BURNER MAINTENANCE Doc No: STS/QAC/SOP/14

Rev No: 00
PROCEDURE Date Rev: 17 Dec 2008
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REVISION HISTORY

Rev Originator Description Of Amendments Date

00 Farid New Document 17.12.2008

Designation Name Signature

Originator Mechanical Eng Mohd Farid Abu Bakar

Reviewed

Approved

Controlled document: No part of this document may be printed or reproduced for external purposes
without the written permission of the management appointee of Science-Tech Solutions Sdn Bhd.

SCIENCE-TECH SOLUTIONS SDN BHD

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1. PURPOSE

This procedure discuss the internal components and applications for different types of burners (gas,
oil and combination), as well as the maintenance procedures that are required to ensure the integrity
and reliability of burners

2. SCOPE

This scope covers the maintenance and cleaning of burners.

3. CODE AND STANDARD REFERENCE

3.1. API Standard 535, “Burners for Fired Heaters in General Refinery Services”

4. PROCEDURE

4.1. BURNER

4.1.1.Gas burners
4.1.1.1. There are two principal types of gas-fired burners, raw gas and pre-mix.
4.1.1.2. Raw-gas burners are used for most applications.
4.1.1.3. In these burners, the fuel gas passes through orifices in the gas tip and is injected
directly into the combustion zone, where it mixes with air.
4.1.1.4. A stabilizer cone is located just below the gas to improve combustion stability.
These burners are suitable for mounting in plenum chambers (the area where air
enters the burner), and can be used with preheated combustion air.
4.1.1.5. Pre-mix burners are sometimes used in specialized applications. In these burners,
the kinetic energy made available by the expansion of the fuel gas through the
fuel gas orifice introduces about half of the combustion air (called primary air)
into the Venturi mixer.
4.1.1.6. This mixture then exits through a large burner tip, where it is mixed with the
balance of the combustion air (secondary air).
4.1.1.7. This secondary airflow enters the burner through the outer, secondary air register.
Premix burners require less furnace draft than raw-gas burners.
4.1.1.8. Premix burners can produce a wide range of flame shapes.

4.1.2.Oil burners
4.1.2.1. Steam is always added to assist in the atomization of liquid fuels.
4.1.2.2. In oil burners, the steam and oil are mixed in specially designed fuel atomizers,
where the kinetic energy of the steam jets breaks up the fuel into small droplets.
4.1.2.3. The resulting mixture of steam and finely dispersed oil is then released into the
airstream through a number of orifices in the burner tip.
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4.1.2.4. The steam used for atomization must be perfectly dry. If there is moisture in the
steam, this moisture will flash when it mixes with the oil, causing erratic oil flow.
4.1.2.5. Furthermore, the atomizing steam should be superheated. Mechanical atomization
can be used when steam is not available.
4.1.2.6. In this method, the kinetic energy in the oil itself is used for atomization by
releasing the oil through the tip under very high pressure.
4.1.2.7. Mechanical atomization is usually used only in very large burners or with
extremely clean fuels, since the very small orifices required in smaller burners can
become plugged by small dirt or coke particles in the fuel.

4.1.3.Combination burners
4.1.3.1. The principles of gas and oil burners can be combined into a third category of
burner, the combination burner.
4.1.3.2. A typical combination gas and oil burner can be used to fire liquid, gas or a
combination of liquid and gas fuels, depending upon the fuel systems supplied
with the burner.
4.1.3.3. Liquid fuel is fired through a centrally located oil gun. The oil and atomizing
steam are fed through separate pipes in the feed tube to the atomizer and burner
tip.
4.1.3.4. The fuel-steam mixture is injected through orifices in the burner tip into the
primary airstream, where combustion begins

4.2. Reducing NOx in burners

4.2.1. Combustion operations frequently create nitrogen oxides (NOx), specifically NO and
NO2, which must be highly controlled, as they can be harmful pollutants. Currently, three
burner configuration methods exist for reducing nitrogen oxides in burners: staged air,
staged fuel and internal flue gas recirculation combined with staged air or staged fuel.

4.2.2. Staged air burners:

4.2.2.1. These types of burners work by introducing 100% of the fuel into the burner and
only part of the combustion air (primary air), thus creating a substoichiometric
flame. This flame has a reduced temperature and therefore inhibits NOx
formation. The flame is completed with the addition of the secondary air to
complete the combustion process. Thisprocess allows for greater control at lower
burner loads and also accommodates a wider range of fuels.

