Fired Heaters - Introduction

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Mar 2014
FIRED HEATERS
INTRODUCTION
DEDICATED TO:
Lynn Evans and Bill Handel, Foster Wheeler, UK

Robert D Reed, John Zink, USA
Today we are able to see further and farther
standing on the shoulders of such giants
Acknowledgment
API RP 530/ 535 Std 560

Project Standards/ Specifications
Pictures from: many sources, suppliers, internet
Fired Heaters Training 1 - 3 days

Introduction (100 slides)
Design (40 slides)
Operations (45 slides)

Plant energy flow; Fired heaters - Source of high temperature heat

Vertical Cylindrical, Box, Cabin, Multi-cell

Fired Reactors
Ethylene Cracker; Steam Hydrocarbon Reformer; EDC Cracker;

Visbreaker; Delayed Coker
Other Types
All Convection; Water Bath

Firing
Single or double sided; Floor up-fired, End or Side wall fired; Multilevel fired and Roof or Down-fired
Burners
Gas or Oil or Combination; Low NOx

Draft
Natural, Forced, Induced and Balanced

Components
Tube & Tube Supports; Soot blowers, Stack, Refractory

Waste Heat Recovery:
38
- 6 ~ 8 hours
- 3 hours + 4 hours in Worksheet
- 2 ~ 4 hours
Introduction
Process Fired Heaters
Since
1976
Steam Generation; BFW Heating, Air Pre-heater, Gas Turbine

Exhaust WHRU
Design
Firebox Heat Transfer A Primer
Radiant Section Sizing
Convection Section Sizing
Coil Design
Stack
Burners
Refractory System
Operations
Safety Alerts
Firebox Explosion
Excess Air Control
Draft Control
Fuel & Firing Control
Heater Control
Coking & Hot Spots
Topics
Furnaces: Direct or indirect heat transfer to solids or

fluids - with physical / chemical changes
Smelters, Ovens, Incinerators, Thermal Oxidizers
Rotary Kilns - Cement, Coke Calcination
Process Fired Heaters, Boilers
Process Fired Heaters

Plant energy flow; Heaters - Source of high temperature heat
Fired Reactors
Ethylene Cracker; Steam Hydrocarbon Reformer; EDC Cracker;
Visbreaker; Coker
Other Types
All Convection; Water Bath
Firing
Single or double sided; Floor up-fired, End or Side wall fired;
Multi-level fired and Roof or Down-fired
Topics
Burners
Gas or Oil or Combination; Low NOx
Draft
Natural, Forced, Induced and Balanced
Components

Tubes &Tube Supports

Soot blowers
Stack
Refractory
Waste Heat Recovery

Steam Generation; BFW Heating
Air Pre-heater
Gas Turbine Exhaust WHRU
PROCESS FIRED HEATERS
Process Unit Energy Flow

All energy inflows end up in atmosphere
Cooling
Product #1
Product #2
Heating
Process
Units
Feed
Feed at ambient
temperature
Product #9
Process at elevated
temperature
Product #n
Products at ambient
temperature
Energy Inflow
Energy Outflow
Electricity
Steam
Fuel
Products
Process
Units
Flue Gas
Cooling Medium
Crude Distillation Unit

CW
110C (24%)
40C
Product
30C
Crude Oil
Top Reflux
125C (4%)
80C
Circulating Reflux
CW
Product
CW
Product
CW
Product
180C (6.5%)
Crude Heater
Crude Column
220C (12%)
150C
Circulating Reflux
250C (7.5%)
350C
260C (7%)
HX Train
325C (39%)
250C
Long Residue to
Downstream Units
Crude Distillation Unit

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Crude Column
Crude Heater
HX Train
Heat Exchangers Save Energy

Energy Inflow
Energy Outflow
Electricity
Products
Steam
Flue Gas
Cooling
Medium
Fuel
Process
Units
Recycled
Heat,
thru Heat
Exchangers
Fired heaters are large fuel

consumers and major sources of
emission
Heat Exchanges
recycle heat; save

energy
Fired Heaters,
Boilers and Motors
provide energy
Heaters provide
high temperature
energy, where
steam is NOT
economical or
viable
Development
Open Pan - See one

in Digboi Refinery
Bridge Wall
Similar to boilers
1850s: Batch mode; Open pan retorts and pot still. 36-hour runs + 24-
hour to scrape tar, coke and foreign matter. Deposits caused

overheating, leak and fire
Continuous, each shell at a higher temperature than its predecessor
Milton James Trumble (1879-1931).. 70 patents credited with developing
continuous run process heater
Temperature: 300 to 1,100C. Duty: 0.5 to 150 MW

Direct radiant heat was considered bad 1910
A bridge wall between firebox and all convection coil
Low inside tube velocity, salt deposits and radiant heat from hot flue
gas overheated the tubes coke deposit + ruptured tubes

Removal of overheated tubes, overloaded the rest, aggravating the
situation. Vicious cycle
Once designers realized how to distribute radiation from hot flue gas over a large surface and
maintain good coil tube velocity, modern design evolved
Heat absorption by tubes reduces gas temperature to convection section and keeps firebox cool
Features
Heat transfer coil:
CS, C-Mo, Cr-Mo, Cr-Ni
Stack
Damper
In
250-700C
Convection Section
Rectangular box on top / side of firebox

Convection Transfer (major) + Radiant (minor)
Shock or Shield Rows of Tubes
700-900C
Out
Flue gas recirculation in firebox heats

backside of tubes and refractory
Vertical cylinder or rectangular box
Radiant Section/
Firebox
Steel casing
with refractory
Burner
Firebox/ Radiant Section Heat transfer:

Direct flame radiation (minor) +
CO2 /H2O in flue gas radiation (major) +
Refractory re-radiation (minor) +
Convection between N2/O2 and CO2/H2O (major)
Convection from flue gas to tubes/refractory (minor)
Components
Stack/ Duct
Convection
Section
In
Convection Tubes
Radiation
Section
Shield
Tubes
Peep Hole
Access Door
Radiant section/ Firebox

70-80% absorbed duty or
Tube
Support
Radiant Tubes
Hearth Platform
Out
Preheats feed
20-30% duty
Recovers heat from hot
flue gas
Plain + Extended surface
Breeching
Refractory
Wall
Convection section
55-60% fired duty

Houses burners
Based on Service:
Continuous/ Intermittent / Start-up
Based on Configuration:
All Radiant; Radiant & Convection; All Convection
Based on Structure or Firebox:
HEATER TYPES
Vertical Cylindrical All Radiant
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No Convection Section
Coil Support
All radiant, no convection < 2.5 MW duty

Low efficiency, 60%. Start-up heaters
Coil - Vertical hair pin or Helical
Helical - good for free draining in molten salt service
Coil removal by removing stack
Old designs may have baffle plate on radiant top
Vertical Cylindrical
Return bends on top and
bottom form hairpins in a circle
Radiant/ Convection
Stack
Horizontal
Convection
Section
Radiant
Section
3 - 30 MW duty. General service. Common type. Good
efficiency. Beyond 30 MW firebox is too tall 18m (>60)

