21 ‘A furnace is safest when st is functioning, properly. op Your main job is to control the air supply by checking a » the draft and keeping the flue gas in the proper excess range. air Few explosions occur when the furnace is at its rated capacity. operating 3, Combustion occurs when fuel and oxygen meet a combustion # ‘source of ignition. ‘ ‘SOURCE OF IGNITION If any one of these three elements is missing, cannot take place. 4, Combustion can occur in an idle furnace, if fuel, oxy- gen, and a source of ignition come together. ‘Wherever there is air, you can be sure there is oxygenpropriate word. Of the two parts that contact the object, only the (anvil/ spindle) moves. A program is a series of frames that work like the ones you have just done: Read the frame. Use the information to fill in the blanks or make a choice. Move the mask down and check the response column. Go on to the next frame, Remember to cover the response column with a mask before ‘you begin each page. Notice thatthe left-hand pages from here on are printed upside down. ‘The program is designed so that you will go through all the right-hand ‘pages first, and then turn the book upside down and go through the other pages. spindleDuring shutdown, flammable vapors may seep into the firebox. ‘Anything that can burn is Fuel and oxygen need only a source of ignition to A furnace contains a confined space open only at the air doors and the stack. Even though a furnace is idle, you must assume that there may be _______ in the firebox. . Rapid ignition or combustion in a confined space is an explosion. Explosions occur when air and fuel have mixed and come into contact with a source of The longer an unblinded furnace has been idle, the more likely it is to lack only a____ of ignition. Over the years, more than half of all furnace explo- sions have occurred during startup. ‘Most explosions happened because fuel that the opera- tor didn’t know was there had mixed with and was waiting for ignition. “iL. A furnace is most dangerous at . Startup procedures are designed to make furnace startup as safe as possible. Precautions in startup procedures have developed from study of the causes of past . Each precaution in the startup procedure is designed to eliminate the known cause of a past explosion. It something has caused an explosion before, it is likely to cause an again, if it is given a chance. BEFORE LIGHTING THE BURNERS - CHECKUP 14. The furnace and the area around it must be clean. Platforms, ladders, and walkways should be cleared. Debris, tools, oil-soaked rags, ete, on or around the furnace are sources of danger which should be |. Flammable imaterials should be removed from the fire- box before the burners. flammable burn fuel ignition source startup explosions explosion removed, or taken away lighting16. Péepholes and header box doors must be closed so that no. can get in. E° a7, All valves in the fuel gas and fuel oil systems and ‘all burner valves must be checked to see that they have been serviced and properly set.” ‘Sone’ leaking“ burner valve can let fuel enter the PILOT HEADER Both the must be checked to be sure they are BURNER HEADER A eS gas valve aud the pilot valve air firebox, or furnace burner closed‘Look at the drawing. zor. W On an oil burner, you normally have two oil vaives and three steam valves to close. All_____and. valves must be closed. 20. Identify the following oil and steam valves: . (i) 01 _____valve : (2) Oil____ valve (3) Steam valve (4) Steam ——______ valve (6) Steam valve 4 he BLOCK VALVE] Ee eel STEAM REGULATING VALVE] oil, steam ~ block regulating bypass block regulatingWrite in the names of all the valves which must be closed. ‘The stack damper mechanism should be tested to make sure that it works freely. ‘After the damper mechanism has been checked, the stack should be fully opened. ‘The secondary air doors on all should be fully opened. ‘To purge the furnace properly later on, the purging steam or air must be able to flow freely through the furnace. ‘The stack damper and all secondary air doors must be (open/closed) to provide this flow. (1) Oil block valve (2) Burner gas valve (3) Oil regulating valve (4) Steam bypass valve (5) Steam block valve (6) Steam regulating valve (7) Gas pilot valve damper burners openAt this point, your furnace should be ready for lining up the fuel system to the burners. The area around the furnace and the furnace itself must be free of any object that can___or cause trouble, . Peepholes and header box doors must be closed and there should be no____ to let in air. 1. Every valve in the gas, oil, or gas and oil fuel sys- ‘tems has been checked and these valves are known > to be (open/closed). All secondary air doors and the stack damper are (open/close). EFORE LIGHTING THE BURNERS - PURGING 29. At any time, there may be flammable vapors mixed 2) + with air in the firebox. Itis dangerous to light any burner without the furnace first. . To stir up the air in the firebox which may be mixed with flammable vapors, and to provide heat for a draft’ to move: fresh air through, a natural draft furnace is purged with steam. A forced draft furnace may be ______ with air from the fan. |. Steam is put into a gas-fired furnace by permanent steam lines in the firebox, or by sliding steam lances in through the burner air Steam is put into an oil-fired furnace by turning on the_____valve of the oil gun, without letting Purging must be thorough to make sure that no flam- mable ______remain in the furnace. A steam purge also provides heat to start the At first some of the _____ condenses on the cold metal and refractory. . Purging steam may be mixed with air and flammable gas or Vapors, and yet appear to be ignite, or burn leaks closed open purging purged opening, or door steam vapors, or gases draft steam steam97. Enough steam must be used to create a movement of fresh air and move out all the air in the furnace ‘and any flammable gas or vapors that may be mixed with the air. ‘Your unit operating instructions tell you how long to the furnace with steam, and may specify a minimum draft during the purge. 