Fired Heater Design & Performance Calculations

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

ENERGY PERFORMACE
Total Absorbed Duty	MW	9.575
Total Heat Release	MW	10.521
Total Efficiency	%	91.015

PROCESS
Process Name		Therminol XP
Heat Duty	MW	9.575
Flow rate (sec)	kg/s	40
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750
OUTLET CONDITIONS
Outlet Temperature	°C	200
Outlet Pressure	kPa a	590.72

AIR
Air Flow	kg/s	4.344
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.21
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	kg/s	4.554
Flue Gas Temp.	°C	171.4
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	3.393
Flue Gas Flow	kg/s	4.554
Max Tube Temp.	°C	217.1
Total Press. Loss (inc. gain)	mmH2O	-2.05

RADIANT SECTION
Radiant Cell		1
Heat Duty	MW	6.182
Heat Release	MW	10.521
Arch Temp.	°C	768.9
Max Tube Temp.	°C	260.1
Average Flux	W/m²	26560
Maximum Flux	W/m²	54321
No. of Burners		4
Arch Pressure	mmH2O	-2.49
Floor Pressure	mmH2O	-12.161

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	91.015
Daily CO2 Emissions	kg	50166

Commercial

BID / PROJECT VALUE

Total:	£ 763,559

Total:	£ 763,559

Total:

£ 763,559

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	260.1	189.2	217.1	169.4
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Commercial

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 584,399
Option items
Detail Engineering (by HeaterSIM)	£ 87,660
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£763,559

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	4.554	4.554	0.21	4.344
Flow (hr)	kg/hr	144000	144000	16396	16396	757	15639
Temperature	°C	100	200	768.9	171.4	Note 1	15.5
Pressure	kPa a	750	590.72	-2.49	0.065	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

40.785 m 19.785 m 17.985 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 1.18 m 5.835 m 4.584 m 4.204 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Name		Therminol XP
Heat Duty	MW	9.575
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	159.28
Max. Film Temp. Calculated	°C	252.1
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	26928
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	344
OUTLET CONDITIONS
Outlet Temperature	°C	200
Outlet Pressure	kPa a	590.72
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	583

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

API 560 Fired Heater, API 560 Fired Heater P&ID, API 560 Fired Heater Control and Instrumentation, API 560 Fired Heater Instruments, API 560 Fired Heater Piping and Instrumentation Diagram

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

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API 560 Fired Heater, VC Fired Heater, API VC Fired Heater

Radiant Cell		1
Radiant Type
Heat Duty	MW	6.182
Heat Release	MW	10.521
Arch Temp.	°C	768.9
Max Tube Temp.	°C	260.1
Tube Cirle Diameter	m	4.204
Average Flux	W/m²	26560
Maximum Flux	W/m²	54321
Flue Flow	kg/s	4.554
Air Flow	kg/s	4.344
Fuel Flow	kg/s	0.21
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-2.49
Floor Pressure	mmH2O	-12.161
Radiant Height	m	11.08
Radiant Width	m	4.58
Radiant Length	m	4.58
No. of Burners		4
Burner Cirle Diameter	m	1.209
Burner Design Firing	MW	3.16
Burner Normal Firing	MW	2.63
Burner Min Firing	MW	0.63
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.262
API Burner-to-Wall Dist.	m	1.13
API Burner-to-Roof/Roof Dist	m	7.984
Floor Flux	W/m²	637803

Flame-tube impingment risk not identified

Firing Notes
1. The Lower Heating Value (LHV) of the fuel efficiencies shall be used for efficiency calculations
2. Typical radiation heat loss value of 1.5% is used typically considered. However, in cases with a flue gas/air preheater, a value of 2.5% is normally considered.
3. Typical Excess Air values can be used as follows:
- Natural Draft - 15% excess air
- Forced Draft - 10% excess air
4. API 560 - Pressure at the Arch should be maintained at -2.5mmH2Og (-0.1inH2Og)

Tube Support Notes
1. Design temp. for tube supports should be Arch temp + 100 C (180 F) 2. No credit should be considered for shielding effect of tube supports by refractory 3. API 560 states if fuel the Vanadium + Sodium content in fuel exceeds 100ppm, supports to be either: - 50Cr-50Ni metallurgy, without any coating
- Covered with 50 mm (2 in) of castable refractory (see API 560)

Combustion

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Type
Flue Flow	kg/s	4.554
Air Flow	kg/s	4.344
Fuel Flow	kg/s	0.21
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°C	1805.6
Flue Gas Emissivity		0.443

Process Burner, Combustion Burner, Burner Flame, Industrial Burner

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Notes
1. The Lower Heating Value (LHV) of the fuel efficiencies shall be used for efficiency calculations
2. Typical radiation heat loss value of 1.5% is used typically considered. However, in cases with a flue gas/air preheater, a value of 2.5% is normally considered.
3. Typical Excess Air values can be used as follows:
- Natural Draft - 15% excess air
- Forced Draft - 10% excess air
4. API 560 - Pressure at the Arch should be maintained at -2.5mmH2Og (-0.1inH2Og)

Convection Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

API 560 Fired Heater Process Flow, Fired Heater process coil, Fired Heater process design, furnace process layout, radiant and convection section process scheme

Convection Sect. No.		1
Heat Duty	MW	3.393
Max Tube Temp.	°C	217.1
Total Flue Press. Loss (ex. gain)	mmH2O	0.63
Total Press. Gain	mmH2O	2.68
Total Press. Loss (inc. gain)	mmH2O	-2.05
Convection Width	m	2.159
Effective Length	m	5.835
Convection Height	m	3.601
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	4.554
Flue Gas Inlet Temp.	°C	768.9
Flue Gas Outlet Temp.	°C	171.4
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.2	210.1	171.4	216.5	172.7	0.73	Solid	9643	11934	8	0.979	0.084	C.S.	C.S.	135.6	144.4
1	7	Coil Section 3	0.31	268.1	210.1	283.6	216.5	0.66	Solid	14734	18209	8	0.979	0.092	C.S.	C.S.	154.8	168.1
1	6	Coil Section 3	0.48	358.1	268.1	388.7	283.6	0.58	Solid	23106	28442	8	0.979	0.105	C.S.	C.S.	184.6	205.1
1	5	Coil Section 2	0.55	458.5	358.1	509.9	388.7	0.5	Solid	26631	32790	8	0.93	0.087	C.S.	C.S.	198.8	226.3
1	4	Coil Section 2	0.85	607.6	458.5	696.4	509.9	0.42	Solid	41025	51120	8	0.93	0.103	C.S.	C.S.	244.4	283.7
1	3	Coil Section 1	0.27	652.9	607.6	754.6	696.4	0.38	None	13628	23805	8	0.866	0.051	C.S.	None	0	0
1	2	Coil Section 1	0.33	704.3	652.9	821.2	754.6	0.36	None	16766	29287	8	0.866	0.054	C.S.	None	0	0
1	1	Coil Section 1	0.41	768.9	704.3	898.7	821.2	0.34	None	22510	39320	8	0.866	0.057	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.2	210.1	171.4	Therminol XP	1	100	102.2	750	740	0	0	1.9	1.9	0	0	1549	1549	56942	58968
1	7	Coil Section 3	0.31	268.1	210.1	Therminol XP	2	102.2	105.7	740	731	0	0	1.9	1.9	0	0	1549	1549	58966	62257
1	6	Coil Section 3	0.48	358.1	268.1	Therminol XP	3	105.7	111.1	731	721	0	0	1.9	1.9	0	0	1549	1549	62264	67972
1	5	Coil Section 2	0.55	458.5	358.1	Therminol XP	4	111.1	117.3	721	712	0	0	1.9	1.9	0	0	1549	1549	67973	75551
1	4	Coil Section 2	0.85	607.6	458.5	Therminol XP	5	117.3	126.8	712	702	0	0	1.9	1.9	0	0	1549	1549	75573	90048
1	3	Coil Section 1	0.27	652.9	607.6	Therminol XP	6	126.8	129.9	702	693	0	0	1.9	1.9	0	0	1549	1549	89990	95589
1	2	Coil Section 1	0.33	704.3	652.9	Therminol XP	7	129.9	133.5	693	683	0	0	1.9	1.9	0	0	1549	1549	95569	102998
1	1	Coil Section 1	0.41	768.9	704.3	Therminol XP	8	133.5	138.1	683	673	0	0	1.9	1.9	0	0	1549	1549	102947	113605

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.2	210.1	171.4	Therminol XP	1	100	102.2	750	740	0	0	1.9	1.9	0	0	1549	1549	56942	58968
1	7	Coil Section 3	0.31	268.1	210.1	Therminol XP	2	102.2	105.7	740	731	0	0	1.9	1.9	0	0	1549	1549	58966	62257
1	6	Coil Section 3	0.48	358.1	268.1	Therminol XP	3	105.7	111.1	731	721	0	0	1.9	1.9	0	0	1549	1549	62264	67972
1	5	Coil Section 2	0.55	458.5	358.1	Therminol XP	4	111.1	117.3	721	712	0	0	1.9	1.9	0	0	1549	1549	67973	75551
1	4	Coil Section 2	0.85	607.6	458.5	Therminol XP	5	117.3	126.8	712	702	0	0	1.9	1.9	0	0	1549	1549	75573	90048
1	3	Coil Section 1	0.27	652.9	607.6	Therminol XP	6	126.8	129.9	702	693	0	0	1.9	1.9	0	0	1549	1549	89990	95589
1	2	Coil Section 1	0.33	704.3	652.9	Therminol XP	7	129.9	133.5	693	683	0	0	1.9	1.9	0	0	1549	1549	95569	102998
1	1	Coil Section 1	0.41	768.9	704.3	Therminol XP	8	133.5	138.1	683	673	0	0	1.9	1.9	0	0	1549	1549	102947	113605

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol XP	138.1	140.5	673.3	749.4	428.9	434.8	0	141.3	1.9	210.8	213.6	218.9	233.9	860.4	Turbulent		26928	54896	0	0
2	Wall	Therminol XP	140.5	142.9	749.4	667.1	434.8	440.8	0	141.3	1.9	212.4	215.2	220.5	235.5	870	Turbulent		26899	54852	0	0
3	Wall	Therminol XP	142.9	145.3	667.1	742.8	440.8	446.7	0	141.3	1.9	214	216.8	222	237	879.9	Turbulent		26870	54808	0	0
4	Wall	Therminol XP	145.3	147.7	742.8	660.8	446.7	452.7	0	141.3	1.9	215.5	218.4	223.6	238.6	889.9	Turbulent		26842	54763	0	0
5	Wall	Therminol XP	147.7	150.1	660.8	736.2	452.7	458.6	0	141.3	2	217.1	220	225.2	240.2	900.1	Turbulent		26813	54718	0	0
6	Wall	Therminol XP	150.1	152.6	736.2	654.6	458.6	464.6	0	141.3	2	218.7	221.5	226.8	241.8	910.6	Turbulent		26784	54672	0	0
7	Wall	Therminol XP	152.6	155	654.6	729.5	464.6	470.5	0	141.3	2	220.3	223.1	228.4	243.4	921.3	Turbulent		26754	54627	0	0
8	Wall	Therminol XP	155	157.4	729.5	648.3	470.5	476.5	0	141.3	2	221.9	224.7	230	245	932.3	Turbulent		26725	54581	0	0
9	Wall	Therminol XP	157.4	159.8	648.3	722.9	476.5	482.4	0	141.3	2	223.5	226.3	231.6	246.6	943.5	Turbulent		26696	54534	0	0
10	Wall	Therminol XP	159.8	162.2	722.9	642	482.4	488.3	0	141.3	2	225.1	227.9	233.2	248.2	955	Turbulent		26666	54488	0	0
11	Wall	Therminol XP	162.2	164.6	642	716.2	488.3	494.3	0	141.3	2	226.7	229.5	234.8	249.8	966.8	Turbulent		26636	54441	0	0
12	Wall	Therminol XP	164.6	167	716.2	635.6	494.3	500.2	0	141.3	2	228.4	231.2	236.5	251.5	978.5	Turbulent		26604	54390	0	0
13	Wall	Therminol XP	167	169.4	635.6	709.6	500.2	506.2	0	141.3	2	230	232.8	238.1	253.1	990.3	Turbulent		26574	54342	0	0
14	Wall	Therminol XP	169.4	171.9	709.6	629.3	506.2	512.1	0	141.3	2	231.6	234.5	239.7	254.7	1002.4	Turbulent		26543	54293	0	0
15	Wall	Therminol XP	171.9	174.3	629.3	702.9	512.1	518.1	0	141.3	2	233.3	236.1	241.3	256.3	1014.9	Turbulent		26512	54244	0	0
16	Wall	Therminol XP	174.3	176.7	702.9	622.9	518.1	524	0	141.3	2	234.9	237.7	242.9	257.9	1027.7	Turbulent		26482	54195	0	0
17	Wall	Therminol XP	176.7	179.1	622.9	696.2	524	530	0	141.3	2	236.5	239.3	244.6	259.6	1040.9	Turbulent		26451	54146	0	0
18	Wall	Therminol XP	179.1	181.5	696.2	616.5	530	535.9	0	141.3	2	238.1	240.9	246.2	261.2	1054.5	Turbulent		26420	54096	0	0
19	Wall	Therminol XP	181.5	183.8	616.5	689.5	535.9	541.8	0	141.3	2	239.7	242.6	247.8	262.8	1066.9	Turbulent		26388	54046	0	0
20	Wall	Therminol XP	183.8	186.1	689.5	610.1	541.8	547.8	0	141.3	2	241.5	244.4	249.5	264.5	1076.3	Turbulent		26354	53991	0	0
21	Wall	Therminol XP	186.1	188.4	610.1	682.8	547.8	553.7	0	141.3	2	243.2	246.1	251.3	266.3	1085.8	Turbulent		26320	53936	0	0
22	Wall	Therminol XP	188.4	190.7	682.8	603.6	553.7	559.7	0	141.3	2	245	247.9	253.1	268.1	1095.5	Turbulent		26285	53881	0	0
23	Wall	Therminol XP	190.7	193	603.6	676	559.7	565.6	0	141.3	2	246.8	249.6	254.8	269.8	1105.3	Turbulent		26251	53825	0	0
24	Wall	Therminol XP	193	195.3	676	597.2	565.6	571.6	0	141.3	2	248.5	251.4	256.6	271.6	1115.3	Turbulent		26216	53769	0	0
25	Wall	Therminol XP	195.3	197.6	597.2	669.2	571.6	577.5	0	141.3	2	250.3	253.2	258.3	273.3	1125.4	Turbulent		26181	53712	0	0
26	Wall	Therminol XP	197.6	200	669.2	590.7	577.5	583.5	0	141.3	2	252.1	254.9	260.1	275.1	1135.7	Turbulent		26146	53655	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Therminol XP	100	100.6	750	747.6	344.2	345.4	0	141.3	1.9	126.7	127.4	128.7	143.7	583.3	Solid	Turbulent	C.S.	9715	13844	0	0
1	2	3	8	Therminol XP	100.6	101.1	747.6	745.2	345.4	346.7	0	141.3	1.9	127	127.7	129	144	585.6	Solid	Turbulent	C.S.	9652	13756	0	0
1	3	3	8	Therminol XP	101.1	101.7	745.2	742.8	346.7	347.9	0	141.3	1.9	127.3	128	129.3	144.3	587.9	Solid	Turbulent	C.S.	9590	13667	0	0
1	4	3	8	Therminol XP	101.7	102.2	742.8	740.4	347.9	349.2	0	141.3	1.9	127.6	128.3	129.5	144.5	590.2	Solid	Turbulent	C.S.	9528	13578	0	0
1	5	3	7	Therminol XP	102.2	103.1	740.4	738.1	349.2	351.1	0	141.3	1.9	141.1	142.2	144.1	159.1	613.7	Solid	Turbulent	C.S.	14845	21137	0	0
1	6	3	7	Therminol XP	103.1	104	738.1	735.7	351.1	353	0	141.3	1.9	141.5	142.6	144.5	159.5	617	Solid	Turbulent	C.S.	14749	20999	0	0
1	7	3	7	Therminol XP	104	104.8	735.7	733.3	353	354.9	0	141.3	1.9	141.9	143	144.9	159.9	620.4	Solid	Turbulent	C.S.	14652	20862	0	0
1	8	3	7	Therminol XP	104.8	105.7	733.3	730.9	354.9	356.8	0	141.3	1.9	142.3	143.4	145.3	160.3	623.8	Solid	Turbulent	C.S.	14556	20725	0	0
1	9	3	6	Therminol XP	105.7	107	730.9	728.5	356.8	359.8	0	141.3	1.9	163.2	164.9	168	183	649.9	Solid	Turbulent	C.S.	23285	33066	0	0
1	10	3	6	Therminol XP	107	108.4	728.5	726.1	359.8	362.8	0	141.3	1.9	163.7	165.4	168.4	183.4	655.4	Solid	Turbulent	C.S.	23128	32844	0	0
1	11	3	6	Therminol XP	108.4	109.7	726.1	723.7	362.8	365.8	0	141.3	1.9	164.2	165.9	168.9	183.9	661.1	Solid	Turbulent	C.S.	22971	32622	0	0
1	12	3	6	Therminol XP	109.7	111.1	723.7	721.3	365.8	368.8	0	141.3	1.9	164.7	166.4	169.4	184.4	666.8	Solid	Turbulent	C.S.	22815	32399	0	0
1	13	2	5	Therminol XP	111.1	112.6	721.3	718.9	368.8	372.2	0	141.3	1.9	173.9	175.9	179.4	194.4	684	Solid	Turbulent	C.S.	26805	38044	0	0
1	14	2	5	Therminol XP	112.6	114.2	718.9	716.5	372.2	375.7	0	141.3	1.9	174.5	176.5	180	195	691	Solid	Turbulent	C.S.	26663	37841	0	0
1	15	2	5	Therminol XP	114.2	115.7	716.5	714.1	375.7	379.1	0	141.3	1.9	175.1	177.1	180.6	195.6	698.3	Solid	Turbulent	C.S.	26520	37638	0	0
1	16	2	5	Therminol XP	115.7	117.3	714.1	711.7	379.1	382.6	0	141.3	1.9	175.7	177.7	181.2	196.2	705.6	Solid	Turbulent	C.S.	26377	37435	0	0
1	17	2	4	Therminol XP	117.3	119.7	711.7	709.3	382.6	387.9	0	141.3	1.9	206.9	210.1	215.6	230.6	746.3	Solid	Turbulent	C.S.	41317	59102	0	0
1	18	2	4	Therminol XP	119.7	122	709.3	706.9	387.9	393.2	0	141.3	1.9	207.5	210.6	216.1	231.1	758	Solid	Turbulent	C.S.	41074	58754	0	0
1	19	2	4	Therminol XP	122	124.4	706.9	704.5	393.2	398.5	0	141.3	1.9	208	211.1	216.6	231.6	770.1	Solid	Turbulent	C.S.	40830	58406	0	0
1	20	2	4	Therminol XP	124.4	126.8	704.5	702.1	398.5	403.8	0	141.3	1.9	208.6	211.7	217.1	232.1	782.6	Solid	Turbulent	C.S.	40587	58058	0	0
1	21	1	3	Therminol XP	126.8	127.6	702.1	699.7	403.8	405.5	0	141.3	1.9	162.2	163.5	165.5	180.5	736.5	None	Turbulent	C.S.	13234	23118	0	0
1	22	1	3	Therminol XP	127.6	128.3	699.7	697.3	405.5	407.2	0	141.3	1.9	162.7	164	166	181	740.9	None	Turbulent	C.S.	13215	23083	0	0
1	23	1	3	Therminol XP	128.3	129.1	697.3	694.9	407.2	408.9	0	141.3	1.9	163.2	164.5	166.5	181.5	745.5	None	Turbulent	C.S.	13195	23049	0	0
1	24	1	3	Therminol XP	129.1	129.9	694.9	692.5	408.9	410.6	0	141.3	1.9	163.7	165	167	182	750	None	Turbulent	C.S.	13176	23015	0	0
1	25	1	2	Therminol XP	129.9	130.8	692.5	690.1	410.6	412.6	0	141.3	1.9	170.5	172	174.5	189.5	763.6	None	Turbulent	C.S.	15747	27507	0	0
1	26	1	2	Therminol XP	130.8	131.7	690.1	687.7	412.6	414.6	0	141.3	1.9	171	172.6	175	190	769.3	None	Turbulent	C.S.	15723	27464	0	0
1	27	1	2	Therminol XP	131.7	132.6	687.7	685.3	414.6	416.7	0	141.3	1.9	171.6	173.1	175.6	190.6	775	None	Turbulent	C.S.	15698	27421	0	0
1	28	1	2	Therminol XP	132.6	133.5	685.3	682.9	416.7	418.7	0	141.3	1.9	172.2	173.7	176.1	191.1	780.9	None	Turbulent	C.S.	15674	27378	0	0
1	29	1	1	Therminol XP	133.5	134.6	682.9	680.5	418.7	421.2	0	141.3	1.9	182.2	184.2	187.3	202.3	802	None	Turbulent	C.S.	19816	34614	0	0
1	30	1	1	Therminol XP	134.6	135.8	680.5	678.1	421.2	423.8	0	141.3	1.9	182.9	184.8	187.9	202.9	809.3	None	Turbulent	C.S.	19783	34557	0	0
1	31	1	1	Therminol XP	135.8	136.9	678.1	675.7	423.8	426.3	0	141.3	1.9	183.5	185.4	188.5	203.5	816.9	None	Turbulent	C.S.	19751	34500	0	0
1	32	1	1	Therminol XP	136.9	138.1	675.7	673.3	426.3	428.9	0	141.3	1.9	184.1	186.1	189.2	204.2	824.5	None	Turbulent	C.S.	19718	34443	0	0

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	260.1	189.2	217.1	169.4
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	275.1	204.2	232.1	184.4
Design Tube Pressure	kPa	2000		2000	2000
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235
No. Rows			3	2	3
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	232.77	62.13	325.88	801.84
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.1	25.4
Fin Thickness	mm			1.3	1.3
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

Notes
1. For vertical-tube, vertical-fired heaters, the maximum radiant straight tube length shall be 18,3 m (60 ft)
2. For horizontal heaters fired from both ends, the maximum radiant straight tube length shall be 12,2 m (40 ft)
3. API 560 - The tube-wall thickness should be in accordance with ISO 13704 (unless otherwise mutually agreed)
4. API 560 - Tube-wall thicknesses should include the minimum allowances for corrosion and/or erosion as follows:
- Carbon Steel Tubes - 3mm (0.125in)
- P Grade Tubes Tubes - 2mm (0.08in)
- Stainless Steel Tubes - 1mm (0.04in)
5. The unsupported length of horizontal tubes shall not exceed 35 times the outside diameter or 6 m (20 ft), whichever is less.

