Calculating Maximum Tube Metal Temperatures

Engineering Encyclopedia Inroduction to Process Heaters
Process Heaters – Purpose and Construction
Calculating Maximum Tube Metal Temperatures

The method for calculating maximum tube metal temperatures
is based on the procedure contained in API RP 530. The
Example Problem 3 illustrates these calculations.
Maximum tube metal temperature is calculated using the
following equation:
Tm = Tb + ∆ Tf + ∆ Tc + ∆ Tw
where: Tb = Bulk fluid temperature, ºF. This is the

temperature of the fluid inside the tube at the
point for which the tube metal temperature is
being calculated. Most cases use the
maximum process fluid temperature in the
section of the furnace in question.
∆Tf = Temperature difference across the fluid film,

ºF. This is a boundary layer between the bulk
process fluid and the inside surface of the
tubewall.
∆Tc = Temperature difference across fouling (a

layer of scale or coke), ºF. This is an
allowance for fouling that may occur on the
inside surface of the tubewall during
operation.
∆Tw = Temperature difference across the tubewall,

ºF (usually small).
Saudi Aramco DeskTop Standards 23

A temperature profile across the tubewall for the Example

Problem 3 is illustrated in Figure 4.
Figure 4. Temperature Profile
The major variable in determining the total temperature

difference between fluid inside the tube and the metal surface is
the maximum heat flux (φm). Maximum heater design heat
fluxes, as specified by SAES-F-001, are shown in Addendum C.
Since φm is, in turn, dependent upon the maximum tube metal
temperature, an iterative calculation procedure is required. The
calculation procedures presented in this module start by
estimating φm, calculating Tm based on this estimation, and then
recalculating φm. Since φm does not change rapidly with
changes in Tm, one or two iterations of these calculations is
usually sufficient.

Temperature differences are determined by the following

equations:
Film temperature difference:

Q
φm = = hi ∆TF - - - - - convection
A
1  Do 
∆Tf = φm  
hi  Di − 2tc 
Coke or scale layer temperature difference:
Q  kc 
φm = = 
A  tc 
(∆Tc ) - - - - - conduction
D 
∆Tc = φm F  o 
 Di 
or
t  Do 
∆Tc = φm c  
k c  Di − t c 
Tubewall temperature difference:
Q  kw 
φm = =  ( ∆Tw ) - - - - - conduction
A  ta 
t a  Do 
∆Tw = φm  
k w  Di − t a 

where: φm = Maximum heat flux (Q/A) (rate of heat transfer)

Btu/hr-ft2. By convention, this is based on the
outside surface area of the tube. In each of
these equations, φm is adjusted by a ratio of
applicable diameters to reflect the actual
surface area over which the term applies. This
is illustrated in Figure 5. The average diameters
of the tubewall and the coke layer are used. The
inside film is assumed to have no thickness.
hi = Fluid heat transfer coefficient at the inside wall
of the tube (also called the inside film
coefficient), Btu/hr-ft2-ºF. This must be
calculated, based on the properties of the fluid.
F = Fouling Factor. This provides an allowance for
coking, scale, or other deposits on the inside
surface of the tube. This factor is usually in the
range of 0.0015-0.005 Btu/hr-ft2-ºF. Fouling
factors for various services are listed in
Addendum C.
tc = Thickness of deposit (or scale, coke or other
deposits) layer, in. This can be used in place of
a fouling factor, or to estimate the effect of a
given layer of deposit. If a fouling factor is used,
assume that tc = 0. The following are typical
design coke thicknesses:
Atmospheric crude heater:
Vacuum crude heater:
kc = Thermal conductivity of a deposit layer. Coke
can be assumed to be 35 Btu-in./hr-ft2-ºF
(based on average coke temperature = 850ºF)
ta = Tubewall thickness, in.

