Sheet1Troubleshooting GuideSymptoms/ProblemPossible CausesRemedy/SolutionConsequencesInsufficient air/poor air distribution between burnersAdjust draught, increase air/fuel ratio/equalise air flow and register settings of burnersInefficient combustion1Smoky FlamesAir register collapsed shut because locking mechanism faultyReadjust register and secureFailure to obtain FOT(high ringlemmann, smoking stack)Overfiring of burnersCheck fuel pressure (refer to high fuel pressure diagnosis)Soot deposit on tube externalToo much heavies in fuelIncrease temp to achieve 20 cSt viscosity or less at burner inletCoke formation in regen tileHigh fuel oil viscosityIncrease temp to achieve 20 cSt viscosity or less at burner inletPoor fuel/air mixingOpen air damper to maintain air flow/throttle air registerCoarse atomisation - by low fuel oil pressureEnsure pressure > 10 barInsufficient atomising steamIncrease steam/oil differential pressure or steam pressureLeaking atomiserCheck burner-barrel headWrong atomiser combinationCheck listDirty/worn/plugged atomiser (tip/plug)Clean/replace atomiser tip/plug as necessaryMoisture in atomising steamIncrease superheat, check steam insulation2Dazzling White Oil FlamesToo much excess airReduce airToo much atomising steamReduce steam3Coke on rim of Cup ThroatWrong spray angleCheck list for correct tip/plugLow dual-fuel gun positionCheck dimensions. Burn coke away with fuel gas. Do not knockoff coke as this can fall back into register and damage throat.4Coke on burner tipLeaking atomiserCheck atomiser cap nut/barrel head are clean and not damaged at contact surfacesCap nut looseTightenTail piece not tightened or washer not presentCheck bothHigh gas rate comparison to oil rate, high heat radiation to oil tipIncrease atomising steam to produce cooling effect, reduce gas firing rate5Sparks in flameToo much excess airReduce airDirty tipClean tip6Slanting flameSlanting burnerCheck alignmentHot spotsGas/oil tip positionCheck alignment, clean tip if necessaryRefractory/obstruction in burner throat/registerClean during shutdownAbnormal furnace aero-dynamics/air flow distributionThrottle air register/open air damper adequately. Reduce furnace load if necessary.7Flame impingementHigh burner load in narrow furnaceThrottle register. Reduce atomiser spray angle and increase excess airHot spots on tubes leading to failure(check proper atomisation, adequate air)Coke in throat/gun tipBurn coke off with gas firingthrough overheating and cokingIncorrect tip position (during start-up)Check alignment of tipWorn/damage tipReplaceAir door looseRepair during shutdownBrick in throat or registerClean during shutdown8Flash-backHigh hydrogen fuelsReduce/shut primary air to burner, new burner/tip drilling may be requiredDamages burner parts and may restrictinsufficient air flowCheck stack damper, increase draughtcapacity of heaterlow fuel gas pressureShut off burners to raise pressure to operating burners, reduce burner orifice size9Flame Lift-OffHigh fuel gas pressureCorrect gas/oil tip alignment; check flame holderPotential safety hazardToo much excess airAdjust primary air10Failure of ignition (main burner)Too low fuel pressureIncrease pressureToo high viscosityIncrease fuel oil temperatureToo much atomising steamReduce steam (ensure during s/u that ignition is established before increasing steam)Wet steamSteam through, ensure appropriate insulation, steam traps functioning.Too much air (primary)Reduce primary airToo small ignition flameIncrease ignition flame gas pressurePilot not in right positionReposition pilot, check height.11Loss of pilot flamePilot fuel different from designAdjust draught; adjust primary air on pilot mixerPotential safety hazardInsufficient fuel pressureAdjust pilot gas pressureCheck flame stability12Flame outGas/air mixture too leanReduce total air, primary airPotential safety hazardHigh draught13Pulsating Flame/Vibration of furnaceInsufficient air to some of the burnersReduce firing rate; establish complete combustion at lower rate; open stackDamages refractory within heater(Alternating between ignition & flame out)damper and/or air registers to increase air/draught; reduce fuel before increasing air.Damages burnerUneven/non symmetrical firingEqualise air and fuel load and register settings of all burnersLow heat releaseIncrease firing rate to burner capacity with available draught or to required heat releaseLess stabilised gas firingUse central gun instead of gas ring, reduce no. of firing gas spud burnersBlockage in supply lineSwitch off burner, look at flow-supply pressure relation14After burningAir shortage on one or more gas or gas/oil burnersReduce furnace load if necessaryEqualise fuel and air load and register setting of all burnersIf necessary clean burners, registers and gas guns during shutdown15Oil SpillageImproper atomisation due to high oil viscosityAdjust oil temperature (to achieve < 20 cSt), increase atomising steam/ pressureSafety hazardHeavies in fuel oilAdjust oil temperature (to achieve < 20 cSt), increase atomising steam/ pressureInefficient operation and combustionclogging of burner tip/dirty oil gunClean/replace oil gun; change tip if standard tip is eroding out the exit ports.Coke formation in regen tileimproper location of tipAdjust oil gun/tip to proper location in oil tileoverfiring of burnerCheck oil pressure16High Fuel PressurePlugged tipsClean gas tips/orifices, place a filter in gas lineIrregular flame patternsChange in fuel qualityHot spotsOverfiring of burnerAdjust burner draught for proper heat releaseFailure to get proper FOT17Long flamesOverfiringCheck fuel pressure, reduce firing ratesToo little primary airIncrease primary air, decrease secondary airWorn burner tipReplace tipTip drilling angle too narrowChange to wide drilling angle tip18Short flamesToo much primary airIncrease secondary air, decrease primary airTip drilling angle too wideChange to narrow drilling angle tip19Unstable/Erratic/Irregular FlameToo high fuel oil viscosityIncrease fuel temperatureHot spots within heaterToo low fuel oil pressureIncrease pressure. Change tip/plug if necessaryInefficient operationDirty/worn atomiser, burner gunClean/replace atomiser or gun as necessaryToo much atomising steamReduce steamOverfiring of burnerReduce burner loadHigh rate of gas firing while firing a low rate of oilReduce gas rateDamaged burner blockRepair burner block to manufacturer's tolerancesInsufficient airAdjust air damper/register, stack damperIncorrect position of burner tipLocate tips per manufacturer's drawingsAir flow distribution problemsAdjust all registers to same opening, adjust draught to insure air flow is same acrossall burners20Insufficient Heat ReleaseLow gas flowIncrease gas flow; increase burner orifice size, make sure sufficient air availableDesired heat release exceeds design capacityLarger burner tips or new burners may be required21High NOxHigh bridgewall temperatureCheck secondary/tertiary air register positionViolation of operating permitTramp airCheck O2Check fuel gas pressure to primary and staged gas tip

&L&8SGSI/John Zink Compiled Version

Sheet2

Sheet3