Furnace Operating Instructions PDF

PETRO-CHEM DEVELOPMENT CO., INC.
122 E. 42ND ST. / NEW YORK, N.Y. 10017
FURNACE
OPERATING
INSTRUCTIONS
Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

Location: Sayanks, Irkutsk, Russia Revision 0 September 14, 2009
Item No.: 141R001 / R-3501
TABLE OF CONTENTS
PART I – DEFINITION OF TERMS 1
PART II – GENERAL FURNACE OPERATION 8
PART III – PREPARATION FOR INITIAL STARTUP 12
1. GENERAL INSPECTION 12
2. FURNACE DRYOUT PROCEDURE ERROR! BOOKMARK NOT DEFINED.
FIGURE 1 – RECOMMENDED REFRACTORY DRYOUT CYCLE 19
PART IV – STARTUP PROCEDURE 20
PART V – NORMAL (PLANNED) FURNACE SHUTDOWN 23
PART VI – EMERGENCY FURNACE SHUTDOWN 24
PART VII – FURNACE TUBE DECOKING 26

PART I – DEFINITION OF TERMS
The definition of all terms used in this document are consistent with those set
forth in API Standard 560, Fired Heaters for General Refinery Services, Second
Edition, Section 1.4. For convenience, this section has been reproduced below.
NOTE: the terms “furnace” and “heater” are used interchangeably throughout this
document.
1.4.1 Air heater or air preheater is a heat transfer apparatus through which
combustion air is passes and heated by a medium or higher
temperature, such as the products of combustion, steam, or other fluid.
1.4.1.1 Direct air preheater is an exchanger, which transfers heat directly

between the flue gas and the combustion air. A regenerative air
preheater uses heated rotating elements and a recuperative design uses
stationary tubes, plates, or cast iron elements to separate the two
heating media.
1.4.1.2 Indirect air preheater is a fluid-to-air heat transfer device. The heat
transfer fluid, process stream, or utility stream, which has been heated
by the flue gas or other means. A heat pipe air preheater uses a
vaporizing/condensing fluid to transfer heat between the flue gas and air.
1.4.2 Arch is a flat or sloped portion of the heater radiant section opposite the
floor.
1.4.3 Atomizer is a device used to reduce a liquid fuel oil to fine mist.
Atomization media are steam, air, or mechanical.
1.4.4 Anchor or tieback is a metallic or refractory device that holds the

refractory or insulation in place.
1.4.5 Backup layer is any refractory layer behind the hot face layer.
1.4.6 Balanced draft heater uses a fan to supply combustion air and to remove
flue gases.
1.4.7 Breeching is the heater section where flue gases are collected after the
last convection coil for transmission to the stack or the outlet ductwork.
1.4.8 Bridgewall, division, or gravity wall separates two adjacent heater zones.

Location: Sayanks, Irkutsk, Russia
Item No.: 141R001 / R-3501 Page 1 of 31
1.4.9 Bridgewall temperature is the flue gas temperature leaving the radiant
section.
1.4.10 Burner introduces fuel and air into a heater at the desired velocities,
turbulence, and concentration to establish and maintain proper ignition
and combustion. Burners are classified by the types of fuel fired, such
as oil, gas, or combination of gas and oil. A secondary consideration in
classifying burners is the means by which combustion air is mixed with
the fuel.
1.4.11 Casing is the metal plate used to enclose the fired heater.
1.4.12 Castable is an insulating concrete poured or gunned in place to form a

rigid refractory shape or structure.
1.4.13 Ceramic fiber is a fibrous refractory insulation composed primarily of

silica and alumina. Applicable forms include blanket, board, module,
rigidized blanket, and vacuum-formed shapes.
1.4.14 Coil pressure drop is the difference between the coil inlet pressure and
the coil outlet pressure between terminals, excluding the effect of static
head.
1.4.15 Convection section is the portion of the heater in which the heat is
transferred to the tubes primarily by convection.
1.4.16 Corbel is a projection from the refractory surface generally used to

prevent flue gas bypassing the convection section tubes.
1.4.17 Corrosion allowance is the additional material thickness added to allow

for material loss during the design life of the component. It is the
corrosion rate times tube design life, expressed in inches (millimeters).
1.4.18 Corrosion rate is the reduction in the material thickness due to the
chemical attack from the process fluid or flue gas or both, expressed in
mils per year (millimeters per year).
1.4.19 Crossover is the interconnecting piping between any two heater coil
sections.
1.4.20 Damper is a device for introducing a variable resistance for regulating

volumetric flow of gas or air.
1.4.21 Butterfly damper is a single blade damper pivoted about its center.

Item No.: 141R001 / R-3501 Page 2 of 31
1.4.22 Louver damper is a damper consisting of several blades each pivoted
about its center and linked together for simultaneous operation.
1.4.23 Duct is a conduit for air or flue gas flow.
1.4.24 Efficiency, fuel refers to the heat absorbed divided by the net heat of
combustion of the fuel as heat input, expressed as a percentage.
1.4.25 Efficiency, thermal refers to the total heat absorbed divided by the total
heat input, expressed as a percentage.
1.4.26 Erosion is a reduction in material thickness due to mechanical attack

from a fluid, expressed in inches (millimeters).
1.4.27 Excess air is the amount of air above the stoichiometric requirement for
complete combustion, expressed as a percentage.
1.4.28 Extended surface refers to the heat transfer surface in the form of fins or
studs attached to the heat absorbing surface.
1.4.29 Extension ratio is the ratio of total outside exposed surface to the outside
surface of the bare tube.
1.4.30 Flue gas is the gaseous product of combustion including the excess air.
1.4.31 Forced draft heater supplies combustion air by a fan or other mechanical
means.
1.4.32 Fouling allowance is a factor to allow for a layer of residue that increases
pressure drop, usually a build up of coke or scale on the inner surface of
a coil, expressed as inches (millimeters). This value shall be used in
calculating the fouled pressure drop.
1.4.33 Fouling resistance is a factor used to calculate the overall heat transfer
coefficient. The inside fouling resistance shall be used to calculate the
maximum metal temperature for design. The external fouling resistance
is used to compensate the loss of performance due to deposits on the
external surface of the tubes or extended surface.
1.4.34 Guillotine blind is a single blade device that is used to isolate equipment
or heaters.
1.4.35 Header or return bend is the common term for a 180-degree cast or
wrought fitting that connects two or more tubes.

