B-29 Furnacestop Gun

1st QTR 2009 TOP GUN
B-29 Furnaces
F-1:
A. ESD System:
The following points will Shut off the fuel gas to F-1
Description DCS Tag Trip Point
F-1 Fuel Gas Pressure Hi PAH-707-125 60 psig
F-1 Fuel Gas Pressure Low PAL-707-125 6 psig
F-1 Outlet Temp. Low- TAL-707-01 350 C
Low
 Any one of these three alarms will shut off the natural gas to F-1
 The Fuel Gas pressure shutdowns cannot be defeated
 The Low outlet temperature can be defeated for start-up
The following Alarm points will put F-1 at minimum fire

F-1 Outlet Temp. Hi-Hi TAH-707-139 550 C
F-1 Low-Low Feed FAL-707-140 0.64 gpm
 The Low-Low Feed Flow and Hi-Hi Outlet temperature have 60 second
delays built into them.
 Either of these alarms will switch the gas controller to pressure control and set
the gas pressure at 8 psig. NOTE: The controller will be in auto to control
the gas pressure at 8 psig. The minimum stop on the gas C/V is set for
lighting and burning TWO burners. If more burners are lit and you put
the gas C/V in Manual and close it – THE FURNACE WILL
SHUTDOWN ON LOW GAS PRESSURE.
 If the alarms have not cleared within 2 hours the fuel gas will be shut off to
the furnace.
 R-1 and R-2 have dual outlet temperatures. Both R-1 temperatures OR both
R-2 temperatures have to be in alarm high to initiate the minimum fire.
NOTE: The Minimum Fire initiation and the ESD do not shut off the feeds to the
furnace. They only affect the gas flow to the furnace.
B-29 Furnaces
B. Burner Configuration:
F-1 has 8 Zeeco RW-3 radiant wall burners with 7/64” orifice bore. These
burners are designed for 0.5 MM BTU/Hr maximum heat release, 0.17
MM BTU/Hr minimum heat release and 15% excess air.
B-29 Furnaces
C. The flame should be mostly blue with a little yellowish orange tip at the
end of the flame. The best place to look at the flame on F-1 is through the
lighting port. Also, when looking through the port, look across the furnace
at the flame from the burner on the opposite wall. The flame should be
steady (not pulsing or dancing).
D. Burner Tuning Tips: Adjustments should be made when the furnace is up

at normal temperatures and feed rates. Be very cautious about making
tuning adjustments. Adjustments to the primary and secondary air registers
will affect how the flames will act when starting up from a cold start.
These are general tips for adjusting.
FLAME APPEARANCE CORRECTIVE ACTION

Reduce firing immediately; Open
stack damper and/or air registers;
Breathing/Pulsating Flame
Reduce Gas Before Increasing
Air!
Dancing Flame Close Primary Air
Increase primary air; Decrease
Flame Too Long
secondary air
Increase secondary air; decrease
Flame Too Short
primary air
B-29 Furnaces
B-29 Furnaces
F-2
A. ESD System
F-2 Fuel Gas Pressure Low PAL-711-48 2.9 psig
Loss of flame from both XA-711-67 Loss of signal
fire eyes
 The loss of flame signal defeated for start-up
 When lighting F-2, at least one fire eye must see flame within 10 seconds or
the block valves will automatically shut off the gas to the burner.

F-2 Low-Low Feed FAL-711-65 0.64 gpm on MIPK and
0.2gpm D-1 O.F. on
Nitriles
 Either of these alarms will set the gas control valve to minimum fire position
which is approximately 3.5 psig.
the furnace.
NOTE: The Minimum Fire initiation and the ESD do not shut off the
feeds to the furnace. They only affect the gas flow to the furnace.
B. Burner Configuration:
F-2 has one single 5” Maxon Ventite inspirator/burner.

B-29 Furnaces
F-3
A. ESD System:
F-3 Fuel Gas Pressure Low PAL-1007-55 6 psig
F-3 Outlet Temp. Low- TAL-1007-48 350 C
Low
 The Low outlet temperature can be defeated for start-up

