1

1
BY:
Er.
K.M.
Tri
pat
hi
DEFNI
TION :Fur
nacei
san encl
osed st
ati
cequi
pment
usedi
nRef
iner
ies/pet
rochemi
cal/Powerpl
ant,
ToHeat
Fl
uidsupt
oDesi
redTemper
atur
ebyusi
ngcombust
ing
Fuel
s.
ModeOfHeatTr
ansf
erI
nFur
nace-
(
1)Radi
ati
on:Radi
ati
oni
sthet
ransf
eroft
her
malener
gy
t
hrought
her
mal
emi
ssi
on.
(
2)Conv
ect
ion :Conv
ect
ion i
sthe t
ransf
eroft
her
mal
ener
gy byact
ual
mot
ionofmat
ter(Gas/
Liqui
d).

UseOfFur
naceI
nOi
l&Gas-
Fur
nacei
suset
o Add t
heHeatener
gyi
nto cr
udeoi
l
[pr
esenti
ntubes]upt
oacer
tai
nTemper
atur
e.
COMPONENTSOFFURNACE-

(
1)Casi
ng

(
2)Tubes

(
3)Ret
urnBands

(
4)TubesSuppor
t[(
i)Gui
de/
Spi
got(
ii
)RoofHanger
s].

(
5)Bur
ner
s(i
)Fuel
gasl
i
ne.

(
ii
)Pi
l
otgun.

(
ii
i)Of
fgasl
i
ne.

(
iv)Ai
rlov
our
s/Ai
rRegi
ster
.

(
v)Oi
lgun

(
vi)At
omi
singst
eam Li
ne.

(
vii
)CupThr
oat
.

(
vii
i
)Muf
fl
eBl
ock.

(
ix)Scer
awool
.

(
6)APH(
i)CAPH(
ii
)GAPH(
ii
i)HotAi
rDuct(
iv)Col
dAi
rDuct
.

(
7)I
DFan[I
nducedDr
aftFan]

(
8)FDFan.

(
9)Damper[Rope&Wi
nch]

(
10)Gul
ati
ne.

(
11)St
ack.

(
12)Radi
ati
onZone (
13)Conv
ect
ionZone (
14)Ref
rect
ori
es.
Radi
ati
onZone-

ThePor
ti
onofHeat
eri
nwhi
cht
heHeati
sTr
ansf
err
edt
oTubesby

r
adi
ati
ont
echni
que.Tubes/Radi
ati
oncoi
lposi
ti
onsar
eei
ther

Ver
ti
cal
orHor
izont
al.

Conv
ect
ionZone-

ThePor
ti
om ofHeat
eri
nwhi
cht
heHeati
str
ansf
err
edt
oTubesby

conv
ect
ion t
echni
que .
Tubes / Conv
ect
ion coi
lposi
ti
ons ar
e

Hor
izont
alandTubesar
eFi
nnedorSt
udded.

Super
Heat
erZone-

The Top Por

ti
on OfHeat
erwher
e Remai
ns Fl
ue gas Heat
,

commi
ngf
rom r
adi
ati
onzone i
sgetut
il
izedt
o HeatLP/
MP

st
eam l
i
ne.

Bur
ner-

Bur
neri
sadev
icet
hati
ntr
oducesf
uel
&ai
rMi
xtur
e i
nto t
he

f
ir
ebox ( Radi
ati
on sect
ion ) atdesi
red r
ati
o&v
eloci
ty&

concent
rat
ionst
omai
ntai
npr
opercombust
iont
opr
oduceHeat
.

APH(Ai
rPr
e-Heat
er)-
Ai
rpr
eheat
eri
sthepar
tofFur
nace,
usedt
orecov
erHeatf
rom f
luegases.
FDFan(For
cedDr
aftFan)-

I
tist hepar
tofAPH ,Usedt osuppl
yat
mospher
icai
r-APH -Bur
nerf
or
Desi
redcombust
ioni
nfi
rebox.

I
DFan(I
nducedDr
aftFan)-

I
tisal
sothepar
tOfAPH, usedt
oremov
efl
uegassesanddustf
rom
Fur
nace-APH-Stack-At
mosphere.

St
ack-

Stackist
hevert
icalpi
pethr
oughwhi
chcombust
edgasorf
luegasi
svent
ed
outint
otheat
mosphere.I
tisal
socal
l
edachi
mney.

Damper/Gul
ati
ne-

Thedamper/Gulati
nearethe I
sol
ati
onval
ve usedto cont
rol thef
low
offl
uegasorai
rfrom st
ack&APH.I
tworksMannual
l
yusi
ngwinchandRope
Techni
que.

Expl
osi
onDoor-

Tor
emov
eExpl
osi
cemi
xtur
eofgasi
nemer
gencysi
tuat
iont
oav
oidexpl
osi
on.

PeepHol
e-

Simpl
yaGlasspr
esenti
nRadi
ati
onzonet
oseet
hebur
nerf
lameandi
nsi
de
condi
ti
ons.

Mat
eri
alComposi
ti
onofRadi
ati
on/Conv
ect
ionCoi
ls:

Al
l
oySt
eel
[ASTM -A335]Gr
ade-P5/P9/P11/P22

I
tisBcozOfpr
esenceofChr
omi
um (
cr)andMol
ybdenum (Mo)i
n

al
l
oyst
eel

Cr:
StandsFor"Cr
ossi
onResi
stance".

Mo:
StandsFor"Cr
eep-
resi
stant".
Mai
ntenanceCheckl
ist

(
1)Open M/
w and cov
erpannelt
hen I
nter
nal
scaf
fol
dingt
henpur
gingbyconnect
inghosei
nI/
L
passes.
(
2)Tube Cl
eani
ng (
To check Pi
tt
ings/
Hot
Spot
s/scal
es/
over
heat
ing)
(
3)Bur
ner
'sCl
eani
ng(ondi
smant
li
ngAl
lguns)
.
(
4)TubeBendCl
eanni
ng(Buf
fi
ng)
(
5)Gui
de/
spi
gotCl
eanni
ng.
(
6)BendRepl
acement
(
7)Coi
lRepl
acement
.
(
8)scer
awool
repl
acementi
fdammage
(
9)Pi
ggi
ng.
(
10)Hy
drot
estt
henAi
rdr
yingofTubes.

I
nspect
ionCheckl
ist-

(
1)TubeNumberMar
kingasperSket
ch.
(
2)Vi
suali
nspect
ion f
or Scal
es /Deposi
ts/
cor
rosi
ons/Bul
gingonTubesf
rom Fl
uegas.
(
4)LowerU.
Bends t
o be r
adi
ogr
aphed (ASME
SEC-
V)f
orThi
nni
ng,deposi
ts,pi
tt
ing,cor
rosi
ons
checki
ng.Bul
gingal
socheck.

(
5)Ther
mocoupl
econdi
ti
ont
obechecked.
(
6)Bur
nercondi
ti
onsspeci
all
yGunTi
pox
idat
iont
o
bechecked.
(
7)Hanger
s/supl
ort
stobechecked.
(
8)conv
ect
ionTubeFi
ns,Ref
rect
ori
escondi
ti
ons
t
obechecked.
(
9) St
acks U.
T measur
ement
s , Hammer
ing
checki
ngandVi
sual
inspect
iont
obedoneatl
ast
.
(
10)Hy
drot
estWi
tness.
 THANK YOU

Er
.KaushalManiTr
ipat
hi
B.
Tech[Mechani
cal
]
ASNTNDTLEVEL-I
I,QA/
QC