FIRED HEATER

Plays and important role in Petroleum and

Petrochemical Industry.
Provide heat to hydrocarbon of all types to
increase temp :
To pass it into vapour state so as to separate into
narrower boiling range cuts by fractionation
To the point where thermal reaction will occur
To the point required for catalytic reaction to occur.
 FIRED HEATER
GENERAL OVERVIEW
DESIGN
INSPECTION & FAILURE ANALYSIS
 FIRED HEATER
MODE OF HEAT TRANSFER
FURNACE AND COIL
BURNER
AIR PREHEATER
DAMPER
 FIRED HEATERS
TYPES OF FIRED HEATER
INDIRECT FIRED HEATER
DIRECT FIRED HEATER
INDIRECT :
BOX TYPE
CYLINDRICAL TYPE
CABIN TYPE
 FIRED HEATER
BOX TYPE
HORIZONTAL TUBE
VERTICAL TUBE
CYLINDRICAL TYPE
HELICAL COIL
VERTICAL TUBE
 FIRED HEATER

TUBES
RADIANT - Radiant heat from heating flame
& incandescent refractory.
SHIELD - Radiant & Convection heat
(Receives highest heat flux)
CONVECTION TUBES - Convection heat from
combustion gases.
 CONVECTION SECTION
After oil convection tubes are installed ,
usually tubes are often installed to preheat
air, superheat steam for process
requirement.
Corbelling is provided to minimise flue gas
bypass.
 DESIGN CONSIDERATION
PROCESS
COMBUSTION
MECHANICAL
 DESIGN - PROCESS
For uniform heat distribution
No. of passes to be minimised
Each pass shall have single circuit from
Inlet to Outlet
Maximum allowable inside film temp. for
process shall not be exceeded
 DESIGN - COMBUSTION
Draft :
Natural : Efficiency shall be based on 20%
excess air when fuel gas is primary fuel &
25% when fuel oil is primary fuel.
Forced : Efficiency shall be based on 15%
excess air when fuel gas is primary fuel &
20% when fuel oil is primary fuel.
 DESIGN - COMBUSTION
VOLUME OF HEAT RELEASED:
For oil fired heater : max. 124 KW / Cu.mt.
For Gasfired heater : max. 165 KW / Cu.mt.
 DESIGN - COMBUSTION
Designed for a negative pressure of at least
0.10 inch of water ( ) is maintained in
radiant and convection sections at
maximum heat release with design excess
air.
 DESIGN
Size and arrangement of tube are
determined by
type of operation
Amount of heating surface required
Flow
 DESIGN MECHANICAL
Thermal expansion considerations
including steam air decoking.
Convection section tube layout : for future
addition of two row of tubes.
For fuel oil firing soot blower shall be
provided for convection section.
Vertical cylindrical heater max.H/D - 2.75
 DESIGN - MECHANICAL
Shield tube shall have at least three row of
bare tubes.
Convection - Corbels or baffles are employed
to minimise flue gas bypassing.
For Vertical heater : Tube L - 60 ft. max.
For Horizontal heater : Tube L- 40 ft. max.
Heater shall allow replacement of tube without
damage to adjacent tubes.
 DESIGN- TUBES
Tube wall thickness - API RP 530.
Calculation shall include erosion and corrosion
allowance.
Maximum metal temp. as per API 530.
All tubes shall be seamless .
Shield tube material and thickness shall be as
connecting radiant tube.
Design life : 100,000 hours.
 TUBE MATERIAL - TEMP. (OISD)
Metallurgy Normal Decoking
Carbon steel 565 Deg C 620 Deg C
5 Cr 1/2 Mo 650 730
9 Cr 1 Mo 685 750
18 Cr - 8 Ni 870 925
18 Cr 8 Ni 2 Mo 870 925
25 Cr 20 Ni 1150 1185
 TUBE MATERIAL
Standardisation of material: To keep low
stock.
Generally used material :
CS upto 300 Deg C
Low alloy steel upto 1200 Deg F
Austenitic SS higher than 1200 Deg F.
 TUBE MATERIAL
4-6 % Cr are superior to plain CS in
resistance to sulphur corrosion .
Oxidation resistance of CS decreases
rapidly above 650 Deg C.
Cr addition increases corrosion resistance
at high temp.
 TUBE MATERIAL
For Heaters in Hydrodesulphurisation and
hydrocracker : Austenitic stainless steel is
used due to their higher temp.strength and
high corrosion resistance.

