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MAJOR COMPONENTS IN A FIRED HEATER

Casing
Tubes
Return bends
Tube supports
Burners
APH/SAPH
ID & FD fans
Types of heaters with different coil arrangements:
Type A-Box heater with arbour coil
Type D-Box heater with vertical tube coil
Type E-Cylindrical heater with vertical coil
Type F-Box heater with horizontal tube coil
Disadvantages in Vertical type of radiant tubes are difficult to replace due to less gap between
wall & tube .
Horizontal type radiant tubes are weld able outside the heater fire box due to more space
available in return header bends/ plugs.

Fig. 1: Figure showing typical fired heaters


Constructional features of heaters:
Casing: The metal plate used to enclose the fired heater. Normally CS plates 6mm thick is used as
casing material. Casing design temp Outside 82 C, Radiant floor 91 C. Max. temperature, CS can
withstand is 440 degree C however oxidation starts at 270 deg.c
Failure of internal refractory lining causes overheating of underlying steel casing. This will be
revealed by local hot spots.
To prevent further damage to casing plate
o Apply air
o Apply steam
o In extreme case put water
o Put additional refractory lined casing plate over hot spot area.
Radiant section: The portion of the heater in which the heat is transferred to the tubes primarily
by radiation.
Convection section: The portion of heater in which the heat transferred to tubes primarily by
convection.
Bridge wall: Section which separates the radiant & convection section. The temperature of flue
gas leaving radiation section is called bridge wall
Arch: A flat or sloped portion of the heater radiant section opposite the floor.
Heater coils:
Radiant Coils: The radiant coils are located in the radiant section of the furnace where the heat
picks from flame &high temperature flue gas & hot refractory.
The radiant tubes may be either vertical or horizontal depending on the construction of the
furnace
Main components / Sections:
Convection section: Bank of coils which receives the heat form hot flue gases mainly by
convection.
Finned/studded tubes are often used in convection coils due to lower flue gas temperature.
Finned tubes ( 1.3 mm thick strip 200turn/meter) are difficult to clean when compared to
studded (12.7 mm dia)
The rate of heat absorption tends to be high at the entrance to the convection section in heaters,
where the convection section is right above the radiant section. Tubes at this section are called
shock / shield tubes .Normally first two rows absorb half of their heat in this section.
Consists of a large tube support plate located in the convection section and supports
number of End supports & intermediate supports are usually low alloy steels.
Replacing /Repair of Convection tube support sheet is difficult & calls for removal of all
convection coils or it is necessary to lower the entire module.
Tube support sheets are 25 cr-20 Ni or 50 cr -50 ni MOC.
Plug header: A bend, provided with one or more openings for the purpose of inspection,initial
measurement of coke before cleaning.
Ensure proper depressurization before opening the plug.
Ensure Arrow mark is maintained on plug to ensure plug nut is guiding
After repair /replacement of plug hydro test of the coil pass is recommended.
Tube supports:
Tube supports are metal devices which supports the weight of the
Tube guide is used to direct movement of tubes in one particular direction.
These are metallic members able to withstand high temperatures used to prevent sagging/
bowing / buckling/ swaying of tubes
Tube supports are more prone to high temperature oxidation and fuel ash corrosion.
Horizontal roof tubes of box type heaters are supported by means of hangers
Fig. 2: Figure showing typical tube supports
Tube supports must be aligned perfectly in one straight line.
The use of fillers of any kind is prohibited.
Ensure perfect contact between supports and tubes.
Coils shall rest uniformly all over the supports.
Failure of tube supports may take place due to mechanical overloading caused by bowing of
tubes, loss of strength of supports and tube vibration.
The tube support / hangers / guides shall be examined for cracks, oxidation, missing sections and
missing/broken or oxidised bolts.
Common problems associated with Heater tubes:
Tubes are designed for approx 11years life-1,00,000 hrs of
Tube distortion Hot spots, Sagging, Bowing, Touching of tubes
Tube surface Pitting, Scale, Evidence of overheating.
Observe & monitor the skin temperature, compare the residual life of tube.
Fig. 3: Heater Tubes in an operating Fired Heater
Tube cleaning:
Generally tubes are cleaned manually making scaffolding inside the heater.
Ensure All burner tips covered while cleaning
Ensure Fire bricks covered to avoid ingress of foreign particles between the bricks to provide
expansion of refractory during operation.
Ensure no damage to refractory while making scaffolding
Hydro testing of heater coils:
Hydro test is performed when the new coil is installed/repair in the coil is
Coils shall be hydrostatically tested, thoroughly drained after test is completed and to be
drained by blowing compressed air to avoid hammering &
During hydro test due to return bends & elevation differences adequate care to be taken
to vent air.Use correct grade of
Stack: A cylindrical steel, insulated shell which carries flue gases to atmosphere & provides
necessary draft. The stacks shall be externally inspected for hot spots and external corrosion. Check, if
any unusual vibration of the stack exists.
Burners:
Burner: Introduces fuel & air into heater at the desired velocities, turbulence and concentration
to establish and maintain proper ignition and combustion.
Pilot: A smaller burner that provides ignition energy to light the main burner.
Plenum or wind box: A chamber surrounding the burners that used to distribute air to the
burners or reduce the combustion noise.
Annual Maintenance:
Tubes visual inspection prior to cleaning
Inspection after cleaning
Dimensional check up (OD of tube),thickness.
Visual inspection of header plug leaks
Inspection tubes supports, hangers etc.
Inspection burner assemblies
Inspection of refractory
Inspection of explosion doors
Dampers external, internal, operating linkages etc.
Decoking by Pigging:
A new method of decoking the tubes is to steam , and then use water pressure to push
Styrofoam pigs with studs and grit on the exterior through the tubes and around u-bends (even
u-bends with clean-out plugs). The pigs scrape out the coke without scratching the tube walls.
Improper size of pig may leave scratches on the tube walls, hence selection of correct size of
pig is
Pigging is faster than steam-air decoking, and refiners generally have longer campaigns on the
heater compared to steam air decoking.
Pigging will not provide temperature shocks & hence pigging has been found effective.
PIGGING Double pumping unit (Fig. 4)
Set up:
Connection is made to pair of passes (coils) with flow / return piping. There are four separate
piping links with furnace & pumping unit.
Launchers / receiver units complete with full port ball valves to be connected to Coils
horizontally.
Ensure safe access to pig launchers / receivers.
Launchers / receivers are provided with hammer lock couplings to connects flexible piping.
Fig. 4: A typical figure showing Pigging method
Cleaning:
Water fill up.
Water circulation for removing hydrocarbons and loose debris.
Special density foam pig launch
Decoke pig selection to clean
Increase pig size incrementally.
Polishing by using oversize abrasive coated foam pig
C Compressor, turbine
E Heat Exchanger
H Fired Heater
P Pump
R Reactor
T Tower
TK Storage Tank
V Vessel

P-101A/B
P=pump
1=area 100
01=specific no
A/B=spare or pump in parallel
P& ID

1. All process equipments and pipings required for start-up, shut-down, emergency and
normal operation of the plant, including valves, blinds, etc.
2. An id number, an identifier of the material of construction, diameter and insulation
requirements for each line.
3. Direction of flow.
4. Identification of main process and start-up lines.
5. All instrumentation, control and interlock facilities with indication of action on
instrument air failure.
6. Key dimensions or duties of all equipments.
7. Operating and design pressures and temperatures for vessels and reactors.
8. Equipment elevations.
9. Set pressure for relief valves.
10.Drainage requirements.
11.Special notes on piping configuration as necessary, e.g. gravity drainage.

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