88. In a forced draft furnace, the fan provides 4 sufll- cient volume of air to drive out any mixture of air and flammable that may be in the firebox. 39. The forced air establishes a draft. ‘The volume of forced air must be maintained long enough to move out all air and ‘vapors. 40, Heat is not needed for a forced air purge. ‘The draft is created mechanically instead of by ‘41. Purging is used to create a and remove all flammable from the furnace. 42, Purging makes sure that you have the three elements of (fuel, air, and heat) under control ‘when you light the burners. BEFORE LIGHTING THE BURNERS - REMOVING BLINDS 48. Now you are ready to let the fuel into the fuel system. From here on, you follow: general startup instructions that apply to all fur- naces, and operating that apply to your furnace. 44. Now the blinds in the main fuel lines to the fur- race should be removed according to unit operating instructions, If either fuel system has been worked on while the furnace was down, purge this system according to instructions. 45. With the blinds removed, the chances that fuel may seep into the firebox through any valve leakage are now (increased/decreased). 46. Open the main valve in the line to the gas header on the furnace. ‘All burner valves remain (open/closed). purge vapors, or gas flammable heat draft vapors, or gas a combustion instructions, or procedures operating increased closed1B 08 or & 47. Any liquid hydrocarbon in the fuel gas must be “imocked out” (eliminated) before the gas is let into the furnace lines. Drain all liquid from the knockout drum nearest the furnace as soon as fuel gas is let into the main gas line. ‘Aly ______ left in the fuel gas can burn un- controlled at the aspirator and in the firebox, If the knockout drum drains into a closed drain, fuel gas allowed to follow the liquid may enter the drain system. Keep checking for liquid or gas by cracking the bleeder valve (opening it a little bit) between the drain and the bottom of the drum. ‘Open the main valve in the fuel oil system. Burner ___-_-_ must be closed. Drain valves in the fuel oil line should be cracked ‘open to check for water in the line. It water comes out of the drain, the drain valve "should be opened and kept open until _____ shows, then tightly closed and plugged. you light the burner. Once the pilot is lighted, it is a steady of ignition for the burner. ;. In cold weather, pilots may be lighted to warm the furnace before the charge is started through the tubes. “Flow of the charge should be established before the first ____ is lighted. |. A furnace burning both gas and oil is normally started with —_. The gas burner provides a steady source of - for the oil. “Gas ignites and burns more easily than oil. The procedure for lighting the pilot is the same as for lighting the 7 Regin lighting the burners immediately after you have finished ______ the furnace. fuel, or gas liquid valve valves oil source burner gas ignition burner purging‘ 58, When you are ready to light the burners, only the necessary people'should be near the ——_-___. 59. Establish pressure on the main gas header up to each . valve. 60.~The primary air:doors can be closed as needed to pre- vent flashbacks in the burner ‘tubes. ‘The __________ air doors are left wide open. 61. Maintaining proper burner pressure will also prevent 62., Lighting may be done with a properly constructed torch made of a stbelrod 3 to 6 feet long, with a 10 inch covering of insulation at one end. ‘The torch is soaked with a fuel like kerosine so that it will steadily. Don't use gasoline. It ignites too easily and is hazardous. 63. The fuel gas line to the furnace may be tied into a gas torch by a flexible tube long enough to reach all the burners. If your furnace is equipped with a gas ————, use it. 64. Before you light the torch, put on a face shield and insulating gauntlet gloves Without this protection for your hands and face, a slight flashback could you badly. 65. ‘Test the direction of the wind and prepare to light the. burner farthest upwind. ‘The strongest occurs at the upwind burner. 