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Safe operation of

equipment Process Heaters

Heat exchangersColumns

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Equipment safety

Design safetySafety in operation

Safety during maintenance

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Safe operation ProcessHeaters

Knowledge of equipmentPurposeType

Tube/refractory materialBurner/Soot blowerDraught

NaturalForcedInduced

Balanced

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Safe operation ProcessHeaters

Knowledge of proceduresNormal operationStart up

Shut downEmergencyDecoking

Refractory dry outSoot blowingHanding

overSpecial procedures

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Safe operation ProcessHeaters

Field monitoringBox conditionTube appearance,

skin temperatureHot spotsFlame pattern

Stack damper/ flue gasBack fireOil dripping

Gas monitor sensors

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Safe operation ProcessHeaters

Process control - DCSFlow,Temperaturedraught, Excess air etc..

Safety interlocks - PLCShutdown interlocksStart up bypass

Emergency shutdownInterlock bypass recordsGas monitors

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Safe operation ProcessHeaters

Start upFlow through coilBox purgingLining up of fuelLining up of atomising steamPilot flameMain flameSlow heating

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Safe operation ProcessHeaters

Shut downSlow cooling

Fuel isolationBurner purging

Box purging

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Interlocks in FurnaceLow Pass Flow

Low Fuel oil pressureLow Fuel gas pressureLow Comb. Air PressureLow Comb. Air flowHigh Arch Pressure

High Arch TemperatureAtom. Steam pre ssure lowFD Fan LEL Alarm / ID fan Failure

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Furnace lighting up

Clean the inside areaBox up the furnaceEnsure all FO/FG valves are closed

Wide open the stack dampersOpen secondary air louversPurge the furnace for 20 mins with box

purging steamEstablish FO CirculationEstablish the flow through the coil

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Furnace lighting up

Ensure primary and secondary air louversare half openEnergize furnace trip system

Light pilot burnerNow open main gas audco valve one byone and light up FG burner( if burner donot light up in 10 secs,close audco valve

and purge the heater once again)Slowly increase the outlet temperatureand increasing firing

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Furnace lighting up

Then light up oil fire after purgingthe oil gun ,adjust the P of theatomizing steamEnsure uniform firing in all burner to

keep the heat distribution uniformBring the heater to normal operating

conditionAPH to be taken in line.

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COLUMN

Safety / Relief valvesBottom Level Controller

Low & High Level switchesTwo temperature point at topLow / High Level Switches for

R.DrumPressure ControllerDiff. Pressure indicators.