Furnace Operation and

Trouble-shooting

By: Vineet Singh

 FURNACE
Furnace, also called heaters are vital equipment in petroleum refineries.
Basic function of Furnace: Furnace is basically a heat-exchanging equipment
in which fuel is burnt and the heat generated by combustion is used to heat up
fluids flowing through tubes housed inside the furnace shell.

In process unit furnace, the fluid inside tube is Hydrocarbon.

Furnace is termed as boiler if the fluid inside tube is boiler feed water.

Different names of furnace:

Process heater, Fired heater, Process furnace, Direct fired heater and heater.

Process objective of furnace in AVU’s:

For main fractionating column heat requirement and for column reboilers.
 FURNACE
Different types of furnaces are broadly classified as based on:

 SIZE :Big or small ( less than 10 MM kcal/hr heat duty)

 SHAPE: Rectangular box, cylindrical

 TUBES: Horizontal, vertical or whether located near or at the center of furnace

wall

 BURNERS: Fuel gas, Fuel oil, or dual type and side burner, bottom or top fired.

 CONVECTION SECTION: arrangement of flue gas path, studded or non studded.

 STACK: Number and height

 DRAFT: Natural , Induced , Forced or Balanced draft furnace.

 FURNACE
COMPONNET AND ACCESSORIES OF FURNACE AND THEIR FUNCTIONS

MAJOR COMPONENT
A) Fire box
B) Burners
C) Tubes
D) Stack

ACCESSORIES:
 Induced draft fan, Forced daft fan, combustion air and flue gas duct
 Air preheater
 Fuel system ( fuel oil, Fuel gas, pilot gas)
FIRE-BOX: The main function of fire box is to house the tubes and burners.

BURNERS: There are four major type of burners.

a) GAS BURNERS

b) OIL BURNERS

c) PILOT BURNERS

d) COMBINATION BURNERS

Gas burners and brief on primary and secondary air

Gas burners are exclusively for burning fuel gas.

Types of gas burners:

Non-premix type: Mixing of air and gas in the furnace

Premix type: Partial or complete mixing of air with fuel before combustion.

Air that is premixed in the burner knows as Primary air and the remaining air
admitted externally is called Secondary air.
OIL BURNERS:

In addition to mixing of fuel and air, oil burners are capable to atomize the fuel
oil in small droplets.

Atomizing media: MP steam

Atomized fuel behaves like fuel gas and readily burns.

The main parameter for proper atomization is fuel oil viscosity. The fuel oil
viscosity should be preferably low. Fuel oil must be heated in fuel oil heater
prior to atomization.

PILOT BURNERS:
These are small gas burner (pre-mix type) used as pilot for safety.

These pilot burners are lit first before main gas and oil burners. In case of
emergency failure of main gas burner, pilot burners prevents the gas
accumulation and consequent explosion.

COMBINATION BURNERS:
Most widely used burner in which fuel gas, fuel oil and pilot gas are fitted
together in one assembly.
STACK: It is a large diameter pipe to dispose off flue gas. The stack damper
is located at the base of stack. The stack damper is butterfly type valve to
regulate the draft ( pressure) in furnace.

FORCED DRAFT FAN: It supplies air to the burners for complete combustion
of fuel fired in heater.

Type: Centrifugal fan equipped with inlet guide vanes or variable frequency
drive for controlling air flow rate. Normally two fans are provided, in case of
failure of any one other one takes full load.

INDUCED DRAFT FAN: It sucks the hot flue gas from down stream of
convection zone via air pre-heater and discharges it to atmosphere through
stack. It helps to maintain balanced draft in the box.

Type: Centrifugal fan equipped with inlet guide vanes or variable frequency
drive for controlling draft. In case of its failure, the stack damper gets full
open to discharge flue gas from the box.
 AIR-PREHEATER ( APH) :

The air pre-heater is installed to improve the efficiency of heater. The heat of
outgoing hot flue gas is utilized to preheat the combustion air from FD fans.

Type: Plate type heat exchanger having large surface area.

To avoid cold end corrosion of APH elements are provided with glass tubes.