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000	2000	2000	2000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750	750	750	750
tblDesignTemp,calcref0	Design Temperature	°C	275.1136	204.1628	232.1274	184.3701
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	123693.8	132642.5	129115.5	135138.9
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1332	1.0573	1.086	1.0379
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.13	4.06	4.09	4.04
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.72	4.64	4.67	4.61
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

HeaterSIM - Fired Heater Simulation Results

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	21
Stack Diameter	m	1.18
Cone Diameter	m	1.184
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	171.4
Flue Gas Flow	kg/s	4.554
Steel Area	m²	78.09
Stack Entry Pressure	mmH2O	0.065
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

HeaterSIM - Fired Heater Simulation Results

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	718.9	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	490.1	1400	V Y Anchors	71.9	Refrac. thickness OK
RADIANT WALL 1	514.5	Fibre (High Density)	75	0.1	None	0	0	732.8	395.2	1260	Twistlock Pins	59.8	Refrac. thickness OK
RADIANT ARCH 1	768.9	Fibre (High Density)	87.7	0.1	None	0	0	824	765.9	1260	Twistlock Pins	77.8	Refrac. thickness OK

CONVECTION SIDEWALL 1	470.2	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	459.4	1100	V Y Anchors	63.9	Refrac. thickness OK

STACK 1	171.4	LW Castable	50	0.3	None	0	0	732.8	450.2	1100	V Y Anchors	63.9	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Notes
1. Environmentally friendly body-soluble fibre is the recommended choice for fire insulation
2. HW and MW Castable is strong enough to be used on floor without a top brick layer
3. Ceramic fibre insulation are typically used in all areas except stack and ducting.
4. Ceramic fibre not suitable for convection sections with sootblowers or steam lances are used for cleaning.
5. Vapour barrier protective coating is required behind all areas lined with ceramic fibre
6. SS foil barrier is required for ceramic fibre lined areas if the sulphur content exceeds 500ppm by mass.

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

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ENERGY PERFORMACE
Total Absorbed Duty	MMBTU/hr	32.67
Total Heat Release	MMBTU/hr	35.9
Total Efficiency	%	91.002

PROCESS
Process Name		Therminol XP
Heat Duty	MMBTU/hr	32.67
Flow rate (sec)	lb/s	88.2
INLET CONDITIONS
Inlet Temperature	°F	212
Inlet Pressure	psi a	108.8
OUTLET CONDITIONS
Outlet Temperature	°F	391.8
Outlet Pressure	psi a	85.691

AIR
Air Flow	lb/s	9.578
Air Temp.	°F	59.9
Excess Air	%	20

FUEL
Fuel Flow	lb/s	0.464
Fuel LHV	BTU/lb	21517
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	lb/s	10.041
Flue Gas Temp.	°F	340.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MMBTU/hr	11.574
Flue Gas Flow	lb/s	10.041
Max Tube Temp.	°F	422.6
Total Press. Loss (inc. gain)	mmH2O	-0.08

RADIANT SECTION
Radiant Cell		1
Heat Duty	MMBTU/hr	21.096
Heat Release	MMBTU/hr	35.9
Arch Temp.	°F	1416.1
Max Tube Temp.	°F	500.1
Average Flux	BTU/hr ft²	8420
Maximum Flux	BTU/hr ft²	17220
No. of Burners		4
Arch Pressure	mmH2O	-0.101
Floor Pressure	mmH2O	-0.488

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	91.002
Daily CO2 Emissions	kg	50169

Commercial

BID / PROJECT VALUE

Total:

£ 736,084

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°F	500.1	372.6	422.7	336.6
No. Tubes		52	24	16	24
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 560,508
Option items
Detail Engineering (by HeaterSIM)	£ 84,076
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£736,084

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	lb/s	88.2	88.2	10.041	10.041	0.464	9.578
Flow (hr)	lb/hr	317520	317520	36149	36149	1670	34479
Temperature	°F	212	391.8	1416.1	340.9	Note 1	15.5
Pressure	psi a	108.8	85.691	-0.101	0.001	Note 2	14.7

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

134 Ft 65 Ft 59 Ft 46 Ft 27 Ft 9 Ft Grade 0.00 Ft 4 Ft 19 Ft 15 Ft 14 Ft 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	inch	10	10	10	10
Vert. Row Spacing (Vert)	inch	N/A	8.7	8.7	8.7
No. Tubes		52	24	16	24
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Name		Therminol XP
Heat Duty	MMBTU/hr	32.67
Flow rate (sec)	lb/s	88.2
Flow rate (hr)	lb/hr	317520
Pressure drop	psi	23.109
Max. Film Temp. Calculated	°F	485.6
Max. Film Temp. Allowed	°F	662
Max Tube Average Flux Calculated (1)	BTU/hr ft²	8536
Average Flux Allowed	BTU/hr ft²	9986
INLET CONDITIONS
Inlet Temperature	°F	212
Inlet Pressure	psi a	108.8
Inlet Vapour Fraction		0
Inlet Enthalpy	BTU/lb	148
OUTLET CONDITIONS
Outlet Temperature	°F	391.8
Outlet Pressure	psi a	85.691
Outlet Vapour Fraction		0
Outlet Enthalpy	BTU/lb	251

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type
Heat Duty	MMBTU/hr	21.096
Heat Release	MMBTU/hr	35.9
Arch Temp.	°F	1416.1
Max Tube Temp.	°F	500.1
Tube Cirle Diameter	Ft	13.793
Average Flux	BTU/hr ft²	8420
Maximum Flux	BTU/hr ft²	17220
Flue Flow	lb/s	10.041
Air Flow	lb/s	9.578
Fuel Flow	lb/s	0.464
Excess Air	%	20
Air Temp.	°F	59.9
Arch Pressure	mmH2O	-0.101
Floor Pressure	mmH2O	-0.488
Radiant Height	Ft	36.37
Radiant Width	Ft	15.04
Radiant Length	Ft	15.04
No. of Burners		4
Burner Cirle Diameter	Ft	3.967
Burner Design Firing	MMBTU/hr	10.77
Burner Normal Firing	MMBTU/hr	8.98
Burner Min Firing	MMBTU/hr	2.15
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	Ft	4.142
API Burner-to-Wall Dist.	Ft	3.709
API Burner-to-Roof/Roof Dist	Ft	26.196
Floor Flux	BTU/hr ft²	202178

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Type
Flue Flow	lb/s	10.041
Air Flow	lb/s	9.578
Fuel Flow	lb/s	0.464
Fuel LHV	BTU/lb	21517
Excess Air	%	20
Air Temp.	°F	59.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°F	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°F	3282
Flue Gas Emissivity		0.443

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Convection Sect. No.		1
Heat Duty	MMBTU/hr	11.574
Max Tube Temp.	°F	422.6
Total Flue Press. Loss (ex. gain)	mmH2O	0.03
Total Press. Gain	mmH2O	0.11
Total Press. Loss (inc. gain)	mmH2O	-0.08
Convection Width	Ft	4.76
Effective Length	Ft	12.864
Convection Height	Ft	11.815
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	lb/s	10.041
Flue Gas Inlet Temp.	°F	1416.1
Flue Gas Outlet Temp.	°F	341
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Upgrade Membership

Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MMBTU/hr	°F	°F	BTU/lb	BTU/lb	lb/ft³		BTU/hr ft²	BTU/hr ft²		lb/s ft²	inchH2Og			°F	°F
1	8	Coil Section 3	0.68	410.7	341	93.3	74.4	0.05	Solid	3060	3789	8	0.2	0.003	C.S.	C.S.	276.4	292.2
1	7	Coil Section 3	1.04	515.1	410.7	122.1	93.3	0.04	Solid	4672	5776	8	0.2	0.004	C.S.	C.S.	310.9	334.9
1	6	Coil Section 3	1.63	676.9	515.1	167.3	122.1	0.04	Solid	7319	9013	8	0.2	0.004	C.S.	C.S.	364.7	401.8
1	5	Coil Section 2	1.88	857.7	676.9	219.5	167.3	0.03	Solid	8438	10393	8	0.19	0.003	C.S.	C.S.	390.3	439.8
1	4	Coil Section 2	2.9	1125.7	857.7	299.6	219.5	0.03	Solid	12991	16194	8	0.19	0.004	C.S.	C.S.	472.8	543.3
1	3	Coil Section 1	0.93	1207.3	1125.7	324.6	299.6	0.02	None	4320	7546	8	0.177	0.002	C.S.	None	32	32
1	2	Coil Section 1	1.11	1299.8	1207.3	353.3	324.6	0.02	None	5315	9284	8	0.177	0.002	C.S.	None	32	32
1	1	Coil Section 1	1.4	1416.1	1299.8	386.6	353.3	0.02	None	7136	12464	8	0.177	0.002	C.S.	None	32	32

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MMBTU/hr	°F	°F			°F	°F	psi a	psi a			ft/s	ft/s	ft/s	ft/s	lb/s ft²	lb/s ft²
1	8	Coil Section 3	0.68	410.7	341	Therminol XP	1	212	216	109	107	0	0	6.2	6.2	0	0	317	317	56952	58983
1	7	Coil Section 3	1.04	515.1	410.7	Therminol XP	2	216	222.2	107	106	0	0	6.2	6.2	0	0	317	317	58981	62278
1	6	Coil Section 3	1.63	676.9	515.1	Therminol XP	3	222.2	231.9	106	105	0	0	6.2	6.2	0	0	317	317	62286	68001
1	5	Coil Section 2	1.88	857.7	676.9	Therminol XP	4	231.9	243.1	105	103	0	0	6.2	6.2	0	0	317	317	68002	75592
1	4	Coil Section 2	2.9	1125.7	857.7	Therminol XP	5	243.1	260.3	103	102	0	0	6.2	6.3	0	0	317	317	75606	90094
1	3	Coil Section 1	0.93	1207.3	1125.7	Therminol XP	6	260.2	265.8	102	100	0	0	6.3	6.3	0	0	317	317	90010	95619
1	2	Coil Section 1	1.11	1299.8	1207.3	Therminol XP	7	265.7	272.3	100	99	0	0	6.3	6.3	0	0	317	317	95581	103022
1	1	Coil Section 1	1.4	1416.1	1299.8	Therminol XP	8	272.3	280.6	99	98	0	0	6.3	6.3	0	0	317	317	102989	113644

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MMBTU/hr	°F	°F			°F	°F	psi a	psi a			ft/s	ft/s	ft/s	ft/s	lb/s ft²	lb/s ft²
1	8	Coil Section 3	0.68	410.7	341	Therminol XP	1	212	216	109	107	0	0	6.2	6.2	0	0	317	317	56952	58983
1	7	Coil Section 3	1.04	515.1	410.7	Therminol XP	2	216	222.2	107	106	0	0	6.2	6.2	0	0	317	317	58981	62278
1	6	Coil Section 3	1.63	676.9	515.1	Therminol XP	3	222.2	231.9	106	105	0	0	6.2	6.2	0	0	317	317	62286	68001
1	5	Coil Section 2	1.88	857.7	676.9	Therminol XP	4	231.9	243.1	105	103	0	0	6.2	6.2	0	0	317	317	68002	75592
1	4	Coil Section 2	2.9	1125.7	857.7	Therminol XP	5	243.1	260.3	103	102	0	0	6.2	6.3	0	0	317	317	75606	90094
1	3	Coil Section 1	0.93	1207.3	1125.7	Therminol XP	6	260.2	265.8	102	100	0	0	6.3	6.3	0	0	317	317	90010	95619
1	2	Coil Section 1	1.11	1299.8	1207.3	Therminol XP	7	265.7	272.3	100	99	0	0	6.3	6.3	0	0	317	317	95581	103022
1	1	Coil Section 1	1.4	1416.1	1299.8	Therminol XP	8	272.3	280.6	99	98	0	0	6.3	6.3	0	0	317	317	102989	113644

