BY GAURAV KANODIA

A heater is a heat transfer equipment where heat of combustion of fuel oil/fuel gas is used to increase the temperature of the desired fluid.

On the basis of Draft ( Natural, Forced, Induced and Balanced Draft) On the basis of Structural Configuration ( Cylindrical, Cabin, Multi cell) On the basis of Radiant Tube Configuration ( Vertical, Horizontal, Helical and Wicket Type) On the Basis of Burner position ( Up fired, Down fired and Wall fired)

Balanced Draft, Twin Cell, Cabin Type, Horizontal Radiant Tubes and Up fired.

API 560 : Fired Heater for Refinery API 530 : Heater Tube thickness in Refinery API RP 550 : Installation of Instruments and Control System for Fired heater and Steam Generation EA 7301 : Guidelines for Noise

Heat Distribution in Radiant Section

1.
2. 3. 4.

Convection Section Losses

Flame Radiation 17% Hot Gas Radiation (Combustion Products) 32% Convection from Flue Gases 7% Refractory Reflection 14% Mirror Effects Total 70% 15%
15%

CDU Heater

Heat Duty Fluid Handled Inlet Crude Temp. Outlet Crude Temp. Fuel Used

: 43.84 MillionKcal/hr. : Crude@18000MT/D. : 310 C : 365 C : Fuel Gas/Fuel Oil/ Hot well gases

Crude
Liquid (Kg/hr) HC Vapour (Kg/hr) Operating pressure (kg/cm2 g) Operating temperature (Deg.C) IN 750000 19.73 OUT 420553 329447 3.73

310

365

MP Steam IN Flow (kg/hr) 13150 Pressure(Kg/cm2 g) 15.5 Temperature (Deg. C) 209 OUT 13150 14.5 315

Topmost part of the Convective Section 100 mm thick Castable type Entrance of the Convective Section 100 mm thick Castable type+50 mm thick C.Fibre board with 8mm dia SS316L lugs+0.1mm thick SS316 foil between Castable and board

Arch Section 125 mm thick C.Fibre module+25mm C.Fibre blanket with SS 316L studs+0.1 mm SS316 foil between blanket and fibre module. Radiant Section 100 mm thick C.Fibre module +25mm C.Fibre blanket with SS316L studs+0.1 mm SS316 foil between blanket and C.Fibre module

No. of Passes No. of Tubes in Convective Section No. of tubes in radiant Section MOC of Tubes O.D. of Tubes Thickness of tubes I.D. of Tubes

: 8 : 96 : 128 : 5Cr,0.5Mo : 168.3 mm : 7.11 mm : 154.08 mm

It is the negative air pressure generated by the buoyancy of hot gases generated inside the furnace. Measured At : 1. Firebox Floor 2. Below the Convective Section 3. At the Duct Inlet

Fuel Gas Hydrogen H2S CO2 Water CH4 C2H6 C2H4 C3H8 C3H6 i-Butane Butenes

(mol %) 48.72 0.015 0.08 0.55 27.10 13.86 1.03 3.48 0.29 0.68 0.01

N Butane C5+ NH3

2.33 1.84 0.01

Pressure at burner (Kg/cm2 g) Temperature at burner (Deg.C) Heating value (Kcal/kg)

1.5 40 11590

Ejector off gas from VDU Flow (kg/hr) Pressure(Kg/cm2 a) Temperature (Deg.C)

2590 1.1 45

Fuel Oil Sulphur Content 1%( wt.) Nitrogen 834 ( wt ppm) Ni <1 wt ppm V <1 wt ppm Na 1 wt ppm Pressure at burner (Kg/cm2 g) Temperature at burner (Deg.C) Viscosity Heating value (Kcal/kg) Atomizing Steam Pressure at burner (Kg/cm2 g)

5.5 50-70 20cSt 9500 7.5

CO2 O2 N2 H2O SO2

FLUE GAS COMPOSITION (Mole %) 11.2 3.28 74.3 11.17 0.05

It is a device which positions a flame in the desired location by delivering fuel and air with sufficient mixing energy to ensure continuous ignition and complete combustion.

