Instructional Manual For Clarification Of Startup In Source Categories Affected By New Source Performance Standards - U.s. Environmental Protection Agency - 1979 Page 77
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146 Pre-Startup Operations
Dryer:
A rotary direct heat or indirect heat dryer is typically used in
the industry.
Four to seven days are allowed for dryer shakedown.
During the
shakedown period, a manufacturer's field engineer is on hand checking electri-
cal, mechanical. hydraulic and combustion systems.
Upon completion of pre-
startup checks, the unit will be turned over to the operator for startup or a
manufacturer's application engineer is available for complex startups.
Nor-
mally, startup is straight forward and an application engineer is not needed.
Pre-startup operation should take no longer than 1 week.
Roaster:.
Multiple Hearth:
Two to three weeks are allowed for pre-startup operations.
If problems develop, an additional week is allowed.
Curing and heatup of the
furnace takes about 5-7 days.
This operation must be done very slowly to pre-
vent stress on refractory material.
Total pre-startup consumes a 3-4 week
period.
Fluidized Bed:
Seven to nine days are required to perform the pre-startup
operations.
Following a successful pre-startup, the system is brought up to
operating temperature (3-4 days); the system is now ready for process material.
Total pre-startup operation may consume a 2-3 week period.
Smelting Furnace
Electric Smelting:
Two to three weeks are required for pre-startup opera-
tions.
According to manufacturers, this period of time is known as green tag.
It
also allows time for replacements of minor defective parts.
As each sub-
unit is installed, they are checked mechanically, electrically and
hydrauli~
cally as needed.
The electrodes and rigging, a major system for the furnace,
is actuated to check alignment and operation.
The electrical system is given
special attention for grounds, insulation,
de~d
shorts, and high resistance.
Secondary voltage is then applied to the transformer conductors at a very low
current.
Transformers are then energized with primary voltage (Power company
electricity).
Curing t.he furnace is usually accomplished by heating with
electric energy or a supplementary fuel.
At this time, the furnace is ready
for charging.
Copper Converters:
When a converter system is being installed, it requires
the cooperation of many suppliers and contractors.
Upon completion of sub-unit
installation and checking, the unit is normally turned over to the owner.
The
period of time consumed during installation and checking is 3-6 months.
During
this time, all electrical, mechanical .and hydraulic systems are debugged.
Other
units and systems checked are:
compressors, fuel lines, levelings, fans, pumps,
gauges, refractory linings and the cooling, chemical feed and emergency systems.
Two to three weeks are allowed to cure the refractory material of the converter.
The final step in
pre~startup
operation is a dry run of the entire system to
check out and coordinate the operation of individual units into a coherent sys-
tem.
A dry run normally takes 1 week.
Heating the co'nverter to operating
temperature requires 3 to 4 days.
The total preliminary startup operation
takes from 5 to 8 weeks.
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