Vertical hairpin coil in firebox; horizontal tubes in convection.
More coil passes. Symmetrical & uniform heat absorption

Burners in a circle on floor. Vertically up fired
Smaller foundation/ plot area / cost
Prefabricated
Tubes pulled up by stack davit
No separate tube pulling plot area required

Access platforms at hearth , arch & damper; Ladder to arch
Tube pulling
davit
Duct
Ladder
Flue gas ducting to / from grade mounted air pre-heater
Isolation
Damper
Box - Arbor
Good for low pressure drop vapour service -
Reactor (Catalyst Reformer) feed heaters

Arbour or wicket coils avoid return bends
(source of high pressure drop) and provide many

parallel flow paths (low pressure drop)
Box heaters have flat arch; Cabin heaters have sloped arch
Box
General service. Vacuum heater
Square or rectangular cross section
Tubes along side wall
Burners on floor, side or end wall
Minimum return bends. Bends housed
inside firebox or in external header box

Extra tube pulling space in plot area
Boxes stacked
during construction
Internal View
External View
End Access Door
Tube Support
Burner Holes
Sloped arch
Cabin
Peep Holes
End Tube Sheet

- return bends
End Access Door
Hip or Arch
Large duty, 60 MW
Single cell Crude Heater

Box heaters have flat arch.
Usually square cross-section

Cabin heaters have sloped arch.
Usually rectangular cross section
Box Twin Cell
For large duty, 30-75 MW,

such as Crude Heaters
Bridge wall fired for Delayed
Coker and Visbreaker

Zoned firing allows controlled
cracking and soaking
Flat Flame Burner

Bridge Wall fired-upon
Double fired twin cells for fired
reactors, such as EDC Cracker

Tubes in center and burners on
either side
Box Multi Cell

For very large duty heaters
One large hi-intensity burner or multiple
burners/ cell
3 x 2 multicell vertical tubes

4 burners/ cell
Center tubes may be double-fired
Convection Section
On single service - same as that of radiant
Different from radiant
In multi-service - radiant fluid pre-heat, air preheat,
BFW (Boiler Feed Water) heating, Steam Generation,

Steam Superheating
Common convection ~ for a few heaters
Convection coils may come in pre-fabricated bundles
Feed
Steam
Convection Section
Top or side mounted

May have additional firing
Bottom 2 rows (shock tubes) are bare -
receive firebox radiation

Low flue gas side heat transfer
coefficient - extended surface tubes
above shock tubes
Finned for gas and light oil firing
Studded with oil firing
Extended surface attain heat flux as high
as radiant at low cost
Studs
Fins
Process Heat Duty

Equilibrium Flash Vaporization Chart
Heat liquid/ vapor/ gas/ 2 phase

Vaporize feed
Preheat in convection + soaking / mild
cracking in radiant
Preheat in convection + reaction

Ethylene Cracker, EDC Cracker and
Hydrogen Reformer
Pressure
Delayed Coker and Visbreaker

0% Vaporized
60% Vaporized
Temperature
Refinery Heaters
Heater
Crude
Vacuum
Visbreaker
Coker
FCC Charge
270-380
350-400
350-400-500
350-500
270-370
P out (P), bar
3-4 (10-12)
50-100 mmHg
(6-8)
18-20 (20-25)
5 (30-35)
3 (3)
Vapor in/out, %
30-50
20-30
30-80
50-80
40 (12,000)
25 (8,000)
25 (8,000)
32 (10,000)
32 (10,000)
60 (200)
40 (130)
44 (150)
40 (140)
32 (110)
Box / Cabin
Box / Cabin
Twin Cell
Twin Cell
VC
2-4 x 6
2-4 x 4/6/8
2-4 x 4/6
2-4 x 4
2-4 x 6
T in/ out, C
Flux, kW/m
(Btu/h.ft)
Duty, MW/tpa
(MMBtu/100 kpbd)
Type
Coil
Design Tip: Higher the flux, lower is radiant section and heater cost. Flux is decided
by coking, product discoloration that can lower its value and decomposition
Refinery Heaters
Vacuum: Dry (no steam) or wet (with steam)
Vacuum, Visbreaker and Coker:
Steam injection in radiant coil return bends
Vaporizing heaters: high fluid temperature may occur
a few tubes ahead of outlet

Other refinery heaters:
Charge, H2 Reformer, Bitumen Heater

H2S off gas Incinerator, Bitumen Incinerator, CO Boiler, Coke
Calcination Kiln
Crude heater may dispose of off-gases
Plot Size
Plot Area
30
Shell DO/ Tube Length, m
25
Box Cabin
20
15
10
0
0.0
10.0
20.0
30.0
40.0
Heat Fired, MW
50.0
60.0
70.0
FIRED REACTORS
Fired Reactors
Visbreaker: Mild cracking of heavy ends
Delayed Coker: Severe cracking of heavy ends
EDC Cracker: Severe cracking
Gas / Naphtha cracker: Severe cracking
Hydrogen Reformer: Catalytic conversion of HC and steam to
produce H2, CO2, CO
High heat density (flux) - kW/m (Btu/h.ft)
Usually double fired uniform heat transfer

minimum metal temperature / stress/ oxidation

minimum coking / carburization
Many small burners fire on a wall, to keep it red hot pure and
uniform refractory radiation

Multi-level burners to match firing rates to changing reaction
demands
Ethylene Cracker
Feed
Dilution Steam
TLE: Quickly quenches

effluents, avoid coking
and secondary reaction
TLE Transfer Line

Exchangers
Steam
Generation
Out
In
In
Out
Multiple inlet small

coils for high heat
transfer
W Coil
Furnace
4 tubes / pass
4 passes / firebox
Large diameter outlet

to minimize coking
Cracks gas and liquid HC with steam. High coil outlet temperature
(COT). Heavier components converted into lighter C2=, C3=

Steam: A diluent and refractory material
High heat density (flux) and short residence time
Ethylene Cracker
High alloy cast tubes
Uniform heat distribution with double-sided and multi-level firing

Carburizing reaction; mirror free inner surface free of boring/ honing
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ID Fan
ID Fan
Steam Drum
Steam Drum
Feed
Dilution
Steam
TLE
TLE
Cross Over
Double sided firing

with many small
burners keeps both
side walls red hot, to
assure uniform heat
transfer to tubes
TLE
Tubes
Inlet Manifold
Hydrogen Reformer
Natural gas or naphtha + steam heated in a catalyst
packed tube to high temperature ~ 800-980C

(1500-1800F), to convert HC into H2, CO, CO2
High heat density (flux)
Hi temp: Tubes of 800/800H; HK40, HP
Double sided top firing with large burners.