Combustion Air Control Air Flow Rate to the Heater Oxygen Percentage in the Flue gases Fuel Oil/ Fuel Gas Control Outlet Temp of Crude Draft Control Suction of the I.D. Fan Crude Pass Control Pass Balancer

Visual Observations of Combustion

1. 2. 3. 4. 5. 6.

Colour of flame Flame Impingement Flame Shape and Stability Burner Air Register Setting Fuel Pressure Draft

Visual Observation of Firebox

1.

2.
3. 4. 5. 6.

Colour of Refractory and tube support Appearance of tube Appearance of refractory Infrared Scan Smoke from Stack Flame Type

Includes all oxides of Nitrogen except N2O

Hazards of NOx Acid Rain Smog

1. 2. 3.

Thermal Nox Prompt Nox Fuel Nox

Formation at High Temperature ( > 1000 C) N2 + O = NO + N N + O2 = NO + O N2 + O2 = 2 NO d[NO]/dt = A e(-Ea/RT) [N2] [O2]

Relatively

Low Temperature conditions Important under Fuel Rich conditions Relatively fast reaction between HC, O2 and N2 Formed mostly at flame base during earliest stage of combustion CH4 +O2 +N2 NO + NO2 + CO + H2O + trace particles CH4 +N2 HCN CN CN + O2 NO + CO + H

Direct Oxidation of organo nitrogenous compounds present in fuel N + O2 NO + NO2 + CO2 + H2O + trace species

Pretreatment Combustion Modification Post Treatment

Fuel Switching or Treatment Using Additives Oxidiser Switching

Excess Air Low NOx Burners

Premix gas Burners Nozzle gas Burners Fuel oil Burners Combination of F.O. and F.G. Burners Low NOX Burners

Air Staging Fuel Staging Internal Furnace Gas Recirculation Water or Steam Injection Ultra Lean Premixing External Flue Gas Recirculation

Advantages

Disadvantages

High Intensity flame (Compact Flame) Large Fuel Gas Orifice Low top plugging in case of unsaturated HC in feed Limited Turndown Flashback Limited use with different fuels Limited Forced Draft application

Advantages

Disadvantages

High Turndown Ratio No Flashback Wide variety of fuels used Tip Fouling due to small ports Less Efficient mixing with air

Sr. No. 1

Actuated By

Action

Need To cut off all the fuels to the furnace. To remove any combustible matter, if any in the firebox along with the flue gases.

Low Low flow Close from P-102 Main FG to F101 (SDV) FO to F101 (SDV) FO return from F101 (SDV) Low Low flow Offgas ex V120 to V133 pass through (SDV) any of the 8 Offgas ex V132 to V133 passes (SDV) Main FG to F101 (PV) Open FG vent of F101 (SDV) Offgas ex V120 to V121 (SDV) V132 offgas KOD vent (SDV) F101 Stack damper FD fans ID fans will trip

Sr. No. 3.

Actuated By Low Low fuel gas pressure to F101

Action Close Main FG to F101 (SDV) Main FG to F101 (PV) Open FG vent of F101 (SDV)

Need Low gas pressure will cause flame supported by gas to extinguish, thus causing build up of combustible matter in the firebox.

4.

Low Low Fuel Oil pressure to F101

Close FO to F101 (SDV) FO return from F101 (SDV)

Low oil pressure will cause flame supported by it to extinguish, thus causing build up of combustible matter in the firebox.

Sr. No.

Actuated By

Action

Need

5.

Emergency shut down switch for F 101 operated from Control Room or field

Close Main FG to F101 (SDV) Pilot FG to F101 FO to F101 (SDV) FO return from F101 (SDV) Offgas ex V120 to V133(SDV) Offgas ex V132 to V133(SDV) Main FG to F101 (PV) RSDV 133A Open FG vent of F101 (SDV) Offgas ex V120 to V121(SDV) V132 offgas KOD vent (SDV) F101 Stack damper FD fans ID fans will trip

In case of emergency, all the fuel supply connections are to to isolated including the pilot gas.

