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HEATER AUDIT By Mehul Patel

SOLVING HEATER PROBLEMS

UOP can help improve refinery profitability by conducting
detailed heater audits and then strategically targeting
heaters for improvement. Fired heaters are one of the
largest utility users in the refinery, and when not operat-
ing efficiently, can significantly increase operating costs.
UOP can also assess remaining heater life and recom-
mend operating conditions to allow safe heater operation
for years to come.

Our focused approach provides quick, implementable

solutions that will achieve:
 Reduced operating costs

 Increased charge rates

 Improved heater safety

 Compliance with government emission regulations.

PHASE I – TARGETING
In the targeting phase of the audit, heaters are reviewed
and prioritized based on their criticality. UOP develops a
short list of heaters for which detailed work will follow.
Screening of heaters is based on an economic and techni-
cal evaluation of the following heater information:
 Reliability  Interviewing operators and observe unit operation
 Operating and maintenance costs in depth
 Collecting data for heater simulation and
 Performance criteria (throughput, cycle length and
environmental limitations) mass/energy balances of associated equipment
 Conducting metallurgical evaluation
 Visual inspection by UOP’s heater specialists
Off-site, the specialist models the heater to evaluate the
PHASE II – DETAILED ANALYSIS thermal performance of the process and flue gas. Current
The heater specialist performs a detailed audit for the heater operation is compared to design.The operating
heaters on the short list.The on-site activities could profits and expenses for each heater are calculated, and
include: most profitable operating point is recommended.
 Observing flame patterns, heat distribution, and
Detailed heater audits evaluate the major mechanical
tube scaling and thermal performance of fired heaters both on the
process and flue gas sides of the heater. Current
operation is compared to original design parameters and
to state-of-the-art heater technology. For processes such
as UOP’s Platforming process, UOP can provide software
for heater optimization while also maintaining the desired
octane and product quality.

Metallurgical evaluations determine the remaining tube

and tube support life. For refiners already operating
heaters at their maximum, UOP can evaluate the remain-
ing heater life at current conditions, estimate replacement
cost for tubes and tube supports, identify revamp possibil-
ities and recommend new operating conditions based on
the time frame for heater tube replacement.

UOP’s final recommendations include the following types

of improvements:

 Changes that can be made immediately

 Changes that can be implemented at the next

turnaround
 Long-term revamp opportunities

REFINERY PROJECTS AND SERVICES

UOP has a unique position in the refining industry since it
has extensive heater operation and design expertise, as
well as in-depth process knowledge. UOP can improve
individual heater performance while taking into account FOR MORE INFORMATION
the affect of heater performance on overall unit and the For more information, contact your local UOP
profitability in your refinery. representative or contact our Des Plaines sales office:
UOP Solutions and Services is a dedicated group of highly e-mail: info@uop.com
skilled and experienced engineers with strong process, fax: +1-847-391-2253
mechanical and metallurgical backgrounds. Additional sup- phone: +1-847-391-2000
port is provided by UOP’s Engineering, Cost Estimating,
Research and Development, and Technical Services
groups.

UOP LLC
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The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation to Des Plaines, IL 60017-5017, U.S.A.
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