PT.

PT.Trans-Pacific
Trans-Pacific Petrochemical
Petrochemical Indotama
Indotama

Furnace Flooding

3rd Nov 2007

Furnace Flooding

Furnace flooding is a situation when

heater box is flooded or filled with
unburned fuel creating the risk of an
explosion.

Furnace flooding occurs when there is

insufficient air to burn all the fuel.

What causes Furnace Flooding?

Furnace flooding may occur:

when there is a sudden change in fuel

quality
(eg. More H2 in FG system. Fuel volume wise requires higher
FG flow and air to maintain same COT)

control problem
(eg. Faulty FDF combustion air pressure indication)

incorrect furnace operation.

(eg. Increasing heater firing to raise COT without
adjusting air requirement)

Physical Indication of Furnace Flooding

Abnormally low heater Coil Outlet Temperature

(COT) combined with high fuel flow
(incomplete combustion / starving of air)

Firebox hazy
(sometimes fire box may appear clear despite furnace
flooding situation)

Furnace puffing or breathing

(due to short of air)

Smoky stack

Indicative signs of Furnace Flooding

Look for following indications:

Bridge Wall Temperature and COT not increasing with

increasing fuel flow

Excess O2 low or falling

Fuel fired high and/or increasing

Furnace breathing or puffing, sometimes with

thumping sound.
(When air gets by the burners to enter the furnace unconsumed, there is
a minor puff or explosion. Gas expansion following the increased burning
reverse air flow at the burners, causing flame and hot gases to be driven
with some violence.)

Actions in event of Furnace Flooding

Fuel flow to furnace must be reduced by

approximately 25% of original stable
condition (ie. pre-flooding)

For combine stack heaters, check

adjoining furnaces for abnormal
conditions/flooding situation.
NEVER ATTEMPT TO INCREASE AIR FLOW
AS THIS COULD RESULT IN AN
EXPLOSION.
Cont./

Safety

Do not increase air draft to overcome

furnace flooding situation. This may result
in heater explosion.
Only when fuel gas, bridge wall
temperature and O2 levels have
stabilized, then field operator may check
the furnace appearance through the peep
hole.
Only if the furnace appears good, then
fuel rates can be increased slowly.

Furnace Oxygen Analyser

Causes of abnormal furnace O2 reading:

Incorrect operation or closure of air inlet

damper or stack damper

Furnace flooding Excess fuel

Failure of O2 analyser

Furnace Oxygen Analyser

Following actions are to be taken to diagnose cause of
abnormal O2 analyser reading:

Reduce furnace duty/firing gradually by up to 10% to

confirm if O2 analyser is working.

If O2 reading does not return, then assume that the O2

analyser has failed. Raise & discuss with Supervisor for
appropriate action.

Conduct normal checks for furnace flooding.

DO NOT VISUALLY CHECK THE HEATER BOX LIKE
OPENING PEEP HOLE WHILE IT MAY BE FURNACE
FLOODING SITUATION.

Furnace Oxygen Analyser

When operating furnace without O2 analyser:

Set stack damper opening in excess of normal

requirement to ensure air supply to furnace is
sufficient.

Monitor Bridge Wall Temperature, Coil Outlet

Temperature & Fuel flow to ensure that furnace is not
flooding.

Carry out routine visual checks to confirm appearance

of furnace box/stack.

Avoid sudden change in furnace duty.

ENDS

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