Professional Documents
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Process Plant Layout & Piping Design
Process Plant Layout & Piping Design
Process Plant Layout & Piping Design
stows a exchanger wt sw oe
nthe ube side and one onthe shell se
"The sel of most heat exchangers constructed
seamless pipe for small dimetes and shaped
welded tel pte for the age sins Tube bundle
‘Hees ca ay fom 810 95 (20 0240) in
Glameter an fom 61 50 (1.00 am 0 15000 en)
fn leg The ens of the shell cn be designed 0
accommodate welded, dished, or Magee shell cosers
2 wells flange or welded heads. Both the abe de
Gnd the sell side ofthe exchangers have ines and
‘ules nazles passione o pride the require! fos
through the exchanges. The uit is supported a the
Shell by atached saddles foe boron isalations
ed by lgs for vera rangement. Tube bundles
fre made up of many smalllameter rues tha re
expanded into tube sheets teach end ofthe bundle
‘One end i usualy Seed the ote allowed 0 fos
for expansion. For the more sinplfied Ube ar
rangement, onl one abe shee used, which lt
emt with thc cha! Hea Habe 6 m9
{shel and tube exchanger ening the key Kem
of constuction.
Wah many shells, sell covers, and hed cenersuz
[Babi 63 Typical hel ma Tube Baan
Arangerm
8 Utube
‘rea Pl ay and Ping BR
salable, exchangers can be arranged in arous co
binont to provide a wide ange of servis, The U
‘ube, xed tube, and hetle arrangements ae ls
tented in Ext 65.
Plate Exchangers
Plae exchangers, shown in Eat 66, ae generally
ted in Tonepreste,low-temperatoe applic
tnd are made up of end covers, crying bas let,
and ude nore, pats, and gases. The exchanger
lies have spacing berwees them for uid ow A
ashy, st ito dane on the perpry of each
lite dies and contains the qui ow distribution
Fonts for net and outlet of ath ie and cok guise
are stamped nto the comers of each plate, When
Sllgned. they foe Four dltrbuon headers through
the plate pack, Duarouson of et ad cald ig
thetnate plate low channels is achieved by the gasket
Ing pater around each por. When the liquids
tends to low tagh othe net plate, he gasket
Tet amact around the por. Alignments acheved by
top an stom carrying bars and ls a each plate
‘When complete antmbled, the plate pack and ge
ess ae compressed by bois berwoen the 0 covers
Supports provided bythe fed end cover and carry
Ing br. Te plate exchanger requies less instalation
el servicing space han shell and tube arene:
‘ments of equalent surface
Spiral Heat Exchangers
Spiral eat exchangers are generally used in chemical
Planta are of dela consrsson, costing ofan
assembly of wo lng rips of plate wrapped form a
Dai of concen spr passages. erate edges of
the passages ae cased, that gu Noms trough
fontinuous channels Removable covers ae ited 1
teach side ete spl assembly access othe spiral
Plate As shown in Exe 67. the inlet and oes
hozaes ae neal the ple housing and te cov.
85. The unt sipped eps tached the plateTexan ee
Pate Recanger
housing for horizontal insalsions and by hs for
vera installations Sima tothe plate excange,
the spiral exchange is conga and reques es i
salation and servic space than conventional ex
‘anges of equvalen sare
Double Pipe Exchangers
‘Te double pipe orf tbe, exchanger used when
‘one liquid asa reser resistance to heat fw than
another or when the surface af small, In eich
‘ses, the additon of is othe inner pipe evens ot
the estance to heat Now afte roids Ae shown
in Exh 6, he double pipe exchange consists of
bipe wihin 2 Pipe; Bath pipes havea seturn bend a
‘ne end The inner pipe i ited with ins the outer
pe ans a he oe The shell nosis art mtd
‘etal from the outer pipe, and the tobe nares
te decay welded othe nee pipe ends The uns
tue generally suppor horizontally by brackets atug
BELPPE Tauge ime pum Ean 6
ae oa le ie tan
qweroer | susie eve!
mee ba Teast 69
ae 1 Cokes Eachanger
tached a foundation oF othe side of cer elp-
‘ment swopons
Air Cooler Exchangers
[cooler nts are euely diferent trom he pre
fusiy mentioned arrangements in thatthe caling
agent ud is clang instead ofa igud AS seen
in Eahite 69, an air cooler unit coasts ofa eube
‘bundleswith a header box atache to each ed Sop
pond bodzonaly by a see! fae or stuure For
the singlepass arrangement, the inlet noes are
‘mounted on the top of the header box, te cult
nozdles are atthe oppose end and mount onthe
Donn ode taker ta Por the Goble pss 2
rangement, the Out no2zes ae lot tte same
fdas fhe inlet nozzlex, For adonal suse are,
tore pisses can be added or ado nis an be
‘ren Plt ay and Pig Bo
inslled and located sie by side
‘ii tele by multblade propeler ype fans
that peonde fxced or induced dats. Fans ean be
‘uppliesth ether ada speed orvarabl pies
Dldes. The fan blade ch can be changed ovary he
sieflow rae to compensate foe sing cling it
temperatures. lr coolers supped wth moliple fms
nay be operated wah some of the fans shut down.
Dampers baffles, and bypass can ako be used 10
fuer consol quid outer temperature, For eleted
Indllaons, plaisir generally fumated for ae
cesta header bones and motors
EXCHANGER LOCATION AND SUPPORT
Neat exchangers are located within the conventional
proces unit plot area cose 9 related equipment,us
Ten eeemgee ta mmr
Nd no
aS / Exoensees,
ama 71 tear
‘GouneT REMOVAL
Torry
Tpawan en
See Exar
Tule eumpee
eMouAL AREA
' Neceee WAY
Tower,6.
ERUBH C12 Spc see ae cher
alis 64¢ Spc Scare somies te
PP SF Biba
‘ asuuaey gear
2 wanreciaces
TBOUBET G13 Pua! an Ses changer
\ i
ae ie i
i | = :
a
suppor: economic pipe runs, ely, proces re
‘Quements, and operator and munienance aces.