66. On a natural dratt furnace, cut off the sleamn furnace burner secondary flashbacks burn torch burn draft purgeSTACK CONVECTION tO < BAFFLE SECTION SLEEVE RADIATING ‘CONE REFRACTORY LINING RADIANT. ‘TUBES BURNERS EXHIBIT 2STACK BREECHING CONVECTION TUBES sHocK BANK RADIANT ‘TUBES REFRACTORY LINING FIREBOX BURNERS EXHIBIT |ee Ss Ifthe rag.:is pulled toward the opening, there is a Light the torch and stand to one side of the upwind Slide the lighted torch through the secondary air opening. Hold the torch in front of the Hold the torch in. place while you crack the burner as ______ slightly. ‘When the fuel ignites, keep the torch in place. Steady the burner — pattern by adjusting the air doors. If the fuel does not ignite promptly, shut off the burner, then:pull out ‘the toreh. Now you know that there is unburned’ fuel and air mixed in the 2 . If the fuel does not ignite at the fist bumier, “ya must (move to another burner/purge again): If you have to. purge ‘again, repeat the whole” procedure, . When the fuel has ignited, and you have adjusted the air doors to steady the to be lighted. lame, move to the next ” . Light as many burners a8 néeded the same way: ‘Stand to one side of the Slide the torch in through the secondary air-opening. Hold the torch in front of the burner spider or ring. Open the burner slowly until the fuel ignites. Keep the torch in place. while you-steady the burner flame by __________ the air doors. One burner should never’ be lighted from another burner. This is a dangerous practice. Only a pilot or a properly constructed can provide a steady and reliable source of ignition.” - ‘As you light more burners, maintain a satisfactory gas header pressure. = If the fuel gas prosoure decreases, tho flame ‘may flash back or go out. 10 draft burner burner, or spider valve firebox, or furnace burner valve adjusting torch burner80. 81. 88. 85. 87. 88. 90. Wear your face mask and continue to check the burners by looking through the peepholes. When the firebox is relatively (hot/cold), the flames may go out easily. ‘The furnace is on manual control when you are set- ting fuel gas valves by hand. Keep the furnace on control until the flow rate of the charge is well established. After switching to instrument control, be sure that all gas header and burner valves are fully opened, unless. there is some reason for pinching down (for example, flame impingement). ‘When the temperature is within the control range of the instrument, switch to fully automatic When you are firing two fuels, one is normally “base loaded” and you control temperature with the other. In other words, one fuel is manually set at a steady base rate and the other is automatically ‘Do Aot try to light the oil yust uf 4 combination burner until the burners are maintaining a stable flame pattern. ‘To bring in the oil, first push the gun forward. ‘Then open the steam regulating valve fully to blow ‘out any condensate and heat up the gun barrel. After all condensate has been blown out of the steam _ line, gradually open the oil regulating valve until the oil spray ignites from the flame. Open the oil regulating valve gradually and feed the oil in slowly to keep oil from falling to the floor. ~ ‘Adjust the steam and oil regulating valves until the cil atomizes and ______ steadily. Correct for dripping oil by adjusting the burner and ______ valves to improve atomi- zation, of the oi During startup, frequently check the individual burner flames and the flame pattern in the firebox, Wear a face mask whenever you look into the A chorry red spot on a radiant ____ is a hot spot. cold manual, or hand control controlled gas oil gas firebox burns oil, steam firebox tubeii Bie a1. 92. 93. 294, 98. 96. « and the heat until the entire unit is Watch for irregular’ burning patterns. Flame im- pingement causes hot spots. Watch the radiant tubes for hot spots and adjust the pattern to eliminate them. Tubes should be checked trom shift to shift to detect hot and to observe how much the spots are changing, and how fast. Once the burners are lighted and: the furnace is operating steadily, the transfer ________ of the ‘charge is increased gradually. The rate of the increase is specified in the unit instructions. After the furnace is on stream and lined out, check the entire operation for draft and air control. “ SHUTDOWN Shutdown of a furnace is ordinarily part af the of an entire unit for inspection and repairs. Occasionally a furnace is shut down for repairs while the rest of the is put on standby. . The flow rate of the charge and the heat of the fur- nace are reduced together. ‘The charge rate and temperature are gradually over a period of several hours. . When the charge rate and temperature have been reduced to a fraction of normal, all furnace____ are shut off, ‘The entire unit is “circulated down.” The oil left in the unit is circulated within the unit oil system, including the ‘tubes. Circulation is continued through most equipment for several hours to cool the unit, When the unit is cool enough not to vaporize the oil anywhere in it, circulation is e If furnace tubes are to be opened, oil is dumped out and the tubes are with steam. ‘Unit shutdown is a gradual reduction of the oil flow cnough to be purged. 