PRESENTATION

ON
FIRED HEATERS

Oct' 2006
 2

Oct' 2006
 FUNDAMENTALS 3

What is a furnace?
Heat is liberated by:

– Burning fuel in air (or oxygen)

– Electrical energy (e.g. resistance, induction, radiant Heating)

A furnace is designed to ‘contain’ the heat energy and prevent its escape
to the surroundings

The furnace provides means of introducing a process material for

heating

Oct' 2006
FUNDAMENTALS 4

Oct' 2006
 FUNDAMENTALS 5

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

Oct' 2006
FUNDAMENTALS 6

Oct' 2006
 APPLICATION OF FIRED HEATER 7

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 OTHERS

Oct' 2006
FEATURES OF FIRED HEATER

Oct' 2006
 FEATURES OF A FIRED HEATER 9

MAIN FEATURES

RADIANT SECTION
SHIELD SECTION Stack
CONVECTION SECTION
FLUE GAS STACK
Convection
AUXILLIARY EQUIPMENT Shield

BURNER
Radiant
AIR PREHEAT SYSTEM
DRAFT SYSTEMS
 FANS & BLOWERS
Burner
DAMPER
SOOT BLOWERS
REFRACTORIES

Oct' 2006
FEATURES OF A FIRED HEATER 10

Oct' 2006
TYPICAL CONFIGURATIONS OF FIRED HEATER

Oct' 2006
 TYPICAL CONFIGURATIONS OF HEATER 12

VARIOUS FACTORS THAT CONTRIBUTE TO

DIFFERENT CONFIGURATIONS ARE

SHAPE OF RADIANT SECTION

ONLY RADIANT OR RADIANT WITH CONVECTION

VARIATIONS IN PLACEMENT OF TUBES

PLACEMENT OF BURNERS IN RADIANT SECTION

Oct' 2006
 TYPICAL CONFIGURATIONS OF HEATER 13

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

CONFIGURATION OF TUBES

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

Oct' 2006
 TYPICAL CONFIGURATIONS OF HEATER 14

VARIATIONS IN PLACEMENT OF TUBES

LOCATION OF TUBES

 REFRACTORY WALL BACKED

 CENTRALLY PLACED

FIRING WITH RESPECT TO TUBES

 SINGLE SIDE FIRING

 DOUBLE SIDE FIRING

Oct' 2006
 TYPICAL CONFIGURATIONS OF HEATER 15

PLACEMENT OF BURNERS
IN RADIANT CHAMBER

FLOOR (UPFIRED)
SIDEWALL
SIDEWALL MULTILEVEL
ENDWALL

Oct' 2006
 TYPICAL CONFIGURATIONS OF HEATER 16

CYLINDRICAL RADIANT WITH VERTICAL TUBES

Most commonly used where duties are

usually small
Tubes are
 Vertically placed
A
 Refractory backed A

 Placed along the inner

circumference of the cylindrical
radiant section
Shield & convection tubes are normally
horizontal
Only radiant configuration is also possible

Section A-A Oct' 2006

 TYPICAL CONFIGURATIONS OF HEATER 17

CYLINDRICAL RADIANT WITH HELICAL COILS

Commonly used where

 Duties are small

 Allowable pressure drop is limiting

 Used in intermittent services

Tubes are

 Helical

 Multi-Helix are also used

With or without convection section

Oct' 2006
 TYPES OF HEATER 18

BOX TYPE WITH VERTICAL TUBES BOX TYPE WITH INVERTED U TUBES
& HORIZONTAL TUBES IN CONVECTION & HORIZONTAL TUBES IN CONVECTION

A A

Section A-A Oct' 2006

 TYPES OF HEATER 19

TWIN CELL BOX TYPE TWIN CELL BOX TYPE CABIN TYPE
WITH VERTICAL TUBES WITH HORIZONTAL TUBES WITH HORIZONTAL TUBES

Oct' 2006
MODES OF OPERATION

Oct' 2006
 MODES OF OPERATION 21

NATURAL DRAFT

FORCED DRAFT

INDUCED DRAFT

BALANCED DRAFT

Oct' 2006
 MODES OF OPERATION 22

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

Stack

Convection
Shield

Radiant

Burner

Oct' 2006
 MODES OF OPERATION 23

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

Radiant
Air

FD Fan
Oct' 2006
 MODES OF OPERATION 24

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.

Flue Gas

Convection Stack
ID Fan
Shield

Radiant

Oct' 2006
 MODES OF OPERATION 25

BALANCED DRAFT OPERATION WITH APH SYSTEMS

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.