Flue gas exits via bottom tunnel
Top fired
Convection
Air Preheater
Section
Side fired
Convection
Section
Hydrogen Reformer
Flexible pigtails connect tubes to inlet

manifold. Pigtails help accommodate
tubes thermal growth
Flue Gas
Side Wall Burner

Tubes
Catalyst inside tubes

Tubes
Hydrogen Reformer
Uniform heat distribution with double-sided and multi-level firing
Red hot refractory
Inclined red hot

side walls
Flat Flame Burner

EDC Cracker
Double-sided multi-level firing

Flat flames firing on walls avoid

tube impingement
Red hot refractory
Uniform heat distribution + Zoned
heating
Radiant coils installed / removed
via arch
Natural or forced draft
FIRED HEATERS OTHER TYPES
All Convection Flue Gas

Recirculation
150-250C
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Heater Coil
Heater Coil
650-800C
Flue gas re-circulated to reduce flame and flue gas temperature to 650-
800C, eliminating radiant heat. Controlled film temperature

Hi flue gas flow; hi convection heat transfer in finned all convection bank
To 500C. To 15 MW. Compact
Easy to maintain absorption rates by adjusting recirculation
Service: regeneration gas for absorption, pipeline oil, crude oil, water/oil
emulsions, LPG, and other sensitive stocks
Uniflux or Radiant
Convection Heater
3 Parts
(1) Fuel Reactor or Combustion chamber. Short

flame. No impingement
(2) Heat Exchanger - radiation + convection
(3) 26 gauge 430 SS liner on fibre insulation on
CS casing. Minimal stored heat. Avoids coking.
Positive pressure
80% eff. With economizer 95%
Convection transfer - more uniform heat flux
Less chances of hot spots
Low stored energy; Fast response to changing
heat load; less chances of coking after a trip
Forced draft - high velocity prevents flashback
Compact
1100F
1000F
2000F
900F
Uniflux Heater
Applications. 0.3 to 20 MW (1 to 70
MM Btu/h
Heat Transfer Fluid
Regeneration Gas
Water; Glycol-water
Air
Steam Superheaters
Crude Oil; Emulsions
Vaporizers
Water Bath Heater

Indirectly heats oil & gas well fluids, oil-
water emulsion
Flue gas in fire tubes in lower part heats
water; hot water heats HC in upper part
Avoids direct contact - flue gas and HC coil
Max water temperature fixed by water side
pressure. Good for sensitive fluids
Glycol reboilers to 12 MW; gas pipeline, well
fluid heaters 2 MW
In high pressure reduction service where
hydrates may form,

Gas first preheated and pressure let down in

an external choke and then post-heated
Internal finning/ turbulators in exit firetube improve efficiency
Caution: Do NOT use to heat oilwater emulsion; external salt

deposit - overheated / burst firetube
Note: Instead of water LP steam
to heat to 70 to 105C; hot oil to
heat regen gas to 315C and
molten salt heater to heat to 200
to 425C
FIRING
Firing
Floor fired: Floor 2 to 2.7m above grade to allow passage.

End fired: Floor raised marginally - air circulation to keep foundation cool.
Floor below and around heater paved and curbed to avoid oil accumulation.
Sidewall Floor
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Floor
End
Floor fired: Vertically up. Many burners enhance uniform heat distribution
Side wall fired: Usually against a fire wall in firebox center
End wall fired: Minimum burners with long flames. Eliminates elevated
floor; reduces costs. Low average flux. Flux mal-distribution high
Firing
Burners in a lane in a rectangular box and in a circle in a
cylindrical box
Top firing - Forced draft. If FD fan fails, flame may lift up and
lick tubes
Radiant Tubes Bottom Guided Top Outlet
Top Fired
Burners in a circle
Firing
Side double sided

1 or 2 levels
Double sided
T0p and side wall-fired as in reactor heaters
Wall fired
May fire on central wall (bridge wall) for
uniform heat in delayed coker / visbreaker

Bridge wall fired
Side double sided

Multi level
Top double sided

BURNERS
Burners
Purpose: To produce and direct flame and

hot gases in a preferred manner in firebox
Type: Oil, Gas, Oil & Gas Combination

Natural draft (80% of refinery heaters); Forced draft
Burner throw and flame shape to match firebox to avoid
flame and hot gas impingement

To provide symmetrical heat distribution
Duty
30 MW (100 MM Btu/h) High Intensity
0.5-5 MW; (1-15 MM Btu/h)
Secondary Air
Concentric doors
Natural draft: 5-15 mm WC
(0.15-0.6WC)
Forced draft: 100-150 mm WC
(4-6) WC
Pilot Gas
Fuel Gas
Atomizing Steam
Gas Manifold
Primary Air
Fuel Oil
Removable Oil Gun
Tramp air warning: Fully closed concentric

cylinder type air doors leak up to 50% air
Combination Oil & Gas Natural Draft
Burners
Fuel Pressure @ Turn Down OR allowable turndown Consider burner tip as an orifice and calculate
With or without preheated air

Noise
100 to 110 dBA. Noise attenuation plenums and mufflers for 85 or 90
dBA
A-weighting ~ human ear response of Sound Power Level SPL
Fuel gas/oil gun - distributes fuel in air

Refractory tile
Shapes and stabilizes flame
Air orifice, controlling air flow
Viewing Ports: To observe pilot and main flame;
to light pilot and main flame
Burner changes to improve flame shape and firing may be justified;

but not for improving fuel efficiency, unless FD burners are selected
Oil Gun
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Gas Tip(s)
Primary Tile
Secondary Tile
Burners
Pilot
Plenum / Windbox for air
distribution and control
Oil Gun
Muffler
Plenum
(Windbox)
Primary/secondary air doors

Plenum or muffler - noise reduction
Common or individual burner plenum
2 concentric slotted cylinders that
slide over each other
single slotted cylinder with damper blades
single / louvered damper at burner plenum/ windbox
Adjust to get equal air
Dampers to be lockable to avoid inadvertent
Air Damper
Louvered Air Damper
closure or on vibration
Opposed blades good
Individual burner damper control is expensive if > 4 burners

Easy to adjust total flow in FD, with fan inlet guide vanes
Burners - Pilot
Kitchen LPG burner = 6,000 to 8,000 Btu/h,

10 times smaller than a single pilot
Constant burning gas burner 22 kW (75,000 Btu/h)

To ignite main burner over full operating range
Not to provide stability to main burners

Lighted by electric igniter; portable igniter, gas torch
and kerosene soaked rag

Usually gas fueled. Smaller tip holes. Filter (#80 mesh or
25% min hole size). Basket type superior to Y-strainer
Should be stable even when main fuel is lost

Usually kept always lit
If no overheat under no-flow or in intermittent service;
to keep refractory dry; to avoid nuisance trips

If fuel is ethane and heavy gas
When fuel gas mol weight change causes swing in
regulated pressure
Burners Flame Deduction