12 flame , spots temperature operating shutdown unit reduced burners fornace stopped purged. Reduction in the transfer temperature automatically ‘the burner fuel supply. ‘The control point on the temperature recorder con- troller (TRC) is reset by hand. ‘The TRC automatically feeds the —_____ at a lower rate. ‘As the temperature drops below the TRC range, operation becomes necessary. As the fuel is cut back, some burners should be shut off to maintain an adequate gas header pressure to prevent flashbacks or flameouts. When the charge rate and temperature are down to the desired level, all _______are shut off by closing each burner fuel valve individually. Each gas pilot is shut off by closing the pilot Steam is left on in each oi] gun as the oil regulating valve is closed. It is used to ____ the oil gun. |. To purge the gun, the oil block valve is closed and the oi] _______ valve opened again. ‘The steam regulating valve is closed and the steam bypass valve is then opened to flush all oil out of the burner. Then the steam bypass valve, and the oil regulating valve are closed. Finally the steam block valve is . After all burner gas valves are closed, the gas header valve is closed. ‘Then all block valves and bypass valves are closed. Bleeder valves downstream from the main gas valve should be opened to depressure the lines in such a manner as to provide for safe disposal of the |. The flow of cooling air through the furnace is in- ereased by opening the air doors, access doors, and the stack If the furnace is to be out of service for some time, blinds should be installed in the _______ lines. If anybody has to enter the furnace to inspect or repair it, _________ shuld be installed in the fuel lines. reduces fuel manual burners valve purge regulating closed fuel damper fuel blinds"116..Emergency shutdown is called for when furnace opera- “i, ton, becomes seriously abnormal. ‘Abnormal conditions in the unit or the furnace may demand the rapid removal of both the fuel and the a : ‘from the furnace. charge F117. In any furnace emergency you mt act to protect “yourself and other workers from injury. 1.) You must act cautiously and minimize ‘| danger, or damage You must minimize damage and maintain the equip- ment in good working order. ‘You must alsa limit as, far as possible the effect of the ________. on the whole operation of the emergency, or shutdown refinery. 119. To deal effectively. with a furnace emergency, you ‘must plan your actions in advance and be ready to carry them out. ‘You must study your equipment and the unit operat- ing 7 instructions, or procedures In order to act wisely, you must know the maximum " allowable temperature and pressure of the —_____ ‘tube * metal. 121. You must know the maximum allowable —_—— ‘temperature for the firebox, breeching, and the stack. 122, You must be ready to stop combustion by removing one or more of the three elements of combustion, air, or heat. fuel 123. You must know in advance that emergency block and |, blowdown valves are in working. order and how to reach them in an emergency. ‘These emergency’ controls are located in a protected area where they can be reached with risk, minimum, or little REVERSING THE PROCESS OF COMBUSTION 124. Combustion occurs when fuel, air, and a source of Be ignition are brought together. ‘When any of these three clements are taken away from each other,125. F126. P 127. 28. 129. IE or 130. 6 131. L 182. 9 133, ¢ ¥ 184. 135. Fuel enters the furnace through the fuel oil and fuel gas lines, You can ordinarily keep fuel oi] and gas out of the firebux by closing ihe burner ‘You may have to go back to the block valves or the header block valve. These valves stop the fuel to BE eee In normal operation, you do not think of the charge as fuel. In the event of a tube rupture, the charge enters the firebox from the ruptured tube and burns. Then you must think of the charge as Since ‘the charge is under pressure, a tube rupture “may dump large amounts of the charge into the firebox. Shutting off the charge and dumping it from the furnace does not get rid of what is in the : This oil is best disposed of by burning it where it is, since the firebox is built to support the heat of ‘burning. ‘To keep temperatures from running too high during this combustion, you may need to control the supply. If the maximum tube and metal temperatures are threatened, trim down on the stack damper. If more air is needed, feed it carefully with the air so that you will not let a rush of fresh ‘You can restrict air entering the furnace by closing off on the stack _____. Ag the damper is closed, air entering the turnace is decreased, combustion is reduced and the heat release is (limited/inereased) A continuous large flow of snuffing steam restricts air by pushing it out. A header box fire can usually be snuffed out with from the header box steam line. ‘You can put more steam in with a steam lance, if the regular snuffing lines do not provide enough In a hot firebox, steam has a cooling effect. ‘Steam will reduce Lwu of the elements of combustion: and enough heat for 15 valves burners fuel firebox doors * damper limited steam steam air; ignition, or combustionp a 7 137. 1 138, 139. e E140. 11. 142, v 148, 144. 145. Ls ‘You may have to choose which of the three elements of combustion to control or get rid of, or try to eliminate all three at once. Stop or control the Restrict the Cool and put out any source of ____ that is present. If you lose your charge for some reason, there is no flow to carry the heat away. ‘You should reduce fuel to the Normally the charge flow absorbs heat and carries it out of the furnace. ‘When the charge flow through the furnace is stopped, you may expect a drastic rise in —________. If you cannot get the charge started immediately, stop all input of heat by closing the ______ valves. There may stifl be ‘tough heat retained in the fur- nace to weaken” * > metal. If 80, ‘lock, off the furnace and dump the charge. ‘Then=,coo! “the tubes and firebox by purging with A tube’ rupture may