ENAR PETROLEUM REFINING FACILITY II

SOP FOR START-UP & SHUT DOWN OF

THERMAL CRACKER HEATER DE-COKING

1 24-05-23 seocond issue for review BJ

0 10-04-23 First issue for review BJ

Rev Date Description Prepared Checked Approved

Unit/Job No Document No Rev Date Sheet

ERP/ 238-2-SOP- 005 0 10-04-2023 1 of 09

 ENAR PETROLEUM REFINING FACILITY II

Table of Contents

1. De-coking introduction: .............................................................................................................. 2

2. Preliminary‐startup activities Check list: .................................................................................... 4

3. Startup procedure ....................................................................................................................... 5

4. Process Parameters: .................................................................................................................... 7

5. Shut down Procedure:................................................................................................................ ..8

6. Major precautions: .......................................................................................................................9

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 ENAR PETROLEUM REFINING FACILITY II

1. De-coking introduction:

Mechanism of De-coking:
Theory of Thermal Cracking Process

When the hydrocarbon is heated and decomposed under thermal cracking condition, it
may be assumed that it is broken up into two or more free radicals. The free radicals then
enter into a series of reactions that results in all total products. In accordance with
thermal cracking theory, the reactions could, for example be proceed as follows:
A portion of the compound disassociates to form free radicals, for example:

C10H22 C8H17* + C2H5*

The highly reactive radicals do not appear in the thermally cracked product effluent, but
depending upon size and environment:
a) react with other hydrocarbons,
(b) decompose to olefins,
(c) combine with other radicals, and
(d) react with metal surfaces.

In general, small radicals are more stable than larger radicals, and will more readily react
with other hydrocarbons by capturing a hydrogen atom, for example:

C2H5* + C6H14 2H6 + C6H13*

Large radicals are unstable and decompose to form olefins and smaller radicals, for example:

C6H13* 5H10 + CH3* (3)

C8H17* 4H8 + C4H9* (4)

*
4H8 +H
C4H9* (5)
The free radical chain reactions are terminated when two radicals combine; for example: .

C8H17* + H 8H18

or when a radical reacts with a metal or poison.

The polymerization and condensation reactions that occur at thermal cracking conditions can
go all the way to aromatic tars: for example:

XC4H8 + YC4H8 + ZC3H6 multi aromatic ring

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 ENAR PETROLEUM REFINING FACILITY II
Coke and bitumen are the ultimate polymers. The molecules become very large with
considerable cross linkage. Lack of hydrogen coupled with high molecular weight
decreases their solubility in hydrocarbons. Cokes have a hydrogen to carbon atomic ration
of approximately 2:1.

Defination:
Decoking is the process of removing coke or scale build up from the process tubes of
fired heaters. There are different types which are used for decoking and the type which
is preferred is according to the available sources.
The main types which are used in industrial heater decoking are as follows:

• Chemical cleaning

• Steam-air decoking

• In-line spalling and mechanical pigging

We are using steam air decoking because availability of the steam and air at plant.

Why de-coking is necessary:

With the passage of time during firing of heater the heat transfer rate decreases and
coils pressure differences also increase due to coke building inside the heater surface.
The described condition is not bearable for smooth plant operation as well as for heater
life.
Effects of coke in heater:

• Decrease in heat transfer rate

• Increased in heater tubes pressure difference

• Increase in fuel consumption

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 ENAR PETROLEUM REFINING FACILITY II

2. Preliminary startup activities Check list: :

• Have all the utilities i.e. steam, plant air, fuel gas, fuel oil , plant water etc available at
the respective unit which has to be de-coked.
• Dcs and area reading sheet should be prepared which is based on two hourly basis.
• All persons who are involved in decoking operation should be briefed about decoking
because it is not a routine activity and it is important to handle it smoothly.
• furnace draught must be maintain and checked time to time (follow heater firing SOP).
• Decoke elbow swung/valves for air & steam are fitted for each pass.
• Temporary lights on decoke drum effluent are available.
• Fire hose connected upto decoke header and decoke drum.
• check out drains etc & decoke drum by introducing the plant water.
• superheated coil should be blocked in & depressured (drain down)
• check out culvert from decoke drain to storm water drain & ensure any
debries/blockages are removed.
• Ensure standby air compressor is available and has be run up tested (utility area).
• one or two pilots in commission per box.
• Introduced decoke steam to each of two passes and then quench fire water to decoke
header and make sure they reported into decoke drum.
• Decoke drum v-609 off gases header connected with on load furnace stack.
• check steam & air FT,S are working correctly.
• blind must be installed on all process lines.
• Before starting the decoke activity carryout pressure drop survey as follows.
• Close valve to pass being examined quickly & note FT flow.
• open valve fully & note incremental increase on FT flow.
• log pressure on each pass inlet (steam/air).

Decoke drum drain temperature should be controlled with raw water with FT controlled flow.
Decoke drum surrounding area should be barricade, because when decoking in peak time steam
are in visible.
Instrumentation of decoking system should be checked & functional.
Fire extinguishing equipment placed properly near covered sump.