Support ofthe equipment (eg. fair coolers or ver
cal rebar) can aso sluence heat exchange oc
‘Son Exh 10 depis «mpl plot plan with s-
cal heat exchange aplcatons Horton shell td
lube exchangers should be possioned 50 that the
‘hannel end faces the aula road or maitenance
cess Way fe ube bundle removal ah sdeqete
Space prod ac the ont endl ofthe exchanger foe
bonnet moval. This exchanger arent shown
{ Eshibe 61
Exchangers can be laced sage ems, in pairs
(asi the mow common insalion), or in larger
_rcape when no intermediate contol required Be
Teen the shell and tube seams. The single apd
Paired installon fs shomm in Exhibit 12. Pale ex
‘hangers may operate in series, parallel or dial
Senne groped exchangersaperae ony inser
Parallel Exh 613 shows samples of pall and
series exchange instalation,
Pale or grouped exchanges should be space touu
[BGM G15, SochodFachanger sane
[EGUBIT 616 Typist Horton Fachage Sapp
patie
— ‘eames
a shogsaaines
‘low a minimum of 18 in 450 mm) beoween the
‘sie of adjacent channel or bonnet Ranges
Tae access 1 flange bois for muntenance Space
Should be provided on ete ie f pated exchang
fe and at bath ends of grouped exchanges fo em
twol and operator acess. Eeubi 614 tusees a
‘Hrucure mounted naalion ad is required acces
Horizontal exchangers may be sacked toa pre:
ferred mazimun tp shell centerline clontion of 1
(G0 em) om grade or plaorm, se pice in
Exhibit 615. tacking of exchangers above ths eight
‘may require plaorming for aces to channel and
Donne anges an xe handling devices
‘orzonal shel and tube exchangers may be Io-
xed at grade or lead in sel of conrete ss.
"ures when process requirement or space avalbility
ica Suppor of horaontl exchanger, 3 shown in
Exhble 616s by saddles ausched to concrete pts
for gradcosourted snsaltions and by sales a.
tached to tel frames in elevated stallions, When
possible, supports shoud be ialine for common oun.
‘Sion design
Tf proces requirement perm, allan tbe ex
changers can als be mounted n'a vertcl poston,
supported by lgs and tower somes in 2 wwer sup.
ported isalaion (as sown in Exist 617), win
onerete sel sauces (shown in Exhibi 18),
snd by concrete pier (a8 shown in Exit 699). The
Same considerations for maintenance, contol, nd
‘rar access shoul be given for vert lalla
$e for horizontal nsalsion.
‘an imporantFenure 1 remember when working
sth ower supported vertical bolts, ae seui.ng
springs i highlghed a xh 617%,
1 The layout designer must st the rebole sp
om lug elevation TI 028 above the plo
2 Before maintenance, the 14.025 gap wll be
stummed thereby enabling the role load tors
er eee ne nee
Team oa
| Tues more Sensed eels
EMoVaL AEA
Mosinee
AoVizeo,
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le - I abo'boo
Maxine
a
_Pustroas
a vol) gt00 mamas
Maso Wintour euaTrogt
es BcT/ae0 MasnMune
Pr
be cae bythe platform ec uring mae
ance vamaround
3. The nol and channel ange wil be unboked
and the change ection remened
4 The ube bundle then ready to Be removes
Spiel and pte exchangers can ope'ate in sexes ot
Jarl but Because athe contpration and mal.
TEnenace requirement, itis prefeable to postion
them as single tems, Space proved bh a.
rangement for con and opertar acces, with
‘enough room alowed athe sia exchanger swig
the ever plates open, s show in xh 20 and at
the plate exchange to remove the nd pes as
sho in Exhibit 62,
Ar eooers are located adacent to the equipment
tt they serve fr piping len and aienance
‘They canbe supported rm grade, tthe top level of
ssructres, or above pipe eal, which is the ms
fommon lasallion, The tbe bundle bank can be20,
‘muust 619
Tuee BUNDLE
REMOVAL AZEA
Mins
BLoY/\200
| i2!o¥/3600 maxon
Without PuAToeM
FoY 900 Munintom
=a
Creenyoe keseog
Conta ot Operate
‘een in Spa
‘rangement
coves Pure
‘Swi AREA (2)
contace
SPRCE (ve)
‘races Pt apo ad PingBy
Gh Ee
(Canzland Oper
conte
| __seace (rye)
Wouceo BEART
Ag conver
oir artgesee
wekver
Box PueTeoRe
vansressaNee
Lappe
Puscpeean
a bpprrena PuTeoes
Popes eo Hl
Lousee Twas122.
—_—_—_—
Fowceo OaarT "Bani 62
ia coer ‘pte tg Suppo
conte rangement
* z
sueroet Moree 7
see 2
Ye¥/2}00_ wow A
Spkehron neces 3
aR
supported by tee es fom the sr cooler enor of
by eendig the pipe ricer suet columesto the
underside of the bank Generally the ar cool ven
‘dor Furniss header box and motor acess plasm.
Ladders a= provided forex © grade to sus mat
‘mum ladder rans and sly cecremenis Fae
22 through 625 show various ar cooler rope an
pla¥orm ciguaios, which ince column 9
one, lepsupponed, fixed plform, and tmvling
‘recs Plt apo and ing Ds
laf arangemens.
‘When designing the ir cooler configuration, the
plant your designer mus consider the source of the
Supporting column. As seen in Exhibit 626, ange
ment A, developed by the contrac, allows changes
tr plarming ant pip pending en peo
fet without alec the alr cools vendor's scheduled
elvery dts wo the fb ste tp arangerent Bary
suck le changes would ese the ai oor vendor23
Ee
SEE ereeeeeee
"pani 2
AT over trang
wove ro
forces
Puartoew
Ge)
lesen Geox
prec to
gence vr)
7a Nowe ve)
yo
1
or TH
| el
eesence | vawrenance / [me-cooee
eouuMNS == PLATFORM ‘Suprogt BeauBs
FoEeED CRAFT "AT 625
NE eooLer “ing atom
stae-onr
PLaTEOaM BAVELING ae
lly eee
—Sl
EN
to edesgn the suppoe eps oF platforming, casing
‘dels in delivery and ears costs,
NOZZLE ORIENTATION
Nose orientation and ocaion can af the piping
‘corfgurations at mos exchange arrangements Ade
fesba by the piping designer wo reloate the ex
tanger nozles can fen produce a mat and co
ffflvearangement hough the png desenet
foes aoc have the freedom to independently relocate
fexcimger nozzles. sugpested alee nose loc
tors can be made the exchanger engineerin the
Interest of emprovng enema ppg aangemens—
forsrample,atermae Bin Bb 6 27hghighs an
‘Barr 626
‘Conerson
(ConuncrrSupted
= ‘Storie Slr
Pca
lnproved arangement by relocating exchanger noe
‘es hie 628 shows allowable acl configs
‘ors
"Elbow or gooseneck aces are expecially wef
In reducing the height of are tacked exchangers
Exhibit 629 highligh the eles fusing elbow no
ales on sacked exchanges
“Air cooler notte Ieations can also alfexpiping
configuntions. A single pase arrangement can make
the rum piping on a overhead condense vey fon
and ean alo increase the height of the aie coler
Reacting the ai ene making the wnt» do
be-pse arrangement an mprore the lng confi
‘aloes. Exibt 630 shows aerate nozzle conf.