kw Thermal conductivity of the tubewall, Btu-in./hr-

ft2-ºF. This is a function of the tube material and
the tubewall temperature. Thermal
conductivities for common tube materials are
given in Work Aid 3E-1. Since thermal
conductivity is temperature dependent, it is first
necessary to assume a tube temperature and
conductivity, then adjust the calculations. Since
thermal conductivity is not extremely sensitive
to temperature changes, this step is usually not
difficult.
Do = Outside tube diameter, in.
Di = Inside tube diameter, in.
It is important to note that units must be consistent in these

equations. Many of the variables are often referenced in
inconsistent units, and these must be adjusted accordingly.
Figure 5. Tube Cross Section

Example Problem 3
The following example illustrates the calculation of maximum tube metal temperature in
a furnace radiant section.
Reference: Adapted from API RP 530, Section C.5, Sample Calculation.
Given:
Tube Outside Diameter, Do in. = 4.50
Average Wall Thickness, ta in. = 0.25
Bulk Fluid Temperature, Tb ºF = 520
Flue Gas Temperature, Tg ºF = 1650
Average Radiant Tube Metal Temperature, Ta ºF = 582
Average Heat Flux, fr Btu/hr-ft2 = 10,000
Tube Material = CS
Maximum Heat Flux, fm (based on 692oF TMT) Btu/hr-ft2 = 22,210
Inside Film Coefficient, hi Btu/hr-ft2-ºF = 201
Fouling Factor, F Btu/hr-ft2-ºF = 0.0015

Service: Reboiler
Solution:
Inside Diameter, Di = Do - 2ta = (4.50) - 2 (0.25) in. = 4.00
Fouling Factor, F (Given) Btu/hr-ft2-ºF = 0.0015
Or: Deposit Thickness, tc in. =
Deposit Thermal Conductivity, kc Btu-in./hr-ft2-ºF =
Approx. TMT = Tb + 1.2 φm [1/hi + F]
= (520) + 1.2 (22,210) [1/(201) + (0.0015)] = 692

Use this TMT to calculate kw = 692ºF
Thermal Conductivity, kw (from Work Aid 3E-1 at TMT): Btu-in./hr-ft2-ºF = 302
Film Temperature Difference:
(4.5) ºF = 124
∆Tf ′ = φm
1 Do
hi Di − 2t c
( )
= 22,210
1
[
(201) 4.0 − 2(0) ]
Coke Layer Temperature Difference:
(4.5) ºF = 37
D
( )
∆Tc = φmF o = 22,210 ( 0.0015)
Di (4.0)
Tubewall Temperature Difference:
(0.25) (4.5) ºF = 19
t
∆Tw = φm a
Do
k w Do − ta
(
= 22,210 )
(302) (4.5 − 0.25)
Total Temperature Difference = ∆Tf + ∆Tc + ∆Tw ºF = 180
Bulk Fluid Temperature, Tb ºF = 520
Maximum Tube Metal Temperature:
Tm = Tb + ∆Tf + ∆Tc + ∆Tw ºF = 700
Check Assumptions Made in Previous Calculations:

Check Inside Film Coefficient:
Liquid Phase Coefficient:
Calculated Wall Temperature, Tw = Tb + ∆Tf ºF = 644
Viscosity at Wall Temperature, µw cP = 1.1
2.42 (cP) = lb/hr-ft = 2.66

0.14
 Original µ w 
hi′ = Original hi  
Revised µ w 
0.14
 ( 2.66 ) 
= ( 86.7) 
2
 Btu/hr-ft -ºF = 86.7
 ( 2.66 ) 
Vapor Phase Coefficient:

0.5
 Original Tw + 460 
hv ′ = Original hv  
 Calculated Tw + 460 
 ( 645 + 460) 
0.5
= ( 388.6)   Btu/hr-ft2-ºF = 388.8
 ( 644 + 460) 
Revised Two-Phase Coefficient:

htp' = hl' wl + hv' wv
= (86.7)(0.62) + (388.8)(0.38) Btu/hr-ft2-ºF = 201.5

where:
wl = weight fraction of liquid
wv = weight fraction of vapor
hl = inside heat transfer coefficient for

liquid, Btu/hr-ºF
hv = inside heat transfer coefficient for

vapor, Btu/hr-ºF
Revised Film Temperature Difference:
Original hi (2014
. ) ºF
∆Tf ′ = Original ∆Tf x = (124)
Re vised hi (2015
. ) = 124
Revised Tubewall Temperature Difference:

