PRESENTATION ON DCU HEATER

Presentation Context
1. 2. 3. 4. 5. Heater and its classification Heater configuration Heater section details Heater Inspection check points Safety Interlocks

What is a Heater?
A heater is a heat transfer equipment where heat of combustion of fuel oil/fuel gas is used to increase the temperature of the desired fluid.

Classification of Heaters
1. On the basis of Draft (Natural, Forced, Induced and Balanced Draft) 2. On the basis of Structural Configuration (Cylindrical, Cabin, Multi cell) 3. On the basis of Radiant Tube Configuration (Vertical, Horizontal, Helical and Wicket Type) 4. On the Basis of Burner position (Bottom fired, Top fired and Side fired)

Design of Heater
API 560 : Fired Heater for Refinery API 530 : Heater Tube thickness in Refinery API RP 550 : Installation of Instruments and Control System for Fired heater and Steam Generation EA 7301 : Guidelines for Noise

DCU HEATER(14-FF-00-101 A/B) CONFIGURATION

Balanced Draft, Twin Cell, Cabin Type, Horizontal Tubes Double Fired. Heat Absorption :- 17.2 MMKcal/Hr No of Tubes in Radiation Zone:- Total-64 (32 / Cell) No of Tubes in Convection Zone:-56 No of Soot Blowers:-16/heater No of Burners:-32/heater

Fluid Handled
Heater Feed:- VR from VDU column
1. Liquid (Kg/hr) 2. HC Vapor (Kg/hr) 3. Operating pressure (kg/cm2 abs) 4. Operating temperature(oC) 297.2 5. Liquid density (kg/m3)

IN 179605 22-28

OUT 143676 35929 5.25

506 751.3

908.5

Heat Distribution in Heater Section

Heat Distribution in Heater Section

Radiant Section : 70-75% Convection Section : 30-25%

DCU-Heater configuration & Air Flow

STACK DAMPER

327 C
CAPH AIR PREHEATER
B R I D G E

CONVECTION ZONE

163 C
GAPH ID FAN FD FAN

215 C

W A L L

RADIATION ZONE PLENUM CHAMBER

Amb

AIR FUEL GAS STEAM FUEL OIL

SOB-03 SOB-09 UV-09 Bird screen

UV-03 SOB-15 UV-08 SOB-08 UV-15 UV-14 SOB-14

SOB-07

CAPH

UV-21 UV-20 UV-19 SOB-05

14-FF-00101A

14-FF-00101B UV-11 UV-13

UV-18 SOB-01

UV-04 GAPH UV-16 SOB-16 SOB-17 SOB-04 UVUV-17

UV-06

IGV IGV SOB-02

UV-22

UV-12 UV-10

Why Two Heater ?

Normally both heater in operation To allow one heater to be offline for decoking while other heater is on 50-60% operation Heater can be decoked by pigging

DCU Heater sections

1. Convection Zone 2. Radiation Zone 3. Soot Blowers 4. Air Preheater Including Glass APH and Cast APH 5. FD Fan 6. ID Fan 7. Superheater 8. Burners 9. Snuffing Steam 10. Stack

DCU Heater sections

1. Convection Zone: DCU heater convection zone having 56 tubes Feed is preheated with flue gases. High skin temp. of convection tubes indicates more negative draft. Lower skin temp. of convection tubes indicates soot deposition. MP steam is superheated in the convection section.

DCU Heater sections

2. Radiation Zone: DCU heater radiation zone having 32 tubes/pass The radiant tubes are horizontal, and double fired. In the radiant section of the heater it receive radiant heat directly from the flames, gas and wall. The radiant zone with its refractory lining is called the firebox. Most of the heat is gained there.

DCU Heater sections

3. Soot Blowers Soot blowers are used for removing of soot deposited on finned tubes in convection zone DCU heater having 32 soot blowers During the soot blowing period keep close watch on the heater parameters (Furnace arch press high, draft) Bypass the Air Pre-Heater Section. Open stack damper slowly to maximum extent keeping close watch on Furnace draft. Inform Utility about increase in steam consumption during soot blowing operation

DCU Heater sections

Before starting the soot blowing, the steam line should be drained thoroughly. Any water carryover will damage the Refractory lining After line condensate draining open gradually steam valve fully Start soot-blowing operation one by one by keeping watch on furnace pressures. Still in case if any excess pressurization is observed soot blower to be stopped and further condensate removal process is to be repeated

DCU Heater sections

4. Air Preheater Including Glass APH and Cast APH An air preheater improves the efficiency of a furnace sometimes by as much as 5 to 10%. a) GAPH

