DCU FIRED HEATER

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Topics of Discussion

Overview of DCU Heater Design Components of DCU Heater Start-up/ Operation Trouble-shooting

Interlocks

Paradip Refinery

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Overview of DCU Heater

Operating & Design Parameters
Heater

Type of Passes

Number

Heat Absorbed Fluid Fluid

Flow-rates, Temperatures & Pressures (inlet and outlet) Properties (API, viscosity, specific heat & thermal conductivity) Drop Allowable

Pressure

Fouling

Factor (or coke lay-down thickness)

Heat Flux Injection Requirements

Average %

Vaporization (25) and Alternate Cases

Condensate Turndown

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Other Special Factors that Influence the Heater Design

Thermal

Efficiency Required (Combustion Air Preheat) Draft Fans & Drivers

Forced

Draft Fans & Drivers

Induced Soot

blowers Emissions-Burner Type (Low NOx Burners) Fluid Pass Control Characteristics (burner and pilots) Input Control

Stack Fuel

Process Heat

Decoking

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Typical Heater Design Parameters

Thermal

Cracking Tendency: High Drop (Kg/cm2 ) Clean & Fouled: 28/35

Outlet

Temperature (C): 496

Fluid Mass Velocity (Kg/s-m2)): 2321 Avg. Heat Flux(kcal/hr-m2):22,116 Avg. Heat Flux(kcal/hr-m2):9,238

Pressure Process Radiant

Convection Fouling

Factor (or coke lay-down thickness) :3mm below a bulk fluid temperature and 7mm at the radiant coil outlet.

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Paradip Refinery

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Steam and oil connection Ignition port

Primary air control Pilot gas connection View port Staged air control

Air Inlet

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Burner Assembly
pilot

oil Tip
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Radiation section
lower 5 tubes have more tube space 305mm and all other tube space are 205mm Radiation Tube material:A213 Gr. T9 (Cr. 8-10% and Mo 0.9-1.1%)

Convection section
Tube Material A213 Gr. T9 (Cr. 8-10% and Mo 0.9-1.1%) Fins material :- 11-13Cr
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Paradip Refinery

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Cross-over section

Velocity condensate injection points

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Steam air decoking swing elbow

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Equipments Of Heater

FD

Fan Blowers

ID

fan

Soot

SAPH CAPH Fuel Fuel

Gas System Oil System

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FD Fan

RPM: 1400
Flow: 24m3/s 42oc

Volumetric

Temperature: Pressure Pressure Control

Inlet: -16 mmWg Outlet: 246 mmWg

Method: Inlet Damper & VFD

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ID Fan

RPM: 980
Flow: 49m3/s 190

Volumetric

Temperature: Pressure Pressure Control

Inlet: -128 Outlet:2

Method: Inlet Damper

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SOOT BLOWER
Each convection section is equipped with 24 retractable steam lances for blowing soot deposits off the convection tubes. (2 rows of 12 soot blowers)

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SAPH
Heat Duty: 2.15 mmKcal/Hr
Tube side: LP steam Channel Side: Air Inlet Temp. 42C Outlet temp. 103C

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CAPH

Heat Duty: 3.31 mmKcal/Hr

Tube
Shell

side: Flue Gas I/L temp: 103 O/L temp: 244

Side: Air I/L temp: 313 O/L temp: 190

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Start-Up Procedure

INITIAL CHECK UP FROM FIELD & ACKNOWLEDGEMENT TEST LIGHT UP

RESET LEAK

PURGING PILOT MAIN FUEL

GAS LIGHT UP OIL LIGHT UP

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Normal Operation

Operating Variables
Flow

rates temperatures Controls

Outlet Firing

Draught

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Operating Parameters
Tube

temperatures air operation

Excess Air

preheating

Burner

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Trouble Shooting
Excessive

temperature in firebox

Positive
Flame

pressure in firebox
of the combustion/High fuel pressure

impingement

Pulsation High High

skin temperature pressure drop in Process coils temperature at convection exit hot spots

Excessive Casing

Low
High

O2 in flue gas
O2 in flue gas

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F G DF Ci Ur i n g

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F O DF Ci Ur i n g

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HEATER INTERLOCK
MANAUL ACTVIATION OF EMERGENCY SHUTDOWN FIELD/DCS HEATER CHARGE PUMP FAILURE MANUAL ACTVIATION OF PILOT/FUEL OIL/FUEL GAS SHUTDOWN FIELD/DCS FD FAN FAILURE ID FAN FAILURE ARCH PRESSURE HIGH & HIGH HIGH PILOT GAS PRESSURE HIGH HIGH & LOW LOW

HEATER INTERLOCK

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HEATER INTERLOCK
MAIN FUEL GAS PRESSURE HIGH HIGH & LOW LOW FUEL OIL PRESSURE HIGH HIGH & LOW LOW STEAM & OIL DELTA PRESSURE LOW LOW