Average Tubewall Temperature,

Tma = (Tm =700) - (∆Tw/2=10) ºF = 690
Thermal Conductivity, kw (at Tma)(Work Aid 3E-1) Btu-in./hr-ft2-ºF = 302
Original k w (302) ºF
∆Tw ′ = Original ∆Tw x = (19)
Re vised k w (302) = 19
Revised Maximum Tube Metal Temperature:
Tm' = Tb + ∆Tf' + ∆Tc' + ∆Tw' ºF = 700

Recalculate Maximum Radiant Heat Flux:
Recalculate FT:
FT =
( Tg + 460) − ( Tm + 460)
4 4
=
(1650 + 460) 4 − (700 + 460) 4 = 0.966
( Tg + 460)4 − (Ta + 460)4 (1650 + 460) 4 − ( 582 + 460) 4
Maximum Radiant Heat Flux:
φm = FC FL FT φr
= (1.91)(1.20)(0.966)(10,000) + φc Btu/hr-ft2 = 22140
FC = Factor accounting for circumferential heat flux variations (Figure 6)

FL = Factor accounting for longitudinal heat flux variations (Table 6)
FT = Factor accounting for effect of metal temperature on radiant heat flux
φr = Average radiant heat flux, Btu/hr.-ft2
φc = Average convective heat flux, Btu/hr.-ft2
22140
, − 22,210
% Difference in φm: x 100 = - 0.3%
22,210
22140
,
Resulting Difference in Tm: ∆T = 180° x = 179.4° F
22,210

Centerline Tube Spacing/Tube Outside Diameter

Note 1:
1. = Double row against wall, triangular spacing.
2. = Double row with equal radiation from both sides and two diameters between rows,
equilateral spacing.
3. = Single row against wall.
4. = Single row with equal radiation from both sides.
Note 2: These curves are valid when used with a tube-center-to-refractory-wall spacing of 1-½
times the nominal tube diameter. Any appreciable variation from this spacing must be
given special consideration.
Source: API RP 530.
Figure 6. Ratio of Maximum Local-to-Average Heat Flux

Furnace Radiant
FL
Section Height, ft
Up to 25 1.20
30 1.23
35 1.28
40 1.33
45 1.40
50 1.48
Table 6. Longitudinal Heat Flux Variation (FL)

PURPOSE AND USE OF PROCESS HEATERS

The purpose of a process heater is to supply heat to a refining
or chemical process. The principle uses of process heat are in
distillation for charge heaters and reboilers and for reaction
temperature control such as hydrotreaters and reformers.
Process heaters are used when there is a large heat duty and
when the process fluid outlet temperature is usually over 500ºF
that is difficult to achieve with steam. A partial list of typical uses
is shown in Table 7.
Duty
Plant Unit Furnace Service Type (Design)
MBtu/hr
Ras Tanura
015
Two Stage Crude
F-100 A&B Atmospheric 2 Cell Box 250.7
F-200 A&B Vacuum 2 Cell Box 124.6
493
Prefractionator
F-101 Lt Ends Reboiler VC 45.2
F-102 Hvy Ends Reboiler VC 64.4
Naphtha
Hydrotreater
F-201 Hydrotreater Charge VC 32.0
F-202 Desulfurizer Reboiler VC 27.0
Rheniformer
F-301 No.1 Reactor Heater Arbor 84.0
Convection section
Superheater 13.0
Steam Generation 79.8
Boiler Feedwater 17.2
Total for Rheniformer 283.0
Uthmaniyah (R-34)
F-101 Reaction Furnace 65.0
VC = Vertical Cylindrical
Arbor = Box with arbor coil
Table 7. Saudi Aramco Furnaces

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Engineering Encyclopedia Inroduction to Process Heaters

Process Heaters – Purpose and Construction