leak/total: Total time off liquor 118 hours ESP? Yes Leak/Incident Loc: Right wall, Liquor nozzle port level, bent tube #34 How discovered: Visual inspection Wash adjacent tube: No Root cause: Consistent with localized weld porosity. Leak detection: Yes Bed cooling enhanc No Last full inspection: May 2016 Sequence of events: 06:15hrs Recovery Field Engineer 4th (aka Spoutman) heard an unusual noise when in the vicinity of “K” liquor nozzle during completion of his first boiler round. Immediately notified the Shift Engineer of suspected leak. “K” nozzle removed and nozzle cleaning bar inserted into opening downward and to the left on the port; bar came out wet, noise and “popping” at location. Chief Engineer notified at 06:40hrs and team went to location and confirmed findings. ESP executed at 07:00hrs using detailed RB5 ESP procedure 37EOP01. Leak detection system detected small (2 tonne/hour) change just prior to ESP but nothing found out of normal with overnight boiler water testing; leak detection system was not alarming. Boiler was cooled for a total of 22.4 hours prior to water washing (bed less than 80C). Hydrostatic testing of #5RB after the ESP event of October 4th revealed a leak on right wall tube #34. This tube intersects liquor gun port “K”. Below and above this opening tubes #33 and #34 are joined by ½” wide membrane, but the membrane stops at the port so tube #34 can bend outward to form half the port opening. The leak occurred at the original termination of the membrane and appeared to be caused by a weld defect. Much of the evidence at the leak was erased by the leak but was reported to be consistent with localized weld porosity. Thermal fatigue over decades of operation may be responsible for the transformation of the original defect into a localized failure. Repair procedure: The leak was excavated and tested using dye penetrant until all indications were removed. The tube material adjacent to the leak was thickness tested to confirm suitable parent material. The closure of the opening, which was 1/16” x 1/8”, was conducted with carbon steel. The CS was inspected and then somewhat leveled prior to application of SS weld overlay. Future prevention: Full inspection in April 2017 planned outage
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LOWER VESTIBULE SPRING 2017-24 Classification: Noncritical Location: WestRock, West Point, Va. Unit: RB#4, 1975, CE, 21975, 2 drums, DCE (cascade) Unit Size: 2.7 MM lb ds/day; 427,000 lb/hr steam at 1225 psig, 900°F, 1360 psig design (MAWP) Incident Date: June 6, 2016 Downtime hrs, leak/total 86/107 ESP? No Leak/Incident Loc: Lower Vestibule. There were leaks found on two left lower sidewall tubes (#44 & #45). How discovered: Operator walk down Wash adjacent tube: No Root cause: Wall wash water (weak wash) hitting tubes. As the boiler grew on start up from annual outage the final position of wall wash shower allowed for weak wash to spray higher than normal. Due to a crack in the skirting under the smelt spout, weak wash was able to enter the lower vestibule and impinge on three tubes that were part of the 10-tube panel that made up one of the smelt spout opening on the left side wall. Leak detection: No Bed cooling enhance: No Last full inspection: March, 2016 Sequence of events: While rodding spouts on the left wall 1st assistant noticed steam escaping from skirting under spout. Operator was contacted who then contacted recovery superintendent. Operator and superintendent investigated source of steam. Initial thought was that wall wash shower was hitting tube causing steam. Shower was cut off and volume of steam did not change. At this time, it was determined that there was a leak in the lower vestibule. Plans were made to burn the bed out and take boiler down for inspection. Once cooled the lower vestibule was entered and it was determined that two lower sidewall tubes (#44 & #45) were leaking between the supply header and the floor tubes. Also, tube #46 had erosion damage. Repair procedure: 3 tubes were replaced with Dutchmen. Future prevention: A deflector plate was installed to keep wall wash out of lower vestibule. After startup and the boiler has completed its growth cycle the wall wash shower will be inspected to make sure that it is located properly.