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°F	°F	psi a	psi a	BTU/lb	BTU/lb			ft/s	°F	°F	°F	°F	BTU/hr ft² °F			BTU/hr ft²	BTU/hr ft²
1	Wall	Therminol XP	280.6	284.9	97.7	108.7	184.5	187.1	0	5.56	6.3	411.6	416.7	426.2	453.2	151.4	Turbulent		8536	17401	0	0
2	Wall	Therminol XP	284.9	289.2	108.7	96.8	187.1	189.6	0	5.56	6.4	414.4	419.5	429	456	153.2	Turbulent		8527	17387	0	0
3	Wall	Therminol XP	289.2	293.6	96.8	107.7	189.6	192.2	0	5.56	6.4	417.2	422.3	431.8	458.8	154.9	Turbulent		8518	17373	0	0
4	Wall	Therminol XP	293.6	297.9	107.7	95.9	192.2	194.7	0	5.56	6.4	420	425.2	434.6	461.6	156.7	Turbulent		8509	17359	0	0
5	Wall	Therminol XP	297.9	302.3	95.9	106.8	194.7	197.3	0	5.56	6.4	422.9	428	437.4	464.4	158.6	Turbulent		8500	17345	0	0
6	Wall	Therminol XP	302.3	306.6	106.8	95	197.3	199.8	0	5.56	6.4	425.7	430.8	440.3	467.3	160.4	Turbulent		8490	17331	0	0
7	Wall	Therminol XP	306.6	310.9	95	105.8	199.8	202.4	0	5.56	6.4	428.5	433.7	443.1	470.1	162.3	Turbulent		8481	17316	0	0
8	Wall	Therminol XP	310.9	315.3	105.8	94	202.4	205	0	5.56	6.4	431.4	436.5	445.9	472.9	164.3	Turbulent		8472	17302	0	0
9	Wall	Therminol XP	315.3	319.6	94	104.9	205	207.5	0	5.56	6.5	434.2	439.3	448.8	475.8	166.3	Turbulent		8463	17287	0	0
10	Wall	Therminol XP	319.6	323.9	104.9	93.1	207.5	210.1	0	5.56	6.5	437.1	442.2	451.6	478.6	168.4	Turbulent		8453	17273	0	0
11	Wall	Therminol XP	323.9	328.3	93.1	103.9	210.1	212.6	0	5.56	6.5	439.9	445	454.5	481.5	170.5	Turbulent		8444	17258	0	0
12	Wall	Therminol XP	328.3	332.6	103.9	92.2	212.6	215.2	0	5.56	6.5	442.9	448.1	457.5	484.5	172.6	Turbulent		8434	17242	0	0
13	Wall	Therminol XP	332.6	336.9	92.2	102.9	215.2	217.7	0	5.56	6.5	445.9	451	460.4	487.4	174.7	Turbulent		8425	17227	0	0
14	Wall	Therminol XP	336.9	341.3	102.9	91.3	217.7	220.3	0	5.56	6.5	448.8	453.9	463.3	490.3	176.8	Turbulent		8415	17211	0	0
15	Wall	Therminol XP	341.3	345.6	91.3	102	220.3	222.9	0	5.56	6.5	451.7	456.8	466.2	493.2	179.1	Turbulent		8405	17196	0	0
16	Wall	Therminol XP	345.6	350	102	90.4	222.9	225.4	0	5.56	6.5	454.6	459.7	469.1	496.1	181.3	Turbulent		8395	17181	0	0
17	Wall	Therminol XP	350	354.3	90.4	101	225.4	228	0	5.56	6.6	457.5	462.6	472	499	183.7	Turbulent		8386	17165	0	0
18	Wall	Therminol XP	354.3	358.6	101	89.4	228	230.5	0	5.56	6.6	460.4	465.4	474.9	501.9	186.1	Turbulent		8376	17150	0	0
19	Wall	Therminol XP	358.6	362.8	89.4	100	230.5	233.1	0	5.56	6.6	463.2	468.4	477.8	504.8	188.4	Turbulent		8366	17134	0	0
20	Wall	Therminol XP	362.8	367	100	88.5	233.1	235.6	0	5.56	6.6	466.4	471.6	480.9	507.9	190	Turbulent		8355	17116	0	0
21	Wall	Therminol XP	367	371.1	88.5	99	235.6	238.2	0	5.56	6.6	469.6	474.8	484.1	511.1	191.6	Turbulent		8344	17099	0	0
22	Wall	Therminol XP	371.1	375.2	99	87.6	238.2	240.8	0	5.56	6.6	472.8	478	487.3	514.3	193.3	Turbulent		8333	17081	0	0
23	Wall	Therminol XP	375.2	379.4	87.6	98.1	240.8	243.3	0	5.56	6.6	476	481.2	490.5	517.5	195	Turbulent		8322	17063	0	0
24	Wall	Therminol XP	379.4	383.5	98.1	86.6	243.3	245.9	0	5.56	6.7	479.2	484.4	493.7	520.7	196.7	Turbulent		8311	17045	0	0
25	Wall	Therminol XP	383.5	387.7	86.6	97.1	245.9	248.4	0	5.56	6.7	482.4	487.5	496.9	523.9	198.5	Turbulent		8300	17027	0	0
26	Wall	Therminol XP	387.7	391.8	97.1	85.7	248.4	251	0	5.56	6.7	485.6	490.7	500.1	527.1	200.3	Turbulent		8289	17009	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°F	°F	psi a	psi a	BTU/lb	BTU/lb			ft/s	°F	°F	°F	°F	BTU/hr ft² °F				BTU/hr ft²	BTU/hr ft²
1	1	3	8	Therminol XP	212	213	108.8	108.5	148.1	148.6	0	5.56	6.2	260.1	261.3	263.5	555	103.2	Solid	Turbulent	C.S.	3083	4395	0	0
1	2	3	8	Therminol XP	213	214	108.5	108.1	148.6	149.2	0	5.56	6.2	260.6	261.9	264	555.9	103.6	Solid	Turbulent	C.S.	3063	4367	0	0
1	3	3	8	Therminol XP	214	215	108.1	107.8	149.2	149.7	0	5.56	6.2	261	262.2	264.6	556.8	104	Solid	Turbulent	C.S.	3043	4338	0	0
1	4	3	8	Therminol XP	215	216	107.8	107.4	149.7	150.2	0	5.56	6.2	261.5	262.8	265.1	557.8	104.4	Solid	Turbulent	C.S.	3023	4310	0	0
1	5	3	7	Therminol XP	216	217.6	107.4	107.1	150.2	151.1	0	5.56	6.2	285.8	287.6	291.2	604.7	108.6	Solid	Turbulent	C.S.	4707	6704	0	0
1	6	3	7	Therminol XP	217.6	219.1	107.1	106.7	151.1	151.9	0	5.56	6.2	286.5	288.5	291.9	606	109.1	Solid	Turbulent	C.S.	4676	6660	0	0
1	7	3	7	Therminol XP	219.1	220.7	106.7	106.4	151.9	152.7	0	5.56	6.2	287.2	289.2	292.6	607.3	109.7	Solid	Turbulent	C.S.	4646	6617	0	0
1	8	3	7	Therminol XP	220.7	222.2	106.4	106	152.7	153.5	0	5.56	6.2	288	289.9	293.4	608.6	110.3	Solid	Turbulent	C.S.	4615	6573	0	0
1	9	3	6	Therminol XP	222.2	224.7	106	105.7	153.5	154.8	0	5.56	6.2	325.4	328.5	334	681.8	114.9	Solid	Turbulent	C.S.	7376	10477	0	0
1	10	3	6	Therminol XP	224.7	227.1	105.7	105.3	154.8	156.1	0	5.56	6.2	326.3	329.4	334.9	683.3	115.8	Solid	Turbulent	C.S.	7326	10407	0	0
1	11	3	6	Therminol XP	227.1	229.5	105.3	105	156.1	157.4	0	5.56	6.2	327.2	330.3	335.7	684.9	116.8	Solid	Turbulent	C.S.	7276	10336	0	0
1	12	3	6	Therminol XP	229.5	231.9	105	104.6	157.4	158.7	0	5.56	6.2	328.1	331.2	336.6	686.5	117.8	Solid	Turbulent	C.S.	7227	10266	0	0
1	13	2	5	Therminol XP	231.9	234.7	104.6	104.3	158.7	160.2	0	5.56	6.2	344.8	348.3	354.7	719.1	120.8	Solid	Turbulent	C.S.	8493	12057	0	0
1	14	2	5	Therminol XP	234.7	237.5	104.3	103.9	160.2	161.6	0	5.56	6.2	345.9	349.3	355.8	721	122	Solid	Turbulent	C.S.	8448	11992	0	0
1	15	2	5	Therminol XP	237.5	240.3	103.9	103.6	161.6	163.1	0	5.56	6.2	347	350.6	356.9	722.9	123.3	Solid	Turbulent	C.S.	8403	11928	0	0
1	16	2	5	Therminol XP	240.3	243.1	103.6	103.2	163.1	164.6	0	5.56	6.2	348.1	351.7	358	724.9	124.6	Solid	Turbulent	C.S.	8357	11864	0	0
1	17	2	4	Therminol XP	243.1	247.4	103.2	102.9	164.6	166.9	0	5.56	6.3	404.1	409.8	419.9	836.3	131.7	Solid	Turbulent	C.S.	13084	18720	0	0
1	18	2	4	Therminol XP	247.4	251.7	102.9	102.6	166.9	169.2	0	5.56	6.3	405.1	410.9	420.8	838	133.7	Solid	Turbulent	C.S.	13007	18610	0	0
1	19	2	4	Therminol XP	251.7	256	102.6	102.2	169.2	171.5	0	5.56	6.3	406.2	411.8	421.7	839.7	135.8	Solid	Turbulent	C.S.	12930	18500	0	0
1	20	2	4	Therminol XP	256	260.3	102.2	101.9	171.5	173.7	0	5.56	6.3	407.3	412.9	422.6	841.4	138	Solid	Turbulent	C.S.	12853	18390	0	0
1	21	1	3	Therminol XP	260.2	261.6	101.9	101.5	173.7	174.4	0	5.56	6.3	324	326.3	329.9	674.5	129.8	None	Turbulent	C.S.	4195	7329	0	0
1	22	1	3	Therminol XP	261.6	263	101.5	101.2	174.4	175.2	0	5.56	6.3	324.9	327.2	330.8	676.1	130.6	None	Turbulent	C.S.	4189	7318	0	0
1	23	1	3	Therminol XP	263	264.4	101.2	100.8	175.2	175.9	0	5.56	6.3	325.8	328.1	331.7	677.8	131.3	None	Turbulent	C.S.	4183	7307	0	0
1	24	1	3	Therminol XP	264.4	265.8	100.8	100.5	175.9	176.6	0	5.56	6.3	326.7	329	332.6	679.4	132.1	None	Turbulent	C.S.	4177	7296	0	0
1	25	1	2	Therminol XP	265.7	267.4	100.5	100.1	176.6	177.5	0	5.56	6.3	338.9	341.6	346.1	703.6	134.5	None	Turbulent	C.S.	4992	8720	0	0
1	26	1	2	Therminol XP	267.4	269	100.1	99.8	177.5	178.4	0	5.56	6.3	340	342.7	347.2	705.4	135.5	None	Turbulent	C.S.	4984	8706	0	0
1	27	1	2	Therminol XP	269	270.7	99.8	99.4	178.4	179.2	0	5.56	6.3	340.9	343.8	348.1	707.2	136.5	None	Turbulent	C.S.	4976	8693	0	0
1	28	1	2	Therminol XP	270.7	272.3	99.4	99.1	179.2	180.1	0	5.56	6.3	342	344.7	349.2	709	137.5	None	Turbulent	C.S.	4969	8679	0	0
1	29	1	1	Therminol XP	272.3	274.4	99.1	98.7	180.1	181.2	0	5.56	6.3	360.1	363.6	369.1	745.1	141.2	None	Turbulent	C.S.	6282	10973	0	0
1	30	1	1	Therminol XP	274.4	276.4	98.7	98.4	181.2	182.3	0	5.56	6.3	361.2	364.8	370.4	747.2	142.5	None	Turbulent	C.S.	6271	10955	0	0
1	31	1	1	Therminol XP	276.4	278.5	98.4	98	182.3	183.4	0	5.56	6.3	362.5	365.9	371.5	749.3	143.8	None	Turbulent	C.S.	6261	10936	0	0
1	32	1	1	Therminol XP	278.5	280.6	98	97.7	183.4	184.5	0	5.56	6.3	363.6	367	372.6	751.3	145.1	None	Turbulent	C.S.	6251	10918	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°F	500.1	372.6	422.7	336.6
Tube Temperature Margin	°F	59	59	59	59
Design Tube Temperature	°F	527.1	399.6	449.7	363.6
Design Tube Pressure	psi	290.1		290.1	290.1
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456
No. Rows			3	2	3
Tube Spacing	inch	10	10	10	10
Vert. Row Spacing (Vert)	inch	N/A	8.7	8.7	8.7
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	ft²	2505.52	668.81	3507.59	8623.6
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	Ft		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	inch			0.75	1
Fin Thickness	inch			0.05	0.05
Serrated Fin Wn
Fin Density	fins/ft			48	60

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	275.0323	204.2386	232.0417	184.2226
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	123704	132633	129126.3	135157.5
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1332	1.0575	1.086	1.0379
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.13	4.06	4.09	4.04
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.72	4.64	4.67	4.61
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	Ft	68.898
Stack Diameter	Ft	3.904
Cone Diameter	Ft	3.887
Cone Height	Ft	1.64
Actual Exit Velocity	ft/s	21.3
Design Exit Velocity	ft/s	25.6
Flue Gas Temp.	°F	340.9
Flue Gas Flow	lb/s	10.041
Steel Area	ft²	841.241
Stack Entry Pressure	mmH2O	0.001
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	inchH2Og	-0.1
Draft at Arch	inchH2Og	-0.1
Draft at Floor	inchH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°F		inch	BTU/hr ft F		inch	BTU/hr ft F	BTU/hr ft²	BTU/hr ft²	°F
RADIANT FLOOR 1	1326	MW Castable	2.95	2.6768	ULW Castable	5.91	0.9552	232.2	155.2972	161.5	2552	V Y Anchors	161.5	Refrac. thickness OK
RADIANT WALL 1	958.1	Fibre (High Density)	2.95	0.4752	None	0	0	232.3	125.4045	139.6	2300	Twistlock Pins	139.6	Refrac. thickness OK
RADIANT ARCH 1	1416	Fibre (High Density)	3.45	0.678	None	0	0	261.2	242.9795	172.1	2300	Twistlock Pins	172.1	Refrac. thickness OK

CONVECTION SIDEWALL 1	878.5	LW Castable	2.95	2.0492	ULW Castable	2.95	0.8796	232.3	145.8051	147.1	2012	V Y Anchors	147.1	Refrac. thickness OK

STACK 1	340.9	LW Castable	1.97	1.746	None	0	0	232.3	142.9593	147.1	2012	V Y Anchors	147.1	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

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ENERGY PERFORMACE
Total Absorbed Duty	MMBTU/hr	32.67
Total Heat Release	MMBTU/hr	35.9
Total Efficiency	%	91.002

PROCESS
Process Name		Therminol XP
Heat Duty	MMBTU/hr	32.67
Flow rate (sec)	lb/s	88.2
INLET CONDITIONS
Inlet Temperature	°F	212
Inlet Pressure	psi a	108.8
OUTLET CONDITIONS
Outlet Temperature	°F	391.8
Outlet Pressure	psi a	85.691

AIR
Air Flow	lb/s	9.578
Air Temp.	°F	59.9
Excess Air	%	20

FUEL
Fuel Flow	lb/s	0.464
Fuel LHV	BTU/lb	21517
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	lb/s	10.041
Flue Gas Temp.	°F	340.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MMBTU/hr	11.574
Flue Gas Flow	lb/s	10.041
Max Tube Temp.	°F	422.6
Total Press. Loss (inc. gain)	mmH2O	-0.08

RADIANT SECTION
Radiant Cell		1
Heat Duty	MMBTU/hr	21.096
Heat Release	MMBTU/hr	35.9
Arch Temp.	°F	1416.1
Max Tube Temp.	°F	500.1
Average Flux	BTU/hr ft²	8420
Maximum Flux	BTU/hr ft²	17220
No. of Burners		4
Arch Pressure	mmH2O	-0.101
Floor Pressure	mmH2O	-0.488

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	91.002
Daily CO2 Emissions	kg	50169

Commercial

BID / PROJECT VALUE

Total:

£ 736,084

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°F	500.1	372.6	422.7	336.6
No. Tubes		52	24	16	24
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 560,508
Option items
Detail Engineering (by HeaterSIM)	£ 84,076
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£736,084

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	lb/s	88.2	88.2	10.041	10.041	0.464	9.578
Flow (hr)	lb/hr	317520	317520	36149	36149	1670	34479
Temperature	°F	212	391.8	1416.1	340.9	Note 1	15.5
Pressure	psi a	108.8	85.691	-0.101	0.001	Note 2	14.7

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

134 Ft 65 Ft 59 Ft 46 Ft 27 Ft 9 Ft Grade 0.00 Ft 4 Ft 19 Ft 15 Ft 14 Ft 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	inch	10	10	10	10
Vert. Row Spacing (Vert)	inch	N/A	8.7	8.7	8.7
No. Tubes		52	24	16	24
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Therminol XP
Heat Duty	MMBTU/hr	32.67
Flow rate (sec)	lb/s	88.2
Flow rate (hr)	lb/hr	317520
Pressure drop	psi	23.109
Max. Film Temp. Calculated	°F	485.6
Max. Film Temp. Allowed	°F	662
Max Tube Average Flux Calculated (1)	BTU/hr ft²	8536
Average Flux Allowed	BTU/hr ft²	9986
INLET CONDITIONS
Inlet Temperature	°F	212
Inlet Pressure	psi a	108.8
Inlet Vapour Fraction		0
Inlet Enthalpy	BTU/lb	148
OUTLET CONDITIONS
Outlet Temperature	°F	391.8
Outlet Pressure	psi a	85.691
Outlet Vapour Fraction		0
Outlet Enthalpy	BTU/lb	251

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type
Heat Duty	MMBTU/hr	21.096
Heat Release	MMBTU/hr	35.9
Arch Temp.	°F	1416.1
Max Tube Temp.	°F	500.1
Tube Cirle Diameter	Ft	13.793
Average Flux	BTU/hr ft²	8420
Maximum Flux	BTU/hr ft²	17220
Flue Flow	lb/s	10.041
Air Flow	lb/s	9.578
Fuel Flow	lb/s	0.464
Excess Air	%	20
Air Temp.	°F	59.9
Arch Pressure	mmH2O	-0.101
Floor Pressure	mmH2O	-0.488
Radiant Height	Ft	36.37
Radiant Width	Ft	15.04
Radiant Length	Ft	15.04
No. of Burners		4
Burner Cirle Diameter	Ft	3.967
Burner Design Firing	MMBTU/hr	10.77
Burner Normal Firing	MMBTU/hr	8.98
Burner Min Firing	MMBTU/hr	2.15
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	Ft	4.142
API Burner-to-Wall Dist.	Ft	3.709
API Burner-to-Roof/Roof Dist	Ft	26.196
Floor Flux	BTU/hr ft²	202178

Flame-tube impingment risk not identified

Combustion

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Radiant Type
Flue Flow	lb/s	10.041
Air Flow	lb/s	9.578
Fuel Flow	lb/s	0.464
Fuel LHV	BTU/lb	21517
Excess Air	%	20
Air Temp.	°F	59.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°F	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°F	3282
Flue Gas Emissivity		0.443

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
Heat Duty	MMBTU/hr	11.574
Max Tube Temp.	°F	422.6
Total Flue Press. Loss (ex. gain)	mmH2O	0.03
Total Press. Gain	mmH2O	0.11
Total Press. Loss (inc. gain)	mmH2O	-0.08
Convection Width	Ft	4.76
Effective Length	Ft	12.864
Convection Height	Ft	11.815
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	lb/s	10.041
Flue Gas Inlet Temp.	°F	1416.1
Flue Gas Outlet Temp.	°F	341
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MMBTU/hr	°F	°F	BTU/lb	BTU/lb	lb/ft³		BTU/hr ft²	BTU/hr ft²		lb/s ft²	inchH2Og			°F	°F
1	8	Coil Section 3	0.68	410.7	341	93.3	74.4	0.05	Solid	3060	3789	8	0.2	0.003	C.S.	C.S.	276.4	292.2
1	7	Coil Section 3	1.04	515.1	410.7	122.1	93.3	0.04	Solid	4672	5776	8	0.2	0.004	C.S.	C.S.	310.9	334.9
1	6	Coil Section 3	1.63	676.9	515.1	167.3	122.1	0.04	Solid	7319	9013	8	0.2	0.004	C.S.	C.S.	364.7	401.8
1	5	Coil Section 2	1.88	857.7	676.9	219.5	167.3	0.03	Solid	8438	10393	8	0.19	0.003	C.S.	C.S.	390.3	439.8
1	4	Coil Section 2	2.9	1125.7	857.7	299.6	219.5	0.03	Solid	12991	16194	8	0.19	0.004	C.S.	C.S.	472.8	543.3
1	3	Coil Section 1	0.93	1207.3	1125.7	324.6	299.6	0.02	None	4320	7546	8	0.177	0.002	C.S.	None	32	32
1	2	Coil Section 1	1.11	1299.8	1207.3	353.3	324.6	0.02	None	5315	9284	8	0.177	0.002	C.S.	None	32	32
1	1	Coil Section 1	1.4	1416.1	1299.8	386.6	353.3	0.02	None	7136	12464	8	0.177	0.002	C.S.	None	32	32

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MMBTU/hr	°F	°F			°F	°F	psi a	psi a			ft/s	ft/s	ft/s	ft/s	lb/s ft²	lb/s ft²
1	8	Coil Section 3	0.68	410.7	341	Therminol XP	1	212	216	109	107	0	0	6.2	6.2	0	0	317	317	56952	58983
1	7	Coil Section 3	1.04	515.1	410.7	Therminol XP	2	216	222.2	107	106	0	0	6.2	6.2	0	0	317	317	58981	62278
1	6	Coil Section 3	1.63	676.9	515.1	Therminol XP	3	222.2	231.9	106	105	0	0	6.2	6.2	0	0	317	317	62286	68001
1	5	Coil Section 2	1.88	857.7	676.9	Therminol XP	4	231.9	243.1	105	103	0	0	6.2	6.2	0	0	317	317	68002	75592
1	4	Coil Section 2	2.9	1125.7	857.7	Therminol XP	5	243.1	260.3	103	102	0	0	6.2	6.3	0	0	317	317	75606	90094
1	3	Coil Section 1	0.93	1207.3	1125.7	Therminol XP	6	260.2	265.8	102	100	0	0	6.3	6.3	0	0	317	317	90010	95619
1	2	Coil Section 1	1.11	1299.8	1207.3	Therminol XP	7	265.7	272.3	100	99	0	0	6.3	6.3	0	0	317	317	95581	103022
1	1	Coil Section 1	1.4	1416.1	1299.8	Therminol XP	8	272.3	280.6	99	98	0	0	6.3	6.3	0	0	317	317	102989	113644

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MMBTU/hr	°F	°F			°F	°F	psi a	psi a			ft/s	ft/s	ft/s	ft/s	lb/s ft²	lb/s ft²
1	8	Coil Section 3	0.68	410.7	341	Therminol XP	1	212	216	109	107	0	0	6.2	6.2	0	0	317	317	56952	58983
1	7	Coil Section 3	1.04	515.1	410.7	Therminol XP	2	216	222.2	107	106	0	0	6.2	6.2	0	0	317	317	58981	62278
1	6	Coil Section 3	1.63	676.9	515.1	Therminol XP	3	222.2	231.9	106	105	0	0	6.2	6.2	0	0	317	317	62286	68001
1	5	Coil Section 2	1.88	857.7	676.9	Therminol XP	4	231.9	243.1	105	103	0	0	6.2	6.2	0	0	317	317	68002	75592
1	4	Coil Section 2	2.9	1125.7	857.7	Therminol XP	5	243.1	260.3	103	102	0	0	6.2	6.3	0	0	317	317	75606	90094
1	3	Coil Section 1	0.93	1207.3	1125.7	Therminol XP	6	260.2	265.8	102	100	0	0	6.3	6.3	0	0	317	317	90010	95619
1	2	Coil Section 1	1.11	1299.8	1207.3	Therminol XP	7	265.7	272.3	100	99	0	0	6.3	6.3	0	0	317	317	95581	103022
1	1	Coil Section 1	1.4	1416.1	1299.8	Therminol XP	8	272.3	280.6	99	98	0	0	6.3	6.3	0	0	317	317	102989	113644