suddenly admit a large amount of fuel into the firebox:*.Your action will depend ‘upon how serious the situation’ is and how well you can control temperatures. If the leak i small,.the charge inay be left in the ‘tubes while thé unit is cireulated down. If burning continues and temperatures are excessive, restrict the input’ of air by adjusting the stack ‘The furnace must be isolated and depressured if the rupture is large. Shut off ‘the burner fires. Dump the furnace and cool the tubes by turning steam into them. Then _______ the firebox with steam. Improper operation of oil burners could lead to large amoimts of oil burning on the floor of the furnace. Correct the burner operation. If temperatures become excessive, restrict the input of _____ by adjusting the stack damper. fuel air ignition burners temperature fuel tube steam furnace damper purgeFlammsble ‘ligitd in, the’ fuel, gas line may fill the firebox with uncontrolled flames. Drain the fuel gas system. If temperatures become excessive, adjust the stack damper to restrict the input of Trouble inthe fuel system may cutoff the fuel entirely. ‘The ,burners go out. There is enough heat left to ignite ‘the fuel with explosive force if it starts again. Shut off the promptly. Then purge the fuel firebox .with steam. Purge the. firebox in. accordance with established procedure. purging ‘When fuel is available, then light the burners as in a normal startup . In any emergency, you may expect to have uncon- trolled combustion. . Restrict or cut off all fuel, whether from the fuel lines or from the charge. If even then the tempera- tures become excessive, restrict air hy adjusting the damper” Cool the firebox with steam. If temperatures still rise in the tubes beyond the maximum, block off the furnace and dump the Put steam into the tubes. charge . Guard your health and safety. Guard your equipment. Suit your actions to the severity of the: emergency An operator who has worked successfully "through an a emergency shutdown has new knowledge of himself and his —__. equipment, or furnace }. He knows how to control. the three elements of com- bustion and how to control ea ‘combustion . He knows how to isolate the three elements of com- bustion from each other and ~ cbmbustion. stop ‘He knows how to bring his furnace’ temperatures and charge flow down with minimum risk and “ damage . By deliberately applying your knowledge and measur- ing your actions by the severity. of the emergency, you turn each = into experience that pre- emergency pares you better for all furnace operating situations. i utUnit 4 Operating Situationsb ALIS Some draft and excess air-problems seem to resist correction. . ‘Draft and excess air readings within the proper Paaye will not always result from adjusting the damper and air doors. 2 In certain eases, the furnace or furnace parts may need repairs. : Leaks in the furnace shell, may Jet in air which dis- torts all excess air readings (upstream/downstream) from the leak. 9. If there ig a leak that you don't know about, you may pinch the burner air doors down too far. ‘Then there is too little air at the burner, but still proper or high excess air. in the. gas readings. a 4. Comparing excess air-readings taken in different parts of the furnace helps:in-logating —-——— ene al Furnace damage’ may ‘happer~ivhere ‘it, cannot “be observed. Ea é Ve rrom'“the lining of the thie’ duct" opening, partly shutdown.” Te has the samé“eifast“ad ‘partly (opening/closing) the stack damper. 7. After the stack damper is open part way, opening it all the way results in more but not much more. f 8. The damper control lever on the stack may work loose and slip on its shaft. Then you are working against yourself when you regulate the ‘control. 9. In other words, the stack damper is not set where you think it is. You may be opening the damper when you think you are it, stack, burner downstream + flue blocking closing Graft damper closingstruments Bio. In other’troublesome draft and excess air problems, i.3- the readings of indicators and anglyzers may be you would normally adjust the damper and air doors to! bring them dawn. “You may’ lower the draft, but then the readings show both, oxygen and carbon in the flue gas. :'When instrument readings do not agree with your observation of the furnace, or with each other, check your, 18, Air may enter the flue gas analyzer from a ysin:the sampling line. fe 4, Make ‘sure that all flue gas sampling lines are “"15. Make sure that the connections on the analyzer sam- pling eystem and the lines within the sampling system are’all bee 7 16.,A leak in any draft sampling line may throw draft readings off. Check for leaks in the sampling lines. “17. When you are using an Orsat flue gas analyzer, watch for __“_ in the sampling train on the Orsat. 18, If the absorbing solutions in an Orsat are spent, the analysis will be 19. Portable indicators or permanent recording flue gas analyzers must” be working properly or the flue gas ‘will be incorrect. 20. The recorder should read properly throughout. its entire range. ‘The temperature and pressure of the should be checked. 21. Any questionable readings should lead you to check your 22, When the air supply is properly controlled, the fire- box is clear and does not have a smoky appearance. Burner are usually steady and well-shaped. wrong, or off monoxide instruments, or analyzer leak airtight airtight draft leaks wrong, or off analysis sample instruments, or equipment flames 7‘Sometimes the flame pulsates and flashes back into the | ‘The flame leaps back and forth between the burner 35. 