GAPH is the first inlet of fresh air in tube side while shell side having flue gas No of glass tubes : 1850 OD & thickness : 32 mm , 2 mm Heating surface area : 394 M2


b) CAPH

DCU Heater sections

Preheated air from GAPH enters the tube side of CAPH The cast iron tubes have integral fins on both internal and external surfaces Heating surface area is 1960 M2

DCU Heater sections

5. FD & ID fan FD fan : To provide combustion air to burners by two nos of FD fan Total air requirement is 61372 kg/hr Both fan are running at 50% capacity In case of tripping of one fan other fan will auto start ID fan remove flue gas from heater, maintained draft in heater The ID fan and FD fan regulate the flow of air to the combustion chamber The ID fan and FD fan supplying combustion air under balanced draft condition

DCU Heater sections

6. Superheater In convection zone above the feed convection bank superheater is provided Saturated MP steam being fed and utilized flue gas heat into superheated MP steam 7. Snuffing steam Snuffing is the action of smothering a fire by using steam. As steam is inert and will not burn, it replaces the air around the fire causing it to suffocate. Snuffing steam is provided on the fire box side

Heater Safety Interlocks

The heater safeguarding system has the following trip initiators

S NO DESCRIPTION OF CAUSES CONSEQUENCES

Emergency switch

If there is manually activated emergency switch either from the DCS or field, the fuel gas, fuel oil supply to all burners including pilot are cut off

Low-Low heater feed flow

In case of low-low heater feed flow through any of the coil, the fuel gas and fuel oil to all burners of the furnace is cut off It is dangerous when the combustion chamber pressure becomes higher than atmospheric pressure since hot flue gas may leak to atmosphere thereby causing a risk to operating personnel and furnace out side wall. In this event damper of ID fan are open. If the condition remain same for 30 second then FD fan tripped and fuel gas and fuel oil supply to all burners including pilot is cut-off

High-High combustion pressure

Heater Safety Interlocks

S NO 4

DESCRIPTION OF CAUSES Low-Low combustion air pressure

CONSEQUENCES In case of low-low combustion air flow, caused for instance by a failure of the FD fan, combustion of fuel is not possible. In this event fuel gas and fuel oil supply to all burners including pilot is cut-off If there is a high level in the fuel gas KO drum there ia a chance of liquid fuel carryover which dose not combust completely in the burners. This is dangerous situation. Therefore, in the event of this condition the fuel gas and fuel oil supply to all burners including pilot is cut-off In case of the pressure of the fuel gas going to the burners can become higher than the maximum pressure for which the burners designed, the fuel gas firing has to be tripped

High-High fuel gas KO drum level

High-High fuel gas pressure

Heater Safety Interlocks

S NO 7

DESCRIPTION OF CAUSES Low atomizing steam/fuel oil differential pressure

CONSEQUENCES If the differential pressure between the steam and fuel oil falls becomes too low, there may be insufficient steam being supplied to the burner to provide sufficient atomizing of the fuel oil. In this case the fuel oil supply to burners are cut-off In case of high-high heater outlet temp., the fuel gas and fuel oil supply to all burners is cut-off In case of failure or mechanical problems with the FD fan the other fan will take full load(100%), if even speed not recovered then fuel gas and fuel oil supply to all burners including pilot is cut-off If the air to fuel ratio is too low, complete combustion of the fuel may not occur. In this event the fuel gas and fuel oil supply to all burners including pilot is cut-off When ID fan is not in operation , draft is lost then by pass around APH will open to ensure air circulation. Bypass auto close when the ID fan restart within 30second

8 9

High-High heater outlet temperature Forced draft fan low speed

10

Air/fuel ratio

11

Loss of ID fan detection

Heater Safety Interlocks

S NO 12

DESCRIPTION OF CAUSES High-high heater outlet pressure

CONSEQUENCES During steam spalling of the heater coils, spalled coke may cause blockage of the coil. This causes overpressure the coils. In this event In this event the fuel gas and fuel oil supply to all burners is cut-off. This trip only be activated during spalling. It shall be bypassed during normal operation to avoid spurious trips due to pressure fluctuation during coke drum switching In this case fuel oil supply to all burners is cut-off In this case the fuel oil and fuel gas supply to all burners is cut-off

13 14

High-High fuel oil pressure High-High pilot gas pressure

15
16

Low-Low fuel gas pressure

Low-Low fuel oil pressure

Fuel gas supply to burners will cut-off

If the pressure of the fuel oil to the main burners falls below the minimum pressure for which the burners designed, the fuel oil supply is cut-off The fuel gas and fuel oil supply is cut-off

