Commissioning, start up, shut down, operation & Control and Decoking of furnaces

By V Suresh Senior Manager-Core Group

Joined IOCL- 1997 Worked in different units like CRU,AUS,MSQ,LAB etc.,

Importance of Safety in Furnaces?

Importance of Safety in Furnaces?

Importance of furnace operation? Explosions While Lighting a Furnace

Incident A Operator tested the atmosphere inside a furnace with a combustible gas detector. No gas was detected, so the Blind plate was removed, and two minutes later, Ignition was done. An explosion occurred. Reason ?

Gas line had liquid

Importance of furnace operation? Explosions While Lighting a Furnace

Incident A reduction in fuel oil pressure caused the burner in an oilfired furnace to go out. and the flame failure device closed the valves in the fuel oil line . The operator closed the two handisolation valves and opened the bleed between them. Again opened when oil pressure came Explosion occurred.

Reason ?
High oil pressure

Importance of furnace operation? The burning of waste products in furnaces to save

Incident For the example, an explosion occurred in a system that collected flammable vapor and air from the vents on a number of tanks and fed the mixture into a furnace. The system was designed to run at 10% of' the lower explosion limit, but when the system was isolated in error, the vapor concentration rose. When the flow was restored, a plug of rich gas was fed into the furnace, there are 10 such Reported incidents in literature

Importance of furnace operation? : Interlock not bypassed properly

Incident ? An instrument mechanic was asked to test the trip on A furnace. He put the controller on manual and then went behind the panel.. The mechanic, who had done the job many times before, took the cover off the wrong instrument , and disconnected one of theleads. The effect was the same as if the recorder had registered a high temperature. The controller closed the fuel gas valve, shutting down the furnace and the rest of the plant

What is a Furnace ?

A furnace consists of three major components: a heating coil, the enclosure, and the combustion equipment. Heat is released from the combustion of fuel. The heating coil consists of tubes connected together in series that carry the charge being heated. Heat is transferred to the material passing through the tubes. The enclosure consists of a firebox. It is a steel structure lined with refractory material that holds the generated heat. Burners create the heat by the combustion of fuel. The furnace is fired by oil or gas. The heating coil absorbs the heat mostly by radiant heat transfer and convective heat transfer from the flue gases.

What is a Furnace?

The flue gases are vented to the atmosphere through the stack. Burners are located on the floor or on the sidewalls. Combustion air is drawn from the atmosphere. For increased heat recovery, an air preFurnace or waste heat boiler is installed downstream of the convection section. Instruments are generally provided to control the firing rate of the fuel and flow through the coils to maintain the desired operating conditions

Typical Furnace
Stack Damper Arch Convection Tubes Shock Bank Radiant Tubes Refractory Lining

Firebox Burners

Vertical Cylindrical Furnace - Side View

Stack

Damper TI Sample Connection Inlet from Process Tube Pulling Door Cross Over Tube Arch Tube Guides Refractory Peep Door Snuffing Steam Cast Burner Block Tube Sheet Convection Section Bridgewall Temperature Draft Gage

Tube Circle Dia. I.D.

Shell Dia. Radiant Section Heating Tube Process Outlet Access Door Burner

Peep Doors

Vertical Cylindrical Furnace

Breeching Inlet from Process Header Box Outlet to Radiant Section End Tube Convection Section

Header Box Drain Snuffing Steam Peep Door Burners Access Door Radiant Section

Burner Circle Diameter

Inlet from Convection Outlet to Process

Firing Controls
Major parameters that need to be controlled and monitored are: 1. Fuel gas/Fuel oil pressure; 2. Excess air in the form of oxygen trim 3. Draft in the furnace. 4. Burner modulation 5. Air/fuel cross-limiting 6. Total heat control in the form of pass balancing

Raw Gas Burner

Burner Tile/Orifice Gas Tip (Flame Shape)

Cone (Flame Holder) Air

Air Register Air

Gas Pilot Gas

HTR-R01-60

Staged Fuel Burner

Secondary Combustion Secondary Fuel

High Air to Fuel Ratio in Primary Zone

Combustion Air Primary Fuel Connection Secondary Fuel Connection

HTR-R00-64

Typical problems observed in fired Furnaces include:

High excess air operation Fouled convection sections High stack temperature Over-firing Bad flames/flame impingement

Excess air control

It essentially involves answering three basic questions:
a)

How much excess air is provided?

Answers : Flue gas analysis

b) How much excess air should be provided?

Answer : The oxygen concentration in the flue gas provides an indication of the excess air supplied to the combustion process
c)

How efficient is the burning equipment?