Tube side fluid: Flue gas

Shell side fluid: Air

FUEL SYSTEM:

Fuel gas is supplied from the refinery gas header. Steady FG pressure is
maintained for control system. Any liquid condensate is settled and drained in
FG KOD pot for liquid free FG supply to burners.

Fuel oil is stored in the tank and supplied by F.O pump ( gear type) to F.O header
of the unit. Separate take off to individual oil burners are provided.

The shut down valves are provided in FG and FO supply line for emergency shut-
off of firing by automatic interlock system.
 FURNACE OPERATION:
START-UP

1. Inspect furnace for readiness . Check all SDV are closed.

2. Establish flow in the furnace coils.

3. Purge the furnace with box purging steam. Minimum 30 min.

4. Start FD fan for air purging in parallel.

5. Ensure that draft is negative.

5. Light up pilot gas burners one by one with the help of ignitors.

6. Once pilot burners are lit, Open SDV and CV of FG and proceed for main FG
burner light up one by one. Adjust air to burners.

7. Open SDV of FO, Light up oil burners one by one to gradually increase the
fluid temp.
 ROUTINE MONITORING OF FURNACES
1. Check that furnace draft at arch is negative ( -2 to - 4 mmwc).

2. Furnace refractory for any damage, Hot spot.

3. Tubes, Tubes supports, Tube hammering, bending of tubes and any

vibration.

4. Check excess air , flame pattern, any flame impingement over tubes.

5. Check that Skin temp. of the tubes, arch temp. are with in range.

6. Check that stack temp. is with in permissible limit.

7. Check and ensure FG and FO pressure above tripping value.

8. Check and inspect healthiness of FD and ID fan.

9. Check for any leak in FG FO line.

10. Ensure the differential pr. of atomizing steam and FO is above 1.0 kg/cm2g.

11. Ensure daily soot blowing of the convection zone.

 FURNACE OPERATION
DO’S
1. Before opening peephole ensure draft is negative.

2. Always use ignitors for pilot burner light up

3. In case of flame failure, immediately close fuel supply valve to burner.

4. Always keep the atomizing steam in open condition in idle FO burners.

5. After total flame failure or furnace trip, ensure all fuel supply is
properly isolated and box is thoroughly purged with steam or air.

6. Regular soot blowing.

7. During soot blowing ensure stack damper is fully open.

8. Always flush the oil burner after stopping the oil firing.

9. Always operate stack damper for draft control and air register for
excess air control.
FURNACE OPERATION :
DONT’S

1. While opening peephole never stand in front of peephole.

2. Never ignite the burner from other adjacent lighted burner.

3. Never allow flame impingement on tubes. Adjust flame pattern.

4. Do not bypass interlocks except during maintenance job/ start up.

5. If the oil burner is in line, never open the flushing steam of oil
burner.

6. Never light up the furnace if there is no flow in the coils.

7. Do not allow O2 % reading less than 2.0 %.

8. Do not allow + ve draft.

 FUEL GAS BURNER FLAME PATTERN

FUEL GAS BURNER FLAME PATTERN

 CORRECT GAS BURNER FLAME SHOULD BE:

 CLEAR, SMOKELESS, BLUE COLOR WITH
YELLO FRINGE.
 THE SHADING FROM BLUE TO YELLOW
DEPENDS UPON CARBON CONTENT IN FUEL
GAS

 MORE CARBON MORE YELLOWISH FLAME

AIR FUEL GAS

 FUEL GAS BURNER FLAME PATTERN

 FUEL GAS BURNER FLAME PATTERN

INCORRECT GAS BURNER FLAME :

 LONG, SMOKY, IMPINGING ON TUBES

 REASON:
LOW AIR, LOW GAS PRESSURE

AIR FUEL GAS

 FUEL OIL BURNER FLAME PATTERN

FUEL OIL BURNER FLAME PATTERN

 CORRECT FUEL OIL BURNER FLAME :

 CLEAR, SMOKELESS, STEADY,
YELLOW TO YELLOWISH- ORANGE
COLOR FLAME

STEAM

AIR FUEL OIL

 OIL BURNER FLAME PATTERN

 FUEL OIL BURNER FLAME PATTERN

INCORRECT FUEL OIL BURNER FLAME :

