PRESENTATION ON DESIGN OF FIRED HEATERS

FOR ESSAR OIL ENGINEERS

by S. Senthil Kumar

3rd January 2005

Jan' 2005

OVERVIEW
INTRODUCTION APPLICATIONS OF FIRED HEATER FEATURES OF FIRED HEATER TYPICAL CONFIGURATIONS OF FIRED HEATER MODES OF OPERATION HEATER COMPONENTS COMBUSTION & RELATED SUBJECTS PROCESS CONSIDERATION

Jan' 2005

INTRODUCTION
WHAT IS A FIRED HEATER ?
MANY A TIMES IT IS REQUIRED TO RAISE THE TEMPERATURE OF PROCESS FLUID, FOR EXAMPLE
REACTOR FEED PREHEATING COLUMN BOTTOM REBOILER HEATING HOT OIL TO EXCHANGE HEAT WITH PROCESS FLUID

TO ACHIEVE THIS, HEAT ENERGY HAS TO BE SUPPLIED TO THE PROCESS FLUID HEAT ENERGY IS OBTAINED BY COMBUSTION OF FUEL

Jan' 2005

FIRED HEATER
IF COMBUSTION OF FUEL IS PERFORMED INSIDE AN INSULATED ENCLOSURE, THEN GENERATED HEAT ENERGY CAN BE UTILIZED EFFECTIVELY THIS ENCLOSURE IS CALLED FURNACE OR FIRED HEATER

THIS EQUIPMENT IS USED TO COMBUST THE FUEL AND TRANSFER

THE HEAT GENERATED TO THE PROCESS FLUID FLOWING THROUGH TUBES PLACED INSIDE THE HEATER

Jan' 2005

UTILIZATION IN PROCESS INDUSTRY

FURNACES ARE MAINLY USED FOR FOLLOWING SERVICES: PREHEATING REACTOR FEED

SOURCE OF HEAT IN DISTILLATION COLUMNS (BOTTOM REBOILERS)

HOT OIL HEATERS

THERMAL CRACKING SERVICES ENDOTHERMIC CATALYTIC REATORS (REFORMERS)

MAINLY CLASSIFIED AS
REACTIVE FURNACES NON REACTIVE FURNACES

FURNACES USED FOR NON REACTIVE SERVICES ARE GENERALLY

TERMED AS FIRED HEATER

Jan' 2005

APPLICATION OF FIRED HEATER

FIRED HEATERS ARE USED FOR VARIOUS PURPOSES IN THE REFINING & PETROCHEMICALS INDUSTRY, SUCH AS: CRUDE FURNACE VACUUM CHARGE HEATER REACTOR CHARGE HEATER (HYDRO-DESULPHURIZATION REACTORS)

REFORMER FURNACE
HYDROCRACKER FURNACE VISBREAKER FURNACE

AIR HEATER
AND MANY, MANY OTHERS

Jan' 2005

FEATURES OF FIRED HEATER

Jan' 2005

FEATURES OF A FIRED HEATER

MAIN FEATURES RADIANT SECTION SHIELD SECTION CONVECTION SECTION FLUE GAS STACK AUXILLIARY EQUIPMENT

Stack Convection Shield

BURNER AIR PREHEAT SYSTEM DRAFT SYSTEMS FANS & BLOWERS DAMPER SOOT BLOWERS REFRACTORIES

Radiant

Burner

Jan' 2005

FEATURES OF A FIRED HEATER

Jan' 2005

TYPICAL CONFIGURATIONS OF FIRED HEATER

Jan' 2005

TYPICAL CONFIGURATIONS OF HEATER

VARIOUS FACTORS THAT CONTRIBUTE TO

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DIFFERENT CONFIGURATIONS ARE

SHAPE OF RADIANT SECTION ONLY RADIANT OR RADIANT WITH CONVECTION VARIATIONS IN PLACEMENT OF TUBES PLACEMENT OF BURNERS IN RADIANT SECTION

Jan' 2005

TYPICAL CONFIGURATIONS OF HEATER

SHAPE OF RADIANT SECTION CYLINDRICAL BOX CABIN HELICAL TUBE VERTICAL TUBE INVERTED U TUBE

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CONFIGURATION OF TUBES

TUBE PATTERNS VERTICAL HELICAL HORIZONTAL U-TUBE & INVERTED U-TUBE

Jan' 2005

TYPICAL CONFIGURATIONS OF HEATER

VARIATIONS IN PLACEMENT OF TUBES LOCATION OF TUBES

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REFRACTORY WALL BACKED

CENTRALLY PLACED

FIRING WITH RESPECT TO TUBES

SINGLE SIDE FIRING DOUBLE SIDE FIRING

Jan' 2005

TYPICAL CONFIGURATIONS OF HEATER

14

PLACEMENT OF BURNERS

IN RADIANT CHAMBER
FLOOR (UPFIRED) SIDEWALL SIDEWALL MULTILEVEL ENDWALL

Jan' 2005

TYPICAL CONFIGURATIONS OF HEATER

CYLINDRICAL RADIANT WITH VERTICAL TUBES
Most commonly used where duties are usually small Tubes are