F-3 Low-Low Feed FAL-1007-49 0.64 gpm
 Either of these alarms will switch the gas controller to pressure control and set
the gas pressure at 8 psig. NOTE: The controller will be in auto to control
the gas pressure at 8 psig. The minimum stop on the gas C/V is set for
lighting and burning TWO burners. If more burners are lit and you put
the gas C/V in Manual and close it – THE FURNACE WILL
SHUTDOWN ON LOW GAS PRESSURE.
the furnace.
 F-3 has a dual thermocouple on the outlet temperature. One temperature
comes in to the DCS and we use it to control the gas. The other thermocouple
goes straight to the PLC. We have installed wiring to series off the analog
input to the PLC so that this temperature can be monitored.
B. NOTE: The Minimum Fire initiation and the ESD do not shut off the
feeds to the furnace. They only affect the gas flow to the furnace
B-29 Furnaces
Lighting Sequence:
A. F-1
Start-Up Checklist – Close all supervisory valves. Open dampers wide open. Set gas
C/V's on manual with zero output to the valves. Close all windows on the furnaces.
The following permissives must be met before the furnace can be lit
Description DCS Tag
Stack Damper The damper must be wide open. A switch is attached to
the cable on the damper
Supervisory Valves All supervisory valves at the burners must be closed
Fuel Gas Double Block and The red double block valves on the gas supply must be
Bleed closed and the position switch making contact to show
they are closed. The red bleed control valve must be
fully open
Temperature (Gas) Control The gas C/V must be closed. There furnace shutdown
Valve dumps the air to the C/V to make it go to the minimum
stop.
The gas C/V should be in manual with ‘0’ output to the valve. The gas control valve will
be closed anyway because the furnace shutdown interlock dumps to air to the C/V.
However, if you don’t have the controller in manual and set on Zero, then when you push
the open fuel valve the solenoid energizes and would open the gas C/V wide open.
Start-Up Checklist – Put the DCS Shutdown Handswitch to "Shutdown" and the
DCS Defeat Switch to "Normal". Then follow the steps below. This ensures that the
PLC is reset.
Set the DCS Shutdown Handswitch (HS07133B) to "Normal". NOTE: The PV on