Flame Deduction Rods & Scanners
Rod: Flame, an ionized reaction zone. Low voltage
applied to rod results in a current thru the flame and

grounded burner assembly
UV Scanners - for main and pilot flame. 1 per/burner; 2 if
fuel gas is not processed
UV: Site at first 1/3 of flame
Self-checking, 6 seconds
Good response in 200-400 nm spectrum
Gas Burner
Gas Tip
Raw Gas or Nozzle Mix

Most refinery burners
Air flow independent of fuel flow;
Air
decided by draft
Air Damper
Concentric Cylinders
Can handle 100-250% variation in HHV/
LHV based on supply pressure

Quieter. No flash-back risk
Large turndowns; lower gas pressure
Gas Tip
Pilot
Burner Tile
Air Inlet
Pilot
Low heating values

HV 300 Btu/ft
Min 50 Btu/ft with CO or H2

Separate guns for wide changes in
heating value and/or pressure
Prone to coking and tip blockage
Plenum
(Windbox)
Air Damper
while firing unsaturates or with liquid

carry over
Turndown 1:5 if supplied 1.75-2.5 barg (25-35 psig). Low 0.35 brag (5 psig). Min 0.07 barg (1 psig)
Gas Burner
Gas Tip
Pre-Mix
Pre-mix/ Inspirating burners
Secondary Air
Fuel flow via venturi pulls in primary
air 30-100%; balance secondary

Short dense flames
not affected by wind gusts
Xs air unaffected by draft. Good for ND
Primary Air
Gas Spud
Pilot
Look: Gas nozzle acting as an
injector, as in a Bunsen Burner
Mol Wt + HHV variation: 10-50%;
Fuel gas pressure affects air-pull

Flash-back: if fuel velocity < flame
speed e.g. Lab Bunsen Burner
Gas Tip or Spider

Secondary Air
High H2. Turndown limited

Pre-Mix not recommended if H2 > 70%
Caution: Preheated air flash back
Turndown 1:3 if supplied at 1.75-2.5 barg (25-35 psig).
Good to have 5 barg (75 psig). Min 0.2 barg (3 psig)
Pilot
Primary Air
Gas Burner
Gas burning: Smaller flame
Good for radiant wall burners
Flame spreads across burner tile and wall

refractory. No forward projection into
firebox
Hydrogen is an efficient fuel - but has
no visible flame
Flat Flame Burners - for firing on wall

Gas Burner with tiles
Gas Forced Draft
Oil Burner
Pressure and air atomization good for light oils. Air

expensive ~ compressor. Steam for atomization: 15-50%
oil flow. Inside mix takes less steam. Dry/ superheated
steam. High velocity Steam shears oil; foams/ emulsifies oil
Usually Oil & Gas combination burners

Bigger flames. Burns after vaporization or
atomization to 10-50
Mechanical spray or air atomization for
light oil; Steam atomization for heavy oil
Small tip passages - heavy oils difficult to
atomize
Superheated steam to 7-10 barg (100-150
psig); 20-27 barg (300-400 psig) for resids
Unburnt light oil (naphtha) may

evaporate dense vapor cloud and
explosion. Safety interlock required to
shut-off fuel to remove gun.
Secondary Air
Steam may vaporize light oils like naphtha
vapor lock
Pilot Gas
Temp to get 20 - 25 CS viscosity at burner Fuel Gas
Different oils ~ different viscosity index Atomizing Steam
Line loss may lead to high viscosity at burner.

Insulate and heat trace
Gas Manifold
Primary Air
Fuel Oil
Removable Oil Gun
Turndown 1:3 if supplied at 5-8 brag (75-120 psig). P= 3-5 barg for steam atomization. Steam at a dP of 1.5-2.0 bar
(20-30 psi) at 15-30% oil flow. Pmin = 5-7 barg (80-100) for pressure. For 1:3 turndown, P = 45-60 (700-900 psig)
Steam Ports
Oil Burner
Tip
Ports
Steam
Oil
Oil Orifice
Steam Atomization Vs Steam Assist
Steam atomization - oil at lower pressure; dp of of 1.5-2.0 bar
(20-30 psi); more steam. 15-30% of oil flow. Large fuel orifice;
less prone to plugging
Oil Orifice
Light oil (naphtha)
may require separate Oil

oil and steam tubes Steam
to avoid vapor lock.
Steam Orifice
Steam assist - oil at higher pressure - steam kept at 7-10 barg
(100-150 psig). Less steam. 10-20% of oil flow. High dP at part

load increase steam rate. Smaller oil orifice; prone to
plugging. Good for high release burners
Foot traffic on yard piping can damage insulation and lead to wet steam water hammer; wire draw of
valves and slug flow to burner and soot blower. Foot traffic can similarly affect fuel oil viscosity to burners
Oil Burning Issues

100% recirculation to maintain back-pressure good during
turndown; minimize heat loss
Dead-end piping chilled oil, poor atomization/ combustion

Flushing connection for residual oil
High asphaltenes or CCR >10% oil prone to tip coking and
plugging; soot and particulate emission

Some cracked oils may not blend well with light cutter stock
asphaltene precipitation and polymer formation; may crack in oil
gun; tip fouling and plugging

Premature vaporization of low boilers pulsating flames. Have
separate oil and steam tubes
Added cost - heating, pumping, atomizing steam; studded
tubes; higher Xs air; large flames - large fireboxes

Easy to switch from oil to gas; difficult to go from oil to gas.
Plan at design stage. Better ask for combination
A yellow-white oil flame is better than a dazzling white flame too much Xs
air. Puffing in firebox is dangerous, wind disturbance or blockage of burner tip.
Oil Burning Issues

Heat to pumping temp only in storage tanks to avoid
polymers. Return oil to pump suction and not to tank
Special Oils

Asphalt: High temp loosens mill scales; plugs burner ports & filters
High aromatics: Increase atomizing steam
Water in oil or steam: Fire flies; sparky flame and smoke at stack
Cat Cracker Oil: Fine abrasive cat solids; erodes atomizers & filters
High metal - Vanadium/ sodium: High ash load + tube supports
corrosion; Eutectic attack on refractory
High Sulfur: Cold end corrosion. V2O5 is a catalyst promoting SO3
Solids: Coke, scale, cat fines; polymers damage oil ports
Sludge from storage: flame out and explosion
Oil from different sources: Changing viscosity at burner
Pyrolysis and polymer oils: Unburnt and particulate emission
Eutectic? V2O5 + SiO2/Al2O3 low melting compounds that damage refractory rapidly
LOW NOX BURNERS
NOx
NOx
Low NOx Burners
Excess Air, %
3 sources
1.
2.
3.
Thermal NOx >1,100C (2,000F)