4.2.3. Staged fuel burners:

4.2.3.1. This burner method introduces 100% of the combustion air into the burner and
splits the fuel supply into primary and secondary volumes. The primary fuel
mixes with the combustion air to create a flame. Again, as with staged air burners,
the peak flame temperature is lower, and NOx formation is reduced. Secondary
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fuel is added to complete the combustion process. Staged fuel burners provide
greater NOx reduction, as the fuel supply has a larger effect on NOx formation.
This method is more commonly used when a consistent fuel supply is available.

4.2.4. Internal fluegas recirculation burners:

4.2.4.1. This method combines either staged air or staged fuel with internal fluegas
recirculation to help reduce NOx formation. The best results are obtained where
internal fluegas recirculation is used to dilute the fuel gas in a staged fuel burner,
creating a gas with a low calorific value.
4.3. Pilot burner

4.3.1. Pilot burners (or, simply pilots) are small burners used for ignition of the main burner
flame. In some systems, a pilot can also act as a stabilizer for the main flame.
4.3.2. Pilots in process-heater burners usually operate continuously. Individual pilots should be
removable for maintenance, even while the process heater remains in operation.
4.3.3. More and more process heaters require the presence of a permanent pilot with electrical
ignition. These types of pilots use a low-tension ignition rod and usually combine the
function of the low-tension rod with ionization detection.
4.3.4. When the ignition transformer is connected directly to the end of the pilot, standard low-
tension cable can be used. This eliminates the need for high-tension cable and, as a result,
longer cable runs can be used from the pilot to the distributed control system (DCS).
4.3.5. An electrical current is conducted between the flame and the flame retention head. The
flame is ionized, and the ionization part of the flame rod detects this change in the
current.
4.3.6. This electrical current change is then relayed by a lamp to indicate the presence of the
flame. It is crucial to ensure that the pilot flame has a very strong core to enable
consistent detection of the flame’s presence in the pilot burner.

4.4. Burner components

4.4.1. Burners are very complex devices not only are there many varieties of burners, each
burner is equipped with a number of integral components that are critical to operations.
4.4.2.Burner air registers.

4.4.2.1. Air enters the burner through the air register. Airflow can be controlled by
adjusting the size of the openings in the register. For natural-draft burners, the
most common type of air register consists of fixed and moveable concentric
cylinders, each with slots.
4.4.2.2. For forced-draft burners, air registers are controlled either manually or
automatically.
4.4.2.3. Burner registers may also be a single-bladed or twin-bladed opposed butterfly
type. This variety is used for greater control of the combustion air pressure.
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4.4.3.Plenum chamber.

4.4.3.1. Sometimes called a windbox, the plenum chamber is where all the air for the
burners enters the device. The plenum chamber may contain control vanes, as
well as the air registers for the burners.
4.4.3.2. The plenum chamber can serve several purposes, including noise and emissions
reduction, single-source combustion air supply and total airflow to the furnace
controls.
4.4.4.Burner fuel-gas piping.

4.4.4.1. Burner fuel-gas piping consists of the manifolds and piping that deliver fuel to the
burner tips.
4.4.4.2. The fuel passes through one or more openings in the tips, which act as restriction
orifices. Here, the fuel is injected into, and mixes with, the airstream.
4.4.4.3. Various types of burner tips are used, depending upon the type of fuel and the
flame pattern desired.

4.4.5.Burner throat tiles.

4.4.5.1. Located at the burner edge are the throat tiles of the burner. Throat tiles help
stabilize combustion and shape the flame.
4.4.5.2. The burner tile is usually shaped so that one section has a minimum cross-
sectional flow area. This area, called the throat, acts as a Venturi component in the
airstream.
4.4.5.3. The opening in most burner tiles is circular. In some cases, the tile and other
components are designed to produce a non-circular flame shape.
4.4.5.4. A rectangular-shaped tile opening can be used to produce a flat flame, which is
needed in some furnace arrangements.

4.4.6.Swirlers.

4.4.6.1. The function of swirl in burners is to increase flow turbulence.

4.4.6.2. Turbulence facilitates the mixing of fuel and air, and various elements within the
burner can induce a swirl phenomenon.
4.4.6.3. Some burners contain tangentially disposed doors in the air registers, which
increase turbulence.
4.4.6.4. Other burners contain axially disposed spin vanes to impart swirl in the
combustion air. Other burners may use adjustable swirl vanes to increase
turbulence.

