GENERAL INSTRUCTIONS FOR GUIDE No.

THERMAL DESIGN OF FIRED 8-0545-2501 Rev. 0

HEATER SYSTEM Page 1 of 12

GENERAL INSTRUCTIONS FOR

THERMAL DESIGN
OF
FIRED HEATER SYSTEM

0 26.10.04 ISSUED AS DESIGN GUIDE NA SCG AKJ

Rev. Prepared Checked Approved
Date Purpose
No by by by

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 GENERAL INSTRUCTIONS FOR GUIDE No.
THERMAL DESIGN OF FIRED 8-0545-2501 Rev. 0
HEATER SYSTEM Page 2 of 12

1.0 INTRODUCTION

This design guide gives the instructions for thermal design of fired heater and its
auxiliaries, like burners, dampers, soot blowers, FD/ID fan, air preheater, steam
generator and grade mounted stack.

These instructions are applicable for fired heater systems designed by EIL for new
plants, land for revamp and/or capacity/efficiency enhancement projects keeping in
view existing system and site constraints.

2.0 DATA/DOCUMENT REVIEW

Thermal design of heater system is based on the process datasheet and P&ID received
from Process deptt. or process licensor. As a first step these documents are to be
reviewed and commented for the following:

a) Process Datasheets

- Completeness of information in the datasheets as per check list

enclosed (Annexure-1).
- Feasibility of optimum design of fired heater within the specified
parameters.

b) P&IDs

- Number of heater passes

- Completeness of the instrumentation and control philosophy as per the
list enclosed (Annexure-2).
- Scope of work of P&IDs to be generated by heater group for the heat
recovery system.

3.0 ENGINEERING DESIGN BASIS

Before starting the design activities, an Engineering design Basis (EDB) is to be

prepared (in format no. 3-0545-2011) with inputs from Process, Electrical, Project
deptts. and heater (Mechanical) group and issued for clients approval. EDB formally
approved by client shall be available before start of any design activity. Alternatively,
Project Manager may issue an IOM based on Project Execution philosophy/ terms of
contract which can act as design basis for job execution.

4.0 FIRED HEATER DESIGN

Thermal design of fired heater system is carried out by the designated job engineer
using the process datasheets and P&IDs marked Issued for Engineering as the basis.

The type of heater and target efficiency is selected based on the EDB, service and data
bank. Based on the desired target efficiency and size of the heater, waste heat recovery
options are decided. Thermal design of heater is carried out using design guides,
computer programs and data bank. Various steps in thermal design are detailed below:
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THERMAL DESIGN OF FIRED 8-0545-2501 Rev. 0
HEATER SYSTEM Page 3 of 12

4.1 Based on fuel specifications/data furnished in process datasheet and excess air (as
specified in Design Guide No. 8-0545-2502) for applicable fuel, use computer
programme COMBUSTION to generate properties / composition of flue gases
generated in combustion process.

4.2 Carry out sizing of radiant section using computer programme RADIANT or
manually using design guide No. 8-0545-2510.

4.3 Carry out convection section sizing using computer programme CONVSEC or
manually using design guide No. 8-0545-2511.

4.4 Optimise radiant & convection section through use of above computer programmes.

4.5 Based on API 560 & design guide for selection of burners (No. 8-0545-2517) burner
location is decided and checked vis--vis heater size computed above.

4.6 Pressure drop of process fluid is calculated using computer programme DELTAP or
manually using design guide No. 8-0545-2512. In case calculated pressure drop
exceeds allowable pressure drop as specified in process datasheet, heater is re-sized.

4.7 In case of two phase flow, ensure that the flow regime complies with design guide no.
8-0545-2512 requirements.

4.8 Heater stack is sized keeping in view draft requirements and stack height as stipulated
in design basis. Sizing is carried out using computer programme STACK or
manually using design guide No.8-0545-2514.

4.9 Select refractory material using design guide No. 8-0545-2521 and calculate heat loss
in the heater using computer programme HITLOSS or manually using design guide
No. 8-0545-2515. Ensure that calculated heat loss is less than or equal to the heat loss
figure assumed for efficiency calculations.

4.10 Fired Heater datasheet is filled up in format no. 3-0545-2001. After review by
designated lead engineer and approval by group leader, it is issued for comments to
Heater (Mechanical) group, Refractory Specialist group (SMMS deptt.) and Process
department. After incorporating the comments, datasheet is issued for engineering to
Heater (Mechanical), for information to Projects/client and SMMS department and for
reference to Process deptt. This datasheet is also issued to client for information and
comments, if required as per contract.

