51315-5903-Extensive Oxidation and Perforation of Radiation Roof of Crude Heater

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Product Number: 51315-5903-SG

ISBN: 5903 2015 CP

Author: Musaed AL-Arada

Publication Date: 2015

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By: Musaed Al-Arada Vinod Kr. BhatiaKuwait National Petroleum Company Mina Abdullah RefineryP.O.Box-69 Safat Kuwait-13001The Crude Heater of Crude Distillation Unit in KNPC MAB Refinery is having castable refractory on all the vertical walls and roof casing plates of radiation and convection sections. The refractory is in two layers – 3” thick light weight and 4” thick ultra- light weight. The heater was performing satisfactorily from 1988 to 2010.In February 2010 hot spots and small perforations were observed on the radiation roof casing plate of this heater. The perforations were due to the damage in the refractory lining which caused oxidation of carbon steel casing plate. The damage was kept on increasing in size with new hot-spots were generated at various locations on the roof.To avoid unit shutdown these hot spots on the radiation roof casing plates were covered with 1" thick ceramic fiber and SS 310 plates. However the extent of damage on the radiant roof gradually increased. The flame pattern of burners was also affected due to fallen refractory inside the burner muffle blocks.To operate the heater safely and to avoid unit shutdown on-stream replacement of refractory lined casing plates and refractory spraying was carried out which was a very difficult and challenging job. This averted an unplanned shutdown of the crude unit resulting in considerable saving to the company and also ensured continued availability of premium petroleum products for exports & local market. After 20 months of operation the whole radiation roof was replaced with new casing plates and body soluble fiber as insulating material.This paper describes the complete work scope and sequence of activities done along with health and safety precautions taken for on line refractory repair of the crude heater of MAB refinery. This paper also discusses the lesson learned and how various challenges and unpredicted difficulties were resolved through numerous brainstorming sessions and new ideas.Key wordsCrude heater Oxidation refractory damage ceramic fiber on-stream refractory repair lesson learned body soluble fiber.