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LOWER VESTIBULE SPRING 2017-25 Classification: Noncritical Location: WestRock, West Point, Va. Unit: RB#4, 1975, CE, 21975, 2 drums, DCE (cascade) Unit Size: 2.7 MM lb ds/day; 427,000 lb/hr steam at 1225 psig, 900°F, 1360 psig design (MAWP) Incident Date: June 9, 2016 Downtime hrs, leak/total 25/118 ESP? No Leak/Incident Loc: Lower Vestibule. During the hydro following the repairs to the left sidewall tubes an additional tube leak was found on the right sidewall in the membrane area between tubes 31 & 32 just below the floor. Upon inspection two leaks were found on tube #31 and tube #32 had a small area of thinning. How discovered: Leaks were discovered during hydro following leak repair on left side wall supply tubes Wash adjacent tube: No Root cause: Appears to have been an arc gouger damage Leak detection: No Bed cooling enhanc No Last full inspection: March, 2016 Sequence of events: During the hydro following the repairs to the left sidewall tubes an additional tube leak was found on the right sidewall in the membrane area between tubes 31 & 32 just below the floor. Upon inspection two leaks were found on tube #31 and tube #32 had a small area of thinning. Repair procedure: Weld repair Future prevention:
BELOW FLOOR, LOWER FURNACE SPRING 2017-26 Classification: Noncritical Location: International Paper, Franklin, VA Unit: RB6, 1977, B&W, PR-185, 2 Drums, Large Economizer, sloped to rear floor Unit Size: 5.0 MM lb ds/day; 655,000 lb/hr steam at 1500 psig, 900°F, 1700 psig design (MAWP) Incident Date: September 6, 2016 Downtime hrs, leak/total 17 days 2 hours to complete header replacement during Annual Outage ESP? No Leak/Incident Loc: Leak in rear wall tube above lower header How discovered: Observation on rounds Wash adjacent tube: No Root cause: Poor workmanship during 2004 spout opening replacement. Later data would suggest that the root cause was weak wash concentrated caustic corrosion thinning. Leak detection: Yes Bed cooling enhance: No Last full inspection: September 2015 Sequence of events: On 9/6/16 vapor and water was observed coming from skirting at rear wall in lower vestibule area. Visual confirmation was made that the leak was coming from the #1 spout panel above the lower rear wall header. Burned bed out of boiler and took boiler offline at 3:15 p.m. on 9/7/16 to begin annual outage for boiler. Repair procedure: All 4 rear wall headers were replaced Future prevention: During the 2016 annual outage, 4 new lower rear wall headers with stubs were installed to address the area of poor weld workmanship.
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BELOW FLOOR, LOWER FURNACE SPRING 2017-27 Classification: Noncritical Location: International Paper, Franklin, VA Unit: RB6, 1977, B&W, PR-185, 2 Drums, Large Economizer, sloped to rear floor Unit Size: 5.0 MM lb ds/day; 655,000 lb/hr steam at 1500 psig, 900°F, 1700 psig design (MAWP) Incident Date: February 20, 2017 Downtime hrs, leak/total 7 days 21 hours ESP? No Leak/Incident Loc: Leak in rear wall tube 13 fillet weld How discovered: Observation on rounds Wash adjacent tube: No Root cause: Corrosion from contact with green liquor/weak wash/smelt Leak detection: Yes Bed cooling enhance: No Last full inspection: September 2016 Sequence of events: Leak observed at 3:01 pm. on 2/20/17. Visual confirmation was made that the leak was coming from the #1 spout panel above the lower rear wall header. Took orderly shutdown on RB6 beginning at 3:33 PM. Bed burned out and boiler taken offline for repairs @ 12:45 a.m. on 2/21/17 Repair procedure: Grind out damaged portion of fillet weld and reweld Future prevention: Seal weld dog house skirting to face of spout refractory box. Improve refractory pour procedure. Improve spout refractory box seal design. Continue RCFA
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DISSOLVING TANK EXPLOSION SPRING 2017 – 28 Classification: Dissolving Tank Explosion #38 Location: Georgia Pacific ARC, Purdue Hill, AL Unit: RB7, 1978, B&W, PR-192, 2-drum,rear-sloped hearth, 2014 large B&W econ Unit Size: 5.4 MM lb ds/day; 697,000 lb/hr steam at 1250 psig, 900°F, 1425 psig design Incident Date: December 11, 2015 Downtime hrs, leak/total: 5 days, 6 hr ESP? No Leak/Incident Loc: DTE, no leak How discovered: Wash adjacent tube: Root cause: SAC. Will conduct further tube testing in area during spring shutdown Leak detection: N/A Bed cooling enhanc No Last full inspection: Sequence of events: A port rodder on ARC7 Recovery Boiler shorted out. The port rodder breaker failed to trip because a higher amperage breaker (15-amp vs 10 amp) had been mistakenly used. This resulted in a PDC tripping, instead of the port rodder breaker. The PDC trip caused the shutdown of the ID fan which led to a Master Fuel Trip on the boiler at 2:45AM. Subsequent to the trip, a leak was found in the boiler feedwater system that needed repair prior to startup. This added downtime resulted in the Recovery Boiler cooling down more than normal following a trip. At about 5:25AM, operators, who had been occupied with repairs and other activities, noticed the smelt spouts were beginning to close and quickly began attempting to insert rods in an effort to re-open the spouts. The rods were inserted in all four spouts, but they could not be inserted to a sufficient depth due to the hardening smelt.