1 86. 8t. ports and the aspirator, and the burner “barks.” Barking can be stopped by proper contrel of the supply. | thece TaAabtOiamne conditions create irregular re- Tease 0, croeseyrs in the firebox. TORS yin the flame results in shing, back into the aspirator exposes the “to heat that it was. not built for. fee Oot iE a SIE Flashbacles tnay’ be corrected by increasing the ———— at the gtack damper. Flashbacks at individual burners may be corrected by adjusting the primary. ai meee AM When the dame can travel back in the burner faster than the’ gas comes through the tube, the fuel 225,18 too: low. ‘The pregguresmay-be ingreased, in burners left lighted by shutting off others. Reduciii (RY 46taT draif? on thie"header inefedsed tHe ‘and steadies heat release. wee ReHuIAG wil UNbs ieee 7 STC Coke, particles of carbon, and foreign materials in the bubiiér “of the: ‘fdel Tine4inayals6 cause ‘redler |. ‘The burner should be shut off and checked for obstruc- tions inthe alk ‘openings. Dirt or carbon in the holes in the spider or burner ring may partly these holes. ‘Anything that blocks the flow of ~« cleaned out. _ should be ‘Hot spots on the tubes are caused by impingement. Flame should never be allowed to tubes. the Flame impingement weakens the metal and favors @ buildup of coke at the hot spot. a spot may cause the inside diameter of the tube to be 20 BIA burner air a u heat. gy heat ss - e ener ig 2 draft doors, or openings H pressure, pressure flames, or heat s plug, or block gas, or fuel flame touch, or impinge on decreased, or reduced. At a hot spot, the tube may or rupture. |. Lock through the peepholes frequently to check the radiant tubes. You may see the flame touching the tube, or a cherry-red spot on the tube. ‘Before opening the peephole, always put on a Correct for impingement by pinching back on the supply to the burner that is giving trouble. . Tf you have directional burners, you may rotate the burner so that the flame no longer touches the Possibly the burner is out of line in its housing. IE so, set it Sometimes no operating correction stops flame For instance, the holes in the spider or burner ring may be enlarged by corrosion or erosion. 'Yhe burner should be pulled for replacement of the defective 21 a a leak mask fuel tube straight impingement part1 2 3 4 SITUATION 1 Present operating conditions: Natural draft furnace ‘Stack damper, position: fully opened Draft readings Stack: 0.35” H,0, ‘Above convection section: +0.04” H.0 Roof: +0.08" H,0 Burners: —0.15" H,0 Excess air readings: Roof: 18% ‘Above convection section: 18% Below convection Section: 65% Desired range: 15-20% oa, piter'the present’ éperating conditions on the drawing 222. Draft is adjusted in the furnace by setting the burner air doors and the stack ————__. 3. These settings should provide suffici draft sampling points. it draft at all ‘The damper position i 4. For proper draft, all readings should show (positive/ negative) pressures. 5. The pressure at the roof is (above/below) the pres- sure of the atmosphere. 6. More draft (can/cannot) be provided by adjusting the stack damper. 7. A positive pressure at the roof (can/cannot) be brought down mueh by pinching the burner air doors. Flue gas analysis at the roof shows an excess air reading of 18%. ‘This reading is safely inside the desired excess air range of — to %e. 9. Enter all excess air readings: Roof: % ‘Above convection section: % Below convection section % 10. The excess air readings indicate that air (is/is not) entering at the roof or upstream of the —_____— section. 1. The readings indicate that air is entering somewhere between the stack and sampling points (at the fire- box roof/above the convection tubes). 12. This air is overloading the convection section breech- ing and the stack enough to be beyond control by the stack 13. This air and the flue gases fowing through the fur- nace are creating a positive at the roof. 14. The most likely sources of unwanted air entering the convection section are leaks (in the firebox roof/at the header box doors). 15. The header box doors are examined and found to be Joose-fitting. Cool air is entering the header boxes and flowing over the headers and ends. 23 damper’ ‘open, or fully opened negative above cannot cannot 15, 20 18, 18 65 is not convection above the convection tubes damper pressure at the header box doors tube16. 19. 20. 21. 25. Look at the drawing. yl TUBE SHEET] HEADER BOX DOOR AIR The air is chilling the tube ends before it joins the flue gas stream, where it then dilutes and cools the flue gas. ‘Thus, when a leak occurs, more must be burned to maintain the transfer temperature. ‘As the leaks around the header box doors are sealed (mudded up), of the tube ends and headers decredses. ‘Stopping the flow of unwanted air reduces the volume of flow in the convection section, the and the stack. As the breeching unloads, pressure at the roof shifts from —__-_.