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°F	°F	psi a	psi a	BTU/lb	BTU/lb			ft/s	°F	°F	°F	°F	BTU/hr ft² °F			BTU/hr ft²	BTU/hr ft²
1	Wall	Therminol XP	280.6	284.9	97.7	108.7	184.5	187.1	0	5.56	6.3	411.6	416.7	426.2	453.2	151.4	Turbulent		8536	17401	0	0
2	Wall	Therminol XP	284.9	289.2	108.7	96.8	187.1	189.6	0	5.56	6.4	414.4	419.5	429	456	153.2	Turbulent		8527	17387	0	0
3	Wall	Therminol XP	289.2	293.6	96.8	107.7	189.6	192.2	0	5.56	6.4	417.2	422.3	431.8	458.8	154.9	Turbulent		8518	17373	0	0
4	Wall	Therminol XP	293.6	297.9	107.7	95.9	192.2	194.7	0	5.56	6.4	420	425.2	434.6	461.6	156.7	Turbulent		8509	17359	0	0
5	Wall	Therminol XP	297.9	302.3	95.9	106.8	194.7	197.3	0	5.56	6.4	422.9	428	437.4	464.4	158.6	Turbulent		8500	17345	0	0
6	Wall	Therminol XP	302.3	306.6	106.8	95	197.3	199.8	0	5.56	6.4	425.7	430.8	440.3	467.3	160.4	Turbulent		8490	17331	0	0
7	Wall	Therminol XP	306.6	310.9	95	105.8	199.8	202.4	0	5.56	6.4	428.5	433.7	443.1	470.1	162.3	Turbulent		8481	17316	0	0
8	Wall	Therminol XP	310.9	315.3	105.8	94	202.4	205	0	5.56	6.4	431.4	436.5	445.9	472.9	164.3	Turbulent		8472	17302	0	0
9	Wall	Therminol XP	315.3	319.6	94	104.9	205	207.5	0	5.56	6.5	434.2	439.3	448.8	475.8	166.3	Turbulent		8463	17287	0	0
10	Wall	Therminol XP	319.6	323.9	104.9	93.1	207.5	210.1	0	5.56	6.5	437.1	442.2	451.6	478.6	168.4	Turbulent		8453	17273	0	0
11	Wall	Therminol XP	323.9	328.3	93.1	103.9	210.1	212.6	0	5.56	6.5	439.9	445	454.5	481.5	170.5	Turbulent		8444	17258	0	0
12	Wall	Therminol XP	328.3	332.6	103.9	92.2	212.6	215.2	0	5.56	6.5	442.9	448.1	457.5	484.5	172.6	Turbulent		8434	17242	0	0
13	Wall	Therminol XP	332.6	336.9	92.2	102.9	215.2	217.7	0	5.56	6.5	445.9	451	460.4	487.4	174.7	Turbulent		8425	17227	0	0
14	Wall	Therminol XP	336.9	341.3	102.9	91.3	217.7	220.3	0	5.56	6.5	448.8	453.9	463.3	490.3	176.8	Turbulent		8415	17211	0	0
15	Wall	Therminol XP	341.3	345.6	91.3	102	220.3	222.9	0	5.56	6.5	451.7	456.8	466.2	493.2	179.1	Turbulent		8405	17196	0	0
16	Wall	Therminol XP	345.6	350	102	90.4	222.9	225.4	0	5.56	6.5	454.6	459.7	469.1	496.1	181.3	Turbulent		8395	17181	0	0
17	Wall	Therminol XP	350	354.3	90.4	101	225.4	228	0	5.56	6.6	457.5	462.6	472	499	183.7	Turbulent		8386	17165	0	0
18	Wall	Therminol XP	354.3	358.6	101	89.4	228	230.5	0	5.56	6.6	460.4	465.4	474.9	501.9	186.1	Turbulent		8376	17150	0	0
19	Wall	Therminol XP	358.6	362.8	89.4	100	230.5	233.1	0	5.56	6.6	463.2	468.4	477.8	504.8	188.4	Turbulent		8366	17134	0	0
20	Wall	Therminol XP	362.8	367	100	88.5	233.1	235.6	0	5.56	6.6	466.4	471.6	480.9	507.9	190	Turbulent		8355	17116	0	0
21	Wall	Therminol XP	367	371.1	88.5	99	235.6	238.2	0	5.56	6.6	469.6	474.8	484.1	511.1	191.6	Turbulent		8344	17099	0	0
22	Wall	Therminol XP	371.1	375.2	99	87.6	238.2	240.8	0	5.56	6.6	472.8	478	487.3	514.3	193.3	Turbulent		8333	17081	0	0
23	Wall	Therminol XP	375.2	379.4	87.6	98.1	240.8	243.3	0	5.56	6.6	476	481.2	490.5	517.5	195	Turbulent		8322	17063	0	0
24	Wall	Therminol XP	379.4	383.5	98.1	86.6	243.3	245.9	0	5.56	6.7	479.2	484.4	493.7	520.7	196.7	Turbulent		8311	17045	0	0
25	Wall	Therminol XP	383.5	387.7	86.6	97.1	245.9	248.4	0	5.56	6.7	482.4	487.5	496.9	523.9	198.5	Turbulent		8300	17027	0	0
26	Wall	Therminol XP	387.7	391.8	97.1	85.7	248.4	251	0	5.56	6.7	485.6	490.7	500.1	527.1	200.3	Turbulent		8289	17009	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°F	°F	psi a	psi a	BTU/lb	BTU/lb			ft/s	°F	°F	°F	°F	BTU/hr ft² °F				BTU/hr ft²	BTU/hr ft²
1	1	3	8	Therminol XP	212	213	108.8	108.5	148.1	148.6	0	5.56	6.2	260.1	261.3	263.5	555	103.2	Solid	Turbulent	C.S.	3083	4395	0	0
1	2	3	8	Therminol XP	213	214	108.5	108.1	148.6	149.2	0	5.56	6.2	260.6	261.9	264	555.9	103.6	Solid	Turbulent	C.S.	3063	4367	0	0
1	3	3	8	Therminol XP	214	215	108.1	107.8	149.2	149.7	0	5.56	6.2	261	262.2	264.6	556.8	104	Solid	Turbulent	C.S.	3043	4338	0	0
1	4	3	8	Therminol XP	215	216	107.8	107.4	149.7	150.2	0	5.56	6.2	261.5	262.8	265.1	557.8	104.4	Solid	Turbulent	C.S.	3023	4310	0	0
1	5	3	7	Therminol XP	216	217.6	107.4	107.1	150.2	151.1	0	5.56	6.2	285.8	287.6	291.2	604.7	108.6	Solid	Turbulent	C.S.	4707	6704	0	0
1	6	3	7	Therminol XP	217.6	219.1	107.1	106.7	151.1	151.9	0	5.56	6.2	286.5	288.5	291.9	606	109.1	Solid	Turbulent	C.S.	4676	6660	0	0
1	7	3	7	Therminol XP	219.1	220.7	106.7	106.4	151.9	152.7	0	5.56	6.2	287.2	289.2	292.6	607.3	109.7	Solid	Turbulent	C.S.	4646	6617	0	0
1	8	3	7	Therminol XP	220.7	222.2	106.4	106	152.7	153.5	0	5.56	6.2	288	289.9	293.4	608.6	110.3	Solid	Turbulent	C.S.	4615	6573	0	0
1	9	3	6	Therminol XP	222.2	224.7	106	105.7	153.5	154.8	0	5.56	6.2	325.4	328.5	334	681.8	114.9	Solid	Turbulent	C.S.	7376	10477	0	0
1	10	3	6	Therminol XP	224.7	227.1	105.7	105.3	154.8	156.1	0	5.56	6.2	326.3	329.4	334.9	683.3	115.8	Solid	Turbulent	C.S.	7326	10407	0	0
1	11	3	6	Therminol XP	227.1	229.5	105.3	105	156.1	157.4	0	5.56	6.2	327.2	330.3	335.7	684.9	116.8	Solid	Turbulent	C.S.	7276	10336	0	0
1	12	3	6	Therminol XP	229.5	231.9	105	104.6	157.4	158.7	0	5.56	6.2	328.1	331.2	336.6	686.5	117.8	Solid	Turbulent	C.S.	7227	10266	0	0
1	13	2	5	Therminol XP	231.9	234.7	104.6	104.3	158.7	160.2	0	5.56	6.2	344.8	348.3	354.7	719.1	120.8	Solid	Turbulent	C.S.	8493	12057	0	0
1	14	2	5	Therminol XP	234.7	237.5	104.3	103.9	160.2	161.6	0	5.56	6.2	345.9	349.3	355.8	721	122	Solid	Turbulent	C.S.	8448	11992	0	0
1	15	2	5	Therminol XP	237.5	240.3	103.9	103.6	161.6	163.1	0	5.56	6.2	347	350.6	356.9	722.9	123.3	Solid	Turbulent	C.S.	8403	11928	0	0
1	16	2	5	Therminol XP	240.3	243.1	103.6	103.2	163.1	164.6	0	5.56	6.2	348.1	351.7	358	724.9	124.6	Solid	Turbulent	C.S.	8357	11864	0	0
1	17	2	4	Therminol XP	243.1	247.4	103.2	102.9	164.6	166.9	0	5.56	6.3	404.1	409.8	419.9	836.3	131.7	Solid	Turbulent	C.S.	13084	18720	0	0
1	18	2	4	Therminol XP	247.4	251.7	102.9	102.6	166.9	169.2	0	5.56	6.3	405.1	410.9	420.8	838	133.7	Solid	Turbulent	C.S.	13007	18610	0	0
1	19	2	4	Therminol XP	251.7	256	102.6	102.2	169.2	171.5	0	5.56	6.3	406.2	411.8	421.7	839.7	135.8	Solid	Turbulent	C.S.	12930	18500	0	0
1	20	2	4	Therminol XP	256	260.3	102.2	101.9	171.5	173.7	0	5.56	6.3	407.3	412.9	422.6	841.4	138	Solid	Turbulent	C.S.	12853	18390	0	0
1	21	1	3	Therminol XP	260.2	261.6	101.9	101.5	173.7	174.4	0	5.56	6.3	324	326.3	329.9	674.5	129.8	None	Turbulent	C.S.	4195	7329	0	0
1	22	1	3	Therminol XP	261.6	263	101.5	101.2	174.4	175.2	0	5.56	6.3	324.9	327.2	330.8	676.1	130.6	None	Turbulent	C.S.	4189	7318	0	0
1	23	1	3	Therminol XP	263	264.4	101.2	100.8	175.2	175.9	0	5.56	6.3	325.8	328.1	331.7	677.8	131.3	None	Turbulent	C.S.	4183	7307	0	0
1	24	1	3	Therminol XP	264.4	265.8	100.8	100.5	175.9	176.6	0	5.56	6.3	326.7	329	332.6	679.4	132.1	None	Turbulent	C.S.	4177	7296	0	0
1	25	1	2	Therminol XP	265.7	267.4	100.5	100.1	176.6	177.5	0	5.56	6.3	338.9	341.6	346.1	703.6	134.5	None	Turbulent	C.S.	4992	8720	0	0
1	26	1	2	Therminol XP	267.4	269	100.1	99.8	177.5	178.4	0	5.56	6.3	340	342.7	347.2	705.4	135.5	None	Turbulent	C.S.	4984	8706	0	0
1	27	1	2	Therminol XP	269	270.7	99.8	99.4	178.4	179.2	0	5.56	6.3	340.9	343.8	348.1	707.2	136.5	None	Turbulent	C.S.	4976	8693	0	0
1	28	1	2	Therminol XP	270.7	272.3	99.4	99.1	179.2	180.1	0	5.56	6.3	342	344.7	349.2	709	137.5	None	Turbulent	C.S.	4969	8679	0	0
1	29	1	1	Therminol XP	272.3	274.4	99.1	98.7	180.1	181.2	0	5.56	6.3	360.1	363.6	369.1	745.1	141.2	None	Turbulent	C.S.	6282	10973	0	0
1	30	1	1	Therminol XP	274.4	276.4	98.7	98.4	181.2	182.3	0	5.56	6.3	361.2	364.8	370.4	747.2	142.5	None	Turbulent	C.S.	6271	10955	0	0
1	31	1	1	Therminol XP	276.4	278.5	98.4	98	182.3	183.4	0	5.56	6.3	362.5	365.9	371.5	749.3	143.8	None	Turbulent	C.S.	6261	10936	0	0
1	32	1	1	Therminol XP	278.5	280.6	98	97.7	183.4	184.5	0	5.56	6.3	363.6	367	372.6	751.3	145.1	None	Turbulent	C.S.	6251	10918	0	0

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°F	500.1	372.6	422.7	336.6
Tube Temperature Margin	°F	59	59	59	59
Design Tube Temperature	°F	527.1	399.6	449.7	363.6
Design Tube Pressure	psi	290.1		290.1	290.1
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456
No. Rows			3	2	3
Tube Spacing	inch	10	10	10	10
Vert. Row Spacing (Vert)	inch	N/A	8.7	8.7	8.7
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	ft²	2505.52	668.81	3507.59	8623.6
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	Ft		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	inch			0.75	1
Fin Thickness	inch			0.05	0.05
Serrated Fin Wn
Fin Density	fins/ft			48	60

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	275.0323	204.2386	232.0417	184.2226
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	123704	132633	129126.3	135157.5
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1332	1.0575	1.086	1.0379
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.13	4.06	4.09	4.04
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.72	4.64	4.67	4.61
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	Ft	68.898
Stack Diameter	Ft	3.904
Cone Diameter	Ft	3.887
Cone Height	Ft	1.64
Actual Exit Velocity	ft/s	21.3
Design Exit Velocity	ft/s	25.6
Flue Gas Temp.	°F	340.9
Flue Gas Flow	lb/s	10.041
Steel Area	ft²	841.241
Stack Entry Pressure	mmH2O	0.001
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	inchH2Og	-0.1
Draft at Arch	inchH2Og	-0.1
Draft at Floor	inchH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°F		inch	BTU/hr ft F		inch	BTU/hr ft F	BTU/hr ft²	BTU/hr ft²	°F
RADIANT FLOOR 1	1326	MW Castable	2.95	2.6768	ULW Castable	5.91	0.9552	232.2	155.2972	161.5	2552	V Y Anchors	161.5	Refrac. thickness OK
RADIANT WALL 1	958.1	Fibre (High Density)	2.95	0.4752	None	0	0	232.3	125.4045	139.6	2300	Twistlock Pins	139.6	Refrac. thickness OK
RADIANT ARCH 1	1416	Fibre (High Density)	3.45	0.678	None	0	0	261.2	242.9795	172.1	2300	Twistlock Pins	172.1	Refrac. thickness OK

CONVECTION SIDEWALL 1	878.5	LW Castable	2.95	2.0492	ULW Castable	2.95	0.8796	232.3	145.8051	147.1	2012	V Y Anchors	147.1	Refrac. thickness OK

STACK 1	340.9	LW Castable	1.97	1.746	None	0	0	232.3	142.9593	147.1	2012	V Y Anchors	147.1	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

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ENERGY PERFORMACE
Total Absorbed Duty	MW	9.628
Total Heat Release	MW	11.132
Total Efficiency	%	86.487

PROCESS
Process Name		Crude Oil 1
Heat Duty	MW	9.628
Flow rate (sec)	kg/s	40
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
OUTLET CONDITIONS
Outlet Temperature	°C	516.4
Outlet Pressure	kPa a	359.307

AIR
Air Flow	kg/s	4.596
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.223
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	kg/s	4.819
Flue Gas Temp.	°C	263.4
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	3.386
Flue Gas Flow	kg/s	4.819
Max Tube Temp.	°C	322.4
Total Press. Loss (inc. gain)	mmH2O	-2.64

RADIANT SECTION
Radiant Cell		1
Heat Duty	MW	6.242
Heat Release	MW	11.132
Arch Temp.	°C	811.8
Max Tube Temp.	°C	539.4
Average Flux	W/m²	30744
Maximum Flux	W/m²	51183
No. of Burners		4
Arch Pressure	mmH2O	-4.413
Floor Pressure	mmH2O	-12.378

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	86.487
Daily CO2 Emissions	kg	53080

Commercial

BID / PROJECT VALUE

Total:

£ 813,264

SAFETY AND COMPLIANCE

Radiant cell no. 1: The burners to tube distance seems OK (API 560)

Radiant cell no. 1: The burners to wall clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Radiant cell no. 1: Single lane of burners considered

Stack No. 1: Auto Stack calc. has converged OK

Convergence has been achieved To within 1% of the specified duty

Radiant section 1,Coil sect. no. 1, does not satisfy API 530 requirements

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	539.4	322.4	319.4	257.1
No. Tubes		48	24	16	24
Effective Length	m	8	5.835	5.835	5.835
Straight Length	m	7.5	6.235	6.235	6.235

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 627,621
Option items
Detail Engineering (by HeaterSIM)	£ 94,143
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£813,264

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Crude Oil 1	Crude Oil 1	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	4.819	4.819	0.223	4.596
Flow (hr)	kg/hr	144000	144000	17348	17348	801	16547
Temperature	°C	200	516.4	811.8	263.4	Note 1	15.5
Pressure	kPa a	750.1	359.307	-4.413	-1.064	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

33.141 m 18.141 m 16.341 m 11.8 m 7.3 m 2.8 m Grade 0.00 m 1.32 m 2.591 m 3.75 m 0 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	304.8	304.8	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1	264.1
No. Tubes		48	24	16	24
Effective Length	m	8	5.835	5.835	5.835
Straight Length	m	7.5	6.235	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Crude Oil 1
Heat Duty	MW	9.628
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	390.793
Max. Film Temp. Calculated	°C	531.5
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	33602
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	217
OUTLET CONDITIONS
Outlet Temperature	°C	516.4
Outlet Pressure	kPa a	359.307
Outlet Vapour Fraction		0.546
Outlet Enthalpy	kJ/kg	457

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type
Heat Duty	MW	6.242
Heat Release	MW	11.132
Arch Temp.	°C	811.8
Max Tube Temp.	°C	539.4
Tube Cirle Diameter	m	N/A
Average Flux	W/m²	30744
Maximum Flux	W/m²	51183
Flue Flow	kg/s	4.819
Air Flow	kg/s	4.596
Fuel Flow	kg/s	0.223
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-4.413
Floor Pressure	mmH2O	-12.378
Radiant Height	m	9
Radiant Width	m	3.75
Radiant Length	m	7.77
No. of Burners		4
Burner Cirle Diameter	m	N/A
Burner Design Firing	MW	3.34
Burner Normal Firing	MW	2.78
Burner Min Firing	MW	0.67
Burner-to-Tube Note		OK
Burner-to-Wall Note		OK
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.336
API Burner-to-Wall Dist.	m	1.179
API Burner-to-Roof/Roof Dist	m	8.356
Floor Flux	W/m²	381900

Flame-tube impingment risk not identified

Combustion

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Radiant Type
Flue Flow	kg/s	4.819
Air Flow	kg/s	4.596
Fuel Flow	kg/s	0.223
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°C	1805.6
Flue Gas Emissivity		0.485

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
Heat Duty	MW	3.386
Max Tube Temp.	°C	322.4
Total Flue Press. Loss (ex. gain)	mmH2O	0.53
Total Press. Gain	mmH2O	3.16
Total Press. Loss (inc. gain)	mmH2O	-2.64
Convection Width	m	2.591
Effective Length	m	5.835
Convection Height	m	4.041
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	4.819
Flue Gas Inlet Temp.	°C	811.8
Flue Gas Outlet Temp.	°C	263.4
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.19	297.1	263.4	317.6	277.4	0.61	Solid	7837	9866	8	0.834	0.075	C.S.	C.S.	226	234.2
1	7	Coil Section 3	0.29	348.1	297.1	377.7	317.6	0.57	Solid	11750	14760	8	0.834	0.08	C.S.	C.S.	243	255.3
1	6	Coil Section 3	0.44	425.5	348.1	469.7	377.7	0.51	Solid	17971	22490	8	0.834	0.088	C.S.	C.S.	269.7	288.1
1	5	Coil Section 2	0.52	513.9	425.5	578.3	469.7	0.46	Solid	21224	27303	8	0.801	0.072	C.S.	C.S.	290.2	314.4
1	4	Coil Section 2	0.82	647.9	513.9	748.1	578.3	0.4	Solid	33160	43872	8	0.801	0.082	C.S.	C.S.	341.2	375.7
1	3	Coil Section 1	0.3	693.7	647.9	806.8	748.1	0.36	None	12462	21607	8	0.756	0.041	C.S.	None	0	0
1	2	Coil Section 1	0.36	745.4	693.7	874.7	806.8	0.34	None	15765	27334	8	0.756	0.043	C.S.	None	0	0
1	1	Coil Section 1	0.46	811.8	745.4	954.5	874.7	0.32	None	22069	38262	8	0.756	0.046	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.19	297.1	263.4	Crude Oil 1	1	200	204.1	750	746	0	0	1.5	1.5	0	0	1073	1073	229542	229542
1	7	Coil Section 3	0.29	348.1	297.1	Crude Oil 1	2	204.1	210.4	746	741	0	0	1.5	1.5	0	0	1073	1073	229542	229542
1	6	Coil Section 3	0.44	425.5	348.1	Crude Oil 1	3	210.4	219.9	741	737	0	0	1.5	1.5	0	0	1073	1073	229542	229542
1	5	Coil Section 2	0.52	513.9	425.5	Crude Oil 1	4	219.9	231.1	737	733	0	0	1.5	1.5	0	0	1073	1073	229542	230773
1	4	Coil Section 2	0.82	647.9	513.9	Crude Oil 1	5	231.1	248.6	733	728	0	0	1.5	1.5	0	0	1073	1073	230773	232631
1	3	Coil Section 1	0.3	693.7	647.9	Crude Oil 1	6	248.6	254.9	728	724	0	0	1.5	1.5	0	0	1073	1073	232631	232775
1	2	Coil Section 1	0.36	745.4	693.7	Crude Oil 1	7	254.9	262.6	724	711	0	0.02	1.5	6.1	0	62.3	1073	1073	232775	237641
1	1	Coil Section 1	0.46	811.8	745.4	Crude Oil 1	8	262.6	272.6	711	687	0.02	0.04	6.1	9.7	62.3	78.9	1073	1073	237641	242719