Answer : The optimum excess air for a particular type of burner varies from one burner type to another and also depends on the type of fuel. Optimum excess air is the minimum excess air because it minimizes the heat loss to the flue gases, minimizes the cooling effect on the flame, and improves the heat transfer. With less than the minimum excess air, the unburned fuel will start appearing in the flue gas due to insufficient air. Minimum excess air should be specified by the burner vendor and should be verified during burner testing.

Tips on excess air control

In natural draft furnaces, the excess air is controlled by adjusting both stack damper and the Air registers. Control schemes are installed in the balanced draft systems to control the excess air and draft more accurately.

Problems on excess air control

Measurement of the fuel and air flowrate accurately because of the fuel, the fuel gas quality (composition) keeps on changing in the refinery.
For liquid fuels, the fuel viscosity is so high and temperature dependent that a reliable flow measurement over a period of time is very difficult to obtain. Combustion air flowrate is also difficult to measure reliably, as straight run-lengths for the installation of instruments are not available except when a venturimeter is installed in the suction stack of the FD fan.

Purpose of oxygen & combustible analyzer in flue gas in Arch

The excess air should be adjusted in such a way that the oxygen level in the flue gas is close to the minimum or optimum excess air level.

Combustibles should read close to zero during normal operation.

The combustible analyzer should not be used to make excess air adjustments. The presence of combustibles is an indication of poor combustion. Combustion air should not be controlled using CO or combustibles as a guide. The presence of CO or combustibles indicates that either the air is deficient or the combustion equipment is not clean, which is generally the case. The dirty burners or poor atomization of oil can easily lead to CO formation

Burner Troubleshooting
Problem
Burners go out

Cause
Gas mixture too lean Too much draft Low gas pressure High hydrogen in fuel Low gas flow Burner tip plugged Lack of oxygen Lack of draft Lack of combustion air Incorrect burner tip location

Solution
Reduce air Adjust stack damper Raise fuel gas pressure Reduce primary air Increase gas pressure Clean burner tips Reduce gas flow rate Lack of draft Open stack damper Open burner air registers Adjust air registers/damper Check burner tip location

Flame flashback

Insufficient heat release Pulsating fire

Erratic flames

Damaged burner tile

Gas flame too long Excessive firing Poor air fuel mixing

Replace burner tile

Reduce firing rate Improve burner design

Tips for proper burner operation & their solution in case of any problem

Sr

Description
Indicators of correct combustion in the firebox

Significance & its remedial procedures

1. The firebox is clear 2. There is no smoky appearance 3. The burner flames are steady and well formed Check burners regularly for any signs of blockage or unusual flame conditions It is a sign of poor mixing Increasing the airflow to the burner can reduce flame length With natural draft burners, increase the primary air and minimize the secondary air to the burners. Primary air mixes with the fuel and creates a short compact flame. Excess of primary air can sometimes lift off the flame and make it unstable For oil firing, flame lift off can be corrected by increasing the atomizing steam.

Burner flames are long and lazy

Recommended Excess Air Levels

Fuel/Draft
Fuel gas

Natural Draft
1520%

Forced Draft
1015%

Light fuel oil

2025%

1520%

Heavy fuel oil

2530%

2025%

Fired Furnace Troubleshooting Guide

Problem
High or uneven tube skin temperature

Cause
Flame impingement Over-firing Unbalanced pass flow Coke build up Bad thermocouple Damper not open enough Firing rate high Convection section fouled Convection Section fouled Fins burnt off After-burning in convection Over-firing

Solution
Modify burners Reduce firing Equalize flow in all passes Decoke tubes Replace thermocouple Open damper Reduce firing rate Clean convection section Clean convection section Replace convection tubes Modify burners Reduce firing

Positive pressure at arch

High flue gas temperature

Fired Furnace Troubleshooting Guide

Problem
High fuel gas pressure

Cause
Burners are plugged

Solution
Clean burners

Variation in pass outlet temperatures High pressure drop through tubes High excess air operation

Unequal pass flow-rates Uneven firing Coke build up High rate of vaporization High furnace draft Poor air fuel mixing Air leakage in the furnace

Equalize flow in all passes Equalize firing in all burners Decoke tubes Reduce flowrate Reduce furnaces draft Modify burners Plug air leakage

Commissioning

INSTRUMENTATION- Commissioning

Process flow control

Pass flows are controlled by flow indicating/ recording control systems consisting of FE, FT, FIC, FV (on process line) Pass flows should be equal Minimum pass flow must be maintained Velocity steam/ water injection

INSTRUMENTATION- Commissioning

Process temperature control

Temperature control system consists of TE, TIC, TV (on FO/ FG line) For FG, a TIC-PIC cascade is generally used For FO, in addition to the TIC-PIC cascade, a DPIC with atomizing steam is also used For dual firing furnaces, a selector switch is provided for switching between FG/ FO modes