5.0 DESIGN OF WASTE HEAT RECOVERY SYSTEM AND PREPARATION OF

P&ID

5.1 Based on information available from the radiant section sizing, process conditions for
heat recovery system (Air preheater or steam generator) are finalised.

5.2 In case of waste heat recovery through air preheating, P&ID is prepared using design
guide no. 8-0545-2524. P&ID is issued for comments to Process, POSD, Piping,
Instrumentation, Rotating equipments department and to Heater (Mechanical). After
incorporating the comments, P&ID is issued for clients approval. Approved P&ID
forms the basis for design of fired heater heat recovery system & further engineering.

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However, engineering may proceed on internally approved P&ID.

6.0 SELECTION AND SPECIFICATION OF AUXILIARIES

6.1 Based on radiant section output, design basis and design guide no. 8-0545-2519,
process datasheets for FD/ID fans (format no. 3-0545-2032) are filled up and issued to
Rotating equipment department for comments. After interaction, the same are finalised
& issued for engineering.

6.2 Radiant section design, fuel specification & design guide no. 8-0545-2517 are used for
preparing burner datasheets (Format No. 3-0545-2006). Type of burner (i.e.
convectional, Low NOx etc.) is selected as agreed in design basis. Burner datasheets
form the basis for preparation of Material Requisition (MR) for procurement of
burners.

6.3 Based on the selected waste heat recovery scheme, following design activities are
carried out:

6.3.1 Air Preheater (Cast & Glass Tubes)

a) Based on radiant section calculations & design basis, air preheater sizing is
carried out using computer programmes CAPH & GLAPH or manually
using design guide no. 8-0545-2525. Datasheet (Format no. 3-0545-2002) is
prepared and issued for comments to Heater (Mechanical) group. After
interaction datasheet is issued for MR preparation by Heater (Mechanical)
group.

b) In case, steam air preheater is required, the same is designed manually using
design guide No, 8-0545-2525 and datasheet is prepared. It is issued for
comments to Heater (Mechanical) group and after incorporation of comments,
issued for MR preparation by Heater (Mechanical) group.

6.3.2 Steam Generator (Outboard)

Based on radiant section sizing, process data summary is issued for comments to
System (Mechanical) group. After necessary interaction, same is updated and issued
for engineering.

6.4 Process data for various instruments specified in P&ID are prepared and issued to
Process & Instrument department for engineering.

6.5 Based on P&ID and heater design details/parameters, damper datasheets (format no.
3-0545-2008) including control schemes are prepared. After necessary interaction with
Heater (Mechanical) group, datasheets are issued for MR preparation and procurement
by Heater (Mechanical) group.

6.6 Based on the thermal design for the fired heater system, the following datasheets, as
applicable are also prepared, issued for comments and issued for engineering after
incorporation of comments:

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Datasheet Format No. Interfacing Department

a) Grade Mounted 3-0545-2009 Structural/SMMS

stack Datasheet

b) Gaseous Effluent 3-0545-2010 Environment Deptt. / Process

datasheet (in case EIL- Environment deptt.
is not involved in approval from
statutory authorities, it is sent to
Projects for clients reference)

6.7 Utility summary is sent to Process for reference and use, on completion of thermal
design activities.

7.0 OPERATING MANUAL

7.1 Operating Manual for heater system is prepared which generally would include the
following:

- Introduction
- Process design parameters
- Process description
- Interlock schemes and alarm set points.
- Pre-commissioning inspection
- Heater dryout instructions
- Normal furnace start-up
- Furnace shutdown
- Operating instructions
- Procedure for gas freeing and isolation for safe entry.
- Maintenance instructions.
- Air preheater operating instructions
- Equipment and instrument datasheets.

Operating manual is sent to POSD and Project Departments.

8.0 ATTACHMENTS

8.1 Check list for Fired Heater Process Datasheet Review (Annexure-1).

8.2 Check list for Fired Heater Process P&ID Review (Annexure-2).

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Annexure-1

CHECK- LIST FOR REVIEW OF FIRED HEATER PROCESS DATASHEET

1.0 Ensure that datasheet is completely filled up and all data are given.

2.0 Proper attention to be given with respect to the following points.

2.1 All the physical properties of the process fluid at inlet and outlet should be compared
with the property data of similar service handled by furnace group previously. Any
major deviation should be discussed with the group leader and if required shall be
pointed out to the Process deptt.

