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    This document summarizes high risk operational concerns when running fired equipment below normal throughput during turndown operations. It identifies three main high risk, high impact concerns: 1) poor combustion system management that can result in uncontrolled combustion and equipment damage, 2) low tube velocity that can cause rapid coking and failure, and 3) operating near limits of operating envelopes which increases risk of accidental trips. The document recommends increasing IR monitoring to validate any operational modifications and ensure stable flame patterns and optimized heat flux. It cautions that low throughput can exponentially increase coking rates and changes in coke formation locations.

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    Equipment Turndown Operations

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    This document summarizes high risk operational concerns when running fired equipment below normal throughput during turndown operations. It identifies three main high risk, high impact concerns: 1) poor combustion system management that can result in uncontrolled combustion and equipment damage, 2) low tube velocity that can cause rapid coking and failure, and 3) operating near limits of operating envelopes which increases risk of accidental trips. The document recommends increasing IR monitoring to validate any operational modifications and ensure stable flame patterns and optimized heat flux. It cautions that low throughput can exponentially increase coking rates and changes in coke formation locations.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    17 views1 page

    Equipment Turndown Operations

    Uploaded by

    sbeniwal
    This document summarizes high risk operational concerns when running fired equipment below normal throughput during turndown operations. It identifies three main high risk, high impact concerns: 1) poor combustion system management that can result in uncontrolled combustion and equipment damage, 2) low tube velocity that can cause rapid coking and failure, and 3) operating near limits of operating envelopes which increases risk of accidental trips. The document recommends increasing IR monitoring to validate any operational modifications and ensure stable flame patterns and optimized heat flux. It cautions that low throughput can exponentially increase coking rates and changes in coke formation locations.

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    © All Rights Reserved
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    Engineering Solutions │ Plant Services │ Software Tools │ Becht.

    com

    Turndown Fired Equipment


    This document covers operational and integrity concerns for Fired Equipment during turndown operations. The
    topics covered in this document are not specific to any particular site but are intended to serve as a general guide.

    It is important to consider the following High Risk, High Impact concerns when running below defined operating
    envelopes on minimum throughput. Unit adjustments require a more detailed, facilitated discussion with experts to
    ensure safe operation. Becht can assist with IR monitoring if needed to help validate operational modifications.

    High Risk, High Impact Concerns Symptom(s) Consequence(s)

    1. Poor combustion system • Local hot or cold spots within • Fuel rich pockets resulting in
    management / process heat equipment / poor flame stability uncontrolled combustion,
    integration • Poor flame pattern / burner equipment damage / fire
    performance • Low oxygen conditions at
    • High draft / tramp oxygen biasing burners, flame blow out,
    true excess oxygen at burners uncontrolled combustion,
    equipment damage / fire
    • Issues lighting burners /
    maintaining burners • Afterburning, damage / fire

    • Convection tube failure • Burners unavailable needed

    2. Low tube velocity • Rapid internal coking of tubes • Exceedance of tube mechanical
    • Unexpected locations of tube design, loss of containment / fire
    coking • Decreased cycle between spall /
    • Radiant/shock tube failure decoke, loss of operating
    flexibility
    • Unexpected loss of throughput
    when units return to high rates
    3. Operation near operating • Operating in or very near • Accidental heater trips, increased
    envelopes – SIS trips, min/max alarm(s) risk recovering from trips and
    • Issues with flame stability operational upsets
    burner pressure, etc

    4. Corrosion in steam generators • Steam – unstable level/pressure • Steam blanketing corrosion


    and air preheaters (APH) • APH – operating at or past dew • Furnace trips via level instability
    point • Damage/plugging to bundles
    1. It is critical to ensure stable flame pattern, optimized heat flux, and keeping equipment biased towards safe
    operating modes. Increase IR monitoring for high risk heaters: Becht maintains best in class Advanced IR
    technology to provide ultra-accurate data coupled with actionable engineering analysis with each monitoring
    report.
    2. Low tube velocity can lead to exponentially faster coking rates or a change in location of coke formation.
    Ensure you have operating limits and monitoring processes, such as Infrared monitoring, in place.
    3. Be aware and cautious of normalization of deviation, if running in or near alarm points confirm validity of the
    alarm points. Accidental trips can result in higher risk activities like lighting a heater or restarting a unit.
    This guideline provides guidance on high risk, high impact concerns, symptoms, and consequences for unit turndown conditions.
    Additional risks should be taken into account before proceeding into a planned shutdown or mothball. For further guidance on these
    issues, we welcome you to reach out to your internal site team, corporate organization, or Becht. We are here to help you succeed
    during these challenging times.

    Becht Knowledge Library – Turndown Operations Becht Confidential

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