Item No.: 141R001 / R-3501 Page 3 of 31
1.4.36 Header box is the internally insulated structural compartment, separated
from the flue gas stream, which is used to enclose a number of headers
or manifolds. Access is afforded by means of hinged doors or removal
panels.
1.4.37 Heat absorption is the total heat absorbed by the coils excluding any
combustion air preheat, expressed in British thermal units per hour
(megawatts).
1.4.38 Heat flux density, average is the heat absorbed divided by the exposed
heating surface of the coil section. Average flux density for an extended
surface tube shall be indicated on a bare surface basis with extension
ratio noted, expressed in British thermal units per hour per square foot
(kilowatts per square meter).
1.4.39 Heat flux density, maximum is the maximum local heat transfer rate in
the coil section, expressed in British thermal units per hour per square
foot (kilowatts per square meter).
1.4.40 Heat release is the total heat liberated from the specified fuel, using the
lower heating value of the fuel, expressed in British thermal units per
hour (megawatts).
1.4.41 Heating value, higher (HHV), is the total heat obtained from the
combustion of a specified fuel at 600F, expressed in British thermal units
per pound or per cubic foot (kilojoules per kilogram or per cubic meter).
1.4.42 Heating value, lower (LHV), is the higher heating value minus the latent
heat of vaporization of the water formed by combustion of hydrogen in
the fuel, also called the net heating value, expressed in British thermal
units per pound or per cubic foot (kilojoules per kilogram or per cubic
meter).
1.4.43 Hot face layer is the refractory layer exposed to the highest
temperatures in a multiplayer or multicomponent lining.
1.4.44 Hot face temperature is the temperature of the refractory surface in

contact with the flue gas or heated combustion air. The hot face
temperature is used to determine refractory or insulation thickness and
heat transmitted. The design temperature is used to specify the service
temperature limit of the refractory materials.

Item No.: 141R001 / R-3501 Page 4 of 31
1.4.45 Induced draft heater uses a fan to remove flue gases and maintain a
negative pressure in the heater to induce combustion air without a forced
draft fan.
1.4.46 Manifold is a chamber for the collection and distribution of fluid to or from
multiple parallel flow paths.
1.4.47 Metal fiber reinforcement is stainless steel needles added to castable for
improved toughness and durability.
1.4.48 Monolithic lining is a single-component lining system.
1.4.49 Mortar is a refractory material preparation used for laying and bonding
refractory bricks.
1.4.50 Multicomponent lining is a refractory system consisting of two or more

layers of different refractory types; for example, castable and ceramic
fiber.
1.4.51 Multilayer lining is a refractory system consisting of two or more layers of

the same refractory type.
1.4.52 Natural draft heater is a unit in which a stack effect induces the
combustion air and removes the flue gases.
1.4.53 Normal heat release is the design heat absorption of the heater divided
by the calculated fuel efficiency expressed in British thermal units per
hour (megawatt).
1.4.54 Pass or stream is a flow circuit consisting of one or more tubes in series.
1.4.55 Pilot is a smaller burner that provides ignition energy to light the main
burner.
1.4.56 Plenum or windbox is a chamber surrounding the burners that is used to

distribute air to the burners or reduce combustion noise.
1.4.57 Plug header is a cast return bend provided with one or more openings
for the purpose of inspection, mechanical tube cleaning, or draining.
1.4.58 Primary air is that portion of the total combustion air that first mixes with
the fuel.

Item No.: 141R001 / R-3501 Page 5 of 31
1.4.59 Protective coating is a corrosion-resistant material applied to a metal
surface; for example, on casing plates behind porous refractory
materials to protect against sulfur in the flue gases.
1.4.60 Radiant section is that portion of the heater in which heat is transferred
to the tubes, primarily by radiation.
1.4.61 Radiant or setting loss is the heat lost to the surroundings from the
casing of the heater and the ducts and auxiliary equipment (when heat
recovery systems are used), expressed as percent of heat release.
1.4.62 Secondary air is the air supplied to the fuel to supplement primary air.
1.4.63 Setting is the heater casing, brickwork, refractory, and insulation,

including the tiebacks or anchors.
1.4.64 Shield section contains those tubes that shield the remaining convection
section tubes from direct radiation.
1.4.65 Sootblower is a mechanical device for discharging steam or air to clean

heat-absorbing surfaces.
1.4.66 Stack is a vertical conduit used to discharge flue gas to the atmosphere.
1.4.67 Strakes or spoilers are metal stack attachments that prevent wind-
induced vibration.
1.4.68 Target wall is a vertical refractory firebrick wall, which is exposed to

direct flame impingement on one or both sides.
1.4.69 Temperature allowance is the number of degrees Fahrenheit (Celsius) to

be added to the process fluid temperature to account for flow
maldistribution and operating unknowns. The temperature allowance is
added to the calculated maximum tube metal temperature or the
equivalent tube metal temperature to obtain the design metal
temperature.
1.4.70 Terminal is a flanged or welded projection from the coil providing for inlet
and outlet of fluids.
1.4.71 Tube guide is used with vertical tubes to restrict horizontal movement
while allowing the tube to expand axially.
1.4.72 Tube retainer is used to restrain horizontal radiant tubes from lifting off
the intermediate tube supports during operation.