Faton for a ook ping,
ry226,
‘Banner 627
ve encgee
AvreewaTive
AurecuaTive ‘8
ANGLE pees SHELL OUPAE pose SHELL
: q----¥4
Asie sriitrow sie povele eplt-rlow ale
som
PNG LEA paee SHELL Parke pees ell
Sn am
lV P
ema “We perils iZ
"pant 625
‘nsec Brchoges
tt
C.D)
Be
i
OO
ALTE«NwATIVE ‘A ALTeRNaTive ‘a!
"Ean 630,
magtucine eer
Dovtue aie evtiar
sue cacao
EXCHANGER PIPING
changer piping mst be routed in sacha manner
thu itmees economy, tently, suppr and oper
tin and malatenance access requ. PIG a
shell and tbe exchanges i pastione tallow ae
‘gate space for remeval of channel hexls and shell
fiver. The fee space atthe sie of harizotl shells
{be used for places of conole Piping ls le
‘red a minimum dance fom grade 2 pation 0
poride operor headroom clesances 1 ofr ese
‘Sf support, and 10 meet designated pe rack ceva
‘ons. Large-dlmeer oc more expensive ppg cn
pot be seo accommodate smaller ot less expensive
Ding. Piping conneced to channel Head nozzles
Should be furnished wats break anges alte he
Femeoal ofthe anne head
Piping a pal and plate exchangers sao po
one allo the opening uf ners de eval
‘of ples. Controls 3 the spiral excunger are located
‘on the ends ofthe unt clear of the cover pie sing
area, and atthe froat 28d on ne side fo the pleManTenance Access
exchange. Piping is elevated in 2 faslon silat to ener ten ar fans and howl be kept eae of
the sell and tube arrangemen's Phung ataced to the designated space for motor mntenance: Exhibits
"he cover plate nome ofthe spiral unis i umshed 631 tough 6:4 show various piping configurations
swith break flanges Piping 2 at coolers isnot roted for het exchanges,
‘recs Plant jon ad ing Diroe GuTTEEELy
ey
car VALVE
ZauDEMS ATE BGT
Sei or reecess
@uovtions12" Auioy
[EXHIBIT 635 Suppor fr Ppng Anangemen
weer
Be aise
Sees,
mee
‘Poca Pant jon and Pig Di
TExHInIT
Economy Arangenent
eal eNb cagpon sree
io auoy | \ cosmerrectve:
‘AEGANGEMENT
TBOHIBIT 636 Piping Amangemen fr Henson
| srwmerca
erHiatt
FLexiuiry
MPECATUR
AUSy Fem
Peowine seem
‘Suppoet at cevree
EXCUAsGER Gaol
exp uty
a
Hele.
i
acteenarive ‘A’
Attewatwe 8
cost EFFECTNEPang Arsene fo
‘paar 610
‘Spr ache
Traces lant jon ad Piping ignELEVATION
TBOMDIT 642A Gols Fping Coegsone
va TD
SYMMeTsIche Ake,wee
Ui
wan ff Ne.
ecousk suPReRT a
Stet = newer \ Sie “
Suey Une te Pow Te Peis
Tee/ee SD CMC apassitereaes)
WithooT Ime 6 ATE
Toweg, ace
eS a ae
DHE PIPE hee cotares
Die A coouna sections
Souk Be suacumntey
‘Aup Tui _STEEL Expewpeo
2
Wie
oes Pan ayo an Fig Dn—————
=a
eres
|
on
sees
PIRTFORM STEEL FROM PLATFORM
caress =
a |
EXCHANGER MAINTENANCE
Lite an automobile raitor the intel of hea ex
changers require period cleaning ard repr ts
Srporant for exchangers snd elated component
be portioned to altate access to tetera pars
For the sell and tue hese exchangers, the foes
andthe interior ofthe sel can be cleaned in pace
tith high pressure steam of water an roxing Ge
“aes. the design ofthe exchanger emis, there
bande can alo be removed fo repar or deaning
‘ube bundles and head ane shell cow can be re
‘moved by buiin fixed bundling devs (eg ds,
ich pois, pling poss) fied sucnes wih ol
Jey beams and traveling gantry cranes or by mabe
‘cuipment (ef canes ad yea undle eae
to). xhbis 6-45 throggh 648 promce eampes of
fe han ema ripen Consiterabe sing
fon be achieved i the plan Is servid By male
ccupment
‘i cooler unis are not funshed wih ie han
lng dence for removal of tube bundles Minor e
pars (eg ube plugging) are usualy accomplished
‘th the air cooler in place; for major repairs, aie
fooler sexton are rerpoved by mobile canes.