Exponentially with temperature
Depends on O2/ N2 concentration and residence
time in flame
Prompt NOx when fuel rich. Thermally
disassociated N attaches to HC instead of O
HCN, usually when fuel is staged and
Fuel NOx - fuels with N e.g. NH3. N2 in gas fuel
does not contribute to NOx
NOx
More, 95-98% NO; balance NO2, NOx

NO NO2 after stack discharge
Regulations define limits in terms of NO2
Flue Gas Temperature

Fuel Rich Air Rich
NOx

From: API RP 535
Air: Fuel Ratio
NOx
Nitrogen oxides form during combustion
Air Temperature
Fuel H2, vol %
unsatuates
Fuel oil produces 3 times more NOx than gas;
generally not used in low NOx projects
NOx
H2 flame temp and NOx. So also C4+
Liquid Fuel N2, wt %

NOx with Xs air in raw gas burner. Peaks at 7-8% O2 and then declines. NOx with Xs air in pre-mix burner
Low NOx Burners 60% Reduction

Air or fuel is staged (lean or rich mix) to reduce flame
temperature. 0.05 Vs 0.13 lb NOx /MMBtu
Staged air - Early approach: 40% air into 100% fuel. Balance in
2nd stage. Cooler and O2 starved flame less NOx

Staged fuel - now: 30% fuel into 100% air; Balance in 2nd stage.
Only with gas fuel. Not with oils since ports get too small
Tertiary Air
Secondary
Fuel
Secondary Air
Oil & Steam
Gas
Primary Air
Air
Primary Fuel
Low NOx Burners

Internal flue gas recirculation burners:
Cooler and O2 starved flame less NOx

Ultra low NOx Burners: 80-95% reduction.
10-20 ppm
Fuel staging + Internal flue gas recirculation
Steam injection into air or fuel. Expensive
Burner
NOx Level
Conventional Raw Gas
60-100
Staged Air/Fuel
20-60
Staged + Internal Flue Gas Recirculation
10-20
#2 Oil Conventional (Staged Air)
300 (200-250)
#6 Oil Conventional (Staged Air)
120-150 (95-110)
From: Successfully design fired heaters using ultra-low-NOx burners, Ahamad S and Vallavanatt R, HP, 6 Jan 2013
Low NOx Burners

Special Issues
Longer flames with staging;

Firebox dimensions to suit
Smaller burner ports mill scale plugging. Ffilter-coalesecer (0.3

0.6) + Superheater + SS piping after KOD

Bigger burner tile diameter + bigger flame = bigger firebox
In retrofits, longer flames may lick tubes
Flames from adjacent burners may merge and get longer
Extra 150 mm (6) clearance to tubes. More burner to burner clearance
for effective flue gas recirculation, min 250 mm (10)
VC: Avoid inner circle burners; may not get cool flue gas more NOx
Unstable during turndown
Flue gas recirculation unstable flame when Xs air is low, specially
when floor temperature < 550C (1000F). Recirculation reduced under
turndown as fuel pressure gets low
CFD model: Burner to tube; burner to burner; heat flux; TMT
BWT may go up by 30C, increasing convection section load

From: Successfully design fired heaters using ultra-low-NOx burners, Ahamad S and Vallavanatt R, HP, 6 Jan 2013
Noise
Not talked about!! Or even asked !!!!
Typical noise

30 to 10,000 cps range

A scale 1,000 - 5,000 cps
90 in car at 100 kmph
103 Inside Jet flight
Natural Draft Burners
107 ~ no muffling
93 ~ with primary muffling
84 ~ with primary + secondary
Each 3dB = doubling

Plenum chambers for ND;
Good ducting for FD burners
Burner Noise
Combustion: 30-300 cps; air:
fuel mixing at hi frequency

Fan operation: Hi frequency
Hi frequency most damaging
Firing Direction: Horizontal,
Vertical up and Vertical Down
Upfire floor reverberation +10 db
Many small burners noise

Hi AIT fuels; Hi Intensity
burners noise
High H2% .. 50% H2 by 10 db
Fuel Piping
Gas: Insulate and heat trace, if required
Filter-coalescer + Superheater + SS piping to avoid mill
scale plugging after KOD
All fuel/ steam tappings from top of headers

Individual burner valves location to allow operation
while observing flames
Branch-off a ring header around firebox at peep hole
height
DRAFT
Draft Control
P - Air side - Burner air door + tile
Natural Draft
Met by Firebox stack effect
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FD/ID/Balanced: + Inlet stack, duct, air preheater
Met by FD fans
Damper
P - Flue Gas side - Convn bank, damper and Stack

Natural Draft + FD: Met by Stack
ID/Balanced: + duct, air preheater:- Met by ID fans
P flue
High Draft
Arch
Tramp air + Misleading Xs air + Potential explosion
Low Draft
Air Inlet
Stack
Hot gas + acid gas damage to casing
Wind action impacts draft reading- higher/lower by 5mm

(0.2WC) and air flow. Flue gas velocity impacts draft reading
use multi-hole piezometric head. Probe to be 90 to flue gas flow.
P air
location.
Floor
How flue gas flows
10,255
from vacuum to atmospheric pressure
How flue gases flow from firebox at
vacuum to stack tip at atmospheric

pressure ??
Bernoullis law invalid? Buoyancy Beats
Bernoulli??
30m
Pressure Profile
Air
250C
Damper
10,290
Because atmospheric pressure at stack
tip is less than pressure in firebox
66m
Less than pressure at grade
525C 16m
Arch
10,309
Atmospheric pressure @
Firebox floor = 101.3 kpaa= 10,333 mm WC
66 m of air = 66*air = 78 mm WC
Stack Tip = 10,333 78 = 10,255 mm WC
With salaams to Shang Zhenhua and Abhishek Jha
20m
800C
10,333
Floor
How flue gas flows
10,255
from vacuum to atmospheric pressure

Location
Draft
P, mm P, mm
Gain,
WC
WC
mm WC
Stack Tip
10,255
10,255
Exit = 3
10,258
10,255
+3
Friction
=2
10,281
10,290
Head =
1
10,282
Friction
= 15
10,304
10,309
10,311
10,333
22
Stack Tip
Above
Damper
30*gas
= 21
Below
Damper
Conan
Bank
16*gas
=7
Firebox
Floor
20*gas
=7
Air P,
Draft,
mm WC mm
WC
Pressure Profile
Flue Gas & Air
Damper
8
10,290
10,282
10,290
8 Damper open
Damper Pinched
Note: P below = P above + h + P

At high altitude, atmospheric pressure is low, gas density is
low reducing draft marginally. Air volume to burners goes up
Pinch Stack Damper to reduce arch draft to 1-2 mm
22
Arch
10,309
10,304
10,311
- ive +ive
22
10,333
Floor
Natural Draft
Firebox chimney effect
Sucks air thru burners
Stack
Stack friction + P of convection bank and damper
Arch kept (-)1-2 mm (-0.05-0.01) WC

Damper
Leak in casing allows cool air thru insulation and

not hot flue gas out, damaging insulation and
casing
Easy to operate and maintain

Control Xs air by adjusting each burner air register
Operating stack damper alone as an easy way out
will have +ive pressure at arch bringing roof down
Wide open damper = Tramp Air ~ hi convection P
Wide open burner register = high Xs air and high
arch pressure. Hot gas leak; damages refractory/
casing

Arch
- ive +ive
Floor
Forced Draft
Inside heater: Same as in ND
FD fan: air P in ducts, pre-heater and
burner
Air flow controlled by fan inlet guide
vanes; may be linked to O2 or CO analyser
Fan Head = 150-200 mm (6-8) WC
FD trip: flexibility to switch to natural draft
Damper
Drop out doors in air ducts + ND burners
advantages of FD and ND burners lost!