the DCS will still remain showing Shutdown until after the first burner is lit.
Set the DCS Defeat Switch (HS07134) to "Defeat". NOTE: There should be one
"Defeat On" Alarm showing next to the Handswitches and the "Burner S/D" alarm
will be on. Ninety seconds after the first burner is lit, you should see a second
"Defeat On" alarm appear and the "Burner S/D" alarm should clear.
The above steps should be done just before pushing the purge button. Start the purge
sequence within 5 minutes of resetting the PLC with the steps above. These steps
ensure that the PLC is reset and the timer sequence is not timed out. If you only see the
one "Defeat On" alarm after lighting the burner and also still see the "Burner S/D"
B-29 Furnaces
alarm, then if F-1 is taken off defeat it will shutdown. The gas should be shut off at this
point and F-1 should be re-lit. The purge sequence is Five minutes long. Once the purge
sequence is complete you will see the “Purge Complete” light come on. You have 5
minutes to light the first burner. The PLC is satisfied that a burner is lit when a
supervisory valve is opened all the way and stays open for more than 90 seconds.
Start-Up Checklist – Light the bottom two burners on F-1 with the gas C/V ON
MANUAL - Zero output to the C/V. The Gas C/V Minimum Stop has been set to
allow lighting the first TWO Burners. The Gas C/V and Regulator have been
replaced. Do not Adjust Regulator or Minimum Stop on the C/V. The Gas regulator
is set for 54 psig and should not have to be adjusted. Open supervisory valves wide
open do not pinch down.
The reason for putting the gas C/V in manual and set on Zero is because when you push
the “Open Fuel Valve” button, the solenoid valve is energized and air is put to the gas
C/V. If it is not in manual and set on Zero then the gas C/V would go open and put too
much gas to the burner.
Start-Up Checklist – Start with all Windows CLOSED and the Damper wide open.
After the first two burners are lit, Put the Gas on Auto on Pressure control
(PC07116) and set pressure at 9.0 psig.
If the regulator is set at 54psig and the gas is in Auto on pressure control at 9.0 to 9.5
psig you should be able to light the other burners without having to make any
adjustments on the gas. Recently the gas had to be increased before lighting the next set
of burners. This was because the regulator had been adjusted down lower and the gas
C/V and regulator couldn’t react fast enough to keep the gas pressure above the S/D
pressure. Check the gas regulator before lighting subsequent burners.
Start-Up Checklist – Leave the windows CLOSED and damper wide open. As furnace
heats up adjust the damper to hold 0.1” water draft. NOTE: F-1 low gas pressure
shutdown is set at 6psi. Watch the temperature rise closely. Follow the steps below
for lighting more burners, and heating up the furnace.
This step was moved up in the lighting sequence. We used to get all the burners lit
before adjusting the damper. Leaving the damper open doesn’t allow the burners to
operate properly. The burners are designed for 0.05 to 0.10 inches of water draft.
Therefore to get complete combustion at the burners and keep the flames stable, we
need to set the damper once the furnace starts heating up. The draft will change as the
furnace heats up. The damper should be adjusted to keep 0.1 inches of water draft.
The windows should always remain closed unless we need rapid cooling due to a safety
issue. Leaving the windows open causes hot and cold spots on the tubes and can lead to
premature tube failure. It also reduces the air flow through the burner registers which
will affect flame integrity.
B-29 Furnaces
Start-Up Checklist – After the lowest tube temperature (not counting the first inlet
bottom temp.) reaches 110 degrees C, or if ANY TUBE temperature reaches 130
degrees cut off the N2 and start the steam.
Treat R-1 and R-2 separately for starting steam. Do not start to both just because one
is at temperature. Start steam to R-1 when temperature is right and start steam to R-2
when temp. is right on it.
R-1 and R-2 should be treated as if they were in two different furnaces. You wouldn’t
start steam on F-3 just because F-1 temperatures were ready. The temperature has to be
up high enough so that the steam doesn’t condense in the tubes. You don’t want it to
get too hot though because the N2 doesn’t have any heat value and so doesn’t transfer
heat well to the thermocouples. That is one reason why you see a jump in temperature
when steam is started through the tubes.
Start-Up Checklist – Hold the steam pressure at 25 psig after the first catalyst tube.
DO NOT OPEN MORE THAN 7 – 8 THREADS ON THE VALVE.
When the steam is started through the tubes, switch the flow to go to T-37. Do not go
to the tailpipe. Leave T-37 draining until just before starting feeds.
Set V-1 and V-2 vaporizers up with the steam back-flowing out the drains on them
with a slight amount of steam until feeds are ready to be started. Use the drain valve
at the bottom of the vaporizers to regulate steam back flow. Open the furnace inlet
valves from the vaporizers wide open. Put steam on the vaporizer jackets. Set steam
pressure controller at 290psig going to the vaporizers.
We back steam the vaporizers to ensure that the lines from the vaporizers to the furnace
and heated up and do not have any condensed material in them. This way when feeds
are started we don’t have a slug of liquid hit the furnaces. Opening the valves at R-1
and R-2 inlets wide open and regulating the steam flow with the valve at the bottom of
the vaporizers makes it much easier to set up when getting ready to start feeds. All that
has to be done is close the vaporizer drains. It also makes sure we don’t dead head the
vaporizers and blow the rupture disc.
Start-Up Checklist – Heat F-1 temperatures as close to 1 degree per minute or less as
possible. Heat Slowly. Decrease Gas Pressure Control Set Point if necessary to keep
from heating too quickly. DO NOT GO BELOW 7.9 PSIG ON THE GAS
PRESSURE. F-1 LOW GAS PRESSURE S/D IS 6 PSIG.
If/When the temperature lines out then light the next two burners(Open supervisory
valve slowly to keep from dropping pressure too quickly). Adjust the Gas Pressure set
point back up to 9.5 psig before lighting the next burners if it was reduced. The Gas
control valve will open up automatically to hold the 9.5 psig set point on automatic as
burners are lit.
B-29 Furnaces
The lower set point limit on the gas pressure controller is 7.9 psig. The set point limit is
there because running at a lower pressure runs the risk of a burner flame going out. You
can’t enter a set point below this. The control valve should NOT be put in manual to
run the pressure lower than this. The furnace will shut down on low gas pressure at 6
psig.
Start-Up Checklist – If/When the temperature lines out then light the next two
burners. Adjust the Gas Pressure set point back up to 9.5 psig before lighting the
next burners if it was reduced. These two burners may not be needed until after feeds
are started.
Leave the last two burners OFF. We will not use the top two burners on this MIPK
run.
All eight burners are used on Nitriles. These start-up checklist items are from the MIPK
start-up checklist.
Start-Up Checklist – The windows should remain closed. Do not open windows unless
it is necessary to cool down the furnace in an emergency. Watch temperature.
After all burners are lit and if more temperature is needed, then adjust the damper.
Watch the draft pressure gage (this is the pressure gauge facing west next to the
damper adjustment lever and reads the vacuum draft). Adjust the damper to keep
draft at 0.1"H2O vacuum. If this does not heat up the furnace enough, then adjust
the damper until the draft is at 0.05"H2O.
The damper should have been adjusted earlier. This step is a reminder about
maintaining the 0.1 “H2O draft and to indicate that we can go down as far as 0.05
inches of H2O draft if needed. If the damper is not closed very much and the draft is
already less than 0.1 “H2O then we have some air leaks. Look at the insulation around
the tubes where they come out the bottom of the furnace. Have insulators tuck up the
insulation around the tubes. Look at the windows and make sure the insulation is
stuffed in behind the window doors. At $4.50/MBTU for natural gas, one square
inch of leakage area can lead to $48,000 in energy cost per 0.1 in. w.c. of excess
draft.
Start-Up Checklist – When damper has been adjusted, then start using gas to heat up
the furnace. Continue to heat the furnace slowly.
Repeat the pressure drop check across the tubes after the steam is going using the
existing pressure gauges. Record the pressure readings on the last page of this
checklist.
B-29 Furnaces
Heat and hold F-1 at 375 degrees on the outlet temperature for feeds. Follow the
steps outlined above for heat-up. Don't heat too fast or high. Slow is Good. Note: F-1
low gas burner pressure shutdown is 6 psig. Do not go below 6 psig with burners lit
B. F-2
F-2 is the same as F-1 with the exception that it only has the one burner to
light and the way it satisfies the permissive that a burner is lit. F-1 and F-3
use the logic that a supervisory valve being open for 90 seconds means the
burner is lit. F-2 uses the fire eye. The fire eye must see a flame within 10
seconds of the valve being opened.
C. F-3
F-3 is the same as F-1 except for the number of burners that are lit. We use
Three burners on MIPK and Four burners on Nitriles.
B-29 Furnaces
B-29 Furnaces
Furnace Configuration:
A. F-1
The flows on F-1 (R-1 and R-2) go from the vaporizers up one 4” preheat
then down a 8” catalyst tube, up another 4” preheat tube and then down
the final 8” catalyst tube. On MIPK we load the bottom half of the first
catalyst tube with catalyst and the top half with saddles. The final catalyst
tube gets a full load of catalyst. On Nitriles both catalyst tubes get a full
load of catalyst.
B-29 Furnaces
Below is a diagram showing how the thermocouples should be hooked up