Item No.: 141R001 / R-3501 Page 6 of 31
1.4.73 Tube support or tube sheet is any device used to support tubes.
1.4.74 Vapor barrier is a metallic foil placed between layers of refractory as a

barrier to flue gas flow.
1.4.75 Volumetric heat release is the heat released divided by the net volume of
the radiant section, excluding the coils and refractory dividing walls,
expressed in British thermal units per hour per cubic foot (kilowatts per
cubic meter).

Item No.: 141R001 / R-3501 Page 7 of 31
PART II – GENERAL FURNACE OPERATION
These instructions and/or precautions are provided as a supplement to the

operating guidelines already in use at each specific operating facility. They are not
meant to replace or counteract any policies (operational, safety or otherwise)
currently in use. Rather, they are suggestions based on Petro-Chem’s experience
that generally will help to optimize heater performance and minimize maintenance
costs.
• Flame condition – the flames should be checked for proper patterns

regularly and often, particularly when changes in heat load are expected.
When multiple burners are installed, the fires should be kept as uniform in
length and size as possible. All adjustments to the burners should be made
in accordance with instructions from the burner manufacturer.
Poor flame patterns can be characterized by, but are not limited to the
following:
o Leaning flames.
o Smoky or hazy appearance.
o “Sparklers” (oil firing).
o Unusually tall flames.
o Unusual color.
Poor flame patterns can be caused by many different factors, including:
o Improper heater operation, such as running with insufficient

combustion air or excessive draft.
o Fuel quality or delivery issues, such as changing composition,

inadequate pressure, moisture, poor oil atomization, fuel
contaminants, etc.
o Problems with the burners, such as misalignment of the tips,

improper port size or angle, damaged or fouled tips, foreign objects
in the burner, etc.
Burners should be adjusted so that there is no flame impingement on any

tubes. Flame impingement creates extremely high heat flux, which elevates
the tube temperature. Tube life can be greatly decreased, and tube failures

Item No.: 141R001 / R-3501 Page 8 of 31
may result from flame impingement. Elevated tube temperature may also
cause undesirable reactions, such as coke formation or degradation of the
process fluid. This in turn can further increase the tube temperature,
potentially beyond its design metal temperature.
In gas-fired furnaces, the true flame pattern may not be visible to the naked
eye. However, local hot spots on the furnace internals, as evidenced by
areas of varied color, suggest impingement by the non-luminous portion of
the flame.
• Excess air should be monitored regularly. Typically, 15 – 20% excess air is

optimal, which corresponds to 3 – 4 vol% excess oxygen in the flue gas for
most fuels.
Reducing excess air below 15% may be practical when using burners
properly designed for such operation. However, this should be done with
caution due to the possibility of incomplete combustion, which can result in
carbon monoxide (CO) and other combustibles accumulating in the flue gas.
Petro-Chem does not recommend operating with low excess air (less than
15%) if the heat load or the fuel quality varies significantly.
The symptoms of incomplete combustion resulting from inadequate excess

air include:
o Afterburning (see below).
o Hazy or smoky flames in the firebox.
o Black smoke coming from the heater stack.
• Afterburning results when there is insufficient excess air for complete

combustion in the radiant firebox. Air leakage into the furnace combines
with any remaining excess air to react with uncombusted fuel downstream
of the firebox. This overheats the heater internals and may subsequently
cause permanent damage. Afterburning may not be visible and may only
be evidenced by a rapid increase in stack temperature.
Afterburning is a potentially dangerous condition and remedial action should

be taken immediately. First reduce the firing rate, and then open the burner
dampers to admit more combustion air. Continue to decrease firing if
afterburning continues.
• Overloading – while Petro-Chem does not recommend operating the

furnace above its design operation, the variability of typical plant

Item No.: 141R001 / R-3501 Page 9 of 31
operations often results in occasional overloading of the heater.
Depending on the severity and frequency of these periods, as well as the
individual heater design, such overloading can degrade the heater’s
performance and reduce its useful life. Flames may become long and
large, potentially impinging on the tubes. Furthermore, extreme
overloading is unsafe due to the possibility of catastrophic failure and the
corresponding risk to plant personnel. If operation above the heater
design is desired, it is recommended that the proposed operating
conditions be forwarded to Petro-Chem for study so that absolute
limitations on the heater duty may be established or design changes
recommended.
• Furnace pressure (draft) – furnaces are typically designed to operate

under negative draft, i.e., so that the absolute pressure in the furnace is less
than the absolute atmospheric pressure. This is primarily achieved through
proper stack sizing, although some designs also utilize separate induced
draft fans to help create negative draft in the furnace.
In sections of the furnace where gas flow is unobstructed, draft generally

becomes more negative at lower elevations. Typically, draft is least
negative at the inlet to the convection section, and most negative at the
hearth (burner) level.
Furnace draft should be carefully monitored, since furnaces are not

designed to be airtight:
o Negative draft causes air to leak into the furnace. Very negative draft
results in increased leakage and poor efficiency, and can have a
negative impact on the burner operation.
o Conversely, positive draft causes flue gas to leak out of the furnace.
This poses a safety hazard for plant personnel and overheats parts
of the furnace that typically are not exposed to hot flue gas.
As such, draft should be kept slightly negative at the point of least negative
draft. In most cases this is at the radiant arch (convection section inlet).
Control is achieved by adjusting the furnace dampers and burner registers
or dampers, being careful to maintain good flame conditions.
• Air leakage into the furnace should be minimized for optimal combustion
conditions because, by design, all combustion air should enter through the
burners. Towards this end, all observation doors should be kept closed
when not in use, as well as pressure relief doors. If leakage continues to be