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.19	297.1	263.4	Crude Oil 1	1	200	204.1	750	746	0	0	1.5	1.5	0	0	1073	1073	229542	229542
1	7	Coil Section 3	0.29	348.1	297.1	Crude Oil 1	2	204.1	210.4	746	741	0	0	1.5	1.5	0	0	1073	1073	229542	229542
1	6	Coil Section 3	0.44	425.5	348.1	Crude Oil 1	3	210.4	219.9	741	737	0	0	1.5	1.5	0	0	1073	1073	229542	229542
1	5	Coil Section 2	0.52	513.9	425.5	Crude Oil 1	4	219.9	231.1	737	733	0	0	1.5	1.5	0	0	1073	1073	229542	230773
1	4	Coil Section 2	0.82	647.9	513.9	Crude Oil 1	5	231.1	248.6	733	728	0	0	1.5	1.5	0	0	1073	1073	230773	232631
1	3	Coil Section 1	0.3	693.7	647.9	Crude Oil 1	6	248.6	254.9	728	724	0	0	1.5	1.5	0	0	1073	1073	232631	232775
1	2	Coil Section 1	0.36	745.4	693.7	Crude Oil 1	7	254.9	262.6	724	711	0	0.02	1.5	6.1	0	62.3	1073	1073	232775	237641
1	1	Coil Section 1	0.46	811.8	745.4	Crude Oil 1	8	262.6	272.6	711	687	0.02	0.04	6.1	9.7	62.3	78.9	1073	1073	237641	242719

Radiant Tube Profile

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Crude Oil 1	272.6	284.8	686.6	683.8	301.3	307.8	0.06	168.3	12	361.6	360.1	371	386	791	Annular		33602	55550	0.5471577	790824.4
2	Wall	Crude Oil 1	284.8	291.7	683.8	658	307.8	314.3	0.08	168.3	12	368.7	370	378.1	393.1	782.3	Annular		33244	55111	0.6415943	790824.4
3	Wall	Crude Oil 1	291.7	298.7	658	654.6	314.3	320.8	0.1	168.3	12.1	375.5	376.7	384.9	399.9	777.9	Annular		32991	54729	0.7303693	790824.4
4	Wall	Crude Oil 1	298.7	305.6	654.6	628.9	320.8	327.3	0.12	168.3	12.4	381.9	383.1	391.2	406.2	778	Annular		32750	54362	0.7896334	790824.4
5	Wall	Crude Oil 1	305.6	312.5	628.9	625.2	327.3	333.8	0.14	168.3	12.5	387.9	389.1	397.2	412.2	782	Annular		32518	54010	0.8869874	790824.4
6	Wall	Crude Oil 1	312.5	319.4	625.2	599.7	333.8	340.3	0.16	168.3	12.9	393.6	394.8	402.8	417.8	789.9	Annular		32297	53672	0.9523991	790824.4
7	Wall	Crude Oil 1	319.4	326.3	599.7	595.5	340.3	346.8	0.18	168.3	13	398.7	399.8	407.8	422.8	805.6	Annular		32099	53366	1.068022	790824.3
8	Wall	Crude Oil 1	326.3	333.2	595.5	570.1	346.8	353.3	0.21	168.3	13.4	403.5	404.6	412.6	427.6	824.7	Annular		31905	53069	1.139341	790824.4
9	Wall	Crude Oil 1	333.2	340.1	570.1	565.3	353.3	359.8	0.23	168.3	13.6	407.6	408.6	416.7	431.7	856.1	Annular		31743	52816	1.273264	790824.4
10	Wall	Crude Oil 1	340.1	352.2	565.3	540.1	359.8	366.3	0.27	168.3	13.7	416	414.5	425	440	896.9	Annular		31503	52324	1.370287	790824.4
11	Wall	Crude Oil 1	352.2	364.3	540.1	535.4	366.3	372.8	0.29	168.3	13.5	398	396.5	407.2	422.2	1734.8	Annular		32228	53452	1.533497	790824.4
12	Wall	Crude Oil 1	364.3	376.4	535.4	510.5	372.8	379.3	0.33	168.3	13.2	407.2	405.7	416.3	431.3	1875.3	Annular		31860	52880	1.632465	790824.4
13	Wall	Crude Oil 1	376.4	388.5	510.5	506.6	379.3	385.8	0.35	168.3	13	416.3	414.7	425.3	440.3	2059.3	Annular		31491	52305	1.770741	790824.4
14	Wall	Crude Oil 1	388.5	400.6	506.6	482.2	385.8	392.3	0.38	168.3	12.6	426.5	424.9	435.5	450.5	2180	Annular		31064	51634	1.857813	790824.4
15	Wall	Crude Oil 1	400.6	412.7	482.2	479.2	392.3	398.8	0.4	168.3	12.4	436.5	434.9	445.4	460.4	2338.6	Annular		30633	50956	1.976361	790824.4
16	Wall	Crude Oil 1	412.7	424.8	479.2	455.1	398.8	405.3	0.43	168.3	11.9	447.3	445.6	456.1	471.1	2442.4	Annular		30160	50205	2.054025	790824.4
17	Wall	Crude Oil 1	424.8	436.9	455.1	453.2	405.3	411.8	0.44	168.3	11.7	457.9	456.2	466.6	481.6	2578.5	Annular		29681	49441	2.154263	790824.4
18	Wall	Crude Oil 1	436.9	449	453.2	429.4	411.8	418.3	0.47	168.3	11.2	468.9	467.2	477.5	492.5	2667.9	Annular		29166	48616	2.223874	790824.3
19	Wall	Crude Oil 1	449	461.1	429.4	428.6	418.3	424.8	0.48	168.3	11	479.9	478.1	488.3	503.3	2783.4	Annular		28642	47772	2.305027	790824.4
20	Wall	Crude Oil 1	461.1	473.2	428.6	405	424.8	431.4	0.5	168.3	10.6	491.1	489.2	499.5	514.5	2860.6	Annular		28088	46875	2.367425	790824.4
21	Wall	Crude Oil 1	473.2	485.3	405	405.3	431.4	437.9	0.51	168.3	10.4	502.3	500.4	510.5	525.5	2956.8	Annular		27522	45953	2.42736	790824.4
22	Wall	Crude Oil 1	485.3	497.4	405.3	381.8	437.9	444.4	0.52	168.3	10.2	513.7	511.7	521.8	536.8	3022.8	Mist		26929	44983	2.483273	790824.4
23	Wall	Crude Oil 1	497.4	507.2	381.8	382.7	444.4	450.9	0.53	168.3	10.1	522.8	521.9	530.8	545.8	3101.7	Mist		26378	44162	2.564702	790824.4
24	Wall	Crude Oil 1	507.2	516.4	382.7	359.3	450.9	457.4	0.55	168.3	10.1	531.5	530.8	539.4	554.4	3150	Mist		25883	43372	2.609149	790824.4

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Crude Oil 1	200	201	750.1	749	216.7	217.9	0	168.3	1.5	216.3	216.7	218.1	233.1	822.5	Solid	Turbulent	C.S.	7960	11464	0	0
1	2	3	8	Crude Oil 1	201	202.1	749	747.9	217.9	219.1	0	168.3	1.5	217.1	217.5	218.9	233.9	822.7	Solid	Turbulent	C.S.	7853	11310	0	0
1	3	3	8	Crude Oil 1	202.1	203.1	747.9	746.8	219.1	220.3	0	168.3	1.5	217.9	218.3	219.7	234.7	822.8	Solid	Turbulent	C.S.	7746	11156	0	0
1	4	3	8	Crude Oil 1	203.1	204.1	746.8	745.7	220.3	221.5	0	168.3	1.5	218.7	219.1	220.5	235.5	823	Solid	Turbulent	C.S.	7639	11002	0	0
1	5	3	7	Crude Oil 1	204.1	205.7	745.7	744.6	221.5	223.3	0	168.3	1.5	228.5	229.1	231.2	246.2	823.7	Solid	Turbulent	C.S.	11937	17166	0	0
1	6	3	7	Crude Oil 1	205.7	207.2	744.6	743.6	223.3	225.1	0	168.3	1.5	229.7	230.3	232.4	247.4	824.1	Solid	Turbulent	C.S.	11774	16932	0	0
1	7	3	7	Crude Oil 1	207.2	208.8	743.6	742.5	225.1	226.9	0	168.3	1.5	230.9	231.5	233.6	248.6	824.4	Solid	Turbulent	C.S.	11611	16697	0	0
1	8	3	7	Crude Oil 1	208.8	210.4	742.5	741.4	226.9	228.7	0	168.3	1.5	232.2	232.7	234.8	249.8	824.8	Solid	Turbulent	C.S.	11448	16463	0	0
1	9	3	6	Crude Oil 1	210.4	212.7	741.4	740.3	228.7	231.5	0	168.3	1.5	247.4	248.3	251.6	266.6	825.9	Solid	Turbulent	C.S.	18263	26200	0	0
1	10	3	6	Crude Oil 1	212.7	215.1	740.3	739.2	231.5	234.3	0	168.3	1.5	249.2	250.1	253.4	268.4	826.4	Solid	Turbulent	C.S.	18007	25832	0	0
1	11	3	6	Crude Oil 1	215.1	217.5	739.2	738.1	234.3	237.1	0	168.3	1.5	251.1	252	255.2	270.2	826.9	Solid	Turbulent	C.S.	17750	25464	0	0
1	12	3	6	Crude Oil 1	217.5	219.9	738.1	737	237.1	239.8	0	168.3	1.5	253	253.8	257.1	272.1	827.3	Solid	Turbulent	C.S.	17493	25095	0	0
1	13	2	5	Crude Oil 1	219.9	222.7	737	735.9	239.8	243.1	0	168.3	1.5	264.1	265.3	269.2	284.2	827.9	Solid	Turbulent	C.S.	21525	31419	0	0
1	14	2	5	Crude Oil 1	222.7	225.5	735.9	734.8	243.1	246.4	0	168.3	1.5	266.4	267.5	271.4	286.4	828.8	Solid	Turbulent	C.S.	21277	31056	0	0
1	15	2	5	Crude Oil 1	225.5	228.3	734.8	733.7	246.4	249.6	0	168.3	1.5	268.7	269.8	273.7	288.7	829.7	Solid	Turbulent	C.S.	21028	30693	0	0
1	16	2	5	Crude Oil 1	228.3	231.1	733.7	732.6	249.6	252.9	0	168.3	1.5	271	272	275.9	290.9	830.6	Solid	Turbulent	C.S.	20779	30329	0	0
1	17	2	4	Crude Oil 1	231.1	235.5	732.6	731.5	252.9	258	0	168.3	1.5	301.1	303.1	309.4	324.4	832.8	Solid	Turbulent	C.S.	33678	50080	0	0
1	18	2	4	Crude Oil 1	235.5	239.8	731.5	730.4	258	263.1	0	168.3	1.5	304.5	306.4	312.7	327.7	834.4	Solid	Turbulent	C.S.	33241	49432	0	0
1	19	2	4	Crude Oil 1	239.8	244.2	730.4	729.3	263.1	268.3	0	168.3	1.5	308	309.8	316	331	835.8	Solid	Turbulent	C.S.	32805	48783	0	0
1	20	2	4	Crude Oil 1	244.2	248.6	729.3	728.2	268.3	273.4	0	168.3	1.5	311.4	313.2	319.4	334.4	837.3	Solid	Turbulent	C.S.	32368	48134	0	0
1	21	1	3	Crude Oil 1	248.6	250.2	728.2	727.1	273.4	275.2	0	168.3	1.5	277.4	278.3	280.8	295.8	836.4	None	Turbulent	C.S.	12025	20848	0	0
1	22	1	3	Crude Oil 1	250.2	251.8	727.1	726	275.2	277.1	0	168.3	1.5	278.9	279.8	282.2	297.2	836.8	None	Turbulent	C.S.	11981	20773	0	0
1	23	1	3	Crude Oil 1	251.8	253.3	726	725	277.1	278.9	0	168.3	1.5	280.4	281.2	283.7	298.7	837.1	None	Turbulent	C.S.	11938	20698	0	0
1	24	1	3	Crude Oil 1	253.3	254.9	725	723.9	278.9	280.7	0	168.3	1.5	281.8	282.7	285.2	300.2	837.5	None	Turbulent	C.S.	11895	20623	0	0
1	25	1	2	Crude Oil 1	254.9	256.8	723.9	722.8	280.7	283	0.0108	168.3	4	289.8	290.9	294	309	838.2	None	Turbulent	C.S.	14596	25306	0	0
1	26	1	2	Crude Oil 1	256.8	258.8	722.8	719.3	283	285.2	0.014	168.3	4.7	292.3	293.4	296.4	311.4	821.6	None	Bubble	C.S.	14540	25210	4376.874	2697.688
1	27	1	2	Crude Oil 1	258.8	260.7	719.3	715.3	285.2	287.5	0.0173	168.3	5.4	294.2	295.3	298.3	313.3	818.1	None	Bubble	C.S.	14485	25114	4367.708	3377.238
1	28	1	2	Crude Oil 1	260.7	262.6	715.3	710.8	287.5	289.7	0.0208	168.3	6.1	296.2	297.3	300.3	315.3	814.5	None	Bubble	C.S.	14430	25018	4358.186	4068.192
1	29	1	1	Crude Oil 1	262.6	265.1	710.8	705.8	289.7	292.6	0.0253	168.3	7	309.3	310.8	314.7	329.7	811.1	None	Bubble	C.S.	18930	32821	4346.749	4870.638
1	30	1	1	Crude Oil 1	265.1	267.6	705.8	700	292.6	295.5	0.03	168.3	7.9	311.8	313.3	317.3	332.3	806.8	None	Bubble	C.S.	18854	32689	4333.189	5788.767
1	31	1	1	Crude Oil 1	267.6	270.1	700	693.6	295.5	298.4	0.0357	168.3	8.8	314.4	315.8	319.8	334.8	802.3	None	Bubble	C.S.	18778	32557	4318.791	6730.021
1	32	1	1	Crude Oil 1	270.1	272.6	693.6	686.6	298.4	301.3	0.0416	168.3	9.7	317	318.4	322.4	337.4	797.5	None	Bubble	C.S.	18702	32426	4302.057	7787.149

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Crude Oil 1	Process 1: Crude Oil 1	Process 1: Crude Oil 1	Process 1: Crude Oil 1
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	539.4	322.4	319.4	257.1
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	554.4	337.4	334.4	272.1
Design Tube Pressure	kPa	2000.2		2000.2	2000.2
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. Too Low (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		48	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	m	8	5.835	5.835	5.835
Straight Length	m	7.5	6.235	6.235	6.235
No. Rows			3	2	3
Tube Spacing	mm	304.8	304.8	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1	264.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	203.03	74.01	380.28	932.46
Intermediate Supports		0 / 0	0 / 1	0 / 1	0 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.05	25.4
Fin Thickness	mm			1.27	1.27
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, does not satisfy API 530 requirements

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	554.3668	337.3528	334.3757	272.0528
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		168.3	168.3	168.3	168.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	7.11	7.11	7.11	7.11
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	7.11	7.11	7.11	7.11
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	0	114584.6	115147.8	124079.8
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	168.3	1.4562	1.4492	1.3457
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	171.3	4.46	4.45	4.35
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	195.77	5.09	5.08	4.97
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Not sufficient	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

HeaterSIM - Fired Heater Simulation Results

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	15
Stack Diameter	m	1.32
Cone Diameter	m	1.324
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	263.4
Flue Gas Flow	kg/s	4.819
Steel Area	m²	62.41
Stack Entry Pressure	mmH2O	-1.064
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

HeaterSIM - Fired Heater Simulation Results

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	761.8	MW Castable	74.9	0.4	ULW Castable	150.1	0.14	732.5	528	1400	V Y Anchors	74.7	Refrac. thickness OK
RADIANT WALL 1	675.6	Fibre (High Density)	74.9	0.1	None	0	0	732.8	686.9	1260	Twistlock Pins	78.5	Refrac. thickness OK
RADIANT ARCH 1	811.8	Fibre (High Density)	100.3	0.1	None	0	0	824	751.1	1260	Twistlock Pins	77.8	Refrac. thickness OK

CONVECTION SIDEWALL 1	537.6	LW Castable	74.9	0.3	ULW Castable	74.9	0.13	732.8	551	1100	V Y Anchors	70.2	Refrac. thickness OK

STACK 1	263.4	LW Castable	75.4	0.3	None	0	0	732.8	619.8	1100	V Y Anchors	74.4	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

ENERGY PERFORMACE
Total Absorbed Duty	MW	11.997
Total Heat Release	MW	13.962
Total Efficiency	%	85.931

PROCESS
Process Name		Therminol XP
Heat Duty	MW	11.997
Flow rate (sec)	kg/s	40
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
OUTLET CONDITIONS
Outlet Temperature	°C	306.9
Outlet Pressure	kPa a	410.879

AIR
Air Flow	kg/s	5.765
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.279
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	kg/s	6.044
Flue Gas Temp.	°C	273.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	3.943
Flue Gas Flow	kg/s	6.044
Max Tube Temp.	°C	295.5
Total Press. Loss (inc. gain)	mmH2O	-1.59

RADIANT SECTION
Radiant Cell		1
Heat Duty	MW	8.055
Heat Release	MW	13.962
Arch Temp.	°C	788.2
Max Tube Temp.	°C	353.2
Average Flux	W/m²	34605
Maximum Flux	W/m²	57481
No. of Burners		6
Arch Pressure	mmH2O	-3.317
Floor Pressure	mmH2O	-13.051

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	85.931
Daily CO2 Emissions	kg	66574

Commercial

BID / PROJECT VALUE

Total:

£ 854,035

SAFETY AND COMPLIANCE

Radiant cell no. 1: The burners to tube distance seems OK (API 560)

Radiant cell no. 1: The burners to wall clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Radiant cell no. 1: Single lane of burners considered

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	353.2	274.2	295.5	253.1
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Commercial

HeaterSIM - Fired Heater Simulation Results

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 663,074
Option items
Detail Engineering (by HeaterSIM)	£ 99,461
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£854,035

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	6.044	6.044	0.279	5.765
Flow (hr)	kg/hr	144000	144000	21759	21759	1005	20754
Temperature	°C	200	306.9	788.2	273.5	Note 1	15.5
Pressure	kPa a	750.1	410.879	-3.317	-1.43	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Name		Therminol XP
Heat Duty	MW	11.997
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	339.221
Max. Film Temp. Calculated	°C	344.5
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	35494
Average Flux Allowed	W/m²	22500
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	584
OUTLET CONDITIONS
Outlet Temperature	°C	306.9
Outlet Pressure	kPa a	410.879
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	882