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Vertically placed
Refractory backed Placed along the inner circumference of the cylindrical radiant section Shield & convection tubes are normally horizontal Only radiant configuration is also possible
A A

Section A-A

Jan' 2005

TYPICAL CONFIGURATIONS OF HEATER

CYLINDRICAL RADIANT WITH HELICAL COILS
Commonly used where Duties are small Allowable pressure drop is limiting Used in intermittent services

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Tubes are
Helical Multi-Helix are also used With or without convection section

Jan' 2005

TYPES OF HEATER
BOX TYPE WITH VERTICAL TUBES & HORIZONTAL TUBES IN CONVECTION BOX TYPE WITH INVERTED U TUBES & HORIZONTAL TUBES IN CONVECTION

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Section A-A

Jan' 2005

TYPES OF HEATER
TWIN CELL BOX TYPE WITH VERTICAL TUBES TWIN CELL BOX TYPE WITH HORIZONTAL TUBES

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CABIN TYPE WITH HORIZONTAL TUBES

Jan' 2005

MODES OF OPERATION

Jan' 2005

MODES OF OPERATION
NATURAL DRAFT FORCED DRAFT

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INDUCED DRAFT
BALANCED DRAFT

Jan' 2005

MODES OF OPERATION
NATURAL DRAFT OPERATION In this system the air required for combustion is drawn by the burner from the atmosphere due to the draft created by the stack

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Stack Convection Shield

Radiant

Burner

Jan' 2005

MODES OF OPERATION
FORCED DRAFT APH SYSTEMS
This system has only a forced fan to provide the combustion air requirements. All the flue gases are removed by stack draft. Because of the low draft generation capabilities of the stack, the APH flue gas side pressure drop must be kept very low, thus increasing the size & cost of APH Stack Convection Shield

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Radiant

Air

FD Fan
Jan' 2005

MODES OF OPERATION
INDUCED DRAFT APH SYSTEMS This system has only a induced draft fan removing the flue gases from the heater and maintain the appropriate system draft.

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Flue Gas Convection Shield ID Fan Stack

Radiant

Jan' 2005

MODES OF OPERATION
BALANCED DRAFT OPERATION WITH APH SYSTEMS

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This system has both a forced draft (FD) fan and an induced draft (ID)
fan. The system is balanced because the combustion air, provided by the forced draft fan, is balanced by the flue gas removal of the induced draft fan.

Jan' 2005

HEATER COMPONENTS

Jan' 2005

RADIANT SECTION
HEAT IS TRANSFERRED MAINLY BY DIRECT RADIATION HEAT ABSORPTION IN THE RADIANT SECTION IS TYPICALLY AROUND 60% HEAT ABSORPTION DEPENDS ON BODY TEMPERATURE & EMISSIVITIES SHAPE & ARRANGEMENT OF SURFACES CHARACTERISTICS OF COMBUSTION PRODCUTS AREAS OF REFRACTORY HEAT ABSORBING SURFACE

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VIEW FACTORS

Jan' 2005

SHIELD SECTION
THE SHIELD SECTION CONTAINS THE TUBE ROWS THAT "SHIELDS" THE CONVECTION ROWS FROM THE DIRECT RADIANT HEAT

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Shield Tubes

Jan' 2005

SHIELD SECTION

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TWO IMPORTANT MONITORING POINTS JUST BELOW THE SHIELD TUBES ARE THE "BRIDGEWALL" TEMPERATURE WHICH IS THE TEMPERATURE OF THE FLUE GAS AFTER THE RADIANT HEAT IS REMOVED THE OTHER IS THE DRAFT MEASUREMENT AT THIS POINT

Jan' 2005

CONVECTION SECTION
THE CONVECTION SECTION IS LOCATED AFTER SHIELD SECTION
IN THE CONVECTION SECTION, HEAT IS TRANSFERRED BY CONVECTION IT CONTAINS ROWS OF EXTENDED SURFACE TUBES TO IMPROVE THE EFFICIENCY OF THE FURNACE

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Convection Tubes

Shield Tubes

Jan' 2005

STACK

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STACK : IMPORTANT FOR GETTING THE FLUE GASSES OUT FROM HEATER INTO THE ATMOSPHERE TO SAFE LOCATION.

Jan' 2005

BURNERS
TYPES OF BURNERS
BASED ON FUEL GAS FIRING OIL FIRING

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COMBINATION FIRING
BASED ON DRAFT NATURAL DRAFT BURNERS FORCED DRAFT BURNERS TYPICAL BURNER COMPONENTS MAIN GAS/OIL TIPS PILOT TIP

FLAME SCANNER (IR / UV)

STEAM ATOMISERS SIGHT PORTS

Jan' 2005

BURNER TYPES
NATURAL DRAFT BURNER
REQUIRES LESS PRESSURE DIFFERENTIAL TO PROVIDE THE

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REQUIRED AIR FOR COMBUSTION THAN THE FORCED DRAFT

BURNER STACK EFFECT INDUCES THE COMBUSTION AIR REQUIRED DRAFT/ PRESSURE DIFFERENTIAL AT BURNER,

TYPICALLY 0.1 1.0 IN H2O.