2.2 Check the operating pressure, temperature and allowable pressure drop and compare
with the data available for similar service

2.3 Check that the over design margins with respect to the following have been specified.

a) Flow rates
b) Duty absorbed

While checking the above also note the following:

- If design duty is higher than normal and no over design margin is considered
on flow rate, operating temperature (in/out) is to be given for design & normal.

- For different vaporisation and flow rate, even if the duty is within maximum
limits pressure drops would vary.

- Turndown requirement must be kept preferably within 50% to 110 %. Lower

turndown should not be accepted normally.

2.4 Ensure vaporization data wherever required should preferably be in the form of curves
& cover the full pressure & vaporisation ranges.

2.5 Wherever coking is specified, coke thickness should be indicated.

2.6 Wherever corrosion constituents are specified, concentration of the same should be
indicated.

2.7 For special services, like delayed coker, visbreaker etc. velocity limits, cold oil
velocity, heat of reaction and its variation with temperature should be specified.

2.8 Maximum allowable film temperature and fouling resistance to be indicated.

2.9 Check that complete fuel oil and fuel gas specification has been furnished.

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2.9.1 Fuel oil specification normally include the following:

Normal Range

a) Viscosity at burner 20 cst

(at operating temperature)

b) CCR 3-4 wt %

c) Ash 0.1 wt %

d) Sulphur 5 wt %

e) Metal cont

Vanadium 200 ppm

Sodium 200 ppm
Nickel 200 ppm
Iron 200 ppm
Copper 50 ppm

f) LHV 9400-10,000 Kcal/Kg

g) Fixed Nitrogen 0.5 wt %

2.9.2 Fuel gas specification normally include the following:

a) Complete fuel gas composition

b) H2S content 3 mole % (normal)
c) H2 content 60 mole % (normal)
d) LHV 10,000-11,000 Kcal/Kg

2.9.3 Ensure fuel gas and atomising steam pressures are specified at burner. Atomising
steam should be dry/slightly superheated.

2.9.4 Check following minimum pressures are available at burner :

Light fuel oils/LSHS etc. : 5.0 6.0 Kg/cm2g

Heavy fuel oils/VR etc.
Fuel gas
Pilot gas pressure
Atomising steam pressure
Off-gas pressure
: 5.5-6.5 kg/cm2 g
: 1.0-2.0 Kg/cm2g
: 0.35-0.5 Kg/cm2g
: (+) 2.5 kg/cm2 above oil pressure
: 100-1000 mm WC

2.9.5 Check if any special requirements are mentioned in the datasheet. If there is any, these
must be discussed with the group leader before the comments are given to process
department.

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2.9.6 Turndown ratio of burners should not exceed 3:1 on oil firing, 5:1 on gas firing, 2:1 on
off gas firing normally and 4:1 for H2 rich FG.

2.10 Check that soot blowing steam pressure is above 10.5 Kg/cm 2 g (preferably 12
kg/cm2g) at blower level.

2.11 Design pressure for different services (FO, FG, Atm. Steam) to be indicated in process
datasheet.

2.12 Check in low pressure services (specially vacuum heaters).

i) Whether heater coils are to be designed for full vacuum also.

ii) Whether heater outlet conditions are specified at heater coil outlet or manifold
outlet.

3.0 Preliminary thermal design shall be carried out and acceptability of allowable pressure
drop shall be communicated to Process Department.

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Annexure-2

CHECK LIST FOR PROCESS P&ID FOR HEATERS

Process P&ID is to be reviewed and the following instruments/controls are to be ensured as a

minimum:

1.0 PROCESS FLUID

a) Flow indicator & controller at inlet of each pass for liquid & 2 phase flow. For
gas flow, a flow indicator at inlet to be provided.

b) Temperature indicator at combined inlet and outlet of each pass.

c) Low flow switch and alarm on each pass.

d) Temperature indicator at cross-over for each pass.

e) Pressure indicator at inlet of each pass after control valve and a pressure
indicator at the common outlet piping at minimum distance from heater outlet.

f) Pressure indicator at cross-over for each pass.

g) Plant Air and Emergency/Decoking Steam (MP steam) to be provided on each

pass if required. Suitable swing-elbow arrangement to be provided. FT/FI to be
provided on MP steam header.

h) Based on preliminary thermal design, no. of passes & coil size shall be
communicated to Process department.

