Safe operation of equipment

Process Heaters Heat exchangers Columns

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R.Sivakumar CDU-2 (MFG)

Equipment safety

Design safety Safety in operation Safety during maintenance

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R.Sivakumar CDU-2 (MFG)

Safe operation Process Heaters

Knowledge of equipment Purpose Type Tube/refractory material Burner/Soot blower Draught Natural Forced Induced Balanced
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Safe operation Process Heaters

Knowledge of procedures Normal operation Start up Shut down Emergency Decoking Refractory dry out Soot blowing Handing over Special procedures
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Safe operation Process Heaters

Field monitoring Box condition Tube appearance, skin temperature Hot spots Flame pattern Stack damper/ flue gas Back fire Oil dripping Gas monitor sensors
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Safe operation Process Heaters

Process control - DCS Flow,Temperature draught, Excess air etc.. Safety interlocks - PLC Shutdown interlocks Start up bypass Emergency shutdown Interlock bypass records Gas monitors
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Safe operation Process Heaters

Start up

Flow through coil Box purging Lining up of fuel Lining up of atomising steam Pilot flame Main flame Slow heating
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Safe operation Process Heaters

Shut down Slow cooling Fuel isolation Burner purging Box purging

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R.Sivakumar CDU-2 (MFG)

Interlocks in Furnace
Low Pass Flow Low Fuel oil pressure Low Fuel gas pressure Low Comb. Air Pressure Low Comb. Air flow High Arch Pressure High Arch Temperature Atom. Steam pressure low FD Fan LEL Alarm / ID fan Failure

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Furnace lighting up

Clean the inside area Box up the furnace Ensure all FO/FG valves are closed Wide open the stack dampers Open secondary air louvers Purge the furnace for 20 mins with box purging steam Establish FO Circulation Establish the flow through the coil
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Furnace lighting up

Ensure primary and secondary air louvers are half open Energize furnace trip system Light pilot burner Now open main gas audco valve one by one and light up FG burner( if burner do not light up in 10 secs,close audco valve and purge the heater once again) Slowly increase the outlet temperature and increasing firing
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Furnace lighting up

Then light up oil fire after purging the oil gun ,adjust the P of the atomizing steam Ensure uniform firing in all burner to keep the heat distribution uniform Bring the heater to normal operating condition APH to be taken in line.
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COLUMN
Safety / Relief valves Bottom Level Controller Low & High Level switches Two temperature point at top Low / High Level Switches for R.Drum Pressure Controller Diff. Pressure indicators.

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