Item No.: 141R001 / R-3501 Page 10 of 31
significant, a program of sealing all heater penetrations is in order. Petro-
Chem can provide leak detection services, if so desired.
• Adequate process flow must be maintained to each heater pass at all

times. Low flow or loss of flow can result in overheating of the tubes, which
in turn could lead to undesirable conditions in the process fluid and/or tube
failure.
Optimal heater operation requires equal flow to each pass. Petro-Chem

does not recommend adjusting the individual pass flows to balance
the pass outlet temperatures. Rather, burner adjustments should be
made to achieve an even pass outlet temperature profile.
• Maintaining convection section performance – optimal performance of

the convection section is achieved when the outside surfaces of the tubes
and extended surfaces are clean. After continued operation this surface
may become fouled with particulates and compounds contained in the flue
gas, greatly reducing heat transfer. When this occurs, the convection
section surfaces can be cleaned in several ways:
o One method is to pass cold water through the tubes after the furnace
has been shut down, while simultaneously introducing steam into the
combustion chamber. The steam will condense on the outside of the
tubes and remove the deposits.
o Another method is to water wash the convection section extended

surfaces during shutdown. Start-up of the furnace should be done
gradually to permit excess moisture to steam off.
o Manual cleaning (lancing) of the convection section is another

method that can be used.

Item No.: 141R001 / R-3501 Page 11 of 31
PART III – PREPARATION FOR INITIAL STARTUP
1. GENERAL INSPECTION
Preparation for startup should begin with a careful physical inspection of

the furnace. The major items to check are as follows.
1.1 External heater inspection
1.1.1 Structural
1.1.1.1. Generally inspect the heater structure and verify

that all fieldwork has been completed. Critical
areas are the main load transfer points, such as
stack base, convection wall trusses, convection to
radiant splices and radiant bases.
1.1.1.2. Verify that terminals are either free to expand or

anchored per design drawings.
1.1.1.3. Verify that all blinds and slide gate guillotines

(isolation blinds) are operational and in the proper
position.
1.1.2 Stack damper
1.1.2.1. The full open and full closed position should be

visually checked for each damper and marked on
the damper linkage or operating cable.
1.1.2.2. The movement of the damper must be free and

unobstructed. It is imperative that the "full open"
position is in accordance with that shown on the
drawings. The damper must be capable of full
range of motion for proper operation of the
heater.
1.1.2.3. The observed damper position should be

checked for consistency with the outside
indicator. The grooves in the damper shafts
should be parallel to the damper blade, to
indicate actual damper position.

Item No.: 141R001 / R-3501 Page 12 of 31
1.1.2.4. Verify that the pneumatic operator moves the
damper blades properly between fully open and
fully closed. The actuator indicator should
correctly indicate damper position. These checks
should be done both from the control room and at
the local manual control station.
1.1.3 Instrumentation
1.1.3.1. Check all instrumentation and associated loops.

In particular, flow meters should be properly
“zeroed” and thermocouples should be checked
for reversed leads.
1.1.3.2. Verify all alarm set points.
1.1.3.3. Test the emergency shutdown system. (If

Applicable)
1.1.3.4. Verify the logic diagram for the Programmable

Logic Controller (“PLC”) and then test the
operation of the PLC. (If Applicable)
1.1.3.5. For start up and burner ignition sequencing refer

to Uhde Interlock Description Specification
(Unde Project No. 03-7354, Job Code: EDC
Cracking, Rev. 01 issue date February 16, 2007)
1.1.4 Blowing-out tubes – make certain that tubes are clear

and unobstructed by water or other foreign matter. Use
compressed nitrogen or air at a high enough pressure to
assure satisfactory flow. For multi-pass heaters each
pass must be blown independently. The inlet valves to
the other passes should be closed and nitrogen/air
forced through one pass at a time. A poly pig can also
be used to remove water and debris.
1.1.5 Verify that the tube coil has been properly tested.
Review construction records to verify that a proper
hydrostatic (or pneumatic) test was conducted, in
addition to any other specified inspections. These might
include field radiographs or weld hardness checks.

Item No.: 141R001 / R-3501 Page 13 of 31
1.1.6 Sampling Points – all connections not used for
instrument connections should be sealed off.
1.1.7 Burners – In addition to the following general items,

refer to the burner manufacturer’s Operating Manual for
a complete list of pre-startup checks.
1.1.7.1. Verify the burner position and orientation.
1.1.7.2. Verify that the burner tips are installed and

oriented correctly, and that the connecting piping
does not affect this orientation.
1.1.7.3. Check that all air shutters and dampers function

freely and handles indicate correct position.
1.1.7.4. Thoroughly blow out all fuel piping to remove any

foreign matter in the lines. This should include all
new or modified piping upstream of the burners.
Compressed nitrogen or air may be used, as long
as adequate pressure is available. This should
be done with the gas tips disconnected. On
multi-burner units fed from a single header, each
burner should be blown out independently, in
addition to all common piping upstream of the
burner.
1.1.7.5. Fuel gas lines should be pressure tested and

purged prior to use.
1.1.7.6. Blow down fuel gas knockout drums prior to use.
1.2 Internal heater inspection
1.2.1 Pressure parts (coils)
1.2.1.1. Verify that all temporary shipping braces, wires

and blocking have been removed. Check both
radiant and convection ends in header boxes.
1.2.1.2. Verify that all tube supports and guides are

properly installed.
1.2.1.3. Verify that sufficient clearance is available to

accommodate coil expansion.
Item No.: 141R001 / R-3501 Page 14 of 31
1.2.2 Refractories
1.2.2.1. Inspect as much refractory in the convection

section as possible prior to erection, since some
areas will become inaccessible after erection.
1.2.2.2. Verify integrity of the radiant refractory. Make

sure all construction joints are packed and that
there are no exposed casings or structure.
1.2.3 Burners – in addition to the following items, refer to the

supplier’s installation manual for pre-startup checks.
1.2.3.1. Inspect each burner to verify all gas tips are

clean, that plastic protection covers and tape
protection covers are removed and that tips are in
the proper position and orientation per burner
drawings.
1.2.3.2. Verify that burner tiles are installed properly,

using high-temperature grout, and are not broken.
All burner components must be free of
construction debris. Space between the tile and
floor refractory must be sealed with ceramic fiber
unless burner manufacturer requires that this
space be left open. Consult the manufactures
burner drawing and curves.
1.2.4 General
1.2.4.1. All construction materials such as unnecessary

scaffolding, ladders, tools, insulating materials,
pipe spool drops, structural steel drops, wood
forms and boards are to be removed for the
operator's safe movement about the furnaces.
1.2.4.2. After final inspection, all man ways and access

doors should be closed.

