TRAINING MANUAL FOR FURNACES AND FIRED HEATERS oy {MECHANICAL - STATIC) DOCUMENT NO. ESSAR” ah R[E[O)-[M¢|-[s[t/c] - T/R[M] -[ofosa] - of DATE OF ISSUE: 07/08/2009 a REFINERY EXPANSION OPERATIONS ESSAR OIL REFINERY, VADINAR er. 27 eee Hiren Shah G Ramanathan / VV Nair OVLSarma PREPARED BY REVIEWED BY ‘APPROVED BY . a Essar sana | - em ESSAR OIL LIMITED: DOC NO. a eer eNO aa. [sareesTRAINING MANUAL FOR FURNACES AND FIRED HEATERS 21. 22. 23. Ba. 32. 4a. 42. 43, 44. TA. 72. 73. 74. 75. 78. at. 82. 83. Ba, a 10. 10.1. 10.2. 103. 10.4. 105. 10.6. 1. 2. 1a. 12.2, 123. 2B. INTRODUCTION ‘TYPES OF HEAT TRANSFER HEAT TRANSFER BY CONDUCTION. ERT TRANSFER BY CONVECTION. EAT TRANSFER BY RADIATION ... PURPOSE AND DESIGN CONSIDERATIONS. PURPOSE OF THE FURNACE... DEsiGn Consivenarions, ‘TYPES OF FURNACES. [NATURAL DRAUGHT FURNACE . INDUCED DRAUGHT FURNACE... FORCED DRAUGHT FURNACE. ‘BALANCED DRAUGHT FURNACE soe AL VERTICAL FURNACE svininnnninnnnnnnnesse 1S HORIZONTAL FURNACE. 7 4 CONSTRUCTION OF A VERTICAL FURNACE eee 15 FURNACE SHELL AND REFRACTORY LINING. RADIANT SECTION AND TURES . CONVECTION SECTION AND TuBES BURNER ASSEMBLY «000 ‘BURNER AIR INLET ‘STACK AND DAMPER FURNACE PARTS. : : : 2) ‘AiR PREHEATER BoweR.. [AIR PREHEATER. 23 ‘START-UP AND SHUTDOWN OPERATIONS PRE START-UP AND COMMISSIONING INSPECTION. Devine Our ProceDune ‘TVPICAL START-UP SEQUENCE . AUTOMATIC IGNITION SySTEM. TVPICAL SHUTDOWN SEQUENCE EMERGENCY SHUTDOWN .. ‘SAFETY PRECAUTIONS sevnnnnnnnnnnnnnensee 30 (GENERAL OPERATING GUIDELINES. . a4 ContRouING ComausTION. FLAME IMPINGEMENT AND AFTER-BURNING.. FLUE GAS ANALYSS.. (GENERAL OPERATING HINTS . 32ow 1. INTRODUCTION Furnaces are a form of heat exchanger which, unlike other forms, employ the three basic forms of heat transmission, namely radiation, convection and conduction, The other forms of heat exchangers only employ the conduction type of heat transfer and to a lesser degree convection. Radiation is the transmission of heat from a hot body to a cold body, not in contact with each other, by wave motion through space. Heat waves (or radiated heat) are very similar to light waves because they move in straight lines as light does and at the same speed. To receive heat by radiation you must be able to see the object which is radiating heat. In a furnace the object radiating the heat is a flame produced by the combustion of J fuel at a’burner. ‘Combustion is the process of releasing the energy of 9 fuel in a form which can be used in a process. This energy form is what we know as heat. Furnaces are employed in a processing plant to provide a large source of heat which is available to heat various process streams. Furnaces may be simply defined, therefore, as an enclosed space where heat is produced by the process of combustion. Fuel burning in a furnace exchanges heat with a process fluid flowing through tubes inside the furnace. The fuel burnt in a furnace may be either solid, liquid or gaseous. In most plants, processing natural gas and its associated liquids, the fuel is mainly gaseous. This manual will explain the purpose, design and construction of typical furnaces employed in a process plant with particular emphasis on the most common type used in natural gas processing plants. This type of furnace is the vertical, cylindrical gas fired type. 2. TYPES OF HEAT TRANSFER Heat can be transferred in three ways:-by conduction;-by convection;-by radiation. 2.1, HEAT TRANSFER BY CONDUCTION Heat is transferred by conduction when heat is moving from one part of an object to another part of the same object, without there being any movement or mixing of particles. ‘An example of heat transfer by conduction is a spoon in a cup of hot tea. After a while the whole spoon gets hot. The heat transfer depends on the conductivity of the substance. Copper, for