Drop-out door locations to ensure air
distribution; avoid exposure to hot air

Note: Doors are known to fail to open on
demand
Arch
Air Inlet
Stack
location.
Air inlet should be elevated above grade, to avoid sucking

in any hydrocarbon leak, that can cause firebox explosion
- ive +ive
Floor
Induced Draft
Usually in high efficiency heaters with

location.
cooler flue gas/ low chimney effect and

high flue gas P
ID fan: flue gas P in convection,
damper, ducts, pre-heater and stack
Flow controlled by fan inlet guide vanes;
may be linked to arch draft
Fan Head = 50-75 mm (2-3) WC
ID trip: flexibility to switch to natural
draft, opening stack damper
Damper
Arch
- ive +ive
Floor
Balanced Draft
A combination of FD and ID Fans usually with

air pre-heater
A welded casing boiler with water wall may
operate under positive pressure
All process heaters operate under -ive pressure
If firebox operates under positive pressure, arch
refractory is first to crack/ damage and fall
Tell-tale signs: Rusted black spot on casing
On opening peep door, hot blast of flue gas
Wind Effect on Stack Draft

In plains, wind action at stack tip creates
small draft
Felt in cold firebox; good to light first burner

Gradual heating to establish draft; Otherwise
furnace will puff
If stack tip is high above surrounding
structures or 600m (2,000) away from hill/

higher structure, wind aids draft
If stack is in a valley or higher structures are
nearby, down draft may occur wind
tending to blow in
Conical down draft diverter may help
2D
Stack Rain Hat / Sleeve

Rain Hat - for standby/ Start-up heater
External corrosion with S bearing fuels
Inhibits dispersion/ Increases GLC
Rain Sleeve - Preferred
Routes rain drop in the annular space,
external to stack
4-5D
FIRED HEATER COMPONENTS
Tubes
Horizontal tubes require tube removal

space; Vertical tubes can be pulled-up
Arranged for easy removal; all free to expand

Radiant tubes - vertical or horizontal hairpins, along firebox wall
In a central lane in reactors. Convection - horizontal
Usually 4 to 6. Smaller in steam / water service. Bigger in vacuum

Material CS,C - Mo, Cr - Ni, SS, 25 Cr - 20Ni

CS to 425C(800F) to avoid spheroidization and graphitization

Cr-Mo to 700C (1300F); SS above 700C (1300F)
Material selection based on:

Internal /external corrosion and oxidation

Max TMT that decides creep-rupture life
Chromium increases resistance to corrosion from H2S, free S, organic S compounds;

increases resistance to external oxidation; low improvement on rupture strength
Molybdenum improves resistance to creep
Nickel does not contribute to corrosion or oxidation or creep. Without Nickel, high
Chromium alloys become brittle
IN
Tubes
4 Passes
Tubes grouped in passes or parallel

flow paths to meet P
Note: In heat exchangers, number of
passes reduce parallel flow paths

and add to frictional length and P
Coil made bigger

internally vaporising
and vacuum service
Corbel reduces
flue gas bypassing
or channelling
Convection coils are in a

bank in rectangular or
square or triangular pitch
OUT
4 pass means, flow in each
pass and frictional lengths
are of total compared to
single pass. Hence P will
be 1/64 of single pass.
Square Pitch
Corbel
Triangular Pitch
location.
Tube End Fittings

Same material as tubes
Usually 180 bends. Welded between two adjacent tubes. Can
be housed in firebox; adds to heat transfer surface

In severe coking services, mule ear plug headers
Plugs removed for mechanical turbining - cleaning tube inside

surface with air operated tool

Cast plug headers: Rolled or welded. Rolled headers may leak
small fires
With C4 and lighter, preferable to seal weld rolled headers
Plug headers are housed in an external header box
Headers are located on top in vertical and on one end in horizontal
tubes
Manifolds
When there is more than 1 pass, to ensure
equal flow to all passes

Flanges: RF or RTJ. In high pressure service,
terminals are welded
Flexible pigtails connect reformer tubes to manifold.

Pigtails help accommodate thermal growth of tubes
Which outlet is better?
RF and RTJ Flange Joints

location.
Radiant Tube Support - Vertical

Wall
Top Guides
Outlet side supported (anchored) to minimize forces to external piping

Vertical radiant tubes: top guided and bottom supported, if outlet is at
bottom; otherwise, bottom guided
Bottom U clamp support, buried in floor refractory - less expensive
Top outlets and top support preferred to go straight into column/ reactor
Intermediate guides @ 70D (10-12) m for taller tubes
Bottom Support

Pipe in Pipe
Bottom Guide
U Clamp in Refractory
Radiant Tube Support - Horizontal

Intermediate along length, at 35D
(5-6m); end tube sheets

End Tube sheets: Castable lined CS
Intermediate supports:
SS 304H to 815C
25Cr-12Ni / 25Cr-20Ni to 870C
50Cr-50Ni for high vanadium +
sodium fuel oil - fuel ash corrosion

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End Tube Sheet
Support with Locking Bar. Tubes

may bend and jump out of support
Convection Tube Support

Intermediate along length, at 35D
(5 -6 m); end tube sheets

End Tube sheets: Castable lined CS
Intermediate supports

Intermediate Tube Sheet

CS to 425C; Cr-Mo to 650C

SS 304H to 815C
25Cr-12Ni, 25Cr-20Ni to 870C
50Cr-50Ni with high vanadium +
sodium fuel oil - fuel ash corrosion
Breeching Space between convection and stack

to smoothen flow profile and ensure uniform draft
Convection Tube Support
Tramp Air Paths

End tube sheets arrangement
Detail showing stud/ fins

End Tube Sheet with return bends

Soot Blowers
Soot blowers (steam lances). MP Steam at sonic velocity
blows away external deposits on extended surface tubes

Normally steam; but air and acoustic types available
Control: automatic and sequential. One at a time. Multiple
blowers can be sequenced for grade or control room
operation
Soot Blowers
Extended
Surface
Bare
Surface

Soot Blowers
Fixed with multi-nozzles - for clean fuel
Retractable blower with 2 opposing nozzles for dirty service.