Item No.: 141R001 / R-3501 Page 15 of 31
2. FURNACE DRYOUT PROCEDURE
2.1 General
2.1.1 The convection section castable refractory has been

partially dried out in the shop. However, full Dry out of the
castable is required at the site.
2.2 Preliminary preparation for dry out
NOTE: It is the responsibility of all parties involved to insure that all

personnel involved in the operation of fired equipment have read and
understood the appropriate manuals, and are familiar with the
procedures to be used.
NOTE: The procedure outlined below represents a general outline of

the steps required. It is the responsibility of the plant personnel to
supplement these procedures with clarifications to accommodate the
integrated PLC safety shutdown system, which has been provided by
a company, if other than Petro-Chem.
2.2.1 Complete all inspections noted in Section 1.
2.2.2 Verify that adequate fire fighting equipment is present and

operational.
2.2.3 All personnel not associated with the dry out should leave
the heater area.
2.2.4 All nearby hot work should be stopped.
2.2.5 Blow down condensate drains on steam snuffing lines.
2.2.6 Verify that the burner and stack dampers are open.
2.2.7 Remove any blanks in the fuel lines.
2.3 Dry out procedure (with no cooling medium; refer to Figure 1 -

Recommended Refractory Dry Out Cycle)
2.3.1 Verify that the stack damper and burner dampers are wide
open.

Item No.: 141R001 / R-3501 Page 16 of 31
2.3.2 Purge the heater of combustible gases with either of the
forced draft fans before lighting burners. Purge for a
minimum of 15 minutes.
2.3.3 After forced draft purging, and before lighting the burners
using a portable igniter, the furnace should be checked for
combustibles using an appropriate instrument. For burner
ignition sequencing, refer to Uhde Interlock Description
Specification (Uhde Project No. 03-7354, Job Code: EDC
Cracking, Rev. 01, issue dated February 16, 2007) in
conjunction with the burner manufacturer’s (Hamworthy
Combustion) instructions.
WARNING: burner light off for dry out may be hazardous.

Refer to Part V – Furnace Startup for proper lighting
procedure.
2.3.4 Monitor the firebox temperature using the bridgewall

thermocouple (350213 & 350214) as a guide. Light
additional burners as necessary while adhering to the
required rate of temperature increase (see below, §2.3.7).
2.3.5 Maintain a minimum of 50% excess air (∼ 8 – 9 vol% O2 in

the flue gas) at all times for an optimal dry out.
2.3.6 Increase firing in order to raise the bridgewall temperature

to 90°C, at a rate of 15- 20 °C / hr, and hold for 4 hours at
90 °C.
NOTE: the recommended rate of temperature increase 10-

15 °C / hr should be carefully adhered to. Rapid increases
in temperature will result in a poor dry out, sacrificing the
integrity of the refractory.

to 150 °C, at a rate of 15- 20 °C / hr.
2.3.8 Hold at 150 °C for 14 hours.


Item No.: 141R001 / R-3501 Page 17 of 31
2.3.13 A good crosscheck on the progress of refractory dry out is

the shell (casing) temperature. When the dry out begins,
the shell is initially cold since the moisture next to the shell
has not yet heated up. After some time the shell heats up
as the moisture behind the casing begins to boil. Finally,
the casing will cool back down to its rated temperature when
the moisture behind the shell is driven off.
It is recommended that plant personnel monitor the shell

temperature throughout the dry out. If the last fall in shell
temperature has not occurred by the end of the 72-hour
period, additional drying is needed and the final hold step
(540 °C) should be maintained until the shell temperature
has dropped to its rated temperature.
2.4 After dry out is complete:
2.4.1 It is good practice to shut down the heater to inspect the

refractory, and make repairs if necessary.
2.4.2 If the heater will be left idle, take measures to prevent

excessive moisture from entering the furnace. Close off all
points of entry, including the dampers, peep doors, access
doors, air registers, etc. Consider a stack rain hood or
canvas cover if the heater is to be left idle for a long period
of time.

Item No.: 141R001 / R-3501 Page 18 of 31
FIGURE 1 – DRY OUT CURVE

Item No.: 141R001 / R-3501 Page 19 of 31
PART IV – STARTUP PROCEDURE
NOTES
• For the initial startup of the heater, first verify that all the checks
outlined in Part III of these Operating Instructions have been
completed.
• This procedure is provided as a supplement to the operating

procedures already in use at each specific operating facility. It is
not meant to replace or counteract any policies (operational,
safety or otherwise) currently in use.
• The furnace should be started up with all control loops initially in

manual. This is because the controllers are tuned for normal
operation. Startup is an unusual operating condition for which the
controllers are not properly tuned.
• The procedure outlined below represents a general outline of the

steps required. It is the responsibility of the plant personnel to
supplement these procedures with clarifications to accommodate
the integrated PLC safety shutdown system, which may have
been provided by a company other than Petro-Chem.
1. Preliminary preparation
1.1 Notify the appropriate plant personnel that the furnace startup is
imminent.
1.2 Verify that all firefighting facilities are operational.
1.3 Verify the following:
• All fuel valves are closed.

