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PROBLEM
INDICATION OF PROBLEM
EFFECT ON OPERATION
SOLUTION TO PROBLEM
INDICATION OF PROBLEM
INDICATION OF PROBLEM
Clean burner
Adjust excess air to proper level
Check gas and or oil tip drilling for
erosion
INDICATION OF PROBLEM
Some burners have longer flames
than other burners with same fuel
pressure
Inefficient operation
High CO readings
INDICATION OF PROBLEM
INDICATION OF PROBLEM
INDICATION OF PROBLEM
Visual observation in firebox shows
long, dirty, smoky flames going into
convection section
Inefficient combustion
INDICATION OF PROBLEM
Operator can not initiate the ignition of
the combustion reaction at the burner
INDICATION OF PROBLEM
Small to large droplets of oil are burning
as they move up the firebox towards the
convection section
Leaning flames
INDICATION OF PROBLEM
INDICATION OF PROBLEM
Pressure gauge on fuel line is reading a
higher fuel pressure than necessary to
get required heat release
Hot spots
INDICATION OF PROBLEM
INDICATION OF PROBLEM
Loss of heater
Loss of production
INDICATION OF PROBLEM
INDICATION OF PROBLEM
Adjust draft
Adjust primary air on pilot mixer
Adjust pilot gas pressure
Observe flame stability
Change pilot tip to a wind resistant pilot tip
INDICATION OF PROBLEM
High NOx level measured in stack
INDICATION OF PROBLEM
High NOx level measured in stack
High CO
Irregular Flame Patterns
Burner Flame Lifts-Off (Ultra-Low
NOx Burners)
C 2005 by John Zink Company, LLC
Damage Burner Tile
x
x
Wet Steam
x
x
x
x
x
Lack Of Atomising Flow
x
x
x
x
x
Lack of Atomising Pressure
x
x
x
x
Insufficient Air
Smokey Flame
PROBLEM
Oil Flashing
Lazy Flame
Instability
Fire Flies
Oil Spills
Coke
C
OPTIONS BEYOND BURNER OR HEATER
ADJUSTMENTS
Combustion rate on
burner center plane
shows:
– flame rollover
– a flame that is
detached from
the wall
Flame ‘rolls
over’ off the wall
and impinges on
tubes
CFD MODELLING
Optimized flame
shape hugs the fired
wall
C 2005 by John Zink Company, LLC Flame shape colored by temperature (°F)
Example 2 – Flame Detachment from Wall
Solution: Change Tile & Burner Tip
LOTIS inspections
can give advance
warning of
problems…
…before problems
lead to failure
• Hydrogen Plant
LOTIS inspection showed maximum creep strain as
3.2% on the side of one tube.
• The rest of the tubes had 1 to 1.5% creep strain
• We highlighted that flame impingement from a
burner was the probable cause of the local
damage
• Burner inspection showed tip had burnt away on
an adjacent burner