Jan' 2005

BURNER TYPES
FORCED DRAFT BURNERS
COMBUSTION AIR IS SUPPLIED BY A FD FAN NORMALLY REQUIRES 0.3 TO 4.0 IN H2O BURNERS HAVE DIFFERENT AIR REGISTERS FOR PRIMARY AND SECONDARY AIR INTAKE. THE AIR MAY BE DELIVERED TO THE REGISTERS BY AN AIR PLENUM

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INCORPORATES STAGED AIR OR FUEL DESIGNS (SPLITTING

COMBUSTION AIR OR FUEL WITHIN BURNER) THESE BURNER TYPES HAVE BECOME STANDARD BECAUSE ENVIRONMENTAL AIR STANDARDS DEMAND THE BEST

COMBUSTION TECHNOLOGY AVAILABLE

Jan' 2005

AIR PREHEATERS
THE AIR PREHEAT SYSTEM IS USED TO PREHEAT THE
COMBUSTION AIR GOING TO THE BURNERS SINCE IT COOLS THE FLUE GAS FURTHER, WHILE REMOVING

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HEAT, IT IMPROVES THE EFFICIENCY OF THE FURNACE

USING AN AIR PREHEAT SYSTEM WILL RESULT IN OVERALL EFFICIENCIES ABOVE 90%.

Jan' 2005

AIR PREHEATERS
MERITS OF APH ENHANCE EFFICIENCY ( ~ 90-93 %). TO ENHANCE AIR-FUEL MIXING (HIGH AIR VELOCITY) REDUCE OIL BURNER FOULING MORE COMPLETE COMBUSTION OF HEAVY FUELS DEMERITS OF APH INCREASES POTENTIAL OF SO3 & NOX GENERATION AS ADIABATIC FLAME TEMPERATURE IS HIGH REDUCES THE STACK TEMP., SO EITHER ID FAN OR TALLER

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STACK WILL BE REQUIRED

Jan' 2005

TYPES OF AIR PREHEATER

DIRECT APH SYSTEMS (MOST COMMON TYPE) REGENERATIVE Direct APH systems

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RECUPERATIVE
Tube type Plate type

INDIRECT APH SYSTEMS EXTERNAL HEAT SOURCE

APH SYSTEMS

Jan' 2005

TYPES OF AIR PREHEATER

DIRECT APH SYSTEMS (MOST COMMON TYPE) REGENERATIVE Indirect APH systems

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RECUPERATIVE
Tube type Plate type

INDIRECT APH SYSTEMS EXTERNAL HEAT SOURCE

APH SYSTEMS

Jan' 2005

TYPES OF AIR PREHEATER

DIRECT APH SYSTEMS (MOST COMMON TYPE) REGENERATIVE

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RECUPERATIVE
Tube type Plate type External Heat Source APH systems

INDIRECT APH SYSTEMS EXTERNAL HEAT SOURCE

APH SYSTEMS

Jan' 2005

TYPES OF AIR PREHEATER

TUBE TYPE TUBES MADE OF CAST IRON OR GLASS WHEN CAST IRON TUBES ARE PROVIDED, THE MIN. METAL TEMP

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IS KEPT 10-15 0C ABOVE DEW POINT.

ADVANTAGES VERY LOW LEAKAGE, EASY TO DESIGN & FABRICATE, NORMALLY LOW UNIT COST, EASY FOR MAINTAINENCE DISADVANTAGES HIGHER PRESSURE DROP AS COMPARED TO PLATE TYPE HEAVY, SO INCREASES THE STRUCTURAL COST IF PLACED

ON BOARD
GLASS TUBES MAY GET DAMAGE AND RESULT IN LEAKAGES

Jan' 2005

TYPES OF AIR PREHEATER

PLATE TYPE TYPICALLY IT CONTAINS CARBON STEEL PLATES (~ 2 mm THICK) ASSEMBLED IN FRAME THESE MODULES ARE STANDARD IN SIZE AND REQUIRED CAPACITY IS OBTAINED BY INCREASING THE NUMBER OF MODULES ADV: LOW PRESSURE DROP, LIGHT IN WEIGHT & COMPACT, SO MOSTLY USED AS ONBOARD UNIT DISADV: DIFFICULT FOR MAINTENANCE

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EASY TO FOUL & CORRODE(SOMETIMES PORCELAIN

ENAMELED PLATES ARE USED ) AND HIGH UNIT COST

Jan' 2005

FANS & BLOWERS

USE OF FANS AND BLOWERS

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FORCED DRAFT FANS

INDUCED DRAFT FANS

PURGE FANS

Jan' 2005

FANS & BLOWERS

FORCED DRAFT FANS

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FORCED DRAFT (FD) FANS ARE USED TO SUPPLY COMBUSTION AIR TO THE BURNER(S)

THEY DRAW AMBIENT AIR AND FORCE IT TO THE BURNER SYSTEM VIA APH FOR THE COMBUSTION OF FUEL.
THEY NORMALLY ARE NOT EMPLOYED TO MOVE THE FLUE GASES THROUGH THE FURNACE. BUT IN SPECIAL CASES, SUCH AS A POSITIVE PRESSURE, SINGLE FAN AIR PREHEAT SYSTEM, THEY MAY ALSO SERVE THIS PURPOSE.

