Heaters troubleshooting

1. CNPCNP PRODUCTION DEPARTMENT
CNPCNP PRODUCTION DEPARTMENT
Heater inspection and related operations

2. CNPCNP PRODUCTION DEPARTMENT
CNPCNP PRODUCTION DEPARTMENT
directory
1.Brief introduction of the Heater
2.Inspection points of the Heater
3.Operation of the Heater
4.Heater failure analysis and handling

3. CNPCNP PRODUCTION DEPARTMENT
1.Brief introduction of the Heater
Function: Increase the temperature of the crude oil, for beter separation..
Pre-haerter : FPF oil heat up to 50 ℃ .
Production heater: heat up to 75 ℃.
Recycle heater: heat up to 70℃.
Fuel：Natural gas.(Pre-heat and stable pressure)

4. CNPCNP PRODUCTION DEPARTMENT
Process principle :
The fuel gas burned and transfer the heat to the water, and the water
transfer the heat to the crude oil.
1.Brief introduction of the Heater

5. CNPCNP PRODUCTION DEPARTMENT
Structural features:
It consists of :heating furnace, burner, process piping, valve , instrumentation, gas system,
operation room, liquid collection bag, skid seat and a ladder.
The furnace body is cylindrical, the heating coil is a snake-shaped coil structure.
The burner is an automatic proportional adjustment gas burner, and the natural gas is
filtered and reduced to reach the pressure required for the normal operation.
1.Brief introduction of the Heater

6. CNPCNP PRODUCTION DEPARTMENT
Process Introduction :
Preheated Heater process
Recyle Heater process
1.Brief introduction of the Heater

7. CNPCNP PRODUCTION DEPARTMENT
Process Introduction :
Production heater process
1.Brief introduction of the Heater

8. CNPCNP PRODUCTION DEPARTMENT
2.Inspection points of the Heater
Check : the water level, the pressure, the temperature, medium inlet and outlet
temperature and pressure , exhaust temperature.

9. CNPCNP PRODUCTION DEPARTMENT
Check the remote instrument , the comparison field instrument.
Check the liquid level of the fuel gas buffer pack the pressure.
Check the burning condition of the burner, observe that the flame jet should be stable,
the furnace chamber should be bright, and keep its parts clean and intact, monitoring
normal.
2.Inspection points of the Heater

10. CNPCNP PRODUCTION DEPARTMENT
Inspection of production parameters:
Check whether the pressure, temperature and liquid level of the heating furnace are normal。
2.Inspection points of the Heater

11. CNPCNP PRODUCTION DEPARTMENT
3.Heater related actions
• Prepare before ignition
• Check that the pressure gauges, thermometers, etc. are clean and intact.
• Check whether the thermal insulation protection of the heater body and the connected pipes is in
good condition.
• Check that the burner is in good condition.
• Whether the fuel supply can meet the requirements of the burner operation. When regulating the
pressure, it should be open and scattered so that the gas flow can be adjusted. The pressure after
secondary pressure regulation is 5-20KPa.
• Check whether each valve of each system has leaks and is in good condition.
• Check whether each discharge port on the equipment is closed, and whether the valve that should be
in the closed state is already closed.
• Check the instrumentation and control system to ensure that the system is working properly and that
the primary meter and actuator are in good condition.

12. CNPCNP PRODUCTION DEPARTMENT
Ignition operation panel introduction
3.Heater related actions

13. CNPCNP PRODUCTION DEPARTMENT
Ignition procedure (AUTO):
1. Place the main switch A on the burner control panel at position 1 and hit CMF to position 3.
2. Check that the device is not in the locked position (LED B is on) and reset it via the reset button C if
necessary.
3. Confirm that the proportional regulator gives the burner operation allowed command.
4. Check whether the supply pressure is above the minimum standard (indicator E is on).
5. The fan starts, the pre-purge starts, and the test procedure of the gas valve leak monitor begins at
the same time. If there is a leak in the gas valve, the gas tightness monitor will lock and the alarm
light will turn on (above the solenoid valve group). Press the reset on the valve block to reset.
6. Since the pre-purge stage requires a maximum amount of air, the control device begins to fully
open the servo controller until the maximum opening is reached. This is the start of the pre-purge
phase (36 seconds).
7. At the end of the pre-purge stage, the servo controller reaches the full off position (ignition
position), at which point the ignition transformer starts (I light on).
8. The ignition transformer is turned off after the gas valve is turned on for 2 seconds, and the light I
is extinguished. At this point the burner ignites and the servo controller opens to the fire position.
After 14 seconds, the second stage of operation is entered, and the burner automatically switches to
a large or low fire according to the requirements of the system.
9. When the burner is running in the large/low fire position, it can be displayed by simulating the on-
off of the indicator light G on the panel.
3.Heater related actions

14. CNPCNP PRODUCTION DEPARTMENT
Adjustment operation:
The burner adjusts the temperature control operation of the heat medium water,
changes the set temperature, press "PGM" to appear "SPI", adjust the up and down
keys to the desired temperature, press "PGM" to determine, press the "EXIT" key to
exit.
3.Heater related actions

15. CNPCNP PRODUCTION DEPARTMENT
Attention in operation:
• If ignition failure, you need to wait enough time (at least 10 minutes).
• The increasing of the temperature should not be too fast, and should be operated at low load
for a period of time. The temperature rise of the first point furnace should be controlled at
about 60 °C/h to keep dry inside.
• When burning normally, there should be no obvious Spark in the flame, the flame should not
be deflected, and the chimney should not have black smoke.
• During the operation, the burning state of the burner should be observed every day, the length
of the flame and the atomization angle should be observed
3.Heater related actions

16. CNPCNP PRODUCTION DEPARTMENT
Symptom Cause Processing methods
1.The flame is undetectable
①The air control valve has no opening
②Flame detector failure
③There is no incoming gas on the gas trunk
Before ignition, the gas control valve should opening of 20%-30%.
Check for burner faults.
Inspect the gas system and gas inlet.
2.Chimney have black smoke
①Insufficient amount of air
②The heater is overloaded
Adjust the air regulator and distribute the air reasonably.
Reduce the opening of the gas control valve.
3. The exhaust temperature
is too high
①Flow breaks in the oil pipe inside
②The temperature gauge fails
Immediately stop heater
Report to replace the temperature gauge
4.Heater failure analysis and handling

17. CNPCNP PRODUCTION DEPARTMENT
4. The pressure is not in the normal range.
①The pressure gauge fails.
②The pipeline condition is abnormal.
Report to change the pressure gauges.
Check processes to eliminate hidden dangers.
5. The medium temperature is continuously too high.
①The pipe flow is reduced.
②The pipe flow interruption.
③The gas control valve fails and the opening
is too large.
Reduce the heater load.
Immediately stop the heater.
Replace the control valve.
6. Efficiency Reduced.
①Changes in the nature of fuel gas.
②Material worse than before.
Overhaul the heater.
Adjust the air and gas ratio.
7. Local overheating on the surface of the heater.
(except near the opening holes in the furnace body）
①The insulation layer falls off.
②Insulation material fails.
③The heater is overloaded.
Repair the insulation layer.
Reduce the load.
8. explosion occurred.
①Ignited several times without carefully
performing the waiting process
When ignition is unsuccessful, must wait 10 minutes
before a second ignition.
9. Leakage of air and water in the valve and pipe.
①The gasket is broken
②Packing loss rings
③The bolts are loose
Stop the heater.
Change the valve and pipe and replace the damaged
gasket or packer, and tighten the bolt.

18. CNPCNP PRODUCTION DEPARTMENT
The end！
A Better you, A Better World.