 FIRE FLIES IN THE FLAME

REASON: FIRE FLY OCCURS DUE TO WET

STEAM, WATER IN THE OIL, LOW FO
[Link] STEAM TO BURNER.
 ADJUST ABOVE PARAMETER TO NORMAL
TO RECTIFY THE FLAME

STEAM

AIR FUEL OIL

 OIL BURNER FLAME PATTERN


INCORRECT FUEL OIL BURNER FLAME :
 FLAME LIFT-OFF

REASON: HIGH STEAM PREESURE

 ADJUST ABOVE PARAMETER TO NORMAL
TO RECTIFY THE FLAME

STEAM

AIR FUEL OIL

 OIL BURNER FLAME PATTERN

 FUEL OIL BURNER FLAME PATTERN

INCORRECT FUEL OIL BURNER FLAME :

 VERY BRIGHT FLAME

REASON:TOO MUCH EXCESS AIR

 ADJUST ABOVE PARAMETER TO NORMAL
TO RECTIFY THE FLAME

STEAM

AIR FUEL OIL

 OIL BURNR FLAME PATTERN

FUEL OIL BURNER FLAME PATTERN

 INCORRECT FUEL OIL BURNER FLAME :

 LONG, SMOKY, IMPINGING ON TUBE.

 REMEDY:

Increase air, Increase steam pressure,

Increase FO temperture, Check alignment
of gun, check for any damage in the tip.

STEAM

AIR FUEL OIL

 TROUBLE-SHOOTING
SL TROUBLE CAUSE SOLUTION.
Flame back-fire Low Furnace draft or +ve Increase damper opening.
1.
pressure
Burners go out Fuel-air mixture too lean Reduce air, clean oil
2.
or burner tip is choke. burner tip.
Erratic flame A) Lack of air A) Adjust air register
3.
pattern B) Excess firing B) Reduce firing rate
C) Burner tip plugged C) Clean the burner
4. Pulsating or A) Lack of draft A) Check stack damper
breathing B) Fuel rate low B) Increase fuel rate
5. Flame too long A) Inadequate air
A) Increase air
B) Low atomizing
B) Increase atom. steam
steam for oil burner
flame
6. Thin oil burner Too much atomizing Reduce steam or increase
flame steam oil pressure.
7. Dazzling white Too much excess air or Adjust air or steam
flame in oil burner atomizing steam
 TROUBLE-SHOOTING
SL
TROUBLE CAUSE SOLUTION.
8. Flame ignites & Lack of draft Reduce firing rate and
goes out check stack damper
alternatively
9. Hazy and yellow Inadequate air Increase air
flame
10 Reddish flame with Inadequate air Increase air
smoke around in oil
flame
11 Sparkles in oil A) High viscosity of FO A) Increase FO temp.
burner flame B) Dirty burner tip B) Clean the burner
C) Water in FO or steam C) Check steam trap
12 Uneven flame at tip Dirty tip Burner tip cleaning

13 High stack temp. A) High excess air/draft A) Reduce excess

B) Fouling in conv. Zone air/draft
C) Stack damper B) Soot blowing
open/passing C) Close stack damper
 TROUBLE-SHOOTING
SL
TROUBLE CAUSE SOLUTION
14 Excess smoke A) Lack of atomizing A) Check oil flame
from stack steam B) Adjust and increase air
B) Increased firing C) Shut down the unit
without increasing air
C) Tube failure

15 High skin temp. A) Coking in tube A) Adjust feed rate

B) Flame impingement distribution and firing
B) Adjust flame pattern
16 Uneven color of Poor flame distribution Readjust flame pattern light
bricks or tube causing uneven up all burners for equal heat
hangers heating distribution
17 Arch Inadequate excess air Open the damper to increase
temperature too draft or adjust excess air
high
 FURNACE INTERLOCKS

(A) LOW FUEL PRESSURE: Low fuel pressure ( FO or FG) may cause flame

failure. This interlocks actuates on sensing low pressure in FG or FO and led

to automatic shut down of SDV to avoid flame failure.