‘Shown in xh 649, Irn sercng a plate ex
‘hangers canbe done manual Inthe ever: of ube
allure, indies are closed by neering apo
‘heough the end ofthe header bax and hammeseg
in place, shown sn Exube 650
“Tease of tobe unl exactrs eliminates the
nee for permanent re bundle removal sroces
‘oath considerable sting © the plant These mechs
isms weigh seven tons tnd ae capable of pl forces
[rene than S000 Ibs. The enact fed fo
Postion by crane and clamped to ie shel Mange of
the exchanger, which srpped for bane eral
Held in postion by te crane and balanced by the
‘euracors eveling cdl: he bundle pulled ox of
ie shell wth prod atch hae drale
fovce The mhote un isthen ered to prade and ean
evel oo auc or of ste vepat or Gann‘roses Plant joa and PDrous
{EXUBIT 649 Removal of A Coker Sector wit»
Tube baby Game
HIRT 648 Remotefe) ==
Pia oat ad Pig osWYORAWIC TUeE BUNDLE ExTeAcTOR Tear 652140
{RIUBIT 653 Tower Mounted Ae Coker
Exubic 651 hstrates a cles exchanger ith the
ceactor and crane in postion foe bundle emer
Exhibie 652 provides details of» hyaulic aeba
dle exeseor
‘This Capter has highlighted the principal layout
requirements forthe heat exchanger coalitions
Traces Plant aon ad Png BO
OHBIT G4 Sein ever
‘mos comment wed in process plans A wide range
Of tems, however can be ent! shea exchange
‘equipment for specific sitions. General these
lems have design fetes sma 0 thoee fr com
‘mon aplicaons Cae shouldbe kent arange the
‘equipment sothat he base rlesfreachanger layout
src lowed. Exhibts 653 and 84 show examples of
‘more unusual hea exchanger equipment.Famaces, als refereed to as heaters, ae one of he
min pieces of equipment ina proces comple. A
fomace may case the temperature of 235 or hydro
‘bon quid to mee specie processing nee on
the cise cf pyrolysis and reformer fraces. case 2
‘rmical or ysl change othe medi, Acieulat
‘orbos ype configuration spray wed variations
torach design are covered Uroaghoxe is cape In
dition because othe various Wes olfernaces this
ctupter covers some bases of fermace dig an dis
‘uses how to aporeach a piping aout relates to
‘marenance, operon, and sy
[BASIC OPERATION AND PRIMARY
PARTS OF A FURNACE
sbi 7.1 astra the base makeup of furnace AS
shcwn in this ea the ase pas of frac i
late
+The atin secon —Houses roms of trian or
verve bes that carry the produc to be heated
+ Burners—These are pial Fie by io asad
se lone inthe radian section.
+The convection section-—Locted above or down
seam fom the redane sation. houses rms of
horizontal tubes that ae hested by the Bor fe
se,
+ Toe stack This usual lead abows the comer
tom section and cares the Hue gases the amo
sphere
+ Tsulation—Lines dhe walled surfaces of the ant
snd convecon sections
‘The furnace operates inthe following manne, Fuel
{sfedio the burners located alog the fumace flor I
{sthen ignite 2 ie go ie artes in he Barner.
‘Thecombuston a Now i equated by asset of
the air egies. For proper operation within a fur
ace, patra rat mst be maintained As the eh.
CHAPTER
Furnaces
perature increases, the hor De gi ses Ou of the
Sack and begins to exer 3 negaive pressure wits,
‘he radiant and conection secon or optimum op.
‘craton, thee should be a peesre of sppronimaely
035 in of water columns jus inside dhe a reget
ofthe burner. Tere shouldbe 3 presure of “02 in
‘ot water columns athe fumace for, with fare
rap to ~05 ina the op ofthe radian secon, ad
=07 in atthe base of the sack. Malesining these
levels ensures adequate air ow to the Bure: Peep
‘doors are povided along the radiant walls «allow
plant operaions perionel © view the bumers while
aking ful aden
‘A produc is iococed ino the radian tubes and
Is heed to the maximum opering tempera I
then ex the furae, Stam enters the conection
Section tubes and is asd oa superheated tempers
tuce by the hoe Me gases.
‘The damper, which suse wo control the dat in
the furnace, is located in the sacle Adgating he
anper canuok the pressure balince win the ue
nace The stack beig i dteemined bythe dra re
quirements ofthe race by maybe ached. Dra
Bruges are used to check pressure level
should be undesiood te there ate many var
sles this descrpion Bumecs maybe located
the ide walls or 00 the rd section tnsulation
‘maybe refractory brick, ceramic Roser, of 4 minetal
‘wool blanket The produc may fo inti the come
tn sean tubes, ex that seton through excsoner
piping and flow through de adant seston Malle
Fnac maybe testo ont common sack by bree.
ng
‘TYPES OF FURNACES
‘he pring pes ol funce reba, cia. o>
iss and elormer
Box-ype Exhibit 7.2 shows box ype farace that
houses rows af orzo or verte usin the ad
a eez STEAM IN
eg —_LLeoarereitl
unt
7 2
Se p+ on
=
4
i
k
p
Ir 4
ee oth | fd
oe ay =
@nzarrause
‘races Pan Tayo od Pina ann
ise Formic Operation443
UBT? Tyykat Bowype Ferman
srt sealon. The convection section is bested down
Stream trom the raat section where five gas my
Das nan upward or downward flow Ras af burners
Se located in he cada set, his the priy
Source of produc eating
Coca Ee 7 3 lseaes a cece furnace that
Foes toes mounted verily or helical sn the
Sud smaller duties as sarep heaters or rebar
Inlet and cet connecions ae usually ocated athe
‘oor the botam ofthe rane ection, depending 00
[BRUBIE 73 “Typial Gree Forace
the prodoat belng heated, and are lose tone ent
ofthe convection section
Pyrolysis Exc 74 ikstates a pyohalsfumace
‘whose product tubes are pce ia the cetera the
‘aan Section because of ele short residence
time, high hear tanser re, and ned for even tom
Decaure dsb inthe tubes An itera wae
Fat acory ecm that cmplys the wc of eam
drum and a waterline exchanger (TX) i aso
shown, Steam decoking is equied wo lean the ner.