Oct' 2006
MODES OF OPERATION 26

Oct' 2006
MODES OF OPERATION 27

Oct' 2006
HEATER COMPONENTS

Oct' 2006
HEATER COMPONENTS 29

Oct' 2006
 RADIANT SECTION 30

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

VIEW FACTORS

Oct' 2006
RADIANT SECTION 31

Oct' 2006
RADIANT SECTION 32

Oct' 2006
 SHIELD SECTION 33

THE SHIELD SECTION CONTAINS THE TUBE ROWS THAT "SHIELDS"

THE CONVECTION ROWS FROM THE DIRECT RADIANT HEAT

Shield
Tubes

Oct' 2006
 SHIELD SECTION 34

TWO IMPORTANT MONITORING PARAMETERS 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

Oct' 2006
 CONVECTION SECTION 35

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

Convection
Tubes

Shield
Tubes

Oct' 2006
 STACK 36

STACK :

IMPORTANT FOR GETTING THE FLUE GASSES OUT FROM

HEATER INTO THE ATMOSPHERE TO SAFE LOCATION.

Oct' 2006
 BURNERS 37

TYPES OF BURNERS
BASED ON FUEL
– GAS FIRING
– OIL FIRING
– 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

Oct' 2006
 BURNER TYPES 38

NATURAL DRAFT BURNER

 REQUIRES LESS PRESSURE DIFFERENTIAL TO PROVIDE THE

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.

Oct' 2006
 BURNER TYPES 39

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
 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

Oct' 2006
 AIR PREHEATERS 40

THE AIR PREHEAT SYSTEM IS USED TO PREHEAT THE

COMBUSTION AIR GOING TO THE BURNERS
SINCE IT COOLS THE FLUE GAS FURTHER, WHILE REMOVING
HEAT, IT IMPROVES THE EFFICIENCY OF THE FURNACE
USING AN AIR PREHEAT SYSTEM WILL RESULT IN OVERALL
EFFICIENCIES ABOVE 90%.

Oct' 2006
 AIR PREHEATERS 41

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

STACK WILL BE REQUIRED

Oct' 2006
 TYPES OF AIR PREHEATER 42

DIRECT APH SYSTEMS

Direct APH systems
(MOST COMMON TYPE)
REGENERATIVE
RECUPERATIVE
– Tube type
– Plate type

INDIRECT APH SYSTEMS

EXTERNAL HEAT SOURCE

APH SYSTEMS

Oct' 2006
 TYPES OF AIR PREHEATER 43

DIRECT APH SYSTEMS

(MOST COMMON TYPE)
REGENERATIVE Indirect APH systems
RECUPERATIVE
– Tube type
– Plate type

INDIRECT APH SYSTEMS

EXTERNAL HEAT SOURCE

APH SYSTEMS

Oct' 2006
 TYPES OF AIR PREHEATER 44

DIRECT APH SYSTEMS

(MOST COMMON TYPE)
REGENERATIVE
RECUPERATIVE
– Tube type
– Plate type
External Heat Source
APH systems

INDIRECT APH SYSTEMS

EXTERNAL HEAT SOURCE

APH SYSTEMS

Oct' 2006
 TYPES OF AIR PREHEATER 45

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

Oct' 2006
 TYPES OF AIR PREHEATER 46

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
EASY TO FOUL & CORRODE(SOMETIMES PORCELAIN
ENAMELED PLATES ARE USED ) AND HIGH UNIT COST

Oct' 2006
 FANS & BLOWERS 47

USE OF FANS AND BLOWERS

FORCED DRAFT FANS

INDUCED DRAFT FANS

PURGE FANS

Oct' 2006
 FANS & BLOWERS 48

FORCED DRAFT FANS

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 FLUE GAS
FROM THE HEATER AND DISCHARGE IT TO ATMOSPHERE DIRECTLY OR
THROUGH AN AIR PREHEATER

Oct' 2006
 FANS & BLOWERS 49

PURGE FANS

 THE PURPOSE OF THE PURGE FAN IS TO DISPLACE ANY

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

Oct' 2006
 DAMPER 50

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

PREVENT FLOW OF FLUID THROUGH

ANY DUCT (ISOLATION DAMPER)
 NORMALLY USED IN FLUE GAS/
COMBUSTION AIR DUCT FOR ISOLATION BYPASS DUCT

PURPOSE OF APH

Oct' 2006
 TYPES OF DAMPER 51

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

Oct' 2006
 TYPE OF DAMPERS 52

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%).