 DESIGN - CONVECTION
Convection - Stud or finned type tubes
Stud to be arc or resistance welded.
Fins to be helically wound and continous
welded to tube.
Stud material : CS - 510 Deg C ( Tip temp)

Stud size : 1/2 dia X 1 height

 DESIGN - PIPING
All flanges to be weld neck type.
Threaded connection are not acceptable.
Low drain and high vent point shall be
accessible from outside heater casing.
Crossover piping shall be of same material
as per process heater tube.
 DESIGN - TUBE SUPPORT
Unsupported length of tube : 35 OD or 20 ft.
whichever is less.
Min.thickness of end tube sheet shall be 1/2.
Material : CS upto 427 Deg C
25Cr- 20 Ni-1093 Deg C
50 Cr 50 Ni - Nb above 649 Deg C if fuel has
Sodium + Vanadium more than 100 ppm
 REFRACTORIES AND INSULATION
Design temp. outside casing : Max. 82 Deg C
with still air at 27 deg C.
Wall arches and floor : Proper expansion .
Min. Service temp of refractories in radiant
section : 982 deg C.
Min service temp for burner block : 1482
Deg C.
 REFRACTORIES AND INSULATION
BRICK AND TILE TYPE.
CASTABLE CONSTRUCTION.
CERAMIC FIBRE CONSTRUCTION.
 BURNER
A device for introduction of fuel and air into a
heater at desired velocities , turbulence and
concentration to establish and maintain
proper ignition and combustion.
Types :
Oil
Gas
Combination of oil and Gas.
 DESIGN - BURNERS
Shall ensure against flame impingement.
Gas pilots shall be provided for all burners
firing liquid fuels.
Burner block shall be able to expand and
contract as a unit.
Burner , gas tip and oil guns shall be
removable in operation.
 DESIGN - BURNER
Time
Temperature
Turbulence
Mix the fuel and air
Maintain ignition
Mould the flame
Minimise emmisions.
 BURNER SELECTION
Furnace configuration and tube location
Fuel(s) available.
Heat release and burner spacing
Process stream consideration
Draft condition
Altitude
Air temperature
 BURNER
Fuel gas pressure : 15 Psig ( Premix burner)
Fuel oil Pressure : 150 Psig.
Steam / oil : 0.15 lb/ lb of oil for natural
draft furnace
 DRAFT
Draft is the negative air pressure generated
by buoyancy of hot gases inside the furnace.
Hot gases are less dense than outside air.
This causes hot gases to move upward out of
stack creating a slight vacuum inside the
furnace.
Smallest negative pressure is at conection
section
 DRAFT
Too little draft can damage metal structure
and snuff out the burners due to heat build
up just under furnace arch and roof.
Too much draft can pull excessive air into
the furnace wastes fuel.
 FURNACE TYPE - DRAFT
Natural Draft Heater : Stack effect.
Induced Draft Heater : Fan to remove flue
gases.
Forced Draft Heater : Fan to supply
combustion Air
Balanced Draft Heater : Combination of ID &
FD .
 COMBUSTION
Combustion is the reaction which takes
place when fuel ( C , Hydrogen or Sulphur)
unites with oxygen ( from air) to liberate
heat.
Well maintained burner and properly
designed can reduce heater fuel cost by as
much as 10%.
 GOOD COMBUSTION
Uniform flame pattern
No haze
 POOR COMBUSTION
Non uniform flame pattern
Haze - Unburnt fuel
Bottom burner needs air
Potential impinging on tubes
 Some Indication of Faulty
Operation
Positive press. At top ID fan not running
of firebox . Excessive firing rates
Excessive temp. in fire Overfiring
box
High flue gas pressure Heat release too high
Incorrect combustion
air flow
Fouled convection
section
 Some Indication of Faulty
Operation
Variation in outlet Unequal flow
temp. of multi pass Flame impingement
High Press. Drop in Coke build up/ fouling
coils
High flow rate
High vapourisation
Low press. Drop in coil
High flue gas press.
Low flow rate.
Drop across convection Excessive fouling
 DETERIORATION OF COIL
MAJOR FACTORS :
Type of Process
Characteristics of charge feed.
Velocity of flow thru coils
Pressure & Temperature
Combustion product
Mechanical damage.
 FORM OF DETERIORATION OF
HEATER COIL
Deterioration due to corrosion.
Metallurgical deterioration.
Mechanical Deterioration.
 Deterioration due to corrosion
High Temp. Oxidation :
Reason : High tube metal temp.due to high
process temp., flame impingement, high heat
flux, internal coking / fouling , flow starvation.
Location : Fire side of radiant / shield tubes
Results in hard brittle oxide scale on tube
surface resulting in tube wall thinning /
bulging and cracking.
 Deterioration due to corrosion
SULPHIDATION :
Conversion of metal to sulphide scale due
to sulphur reaction at high temp. ( 316 to
427 Deg C)
Rate of corrosion of sulphur increases with
temperature.
Results in internal pitting.
 Deterioration due to corrosion
Low Temp. Acidic Corrosion ;
Flue gases contain SO2 . At low this may
combine with moisture and condense as
acids which is corrosive.
Convection section is prone to acidic