• All burner air dampers are 100% open.
• The stack damper is 100% open.
1.4 As fuel gas is brought into the area, check all gas valves and blinds
for potential leaks.
2. Start flow to furnace.
2.1 If there is a process fluid bypass around the furnace, verify that it is
closed.
Item No.: 141R001 / R-3501 Page 20 of 31
2.2 Initiate circulation of process fluid through the coils. Increase flow
rate to as close to design as possible, with equal flow to all passes.
3. Purge the heater firebox with either of the two forced draft fans prior to
igniting any burners. Purging should be sufficient to allow 4 volume
changes in the heater or purging for a minimum of 15 minutes will achieve
this.
Petro-Chem strongly recommends gas testing the radiant firebox prior to

igniting any pilots, if applicable, or burners to verify that no combustibles are
present.
4. For start up and burner ignition sequencing refer to Uhde Interlock

Description Specification (Uhde Project No. 03-7354, Job Code: EDC
Cracking, Rev. 01 issue dated February 16, 2007).
5. With portable igniter, begin igniting the burners, following the

instructions from Hamworthy Combustion. Initially maintain minimum firing
on each burner, igniting additional burners, in a symmetrical fashion, as
more heat is required. This will result in the most even heat distribution, and
minimizes the potential for problems due to localized areas of high heat
release.
6. Verify that proper flow is established to the process coil by noting the
individual pass outlet temperatures. If one or more temperatures are not
increasing, this may be a sign of blocked flow. Since this can quickly lead to
overheating of the tubes, action must be quickly taken to either verify or
discount the low temperature reading(s) in order to avoid a potentially
unsafe situation. A qualitative way to crosscheck the outlet temperature
reading is to check if the outlet flange for that pass is cooler than the other
passes. If it is determined that any one of the pass outlet flanges is
not getting hotter, the flow is probably restricted in some manner and
the furnace must immediately be shut down to investigate the cause.
7. Slowly increase firing as required by increasing the fuel pressure while

maximizing the process fluid flow rate.
7.1 With the burner dampers 100% open, adjust the operating air inlet
fan damper to obtain good flame color and pattern. However, do
not be overly concerned with minimizing excess air during the
furnace startup. Maintaining sufficient combustion air is the primary
consideration, and takes precedence over efficiency for this special
operating condition. Furthermore, additional combustion air will be

Item No.: 141R001 / R-3501 Page 21 of 31
required as firing is increased, so closing back the fan air inlet
damper is counterproductive for later stages of the startup.
7.2 If draft becomes too strong and affects flame quality, close back on
the stack damper.
NOTE: it is important to maintain a slow, gradual heat-up in order to avoid

potential over-firing. Over-firing potentially results in damage to the furnace
and/or undesirable process conditions (e.g., coking, cracking, chemical
degradation, unwanted vaporization, etc.), which in turn may lead to an
unsafe condition for plant personnel. For these reasons, Petro-Chem
recommends a maximum outlet temperature increase in any individual pass
of 100 °F/hr.
NOTE: as vaporization begins, there is a potential for surging between

passes. The pass flows and outlet temperatures should be carefully
monitored to detect potential overheating or vapor locking. If this occurs, the
flow to the problem pass should temporarily be increased until pass balance
is restored. Surging will become less significant as the heater approaches
its design operating condition due to increased pressure drop across the
passes resulting in a better flow distribution.
8. Begin placing controllers on automatic as the furnace operation

approaches normal. If this is the initial startup for the heater, use extra
caution when placing controllers on automatic to avoid upsets that can
result from potentially poorly tuned controllers.

Item No.: 141R001 / R-3501 Page 22 of 31
PART V – NORMAL (PLANNED) FURNACE SHUTDOWN
1. Shift firing to manual control and decrease firing while maintaining

normal process flow, at a rate such that the individual pass outlet
temperatures does not decrease quicker than 56 °C/hr.
2. Burners may be shut off when the coil outlet temperatures are 56 °C
below normal, although it may be advantageous to keep some burners on
for a continued gradual cool-down of the process fluid.
3. Circulation of process fluid through tubes may be shut off when all the
burners are extinguished and the coil outlet temperature is the lesser
of 111 °C below normal or 371 °C.
4. For the EDC liquid Preheat Coil, introduce steam into the tubes via
steaming-out line immediately after the process fluid is withdrawn
from the coil. Continue steaming-out for at least an hour, or until liquid feed
no longer appears in the outlet drains.

Item No.: 141R001 / R-3501 Page 23 of 31
PART VI – EMERGENCY FURNACE SHUTDOWN
1. Shut off all burners immediately by tripping the main fuel gas shutoff valve.
2. If a tube has ruptured, shut off process circulation to the furnace and
introduce snuffing media to the firebox as quickly as possible to extinguish
any fires and to cool the firebox.
3. If the emergency is due to reasons external to the heater, continue to

circulate the process fluid.

Item No.: 141R001 / R-3501 Page 24 of 31
PART VII – STEAM-AIR DECOKING
Coke formation is a normal consequence of processing heavy oils or EDC

Cracking Feed at high temperatures. The effect of coke formation in a heater tube
is to create an insulating layer that inhibits heat transfer. In order to maintain the
heater duty the tube metal temperature must increase to overcome this insulating
layer, which in turn requires increased firing. As coke accumulates the metal
temperature continues to increase, until it approaches the tube design
temperature. When this happens, firing must be decreased for continued safe
operation. It is typically at this point that it becomes economic to shut down the
heater to remove the coke layer via steam-air decoking, or by other mechanical
means (e.g., pigging).
Coke formation may also be evidenced by increased coil pressure drop, caused by
a restriction to flow resulting from the coke layer. In some cases, increased
pressure drop may become the determining factor in the decision to decoke, rather
than tube metal temperature.
Typically, furnace operation is controlled so that coke formation occurs at a