Steam flow per nozzle high. Cleaning range high

Retractable: Coverage 1.2 m (4 ft) or 4-5 rows. Tube supports
limit to coverage. Bare shield tubes not covered.
Erosion protection for convection-section walls: castable
refractory with a min density of 2 000 kg/m3 (125 lb/ft3)
Steam lancing doors - for clean gas fuel firing
Fuel chemical additives - running cost
Caution: You must drain steam feed lines FIRST to avoid high velocity condensate
hit and damage extended surface fins/ studs and refractory parts
Stack & Dampers

Stack - top of heater/ on grade. Usually self-supporting
Height decided by draft; Mostly by GLC of SO2/ SO3/ NOx
Mostly lined to keep flue gas hot/ maintain draft; internally
coated
Dampers
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Manually opened and closed, winch at grade; can be made
automatic with air cylinders

Multiple bladed louver damper better than single bladed
butterfly damper for control
Strakes or wind
spoilers on stack top
Multi-blade stack damper
Grade mounted winch

Stack sections
IFB behind FB
Refractory Insulation
Protects external steel casing from hot gases
Help in re-radiation to the back of the tubes;
YYYYY
Fire bricks - exposed and fired walls

Insulating fire brick for covered walls
A layer of loose fire bricks on floor
V & Y Hooks
for cement
VVVVV
No-flux surface
Bricks
VC - looking up;
Looking down
Castable (insulating cement) for non-fired wall

Firebox, convection, tube sheets and stack
Ceramic fibre for non-fired wall

Aluminium foil vapour barrier prevents acid
migration and condensation/ corrosion with

H2S bearing fuel
Refractory system: Suitably anchored and
supported by high alloy and CS members
welded to casing
CF Blanket Radiant Side Wall
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Miscellaneous
Tube removal
door
Peep Hole,
with internal
refractory
protection
Peep holes: All around + floor to

inspect all radiant and shock tubes

Tube removal door on arch for
vertical tubes
Explosion door: to relieve excess
firebox pressure and avoid damage
to heater structure. On roof facing
up or on vertical walls facing away
from control room etc.
Piping not to block tube removal or
explosion door
Access: At firebox and top of
Stair access to
Hearth Platform
convection
Stairs to hearth level platform +
ladder access to others
Explosion door
Peep Hole
Access Door
Hearth Platform
Good insulation for casing

Good combustion with proper burners with regular cleaning of burner guns
Regular check on excess air and adjustment
ENERGY CONSERVATION
WASTE HEAT & AIR PREHEATER
Waste Heat Recovery
370C
Feed preheat reduces heater
duty; saves energy

Hotter feed hot stack gas;
reduces heater efficiency
Every 25C = 1% fuel
Heat recovery by:
Generation and Superheating
On turndown, secondary
services may not get enough

heat
Additional firing in ducts/
convection base
100
90
80
Xs Air, %
0
10
30
50
70
60
Efficiency, %
Boiler Feed Water heating, Steam
270C
300C
200C
50
40
30
20
10
0
0
200
400
600
Flue Gas Temp,C
800
1,000
Waste Heat Recovery
Common Convection
Section
Waste Heat Recovery - BFW heating,
Steam Generation - recovers energy.

Fuel not reduced
Pre-heating combustion air with flue
gas reduces fuel fired
Air Pre-heater
Part of convection or on grade
Requires FD and ID fans
Viable: High stack gas temperature,
high duty and expensive fuel

Better flame control
High radiant split
In retrofits:
High radiant flux, firebox/ tube & tube

support temperature
Reduced convection duty/ flue gas
velocity; Independent convection
services may not get enough heat
Fans: High maintenance
Cold end corrosion + acid mist plume
Low stack exit velocity/ dispersion
Air from APH

Safe Area
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FD
Fan
ID
Fan
Air Pre-heater
Requires large surface (gas and air heat
transfer coeffts low)

Tubes, plates, extended surfaces or light
metal elements in high density baskets;
heat pipes
Glass tubes, to cool flue gas below acid
dew point, to with stand acid corrosion.
Avoided in process heaters
Regenerative Air pre-heater heat absorbing elements

housed in a rotating wheel alternatively heated by flue
gas and cooled by air .
Heat Pipes - sealed

pipes with heat transfer
fluids that vaporizes on
flue gas side and
condenses on air side
Cast Air pre-heater with

inside and outside fins
Air Pre-heater
Air
Rotary
Basket
Flue Gas
Plate
Tubular
Rotary
Ducts
Air Pre-heater
Switch-over to natural draft requires
auto-drop out doors in air ducts
Extensive duct work for
air and flue gas

Plot limitations
FD and ID Fans
Rotary equipment trip/

failure
Optional switch-over to
part load natural draft

operation
Use of natural draft

burners limits gains
FD burners with high
air pressure drop

Good flame and air

distribution but unable
to revert to natural
draft operation
Air Pre-heater
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ID Fan
Expansion
Vessel
HT Medium
Air from
Safe Area
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APH
FD Fan
Heating
Medium
Air from
Safe Area
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APH
FD Fan
May employ water or heat transfer fluid in a circulating loop

Minimizes duct runs; but 2 equally rated heat exchangers required
Process fluid may be used to heat air and then get heated
Low temperature waste streams like excess LP steam may heat air
Ideal to temper cold combustion air to avoid cold end corrosion
Air Pre-heater
H2S and Sulphur in fuel: convert to SO2 (94-98%) and SO3
(balance) sulphurous acids that corrode cold end

Cold End Metal Temperature > acid dew point at all operating
conditions to avoid corrosion of tubes, ducts and fans; acid-mist
Flue Gas Temperature may fall
During part load operation, changes in excess air or fuel composition
or low air temperature,
Cold air bypass in air pre-heater
Preheat cold air with LP steam
External sulfate deposits on tubes is harmless during operations.

During shutdown the deposits cool down, absorb moisture from
the air to produce sulphuric acid, that corrodes the tubes
Min Cold End Metal Temp, C (F)
Maintain Cold End Temperature by

Mass % Sulfur in Fuel
Summary Impact Analysis

Add Convection
Section
Add Steam
Generation
Add
Air pre heater
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Stack temperature Reduced Reduced Reduced

Furnace Firing.. Reduced .. No Change Reduced
Firebox Temperature. No Change .. No Change.Increased
Radiant Heat Flux .. Reduced No Change.Increased
Flue gas pressure drop .... in the convection section is increased.
Draft .. Decreased. Decreased..Decreased
Tube side pressure drop .. Increased ..No Change.No Change
NOx . Reduced No Change No Change
Burner .... No Change No Change. Changed
More weight . from added convection tubes/.... air pre-heater.
1.
Structure and foundation to be checked to see if added weight can be supported. If

not, design adjacent structure to house convection tubes and support stack
Check impact on steam superheater on account of reduced heater load
Air pre-heating requires, extensive ducting, additional plot area, FD/ID Fans, check on
tube supports/ refractory due to increased temperature, additional instruments. If fuel
is to be changed, some existing convection tubes may have to be removed to
accommodate soot blowers
2.
3.
Gas Turbine WHRU