corrosion.
 Deterioration due to corrosion
Fuel Ash Corrosion:
If fuel contains more than 50 ppm
Vanadium and sodium salts , the deposits
formed are corrosive above 650 Deg C.
 Deterioration due to corrosion
Polythionic acid Corrosion :
Generation of Ploythionic acid from wet
sulphide scaled during downtime may
pose similar corrosion problem to SS.
 Metallurgical Deterioration
Rare cause of thickness reduction however
reduces mechanical strength / ductility which
may cause tube failure.
Grain Growth : Smaller Grain size has high
strength and low creep strength. Grain growth
above 600 Deg C for Steel.
Graphitisation : Carbide breaks into iron (Soft) and
graphite ( Brittle) when operated for long period in
range of 440 Deg C.
 Metallurgical Deterioration
Carburisation : Diffusion of elemental carbon
into solid steel. Operating at high temp. /
presence of coke . Forms hard and brittle
structure resulting in cracking.
High Temp. Hydrogen attack : Above 230 Deg C
hydrogen dissociate into atomic hydrogen and
diffuse thru metal . Carbon migrates to grain
boundary and form methane. Causes internal
pressure rise at grain boundary.
 MECHANICAL DETERIORATION
Due to Overstressing , weakening , poor
workmanship , vibration ,thermal shocks.
 MECHANICAL DETERIORATION
Bulging : Due to localised hot spots.
Sagging : Due to reduction in structural
strength of tube on overheating , unequal
metal temp.
Bowing : Unequal metal temp. and restriction
in thermal expansion.
Vibration : Due to flow fluctuation , rapid
evaporation . Wear of tube at tube support.
 OTHER DETERIORATION
Tube support : Overloading , Vibration.
Refractory Lining : Spalling , thermal shock,
vanadium .
Casing : Spalling of refractory.
Air preheater elements : Acid dew point
corrosion.
 ON STREAM INSPECTION
Frequency( OISD) :
Daily : Visual inspection of firing condition,
flame pattern , tube condition,TST , Temp.,
Pressure drop, flue gas temp.
Monthly : Thermography for hot spot on
stack , casing.
 ON STREAM INSPECTION
Structurals.
Ducting.
Insulation / painting.
Stacks
Heater tube - Condition / Hot spot/ TST.
Tube support.
Internal refractory lining.
 ON STREAM INSPECTION
Main burner .
Vibration of tube.
Flue gas leakage from joints / expansion
bellow.
 PLANNED S/D INSPECTION
Visual Inspection : Sulphur deposits.
Sagging /Bowing : > 1.5 OD - replaced.
Bulging/ scaling / cracking / splitting.
Bulging upto 5% is allowed.
Mechanical Damage - At tube support.
Weld joint .
Welding of TST points : DP
SS tubes - Passivation shall be done before opening.
 PLANNED S/D INSPECTION
TUBE THICKNESS :
UTM at four or more locations.
Check UT on locations close to flame,
return bend, Excessive oxidised
area,Bulged location, hot spot .
 PLANNED S/D INSPECTION
Other Type of Examination :
Hardness testing : Spot check
(Carburisation , Hardening).
OD Measurement.
Metallurgical Examination.
 PLANNED S/D INSPECTION
Additional Inspection of Convection tubes :
External corrosion due to lower flue gas
temp/ downtime sulphurous
scales/bowing / sagging.
Inspection of tube supports : Crack /
Metallurgical degradation/ oxidation.
Refractory Damage : Spalling / cracks.
 PLANNED S/D INSPECTION
Foundation.
Structural.
Casing.
Flue gas ducts : Internal corrosion.
Soot blowers.
Air preheaters : Corrosion/ fouling.
Dampers : Operability.
Stacks : Internal lining/ UTM/ Foundation.
 AIR PREHEATER
Air preheater is used to heat the air
required for combustion recovering the
heat of flue gases which otherwise would
be lost with stack gases.
Increases heater efficiency.
 AIR PREHEATER
Advantages :
Improved control of combustion air flow.
Reduced oil burner fouling.
Better flame pattern control.
More complete combustion of difficult fuel.
 AIR PREHEATER
Disadvantages :
Increased corrosion.
Formation of acid mist , if fuel sulphur
content is high.
Increased maintenance.
Reduced stack effluent velocity.
 AIR PREHEATER- TYPE
Direct : Direct heat transfer
Indirect : Intermediate fluid is used.
 AIR PREHEATER
Direct : Regenerative and Recuperative.
Regenerative :
Matrix of metal or refractory
May be stationary or rotary.
Recuperative :
Separate passage for flue gas and air
Tubular
 AIR PREHEATER
Temp at which corrosion and fouling becomes
excessive are affected by:
Fuel sulphur and other contaminant.
Fuel or flue gas additives
Flue gas oxygen and moisture
Combustion temp.
APH / Burner Design
Furnace cleanliness
Ash content in heavy fuel.
 AIR PREHEATER
COLD END TEMP. :
Corrosion due to condensation of sulphuric
acid vapours fromed from sulphur of
combustion product.
Desirable to operate APH at temp. above
acid dew point level.
 AIR PREHEATER
COLD END TEMP. CONTROL
Cold air bypass
External preheat of cold air
Recirculation of hot air

