Troubleshooting Guide

Symptoms/Problem Possible Causes

Insufficient air/poor air distribution between burners Air register collapsed shut because locking mechanism faulty Overfiring of burners Too much heavies in fuel High fuel oil viscosity Poor fuel/air mixing Coarse atomisation - by low fuel oil pressure Insufficient atomising steam Leaking atomiser Wrong atomiser combination Dirty/worn/plugged atomiser (tip/plug) Moisture in atomising steam

Remedy/Solution
Adjust draught, increase air/fuel ratio/equalise air flow and register settings of burners Readjust register and secure Check fuel pressure (refer to high fuel pressure diagnosis) Increase temp to achieve 20 cSt viscosity or less at burner inlet Increase temp to achieve 20 cSt viscosity or less at burner inlet Open air damper to maintain air flow/throttle air register Ensure pressure > 10 bar Increase steam/oil differential pressure or steam pressure Check burner-barrel head Check list Clean/replace atomiser tip/plug as necessary Increase superheat, check steam insulation

Consequences
Inefficient combustion Failure to obtain FOT Soot deposit on tube external Coke formation in regen tile

Smoky Flames (high ringlemmann, smoking stack)

Dazzling White Oil Flames

Too much excess air Too much atomising steam

Reduce air Reduce steam

Coke on rim of Cup Throat

Wrong spray angle Low dual-fuel gun position

Check list for correct tip/plug Check dimensions. Burn coke away with fuel gas. Do not knock off coke as this can fall back into register and damage throat.

Coke on burner tip

Leaking atomiser Cap nut loose Tail piece not tightened or washer not present High gas rate comparison to oil rate, high heat radiation to oil tip

Check atomiser cap nut/barrel head are clean and not damaged at contact surfaces Tighten Check both Increase atomising steam to produce cooling effect, reduce gas firing rate

Sparks in flame

Too much excess air Dirty tip

Reduce air Clean tip

Slanting flame

Slanting burner Gas/oil tip position Refractory/obstruction in burner throat/register Abnormal furnace aero-dynamics/air flow distribution

Check alignment Check alignment, clean tip if necessary Clean during shutdown Throttle air register/open air damper adequately. Reduce furnace load if necessary.

Hot spots

Flame impingement (check proper atomisation, adequate air)

High burner load in narrow furnace Coke in throat/gun tip Incorrect tip position (during start-up) Worn/damage tip Air door loose Brick in throat or register

Throttle register. Reduce atomiser spray angle and increase excess air Burn coke off with gas firing Check alignment of tip Replace Repair during shutdown Clean during shutdown

Hot spots on tubes leading to failure through overheating and coking

Flash-back

High hydrogen fuels insufficient air flow low fuel gas pressure

Reduce/shut primary air to burner, new burner/tip drilling may be required Check stack damper, increase draught Shut off burners to raise pressure to operating burners, reduce burner orifice size

Damages burner parts and may restrict capacity of heater

SGSI/John Zink Compiled Version

Flame Lift-Off

High fuel gas pressure Too much excess air

Correct gas/oil tip alignment; check flame holder Adjust primary air

Potential safety hazard

10

Failure of ignition (main burner)

Too low fuel pressure Too high viscosity Too much atomising steam Wet steam Too much air (primary) Too small ignition flame Pilot not in right position

Increase pressure Increase fuel oil temperature Reduce steam (ensure during s/u that ignition is established before increasing steam) Steam through, ensure appropriate insulation, steam traps functioning. Reduce primary air Increase ignition flame gas pressure Reposition pilot, check height.

11

Loss of pilot flame

Pilot fuel different from design Insufficient fuel pressure

Adjust draught; adjust primary air on pilot mixer Adjust pilot gas pressure Check flame stability Reduce total air, primary air

Potential safety hazard

12

Flame out

Gas/air mixture too lean High draught

Potential safety hazard

13

Pulsating Flame/Vibration of furnace (Alternating between ignition & flame out)

Insufficient air to some of the burners Uneven/non symmetrical firing Low heat release Less stabilised gas firing Blockage in supply line

Reduce firing rate; establish complete combustion at lower rate; open stack damper and/or air registers to increase air/draught; reduce fuel before increasing air. Equalise air and fuel load and register settings of all burners Increase firing rate to burner capacity with available draught or to required heat release Use central gun instead of gas ring, reduce no. of firing gas spud burners Switch off burner, look at flow-supply pressure relation Reduce furnace load if necessary Equalise fuel and air load and register setting of all burners If necessary clean burners, registers and gas guns during shutdown

Damages refractory within heater Damages burner

14

After burning

Air shortage on one or more gas or gas/oil burners

15

Oil Spillage

Improper atomisation due to high oil viscosity Heavies in fuel oil clogging of burner tip/dirty oil gun improper location of tip overfiring of burner

Adjust oil temperature (to achieve < 20 cSt), increase atomising steam/ pressure Adjust oil temperature (to achieve < 20 cSt), increase atomising steam/ pressure Clean/replace oil gun; change tip if standard tip is eroding out the exit ports. Adjust oil gun/tip to proper location in oil tile Check oil pressure

Safety hazard Inefficient operation and combustion Coke formation in regen tile

16

High Fuel Pressure

Plugged tips Change in fuel quality Overfiring of burner

Clean gas tips/orifices, place a filter in gas line Adjust burner draught for proper heat release

Irregular flame patterns Hot spots Failure to get proper FOT

17

Long flames

Overfiring Too little primary air Worn burner tip Tip drilling angle too narrow

Check fuel pressure, reduce firing rates Increase primary air, decrease secondary air Replace tip Change to wide drilling angle tip

18

Short flames

Too much primary air Tip drilling angle too wide

Increase secondary air, decrease primary air Change to narrow drilling angle tip

SGSI/John Zink Compiled Version

19

Unstable/Erratic/Irregular Flame

Too high fuel oil viscosity Too low fuel oil pressure Dirty/worn atomiser, burner gun Too much atomising steam Overfiring of burner High rate of gas firing while firing a low rate of oil Damaged burner block Insufficient air Incorrect position of burner tip Air flow distribution problems

Increase fuel temperature Increase pressure. Change tip/plug if necessary Clean/replace atomiser or gun as necessary Reduce steam Reduce burner load Reduce gas rate Repair burner block to manufacturer's tolerances Adjust air damper/register, stack damper Locate tips per manufacturer's drawings Adjust all registers to same opening, adjust draught to insure air flow is same across all burners Increase gas flow; increase burner orifice size, make sure sufficient air available Larger burner tips or new burners may be required

Hot spots within heater Inefficient operation

20

Insufficient Heat Release

Low gas flow Desired heat release exceeds design capacity

21

High NOx

High bridgewall temperature Tramp air

Check secondary/tertiary air register position Check O2 Check fuel gas pressure to primary and staged gas tip

Violation of operating permit

SGSI/John Zink Compiled Version