PROCESS FIRED HEATERS/FURNACES IN REFINERIES: INTRODUCTION: WHY FIRED HEATERS ARE IMPORTANT?

ONLY PLACE IN THE UNIT WHERE EXPOSED FIRES ARE USED TO PROCESS INFLAMMABLE FLUIDS. IMPROPER OPERATION CONSEQUENCES. CAN LEAD TO DISASTER

OPERATOR JUDGEMENTS ARE FREQUENTLY MADE WITH A LACK OF UNDERSTANDING. PURPOSE OF HEATER/FURNACE: A SOURCE OF HEAT REQUIRED RAISING THE TEMP. OF PROCESSING STREAMS SO THAT PROPER PROCESSING CAN BE ACCOMPLISHED. REFINERY HEATER CAN BE DIVIDED INTO THREE MAIN GROUP ACCORDING TO THE PROCESS FUNCTION: A. HEATERS USED FOR FRACTIONATION. ( REBOILERS, CRUDE VACUUM HEATERS!. B. HEATERS UPSTREAM OF CATALYTIC REACTORS. ( HYDROTREATING!. C. BLACK OIL CRACKING HEATERS (VISBRACKING, COKING!. o HEATERS OF FIRST GROUP ARE CHARACTERISED BY LOWER OPERATING TEMPERATURE AND PRESSURES. MILD OPERATION IS MOST FORGIVING TO MISOPERATION. o HEATERS OF SECOND GROUP IS CHARECTERISED BY HIGH TEMPERATURES AND"OR PRESSURES. RESULT IN HIGH ALLOY HEATER TUBE.

o HEATER OF THIRD GROUP IS MOST DIFFICULT TO DESIGN. MUST BE DESIGNED TO PERMIT THE HIGHEST COIL OUTLET TEMPERATURES WITHOUT UNACCEPTABLE COKE DEPOSITION RATES. HEAT TRANSFER BASICS: A. RADIANT HEAT TRANSFER # TRANFER OF HEAT BY DIRECT HEAT OR LIGHT WAVES E.G SUN$S ENERGY TO EARTH. B. CONDUCTION HEAT TRANFER # HEAT TRAVELS THROUGH SOLIR SURFACE E.G HEATING OF A METAL BAR. C. CONVECTION HEAT TRANSFER # TRANSFER OF HEAT BY FLOW OF A LIQUID OR GAS HEATING A ROOM BY HOT AIR. BASED ON ABOVE VARIOUS SECTIONS IN THE HEATERS ARE: RADIANT SECTION: COMMOMLY KNOWN AS FIRE BOX. %&' %( ) OF THE TOTAL HEAT IS ABSORBED IN RADIANT SECTION.FLUE GAS EXIT TEMPERATURE FROM RAD. *ONE IS +,&& # +(&& DEG. F. HYDROGEN AND ETHYLENE FURNACE # -&&& DEG F. CONVECTION SECTION: SHOCK *ONE"BANK: RECEIVES BOTH RADIANT AND CONVECTION HEAT. DESCRIPTION OF HEATER: A. CABIN TYPE HORI*ONTAL FIRED B. BOX TYPE VERTICAL FIRED: C. BOX TYPE DOUBLE FIRED: D. NATURAL DRAFT: E. FORCED DRAFT:

F. BALANCED DRAFT:

VARIOUS COMPONENTS IN A HEATER: LET US WRITE: HEATER INSTRUMENTATION: A. PASS FLOW CONTROL (FRC!: B. OUTLET TEMP. CONTROL (TRC!: C. INLET PRESSURE D. OUTLET PRESSURE: E. FIRING CONTROL ON OIL"GAS (PIC!: F. FLUE GAS SIDE (TEMP DRAFT!: TEMPERATURE:

G. AIR SIDE FOR FORCED DRAFT"BALANCED DRAFT ( AIR FLOW " TEMP " PRESSURE! H. FIELD CHECKING OF FURNACE OPERATION: I. BURNERS: J. DRAFT: VISUAL OBSERVATION (FIELD): A. B. C. D. E. APPEARANCE OF FLUE GAS FROM STACK FLAME IMPINGEMENT FLAME SHAPE AND STABILITY EVIDENCE OF INCOMPLETE COMBUSTION FUEL OIL ATOMISATION"DUMPING OF OIL IN THE FIRE BOX

F. BURNER AIR REGISTER SETTING FOR RUNNING AND IDLE BURNERS G. TUBE CONDITION +. BOWING -. HOT SPOT ,. TUBE SUPPORT H. I. J. K. REFRACTORY SKIN THERMOCOUPLES ID"FD FAN CONDITION CONDENSATE DRAINING

MONITORING FROM CONTROL ROOM: A. PASS FLOWS B. BFW FLOWS C. COT D. INLET PRESSURE E. OUTLET PRESSURE F. CROSS OVER TEMP G. DRAFT H. FO PRESS. I. FG PRESS. J. FO BACK PRESS K. FD ID FAN RPM L. APH INLET TEMP M. APH OUTLET TEMP N. MAIN STACK DAMPER OPENING O. DAMPER OPENING IN AIR DUCT P. SKIN TEMP Q. FURNACE INTERLOCKS