INDUCED DRAFT FANS

INDUCED DRAFT (ID) FANS ARE GENERALLY USED TO PULL THE THROUGH AN AIR PREHEATER
Jan' 2005

FLUE GAS

FROM THE HEATER AND DISCHARGE IT TO ATMOSPHERE DIRECTLY OR

FANS & BLOWERS

PURGE FANS THE PURPOSE OF THE PURGE FAN IS TO DISPLACE ANY

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POTENTIALLY EXPLOSIVE GAS MIXTURES FROM HEATER

FIREBOX, PRIOR TO LIGHTING OF THE BURNERS PURGE FANS ARE ESPECIALLY DESIRABLE ON HEATERS

THAT ARE SHUT DOWN AND RELIGHTED ON A REGULAR

BASIS HEATERS EMPLOYING FD OR ID FANS DO NOT NORMALLY REQUIRE ADDITIONAL PURGE FANS. RUNNING THE FD OR ID FAN USUALLY WILL PURGE THE SYSTEM

Jan' 2005

DAMPER
FUNCTIONS OF DAMPER ARE
CONTROL OF FLUID FLOW THROUGH ANY DUCT (CONTROL DAMPER)
NORMALLY USED IN STACK, FD/ID FAN AND COMBUSTION AIR BYPASS AROUND THE APH MAIN DAMPER IN THE STACK IS USED TO CONTROL DRAFT AT ARCH

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PREVENT FLOW OF FLUID THROUGH ANY DUCT (ISOLATION DAMPER)

NORMALLY USED IN FLUE GAS/ COMBUSTION AIR DUCT FOR ISOLATION PURPOSE OF APH
BYPASS DUCT

Jan' 2005

TYPES OF DAMPER

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CONTROL DAMPER IT CAN BE EITHER MANUAL OR AUTOMATIC IN OPERATION IT ALWAYS HAS SOME LEAKAGE ( ~3%) IT CAN BE SINGLE BLADE ( LIKE BUTTERFLY DAMPER ) OR MULTIPLE BLADE ( LIKE LOUVER DAMPER ) NO. OF BLADES ~ INSIDE AREA OF THE DUCT OR STACK (M2) 1.2

Jan' 2005

TYPE OF DAMPERS

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SHUT OFF DAMPER

IT CAN BE OPERABLE MANUALLY BY CHAIN & PULLEY

ARRANGEMENT (GUILLOTINE BLIND) OR BY AN ELECTRIC MOTOR (SWING GATE)

IT IS DESIGNED FOR A HIGH SEALING EFFICIENCY ( ~99.9%).

Jan' 2005

SOOT BLOWERS
SOOT IS GENERATED AS A RESULT OF IMPROPER COMBUSTION THIS SOOTS DEPOSITS OVER EXTENDED SURFACE AND DECREASES HEAT TRANSFER RATE SOOT HAS TO BE REMOVED TO MAINTAIN HEAT TRANSFER COEFFICIENT

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TYPE OF SOOT BLOWERS

RETRACTABLE TYPE FIXED ROTARY TYPE

VIBRATION TYPE

Jan' 2005

SOOT BLOWERS
RETRACTABLE TYPE
MOSTLY USED FOR HIGH TEMPERATURE & DIRTIER FUEL

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APPLICATION. IT IS MORE COSTLY BUT HAS BETTER CLEANING

CHARACTERISTICS

FIXED ROTARY TYPE

IT IS CHEAPER THAN RETRACTABLE TYPE BUT CAN NOT BE USED

IN HIGH TEMPERATURE OR DIRTY FUEL SERVICES

VIBRATION TYPE
ULTRASOUND WAVES ARE USED IN THIS TYPE TO CREATE

VIBRATION TO DISENGAGE THE SOOT FROM THE COILS. VERY LIMITED EXPERIENCE IS AVAILABLE FOR THIS TYPE

Jan' 2005

REFRACTORY
REFRACTORY : TO REDUCE THE HEAT LOSS TO
ATMOSPHERE. THREE COMMON TYPES: FIREBRICKS
GENERALLY USED FOR BRIDGEWALLS AND FLOORS WITH DENSITY ABOUT 150 LB/CUFT, MUST BE DRIED OUT SLOWLY

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CASTABLES
IT IS A MIXTURE OF LUMNITE(CEMENT),HAYDITE (AGGREGATE) AND VERMICULITE(INSULATION) WITH DENSITY OF ABOUT 55 LB/CUFT. NEEDS CURING & DRYOUT BEFORE STARTUP

CERAMIC FIBRE
IT IS AVAILABLE IN LAYERED & MODULAR TYPE. A SANDWICH CONSTRUCTION OF THIS MATERIAL IN TWO DENSITIES (23INCHES LAYER OF 4 LB/CUFT AND 1 INCH LAYER OF 8 LB/CUFT) IS USED.
Jan' 2005

55

COMBUSTION AND RELATED SUBJECTS

Jan' 2005

COMBUSTION AND RELATED SUBJECTS

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NOX PURPOSE OF EXCESS AIR ACID DEW POINT OF FLUE GAS

Jan' 2005

NOX AND OTHER CONSIDERATIONS

THE FIRED HEATER INDUSTRY HAS CONCENTRATED ON THE TWO PRIMARY SOURCES OF NITROGEN OXIDES (NOX)