moderate rate, such that a reasonable run length is achieved and decoking can be
done during planned shutdown periods. Many factors influence the rate of coke
formation, including:
• Heat flux
• Film temperature
• Oil or feed fluid velocity (residence time)
• Feedstock characteristics
• Feedstock contaminants
It is important to note that there is a point beyond which the rate of coke formation
increases exponentially. This point is unique to each heater, and generally it is
determined through operating experience. The closer one operates to this point,
the greater the probability that minor operational upsets will cause rapid coke
formation.
Coking may also occur in very localized areas of the coil. Typically, this results
from localized areas of high heat flux, which in turn is a function of the flame
pattern, and hot flue gas patterns. Process side conditions such as phase regime
may also contribute to localized coking. Localized coking can (and often does)
occur at locations where there are no tube skin thermocouples. It is therefore very
important to monitor the furnace tubes regularly. Visual inspection provides a good
starting point, particularly when done by an experienced furnace operator.
Variations in tube appearance, such as a slick, oily red color denote coke
Item No.: 141R001 / R-3501 Page 25 of 31
formation. Infrared thermography also provides useful information, although it is
important to realize that interpretation of thermography is somewhat subjective,
depending on the technician collecting the data, the equipment type and the
equipment settings.
Steam-air decoking is normally conducted in two phases, spalling and burning:
• Spalling. During spalling, steam flows through the coil while

firing the heater. The shrinking and expanding caused by the
changes in temperature break the coke loose. Coke is also
mechanically removed by scouring resulting from other rapidly
moving coke particles.
• Burning. During burning, steam and air flow through the coil.
Coke is consumed via reforming and combustion reactions,
producing CO, CO2, H2, HCl, and H2O.
In some cases, only spalling may be required to clean the tubes satisfactorily,
depending on the character of the coke deposit.
RECOMMENDED STEAM-AIR DECOKING PROCEDURE
NOTES
• The following procedure is provided as a supplement to the operating

procedures already in use at each specific operating facility. It is not
meant to replace or counteract any policies (operational, safety or
otherwise) currently in use.
• The burning phase of the decoking operation shall be limited to the radiant
section tubes only.
• All passes may be decoked simultaneously, if adequate utilities (steam, and

compressed air) and personnel are available. If one or more passes are not
being decoked, cooling steam must be circulated through these passes,
admitted at the convection section inlets.
• Cooling steam, or another suitable cooling medium must also be circulated

through any other process coils (e.g., EDC liquid preheat coils, steam coils,
etc.) located in the furnace in order to avoid overheating.

Item No.: 141R001 / R-3501 Page 26 of 31
• If there is a choice of fuels for use during steam-air decoking, the one that
produces the dullest flame is preferred.
• It is advantageous to conduct the burning phase of decoking at night, when

changes in tube color are more easily detected.
• Excess air should be minimized so as to reduce external tube oxidation,

although sufficient excess air should always be provided for complete
combustion.
• All of the following variables should be carefully monitored throughout the

decoking procedure:
o Bridgewall temperature
o Tube metal temperature
o Pass outlet temperatures (all process coils, all passes)
o Steam flow rate (all process coils, all passes)
o Excess oxygen
WARNING: steam air decoking is a complex procedure. It is a special operating

condition during which tube metal temperatures approach their design limits.
Temperature excursions, however brief, can heat tubes beyond their design limit,
potentially resulting in rapid loss of tube thickness, and greatly shortened tube life.
For this reason, close and careful monitoring is essential throughout the procedure
to avoid the possibility of overheating tubes. It is recommended that this procedure
be applied by a knowledgeable operator and/or engineer who is experienced in the
complex procedure of steam-air decoking.
PRECAUTIONS:
• Avoid overheating tubes. Watch closely for local hot spots. Tube metal
temperature should not exceed 705 °C.
• Avoid excessive velocities through tubes. Coke particles are very

abrasive and can cause serious erosion of return bends.
• Maintain steam flow in the convection section to avoid excessive

temperature of the tubes or extended surfaces.
• Steam and air decoking should not be used where tube deposits
contain a large portion of salt or lime.

Item No.: 141R001 / R-3501 Page 27 of 31
• Furnace temperature must be kept down so that the tubes generally
do not show red. The only hot spots on tubes should be where coke is
burning.
1. Preliminary preparation.
1.1 The normal shutdown procedure of blow-down, steam-out and water-

wash, if practical, shall be conducted prior to the decoking operation.
1.2 The holding screws on all plug-type headers, if applicable, should be

loosened about 1/8 of a turn in order to relieve the stress imposed by
the steam-air decoking procedure. However, use caution not to
loosen the screws too much, since this will cause the header plugs to
leak and "wire draw" during the decoking operation.
1.3 Header box doors shall be shut to prevent chilling of the headers.
2. Heat-up for spalling.
2.1 Initiate steam flow to all the coil passes, in sufficient quantity to blow
the tubes clear of all condensate pockets. Maintain steam flow to all
passes throughout the procedure.
For all passes being decoked, the steam flow rate should be 88
kg/(s-m2).
2.2 Verify that the stack damper and burner dampers are wide open.
2.3 Purge the heater of combustible gases before lighting burners by

using either of the two FORCED DRAFT fans provided. Purge for a
minimum of 15 minutes.
Petro-chem strongly recommends gas testing the radiant firebox prior

to igniting any pilots (if applicable) or burners to verify that no
combustibles are present.
2.4 After completing the purge, light the burners, one at a time as
required, in accordance with Hamworthy Combustion burner
operation instructions.
WARNING: burner light off may be hazardous. Refer to Part IV –

Furnace Startup for proper lighting procedure.