4.5. Burner inspection

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4.5.1. Burners are expected to be continuously reliable and efficient enough to meet the
rigorous requirements.
4.5.2. Periodic inspection and maintenance should be conducted according to the burner
manufacturer’s guidelines.
4.5.3. Malfunctioning burners can result in inefficient combustion or poor flame patterns. This
can lead to localized overheating and damage to furnaces or equipment components,
resulting in increased maintenance costs.
4.5.4. This damage can also cause premature shutdowns due to failure of critical equipment
components, such as tubes or refractory lining.
4.5.5. The following is a checklist of the main burner components that operations and
maintenance personnel should inspect when developing an inspection worksheet:

• The atomizer of an oil burner should be inspected for any defects or

misalignment
• The gas nozzles of a gas burner should be inspected for any defect or
deterioration
• The nozzle diameter of an atomizer or gas nozzle should be inspected to
ensure that it is within the burner vendor’s specification datasheet
• The movement of the mechanical air registers should be inspected to
ensure proper free movement
• The gasket at the atomizer of an oil burner must be inspected
• The burner throat should be inspected by measuring its dimension and
ensuring it matches the vendor’s drawings
• The burner throat must be inspected to detect any damage

4.5.6. In addition to inspecting the various burner components, there are several physical
dimensions that must be confirmed in order to ensure correct operations. The main
components and allowable deviations from vendors’ datasheets that must be measured
and verified in the burners are as follows:
• The burner tile diameter must be within ±1/8 in.
• The burner tile concentricity (roundness) must be within ±1/8 in.
• The tip port angles must be ±4 deg
• The bolting dimensions must be ±1/8 in.
• The gas tip locations should be no more than ±1/8 in. deviation in the
horizontal direction, and no more than ±1/4 in. deviation in the vertical
direction

4.5.7.Piping and auxiliaries

4.5.7.1. The integrity of the piping and auxiliaries of the burners also requires attention,
and there are certain tasks that must be performed to maintain normal operations.
Some best practices for maintaining burner piping are as follows:
• Perform leakage tests on the burners’ associated piping and valves by
conducting a soap test or three-in-one gas tester procedure
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• Check the pilot pressure regulator setting to ensure that it is within the
recommended setpoint
• Verify the tightness of scanners and conduit connections to prevent water
intrusion
• Inspect electrical components to ensure that they are working properly,
including switches, lights, relays and other related parts
• Check that the pilot gas jet is clear and that the pilot flame is strong

4.5.8. Most burners are fitted with optical main flame-detection systems, which also require
maintenance. The following must be checked to ensure best performance of flame
detection systems:

• The sight path from the viewing head to the flame is aligned correctly to
provide visibility of the flame
• The head mount and sighting tube are clear from any fouling
• The wiring is installed as specified by the original operation and
maintenance manual

4.6. Burner maintenance

4.6.1. A burner’s performance deteriorates with operating time due to fouling, plugging and
wear on burner components.
4.6.2. Fouling, plugging and wear reduce the effectiveness of fuel-air mixing and can affect the
flame and heat flux patterns, resulting in lower heater efficiency and heating capability.
4.6.3. Burner parts requiring frequent maintenance to avoid serious performance loss or safety
issues include the orifice, tip, atomizer, tile, flame stabilizer, register, damper, pilot
burner and detection systems.
4.6.4.Gas tip and orifice.

4.6.4.1. In a burner, the fuel-gas tips and fuel-gas orifice have drilled ports that direct the
stream of fuel into the airstream and combustion zone.
4.6.4.2. These ports must be kept free of foreign material that could decrease the effective
port size.
4.6.4.3. If the ports become partially or completely plugged, the quantity and distribution
of fuel entering the burning zone may vary from the design objective, and
combustion problems may occur.
4.6.4.4. The type of material plugging the ports determines how it should be cleaned.
4.6.4.5. Foreign material must be carefully removed from the fuel orifices so as not to
affect the orifice dimensions.
4.6.4.6. Fuel tips should be replaced if any orifices exceed the specified diameter by more
than one to two twist-drill sizes.
4.6.4.7. If the material is not easily removed, some cleaning guidelines should be
followed:

• Soak the burner part in a solvent to loosen the deposit

• Use a twist drill to remove the deposit. Never use a power tool with the
twist drill because it is likely to enlarge the ports
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• Use a welder’s file to gently remove the scale from the orifices. If the
scale cannot be removed, the fuel tip or orifice must be replaced
• Use wet steam or hot water if the source of the foreign material is an
amine compound, because amines are water-soluble
• Shut down the fuel gas valve and inject steam into the burner if the amine
plugging occurs frequently without removing the burner. Note that
injection cleaning may not clear all tip ports equally
• Soak the tips in a hydrocarbon solvent, followed by cleaning with a twist
drill if the tips are plugged with polymers
• Remove the coking, polymer or solid deposit by oxidation in a small,
high-temperature furnace. Many tips can be cleaned at the same time with
this technique

4.6.5.Oil tip and atomizer.