ral was of the proces tubesug,
Reformer In a sefocmer furnace, shown in Exhibit
75, preted process Tid lows through aly
fled tutes, which ace usually lead in he center of
the ada section Ths ype of furnace may hive sn
fe or multiple comparmens; burners maybe
‘ountdin the rok, nal or lao. Hest eco sj
tems may ao be employed through the wee ate
‘eat bles othe convection sections team ener
‘TERMINOLOGY
‘The flloming sections ts conon furnace ers,
Blowdown stim Slowdonn scum i Se fr tbe
cleaning oe remeval of res fm the ne ii
inthe eet of he
Blowdown system Ablowdown system ithe pp,
‘roc Plt aya and Png Do
‘ype Prt rrnace
system used 0 cary waste 38a fom piping tes
foe ape
Brecchingtrecching refers to the duct work hse
collet fue gases song the Force Box oe for
transmission othe stack
‘burners Supplied wath ale and fuck acesary for
combussion, Humes heat the product nthe tubes i
the racant seaion of he frnace. The mos ominon
Iypes of burners are gas sr and gs air and oll ot
1s and ol, whi requires a, a and amin
Burner management package Tis devie is de
signe cont sich burner operations as mano:
filo ame, main Hane apd heater conden, Lit
ing devices are hut io the package ta shutdown
the furce if usafe operating conditions ase,1s
Can-ou access doors Acces is provided tthe in
ter ofthe firme for muntenance pecan
CCensection section This compurment houses ome
‘of primary horizon tubes lcsed downsrean
rem the e2dlan sein that are wed for addon
Jheiag ia 2 proces unk. Passing the hot Pe pases
‘ver these tes can prove ado dy. am.
le ncude preheating proces streams seam sop.
heating, and addeional seam generaion. Provisions
ss be made to emove these tubes fe inspection,
pao replacetent
“crosover piping. This ping intercomeets the ra
anand contecson sections and i wuly fused
bythe face vendor
Damper Located inthe stack or duc hi dence is
used to contol dks in the fence Dampers ae
‘Ban 75
sully ar plates that rate on sh resting o pil
low blocks sein the steel shell silt a baste
vale
Decoking. The coke bul up in many hytracarbon
fumace res during pecaton is removed by inet
ing tea and at into te tbes.
Draft gauge This insrument is wed 0 check pres
sure a fomace
[Explosion dooes In the event ofan explosion in &
furnace, dors specifely designed to blow cut and
protec agains a major ruc aire are prvices
‘hey ake safety ae opis sisters
Header A header 36 the fing that connects 80
tubes in & ow pater,17
Header boxes Mos ends of tbs ar cont by
ends that make inspection dficule Merfoe, pe
al return figs wth phages connections ae pro
‘Weal da emt nepetion and cleaning, Hecate
morale pgs are sbjet to leak, all heads
‘mus be complete enclosed in ewer boxes. Sul
Ing team eed to sppres re in ths aren.
Peep doors Small doors ae proves inthe wall o
oor of he dant Secon to permit val especton
ofburners during arc oe operation
Pils Smaltbore Alexie piping coaiguations
anne the radio tubes the ne nd tt head.
fa laste In Ex.
adancsection The man companmes ofa umace
Isthe radant sean, tn whuch proces Seams ae
Fratelli erica, by het rm bares
‘mounted in the wal, ro, oF Root
Raactory_ The refractory 6 mae up of nslting
‘els capable of htc high tener
faces
Sot blowers Soot blowers are mechanical devices
tha cea ese uid wp onthe exter o ofthe com
vestion tubes They are usally fumed when 0
Frsd burners are wed
Suck_tncated downsream from the cnwection sec
Hem the wack dene cary Me pre cleety 0
the smorpete ort den tem hea scandy
‘dass to an at preheating sytem. Stack sleatons are
‘sully esablahed a firmace deiner to epeste
Con paul drat. the height the tacks incensed
10 su ley condos fan mist beaded er
Son probes ae needed ia sick, ladders and pat
foc are ade as rece,
Sufng seam This seam tat need ino the
‘omburion chambers or header box of face 10
suppres a fee
‘Tansee the oul ofthe proces es ae ed
too piping header called a waterline, which fed
the main proces tower
“Tubes Piping within the race carries the medium
tobe heed. A pal ria cl shown in Exh
BURNERS
Furnace suucute and heareease requirements ate
the determining fares in the selection of the corres
Durer design Burners are fred by a wide range of
fscous and liquid fel, and 3 vale of congur
Hons are used thoughout the indus. I is recom
tended dat the designer tke fll advange ofa
tomer dis arable from vendors to gin preter
Usdersanding ofthe operason and maintenance re
‘girerents ofeach des
‘he combination oil an gas burner & shows in
Exnic 78 Some of the fees of this burner In
clude
+ Tes designe to fie hosizotaly overtly
+ Ol spillage inthe rant semion cannot cause
burner png148
[EUURIT 7.9 Mastcmnce Ae fr 4 Combntin OF
os
zany oll har can be pumped,
13 burs an fuel gas safely and uly
“All pans of the burner can be inspected osely
le ee burner i in cperation
Ext 79 shows the martnance ares tt mast
be prosded when developing a ajut for a combina
Steam othe ol gun the of pacing ase can
be changed while the ewer sn operate
‘The mindproot gs ures, soma ia Ext 7-10,
‘roe Pant apt and Pip Dvn
HIRT 70 Windproot Gar rer
‘Seayto light and fies many poston. requires no
ombusion controls to maintain maximo eficency.
‘Te burmer may be salto L-shaped, scordng
layout requrement
‘Bumers may be arranged in singe or mule
and lene inthe roo wall of loc, 2 show
Im Exhibe 7-11. Many burners are operated and con
tolled though the use of burner management
‘COMBUSTION AIR PREHEATING
SYSTEMS
The overall hema eficieney of nace mproved
burners i preheated, Economic ses are pe.
focrned earyina projet determine the fealty of
sucha sytem. The two most common preheating 5ee
"pou 7a
‘Spl Bene Loctons
[ewe fies
tens are regenerative stems and reciperaive
‘pica regenerative tem is shown in Exhibit
7A Hot ve gas ening the conection section is
Adnened trough a duct oa heat exctagerelled an
sirpreheater Incoming fresh ai head and ent by
{fered dat an to the bumer plenum, where Ken
{ex the burner though the ar register for combus
tion An iced dra fan raw the Te ie Eoah
the preheuter and sends the cooled gas back ito the
mosphere trough the sack
's consendonalrecyperative (closedloop) syem
‘ilusted in Fahd 713. Oil's ceusted rough
"heconvection sein tubes ested, ne set through
‘einer duet where i eleases ts hex The hoc t
thn eners the burner fr combustion, the hoo
is eieulted oa storage tank fr feeling, From 2
layout sandpoie, the ho ol system wah 2 storage
‘tank and pump is far les comple than the regen
te item
GENERAL ARRANGEMENT OF
FURNACES
‘Tis seson deserves the general rangement
tous ypes of frnaces and dicusees how epertion
nd matrenace ale furace eleva, how o plan
ll necessary acces, and platorm requirement, 80
‘net equpmenn, and sack design, Ext 714
shoms 2 pial arrangement ofa cea race
Setuing Furiace Elevation,
‘The locaton of burners and the posse ace for sr
reheaing dacs are mo primary frst be cons150.