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THESE ARE NORMALLY REFERRED TO AS THERMAL NOX AND

FUEL NOX THE THREE MAIN STRATEGIES FOR REDUCING NOX EMISSIONS:
REDUCE PEAK TEMPERATURES OF THE FLAME ZONE REDUCE GAS RESIDENCE TIME IN FLAME ZONE REDUCE OXYGEN CONCENTRATION IN THE FLAME ZONE

Jan' 2005

NOX AND OTHER CONSIDERATIONS

MAIN STRATEGIES FOR REDUCING NOX EMISSIONS
REDUCE PEAK TEMPERATURES
USING A FUEL-RICH PRIMARY FLAME ZONE DECREASING THE ADIABATIC FLAME TEMPERATURE BY DILUTION DILUTING AIR-FUEL MIXTURE BY FLUE GAS MIXING

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REDUCE THE GAS RESIDENCE TIME IN THE HOTTEST PART OF THE

FLAME ZONE
CHANGING THE SHAPE OF THE FLAME ZONE USING THE STEPS LISTED IN STRATEGY 1

REDUCE THE O2 CONTENT IN THE PRIMARY FLAME ZONE

DECREASING THE OVERALL EXCESS AIR RATES CONTROLLED MIXING OF FUEL AND AIR USING A FUEL-RICH PRIMARY FLAME ZONE
Jan' 2005

PURPOSE OF EXCESS AIR

PERFECT COMBUSTION
PERFECT COMBUSTION IS ACHIEVED WHEN ALL THE FUEL IS BURNED USING ONLY THE THEORETICAL AMOUNT OF AIR PERFECT COMBUSTION CANNOT BE ACHIEVED IN A FIRED HEATER

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INCOMPLETE COMBUSTION
INCOMPLETE COMBUSTION OCCURS WHEN ALL THE FUEL IS NOT BURNED, WHICH RESULTS IN THE FORMATION OF CO, SOOT AND SMOKE

Jan' 2005

PURPOSE OF EXCESS AIR

COMPLETE COMBUSTION
COMPLETE COMBUSTION IS ACHIEVED WHEN ALL THE FUEL IS

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BURNED USING THE MINIMAL AMOUNT OF AIR ABOVE THE

THEORETICAL AMOUNT OF AIR NEEDED TO BURN THE FUEL THIS MINIMAL AMOUNT IS CALLED THE EXCESS AIR

PERCENTAGE OF EXCESS AIR RANGES FROM 10 TO 25%

WITH COMPLETE COMBUSTION, THE FUEL IS BURNED AT THE HIGHEST COMBUSTION EFFICIENCY

Jan' 2005

ACID DEW POINT

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SULFUR DIOXIDE PRODUCED AS A RESULT OF COMBUSTION GETS CONVERTED INTO SO3 AND REACTS WITH WATER VAPOR PRESENT IN THE FLUE GAS TO FORM SULFURIC ACID SULFURIC ACID AT LOW TEMPERATURE CONDENSES ON THE INSIDE SURFACE OF THE REFRACTORY

HARMFUL FOR TUBES, REFRACTORY & THE CASING

Jan' 2005

ACID DEW POINT

FLUE GAS DEW POINT DEPENDS ON FUEL SULFUR CONTENT FLUE GAS O2 CONTENT FLUE GAS MOISTURE CONTENT COMBUSTION TEMP FUEL & FLUE GAS ADDITIVES TO AVOID FLUE GAS CONDENSATION, THE MIN. METAL TEMP IS KEPT 10-15 deg C ABOVE THE FLUE GAS DEW POINT

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Jan' 2005

63

PROCESS CONSIDERATIONS

Jan' 2005

PROCESS CONSIDERATIONS
PRIMARY CONSIDERATIONS CLIENTS REQUIREMENTS APPLICABLE STANDARDS

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API STANDARD 560 (FIRED HEATERS FOR GENERAL REFINERY SERVICE)

THIS STANDARD COVERS THE MINIMUM REQUIREMENTS FOR THE

DESIGN, MATERIALS, FABRICATION, INSPECTION, TESTING, PREPARATION FOR SHIPMENT AND ERECTION OF FIRED HEATERS, AIR PREHEATERS, FANS AND BURNERS FOR GENERAL REFINERY SERVICE.