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type
Heat Duty	MW	8.055
Heat Release	MW	13.962
Arch Temp.	°C	788.2
Max Tube Temp.	°C	353.2
Tube Cirle Diameter	m	N/A
Average Flux	W/m²	34605
Maximum Flux	W/m²	57481
Flue Flow	kg/s	6.044
Air Flow	kg/s	5.765
Fuel Flow	kg/s	0.279
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-3.317
Floor Pressure	mmH2O	-13.051
Radiant Height	m	11.08
Radiant Width	m	4.62
Radiant Length	m	6.98
No. of Burners		6
Burner Cirle Diameter	m	N/A
Burner Design Firing	MW	2.68
Burner Normal Firing	MW	2.33
Burner Min Firing	MW	0.54
Burner-to-Tube Note		OK
Burner-to-Wall Note		OK
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.135
API Burner-to-Wall Dist.	m	1.005
API Burner-to-Roof/Roof Dist	m	7.01
Floor Flux	W/m²	432897

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Type
Flue Flow	kg/s	6.044
Air Flow	kg/s	5.765
Fuel Flow	kg/s	0.279
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°C	1805.6
Flue Gas Emissivity		0.517

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Convection Sect. No.		1
Heat Duty	MW	3.943
Max Tube Temp.	°C	295.5
Total Flue Press. Loss (ex. gain)	mmH2O	1.22
Total Press. Gain	mmH2O	2.8
Total Press. Loss (inc. gain)	mmH2O	-1.59
Convection Width	m	2.159
Effective Length	m	5.835
Convection Height	m	3.601
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	6.044
Flue Gas Inlet Temp.	°C	788.2
Flue Gas Outlet Temp.	°C	273.5
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.25	309.7	273.5	331.6	289.5	0.6	Solid	12252	14814	8	1.299	0.175	C.S.	C.S.	230.7	240
1	7	Coil Section 3	0.38	362.2	309.7	394.2	331.6	0.56	Solid	18242	22010	8	1.299	0.188	C.S.	C.S.	247.6	261.1
1	6	Coil Section 3	0.57	441.2	362.2	488.9	394.2	0.5	Solid	27594	33189	8	1.299	0.207	C.S.	C.S.	273.2	293.3
1	5	Coil Section 2	0.65	529.4	441.2	597.3	488.9	0.45	Solid	31571	38896	8	1.234	0.164	C.S.	C.S.	287.2	313.1
1	4	Coil Section 2	0.98	657.3	529.4	760.3	597.3	0.39	Solid	47538	59798	8	1.234	0.186	C.S.	C.S.	328.9	365
1	3	Coil Section 1	0.3	695.3	657.3	808.6	760.3	0.36	None	15169	26497	8	1.149	0.095	C.S.	None	0	0
1	2	Coil Section 1	0.35	736.1	695.3	862.6	808.6	0.34	None	18517	32346	8	1.149	0.099	C.S.	None	0	0
1	1	Coil Section 1	0.44	788.2	736.1	923.7	862.6	0.33	None	25003	43675	8	1.149	0.104	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.25	309.7	273.5	Therminol XP	1	200	202.5	750	740	0	0	2	2	0	0	1549	1549	230808	236114
1	7	Coil Section 3	0.38	362.2	309.7	Therminol XP	2	202.4	206.1	740	730	0	0	2	2	0	0	1549	1549	236095	244332
1	6	Coil Section 3	0.57	441.2	362.2	Therminol XP	3	206.1	211.6	730	720	0	0	2	2.1	0	0	1549	1549	244348	257648
1	5	Coil Section 2	0.65	529.4	441.2	Therminol XP	4	211.6	217.9	720	710	0	0	2.1	2.1	0	0	1549	1549	257528	274124
1	4	Coil Section 2	0.98	657.3	529.4	Therminol XP	5	217.8	227.3	710	700	0	0	2.1	2.1	0	0	1549	1549	273847	301711
1	3	Coil Section 1	0.3	695.3	657.3	Therminol XP	6	227.3	230	700	689	0	0	2.1	2.2	0	0	1549	1549	301636	307864
1	2	Coil Section 1	0.35	736.1	695.3	Therminol XP	7	230	233.1	689	678	0	0	2.2	2.4	0	0	1549	1549	307786	315322
1	1	Coil Section 1	0.44	788.2	736.1	Therminol XP	8	232.9	236.8	678	665	0	0	2.4	2.7	0	0	1549	1549	314751	324521

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.25	309.7	273.5	Therminol XP	1	200	202.5	750	740	0	0	2	2	0	0	1549	1549	230808	236114
1	7	Coil Section 3	0.38	362.2	309.7	Therminol XP	2	202.4	206.1	740	730	0	0	2	2	0	0	1549	1549	236095	244332
1	6	Coil Section 3	0.57	441.2	362.2	Therminol XP	3	206.1	211.6	730	720	0	0	2	2.1	0	0	1549	1549	244348	257648
1	5	Coil Section 2	0.65	529.4	441.2	Therminol XP	4	211.6	217.9	720	710	0	0	2.1	2.1	0	0	1549	1549	257528	274124
1	4	Coil Section 2	0.98	657.3	529.4	Therminol XP	5	217.8	227.3	710	700	0	0	2.1	2.1	0	0	1549	1549	273847	301711
1	3	Coil Section 1	0.3	695.3	657.3	Therminol XP	6	227.3	230	700	689	0	0	2.1	2.2	0	0	1549	1549	301636	307864
1	2	Coil Section 1	0.35	736.1	695.3	Therminol XP	7	230	233.1	689	678	0	0	2.2	2.4	0	0	1549	1549	307786	315322
1	1	Coil Section 1	0.44	788.2	736.1	Therminol XP	8	232.9	236.8	678	665	0	0	2.4	2.7	0	0	1549	1549	314751	324521

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol XP	236.8	239.6	665.3	716.2	680.9	688.7	0	141.3	2.9	288.3	291.4	297.3	312.3	1330.3	Turbulent		35494	58762	0	0
2	Wall	Therminol XP	239.6	242.4	716.2	660.3	688.7	696.4	0	141.3	3.1	290.6	293.7	299.5	314.5	1341.9	Turbulent		35424	58662	0	0
3	Wall	Therminol XP	242.4	245.1	660.3	701.8	696.4	704.1	0	141.3	3.4	292.8	295.9	301.8	316.8	1353.8	Turbulent		35353	58560	0	0
4	Wall	Therminol XP	245.1	247.9	701.8	653.4	704.1	711.9	0	141.3	3.8	295.1	298.2	304	319	1366	Turbulent		35282	58458	0	0
5	Wall	Therminol XP	247.9	250.7	653.4	685.3	711.9	719.6	0	141.3	4.2	297.3	300.4	306.3	321.3	1378.4	Turbulent		35210	58355	0	0
6	Wall	Therminol XP	250.7	253.4	685.3	643.8	719.6	727.4	0	141.3	4.8	299.6	302.7	308.5	323.5	1391	Turbulent		35138	58252	0	0
7	Wall	Therminol XP	253.4	256.2	643.8	665.8	727.4	735.1	0	141.3	5.4	301.9	304.9	310.7	325.7	1404	Turbulent		35066	58148	0	0
8	Wall	Therminol XP	256.2	258.9	665.8	630.1	735.1	742.9	0	141.3	6.3	304.1	307.2	313	328	1417.1	Turbulent		34993	58043	0	0
9	Wall	Therminol XP	258.9	261.7	630.1	641.1	742.9	750.6	0	141.3	7.6	306.4	309.4	315.3	330.3	1429.9	Turbulent		34920	57936	0	0
10	Wall	Therminol XP	261.7	264.5	641.1	609.3	750.6	758.4	0	141.3	9.4	308.7	311.7	317.5	332.5	1442.9	Turbulent		34846	57828	0	0
11	Wall	Therminol XP	264.5	267.2	609.3	606.3	758.4	766.1	0	141.3	12.4	310.9	314	319.8	334.8	1456.3	Turbulent		34771	57720	0	0
12	Wall	Therminol XP	267.2	270	606.3	572.1	766.1	773.8	0	141.3	18	313.2	316.2	322.1	337.1	1469.9	Turbulent		34696	57611	0	0
13	Wall	Therminol XP	270	272.7	572.1	547.9	773.8	781.6	0	141.3	14.8	315.4	318.5	324.3	339.3	1483.3	Turbulent		34621	57503	0	0
14	Wall	Therminol XP	272.7	275.3	547.9	515.8	781.6	789.3	0	141.3	9.9	317.6	320.7	326.5	341.5	1494.7	Turbulent		34546	57395	0	0
15	Wall	Therminol XP	275.3	277.9	515.8	520	789.3	797.1	0	141.3	7.5	319.9	323	328.7	343.7	1506.1	Turbulent		34471	57285	0	0
16	Wall	Therminol XP	277.9	280.6	520	486.3	797.1	804.8	0	141.3	6	322.1	325.2	330.9	345.9	1517.8	Turbulent		34396	57175	0	0
17	Wall	Therminol XP	280.6	283.2	486.3	505.3	804.8	812.6	0	141.3	5	324.3	327.4	333.1	348.1	1529.6	Turbulent		34321	57064	0	0
18	Wall	Therminol XP	283.2	285.8	505.3	464.9	812.6	820.3	0	141.3	4.3	326.6	329.6	335.4	350.4	1541.7	Turbulent		34245	56952	0	0
19	Wall	Therminol XP	285.8	288.5	464.9	496.1	820.3	828.1	0	141.3	3.8	328.8	331.9	337.6	352.6	1553.9	Turbulent		34168	56840	0	0
20	Wall	Therminol XP	288.5	291.1	496.1	447.7	828.1	835.8	0	141.3	3.4	331	334.1	339.8	354.8	1566.4	Turbulent		34091	56726	0	0
21	Wall	Therminol XP	291.1	293.7	447.7	489.8	835.8	843.6	0	141.3	3.1	333.2	336.3	342	357	1579.2	Turbulent		34014	56612	0	0
22	Wall	Therminol XP	293.7	296.4	489.8	433	843.6	851.3	0	141.3	2.8	335.5	338.5	344.2	359.2	1592.1	Turbulent		33936	56497	0	0
23	Wall	Therminol XP	296.4	299	433	485.4	851.3	859	0	141.3	2.6	337.7	340.8	346.5	361.5	1605.4	Turbulent		33858	56381	0	0
24	Wall	Therminol XP	299	301.6	485.4	420	859	866.8	0	141.3	2.4	339.9	343	348.7	363.7	1618.9	Turbulent		33779	56264	0	0
25	Wall	Therminol XP	301.6	304.3	420	482.3	866.8	874.5	0	141.3	2.3	342.2	345.2	350.9	365.9	1632.6	Turbulent		33700	56147	0	0
26	Wall	Therminol XP	304.3	306.9	482.3	410.9	874.5	882.3	0	141.3	2.3	344.5	347.5	353.2	368.2	1645.4	Turbulent		33619	56025	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Therminol XP	200	200.6	750.1	747.6	583.6	585.2	0	141.3	2	218	219	220.6	235.6	1095.7	Solid	Turbulent	C.S.	12352	17335	0	0
1	2	3	8	Therminol XP	200.6	201.2	747.6	745.1	585.2	586.8	0	141.3	2	218.5	219.5	221	236	1098.5	Solid	Turbulent	C.S.	12267	17215	0	0
1	3	3	8	Therminol XP	201.2	201.8	745.1	742.6	586.8	588.3	0	141.3	2	218.9	219.9	221.5	236.5	1101.3	Solid	Turbulent	C.S.	12181	17095	0	0
1	4	3	8	Therminol XP	201.8	202.5	742.6	740.1	588.3	589.9	0	141.3	2	219.4	220.3	221.9	236.9	1104.1	Solid	Turbulent	C.S.	12096	16975	0	0
1	5	3	7	Therminol XP	202.4	203.4	740.1	737.5	589.9	592.3	0	141.3	2	228.7	230.2	232.5	247.5	1121	Solid	Turbulent	C.S.	18395	25780	0	0
1	6	3	7	Therminol XP	203.4	204.3	737.5	735	592.3	594.6	0	141.3	2	229.4	230.8	233.2	248.2	1125	Solid	Turbulent	C.S.	18265	25598	0	0
1	7	3	7	Therminol XP	204.3	205.2	735	732.5	594.6	597	0	141.3	2	230	231.4	233.8	248.8	1129	Solid	Turbulent	C.S.	18135	25415	0	0
1	8	3	7	Therminol XP	205.2	206.1	732.5	730	597	599.3	0	141.3	2	230.7	232.1	234.4	249.4	1133	Solid	Turbulent	C.S.	18005	25233	0	0
1	9	3	6	Therminol XP	206.1	207.5	730	727.5	599.4	602.9	0	141.3	2.1	244.7	246.9	250.5	265.5	1154.8	Solid	Turbulent	C.S.	27831	38924	0	0
1	10	3	6	Therminol XP	207.5	208.9	727.5	725	602.9	606.5	0	141.3	2.1	245.6	247.8	251.3	266.3	1161.1	Solid	Turbulent	C.S.	27628	38640	0	0
1	11	3	6	Therminol XP	208.9	210.3	725	722.4	606.5	610.1	0	141.3	2.1	246.5	248.7	252.2	267.2	1167.4	Solid	Turbulent	C.S.	27425	38355	0	0
1	12	3	6	Therminol XP	210.3	211.6	722.4	719.9	610.1	613.7	0	141.3	2.1	247.4	249.6	253.1	268.1	1173.9	Solid	Turbulent	C.S.	27221	38071	0	0
1	13	2	5	Therminol XP	211.6	213.2	719.9	717.4	613.5	617.6	0	141.3	2.1	255	257.6	261.8	276.8	1189.8	Solid	Turbulent	C.S.	31803	45155	0	0
1	14	2	5	Therminol XP	213.2	214.8	717.4	714.8	617.6	621.7	0	141.3	2.1	256.1	258.7	262.8	277.8	1197.5	Solid	Turbulent	C.S.	31615	44888	0	0
1	15	2	5	Therminol XP	214.8	216.3	714.8	712.3	621.7	625.8	0	141.3	2.1	257.2	259.7	263.9	278.9	1205.2	Solid	Turbulent	C.S.	31427	44622	0	0
1	16	2	5	Therminol XP	216.3	217.9	712.3	709.8	625.8	629.9	0	141.3	2.1	258.2	260.8	264.9	279.9	1213.1	Solid	Turbulent	C.S.	31240	44355	0	0
1	17	2	4	Therminol XP	217.8	220.2	709.8	707.2	629.6	635.8	0	141.3	2.1	280.9	285	291.4	306.4	1252.4	Solid	Turbulent	C.S.	47917	68970	0	0
1	18	2	4	Therminol XP	220.2	222.6	707.2	704.7	635.8	641.9	0	141.3	2.1	282.3	286.3	292.7	307.7	1264.3	Solid	Turbulent	C.S.	47606	68523	0	0
1	19	2	4	Therminol XP	222.6	225	704.7	702.1	641.9	648.1	0	141.3	2.1	283.8	287.7	294.1	309.1	1276.5	Solid	Turbulent	C.S.	47296	68076	0	0
1	20	2	4	Therminol XP	225	227.3	702.1	699.6	648.1	654.2	0	141.3	2.1	285.2	289.1	295.5	310.5	1289	Solid	Turbulent	C.S.	46985	67629	0	0
1	21	1	3	Therminol XP	227.3	228	699.6	697	654.1	656	0	141.3	2.1	250.6	252.2	254.4	269.4	1245.4	None	Turbulent	C.S.	14647	25584	0	0
1	22	1	3	Therminol XP	228	228.6	697	694.3	656	657.9	0	141.3	2.2	251.2	252.8	255	270	1248.1	None	Turbulent	C.S.	14625	25547	0	0
1	23	1	3	Therminol XP	228.6	229.3	694.3	691.7	657.9	659.8	0	141.3	2.2	251.8	253.4	255.6	270.6	1250.8	None	Turbulent	C.S.	14604	25510	0	0
1	24	1	3	Therminol XP	229.3	230	691.7	689	659.8	661.7	0	141.3	2.2	252.4	254	256.2	271.2	1253.6	None	Turbulent	C.S.	14583	25473	0	0
1	25	1	2	Therminol XP	230	230.8	689	686.2	661.6	663.8	0	141.3	2.3	256.9	258.8	261.5	276.5	1262.3	None	Turbulent	C.S.	17173	29997	0	0
1	26	1	2	Therminol XP	230.8	231.5	686.2	683.4	663.8	666	0	141.3	2.3	257.6	259.5	262.1	277.1	1265.5	None	Turbulent	C.S.	17147	29952	0	0
1	27	1	2	Therminol XP	231.5	232.3	683.4	680.5	666	668.3	0	141.3	2.4	258.3	260.2	262.8	277.8	1268.8	None	Turbulent	C.S.	17121	29907	0	0
1	28	1	2	Therminol XP	232.3	233.1	680.5	677.6	668.3	670.5	0	141.3	2.4	259	260.8	263.5	278.5	1272.1	None	Turbulent	C.S.	17095	29862	0	0
1	29	1	1	Therminol XP	232.9	233.9	677.7	674.7	669.8	672.6	0	141.3	2.5	266	268.4	271.7	286.7	1284.9	None	Turbulent	C.S.	21458	37483	0	0
1	30	1	1	Therminol XP	233.9	234.9	674.7	671.7	672.6	675.4	0	141.3	2.5	266.9	269.2	272.5	287.5	1289.1	None	Turbulent	C.S.	21425	37424	0	0
1	31	1	1	Therminol XP	234.9	235.9	671.7	668.5	675.4	678.1	0	141.3	2.6	267.7	270	273.3	288.3	1293.3	None	Turbulent	C.S.	21391	37366	0	0
1	32	1	1	Therminol XP	235.9	236.8	668.5	665.3	678.1	680.9	0	141.3	2.7	268.5	270.9	274.2	289.2	1297.6	None	Turbulent	C.S.	21358	37308	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	353.2	274.2	295.5	253.1
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	368.2	289.2	310.5	268.1
Design Tube Pressure	kPa	2000.2		2000.2	2000.2
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235
No. Rows			3	2	3
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	232.77	62.13	325.88	801.84
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.1	25.4
Fin Thickness	mm			1.3	1.3
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	368.1863	289.1645	310.4541	268.0912
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	109341.3	121921.6	118864.9	124579.5
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.2807	1.1496	1.1789	1.1253
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.28	4.15	4.18	4.13
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.89	4.74	4.78	4.71
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	15
Stack Diameter	m	1.48
Cone Diameter	m	1.484
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	273.5
Flue Gas Flow	kg/s	6.044
Steel Area	m²	69.925
Stack Entry Pressure	mmH2O	-1.43
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	738.2	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	506.9	1400	V Y Anchors	73.3	Refrac. thickness OK
RADIANT WALL 1	570.7	Fibre (High Density)	75	0.1	None	0	0	732.8	487.8	1260	Twistlock Pins	66	Refrac. thickness OK
RADIANT ARCH 1	788.2	Fibre (High Density)	87.7	0.1	None	0	0	824	807.2	1260	Twistlock Pins	80.6	Refrac. thickness OK

CONVECTION SIDEWALL 1	530.8	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	541.5	1100	V Y Anchors	69.5	Refrac. thickness OK

STACK 1	273.5	LW Castable	75.4	0.3	None	0	0	732.8	656.1	1100	V Y Anchors	76.4	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

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ENERGY PERFORMACE
Total Absorbed Duty	MW	12.003
Total Heat Release	MW	13.118
Total Efficiency	%	91.5

PROCESS
Process Name		Therminol XP
Heat Duty	MW	12.003
Flow rate (sec)	kg/s	40
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
OUTLET CONDITIONS
Outlet Temperature	°C	307.5
Outlet Pressure	kPa a	403.159

AIR
Air Flow	kg/s	5.416
Air Temp.	°C	150
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.262
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	kg/s	5.416
Flue Gas Temp.	°C	162.1
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	4.279
Flue Gas Flow	kg/s	5.679
Max Tube Temp.	°C	304
Total Press. Loss (inc. gain)	mmH2O	-0.39

