Safety Talk 9 / 1 Safety Talk 9 Safe Operation of Fired Heaters: start-up

Safety Talk 9 / 2 Fire or explosion ?

Safety Talk 9 / 3 Summary of prestart-up checks 1.Check that process pressure tests and mechanical integrity inspections are complete 2.Inspect internally and externally (no oil / material left in the heater) 3.Check blanks / blinds are installed and all isolation valves are closed 4.Check air registers for movement 5.Check stack damper and burner for ease of movement 6.Check burners and pilots for installation and condition 7.Check purge and snuffing steam and instrument tappings for operability 8.Brick access opening and secure doors 9.Leave header box doors open 10.Remove stack guillotine 11.Check that fuel gas pilot gas and fuel systems are tight – no open ends etc. 12.Check all instrumentation is working / proved

Safety Talk 9 / 4 Sketch of pilot gas and fuel gas lines

Safety Talk 9 / 5 Procedures for purging and testing fuel lines 1.Check fuel blinds / blanks are in place 2.Purge each fuel line with nitrogen through each individual burner in turn 3.Pressure test for tightness with 40 psig (2.5 bar. g.) 4.Pressure test oil burner safety interlock and associated steam purge valve 5.Test safety shut off valves for actuation and tightness, then depressure system 6.Remove blind from pilot gas line only and re-pressure test disturbed flange with nitrogen, then reduce pressure to about 2 to 3 psig (0.2 bar. g.)

Safety Talk 9 / 6 Establishing flow and purging heater Establish flows Safe minimum flows in heater tubes Check flow instrumentation Purge the heater Ensure stack damper is fully open Natural draft – steam purge for a maximum of 15 minutes or until steam plume see from stock Forced / induced / balanced draft – air purge

Safety Talk 9 / 7 Gas test Instrument ? Explosimeter –calibrated ? –trained to use it ? Where ? Inspection ports Convection section Flue gas ducting Air space immediately above the burner

Safety Talk 9 / 8 Lighting pilots – forced draft burners (or natural draft burners)

Safety Talk 9 / 9 Safe light-off of pilots

Safety Talk 9 / 10 Good pilot flame

Safety Talk 9 / 11 Good gas firing and good oil firing Gas firing Oil firing

Safety Talk 9 / 12 Lessons learned Operating procedures available and up-to-date Trained, competent operators Checklists used for all stages of the operation Instrumentation checked prior to start-up Correct PPE to be worn (face shield, gloves, helmet) Minimise numbers of people in vicinity Positively isolate fuel supplies Fully open stack damper

Safety Talk 9 / 13 Lessons learned (cont’d) Drain liquid from fuel gas K.O. drum Repeat gas tests if 1st pilot not lit within 5 minutes Do not de-blind main fuel or waste gas until pilot burners lit and stable Light main burners from own pilot Ensure lit burners on one level are stable before lighting burners on other levels