Jan' 2005

EXCESS AIR CONSIDERATIONS

(A) NATURAL DRAFT:GAS FIRING : 20%

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OIL FIRING

25%

(B) FORCED DRAFT:GAS FIRING OIL FIRING : : 15% 20%

Jan' 2005

GENERAL CONSIDERATIONS
MAINTAIN HYDRAULIC SYMMETRY IN INLET/ OUTLET MANIFOLDS: PIPE LENGTHS, FITTINGS SHALL BE SAME FOR ALL PASSES MIN.NO. OF PASSES FOR VAPORIZING FLUIDS MIN. RADIATION LOSS ( BASED ON LHV):

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WITHOUT APH=1.5%
ARCH PRESSURE: NORMAL VALUE

WITH APH=2.5%

-2.5 mm WG

Jan' 2005

BURNER
GENERALLY THERE SHOULD BE MORE THAN ONE BURNER IN A FURNACE

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NO. OF BURNERS IN A CYLINDRICAL FURNACE SHOULD

PREFERABLY BE A MULTIPLE OF THE NO. OF PROCESS PASSES FOR EVEN HEAT DISTRIBUTION

IN A CYLINDRICAL FURNACE WITH SEVERAL BURNERS ARRANGED IN A CIRCLE, THERE IS A MINIMUM DIMENSION OF THE BURNER CIRCLE

Jan' 2005

BURNER
NO. OF BURNERS REQUIRED FOR A GIVEN HEAT RELEASE SHALL BE OPTIMIZED BASED ON FOLLOWING CRITERIA:
IN NORMAL CASES, MAX HEAT RELEASE PER BURNER SHALL NOT EXCEED 3.0 MMKCAL/HR. TURNDOWN REQUIREMENTS TO BE CONSIDERED

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FLAME DIMENSION: FLAME IMPINGEMENT ON TUBES,

REFRACTORY & ADJACENT BURNERS SHALL BE AVOIDED

Jan' 2005

BURNER
NO. OF BURNERS <5 6-7 >8 MIN PILOT HEAT RELEASE OIL ATOMIZATION:
STEAM ATOMIZATION : STEAM/OIL ~ 0.3 KG/KG
PRESSURE DIFFERENTIAL BETWEEN FUEL OIL & STEAM ~2.1 kg/cm2g FOR OIL FIRED BURNERS, MAX. VISCOSITY IS 43 CST.

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MAX./NOR. HEAT RELEASE 1.25 1.20 1.15 20000 KCAL/HR

Jan' 2005

BURNER
POLLUTANTS FROM COMBUSTION: SOX : SOX (SO2 & SO3 ) GENERATION DEPENDS THE SULFUR CONTENT OF THE FUEL NOX : NOX (NO & NO2 ) IS GENERATED THERMALLY BY THE REACTION OCCURRING ABOVE 700-800 0C UNBURNT HYDROCARBON: RESULT OF IMPROPER MIXING OF FUEL WITH AIR SPM: SOOT, ASH ETC.

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Jan' 2005

BURNER
MIN PARAMETERS REQUIRED FOR BURNER SELECTION HEAT RELEASE : MIN / NOR / MAX TYPE OF BURNER : NATURAL DRAFT, FORCED DRAFT, LOW NOX, COMBINATION FUEL DETAILS : COMPOSITION, LHV, PRESSURE, TEMPERATURE

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COMBUSTION AIR : TEMPERATURE, PRESSURE, RELATIVE HUMIDITY

NO. OF BURNERS, IGNITION DETAIL

EMISSION REQUIREMENTS: SOX, NOX, UHC, SPM, CO ETC

NOISE LIMITATION: 85 DBA AT 1M FROM BURNER

Jan' 2005

RADIANT SECTION DESIGN

RADIANT AVERAGE FLUX ( KCAL/HR/M2 ): CRUDE VACUUM / NAPHTHA / DHDS 32500 27100

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DELAYED COKER / VISBREAKER

PROCESS MASS VELOCITY (KG/S/M2) CRUDE HEATER REBOILERS HOT OIL HEATERS HYDROTREATERS

25000

1200 TO 1700 700 TO 1200 1700 TO 2200 700 TO 1000

MAXIMUM FILM TEMP SHALL NOT BE EXCEEDED MAXIMUM METAL TEMP SHALL NOT BE EXCEEDED

Jan' 2005

RADIANT SECTION DESIGN

VERTICAL CYLINDRICAL HEATERS: HORIZONTAL TUBE HEATERS: H / D < 2.75

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H / W < 2.75

MAX. LENGTH FOR VERTICAL TUBES = 18.3 M

MAX. UNSUPPORTED LENGTH FOR HORIZONTAL TUBES SHALL

BE 35 TIMES OD OR 6M WHICHEVER IS LESS MIN. DISTANCE B/W REFRACTORY & TUBE CENTER = 1.5 x NOMINAL DIAMETER DUTY ABSORBED IN RADIANT = AROUND 60% OF TOTAL ABSORBED DUTY NORMAL BRIDGE WALL TEMP = 600 TO 800 DEG C

Jan' 2005

CONVECTION SECTION DESIGN

FLUE GAS MASS VELOCITY ( KG/S/M2): NATURAL DRAFT : 1.5 - 3.0

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FORCED DRAFT

: 3.0 - 4.5

TYPES OF EXTENDED SURFACES: STUDS : FOR HEAVY FUELS ( e.g. FUEL OIL ) FINS : FOR LIGHTER FUELS ( e.g FUEL GAS)

STUDS

SOLID FINS

SERRATED FINS

Jan' 2005

CONVECTION SECTION DESIGN

NORMALLY FIRST 3 ROWS ARE CONSIDERED AS SHIELD TUBES. HENCE NO EXTENDED SURFACES ARE PROVIDED TO PREVENT OVERHEATING OF THESE TUBES NEVER EXCEED CRITICAL VELOCITY MAXIMUM FILM TEMP SHALL NOT BE EXCEEDED MAXIMUM METAL (TUBE & EXTENDED SURFACES) TEMP SHALL NOT BE EXCEEDED