17

Low-Low pilot gas pressure

Heater Start-up

Commission steam tracing on fuel gas & fuel oil lines to the heater and check that the fuel gas knock-out drum is free of liquid. Open snuffing steam to the fire box and purge the heater for 15 minutes minimum Gas test the firebox at representative points for the presence of inflammable gas/vapour. Use inspection ports Start FD fan and ensure the FD fan discharge dampers are in open condition. Purge the heater with 6 times of furnace volume of air for 15 minutes to eliminate explosive mixture and followed by a gas free test. If not done there will be accumulation of fuel gas inside the heater

Heater Start-up
due to passing of fuel gas block valve, which results in the formation of explosive mixture and it may explode while introducing igniter for lighting burner. Open the stack or flue gas damper fully and ensure the damper indications in field and control room are in ON condition. If there is a delay between the gas free test, and lighting of the burners, the fire box must be re-purged and retested. Bypass the APH initially and start ID fan Bypass fuel shutoff interlocks Drain condensate from the fuel gas pilot line before light-up pilot burners. same procedure is applicable to fuel gas line Gas oil would be utilized for the cold & hot oil circulation

Heater Start-up

Open pilot gas main block valve. Open gas to the pilot burner and press the igniters. Observe that the pilot burner has ignited. If necessary, adjust the air control of the pilot burner, so that the flame is stable and satisfactorily Do not attempt to light pilot burners from an adjacent pilot burner If the initial pilot fails to ignite, shut off the gas supply to that burner, try the adjacent pilot and repeat the sequence Ignite all pilot burners individually and adjust the pressure in the pilot fuel gas header to obtain steady flames

Heater Start-up

Slowly open the main fuel gas supply valve. Reset the shutdown valve and pressurise the system up to the burner valves. Drain condensate from the header. Condensate carryover inside the fire box will result in explosion and back fire which may damage to the equipment and the persons employed. Gradually open the burner gas valve until the burner ignites from the pilot Continue opening the valve until a stable flame is obtained. Ignite remaining burners as required and regulate to slowly increase the heater COT to about 90 C Residual water in the equipment and circulating gas oil (cold oil circulation- 50 % of normal feed rate) may start

Heater Start-up

vaporizing in the towers. Now ready to start fuel oil burner The fuel oil system must be circulating steadily at the required temperature, pressure and at a sufficient rate of flow. Check that the steam tracing on the heater fuel oil supply system is in commission and operating satisfactorily Commission the atomizing steam supply to all burners, then adjust the desired light up pressure Slowly open the main fuel oil supply valve, reset the shutdown valve and pressurise the system up to the burner valves - check for leaks. Adjust the main fuel oil supply valve (such that) to give the recommended fuel oil pressure at the burner

Heater Start-up

Gradually open the burner oil valve until the oil spray ignites from the pilot flame. Continue opening oil to the gun until a stable flame is obtained. Adjust air registers for proper flame shape Inspect the flames frequently. If any one of them is unsatisfactory or goes out, shut off the fuel, replace the oil gun with a clean one, and re-ignite. After satisfactory ignition of all burners check for heater outlet temp. and rate of vaporization in coker fractionator column High vaporisation may cause rapid overfilling of overhead system and tube fouling

Heater Start-up

Make sure that this vaporization is not excessive by checking the overhead separator levels Drain off water as required Then increase the heater outlet temp. @ 10 C/hr Light up additional burners as necessary when heater outlet temp have reached 150 C then hold this temp. for 4 hour or until the temp. of all circulating systems have stabilized Start HP steam injection to the inlet tubes of coker heater Start MP steam flow through the steam superheater coil if necessary and vent to atmosphere until the product strippers are ready

Heater Start-up
When the temp has risen sufficiently some vaporization will occur in the coker fractionator and will flow to the overhead condensing system The heater outlet temp is raised up to 290 0C @ 30 0C /hr. now VR can be line up When flue gas temp reached to 300 0C then line-up APH Increase the firing rate to bring the COT to 493 0C in about 2 hr Commission the heater outlet temp controller Closely monitor the heater firing conditions both from field & from DCS Switch all fuel firing controls from manual to automatic After getting desired heater outlet temp.(506 0C) optimize heat load on heater

Heater Shutdown

Take the heater coil outlet TIC in manual mode and place the fuel on manual pressure control The firing rate on the burners is decreased under manual control lowering the process outlet temperature at a rate of 25-30 C per hour till 426 C Shut down main burners as and when required and keep pilot burner in service As COT reaches 426 C bypass coke drum Discontinue fresh feed to feed surge drum Continues reduce COT to 385 C @ 70 C/hr (max) and stop HP steam injection to heater Reduce heater coil HC flow rate to 60% of design flow

Heater Shutdown

After attaining COT of 285 C isolate main feed valve and flush the line with FO for 15 minutes Vent the superheater MP steam to atmosphere At COT of 230 C actuate the ESD of fuel gas Purge coil inlet with steam to displace HC from the coil tubing for 30 min(min) Stop pilot burners

Thanks