PROCESS HEATERS OPERATIONS & PRACTICES TYPICAL CONTROLS

TRC

PIC

SS PIC DPIC

Fuel Oil Atomiz ing Steam

Select or Switc h Fuel Gas

PROCESS HEATERS OPERATIONS & PRACTICES INSTRUMENTAION

Skin Points

For Monitoring Tube Wall Temperatures, Thermocouples Are Provided on Heater Tubes Maximum Permissible Skin Temperatures Must Be Adhered to

Box Temperature

Facilitates the Operator to Regulate the Furnace Firing and to Maintain Even Heat Distribution

Draft Gauges

Draft Profile of the Furnace Is Indicated by Draft Gauges Positive Pressure Must Be Avoided

PROCESS HEATERS OPERATIONS & PRACTICES INSTRUMENTATION

Convection Bank Temperature Thermocouples U/s and D/s of Convection Bank Indicate the Amount of Heat Transfer Stack Temperature Higher Than Normal Stack Temperatures Indicate Low Efficiency in Furnace Operation Process Fluid I/l and O/l Pressure Pressure Drop Across Furnace Indicates Coking/ Plugging in the Furnace Tubes Oxygen Analyzers Direct Indication of Excess Air in the Furnace CO, NOx & SOx Analyzers Emission Monitoring

PROCESS HEATERS OPERATIONS & PRACTICES INSTRUMENTATION

Combustion Control System

Draft Control by Adjusting ID Fan RPM or Its Suction Vanes Combustion Air Control by Adjusting FD Fan RPM or Its Suction Vanes Excess Air Control, Based on the On-line Measurement of O2 & CO in Flue Gas Process Fluid O/l Temperature Control by Adjusting FO & FG Pressure

PROCESS HEATERS OPERATIONS & PRACTICES TYPICAL INTERLOCKS

Low Feed Flow Thru Tubes Low FO Pressure Low FG Pressure Low Combustion Air Pressure ID Fan Failure Fuel Oil & Fuel Gas to Furnace to Be Cut-off Fuel Oil to Furnace to Be Cut-off Fuel Gas to Furnace to Be Cut-off FO & FG to Furnace to Be Cut-off Stack Damper to Open Fully; If Stack Damper Doesnt Open Within a Stipulated Time-FO & FG To Furnace Cut-Off

PROCESS HEATERS OPERATIONS & PRACTICES TYPICAL INTERLOCKS

FD Fans Failure
High Arch Pressure

Fuel Oil and Fuel Gas to Furnace to Be Cut-off

Stack Damper to Open Full If Stack Damper Doesnt Open Within a Stipulated Time; Fuel Oil & Fuel Gas to Furnace to Be Cutoff Stack Damper to Open Fully

Fuel Cut-off to Furnace

PROCESS HEATERS Fired Process Heaters Safety Features

Firefighting Water Monitor ?Curtain : The firefighting nozzles are installed almost 15 meter away of heater. In the case of the fire the water will be used through this equipment extinguish the fire. Explosion Doors: These doors are installed in heater walls. In the case of explosion the door will be raptured and will cause the combustion and explosion gases to be exited and avoid from destruction of heaters walls and other different parts.

PROCESS HEATERS Fired Process Heaters Safety Features

Emergency shutdown systems

Where are they located ?

PROCESS HEATERS OPERATIONS & PRACTICES SAFE START-UP

Preparation

Inspect Furnace for Readiness Check Heater Isolation (Specially FO and FG) Check Dampers/ Air Registers Operation Check Igniters Check Instruments Check Fire Fighting Equipment Ensure No Loose Ends in FO & FG Circuit Check Burner Gaskets Ensure Required Flow Thru the Tubes Leave Header Box Doors Open

PROCESS HEATERS OPERATIONS & PRACTICES SAFE LIGHTING PROCEDURE

Furnace Box Purge

It Is an Important Step Because It Safe-guards Against Formation of Explosive Mixture Due to Presence of Inflammable Gases in the Box Open Stack Damper and Air Registers Purge the Fire Box With Steam (Generally)

Fuel Lines Purge

N2 Purge Thru FO / FG/ Pilot Lines of Each Burner Pressurize Each Fuel System With N2 and Check for Leaks Pilot Gas Line Is to Be De-blinded After the Box Purging Has Commenced

PROCESS HEATERS OPERATIONS & PRACTICES SAFE LIGHTING PROCEDURE

Lighting Pilot Burners Open Pilot Gas Main Valve Place the Igniter Tip at the Burner Tip and Open Pilot Gas Valve to Burner and Press the Igniter Button Adjust Air to Prevent Pilots From Blowing Out(pilot Burner Valve Should Be Shut-off If It Fails to Ignite Within 15 Seconds) Lighting Gas Burners After the Pilot Burners Are Lit. Deblind the FG Line and Light-up the Gas Burners From Pilots Lighting Oil Burners Open Atomizing Steam and Bypass Between Oil and Purging Steam and Heat up the Burner and Tip Close the Bypass and Open the FO