HEATER INTERLOCK

COIL OUTLET TEMP. HIGH HIGH HEATER PASS FLOW LOW LOW PASS COMBUSTION AIR VALVE CLOSE FUEL GAS KOD

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INTERLOCK
MAIN FUEL GAS SDV CLOSE MAIN FUEL GAS VENT SDV OPEN PILOT GAS SDV CLOSE PILOT GAS VENT SDV OPEN
TOTAL HEATER SHUTDOWN

FUEL OIL SUPPLY/RETURN SDV CLOSE FUEL OIL DRAIN SDV OPEN

EMERGENCY SHUT DOWN ACTVIATION - FIELD

EMERGENCY SHUTDOWN ACTIVATION HWC

FUEL GAS KOD LEVEL HIGH

ID FAN STOP

FD FANS STOP STACK DAMPERS/MAIN STACK DAMPER OPEN PASS FLOW SUPPLY CLOSE

EMERGENCY STEAM TO PASS SDV OPEN

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INTERLOCK

MAIN FUEL GAS SDV CLOSE MAIN FUEL GAS VENT SDV OPEN

ALL HEATERCHARGE PUMPS STOP

FUEL OIL SUPPLY/RETURN SDV CLOSE FUEL OIL DRAIN SDV OPEN PASS FLOW CONTRL VALVE CLOSE EMERGENCY STEAM VALVE OPEN

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INTERLOCK
MAIN FUEL GAS SDV CLOSE MAIN FUEL GAS VENT SDV OPEN FUEL OIL SUPPLY/RETURN SDV CLOSE
FD FAN SHUTDOWN

FUEL OIL DRAIN SDV OPEN ID FAN STOP

LOW LOW POWER

INLET VANE CLOSED

NOT RUNNING

LOW RPM

FD FAN STOP

STACK DAMPER OPEN

MSD OPEN

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INTERLOCK

ID FAN STOP

ID FAN SHUTDOWN

LOW LOW POWER

INLET VANE CLOSED

STACK DAMPER OPEN

NOT RUNNING

MSD OPEN

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INTERLOCK

STACK DAMPERS OPEN

ARCH PRESSURE

HIGH
MSD OPEN

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INTERLOCK
MAIN FUEL GAS SDV CLOSE MAIN FUEL GAS VENT SDV OPEN FUEL OIL SUPPLY/RETURN SDV CLOSE FUEL OIL DRAIN SDV OPEN

ARCH PRESSURE
HIGH HIGH

ID FAN STOP

FD FAN STOP

STACK DAMPER OPEN

MSD OPEN

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F G DF Ci Ur i n g

INTERLOCK

CELL-MAIN FUEL GAS SDV CLOSE CELL- MAIN FUEL GAS VENT SDV OPEN

PASS COMBUSTION VALVE CLOSE

CELL-FUEL OIL SUPPLY/RETURN SDV CLOSE CELL-FUEL OIL DRAIN SDV OPEN CELL- STACK DAMPER OPEN

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INTERLOCK

CELL- MAIN FUEL GAS SDV CLOSE

PASS COIL OUTLET TEMPERATURE

CELL- MAIN FUEL GAS VENT SDV OPEN CELL- FUEL OIL SUPPLY/RETURN SDV CLOSE CELL- FUEL OIL DRAIN SDV OPEN

HIGH HIGH

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INTERLOCK

CELL- MAIN FUEL GAS SDV CLOSE CELL- MAIN FUEL GAS VENT SDV OPEN

PASS FLOW LOW-LOW

CELL- FUEL OIL SUPPLY/RETURN SDV CLOSE CELL -FUEL OIL DRAIN SDV OPEN CELL- PASS FLOW CONTROL VALE CLOSE CELL- EMERGENCY STEAM VALVE OPEN

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INTERLOCK

CELL- PILOT GAS SDV CLOSE

PILOT GAS PRESSURE HIGH-HIGH LOW -LOW

CELL- PIOLT VENT VALVE OPEN CELL- MAIN FUEL GAS SDV CLOSE CELL- MAIN FUEL GAS VENT SDV OPEN CELL- FUEL OIL SUPPLY/RETURN SDV CLOSE CELL -FUEL OIL DRAIN SDV OPEN

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P Di Cl Uo t

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INTERLOCK

PASS FUEL GAS PRESSURE HIGH-HIGH LOW -LOW

CELL MAIN FUEL GAS SDV CLOSE CELL MAIN FUEL GAS VENT SDV OPEN

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F G DF Ci Ur i n g

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INTERLOCK

PASS FUEL OIL PRESSURE HIGH-HIGH LOW -LOW

CELL- FUEL OIL SUPPLY/RETURN SDV CLOSE CELL -FUEL OIL DRAIN SDV OPEN

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INTERLOCK

PASS STEAM FUEL OIL RATIO PRESSURE LOW -LOW

CELL- FUEL OIL SUPPLY/RETURN SDV CLOSE CELL -FUEL OIL DRAIN SDV OPEN

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F O DF Ci Ur i n g

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THANK YOU

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