Discussion Points:

Flame Impingement:

Will results in High TMT of radiant tubes.

Possible reasons for flame impingement are:

 Low excess air
Inadequate primary air
After burn
Too much draft
Fuel composition change

Common problems/solution in furnace operation

Sl No. Problem Solution

1 Flame lift off Incorrect air /fuel ratio

2 Pulsating flame Low excess air

Poor or low draft

3 Flame interaction Poor setting of air/fuel ratio

Burner pitching too close

4 Flashback High excess air

Higher than normal hydrogen contents in fuel
Low fuel gas pressure

5 Flame length high Low excess air

Excessive firing
Burner tip worn out
Poor air-fuel mixing

6 Positive pressure at arch Excessive firing

Stack or ID fan inlet damper not open
Excessive fouling of convection section
7 Damaged tube refractory Excessive firing
Flame impingement
Heat flux shift

8 Excessive noise Unstable flame

Poor burner design

9 High temperature in convection Heat flux shift

box

10 Tube coking Flame impingement

Low pass flow

11 Positive pressure inside the fire Excessive firing

box Stack or ID fan inlet damper not open
Excessive fouling of convection section

12 High fuel gas pressure Excessive firing

Plugged burner tip
Fuel composition charge
Not enough burners operating

13 Afterburn Fuel composition change

Incorrect oxygen measurement
Excessive heater leaks
Poor burner condition/adjustment

14 High combustibles/ emissions Low excess air

Fuel composition change
Incorrect oxygen measurement
Poor burner condition/adjustment

15 Tube bulging Excessive firing

Flame impingement

16 High stack or flue gas temperature Excessive firing

High excess air
Excessive fouling of convection section
Convection section tube fins burn out
 17 Corrosion of convection tube Higher than normal sulfur contents in fuel gas
TMT below acid dew point temperature

18 Variation in COT Unequal heater pass flow distribution

Uneven firing

19 High pressure drop of radiant tubes Coke buildup

High pressure flow rate
High pressure of vaporization

20 Heater vibration Fuel composition charge

Unstable flame
Poor burner design

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