"races Pt oat ad Pig sg151a §
ELEVATION,
‘4 hen the eleraion of func is exalted.
4 shown in Exhibit 7.5, the turers are Hoot
‘nounte he eleation shal best high enugh
Gung But not neces under al the burner
Pine
The preferred kxation of the bumer opening
‘raeas Plant joa ad Ppog De
‘Ban 718
pe Acta
C
valves i onthe Fig lator at the peep Sos ck
beneath the furnace When walbmountedbutnes re
se the eleation ofthe Rrace ca be homes be
Fequcemes beneath the furnace o be adresied
Access for operation and maitenance i 9 moe
consierace inthe development of funace layout‘Aces requirements are eeviewed fo ube sem
‘sontblower, damper conta, beades bones, burners
an bummer management si and consol panels
Because furnace cubes must be periodically re
ped, clear ares are provides dirty in ne with
theres. The removal mechanism may be a woley
beam located on the sac of 2 cecuar furnace, 3
‘eae. ov a cherry picker If only ane re aes
Feuire remo afbe exractoesmilt othe SPE
‘sd for exacting sell and be exchanger bundles,
my be wsed. A can be Seen in Exhibt 716, aan,
153
‘Seti Frmce
tube removal in circa armace accomplices by
paling the rbes trough an access dooe located in
‘he tp ofthe radiant secon Ti s performed by
‘og hols atached othe cecil ole beam on
top ofthe sack. Once the tubes ae Med out of the
radiant compartment, they are pled ay fom the
‘mace and lowered io gre. The convecon secon
tubes are removed ia 4 manne sila the ce
shown fr the bore fre in Exe 717 Here
‘uae the access ares must allow the tbes 1 be
piled clear ofthe furnace, permiing the crane 10‘ren lt ap nd Ping DO155‘email
—ea
‘rac Pa Lent and PingsTDRHIBIE7.21 Burner Mangere Cone! Pel,
sted operaoes ate les commonly used for dae
adjusens, which ae routinely made during ta up
‘when the proper pressure balance win the fumace
‘st be obained,
Header bores 38 shown in Exhibit 719, ae cor
wing aay and lower the bes rade
‘Soot blowers have dlferent access requirements,
epending on te pe used. One ype fixed 1 the
‘omcton section wall nd occupies a eave small,
ten unlike te reracable ype, which furished
‘with horizontal suppor beam ta enables the mech
{om inser the lance daring operation
‘Dangers les inthe sack ae sual regulated
by a device lected at grade. 25 depicted Exit
78, Cables sing, Urough uices fed to the
arnper and astment lever, oF contol hale, my
be locked into varlous postions a dei. pac
sures around the fitings that connert 80 fbes. The
flog, called headers, are furnited with plogged
‘ennecsons fo ean, The header bones ar sled
from the inside of the furnace by an insulted tbe
sheet, ad, because tis area 2 posible source of
fire fing steam conection Is provided or Bie
sppression A dain connection I alo provided oe
leak deen, Gear access mus be provided sound
‘he heaser bax to pent npeation and ube clening
for repacenent
Bumer aces i quire for ignition on sactup,
sic Now control taro eine adjsment control
handles, and oll gun maintenance. Access also ce
guid fo allow routine operator inspection foray
Sgn of leas, pariclariy when enble hoses are
ed,
Burner management sjstems are vendor supped
packages enssting ofall primacy ving at
‘mention necessary to sit up, operte, and shut
‘down all burners of famace under rela or emer.
ency condions. pel burner management sis
Shon in xt 720 anda burner management co
{eo panels showin Exit 7.21
Puce requirement for furnaces aren dierent158.
Teena 722
Seguremene
Le
a
eete onl
{rom ay cher large plece of equipment at needs
‘opera’ and maintenance stenion, Bese each
eaters designe o meet spect paces reeds, sy
See wah ciferetfoels and requ a peeteatng
tc Devers, and is subject olen ces ech ot
"gn shuld be approached asa unique aes, follow
ing base guidelines.
Treen la ap Pi Di
Bo
igi sae!
yp eae
A cela furnace platform layout shown in Ex
Iu 722. The fing lator, wich sual 2 fll
Yoel, can be teaches by a vary of sey
configurations and ladders, sMsrated onthe lower
plano hse ach scene shown ty Best
Accommodate the lyou a required. Saisay wari
tions shown here are+ Suieway A—Ferpendicula, whlch cn beset 10 6:
ther side ofthe landing
+ Sairway B Rada
4 Siaieway C—Targental
‘cess o al ter plafoems on ths pe of fuemace s
Dy lander, sical onthe ex as flows
+ ackersD and E—Limited08 304 (9150) ma
mum ladder run per Occupational Say and Health
‘minstation (OSHA) an strmedte plaorn
required
+ Laker Fables plane personne gain acess 10
Dot sides of the upper furnace by te convection
section platform,
Adina! plaoem requcemens—for example,
fo: aczess to Son blowers or interconnecting Pa.