Item No.: 141R001 / R-3501 Page 28 of 31
2.5 Start the flow of quench water into the effluent line when the coil
outlet temperature exceeds 177 °C.
2.6 Increase firing to raise the bridgewall temperature at a rate of

approximately 165°C per hour to 590-620°C. Light additional
burners as needed to achieve this heat-up rate.
WARNING: do not exceed 705°C at any time.
3. Spalling is evidenced by coke particles appearing in the water in the coke

drum effluent, which will appear dark gray or black in color. If spalling has
not started when the bridgewall has reached 704°C, attempt to promote
spalling by one of the following procedures:
• Alternately increase and decrease the flow of steam, taking care not
to overheat the tubes.
• Reverse the flow through the coil.
• Lower the flue gas temperature by 38-93°C.
• Intermittently add small bursts of air.
When heavy spalling starts, reduce the steam flow to prevent erosion,
taking care not to overheat the tubes. The experience of the operator is the
best guide; however, the production of small abrasive particles should be
avoided. A steady flow of large coke particles is desired, 3 mm. to 6 mm. in
size.
When spalling stops, repeat the above steps in an attempt to restore

spalling action.
4. Burning. When all spalling has ceased, proceed to the burning phase of
the procedure.
4.1 Reduce the flue gas temperature by 10-38°C and adjust the steam
flow to a mass velocity 30 kg/(s-m2).
4.2 Introduce air at a flow of 3 kg/(s-m2).
4.3 Carefully monitor the tube metal temperature and appearance of the
tube. Burning will be evidenced by a dark red spot moving slowly
along the tube. Do not allow the tube to attain a cherry red color, as
this indicates an excessively hot tube temperature. If the tube
temperature quickly rises, decrease the airflow, or discontinue it if
necessary. Hold the furnace flue gas temperature as low as
possible.
Item No.: 141R001 / R-3501 Page 29 of 31
4.4 Let the burn progress completely through the tube passes.
4.5 When burning has stopped, flush the tubes with steam and reverse
the flow.
4.6 When no further burning is apparent, double the air flow to 6 kg/(s-
m2) and check the effluent for CO2.
4.7 When no CO2 can be detected, reverse the flow and repeat the CO2
check.
4.8 When no CO2 can be detected, cut firing and steam flow while
maintaining the airflow, taking care not to overheat the tubes. Any
remaining coke formation will burn and produce red spots on the tube
surface. Hold the airflow until the red spots disappear.
5. Final flush and cool down.
5.1 When all burning has ceased, cut the airflow and flush the coils with
steam at full line pressure. Hold for a few minutes and flush in the
reverse direction.
5.2 Repeat these three or four times to remove all loose ash or scale.
5.3 Reduce firing rate. Maintain some steam flow until the tube metal
temperature has dropped to 260°C.
5.4 Flush the tubes with water before hydrostatic test.

Item No.: 141R001 / R-3501 Page 30 of 31

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PETRO-CHEM DEVELOPMENT CO., INC.

122 E. 42ND ST. / NEW YORK, N.Y. 10017

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

PART I – DEFINITION OF TERMS 1

PART II – GENERAL FURNACE OPERATION 8

PART III – PREPARATION FOR INITIAL STARTUP 12

PART IV – STARTUP PROCEDURE 20

PART V – NORMAL (PLANNED) FURNACE SHUTDOWN 23

PART VI – EMERGENCY FURNACE SHUTDOWN 24

PART VII – FURNACE TUBE DECOKING 26

1.4.1.1 Direct air preheater is an exchanger, which transfers heat directly

1.4.4 Anchor or tieback is a metallic or refractory device that holds the

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

1.4.12 Castable is an insulating concrete poured or gunned in place to form a

1.4.13 Ceramic fiber is a fibrous refractory insulation composed primarily of

1.4.16 Corbel is a projection from the refractory surface generally used to

1.4.17 Corrosion allowance is the additional material thickness added to allow

1.4.20 Damper is a device for introducing a variable resistance for regulating

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

1.4.23 Duct is a conduit for air or flue gas flow.

1.4.26 Erosion is a reduction in material thickness due to mechanical attack

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

1.4.44 Hot face temperature is the temperature of the refractory surface in

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

1.4.48 Monolithic lining is a single-component lining system.

1.4.50 Multicomponent lining is a refractory system consisting of two or more

1.4.51 Multilayer lining is a refractory system consisting of two or more layers of

1.4.56 Plenum or windbox is a chamber surrounding the burners that is used to

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

1.4.63 Setting is the heater casing, brickwork, refractory, and insulation,

1.4.65 Sootblower is a mechanical device for discharging steam or air to clean

1.4.68 Target wall is a vertical refractory firebrick wall, which is exposed to

1.4.69 Temperature allowance is the number of degrees Fahrenheit (Celsius) to

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

1.4.74 Vapor barrier is a metallic foil placed between layers of refractory as a

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

These instructions and/or precautions are provided as a supplement to the

• Flame condition – the flames should be checked for proper patterns

o Smoky or hazy appearance.

o “Sparklers” (oil firing).

o Unusually tall flames.

Poor flame patterns can be caused by many different factors, including:

o Improper heater operation, such as running with insufficient

o Fuel quality or delivery issues, such as changing composition,

o Problems with the burners, such as misalignment of the tips,

Burners should be adjusted so that there is no flame impingement on any

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

• Excess air should be monitored regularly. Typically, 15 – 20% excess air is

The symptoms of incomplete combustion resulting from inadequate excess

o Afterburning (see below).

o Hazy or smoky flames in the firebox.

o Black smoke coming from the heater stack.

• Afterburning results when there is insufficient excess air for complete

Afterburning is a potentially dangerous condition and remedial action should

• Overloading – while Petro-Chem does not recommend operating the

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

• Furnace pressure (draft) – furnaces are typically designed to operate

In sections of the furnace where gas flow is unobstructed, draft generally

Furnace draft should be carefully monitored, since furnaces are not

Client: Sayanskchimplast Petro-Chem Job. No.: F-08-1950

• Adequate process flow must be maintained to each heater pass at all

Optimal heater operation requires equal flow to each pass. Petro-Chem