Oct' 2006
 SOOT BLOWERS 53

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
TYPE OF SOOT BLOWERS
RETRACTABLE TYPE
FIXED ROTARY TYPE
VIBRATION TYPE

Oct' 2006
 SOOT BLOWERS 54

RETRACTABLE TYPE
MOSTLY USED FOR HIGH TEMPERATURE & DIRTIER FUEL

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

Oct' 2006
 REFRACTORY 55

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

 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 (2-
3INCHES LAYER OF 4 LB/CUFT AND 1 INCH LAYER OF 8

LB/CUFT) IS USED.
Oct' 2006
 61

COMBUSTION AND RELATED SUBJECTS

Oct' 2006
COMBUSTION AND RELATED SUBJECTS 62

NOX

PURPOSE OF EXCESS AIR

ACID DEW POINT OF FLUE GAS

Oct' 2006
 NOX AND OTHER CONSIDERATIONS 63

THE FIRED HEATER INDUSTRY HAS CONCENTRATED ON THE

TWO PRIMARY SOURCES OF NITROGEN OXIDES (NOX)

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

Oct' 2006
 NOX AND OTHER CONSIDERATIONS 64

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

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

Oct' 2006
 PURPOSE OF EXCESS AIR 65

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

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

SMOKE

Oct' 2006
 PURPOSE OF EXCESS AIR 66

COMPLETE COMBUSTION

 COMPLETE COMBUSTION IS ACHIEVED WHEN ALL THE FUEL IS

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

Oct' 2006
 ACID DEW POINT 67

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

Oct' 2006
 ACID DEW POINT 68

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

Oct' 2006
 69

PROCESS CONSIDERATIONS

Oct' 2006
 PROCESS CONSIDERATIONS 70

PRIMARY CONSIDERATIONS
CLIENTS REQUIREMENTS
APPLICABLE STANDARDS

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.

Oct' 2006
 EXCESS AIR CONSIDERATIONS 71

(A) NATURAL DRAFT:-

GAS FIRING : 20%

OIL FIRING : 25%

(B) FORCED DRAFT:-

GAS FIRING : 15%

OIL FIRING : 20%

Oct' 2006
 GENERAL CONSIDERATIONS 72

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):

WITHOUT APH=1.5% WITH APH=2.5%

ARCH PRESSURE:
NORMAL VALUE -2.5 mm WG

Oct' 2006
 BURNER 73

GENERALLY THERE SHOULD BE MORE THAN ONE BURNER IN A

FURNACE

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

Oct' 2006
 BURNER 74

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

FLAME DIMENSION: FLAME IMPINGEMENT ON TUBES,

REFRACTORY & ADJACENT BURNERS SHALL BE AVOIDED

Oct' 2006
 BURNER 75

NO. OF BURNERS MAX./NOR. HEAT RELEASE

<5 1.25
6-7 1.20
>8 1.15

MIN PILOT HEAT RELEASE 20000 KCAL/HR

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.

Oct' 2006
 BURNER 76

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.

Oct' 2006
 BURNER 77

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

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

Oct' 2006
 RADIANT SECTION DESIGN 78

RADIANT AVERAGE FLUX ( KCAL/HR/M2 ):

CRUDE 32500
VACUUM / NAPHTHA / DHDS 27100
DELAYED COKER / VISBREAKER 25000

PROCESS MASS VELOCITY (KG/S/M2)

CRUDE HEATER 1200 TO 1700
REBOILERS 700 TO 1200
HOT OIL HEATERS 1700 TO 2200
HYDROTREATERS 700 TO 1000

MAXIMUM FILM TEMP SHALL NOT BE EXCEEDED

MAXIMUM METAL TEMP SHALL NOT BE EXCEEDED

Oct' 2006
 RADIANT SECTION DESIGN 79

VERTICAL CYLINDRICAL HEATERS: H / D < 2.75

HORIZONTAL TUBE HEATERS: 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

Oct' 2006
 CONVECTION SECTION DESIGN 80

FLUE GAS MASS VELOCITY ( KG/S/M2):

NATURAL DRAFT : 1.5 - 3.0
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

Oct' 2006
 CONVECTION SECTION DESIGN 81

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

Oct' 2006
 STACK DESIGN 82

STACK IS DESIGNED TO MAINTAIN -2.5 MMWG PRESSURE AT

MINIMUM 120% OF DESIGN HEAT RELEASE WITH DESIGN EXCESS AIR &
MAX. AMBIENT TEMP

• TOTAL DRAFT GAIN = DRAFT GAIN IN CONVECTION

+
DRAFT GAIN IN STACK

• TOTAL PRESSURE LOSS = PRESSURE LOSS IN CONVECTION

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

• NORMAL FLUE GAS VELOCITY IN STACK:

NATURAL DRAFT 8M/S

INDUCED DRAFT 15 - 20 M / S

Oct' 2006
 FORCED DRAFT FAN 83

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
Oct' 2006
 FORCED DRAFT FAN 84

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

BUT MORE RELIABLE

MOC OF CASING - CS

MOC OF IMPELLER - CS

Oct' 2006
 FORCED DRAFT FAN 85

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

Oct' 2006
 INDUCED DRAFT FAN 86

- ID FANS ARE DESIGNED WITH MIN 20 % MARGIN

OVER FLUE GAS FLOW RATE CORRESPONDING TO
DESIGN HEAT RELEASE

- 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 ~12 M / S
- MOC OF CASING - CS / SS
- MOC OF IMPELLER - CS / SS / CORTEN STEEL
Oct' 2006
 INDUCED DRAFT FAN 87

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

Oct' 2006
 DRIVES FOR FAN 88

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

QN , H  N2 , P  N3

Oct' 2006
 AIR PREHEATERS 89

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

Oct' 2006
 SOOT BLOWERS 90

• 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

• SOME TIMES STEAM LANCING NOZZLES ARE

PROVIDED TO REMOVE SOOT FOR SMALLER
INSTALLATIONS

Oct' 2006
 HEATER COIL METALLURGY 91

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

Oct' 2006
 METALLURGY 92

FOLLOWING TUBE MATERIALS ARE NORMALLY USED:

- CARBON STEEL ~ 540 DEG C

- LOW ALLOY STEEL (P11,P22) ~ 650 DEG C
- HIGH ALLOY STEEL ( P5, P9) ~ 650- 705 DEG C
- AUSTENITIC STAINLESS STEEL ~ 815 DEG C
( SS304 / 310 / 321 / 347)

FOLLOWING SUPPORT MATERIALS ARE NORMALLY USED:

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

HEATER CASING IS ALWAYS MADE OF CARBON STEEL

Oct' 2006
 METALLURGY 93

TYPICAL TUBE MATERIAL FOR VARIOUS SERVICES:

CRUDE P5
VACUUM P9
DELAYED COKER / VISBREAKER P9
HYDROTREATER SS 321 / SS 347
HOT OIL HEATER CS
REBOILERS CS

Oct' 2006
TYPICAL INPUT DATA FOR THERMAL DESIGN OF FIRED HEATERS 94

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)

Oct' 2006
TYPICAL INPUT DATA FOR THERMAL DESIGN OF FIRED HEATERS 95

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

Oct' 2006
TYPICAL INPUT DATA FOR THERMAL DESIGN OF FIRED HEATERS 96

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

Oct' 2006
THERMAL DESIGN OUTPUT FOR FIRED HEATER 97

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

Oct' 2006
THERMAL DESIGN OUTPUT FOR FIRED HEATER 98

DATA SHEETS FOR BOUGHT OUT ITEMS

 BURNERS

 FANS

 DAMPER

 SOOT BLOWER

 APH

Oct' 2006
FLUE GAS O2 % VS EXCESS AIR % 99

Oct' 2006
 AIR PREHEAT EFFECTS 100

INCREASING THE COMBUSTION AIR TEMPERATURE FROM 15.5

° CTO 200 ° C HAS THE FOLLOWING EFFECTS:

IN ALL RADIANT HEATER

1. FLAME TEMPERATURE INCREASES BY APPROX 100° C.

2. THE BWT CHANGES BY FEW DEGREE.

3. THE FUEL OUT LET DECREASES BY 10-12 %.

Oct' 2006
 AIR PREHEAT EFFECTS 101

ON RADIANT –CONVENCTION HEATER,

1. DUTY SHIFTED FROM CONVENCTION SECTION TO RADIANT SECTION.

2. THE RADIANT FLUX RATE INCREASES BY 7-10 %

3. THE HOTTER FLAME TEMPERATURE THE RADIANT EFFICIENCY.

4. LESS FUEL FIRING DECREASES THE FLUE GAS RATE AND THE HEAT

PICKUP IN THE CONVENCTION SECTION.

Oct' 2006
 FUEL EFFICIENCY 102

FUEL FIRED = PROCESS ABSORPTION + HEAT TO STACK+ RADIATION

LOSSES.

PROCESS ABSORPTION
FUEL EFFICIENCY =
FUEL FIRED

Oct' 2006
THANK YOU

Oct' 2006