(B) LOW FLOW IN COILS: Low flow in any of the pass may cause

overheating, coking and damage of tubes

This interlock actuates automatic SD of FG and FO firing in case any pass

flow is less than minimum.

(C) LOW COMBUSTION AIR PRESSURE: Less combustion air to furnace

creates accumulation of unburnt [Link] interlock actuates on low pressure

of air and led to automatic SD of FG and FO SDV’s

 FURNACE INTERLOCKS
(D) HIGH ARCH PRESSURE: positive pressure in the furnace causes back fire.
This interlock actuates on sensing high arch pressure and led to automatic SD of
FG and FO SDV’s.

(E) FD FAN FAILURE: In the event of FD fan failure Fuel supply to furnace will cut-
off followed by opening of stack damper and tripping of ID fan.

(F) ID FAN FAILURE: ID fan failure causes pressurization of furnace if the dampers
are closed. This interlock actuates automatic opening of stack damper with in set
time, failing which fuel supply to furnace will cut off and FD fan shall trip to stop
cold air entry to avoid thermal shock.

(G) HIGH ID SUCTION TEMPERATURE: High temp. at ID fan suction may damage
the IGV. This interlock actuates tripping of ID fan.
 BURNER MANAGEMENT SYSTEM
Burner Management System (BMS):
The control system dedicated to boiler-furnace safety, operator
assistance in the starting and stopping of fuel preparation and burning
equipment, and prevention of damage to fuel preparation and burning
equipment.
 ENERGY CONSERVATION
BENEFIT OF LOW EXCESS AIR: (10-15 % excess air is optimum for gas firing
and 20 % for oil firing)
 Reduced stack losses
 Reduced stack temperature
 Reduced firebox temperature.
 Reduced cold end corrosion
 Reduced Nox
 Reduced flue gas pressure drop
 Fuel savings
 Increased capacity

However, too low excess air can be dangerous as it can lead to secondary
burning, localized heating, flame impingement, high skin, and coking.
Air deficiency may lead to Furnace explosion , High CO emission.
 DEFINITIONS OF THE TERMS COMMONLY USED IN HEATERS

Atomizer: a device used to turn a liquid stream in to very fine droplets.

Blow-off: The loss of stable flame in a burner when the fuel exit velocity from
burner tip exceeds the flame velocity.

Burn-back: The internal burning with in the tip is called as burn-back.

Burner block: it is the especially formed refractory pieces that mount around the
burner opening inside the furnace and forms the part of the burner throat.

Burner throat: The opening formed by burner tile where the air flow is regulated
by air registers is the burner throat. It helps to stabilize the flame.

Burner velocity: The speed at which a flame front travels into an unburned
combustible mixture.

Detached stable flame: A flame that is not in contact with the burner itself but
burns with a stable flame front near the burner.

Diffuser: A device used in natural draft burner to create the continuous ignition
zone required for stable operation.
 DEFINITIONS OF THE TERMS COMMONLY USED IN HEATERS
Diffusion flame: The combustion state controlled by mixing phenomenon where
the air and fuel diffuse into one another until a flammable mixture is formed.
Arch pressure (draft): The pressure difference between the atmosphere and the
inside of the heater at a particular location where the draft is being measured.

Excess air: The amount of air needed by a burner that is in excess of the perfect
amount required for complete combustion of a given fuel.

Firing port: The orifice in the fuel tip where fuel is released in to the air stream for
mixing and burning.
Lift-off: A condition where the fuel/air mixture velocity is higher than the flame
velocity, causing it to detach from the burner.
Mounting plate: The part of a burner assembly that attaches the burner plenum to
the heater floor/wall.

Regen tile: A block of refractory material in oil burners, to redirect the intense
flame radiation back to the root of the spray to enhance the vaporization rates and
help to stabilize the oil flame.

Tramp air: The air that infiltrates in the heater through leaks.
 SUMMARY

The efficient operation of furnace require

continuous monitoring of firebox conditions,

excess air, draft, stack temperature, burner

flame pattern etc. and skill of identifying the

problem and taking appropriate timely action.