forms beeween groups of similar heaes are shown
ia ae 723. Caras ae planned forthe fri
plac and top ofthe radiant section for operator
“APWobs urace, shown n Exh 24, has both
wala hor muted burners, The wal suc
bemer piping an be operate rom te fi plac
Taam 720
Bt ace ar
egarements
{orm and viewed from he peep door onthe end wall
‘The foocmouned bumers cn be opeated fern
grade athe ee of the race o fom an optional
omer fring plaorm, Adon! platforming ©
quired for access wo deal gauges, peep doors an the
‘omection section Becsse the primny opertor
level atthe burners, salrens are use fo aces
and ladders are provid forall hs levels
"A reformer frmace, shown in Exh 7-25, has 2
pendouse and roofouned buroers. i adian 0
plaoems and a aia for regula maintenance and
‘peration, ides ae provided In ese of 3 ere
‘eng Other platforms are fr acces o pep doors,
alt gauges, and piping 3 equired
Ausilary Equipment
‘A soot blower mechasicaly cleans sot buldup on
comecion sexton tues in iclafied ewees A
$00 blower esenlly consis ofa lane (Le, pipe)
[pe dlemed anda connection forthe blowing medium,
‘hich is seam oc aie There ae two apes oF blowers:
Fixed and revucableCONVECTION
‘Trees Pla aj and ing Ds4 fixed soot blower, shown ia Exhibit 726, is
-mcunted cet on the convection ston wall an
Fpiped 3s shown, erable sootblower, ils
‘raed in Exibe 727, allows the lance be removed
from the coavecion secon doring operon, Some
fhe principal component are the ufpor chanel,
the gear deven catrage, dhe poppet ake (wed 10
contol the flow of the ceanag medium), and the
lage with nozles bt 7-28 dep soc blower
Ineperaion asthe lance enters the heer, the blow
Ingmedium cuts apa trough the depts ual the
lance reaches ls apex. The lance then -eerses cot
‘andi indexed! so that on the rection path
‘deans srfices not covered on lnsenton The reversed
‘ution and indexing alow the sot blower f peel
and spall epost efiiemy and mith ee chance of
heer tube ere,
‘a ndced draft fn ay be equi fr furnace
‘operon, 2 shown ontop ofthe cnvecon section
Sout Blower in Operation
In Bebe 729. Maforms designed specially fr,
‘ach an coniguration shou be desu for mate
‘nee and operation ofthe deve and fan mechan,
"xhbie 730 shows a ypicl arrangement of sn
leone peaks fumace wath an itera wae bet
System, which requires a seam ds 3 heat ex
‘hangs often calle a tases line eachange). Be
(ase the preheat and dtng on an aterage sine
‘combustion ai preheating tom te some age,
the plant ayoue designer should pay ens atenton to
{he amount of space hat rally used foe ths equ.
‘ment Aer enc room i alloted or maintenance
{ind operon ofthe fore and induced dat fs nd
‘lowers, he cance fom the outer ede othe pe
heater tthe centerline ofthe furnace oul be Rep
{0 mim, shown in Exit 231
‘Whenever fumaces are arranged io roups on a
pr plan. the plan layour desgher should consider
sing 2 common sick, as depicted in Exhibit 732‘rea Plt ajo a ig Dsfeet omerscnt
"To MiNi164
"Foes ant yo Piping165
Tpauner 734
Png aut
Innrmencaon Digan
Economic consrais usualy determin the fessley
of tus design feature, ll nace configurations can
tue this Brechin concept.
PIPING LAYOUT FOR A FURNACE
Tis section deals the piping layout cf circular a
beep furnaces lbough such spec ears
snufing seam are actualy equired for both heaters
‘ty ar explained for ane spicmion oy
Grenlar Famace Piping
ibis 733 and 7.34 present simple piping and
Inseumeniaion dgeans foe crea furnace” Te
‘nace has 6 inlet and att ines, with cont
saves, combination Parmer and oot lowers he
‘onveaton section Thefurae pln ad leat or
the upper level of ts fumace ee show ia Fah
1'3sand 736 eespechely. The tack hown in Exh
7-36 equipped witha trolley bears an opto fe
cure) ht pls the radiant nabe bones during rin
tenance. The ned for plavorms depends onthe in
strument requirements. The damper sclng
‘regulated rom grate by a cibleopersed cts
supplied by te force vendo
In the éonmecton secon, three saonary soot
bowers ae fe by 15nd oon the fie sea
header located below them This piping i ep one
tothe convecuon seaion walt maximize the wal
thie work ares for plant personnel The fou in
Product ine les Have manal contol valves and
local ow adios eset be vile whe perso
el ae gperiting the valves. Tey ae loca a he‘Freca Pt apont and ips B167
\
bit [tazarecur 757
"upper plaform far economic ressons—placing them
3 grade would require runing four Idi nes
Upithe enre force The snling steam lines are
‘ouped together for common suppor unl they
‘each the tp ofthe radiane section. The ine to the
‘healer box onthe paste sie run radially ound
‘he eater Bending smal ins generally nota prob-
Jem and sve ftings and welds. Ploms ae de-
signed io permi plant operasons and maintenance
Detsnel lea aces tall vale, struments, and
“Te lower level ofthe cular force shonin
Ecubis 737 trough 7.39. lathe radiant secon, all
Piping shoul be grouped gees fr eomman sup
Trace Pant jon and Pps
‘ot when practical, s show in Exhibie 7-8,
‘Srofing stam, whic used to supe a fire in
{he header box inthe conection or mint seco,
‘is sopplied through ll and remote manolds The
emote manifold should be no closer than 50
(15000 mm) fom the furnace In Exh 737, the
local manifold is located trade, next to the interme
tie pipe suppor column fhe ea area unreach
be ian emergeney, seam would be supplied fom
‘he verote maifola The inlet and oe contol
Non are eet along the pipe ack acento the
Furnace. This patie furace uses manually con
trolled vals foreach burner The burner pay
headers™fuel gas, fie steam, and fuel oare un2
ree Pog Dtsadialy ver one anes to keep te ade close 0
the farrace wal This pontonig lo allows thei
‘tua tamer piping leds um agacet tte peep
Sows, eating accesso the valves during cpeation,
as shown in Exhibit 739. The pl gas ve located
below he fornce, providing opersor aces arng,
Ignite It should be need that lug est new
farce insaltions use burner managemen jes
this design approach is accopable st manu contol
td igalion i cece
“The fuel fuel gas, and ple gas contol vas
ace cued athe pie rock The fuel gas run 5
Imeedly 1 provide an even as few to ee burnee
‘Thissysem mustbe kept dey by the eimiatin flow
points where condensate may collec. The header
‘ren Plant ayo aed eg Det
should have 4 drip leg to remove any condensite
bulb piping te the Rare sytem. Te re sear
lie that stomaes sea mum be eon and insted
‘wh the fel line o decrease el vscosty. Am
ing seam is jected io the burner with che fe
robin efecve combustion.