2.0 FUEL OIL

a) Fuel oil flow indicator/recorder and controller to be provide on supply and

return line.

b) Fuel oil ring bypass line to be provided with globe valve close to the globe
valves on fuel oil supply/return lines.

c) Fuel oil pressure and temperature indicators on supply and return line as close
as possible to the furnace after control valve.

d) Low pressure switch/alarm and trip on fuel oil line after control valve as close
as possible to the furnace.

e) Filter of 80-100 mesh size with isolation valves to be provided upstream of

control valve, on horizontal section of line.

f) For 10% burners one PG (minimum one no.) shall be provided at burner inlet
and connections for rest of the burners.

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3.0 ATOMISING STEAM

a) Flow indicator.

b) Pressure and temperature indicator on steam line close to furnace after control
valve, which should be marked FO.

c) Differential pressure indicator and controller or PIC etc. as the case may be.

d) Low differential pressure alarm.

e) For 10% burners one PG (minimum one no.) shall be provided at burner inlet
and connections for rest of the burners.

f) Filter of 80-100 mesh size with isolation valves to be provided upstream of

control valve, on horizontal section of line.

4.0 FUEL GAS

a) Fuel gas flow indicator and controller.

b) Fuel gas pressure and temperature indicator as close to the ring header as
possible, after control valve.

c) Low pressure switch, alarms and trip on fuel gas line after control valve as
close as possible to furnace.

d) Pilot fuel gas pressure indicator as close as possible to furnace after

PCV/Globe Valve.

e) Pilot fuel gas line low pressure alarm as close as possible to furnace.

f) Filter of 80-100 mesh size with isolation valves to be provided upstream of

control valve, on horizontal section of line.

g) For any off gas, if used, flow, temperature and pressure indicators at furnace
inlet.

h) For 10% burners one PG (minimum one no.) shall be provided at burner inlet
and connections for rest of the burners.

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5.0 FIRE BOX

a) Temperature indicators at fire box arch level (min.1), between process and
utility coils (min.1), after convection bank (min.1) and at furnace burner level
(min.1). Actual numbers will depend on the duty of heater.

b) High temperature and low temperature switch, alarm at stack.

c) Tube skin thermocouples at shock tubes, at intermediate and outlet of radiant

section for each pass.

d) Draft gauges at burner level (min.1), at arch level (min.2), between process and
utility coil (min.1), after convection section (min.1) and at downstream of
stack damper (min.1). (Note-1).

e) Sample point at arch level and at stack. Number and exact location as per
pollution control board.

f) O2 and CO analysers at arch level, and SO2 & NOx analysers at stack, as per
design basis. CO analyser may be provided at stack also.

g) Purging steam line to be provided for liquid process fluids.

h) A typical detail for burner with fuel oil, steam, pilot gas, main gas supply to
each burner shown.

i) Snuffing steam (MP steam) line provision for both radiant and convection
sections.

j) Soot blowing steam line shall be provided with a PI.

k) Pressure indicator on soot blowing lines.

l) If main process lines are of different size than the heater coil size,
expander/reducer to appear in piping scope.

Note 1. For heaters of duty < 10 MM Kcal/hr the following are

recommended:

- Draft gauges at burner level-1 number

- Draft gauges at arch-1 number
- Temperature indicator at burner level-1 number
- Temperature indicator at arch-1 number.

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5.1 For a heater system with outboard APH, all instruments inside/on the firebox shall be
shown in the APH P&ID prepared by HMTD and should not be shown on Process
P&ID (including cross-over instruments).

Following requirements shall be covered in notes in Process P&ID:

1. FI on plant air and decoking steam lines to each pass shall be visible from
respective globe valves.

2. Hand valve on Emergency (MP steam) line shall be located at minimum 15m
away from heater, at grade and at safe and accessible location.

3. Decoking flow reversal valves for each pass should be located in one place for
operational convenience.

4. Decoking manifolds shall be provided at 15 meters from furnace at safe and

accessible location.

5. Pinch valves on individual gas and oil lines to burners should be located close
to peep doors at furnace hearth.

6. For heaters where steam injection is to be done, check valve on steam line is to
be located at minimum distance from heater tube (i.e. steam injection point).

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