Sr. No.

Actuated By

Action

Need

One FD fan trip, as sensed by:Low speed of either of the FD fans Motor Contact of either of the FD fans

Close Discharge damper of the tripped fan will close automatically in 10 seconds and its motor will stop. Open Inlet damper of running fan will open fully and combustion action will shift to VFD mode automatically. When VFD is set manually and air flow is being controlled by inlet box damper, in case of overloading of inlet box damper, combustion control action will shift to VFD mode automatically.

Isolate the tripped FD fan and take the full load on the other running fan.

Sr. No.

Actuated By

Action

Need

Failure of both FD fans, as sensed by:Combustion Air flow low low Low speed of RST 394/398

Close Main FG to F101 (SDV) FO to F101 (SDV) FO return from F101 (SDV) Offgas ex V120 to V133(SDV) Offgas ex V132 to V133(SDV) Main FG to F101 (PV) Open FG vent of F101 (SDV) Offgas ex V120 to V121(SDV) V132 offgas KOD vent (SDV) Pilot gas will remain online

Isolation of the heater as no air for combustion will be supplied.

Sr. No. 9

Actuated By Failure of ID fans, as sensed by:Low Speed setting Motor Contact

Action Open Stack Damper If Stack Damper fails to open within 20 sec., then Close Main FG to F101 (SDV) FO to F101 (SDV) FO return from F101 (SDV) Offgas ex V120 to V133(SDV) Offgas ex V132 to V133(SDV) Main FG to F101 (PV) Open Stack Damper will open automatically within 20 sec. FG vent of F101 (SDV) Offgas ex V120 to V121(SDV) V132 offgas KOD vent (SDV) FD fans will trip

Need Isolation of the heater is required, if stack damper doesn't opens, as it can lead to pressure build up in the heater.

Sr. No.

Actuated By

Action

Need

10

High High Arch Close pressure of F Main FG to F101 (SDV) 101 (2 out of 3 FO to F101 (SDV) logic) FO return from F101 (SDV) Offgas ex V120 to V133(SDV) Offgas ex V132 to V133(SDV) Main FG to F101 (PV) Open Stack Damper will open FG vent of F101 (SDV) Offgas ex V120 to V121(SDV) V132 offgas KOD vent (SDV) FD fans will trip

Indicates the failure of ID fan or signal failure to Stack damper. So the need for isolation arises.

Sr. No. 11

Actuated By Actuation of the following together:FG to F101 trip Vap Naptha to F 101 trip FO to F101 trip Stack damper cannot be closed unless ID fan is running

Action Open Stack Damper will open FD fans will trip ID fan will trip after 5 mins.

Need Isolation of the heater is necessary if fuel fails.

12

If the Stack damper closes with the ID fan out of service, pressure will build up in the furnace and can be hazardous. Open Stack damper will be opened ID fan will trip

13

F 101 CAPH flue gas outlet temp High High (2 out of 3 logic)

Need To Blast off the impinged combustion particles off the tubes with sufficient energy Time When the flue gas temperature from outlet of convection section is sufficiently high / When crude temp. from the outlet of convection section is relatively low. Soot It is sticky, consists of high mol. wt. polycyclic HC.

Rotating element Soot Blower Retractable Lance Soot Blower Two Rows of soot blowers Each row of soot blower covers 3 +3 tube rows 3 minute Cycle

PROCEDURE Bypass I-103 ( ID Fan Failure), I-106 ( Stack Damper bypass) Open the Stack Damper Shut off the ID fan Increase the fuel pressure to accommodate the low combustion air temperature

Field Operator will first drain the steam line before starting the soot blowing activity. Open the main steam valve to soot blower header Start the soot blowing cycle Observe the stack to gauge the extent of soot blowing Continuously monitor the field panel during the operation

After the soot blowing cycle has been completed, physically verify the blower assembly When the stack outlet is sufficiently clear, take the ID fan online and close the stack damper. Adjust the fuel and draft accordingly.