__ to negative. Excess air readings at the stack come within the desired range of 15 to %. Less fuel ean now maintain the ‘present transfer Keeping the same charge rate. The same amount of fuel as before can now maintain an (inereased/reduced) charge rate. ‘The furnace is now under the control of normal air door and stack adjustments. Because there has been so much extra air, proper air rates can probably be established by partially closing the stack —____.. ° If partially. closing the damper does not bring the air rates within the desired range, further adjustment can be made by pinching the burner air —_____. py fuel cooling breeching positive 20 temperature increased damper damper doors, or openingswasn trae sega lesa tee Be Ee Present operating conditions: 1. Natural draft furnace with no stack damper. 2. Holes at the stack base admit air to cool the flue gases. 3. The furnace is designed to run at very low excess air rates. 4, The desired excess air range is from 10 to 15%. 5. The excess air reading in the stack below the air holes is 3%. 1. Enter the excess air reading on the drawing. 25 a| 2. Newer furnaces are usually designed to run at lower excess rates than older furnaces. Operation at lower excess air rates requires (more/ Jess) delicate contro! than operation at higher rates. 4, Precise control of excess air in this furnace is neces- sary for dow consumption. "©, Burner air control in this furnace is done at the yo air doors. © 6, To reduce stack temperatures, air is admitted through holes in the stack base. ‘This’ air cools the flue gases and protects the upper structure of the furnace from excessive 7. Look at the air flow on the drawing. The cooling air is directed (upward/downward) by.a baffie before joining the hot flue gases. 8. The fiue gases mect the cooling air (before/after) passing the convection section. 9. The last heal-absorbing surfaces below the stack aro the tubes. 10." "The desired excess air range for this furnace is eo to 11. The lower limit of the excess air range is high enough to offset: imperfect mixing of fuel and air for slight drops in the BTU content ofthe. slight drops in the preheat temperature of the ‘charge that require fuel. slight increases in the charge rate that require fuel. 12. The present excess air rate, from flue gas samples below 4 the stack air holes, "is Ie. 18. Operation below the proper excess air range causes some incomplete 14. Complete combustion of fuel and oxygen would pro- @uce carbon dioxide (CO.) and water vapor (H:0)- Any incomplete combustion produces some carbon ——_—_ (00). 15. During complete combustion, one carbon atom joins two ‘atoms to form earhon dioxide (CO>). more fuel burner heat downward after convection 10 15 combustion fuel more more combustion monoxide. Keeping excess air rates within 10-15% saves During incomplete combustion, one carbon atom may react with one atom to form carbon monoxide (CO). When carbon monoxide mixes with air at a high tem- perature, it burns with oxygen and releases Incomplete combustion caused by pinching the air doors too close releases. monoxide into the flue gases. . When the'flue gases rise to the stack, they meet the cooling’ air entering at the holes. ‘The stack temperature below the holes is high enough to ignite the carbon ‘as it meets the incoming air. This is ealled “afterburning.” ‘The afterburning in the stack raises the temperature of the_____ metal and upper furnace structure. ‘The upper structure of the furnace is not designed to endure the of afterburning. Carbon combining to form carbon monoxide in the burner flame releases only 28% of the heat released in forming dioxide.’ ‘The presence of any carbon monoxide in the flue gas is a-sign that (more/less) heat is being released in the firebox. ‘As less heat: is released and absorbed by the charge, the TRC automatically feeds more ‘Vo bring excess air readings up to the desired excess air range, you may adjust (the stack damper/the burner air doors). Adjusting the burner air doors provides more. for combustion. With the increase in oxygen, release of carbon mon- oxide is cut down, and the burners release (more/ Jess) heat. When more heat is released at the burners, the TRC iGinereases/decréases) the fuel supply. With no.carbon monoxide in the hot flue gases, the stops. . and protects the furnace structure trom damage. oxygen heat earbon air 7 monoxide stack heat 4 carbon less. fuel the burner air. doors air, or oxygen more decreases afterburning fuelTHERMOCOUPLE Present operating conditions: 1. A natural draft furnace with burne: 2. Draft readings show a satisfactory negative pressure at the sampling points. 8, Exeess air is within the desired range at all flue gas ‘ sampling points. 4 . 4. Flue gas temperatures at two opposite points in the firebox may not be permitted to exceed certain maxi- . mum limits, ‘5. One temperature point is at the maximum: the other is considerably lower. in the floor.