STACK TEMP. CONTROL : Curve

 HEATERS IN DESULPHURISATION
UNIT
Uses Austenitic stainless steel tubes.
The sulphide scales formed inside may react
with water and oxygen to form weak
sulphurous acid called polythionic acid.
This acid attack steel and cause
Intergranular Corrosion at location of high
residual stresses such as heat affected zone
of Weld, resulting in cracking of ASS.
 HEATERS IN DESULPHURISATION
UNIT
Protection against Polythionic acid attack :
PREVENTION :
Preventing formation by maintaining temp.
of ASS equipment above dew point of water.
Nitrogen purging in the system to prevent
any air from entering the system.
 HEATERS IN DESULPHURISATION
UNIT
NEUTRALISATION :
Use of soda ash solution ( Na2CO3) in range of 2 to
5% by weight.
Fill the system with the soln. And soak for minimum 2
hours before draining soda ash soln. And exposing
equipment to air.
Wash the system with soda ash soln.
Protective film of soda ash should not be rinsed with
steam / water.
 REFORMER
Operating temp. 815 to 980 Deg C.
Tube metallurgy : Incoloy 800 / HK 40/Para
alloy.
Down fired from roof / side fired for even heat
distribution.
Tubes are centrifugally cast.
Pigtails - Connecting pipe between inlet /
outlet header and tube.
 REFORMER
FAILURE : Due to stress rupture at hottest
and highly stressed portion.
Thermal stresses highest at midwall.
Fissuring starts from midwall and
progresses inside, final stage of rupture
occurs when fissure reaches outside wall.
Pigtails fails from bends.
 DAMPERS
Provided in duct system design for control
and isolation of various elements of the
system.
Consideration must be given to operating
differential pressure and temp. across.
 DAMPERS
Tight shut off : Low leakage ( max. 1/2%)
Isolation or guillotine ( slide gate) : No
leakage ( 0%)
Flow control or distribution : medium to
high leakage.
Natural draft air inlet doors : Low leakage to
full open.
 DAMPERS
Multiple Louvers : Preferred for control
application.