“The header box drain mnt have 4 seal loop and
clean. pig for nspecton jst above te ran ub
(see Eslube 737). Removal Of this plug perms in
specson fr small lesks inthe tobe headers inthe
Header box
The 360 lng platform alow fl acess around
the radiant Seton to the bumer sales the peep
tors) and isruments Te inetd plains
Fumhed ro meet OSHA requirement, which seeUhatany single der run must not exceed 304 (9,50
‘nm The pln layout designer must ena hat tbe
‘empral areas eran cleat ofan cbc.
Box-Type Furnace Piping
Exhbit 740 i 2 sample piping and insrumentaion
saga fr a bonsype face. This heer has 0
roduc inlet and ouet leads, a swing el wed for
‘ecokng 2 contection seu cl, rl bes ma
2genent sistem. xi 741 provides an oneal view
ft furnace inthis example and indica the major
Pars of the rumace.
bit 7-42 shows the decking operation. rot
Inkling shown nthe eecoking mos, an net 8
1
"eat 7
Swipe Farace
{se for regular operon With he swing el bod
to the seam and a line the we caring poses
ray begin. Each col desing and Bown ou ih
steam. Header plug are cemne—the rem
Feadecbox panes te lusuated in Fuab 743.8
leaning tool fused to eemne coke depots
the inner wall of each tube Once this complete,
the plugs are replaced and de burners are fed
Steam i inroduced to remove a remaining coke
eposts. The seam flow rate must be slicent to
prevent overheating ofthe tu: wally ai then
{ded to bur fay remaining coke depots Steam
And air discharge to the stack above the Samper
‘through the vest le. Sean is eoduced oe al
‘ume to Fah the tes lean ll doing Honea1
IBaURIT a2 Decoing Operon fr 4 Ror Npe race
wns,
phete sections
Sees Ge ybgei
Se ese ae
gcc tah5
‘mist avoid blocking acest the header boxes when
developing the piping yout in tis area of the
fmace
Convection Section Piping
‘btu 7.4 illstrstes the convection section seam
cal piping along wih some misellncous soc
‘alls The seam ine line can be run toronto
{helt noznles heease the elevations above eat.
‘om. The superheated steam oulet piping can be
‘ested below the platorm 50 that wll ot pose 8
‘exer 46
‘hazard eo plant operations and maintenance person
‘el The suc Tenure highlighted here ite ab
Sence of handeals to permit aces othe deoking
Piping, The plan lout designer mst sy the
ace Yendor of dus vequrement ona markup othe
Place arrangement ding
Bummer Management System Piping
Exhbic 745 i sample piping nd insromenation
clageam ofa burner management een supplied By
the burner vendor The engage oneie supus
[BOURIT #7 Trance ne Layo
lies he ue gs to the burner sid and mat be x
"ole on the uel gas an pls gas to thei
Uh burrs
Txhibt 746 i plan at grade ofthe burner man
agement ane contol panel in relation tthe fu
face ané burners Te sii located dct inline
ith the famace centerline to pride the mox direct
Piping che ind burners. The burner manage
‘ene cool pane! remotely located at a mmm
€ 2013600 mun) from the furnace Pan: oper
tions enonnel may ignite the barers orm his panel
by sonang a spark to the igniter located at the ple
‘sup win the burner and acvating the wlenoid
‘ales on the st
‘Transfer Line Piping
| furnace tans line isthe primary produc outlet
header fom a heater or furnace 4 process mee A
‘gpl acum tower transfer line layout som
Esubi 47 Becnuse many rans lines ent coke,
the lengh of the line should be hep io minimum,
‘Quench injection nea the face ut sano
means deducing line coking, as shown i the
Trace Plant joa and Piping ee
L rm
axmjessacte
bi, de wansfer tine should run Hoezonally ap a
the mest divert coute possible t sy all stress and
exdbiliy requirements The addon of line Manges
should be planaed to facta ceaning if coking De
“hpi steam generation dhemesiphon cuts
shown in Exit 7-48 Brey hs carat the dle.
‘noe ofthe water seam mitre andthe ste head
the downcomer that ainsi fd celina
Ing the team dru atthe tp ofthe furnace prowites
the sac head and collects the steam being generated
‘Stim reruns to the op poron of the drum, wile
the water ines come of te Baton. Laops and pock
{ce mus be avoid when ying oat the downer,
fc riser pping and any horizon ines mst slope
toward the ate eat ole or convection eo When
[pumps are use ince, tale eed ec
ton
‘Transfer line exchanger piping shown in Exhibit
749. Tals exanple shows how the hese product,
‘tet of profs fice used to generate sea,
‘The main Consderston is the downcomer a see
piping Denween the stam deur abd wansler line ex
‘Gangers. Lines should be run wit a pronounced
Slope io avoid undesirable slug flow, which tends ©
‘occur in horizontal piping uns. Vera expansion
Toons cin be essly spring soppored fen the ise
ture. The waner ne exchanger Is supported by two
igs os above the boom channel Mange, anda wok
ley beam is provid a remone the top hed fe main
tenance in th stem, the product line enters the[RIB 749 Traner tne Fachanger ng
‘comecton sein, ets the coll ni the rostover
piping, a then eners the radian tubes through the
top ofthe hear The hested proc ont rom the
‘we eows of aan tubes enters the taser line x
‘Gonger tnt me Dotom, tarstering exe eat
energy to the Sears piping. and ete athe top athe
exchanger
TAIL GAS INCINERATOR AND
WASTE HEAT UNIT
‘Wase gases containing liquids that mis be dspsed
be directed the dare sym are burned nal gas
Incinerator, shown in Exhibit 750, The borizontal inws.
Tear 750
Tl Tal Ga Inder
© Weegee © GE
‘inert is bod deal wo the sack The waste
Prosct ters the vp inlet and daposed of by a
‘burner fang dre note camber Piping sly
_sssocited wid this equipment ncdes fe gi ple
{B,stean,nezogen, and hgud din ult ote
Inthe sce
‘The nase heat recovery uni, lasted in Exit
1751, ses the wae gases of WN 0 LID Ft
{07 C) fom a gas turbine o generate high xd lo
reste steam for plant ue. Ae i be seen hs
‘exhibit, uct burmes located in the ine ofthat
an be wed ithe mine is shut down, posing
‘acs Pat Epo ad ip i