on F-1. The metal plates attached to the wires are labeled correctly. Do not
go by the tags on the thermowells. The thermowells could get put back in
a different place. Look at the tags on the cables and hook them into the
proper tubes.
B-29 Furnaces
B-29 Furnaces
B. F-2
The flows on F-2 go from the vaporizer through 3 preheat tubes then down
a 8” catalyst tube, up another preheat tube and then down parallel catalyst
tubes. On MIPK we only load catalyst in the parallel outlet catalyst tubes.
The inlet catalyst tube has saddles. On Nitriles all three catalyst tubes get a
full load of catalyst.

proper tubes.
B-29 Furnaces
B-29 Furnaces
C. F-3
The flows on F-3 go from the vaporizer up one 4” preheat then down a 8”
catalyst tube, up another 4” preheat tube and then down the final 8”
catalyst tube. On MIPK we only put catalyst in the outlet catalyst tube.
The first catalyst tube is loaded with saddles. The final catalyst tube gets a
full load of catalyst. On Nitriles both catalyst tubes get a full load of
catalyst.
B-29 Furnaces

proper tubes.
B-29 Furnaces
Furnace Catalyst (Decoking) Regeneration
A. When carbon builds up on the reactor catalyst, the inlet pressures increase
and the conversion/yield decreases. A catalyst regeneration procedure was
developed and utilized several times to try extending catalyst life. It was
determined that the regeneration procedure was not effective in extending
catalyst life. Additionally, PSV evaluations determined that PSVs would
need to be added to the air piping to protect the furnace feed piping and
furnace tubes from overpressure during the regeneration process due to
failure of the air regulator:
Air regulator failure – The maximum discharge pressure of the plant air
compressor, 10C-1, is 151 psig. While this pressure is well within the
150# piping system limits at ambient conditions, it exceeds 110% of the
pressure rating at furnace conditions.
Since the decision was made to no longer regenerate/decoke the catalyst

PSVs were not added to the air piping.
The procedure for catalyst regeneration was removed from N-69-14 in

December 2018.

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1st QTR 2009 TOP GUN

The following Alarm points will put F-1 at minimum fire

D. Burner Tuning Tips: Adjustments should be made when the furnace is up

FLAME APPEARANCE CORRECTIVE ACTION

The following Alarm points will put F-2 at minimum fire

F-2 has one single 5” Maxon Ventite inspirator/burner.

The following Alarm points will put F-3 at minimum fire

Set the DCS Shutdown Handswitch (HS07133B) to "Normal". NOTE: The PV on

Below is a diagram showing how the thermocouples should be hooked up

Below is a diagram showing how the thermocouples should be hooked up

Below is a diagram showing how the thermocouples should be hooked up

Furnace Catalyst (Decoking) Regeneration

Since the decision was made to no longer regenerate/decoke the catalyst

The procedure for catalyst regeneration was removed from N-69-14 in

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