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Jan' 2005

STACK DESIGN
STACK IS DESIGNED TO MAINTAIN -2.5 MMWG PRESSURE AT MINIMUM 120% OF DESIGN HEAT RELEASE WITH DESIGN EXCESS AIR & MAX. AMBIENT TEMP

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TOTAL DRAFT GAIN =

DRAFT GAIN IN CONVECTION + DRAFT GAIN IN STACK PRESSURE LOSS IN CONVECTION

(ENTRY LOSS, LOSS ACROSS TUBES & EXIT LOSS)

TOTAL PRESSURE LOSS =

+
PRESSURE LOSS IN STACK
(ENTRY & EXIT LOSSES,DAMPER LOSS, FRICTION LOSS)

NORMAL FLUE GAS VELOCITY IN STACK: NATURAL DRAFT INDUCED DRAFT 8M/S 15 - 20 M / S
Jan' 2005

FORCED DRAFT FAN

FD FANS ARE DESIGNED WITH MIN 15 % MARGIN OVERAIR FLOW RATE CORRESPONDING TO DESIGN HEAT RELEASE FD FAN DISCHARGE PRESSURE SHOULD BE CAPABLE ENOUGH TO OVER COME: COMBUSTION AIR DUCT PRESSURE LOSS (STRAIGHT& FITTINGS) APH BURNERS DESIGN VELOCITIES IN COMBUSTION AIR DUCT: STRAIGHT, TEE, TURNS ~15 M / S BURNER AIR SUPPLY & PLENUM DUCT 7.5 - 10.5 M / S NORMALLY CENTRIFUGAL FAN WITH FIXED SPEED DRIVE ARE USED

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Jan' 2005

FORCED DRAFT FAN

FOR CRITICAL APPLICATIONS ( VIZ. CDU/VDU ETC.) 2 FD FANS ARE PROVIDED
TWO OPTIONS ARE AVAILABLE IN CASE OF 2 FD FANS PROVIDED: ONE FAN IS RUNNING, OTHER IS STANDBY - SIMPLE & CHEAPER BUT LESS RELIABLE BOTH THE FANS ARE RUNNING AT 50 % LOAD - COSTLY

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BUT MORE RELIABLE

MOC OF CASING - CS MOC OF IMPELLER - CS

Jan' 2005

FORCED DRAFT FAN

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FOLLOWING PARAMETERS TO BE SPECIFIED FOR THE SELECTION OF FD FAN: (A) FLOW RATE: MIN / NOR / MAX (B) TEMP: MIN / NOR / MAX / DESIGN (C) INLET PRESSURE: MIN / NOR (D) OUTLET PRESSURE : NOR / MAX (E) HUMIDITY (F) DRIVER : MOTOR / STEAM TURBINE (G) SPARES

Jan' 2005

INDUCED DRAFT FAN

- ID FANS ARE DESIGNED WITH MIN 20 % MARGIN
OVER FLUE GAS FLOW RATE CORRESPONDING TO DESIGN HEAT RELEASE

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- NORMAL DISCHARGE PRESSURE OF ID FAN IS

AMBIENT PRESSURE -SUCTION PRESSURE = ARCH PRESSURE -

TOTAL PRESSURE LOSS IN CONVECTION TOTAL PRESSURE LOSS IN OFF TAKE DUCT PRESSURE DROP IN INLET DAMPER - DESIGN VELOCITIES IN OFF TAKE DUCT: STRAIGHT, TEE, TURNS - MOC OF CASING - CS / SS - MOC OF IMPELLER - CS / SS / CORTEN STEEL
Jan' 2005

~12 M / S

INDUCED DRAFT FAN

FOLLOWING PARAMETERS TO BE SPECIFIED FOR THE SELECTION OF ID FAN:
(A) FLOW RATE: MIN / NOR / MAX
(B) TEMP: MIN / NOR / MAX / DESIGN (C) INLET PRESSURE: MIN / NOR (D) OUTLET PRESSURE : NOR / MAX (E) FLUE GAS COMPOSITION (F) DRIVER : MOTOR / STEAM TURBINE (G) SPARES

81

Jan' 2005

DRIVES FOR FAN

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TYPE OF DRIVE:

FIXED SPEED MOTOR (1000 OR 1500 RPM ) - CAPACITY CONTROL BY INLET GUIDE VANS/ INLET DAMPER

VARIABLE SPEED DRIVE (FLUID COUPLING, VFD) CAPACITY CONTROL BY VARYING SPEED QN , H N2 , P N3

Jan' 2005

AIR PREHEATERS
MIN DATA REQUIRED FOR AIR PREHEATER SPECIFICATION
AIR / FLUE GAS FLOWRATES : MIN / NOR / MAX AIR / FLUE GAS TEMPERATURES (IN/OUT): MIN / NOR @ MAX / DES AIR / FLUE GAS PRESSURES (IN) : MIN / NOR / MAX / DES TYPE OF APH DUTY : NOR/ MAX ALLOWABLE PRESSURE DROP (AIR SIDE / FLUE GAS SIDE) SULFUR DEW POINT OF FLUE GAS FLUE GAS COMPOSITION REQUIREMENTS OF TUBE SKIN THERMOCOUPLE