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 ENAR PETROLEUM REFINING FACILITY II

3. De-coking start up procedure:

Procedure of steam air decoking:
1 The swing elbows of the respective heater inlet and outlet tubes need to be turned and
connected with steam/air decoking system.
2 Installation of decoking manifold with air and steam flow indicators and mixing header should
be assured
3 Water should be available for checking sample line, discharge line and pre-quench water line
for quenching.
4 Fire the respective heater on fuel gas (238-2-SOP-001) to raise the temperature with the rate of
100 F/hr and don’t allow the heater temperature increased drastically. Increase the
temperature gradually to (480 - 510C)
5 The steam should be introduced in coils when the temperature reached to 140C (284 F) and the
quantity of steam is provided according to decoking manual which is mention below.
6 The amount of steam in coils maintain high enough to flush deposit readily & steam are suggested
Tubes sizes (inches) Steam flow(Kg/hr)
2 680
2.5 998
3 1452
3.5 1996
4 2540
7 By introducing steam in coils the process of spalling will start if spalling has not started yet
then follow the following method to increase spalling rate.
a) Reverse the flow chemistry
b) increase and decrease steam quantity
c) Introduce small quantity of air for five to ten minutes for hourly basis.

d) lower flue gas temperature 37-93 C.

(Effectively spalling involves the rapid introduction of steam as a quench medium to a pass
8
the thermal shock cause coke particles to break away from pipe wall etc.)
Each pass should be spalled separately. open up the decoke steam to the pass be spalled
a)
rapidly & quickly. when open fully wait of few minutes & return to origional position.
b) Examine decoke drum effluent quality for signs of the spalling log finding.
c) Continue spalling untill the effluent quality remains clean. fill in log every 2 hour.
when effluent shows no signs of spalling on all passes particularly these passes which had
d)
shown a high pressure. carry out another pressure survey as previously described and log finding.
The sample from the decoking vessel checked regularly because decoking is measured with
e)
respected to the resultant color of the sample effluents.

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 ENAR PETROLEUM REFINING FACILITY II

9) De-coking drum color observation for checking the burning and spalling rate as
follows:
a) Decoking stream color is grayish milky before beginning and after completion of decoking
b) The color is light gray when the discharge sample is having fine soot.
c) The stream color is dark gray to black when the coke particles size and quantity increases.
d) When the air blowing cycle carried out the color is reddish brown.
e) With the increase in spalling the steam rate in the tubes should be reduced otherwise the
erosion will starts which is not desirable during decoking.

10) After spalling has stopped and cannot be restored, reduced flue gas to 650 C (1200 F)
and steam flow approximately as follows

Tubes sizes (inches) Steam flow(Kg/hr)

2 227
2.5 316
3 499
3.5 680
4 816

The amout of air added in the tubes for burning is almost 10% of the the steam flow. after
adding air watch the metal temperature and apperance of tubes.
11)
Burning will be started probably at the end of tubes where steam and air are entering and
can be seen by the hot spots on the tubes. hot spot on the tube one to two feet long

12) Do not allow the tube metal temperature to exceed 620-670 C (medium cherry red) if
temperature rises , decrease air flow.
13) if possible, take CO2 reading and maintain around 19% CO2 by controlling temperature to
maintain stable burning. if it drops below this, raise coil outlet to a maximum of 650 C.
when effluent shows no CO2 and no hot spot, a glow test or analysis can be use to show
completion of operation.
The water is cut of the line and a glowing wood ember is held in the discharge. if burning is
14) not completed, ember will be extinguished. if glow increases in brightness the decoking is
assumed to be complete. if analyze the presence of significant oxygen is an even better
indication of burn completion.

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 ENAR PETROLEUM REFINING FACILITY II

4. Process Parameters:

Thermal cracker furnace De-coking parameters are mentioned in the table below.

Unit parameter Range

steam flow for spalling 998 lb/hr
metal temp. (COT) Increase rate 100 F/ hr
max. allowable box temperature 1200 - 1250 F
metal temp. during spalling 925 - 975 oF
steam flow for burning (fire inside tube) 300 - 350 lb/hr
Air pressure 10 % steam

AIR duration for fire 5 - 10 mints.

metal temp. during burning 900 - 950 F

CO2 % Not less then 19%

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 ENAR PETROLEUM REFINING FACILITY II

5. Shut down Procedure:

1) shutoff air and increase steam as per spalling rule to remove ash or scale

Tubes sizes (inches) Steam flow(Kg/hr)

2 680

2.5 998

3 1452

3.5 1996

4 2540

2) when the heater temperature is cooled to 500 F, Flush with water before hydrostatic test
unless tubes are stainless and significant chlorides are present in the flush. in these cases a
soda ash solution wash or high velocity air blow is recommended.
3) when decoking procedure is completed, turn back swing elbows on heater inlet and outlet
tubes

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 ENAR PETROLEUM REFINING FACILITY II

8. Major Precautions:

1. Avoid overheating tubes. watch closely for local hot spots. Do not exceed 676 C (1250
F ) Box temperature & 510 C (COT) metal temperature. Record reading Two hourly.

2. Avoid excessive velocities through tubes. coke particles are very abrasive

and can cause serious erosion of return bends

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