A normal startup was begun at 6:10AM, with the first igniter placed in the boiler and beginning the warm-up curve. The first oil gun was placed in the boiler at 6:37AM. A second NG burner and oil gun were placed in the boiler at 8:24AM and 10:38AM respectively. At 11:00AM, the boiler was online and was ready to accept liquor at 12:30PM. Liquor was not introduced at this time, as all four smelt spouts were plugged. During the entire startup process, operators worked on trying to get the spouts open using rods and sledge hammers. Observation of the smelt bed, via camera and viewing port, showed the bed had laked out with a slightly higher level than normal, but it did not appear to be excessive. The higher level was attributed to the existing smelt left over from the shutdown and the slag that sloughed off from the upper areas of the boiler and fell down into the bed as a result of the cool down. After several more hours of working on the plugged spout it was decided, as a last resort, to put one liquor gun in the boiler for a short period of time in an attempt to add enough heat to induce smelt flow. The liquor gun was only used for 41 minutes (2:54PM – 3:35PM), based on operational experience, and was used on the front wall to direct liquor flow towards the spouts. Based on the observed bed level, it was believed that the short term use of one liquor gun would not significantly contribute to the overall smelt bed volume. The 4th spout was finally opened at approximately 5:05PM, resulting in a smelt rush that was of sufficient flow rate to overwhelm (or miss due to trajectory) the shatter jets, causing a smelt-water explosion in the dissolving tank. The operators evacuated the area and the Control Room Operators initiated a Master Fuel Trip on the Recovery Boiler.
This event resulted in significant damage and loss of production. No personnel were injured, and the structural integrity of the tank was not compromised due to the smelt-water explosion. The force of the explosion did cause the tank anchor bolts to fail resulting in the slight shifting of the tank on its foundation (Dissolving Tank moved 6-8 inches laterally/to the East or “left” side of the boiler). Due to the tank movement, additional piping misalignment resulted.
The only equipment contribution to the event (other than the original Port Rodder failure) was that Fuel Oil Burner that had been previously inserted at different position was finally inserted in the position which allowed it to be directly on top of ‘laked’ and plugged portion of boiler, which contributed indirectly to the event only in that it was not inserted into this position earlier (due to Fuel Oil Burners having trouble working at this particular position/orientation that would have allowed for maximum oil burning/highest temperatures at the Rear Furnace Floor and possibly Meeting Minutes BLRBAC April 12, 2017 Page 92 of 116
mitigated the amount of black liquor which was ‘laked’ behind the spouts) Repair procedure: Moved Dissolving Tank back to original position using winches (come-a-longs), replaced anchor bolts, repaired/replaced explosion window (s), repaired Dissolving Tank Agitator motor, repaired “Dog houses” and associated supports and piping, replaced damaged spools from Dissolving Tank Standpipe to Green Liquor pumps (X3), inspected smelt spout and replaced it (also replaced it again during the next Annual Outage) Future prevention: Amended procedures to cover what to do if smelt spouts remained plugged (get Production Leader involved to determine Path Forward – decision rights moved up the organization from Crew Leaders/Control Room Operators), added proper use of “torches” in unplugging smelt spouts, ordered and obtained 1 torch for each boiler.
