DECOKING PROCEDURE FOR FIRED

HEATER
Following are the steps which are required to be followed for decoking process.
1. Ensure that the decoking lineup is completed by rotating swing elbows.
2. Ensure steam/air/water lined up with flow indicators.
3. Follow the SOP for heater start‐up and fire the pilot burners.
4. For temperature monitoring Tube skin temperature of reaction side coils (follow the
temperature of highest value).
5. Achieve 300 oF tube skin temperature before introducing steam in both coils.
6. Introduce steam in the both coils gradually upto 250 lbs/hr.
7. Steam pressure at each coil to be maintained at 50‐60 psig.
8. Quench water is to be turned on to the decoking product manifold at the same time steam
injection started in coils.
9. Maintain “spalling” at 350 oF tube skin temperature and 250 lbs/hr each coil flow for 06
hrs and monitor reading.
10. Start BFW and saturated steam flow in their respective coils throughout the decoking
process.
11. Temperature increase rate shall be 75 oF/hr.
12. Increase tube skin temperature to 500 oF and coils flow @ 350 lbs/hr each coil and
maintain for 06 hrs.
13. Increase tube skin temperature to 650 oF and coils flow @ 450 lbs/hr each coil and
maintain for 08 hrs.
14. Increase tube skin temperature to 750 oF and coils flow @ 600 lbs/hr each coil and
maintain for 08 hrs.
15. Increase tube skin temperature to 900 oF and coils flow @ 800 lbs/hr each coil and
maintain for 08 hrs.
16. Keep maintaining above conditions for reverse flow spalling for 08 hrs.
17. Increase tube skin temperature to 1000 oF and coils flow @ 950 lbs/hr each coil and
maintain for 08 hrs.
18. Keep maintaining above conditions for reverse spalling for 08 hrs.
19. If spalling not increased with increase in steam flow or temperature then, reverse steam
flow decoking shall be practiced.
20. Attempt burning at these conditions in forward direction for an hour with time gap of 15‐
20 minutes between each air shot.
21. Burning of coke shall be attempted at 900‐1100 oF.
22. During burning, air flow shall be maintained 10% of steam flow. It could be decrease
keeping in view the extent of burning. During burning vigilant observation to be kept of
skin temperature and decoking product. For burning, air flow need to maintain for max
2‐4 minutes.

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DECOKING PROCEDURE FOR FIRED
HEATER
23. It is recommended to decrease skin temperature prior to burning, as it exceeds suddenly
due to burning.
24. Maximum limit of tube skin temperature is 1200 oF for decoking process
25. Increase tube skin temperature to 1100 oF and coils flow @ 1000 lbs/hr each coil and
maintain for 08 hrs.
26. Keep maintaining above conditions for reverse flow spalling for 08 hrs.
27. Attempt burning at these conditions in forward direction for an hour with time gap of 15‐
20 minutes between each air shot.
28. Increase tube skin temperature to 1150 oF and coils flow @ 900‐1000 lbs/hr each coil and
maintain for 08 hrs. This step shall be taken depends on decoking condition.
29. Avoid Excessive steam, as it will erode bends and fittings.
30. The discharge coke drum will be milky with slight grey color after decoking has been
completed.
31. “Reverse flow “decoking is used to increase the decoking effectiveness.
32. Temperature shall be decreased upon successful completion of decoking.
33. Water washing of the tubes for ash removal, if any shall be done at the end only after the
tube metal temperature have cooled to 300oF. Use BFW for this purpose.
34. Hydrotesting of coils shall be done after completing the process at 1500 psig.
35. Fill the reading sheets of decoking on regular basis.
36. Keep in close coordination with utilities section.
37. Any changes shall be done with prior discussion.