Gas Turbines: Run large compressors and generators
300 400% Xs air to limit combustion chamber metal
temperature
WHRU
Exhaust at 500C with 16-18% O2: A rich source of waste heat
either as hot combustion air or for waste heat recovery

Combustion Air: Requires ducting and load co-ordination
between GT and fired heater
Combustion air
Air
Fuel
Common WHRU
for 2 Turbines
GT WHRU
Bypass
Bypass
Bypass
WHRU
WHRU
Heat hot oil, generate and superheat steam

Finned tubes, similar to heater convection section
Balance heat load: GT exhaust cooler on part load
GT WHRU Supplementary Firing

Additional firing to boost exhaust temperature
/ available waste heat, specially during GT part

load
High exhaust velocity (30m/s) and proper
distribution
As exhaust has 16-18% O2, fuel (oil or gas or
both ) can be directly fired in the duct
FD fans: To continue steam generation etc.
when GT is down
Duct Burners: Many small burners across duct cross section

location.
Heater Decoking
Decoking Pig
Intelligent Pig
Decoking
Regular decoking will avoid hot spots and premature tube failure.

Remove coke deposited inside tubes by

Gas oil circulation to soften and remove deposits. Not for heavy
coking
Chemical cleaning circulating inhibited acid or chemical + water
wash for salt deposits
Hydroblasting high pressure water jet; abrasive grit.. Shot/sand
Steam: air decoking: In-situ combustion with steam and air
While tubes in 1 pass are decoked, tubes in other passes kept cool
with steam
Cooling steam is 5-15% of decoking steam flow
Decoking air 5-15% of decoking steam flow
Pigging abrasive pigs. Less damage than decoking or acid wash

Mechanical turbine thru Mule Ear Plugs
Multi-pass (arbor) radiant inlet/ outlet header
Process Piping
Symmetrical inlets and outlets in multi-pass vaporizing
service, to ensure equal flow and avoid coking
Split or join in stages - 2 passes or streams at a time

One large header to split/ combine in all liquid or vapor service
Transfer lines from heater to column: Elevated above
column nozzle and slope towards the column
Radiant Outlet
Pipe Rack
Convection Inlet
Convection Inlet
Radiant Outlet
Control Valves
@ Grade
15 m
Radiant Outlet
Convection Inlet
Convection Inlet
Pipe Rack
Header Box
Header Box
Header Box
Platform
Header Box
Platform
15 m
Control Valves
@ Grade
Tube Removal Area
Tube Removal Area
Check List
While buying
While running
Duty and margin

Type VC, Box, Multi-cell;
Caution board near heater

single or double fired

Efficiency and Xs air
Flux and max metal temp
Vaporization - Temp profile
Plot limitations
Inlet/ Outlet locations
Extended surface
Soot blowing
Damper operation location
Sky walk to adjacent heaters

on purging
O2 reading and Xs air
Draft at arch
Casing hot spots or rust
marks
Flame lick / hot spots
Wind induced combustion
pulsation
Drain steam supply piping
before soot blowing
Clean oil guns / tips
Safety
More on Safety in the Operations Part
Heater location:
Upwind or side wind to avoid any hydrocarbon ingression
15 m from other equipment or road; edge of unit for easy fire
fighting
FD fans air intake from , safe location, 5-15m above grade

Floor fired: Floor 1.75 m above paved grade
Coil purging valve: 10-15 m away. Steam or purge gas.
Firebox snuffing steam valve: 10-15 m away. FD Fan or
steam ejectors are acceptable alternatives

Fuel gas isolation valve 10-15 m away; FD fan should be
stoppable 10-15 m away/ remotely.
Recommended Reading
Furnace Operations, R D Reed

Petroleum Refinery Engg, W L Nelson, Chapter
18
Engineering Data Book, GPSA, Section 8
API Publications

Spec 12K Specification for Indirect Type Oilfield

Heaters
Std 530/ISO 13704:2007 Calculation of HeaterTube Thickness in Petroleum Refineries
RP 535 Burners for Fired Heaters in General
Refinery Services
RP 556 Instrumentation, Control, and Protective
Systems for Gas Fired Heaters
Std 560/ISO 13705:2006 Fired Heaters for
General Refinery Services
RP 573 Inspection of Fired Boilers and Heaters
Stay Safe. The best for many years of safe and sustained operations
THANK YOU

Fired Heaters - Introduction

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Lynn Evans and Bill Handel, Foster Wheeler, UK

API RP 530/ 535 Std 560

Fired Heaters Training 1 - 3 days

Plant energy flow; Fired heaters - Source of high temperature heat

Ethylene Cracker; Steam Hydrocarbon Reformer; EDC Cracker;

All Convection; Water Bath

Gas or Oil or Combination; Low NOx

Natural, Forced, Induced and Balanced

Tube & Tube Supports; Soot blowers, Stack, Refractory

Steam Generation; BFW Heating, Air Pre-heater, Gas Turbine

Furnaces: Direct or indirect heat transfer to solids or

Process Fired Heaters

Multi-level fired and Roof or Down-fired

Tubes &Tube Supports

Waste Heat Recovery

PROCESS FIRED HEATERS

Process Unit Energy Flow

Crude Distillation Unit

Crude Distillation Unit

Heat Exchangers Save Energy

Fired heaters are large fuel

recycle heat; save

Open Pan - See one

hour to scrape tar, coke and foreign matter. Deposits caused

Temperature: 300 to 1,100C. Duty: 0.5 to 150 MW

gas overheated the tubes coke deposit + ruptured tubes

Rectangular box on top / side of firebox

Flue gas recirculation in firebox heats

Vertical cylinder or rectangular box

Firebox/ Radiant Section Heat transfer:

Radiant section/ Firebox

55-60% fired duty

Vertical Cylindrical All Radiant

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All radiant, no convection < 2.5 MW duty

3 - 30 MW duty. General service. Common type. Good

efficiency. Beyond 30 MW firebox is too tall 18m (>60)

More coil passes. Symmetrical & uniform heat absorption

No separate tube pulling plot area required

Flue gas ducting to / from grade mounted air pre-heater

Reactor (Catalyst Reformer) feed heaters

(source of high pressure drop) and provide many

inside firebox or in external header box

End Access Door

End Tube Sheet

Single cell Crude Heater

Usually square cross-section

Box Twin Cell

For large duty, 30-75 MW,

Bridge wall fired for Delayed

Coker and Visbreaker

cracking and soaking

Flat Flame Burner

Bridge Wall fired-upon

Double fired twin cells for fired

reactors, such as EDC Cracker

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Box Multi Cell

3 x 2 multicell vertical tubes

BFW (Boiler Feed Water) heating, Steam Generation,

Top or side mounted

receive firebox radiation