We experienced a tube failure in one of the fined tubes at convection zone then jet fire inside the Furnace (Fired Heater) and consequently Tubes in the Fire box and convection zones are damaged and going to be replaced.
Simulation shows more Fuel Gas needed for running the heater in order to get the same outlet temp of the Process Gas before incident that causes higher temp in convection zone as we are not going to install fined tubes in convection zone due to lack of time (order/manufacture/delivery for fined tubes need more time).
This causes high temp in arc, convection and stack (about 300 C higher in stack)
any idea about problems we are going to be faced with due to higher temp in mentioned areas ?
I am worried about:
1. Instability of the flame due to higher flue gas draft rate.
2. Hot surface at external body of the furnace, convection zone and stack.
3. Deformation of the stack.
Are they going to be the case?