‘Maximum temperature limits must not be exceeded at two points in the firebox where thermocouples are installed to provide _______ readings. . These temperature limits are set to protect the radiat- ing cone tip material and the cone support rods. If ‘the firebox temperatures are allowed to exceed these limits, the cone and its supporting structure sutter . If one half of the firebox is at maximum temperature, the other half must be kept at about the same tempera- ture or (more/less). |. The temperature is considerably lower than the maxi- mum in-one half. This unbalanced condition restricts the total output. This restriction limits the amount of charge that can be heated to the ______ temperature. . Less heat released in the firebox means heat: absorhed. ‘The unbalanced temperature condition may be caused by a poor distribution of the being released at the burners. . The ‘burner flame pattern may favor one half of the furnace more than the __—____ half. ‘The burners in this furnace are set in the ). The burners are set in two circular clusters, one around the center of the firebox, and the other nearer the outside ring of ______—_ tubes. |. The burners have slightly tilted spiders that point the flame a little off center. Rotating a burner in its housing changes the direction of the : . ‘The burners are equipped with-handles by which they can be rotated. Such burners are directional —_____. ‘The flame pattern in’ the firebox can be adjusted to balance the heat distribution with ———______ ‘burners. a ‘This ability to-change the flame pattern can be used in this furnace to equalize the heat distribution in both - of the firebox. temperature damage less. heat transfer less heat + other floor radiant flame burners directional halves» 16. 1. 16. ‘Holding the total heat release steady, the burners can be rotated little by little until the temperatures in halves are balanced. Firebox temperatures should be read frequently while the directions are being adjusted. ‘The, temperatures in both halves are now balanced out ‘at a level which is below the maximum allowed for safe operating conditions. With this “room,” it is now possible to increase the charge ________ to the furnace, if so desired. both burner rate1. Large'natural draft fur- pace, with one , firebox which may be dealt with ‘as four equal areas for draft and excess air control. 2. ‘The fuel supply is equal- ly distributed to all the burners in the four areas. 3, ‘The’ stack damper set- ting: +4 open. “4, Dampers in the 4 ducts an be used for minor draft adjustments. Present operating conditions: 6 ©]. Bnter the excess air readings un the drawing. Draft readings at all draft sampling points: about 0.02 to —0.05" ¥,0. ‘The desired excess air range: 10 to 20%. ‘Exeess air readings: NE sampling point: 30% NW sampling point: 7% SE sampling point: 21% SW sampling point: 2% Stack sampling point: 15%2, Draft measurements at the sampling points in all 4 + area. show (proper/improper) draft. proper 8. The excess air reading at the stack shows a (proper/ improper) rate. proper, 4, The excess air readings at the sampling points in all 4 areas show (proper/improper) rates. 7 improper 5. The maximum variation in excess air rates between areas is (18%/28%). 28% 6. The desired excess air rate in each area is (the same as/ different from) the stack rate. the same as 7. Excess air rates should be brought up in the sw and areas. NW 8, Excess air rates should be brought down in the SB . and areas. NE 9. Closing the stack damper would decrease the excess air rates at the sampling points in (some/sll) areas. all 10, Any decrease in excess air rates would starve the - * burners in the and areas. sw, NW 11. If, by closing the stack damper, we starve these areas even more, this (is/is not) the solution to, the problem. is not i a 7 | 12. Opening the damper would create more draft in ~ areas. all, or 4 18, Draft would then increase at the burners and stack, and pull more ______ in at the burners. air 14,, In order to balance the exeess air rates, the rates for all should temporarily be (increased/decreased). increased 15. Excess air rates in the areas with the lowest readings should be brought ‘temporarily to at Teast 30%. To bring up excess air rates in the lowest areas, the stack damper should be (closed /opened) . opened 16: The draft at all sampling points will then be above the _____ range. proper , 17. When the’ rates have been brought up to about 309% th.the areas with the lowest readings,’ all burnérs ~ should be adjusted to bring ______ areas to 20-25% all, or 4 excess air. - : 18. You adjust the air rates at the burners to a level above the proper range so that you can bring the readings within the proper: range later. draft 3219. These-air adjustments (can/eannot) be made without seriously affecting the draft under the roof. 2. After the burners have been adjusted so that all areas show 20-25% excess air, the stack damper should be slightly to lower the excess air in all areas, J 21. The new excess air range should be about tp 20%. % Closing the damper slightly draws less at all burners and brings the draft w range. in in the proper |, 2%. If the draft is uneven in the different areas of the furnace, in the individual ducts may be used to make minor adjustments. ‘U. To equalize excess air rates in a large furnace: treat the furnace as a number of equal areas, each with its own draft aud flue gas sampling points. (raise/lower) the excess air rates in all areas by increasing the draft. adjust the burner air doors. (raise/lower) the excess air rates in all areas by slightly closing the stack damper. make minor draft adjustments by using the indi- vidual damper in each duct. p25. In this situation, you have corrected conditions in- volving too little and too much excess air. Both of these excess air conditions’ consume more fuel than is needed for proper furnace operation. You save more by raising low excess air rates than by lowering high excess air rates. FEN rete ET closed 10 oo air dampers raise lower fuel