International ECONOMIZER SPRING 2017 – x1155 Classification: Location: International Paper, Saillat sur Vienne, Limousin, France Unit: Gotaverken, 1993, 74401, single drum Kraft Recovery Boiler, long flow econ, low odor Unit Size: 4.0 MM lb ds/day; 577,611 lb/hr steam at 1015 psig, 824°F, 1305 psig design (MAWP) Incident Date: October 9, 2016 Downtime hrs, leak/total Downtime 0/0 ESP? No Leak/Incident Loc: Rear economizer, platen 8, first tube to rear of sootblower cavity, two pinholes 5m & 10m down from top access door. How discovered: Pre-outage hydro test Wash adjacent tube: yes Root cause: Still under investigation Leak detection: Yes Bed cooling enhance: No Last full inspection: March, 2015 (found during start of October, 2016 outage) Sequence of events: Found during pre-outage hydro Repair procedure: Dutchman Future prevention: Awaiting complete investigation
Meeting Minutes BLRBAC April 12, 2017 Page 93 of 116
APPENDIX II AF&PA
Meeting Minutes BLRBAC April 12, 2017 Page 94 of 116 THE AMERICAN FOREST & PAPER ASSOCIATION RECOVERY BOILER PROGRAM UPDATE
BY
WAYNE GRILLIOT April 12, 2017
BLRBAC MEETING ATLANTA, GEORGIA
Page 95 of 116 AF&PA Recovery Boiler Program
The AF&PA Recovery Boiler Program was established in 1974 Objective: • Develop programs and assist companies operating recovery boilers to improve the safety, integrity and reliability of recovery boiler operations
2 Page 96 of 116 AF&PA Recovery Boiler Program
Purpose: Provide a forum for companies operating recovery boilers to develop information useful in evaluating: 1. Safe Operating Procedures 2. Specifications and Construction 3. Maintenance Programs 4. Organization and Training 5. Research and Development Programs
3 Page 97 of 116 AF&PA Recovery Boiler Program
Information developed by the Program includes: • Reference Manuals • Audit Guidelines • Checklists • Training Aids
4 Page 98 of 116 AF&PA Recovery Boiler Program
The Program sponsors R&D projects • Safety Improvements • Process Improvements Strong focus on industry best practices Helps drive improvements in: • Safety • Operations • Maintenance • Recovery Boiler Integrity
5 Page 99 of 116 AF&PA Recovery Boiler Program
Membership is open to all companies operating recovery boilers The Program is under the direction of a Steering Committee • 4 Representatives from Member Companies Karl Morency – Georgia-Pacific Frank Navojosky – International Paper Chris Verrill – International Paper Don Flach – Georgia-Pacific
6 Page 100 of 116 AF&PA Recovery Boiler Program
Two Standing Subcommittees • Operation & Maintenance (O&M) Subcommittee Frank Navojosky – International Paper (Co-Chair) • Email: [email protected] Don Flach – Georgia-Pacific (Co-Chair) • Email: [email protected] • Research & Development (R&D) Subcommittee Karl Morency – Georgia-Pacific (Co-Chair) • Email: [email protected] Chris Verrill – International Paper (Co-Chair) • Email: [email protected] • Subcommittee Membership • Representatives from the Member Companies
7 Page 101 of 116 Membership
We currently have 21 member companies in the AF&PA Recovery Boiler Program Member companies produce over 96% of the chemical and semi-chemical pulp in the USA Efforts continue in encouraging additional companies to join We would very much enjoy having these companies in our group and participating in the shared learning promoted by the Program
8 Page 102 of 116 Operational Safety Seminars
The O&M Subcommittee sponsors the Operational Safety Seminars • 2016 - Two (2) Safety Seminars were held • April 19-20, 2016 • May 17-18, 2016 Operators, supervisors, superintendents, maintenance professionals, and engineers attended In 2016: • 12 companies were represented • 24 mills were represented Over 3,500 people have attended the seminars since they were started in 1985
9 Page 103 of 116 Operational Safety Seminars
We continue to receive excellent comments and ratings from the attendees The attendees receive valuable information and insight from the dialogue among the attendees and monitors of the seminars • Bob Phelps, Extra Hand Plant Support Services, LLC • Dean Clay, Boiler Services & Inspection (BSI) The table top exercises (based on actual Recovery Boiler Incidents) help operators and supervisors make decisions when to ESP a Recovery Boiler
10 Page 104 of 116 Operational Safety Seminars
As more senior operators and supervisors retire, training will continue to increase in importance Companies are finding these seminars to be an important part of their training program We recommend that all companies and mills seriously consider sending people to these valuable seminars
11 Page 105 of 116 Operational Safety Seminars
The 2017 Operational Safety Seminars • April 25-26, 2017 • May 16-17, 2017 • Atlanta Airport Marriott Hotel • Only $320 per attendee for member companies • Non -member companies - $640 per attendee • Attendance is limited – Register Early!