RADIANT SECTION
Radiant Cell		1
Heat Duty	MW	7.724
Heat Release	MW	13.118
Arch Temp.	°C	865.8
Max Tube Temp.	°C	364.1
Average Flux	W/m²	33182
Maximum Flux	W/m²	70126
No. of Burners		6
Arch Pressure	mmH2O	0
Floor Pressure	mmH2O	0

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	91.5
Daily CO2 Emissions	kg	59660

Commercial

BID / PROJECT VALUE

Total:

£ 799,899

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	364.1	282.6	304	255.2
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Commercial

HeaterSIM - Fired Heater Simulation Results

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 615,999
Option items
Detail Engineering (by HeaterSIM)	£ 92,400
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£799,899

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	5.679	5.416	0.262	5.416
Flow (hr)	kg/hr	144000	144000	20443	19499	944	19499
Temperature	°C	200	307.5	865.8	162.1	Note 1	15.5
Pressure	kPa a	750.1	403.159	0	2.207	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

60.785 m 19.785 m 17.985 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 2.07 m 5.835 m 4.584 m 4.204 m 6 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Therminol XP
Heat Duty	MW	12.003
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	346.941
Max. Film Temp. Calculated	°C	353.3
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	33777
Average Flux Allowed	W/m²	22500
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	584
OUTLET CONDITIONS
Outlet Temperature	°C	307.5
Outlet Pressure	kPa a	403.159
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	884

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type
Heat Duty	MW	7.724
Heat Release	MW	13.118
Arch Temp.	°C	865.8
Max Tube Temp.	°C	364.1
Tube Cirle Diameter	m	4.204
Average Flux	W/m²	33182
Maximum Flux	W/m²	70126
Flue Flow	kg/s	5.679
Air Flow	kg/s	5.416
Fuel Flow	kg/s	0.262
Excess Air	%	20
Air Temp.	°C	150
Arch Pressure	mmH2O	0
Floor Pressure	mmH2O	0
Radiant Height	m	11.08
Radiant Width	m	4.58
Radiant Length	m	4.58
No. of Burners		6
Burner Cirle Diameter	m	1.609
Burner Design Firing	MW	2.51
Burner Normal Firing	MW	2.19
Burner Min Firing	MW	0.5
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.103
API Burner-to-Wall Dist.	m	0.962
API Burner-to-Roof/Roof Dist	m	6.682
Floor Flux	W/m²	795243

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

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Radiant Type
Flue Flow	kg/s	5.679
Air Flow	kg/s	5.416
Fuel Flow	kg/s	0.262
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	150
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°C	1805.6
Flue Gas Emissivity		0.427

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Convection Sect. No.		1
Heat Duty	MW	4.279
Max Tube Temp.	°C	304
Total Flue Press. Loss (ex. gain)	mmH2O	1.12
Total Press. Gain	mmH2O	1.51
Total Press. Loss (inc. gain)	mmH2O	-0.39
Convection Width	m	2.159
Effective Length	m	5.835
Convection Height	m	3.601
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	5.679
Flue Gas Inlet Temp.	°C	865.8
Flue Gas Outlet Temp.	°C	275.7
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.26	313.7	275.7	336.9	292	0.6	Solid	12315	14932	8	1.22	0.158	C.S.	C.S.	230.9	240.6
1	7	Coil Section 3	0.38	370.9	313.7	404.7	336.9	0.55	Solid	18589	22487	8	1.22	0.17	C.S.	C.S.	248.6	263
1	6	Coil Section 3	0.6	458.3	370.9	509.7	404.7	0.49	Solid	28771	34746	8	1.22	0.189	C.S.	C.S.	276.3	298.1
1	5	Coil Section 2	0.7	557.6	458.3	633	509.7	0.44	Solid	33798	41983	8	1.16	0.152	C.S.	C.S.	292.9	321.4
1	4	Coil Section 2	1.09	707.3	557.6	824.5	633	0.38	Solid	52424	66631	8	1.16	0.174	C.S.	C.S.	341	381.6
1	3	Coil Section 1	0.34	752.2	707.3	883	824.5	0.34	None	17177	30004	8	1.079	0.089	C.S.	None	0	0
1	2	Coil Section 1	0.41	801.7	752.2	949.4	883	0.32	None	20991	36666	8	1.079	0.093	C.S.	None	0	0
1	1	Coil Section 1	0.51	865.8	801.7	1025.5	949.4	0.31	None	28151	49173	8	1.079	0.098	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.26	313.7	275.7	Therminol XP	1	200	202.5	750	740	0	0	2	2	0	0	1549	1549	230808	236142
1	7	Coil Section 3	0.38	370.9	313.7	Therminol XP	2	202.5	206.2	740	730	0	0	2	2	0	0	1549	1549	236139	244539
1	6	Coil Section 3	0.6	458.3	370.9	Therminol XP	3	206.2	212	730	720	0	0	2	2.1	0	0	1549	1549	244562	258472
1	5	Coil Section 2	0.7	557.6	458.3	Therminol XP	4	212	218.8	720	710	0	0	2.1	2.1	0	0	1549	1549	258489	276422
1	4	Coil Section 2	1.09	707.3	557.6	Therminol XP	5	218.8	229.1	710	700	0	0	2.1	2.2	0	0	1549	1549	276507	305818
1	3	Coil Section 1	0.34	752.2	707.3	Therminol XP	6	229.1	232.2	700	688	0	0	2.2	2.4	0	0	1549	1549	305800	313036
1	2	Coil Section 1	0.41	801.7	752.2	Therminol XP	7	232.3	235.9	688	676	0	0	2.4	2.6	0	0	1549	1549	313323	322185
1	1	Coil Section 1	0.51	865.8	801.7	Therminol XP	8	235.9	240.4	676	663	0	0	2.6	2.9	0	0	1549	1549	322179	333787

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.26	313.7	275.7	Therminol XP	1	200	202.5	750	740	0	0	2	2	0	0	1549	1549	230808	236142
1	7	Coil Section 3	0.38	370.9	313.7	Therminol XP	2	202.5	206.2	740	730	0	0	2	2	0	0	1549	1549	236139	244539
1	6	Coil Section 3	0.6	458.3	370.9	Therminol XP	3	206.2	212	730	720	0	0	2	2.1	0	0	1549	1549	244562	258472
1	5	Coil Section 2	0.7	557.6	458.3	Therminol XP	4	212	218.8	720	710	0	0	2.1	2.1	0	0	1549	1549	258489	276422
1	4	Coil Section 2	1.09	707.3	557.6	Therminol XP	5	218.8	229.1	710	700	0	0	2.1	2.2	0	0	1549	1549	276507	305818
1	3	Coil Section 1	0.34	752.2	707.3	Therminol XP	6	229.1	232.2	700	688	0	0	2.2	2.4	0	0	1549	1549	305800	313036
1	2	Coil Section 1	0.41	801.7	752.2	Therminol XP	7	232.3	235.9	688	676	0	0	2.4	2.6	0	0	1549	1549	313323	322185
1	1	Coil Section 1	0.51	865.8	801.7	Therminol XP	8	235.9	240.4	676	663	0	0	2.6	2.9	0	0	1549	1549	322179	333787

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol XP	240.4	243.1	662.7	707.5	691	698.4	0	141.3	3.2	300.8	305	311.7	326.7	1359.2	Turbulent		33777	71166	0	0
2	Wall	Therminol XP	243.1	245.7	707.5	656.3	698.4	705.8	0	141.3	3.5	302.9	307	313.8	328.8	1370.8	Turbulent		33731	71085	0	0
3	Wall	Therminol XP	245.7	248.4	656.3	692.1	705.8	713.3	0	141.3	3.9	305	309.1	315.9	330.9	1382.4	Turbulent		33684	71004	0	0
4	Wall	Therminol XP	248.4	251	692.1	647.8	713.3	720.7	0	141.3	4.3	307.1	311.3	318	333	1393.8	Turbulent		33636	70922	0	0
5	Wall	Therminol XP	251	253.7	647.8	674.3	720.7	728.1	0	141.3	4.8	309.3	313.4	320.1	335.1	1405.4	Turbulent		33589	70838	0	0
6	Wall	Therminol XP	253.7	256.3	674.3	636.1	728.1	735.5	0	141.3	5.5	311.4	315.5	322.2	337.2	1417.3	Turbulent		33540	70755	0	0
7	Wall	Therminol XP	256.3	259	636.1	652.6	735.5	743	0	141.3	6.4	313.5	317.6	324.4	339.4	1429.4	Turbulent		33492	70670	0	0
8	Wall	Therminol XP	259	261.6	652.6	619.2	743	750.4	0	141.3	7.5	315.6	319.7	326.5	341.5	1441.7	Turbulent		33444	70585	0	0
9	Wall	Therminol XP	261.6	264.3	619.2	624.2	750.4	757.8	0	141.3	9.3	317.7	321.8	328.6	343.6	1454.3	Turbulent		33395	70499	0	0
10	Wall	Therminol XP	264.3	266.9	624.2	592.6	757.8	765.2	0	141.3	12	319.8	323.9	330.7	345.7	1467.2	Turbulent		33346	70413	0	0
11	Wall	Therminol XP	266.9	269.6	592.6	580.9	765.2	772.7	0	141.3	16.8	322	326.1	332.8	347.8	1480.3	Turbulent		33296	70326	0	0
12	Wall	Therminol XP	269.6	272.2	580.9	539.7	772.7	780.1	0	141.3	16.3	324	328.1	334.9	349.9	1493.6	Turbulent		33247	70241	0	0
13	Wall	Therminol XP	272.2	274.7	539.7	530.6	780.1	787.5	0	141.3	10.7	326.1	330.3	336.9	351.9	1504.7	Turbulent		33198	70154	0	0
14	Wall	Therminol XP	274.7	277.2	530.6	499.1	787.5	795	0	141.3	8	328.2	332.3	339	354	1515.7	Turbulent		33148	70066	0	0
15	Wall	Therminol XP	277.2	279.7	499.1	509	795	802.4	0	141.3	6.4	330.3	334.4	341.1	356.1	1527	Turbulent		33098	69978	0	0
16	Wall	Therminol XP	279.7	282.3	509	473.3	802.4	809.8	0	141.3	5.3	332.3	336.5	343.2	358.2	1538.4	Turbulent		33048	69889	0	0
17	Wall	Therminol XP	282.3	284.8	473.3	496.3	809.8	817.2	0	141.3	4.6	334.4	338.6	345.3	360.3	1550	Turbulent		32998	69799	0	0
18	Wall	Therminol XP	284.8	287.3	496.3	453.7	817.2	824.7	0	141.3	4	336.5	340.7	347.3	362.3	1561.8	Turbulent		32948	69709	0	0
19	Wall	Therminol XP	287.3	289.8	453.7	487.9	824.7	832.1	0	141.3	3.6	338.6	342.7	349.4	364.4	1573.8	Turbulent		32897	69618	0	0
20	Wall	Therminol XP	289.8	292.3	487.9	437.5	832.1	839.5	0	141.3	3.2	340.7	344.8	351.5	366.5	1586	Turbulent		32846	69526	0	0
21	Wall	Therminol XP	292.3	294.9	437.5	482	839.5	846.9	0	141.3	3	342.8	346.9	353.6	368.6	1598.5	Turbulent		32794	69434	0	0
22	Wall	Therminol XP	294.9	297.4	482	423.4	846.9	854.4	0	141.3	2.7	344.9	349	355.7	370.7	1611.2	Turbulent		32743	69341	0	0
23	Wall	Therminol XP	297.4	299.9	423.4	477.7	854.4	861.8	0	141.3	2.5	346.9	351.1	357.7	372.7	1624.1	Turbulent		32691	69248	0	0
24	Wall	Therminol XP	299.9	302.4	477.7	410.8	861.8	869.2	0	141.3	2.3	349	353.1	359.8	374.8	1637.3	Turbulent		32639	69154	0	0
25	Wall	Therminol XP	302.4	305	410.8	474.5	869.2	876.6	0	141.3	2.3	351.1	355.2	361.9	376.9	1650.7	Turbulent		32586	69058	0	0
26	Wall	Therminol XP	305	307.5	474.5	403.2	876.6	884.1	0	141.3	2.3	353.3	357.4	364.1	379.1	1662.5	Turbulent		32532	68959	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Therminol XP	200	200.6	750.1	747.6	583.6	585.2	0	141.3	2	218.2	219.1	220.7	235.7	1095.9	Solid	Turbulent	C.S.	12413	17452	0	0
1	2	3	8	Therminol XP	200.6	201.2	747.6	745.1	585.2	586.8	0	141.3	2	218.6	219.6	221.2	236.2	1098.7	Solid	Turbulent	C.S.	12329	17334	0	0
1	3	3	8	Therminol XP	201.2	201.9	745.1	742.6	586.8	588.4	0	141.3	2	219.1	220	221.6	236.6	1101.5	Solid	Turbulent	C.S.	12246	17217	0	0
1	4	3	8	Therminol XP	201.9	202.5	742.6	740.1	588.4	590	0	141.3	2	219.5	220.5	222.1	237.1	1104.3	Solid	Turbulent	C.S.	12162	17099	0	0
1	5	3	7	Therminol XP	202.5	203.4	740.1	737.5	590	592.4	0	141.3	2	229.2	230.7	233.2	248.2	1121.7	Solid	Turbulent	C.S.	18738	26307	0	0
1	6	3	7	Therminol XP	203.4	204.3	737.5	735	592.4	594.8	0	141.3	2	229.9	231.4	233.8	248.8	1125.8	Solid	Turbulent	C.S.	18609	26126	0	0
1	7	3	7	Therminol XP	204.3	205.3	735	732.5	594.8	597.2	0	141.3	2	230.6	232	234.4	249.4	1129.9	Solid	Turbulent	C.S.	18480	25944	0	0
1	8	3	7	Therminol XP	205.3	206.2	732.5	730	597.2	599.6	0	141.3	2	231.2	232.7	235.1	250.1	1134	Solid	Turbulent	C.S.	18351	25763	0	0
1	9	3	6	Therminol XP	206.2	207.6	730	727.5	599.6	603.3	0	141.3	2.1	246.4	248.7	252.5	267.5	1157.5	Solid	Turbulent	C.S.	29011	40682	0	0
1	10	3	6	Therminol XP	207.6	209.1	727.5	725	603.3	607.1	0	141.3	2.1	247.3	249.6	253.4	268.4	1164.1	Solid	Turbulent	C.S.	28803	40391	0	0
1	11	3	6	Therminol XP	209.1	210.5	725	722.4	607.1	610.8	0	141.3	2.1	248.3	250.6	254.3	269.3	1170.7	Solid	Turbulent	C.S.	28595	40099	0	0
1	12	3	6	Therminol XP	210.5	212	722.4	719.9	610.8	614.5	0	141.3	2.1	249.2	251.5	255.2	270.2	1177.5	Solid	Turbulent	C.S.	28387	39807	0	0
1	13	2	5	Therminol XP	212	213.7	719.9	717.4	614.5	618.9	0	141.3	2.1	258.5	261.3	265.8	280.8	1196.3	Solid	Turbulent	C.S.	34042	48595	0	0
1	14	2	5	Therminol XP	213.7	215.4	717.4	714.8	618.9	623.3	0	141.3	2.1	259.6	262.4	266.8	281.8	1204.6	Solid	Turbulent	C.S.	33843	48310	0	0
1	15	2	5	Therminol XP	215.4	217.1	714.8	712.3	623.3	627.6	0	141.3	2.1	260.7	263.5	267.9	282.9	1213	Solid	Turbulent	C.S.	33644	48026	0	0
1	16	2	5	Therminol XP	217.1	218.8	712.3	709.8	627.6	632	0	141.3	2.1	261.8	264.6	269	284	1221.6	Solid	Turbulent	C.S.	33444	47741	0	0
1	17	2	4	Therminol XP	218.8	221.4	709.8	707.2	632.1	638.9	0	141.3	2.1	288.1	292.6	299.7	314.7	1266.1	Solid	Turbulent	C.S.	52832	76568	0	0
1	18	2	4	Therminol XP	221.4	224	707.2	704.7	638.9	645.7	0	141.3	2.1	289.5	294	301.1	316.1	1279.3	Solid	Turbulent	C.S.	52493	76077	0	0
1	19	2	4	Therminol XP	224	226.5	704.7	702.1	645.7	652.5	0	141.3	2.1	291	295.5	302.5	317.5	1292.7	Solid	Turbulent	C.S.	52155	75586	0	0
1	20	2	4	Therminol XP	226.5	229.1	702.1	699.5	652.5	659.2	0	141.3	2.2	292.6	297	304	319	1305.2	Solid	Turbulent	C.S.	51816	75095	0	0
1	21	1	3	Therminol XP	229.1	229.9	699.5	696.8	659.2	661.4	0	141.3	2.2	255.4	257.2	259.7	274.7	1257.5	None	Turbulent	C.S.	16651	29085	0	0
1	22	1	3	Therminol XP	229.9	230.6	696.8	694	661.4	663.5	0	141.3	2.3	256	257.8	260.4	275.4	1260.6	None	Turbulent	C.S.	16626	29042	0	0
1	23	1	3	Therminol XP	230.6	231.4	694	691.2	663.5	665.7	0	141.3	2.3	256.7	258.5	261.1	276.1	1263.8	None	Turbulent	C.S.	16601	28999	0	0
1	24	1	3	Therminol XP	231.4	232.2	691.2	688.4	665.7	667.8	0	141.3	2.4	257.4	259.2	261.7	276.7	1267	None	Turbulent	C.S.	16577	28956	0	0
1	25	1	2	Therminol XP	232.3	233.2	688.3	685.4	668.2	670.7	0	141.3	2.4	262.8	264.9	267.9	282.9	1277.9	None	Turbulent	C.S.	19630	34290	0	0
1	26	1	2	Therminol XP	233.2	234.1	685.4	682.4	670.7	673.2	0	141.3	2.5	263.5	265.7	268.7	283.7	1281.8	None	Turbulent	C.S.	19600	34237	0	0
1	27	1	2	Therminol XP	234.1	235	682.4	679.3	673.2	675.8	0	141.3	2.5	264.3	266.4	269.5	284.5	1285.6	None	Turbulent	C.S.	19570	34184	0	0
1	28	1	2	Therminol XP	235	235.9	679.3	676.2	675.8	678.3	0	141.3	2.6	265.1	267.2	270.2	285.2	1289.5	None	Turbulent	C.S.	19540	34131	0	0
1	29	1	1	Therminol XP	235.9	237	676.2	673	678.3	681.5	0	141.3	2.7	273.3	276	279.8	294.8	1304.9	None	Turbulent	C.S.	24558	42897	0	0
1	30	1	1	Therminol XP	237	238.2	673	669.6	681.5	684.6	0	141.3	2.8	274.2	276.9	280.7	295.7	1309.5	None	Turbulent	C.S.	24518	42828	0	0
1	31	1	1	Therminol XP	238.2	239.3	669.6	666.2	684.6	687.8	0	141.3	2.9	275.2	277.8	281.6	296.6	1314.2	None	Turbulent	C.S.	24479	42759	0	0
1	32	1	1	Therminol XP	239.3	240.4	666.2	662.7	687.8	691	0	141.3	2.9	276.1	278.8	282.6	297.6	1318.8	None	Turbulent	C.S.	24439	42689	0	0

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Upgrade Membership

Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	364.1	282.6	304	255.2
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	379.1	297.6	319	270.2
Design Tube Pressure	kPa	2000.2		2000.2	2000.2
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235
No. Rows			3	2	3
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	232.77	62.13	325.88	801.84
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.1	25.4
Fin Thickness	mm			1.3	1.3
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	379.0543	297.5762	319.0039	270.2005
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	107495.1	120860.7	117501.3	124313.5
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.3025	1.1596	1.1925	1.1277
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.3	4.16	4.19	4.13
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.92	4.75	4.79	4.72
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		8.113359	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	41
Stack Diameter	m	2.07
Cone Diameter	m	1.269
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	162.1
Flue Gas Flow	kg/s	5.416
Steel Area	m²	266.522
Stack Entry Pressure	mmH2O	2.207
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Air Preheater