83

Jan' 2005

SOOT BLOWERS
MIN STEAM FLOWRATE REQUIRED : 4535 KG/HR MIN STEAM PRESSURE REQUIRED : 10 KG/CM2 G EACH SOOT BLOWER SHOULD COVER MAXIMUM 1.2M OR 5 TUBE ROWS, WHICHEVER IS LESS

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SOME TIMES STEAM LANCING NOZZLES ARE PROVIDED TO REMOVE SOOT FOR SMALLER INSTALLATIONS

Jan' 2005

HEATER COIL METALLURGY

PROCESS FLUID GOVERNS THE MATERIAL SELECTION
VANADIUM & SODIUM ATTACK IN PRESENCE OF SULFUR OXIDATION AT HIGH TEMPERATURE ATTACK BY H2S ATTACK BY POLYTHIONIC ACID ATTACK BY CHLORINE ATTACK BY H2 CARBURISATION

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Jan' 2005

METALLURGY
FOLLOWING TUBE MATERIALS ARE NORMALLY USED:
- CARBON STEEL - LOW ALLOY STEEL (P11,P22) ~ 540 DEG C ~ 650 DEG C

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- HIGH ALLOY STEEL ( P5, P9)

- AUSTENITIC STAINLESS STEEL ( SS304 / 310 / 321 / 347)

~ 650- 705 DEG C

~ 815 DEG C

FOLLOWING SUPPORT MATERIALS ARE NORMALLY USED:

CS 25CR-20NI 50CR-50NI-CB : 427OC, : 871OC, : 982OC

HEATER CASING IS ALWAYS MADE OF CARBON STEEL

Jan' 2005

METALLURGY
TYPICAL TUBE MATERIAL FOR VARIOUS SERVICES:

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CRUDE VACUUM DELAYED COKER / VISBREAKER HYDROTREATER HOT OIL HEATER REBOILERS

P5 P9 P9 SS 321 / SS 347 CS CS

Jan' 2005

TYPICAL INPUT DATA FOR THERMAL DESIGN OF FIRED HEATERS

88

HEATER DESIGN DUTY AND THROUGHPUT PROCESS INLET AND OUTLET TEMPERATURES PROCESS INLET OR OUTLET PRESSURE PROCESS FLUID ENTHALPY CURVE AT OPERATING CONDITIONS PROCESS FLUID TRANSPORT PROPERTIES AT OPERATING CONDITIONS FLASH VAPORISATION CURVE FOR 2-PHASE HEATERS WHERE FLASHING OCCURS (E.G. VACUUM FURNACES AND CRUDE FURNACES FUEL TYPE AND COMPOSITION CORROSIVE ELEMENTS IN FUEL (SULPHUR, VANADIUM)
Jan' 2005

TYPICAL INPUT DATA FOR THERMAL DESIGN OF FIRED HEATERS

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ALLOWABLE PRESSURE DROP AVERAGE ALLOWABLE RADIANT HEAT TRANSFER RATE MAXIMUM ALLOWED FILM TEMPERATURES FOR FEEDSTOCK IF THE SERVICE IS SUSCEPTIBLE TO COKE FORMATION

TUBE MATERIAL
TYPE OF HEATER TO BE USED (e.g ALL-RADIANT, CYLINDRICAL, BOX/ CABIN TYPE) DESIRED OVERALL FURNACE EFFICIENCY

Jan' 2005

TYPICAL INPUT DATA FOR THERMAL DESIGN OF FIRED HEATERS

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EXCESS AIR TO BE USED

TYPE OF BURNERS : FORCED OR NATURAL DRAFT FURNACE HEAT LOSSES AS PERCENT OF HEAT LIBERATION DETAILS OF ANY LONG-TERM TURN-DOWN CONDITIONS TO BE TAKEN INTO ACCOUNT IN DESIGN

AVAILABLE PLOT AREA FOR HEATER

Jan' 2005

THERMAL DESIGN OUTPUT FOR FIRED HEATER

API DATASHEET PROCESS PARAMETERS (FLOW, TEMPERATURE,
PRESSURE, COMPOSITION, ETC OF PROCESS FLUID AS WELL AS

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FLUE GAS AND AIR) IN COILS AND FIREBOX

COIL DETAILS (DIAMETER, LENGTH, THICKNESS, MOC, NO OF PASSES, ROWS, ETC.) AVERAGE/ MAXIMUM RADIANT FLUX, MAX. TUBE METAL TEMP.,

INSIDE FILM TEMP.,

REFRACTORY (THICKNESS, TYPE, ETC.) STACK (DIAMETER, HEIGHT) BURNERS (DUTY, NUMBER)

Jan' 2005

THERMAL DESIGN OUTPUT FOR FIRED HEATER

DATA SHEETS FOR BOUGHT OUT ITEMS
BURNERS FANS DAMPER SOOT BLOWER APH

92

Jan' 2005

THANK YOU
ssekumar@technip.com

Jan' 2005