12 Page 106 of 116 2017 Annual Conference
The 2017 AF&PA Recovery Boiler Annual Conference and Meetings • February 7-8, 2017 @ the Atlanta Airport Marriott Hotel • 69 Participants • Well received…Many very positive comments The presentations included: • New equipment & process technology • New research developments • Industry best practices • AF&PA Program activities & projects update • BLRBAC activities update • Industry ESP & incident history • Updates from the Canada, Sweden, Norway, and Finland Recovery Boiler Committees
13 Page 107 of 116 2018 Annual Conference
The 2018 AF&PA Recovery Boiler Annual Conference & Committee Meetings • February 6-7, 2018 @ the Atlanta Airport Marriott Hotel • Conference is open to: o Operating companies o Insurers o Vendors o Manufacturers Objective: Keep the members and the recovery boiler community advised of: • New developments • Best practices We hope you will join us on February 6-7, 2018 in Atlanta at the 2018 Annual Conference & Meetings!
14 Page 108 of 116 Study on Smelt Dissolving Tank Explosions
The O&M and R&D Subcommittees are both working to develop best practices around dissolving tank related issues The R&D Subcommittee has recently sponsored some very exciting new research projects with the University of Toronto for improved safety and reduced operating risk of Dissolving Tanks • The 4 new projects focus on: o Dissolving Tank key operating conditions o Advanced monitoring techniques The 2.5-year program will build on prior AF&PA studies and related research underway at the University of Toronto, currently funded by a consortium of 22 companies We are very pleased to have Dr. Markus Bussmann of the University of Toronto leading these projects
15 Page 109 of 116 Best Practice for Functional Testing of Interlocks and Trips on Recovery Boilers
The O&M Subcommittee completed its work on developing the “Recovery Boiler Functional Checks AF&PA Example Document” at the February 7, 2017 meeting in Atlanta • The new document has been distributed to member companies and is posted on the AF&PA Recovery Boiler Program website Future activities, for the O&M Subcommittee, include work on identifying best practices for clearing and preventing plugged and bridged ash hoppers, as well as external line maintenance, inspection, and testing
16 Page 110 of 116 “Kraft Recovery Boilers” Blue Book Update
We are very pleased to have Dr. Honghi Tran of the University of Toronto leading the effort to update the AF&PA “Kraft Recovery Boilers” Textbook Dr. Tran has been awarded the 2017 TAPPI Gunnar Nicholson Award, the highest honor that TAPPI bestows Dr. Tran and other well-known recovery boiler experts are currently updating the 16 chapters of the book We expect to complete the Textbook in 2017 The new Textbook will help advance the knowledge and understanding of recovery boilers Great help to the industry!
17 Page 111 of 116 Research of Protective Clothing and Equipment
The R&D Subcommittee continues work on an industry survey on recommended clothing for safe use around recovery boilers. Clothing must be: • Heat resistant • Resistant to chemical attack • Provide mobility • Comfortable
18 Page 112 of 116 Recovery Boiler Generating Bank and Screen Tube Studies
The R&D Subcommittee has reviewed a proposal for studies of generating bank and screen tubes These studies would build on the work from several other studies sponsored by the AF&PA Recovery Boiler Program The R&D Subcommittee is very interested in these proposed studies, but will focus current efforts on the new Textbook Project and the new University of Toronto Dissolving Tank Projects The additional studies will be reconsidered at the February 6, 2018 R&D Subcommittee meeting
19 Page 113 of 116 Other Research Projects Under Review
The R&D Subcommittee is also discussing other possible new research projects related to recovery boiler safety These include: • Shatter jet design improvements • Burning CNCGs • Ash hopper best practices • Develop procedures for safe inspection of boiler leaks • Boiler inspection protocols • Combustible meters
20 Page 114 of 116 AF&PA Website: http://www.afandpa.org
AF&PA Recovery Boiler Program Website: http://www.afandpa.org/our-industry/recovery-boiler-program
21 Page 115 of 116 Q uest i ons?
Wayne Grilliot AF& PA Recover y Boiler Pr ogr am Email: [email protected] M obile: (937) 602-1892 Website: http://www.afandpa.org/our-industr y/r ecover y-boiler-pr ogr am
22 Page 116 of 116