4.6.5.1. Fuel-oil tips are harder to maintain than gas tips and require more frequent
cleaning. Tips in light fuel-oil service may have only a slight carbon like deposit
on the surface. To clean fuel-oil tips, do the following:
• Use a wire brush to remove slight carbon-like deposits. Tips in heavy
fuel-oil service will usually have stubborn hard deposits on the surface
and in the ports
• Use steam cleaning or a twist drill, in combination or individually, to
remove harder deposits. It is not recommended to use a power drill or tool
to clean ports or oil tip surfaces, as any nick or notch on the oil tip’s
surface acts as a site to collect oil and accelerate tip-coking problems
• Soak the tip in a solvent, followed by blowing steam through the orifice to
remove the remaining oil or solid deposits
• Handle the atomizer carefully when removed from the oil gun to protect
the labyrinth seal. This seal separates the oil from the steam by a series of
rings on the atomizer with a tight tolerance between the atomizer and the
gun body. If the atomizer is continuously getting stuck and cannot be
removed from the gun without breaking the atomizer, the metallurgy may
be at fault. In this case, it is recommended to exchange the atomizer
metallurgy with a different metallurgy than that of the oil tip
4.6.6.Burner tiles.

4.6.6.1. The unique profile of a burner tile’s surface is challenging to reproduce, making
tiles difficult to fix and return to service successfully.
4.6.6.2. Also, the refractory of the tile undergoes phase transformation while in service,
and refractory repairs usually do not adhere to the surface for very long periods of
time.
4.6.6.3. Burner tiles should be replaced if they experience any cracks or deformations.
Especially of concern are major cracks, mainly in wall- or roof-mounted burner
tiles, where the tile pieces are expected to fall.
4.6.6.4. Also, one should look carefully for multiple cracks in a section, which present
evidence of crushing due to restrained expansion, and are reason for replacement.
4.6.6.5. The primary or oil tile shall be checked as well. If it is badly pitted or cracked, the
recirculation of gases within the tile is uneven, and coking can occur on the tile.
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4.6.6.6. This coking can lead to oil dripping and spilling from the burner. If this is
observed, the tile must be removed and cleaned.

4.6.7.Flame stabilizer.

4.6.7.1. Different flame-stabilizer designs are used to maintain a stable flame in the
combustion zone.
4.6.7.2. For natural-draft burners, these designs take into account the diffuse cones, ledges
and tapered tiles of the burner.
4.6.7.3. Poor conditions or the absence of a stabilizer can result in unsatisfactory flame
shape or an unsafe flame that can lift off the burner and leave the zone where
combustion is initiated.
4.6.7.4. Operations suffer when part of the flame lifts off the burner due to a damaged
stabilizer because irregular, erratic flame patterns occur, and new risks are
introduced into the process.
4.6.7.5. A damaged stabilizer must be replaced. Air registers and dampers. All registers
and dampers should be exercised periodically to ensure that they are functional.
4.6.7.6. If dampers are inoperable, check the actuator and repair if necessary. Dampers are
often inaccessible during operation and repairs must wait until the equipment has
been shut down.
4.6.7.7. Clean the register of foreign materials, spilled oil, sand, rust and insulation that
blocks airflow.
4.6.7.8. If the register is deformed, possibly due to incorrect operating procedures, or the
operating handle is broken, repair or replace the
part.

4.6.8.Pilot burners.

4.6.8.1. The most common pilot burners used are small, heat-release pre-mix burners.
4.6.8.2. The basic parts of these pilot burners include the pilot tip, gas mixer, mixing tube
and orifice.
4.6.8.3. The gas orifice is commonly 1/16 in. in diameter and can be easily plugged by
pipe scale.
4.6.8.4. This element is cleaned by hand with a twist drill, as previously described.
4.6.8.5. If inspection reveals a damaged pilot tip, the tip should be replaced.

4.6.9.Pilot burners with flame detection.

4.6.9.1. In addition to checking the gas jet above the burner, check that the ionization rod
is set at the correct spark-gap distance for ionization and ignition.
4.6.9.2. Also ensure the integrity of the ionization rod’s insulation by checking for earth
leaks between the rod and pilot body casing by connecting a multimeter at the rod
and to the pilot flame retention head.

5. RECORDS AND REPORTS

5.1. Nil