Purging and Testing of Fuel Lines Establish fluid flow and purge firebox Light the Pilot Burner Light Fuel Gas and Fuel Oil Raise HOT

Manual Control Decrease Firebox Temperature Bypass APH Pilots on until main FO/FG system purged Depressurize the Offgas and Main FG lines N2 purging

Thermal Efficiency = Heat tr. to process fluid Net Heat Released Radiant Section Efficiency Radiant Flux rate Bridge wall Temperature

Direct Method Indirect Method direct = Heat Transferred to crude Total Heat Input

indirect = 1-

Heat Loss Total Heat Input

Total Heat Input = Hair+ HFO +HFG + HSteam +

MFOCv,FO + MFGCv,FG

Direct Method
Heat Transferred to Crude = M Cp(T2-T1)
= Mliq2{Cp,liq2(T2-Ta)} +Mvap2{Cp,vap2(T2-Ta)} -Mliq1{Cp,liq1(T1-Ta)}

Indirect Method
Losses Setting Losses o Radiant Zone Losses o Convection Zone Losses Stack Losses Stack Losses = Mflue {Cp,flue(Tstack-Ta)} Mflue = Mair + MFO +MFG +Msteam

Mair = Mair,FO + Mair,FG

Mair,FO = MFO (x+y/4)(1+)138.095 (12x+2y) where the formula for FO is CxHy.

Mair,FG = MFG(a+b/4)(1+)138.095 (12a+2b) where the formula for FG is CaHb. Where is % excess air.

1 kg C requires 11.51(1+x) kg air 1 kg H requires 34.52(1+x) kg air where x = % excess O2

If C/H = y, S content in fuel = 1% C in fuel burnt = y*m*0.99/(y+1) kg H in fuel burnt = m*0.99/(y+1) kg Where m = kg of fuel burnt

Radiant Zone Losses = FAfirebox (T4firebox T4amb) Convection Section Losses = h Aconvection (Tconvection Tamb) h = (1 + 0.225 * V) where V = wind velocity (ft/sec)

O2, Steam, Air Qnty., Insulation, Stack Temp., Air Ingress, Air Inlet Temp., Area of Heat Transfer on process side ( soot removal, geometry), Area of heat transfer on flue gas side

Use of APH Finned Tubes / Studded Tubes O2 Analyzer & CO Analyzer Glass Window Peep Hole Twist Caps/ Covers Vertical Furnace instead of Box Refractory Coating Soot Blowers

Proper Burner Alignment Steam Atomization Additional Coils Installation

TROUBLE
Pulsating Flame

CAUSES & Effects

Lack of O2, Refractory breakdown,

SOLUTION
Increase Air

Flame Impingement on Tubes

Overfiring, Lack of O2,Tube colour, coke formation, high firing

Check excess O2 levels, Steam Atomization Pressure, Oil tip check for erosion and regular cleaning, Check temp. of oil, atomizing steam, placement of oil gun, oil gun position.

Oil Spillage

Poor Steam Atomization, Low temp. of Oil, Erosion of burner and atomizer tip, Improper placement of oil gun, coke formation on burner tile

TROUBLE
High Stack Temperature

CAUSES & Effects

After burning in convection section, Lower efficiency of heater, Loss of air in firebox Failure of Shock tubes, High TI and PI indication at Convection Section Inlet,

SOLUTION
Check air leaks, Increase Air, soot blowing,

Overheating of Convection Section

Open Stack Damper if high arch pressure, Check excess air,

Motor Boating when Light Oil firing, Low firing FO pressure of oil, Low Flash Point of oil, Pulsating Flame, Noise

Check FO and atomizing steam pressure, Steam leak in oil, water in the oil,