PROCESS HEATERS OPERATIONS & PRACTICES ROUTINE MONITORING

Check Furnace Draft at Arch Level Check Refractory: Should Not Be Damaged Check Tube Hangers and Lock-rods: Should Be Firmly Fixed and Should Not Be Red Hot Check Tubes: Hammering, Vibrations, Hot Spots, Bending, Sagging, Bowing Check the Flame Pattern and Try to Correlate With O2 Analyzer Check That Skin and Box Temperatures Are With Permissible Limits

PROCESS HEATERS OPERATIONS & PRACTICES ROUTINE MONITORING

Ensure FO and FG Pressure Are Above Tripping Values Ensure Differential Pressure Between FO and Atomizing Steam Is Being Maintained Check for Heat Tracing on Instrument Pulse Line/ Seal Pots on Flow/ Pressure Taping of Process Fluid, Fuel Oil Etc.

PROCESS HEATERS OPERATIONS & PRACTICES DOS

Before Opening Peep-hole Covers, Ensure Fire Box Is Under Draft Always Use Pilot Burner for Lighting up Main Burner After Total Flame Failure, Ensure All Fuel Supply Is Properly Isolated and Fire Box Is Thoroughly Purged Always Steam Flush the FO Burner After Stopping Oil Firing Religiously Drain the FG KOD

PROCESS HEATERS OPERATIONS & PRACTICES DONTS

While Opening Peep-hole Covers, Never Stand Directly in Front of Hole Never Try to Ignite a Burner From Another Lighted Burner Never Allow Impingement of Flame on Tubes Never Light-up Main Burner Without Ensuring Flow Thru Coils Do Not Bypass Furnace Interlocks Except During Maintenance Jobs

PROCESS HEATERS DECOKING

STEAM / AIR DECOKING

Mechanics of steam-air decoking

Principles used to complete the task of heater coil decoking Precautions

STEAM / AIR DECOKING

Steam-air decoking is the art of removal of coke deposited inside heater tubes by spalling and/or burning, using steam and air as agents.

STEAM / AIR DECOKING

The mechanics of steam-air decoking for heater tubes are: A. Contraction of the tubes due to cooling will cause the coke deposits within the tube to crack and spall (fall off). This action is enhanced by reduction in firing of the heater and the introduction of steam. Steam injection and sweeping, in addition to the manipulation of heater firing will remove (spall) loose coke from the tubes.

STEAM / AIR DECOKING

The mechanics of steam-air decoking for heater tubes are: B. It is required that steam be injected into the tubes not being decoked to prevent damage to these tubes. Injection of steam into the tubes generates a chemical reaction 3H2O + 2C CO2 + CO + 3H2

The oxygen in the air also generates a chemical reaction with the heated coke 3O2 + 4C 2CO2 + 2CO ______________________

STEAM / AIR DECOKING

The decoking requires that operators continuously monitor the coke burning rate by observing the meta temperature of the tubes and checking the effluent water Night is the best time TO CHECK The metal content of the tubes governs the controlling temperature a which the operation shall be conducted. Coke will burn at temperatures between 565C to 650C The time required for completion of the decoking operation can vary from six hours to three days, dependent upon the thickness of coke deposits

STEAM / AIR DECOKING Schematic piping diagram

STEAM / AIR DECOKING

When the pressure drop across a pass of the heater increases by around 10%, the tubes require decoking. An alternative method is to schedule decoking at regular intervals. Normally there is no requirement for reversible flow. The deposition of coke is toward the outlet end of the heater.

STEAM / AIR DECOKING OPERATING PROCEDURES

Introduce steam into the tubes. Approximate steam flows various tube diameters are:
Tube ID, mm
50.8 ( 2) 63.5 76.2

Steam Flow, Kg/hr

304 476 703

101.6 ( 4)
127( 6)

1270
2042

STEAM / AIR DECOKING OPERATING PROCEDURES

A pressure-drop of 0.68 Kg/cm2 per 30.5 meters is to be expected when the recommended steam is introduced. If pressure drop is more do reverse Turn on quench water Introduce small amount of air When it appears that coke burning is about to stop or is nearing completion, gradually increase the quantity of air being injected with the steam
During decoking operations the CO2 content will be about (1-5%), and the CO:CO2 ratio will be high because of insufficient oxygen. As the decoking operation nears Completion, the CO:CO2 ratio will decrease, and in the last stages O2 will be evident in the sample.

Note: tubes are not overheated during the burning operation.

Thank you