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Air Pre Heater, APH, Air PreHeat, Combustion Air Pre-heat for Fired Heater

Air Flow Rate	kg/s	5.416
Air Inlet Temp.	°C	15.5
Air Outlet Temp.	°C	150
Flue Gas Flow Rate	kg/s	5.679
Flue Gas Inlet Temp.	°C	275.7
Flue Gas Outlet Temp.	°C	162.1
Absorbed Duty	MW	0.735
Flue Gas Dew Temp.	°C	56.4
Min Allowable Metal Temp.:	°C	76.4

APH calculation results should be confirmed with APH specialist vendor

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	815.8	MW Castable	75	0.4	ULW Castable	150	0.13	732.5	552.7	1400	V Y Anchors	76.8	Refrac. thickness OK
RADIANT WALL 1	614.9	Fibre (High Density)	75	0.1	None	0	0	732.8	571	1260	Twistlock Pins	70.9	Refrac. thickness OK
RADIANT ARCH 1	865.8	Fibre (High Density)	113.1	0.1	None	0	0	824	757.6	1260	Twistlock Pins	77.8	Refrac. thickness OK

CONVECTION SIDEWALL 1	570.7	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	595.2	1100	V Y Anchors	73	Refrac. thickness OK

STACK 1	162.1	LW Castable	50	0.3	None	0	0	732.8	402.4	1100	V Y Anchors	60.5	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

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ENERGY PERFORMACE
Total Absorbed Duty	MW	9.576
Total Heat Release	MW	10.626
Total Efficiency	%	90.122

PROCESS
Process Name		Therminol XP
Heat Duty	MW	9.576
Flow rate (sec)	kg/s	40
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750.1
OUTLET CONDITIONS
Outlet Temperature	°C	199.9
Outlet Pressure	kPa a	-308.087

AIR
Air Flow	kg/s	4.387
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.212
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	kg/s	4.6
Flue Gas Temp.	°C	189.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	3.458
Flue Gas Flow	kg/s	4.6
Max Tube Temp.	°C	201.6
Total Press. Loss (inc. gain)	mmH2O	-1.67

RADIANT SECTION
Radiant Cell		1
Heat Duty	MW	6.119
Heat Release	MW	10.626
Arch Temp.	°C	791
Max Tube Temp.	°C	241.9
Average Flux	W/m²	31383
Maximum Flux	W/m²	59222
No. of Burners		12
Arch Pressure	mmH2O	-2.523
Floor Pressure	mmH2O	-12.266

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	90.122
Daily CO2 Emissions	kg	50666

Commercial

BID / PROJECT VALUE

Total:

£ 889,593

SAFETY AND COMPLIANCE

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	241.9	176.6	201.6	161.4
No. Tubes		36	24	16	24
Effective Length	m	12.2	4.5	4.5	4.5
Straight Length	m	12.2	4.9	4.9	4.9

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 693,994
Option items
Detail Engineering (by HeaterSIM)	£ 104,099
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£889,593

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	4.6	4.6	0.212	4.387
Flow (hr)	kg/hr	144000	144000	16559	16559	765	15795
Temperature	°C	100	199.9	791	189.9	Note 1	15.5
Pressure	kPa a	750.1	-308.087	-2.523	-0.522	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

39.785 m 19.785 m 17.985 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 1.21 m 4.5 m 5 m 2.911 m 12 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
No. Tubes		36	24	16	24
Effective Length	m	12.2	4.5	4.5	4.5
Straight Length	m	12.2	4.9	4.9	4.9

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Therminol XP
Heat Duty	MW	9.576
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	1058.187
Max. Film Temp. Calculated	°C	233.2
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	31811
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	344
OUTLET CONDITIONS
Outlet Temperature	°C	199.9
Outlet Pressure	kPa a	-308.087
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	583

Therminol XP: Calculated outlet pressure is excessively below atmospheric pressure

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type
Heat Duty	MW	6.119
Heat Release	MW	10.626
Arch Temp.	°C	791
Max Tube Temp.	°C	241.9
Tube Cirle Diameter	m	2.911
Average Flux	W/m²	31383
Maximum Flux	W/m²	59222
Flue Flow	kg/s	4.6
Air Flow	kg/s	4.387
Fuel Flow	kg/s	0.212
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-2.523
Floor Pressure	mmH2O	-12.266
Radiant Height	m	11.08
Radiant Width	m	5
Radiant Length	m	5
No. of Burners		12
Burner Cirle Diameter	m	2.338
Burner Design Firing	MW	0.47
Burner Normal Firing	MW	0.43
Burner Min Firing	MW	0.09
Burner-to-Tube Note		OK
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	0.697
API Burner-to-Wall Dist.	m	0.427
API Burner-to-Roof/Roof Dist	m	2.538
Floor Flux	W/m²	541436

Flame-tube impingment risk not identified

Combustion

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Radiant Type
Flue Flow	kg/s	4.6
Air Flow	kg/s	4.387
Fuel Flow	kg/s	0.212
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°C	1805.6
Flue Gas Emissivity		0.449

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
Heat Duty	MW	3.458
Max Tube Temp.	°C	201.6
Total Flue Press. Loss (ex. gain)	mmH2O	1.06
Total Press. Gain	mmH2O	2.73
Total Press. Loss (inc. gain)	mmH2O	-1.67
Convection Width	m	2.159
Effective Length	m	4.5
Convection Height	m	3.601
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	4.6
Flue Gas Inlet Temp.	°C	791
Flue Gas Outlet Temp.	°C	189.9
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.23	233.1	189.9	242.9	193.2	0.7	Solid	14304	17376	8	1.278	0.137	C.S.	C.S.	137.2	148.1
1	7	Coil Section 3	0.34	296.2	233.1	316.5	242.9	0.63	Solid	21202	25706	8	1.278	0.152	C.S.	C.S.	156.1	172.2
1	6	Coil Section 3	0.52	390.9	296.2	428.7	316.5	0.55	Solid	32271	38972	8	1.278	0.173	C.S.	C.S.	185.3	209.1
1	5	Coil Section 2	0.57	493.5	390.9	553.1	428.7	0.48	Solid	35812	43286	8	1.216	0.143	C.S.	C.S.	196.9	227.6
1	4	Coil Section 2	0.87	642.5	493.5	741.2	553.1	0.41	Solid	54164	66773	8	1.216	0.168	C.S.	C.S.	240.9	283.4
1	3	Coil Section 1	0.26	685.5	642.5	795.9	741.2	0.36	None	16770	29294	8	1.134	0.091	C.S.	None	0	0
1	2	Coil Section 1	0.3	732.2	685.5	857.4	795.9	0.35	None	20281	35426	8	1.134	0.096	C.S.	None	0	0
1	1	Coil Section 1	0.37	791	732.2	927.3	857.4	0.33	None	26798	46810	8	1.134	0.101	C.S.	None	0	0

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.23	233.1	189.9	Therminol XP	1	100	102.6	750	684	0	0	3.7	3.8	0	0	3099	3099	113885	118534
1	7	Coil Section 3	0.34	296.2	233.1	Therminol XP	2	102.6	106.4	684	617	0	0	3.8	3.8	0	0	3099	3099	118530	125918
1	6	Coil Section 3	0.52	390.9	296.2	Therminol XP	3	106.4	112.2	617	551	0	0	3.8	3.8	0	0	3099	3099	125919	138482
1	5	Coil Section 2	0.57	493.5	390.9	Therminol XP	4	112.2	118.6	551	484	0	0	3.8	3.8	0	0	3099	3099	138458	154675
1	4	Coil Section 2	0.87	642.5	493.5	Therminol XP	5	118.6	128.3	484	417	0	0	3.8	3.8	0	0	3099	3099	154629	185312
1	3	Coil Section 1	0.26	685.5	642.5	Therminol XP	6	128.3	131.2	417	350	0	0	3.8	3.8	0	0	3099	3099	185265	196384
1	2	Coil Section 1	0.3	732.2	685.5	Therminol XP	7	131.2	134.6	350	283	0	0	3.8	3.9	0	0	3099	3099	196315	210741
1	1	Coil Section 1	0.37	791	732.2	Therminol XP	8	134.5	138.7	283	215	0	0	3.9	3.9	0	0	3099	3099	210530	228727

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.23	233.1	189.9	Therminol XP	1	100	102.6	750	684	0	0	3.7	3.8	0	0	3099	3099	113885	118534
1	7	Coil Section 3	0.34	296.2	233.1	Therminol XP	2	102.6	106.4	684	617	0	0	3.8	3.8	0	0	3099	3099	118530	125918
1	6	Coil Section 3	0.52	390.9	296.2	Therminol XP	3	106.4	112.2	617	551	0	0	3.8	3.8	0	0	3099	3099	125919	138482
1	5	Coil Section 2	0.57	493.5	390.9	Therminol XP	4	112.2	118.6	551	484	0	0	3.8	3.8	0	0	3099	3099	138458	154675
1	4	Coil Section 2	0.87	642.5	493.5	Therminol XP	5	118.6	128.3	484	417	0	0	3.8	3.8	0	0	3099	3099	154629	185312
1	3	Coil Section 1	0.26	685.5	642.5	Therminol XP	6	128.3	131.2	417	350	0	0	3.8	3.8	0	0	3099	3099	185265	196384
1	2	Coil Section 1	0.3	732.2	685.5	Therminol XP	7	131.2	134.6	350	283	0	0	3.8	3.9	0	0	3099	3099	196315	210741
1	1	Coil Section 1	0.37	791	732.2	Therminol XP	8	134.5	138.7	283	215	0	0	3.9	3.9	0	0	3099	3099	210530	228727

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol XP	138.7	140.4	215.5	297	430.4	434.6	0	141.3	3.9	185.9	189.4	194.6	209.6	1452.3	Turbulent		31811	59849	0	0
2	Wall	Therminol XP	140.4	142.1	297	187	434.6	438.9	0	141.3	3.9	187.2	190.7	195.9	210.9	1464	Turbulent		31787	59814	0	0
3	Wall	Therminol XP	142.1	143.9	187	268.2	438.9	443.1	0	141.3	3.9	188.5	192	197.3	212.3	1475.9	Turbulent		31763	59780	0	0
4	Wall	Therminol XP	143.9	145.6	268.2	158.5	443.1	447.4	0	141.3	3.9	189.9	193.4	198.6	213.6	1488	Turbulent		31739	59745	0	0
5	Wall	Therminol XP	145.6	147.3	158.5	239.3	447.4	451.6	0	141.3	3.9	191.2	194.7	199.9	214.9	1500.3	Turbulent		31715	59710	0	0
6	Wall	Therminol XP	147.3	149	239.3	129.8	451.6	455.9	0	141.3	3.9	192.5	196	201.3	216.3	1512.7	Turbulent		31691	59675	0	0
7	Wall	Therminol XP	149	150.8	129.8	210.4	455.9	460.1	0	141.3	3.9	193.9	197.4	202.6	217.6	1525.4	Turbulent		31667	59639	0	0
8	Wall	Therminol XP	150.8	152.5	210.4	101.1	460.1	464.4	0	141.3	3.9	195.2	198.7	204	219	1538.2	Turbulent		31642	59604	0	0
9	Wall	Therminol XP	152.5	154.2	101.1	181.3	464.4	468.6	0	141.3	3.9	196.5	200.1	205.3	220.3	1551.3	Turbulent		31618	59568	0	0
10	Wall	Therminol XP	154.2	155.9	181.3	72.4	468.6	472.9	0	141.3	3.9	197.9	201.4	206.6	221.6	1564.5	Turbulent		31593	59532	0	0
11	Wall	Therminol XP	155.9	157.7	72.4	152.2	472.9	477.1	0	141.3	3.9	199.2	202.7	208	223	1578	Turbulent		31569	59496	0	0
12	Wall	Therminol XP	157.7	159.4	152.2	43.5	477.1	481.4	0	141.3	3.9	200.6	204.1	209.3	224.3	1591.7	Turbulent		31544	59459	0	0
13	Wall	Therminol XP	159.4	161.1	43.5	123.1	481.4	485.6	0	141.3	3.9	201.9	205.4	210.7	225.7	1605.7	Turbulent		31519	59423	0	0
14	Wall	Therminol XP	161.1	162.8	123.1	14.6	485.6	489.9	0	141.3	3.9	203.2	206.8	212	227	1619.9	Turbulent		31494	59386	0	0
15	Wall	Therminol XP	162.8	164.6	14.6	93.8	489.9	494.1	0	141.3	4	204.6	208.1	213.3	228.3	1634.3	Turbulent		31469	59349	0	0
16	Wall	Therminol XP	164.6	166.3	93.8	-14.4	494.1	498.4	0	141.3	4	205.9	209.4	214.7	229.7	1649.1	Turbulent		31444	59312	0	0
17	Wall	Therminol XP	166.3	168	-14.4	64.5	498.4	502.6	0	141.3	4	207.3	210.8	216	231	1664.1	Turbulent		31419	59275	0	0
18	Wall	Therminol XP	168	169.7	64.5	-43.4	502.6	506.9	0	141.3	4	208.6	212.1	217.4	232.4	1679.4	Turbulent		31394	59237	0	0
19	Wall	Therminol XP	169.7	171.4	-43.4	35.2	506.9	511.1	0	141.3	4	210	213.5	218.7	233.7	1695	Turbulent		31369	59200	0	0
20	Wall	Therminol XP	171.4	173.2	35.2	-72.6	511.1	515.4	0	141.3	4	211.3	214.8	220	235	1711	Turbulent		31343	59162	0	0
21	Wall	Therminol XP	173.2	174.9	-72.6	5.8	515.4	519.6	0	141.3	4	212.6	216.1	221.4	236.4	1727.3	Turbulent		31318	59124	0	0
22	Wall	Therminol XP	174.9	176.6	5.8	-101.8	519.6	523.9	0	141.3	4	214	217.5	222.7	237.7	1743.9	Turbulent		31292	59086	0	0
23	Wall	Therminol XP	176.6	178.3	-101.8	-23.7	523.9	528.1	0	141.3	4	215.3	218.8	224.1	239.1	1760.9	Turbulent		31267	59047	0	0
24	Wall	Therminol XP	178.3	180.1	-23.7	-131	528.1	532.4	0	141.3	4	216.7	220.2	225.4	240.4	1778.3	Turbulent		31241	59009	0	0
25	Wall	Therminol XP	180.1	181.8	-131	-53.2	532.4	536.6	0	141.3	4	218	221.5	226.7	241.7	1796.1	Turbulent		31215	58970	0	0
26	Wall	Therminol XP	181.8	183.5	-53.2	-160.3	536.6	540.8	0	141.3	4	219.3	222.8	228	243	1811.8	Turbulent		31189	58932	0	0
27	Wall	Therminol XP	183.5	185.1	-160.3	-82.9	540.8	545.1	0	141.3	4	220.7	224.2	229.4	244.4	1824.2	Turbulent		31162	58892	0	0
28	Wall	Therminol XP	185.1	186.7	-82.9	-189.7	545.1	549.3	0	141.3	4	222.1	225.6	230.8	245.8	1836.8	Turbulent		31136	58851	0	0
29	Wall	Therminol XP	186.7	188.4	-189.7	-112.6	549.3	553.6	0	141.3	4	223.4	227	232.2	247.2	1849.4	Turbulent		31109	58811	0	0
30	Wall	Therminol XP	188.4	190	-112.6	-219.2	553.6	557.8	0	141.3	4	224.8	228.4	233.5	248.5	1862.3	Turbulent		31082	58770	0	0
31	Wall	Therminol XP	190	191.7	-219.2	-142.4	557.8	562.1	0	141.3	4	226.2	229.7	234.9	249.9	1875.3	Turbulent		31055	58729	0	0
32	Wall	Therminol XP	191.7	193.3	-142.4	-248.7	562.1	566.3	0	141.3	4.1	227.6	231.1	236.3	251.3	1888	Turbulent		31027	58687	0	0
33	Wall	Therminol XP	193.3	195	-248.7	-172.2	566.3	570.6	0	141.3	4.1	229	232.5	237.7	252.7	1900.3	Turbulent		31000	58645	0	0
34	Wall	Therminol XP	195	196.6	-172.2	-278.4	570.6	574.8	0	141.3	4.1	230.4	233.9	239.1	254.1	1912.7	Turbulent		30972	58603	0	0
35	Wall	Therminol XP	196.6	198.3	-278.4	-202.2	574.8	579.1	0	141.3	4.1	231.8	235.3	240.5	255.5	1925.2	Turbulent		30944	58560	0	0
36	Wall	Therminol XP	198.3	199.9	-202.2	-308.1	579.1	583.3	0	141.3	4.1	233.2	236.7	241.9	256.9	1937.9	Turbulent		30916	58518	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Therminol XP	100	100.3	750.1	741.8	344.2	344.9	0	141.3	3.7	122.6	123.9	125.5	140.5	1004.1	Solid	Turbulent	C.S.	14429	20312	0	0
1	2	3	8	Therminol XP	100.3	100.6	741.8	733.5	344.9	345.6	0	141.3	3.8	122.8	124.1	125.7	140.7	1006.4	Solid	Turbulent	C.S.	14386	20252	0	0
1	3	3	8	Therminol XP	100.6	101	733.5	725.3	345.6	346.3	0	141.3	3.8	123	124.3	125.9	140.9	1008.7	Solid	Turbulent	C.S.	14344	20192	0	0
1	4	3	8	Therminol XP	101	101.3	725.3	717	346.3	347	0	141.3	3.8	123.2	124.5	126.1	141.1	1011	Solid	Turbulent	C.S.	14301	20132	0	0
1	5	3	8	Therminol XP	101.3	101.6	717	708.7	347	347.7	0	141.3	3.8	123.4	124.7	126.3	141.3	1013.3	Solid	Turbulent	C.S.	14258	20071	0	0
1	6	3	8	Therminol XP	101.6	101.9	708.7	700.4	347.7	348.5	0	141.3	3.8	123.6	124.9	126.5	141.5	1015.7	Solid	Turbulent	C.S.	14215	20011	0	0
1	7	3	8	Therminol XP	101.9	102.2	700.4	692.1	348.5	349.2	0	141.3	3.8	123.9	125.1	126.7	141.7	1018	Solid	Turbulent	C.S.	14173	19951	0	0
1	8	3	8	Therminol XP	102.2	102.6	692.1	683.8	349.2	349.9	0	141.3	3.8	124.1	125.3	126.9	141.9	1020.4	Solid	Turbulent	C.S.	14130	19891	0	0
1	9	3	7	Therminol XP	102.6	103	683.8	675.6	349.9	350.9	0	141.3	3.8	134.5	136.5	138.9	153.9	1053	Solid	Turbulent	C.S.	21391	30074	0	0
1	10	3	7	Therminol XP	103	103.5	675.6	667.3	350.9	352	0	141.3	3.8	134.8	136.7	139.1	154.1	1056.7	Solid	Turbulent	C.S.	21326	29983	0	0
1	11	3	7	Therminol XP	103.5	104	667.3	659	352	353.1	0	141.3	3.8	135.1	137	139.4	154.4	1060.3	Solid	Turbulent	C.S.	21262	29893	0	0
1	12	3	7	Therminol XP	104	104.5	659	650.7	353.1	354.1	0	141.3	3.8	135.4	137.3	139.6	154.6	1064	Solid	Turbulent	C.S.	21197	29802	0	0
1	13	3	7	Therminol XP	104.5	104.9	650.7	642.4	354.1	355.2	0	141.3	3.8	135.6	137.5	139.9	154.9	1067.8	Solid	Turbulent	C.S.	21133	29711	0	0
1	14	3	7	Therminol XP	104.9	105.4	642.4	634.1	355.2	356.2	0	141.3	3.8	135.9	137.8	140.2	155.2	1071.5	Solid	Turbulent	C.S.	21068	29620	0	0
1	15	3	7	Therminol XP	105.4	105.9	634.1	625.8	356.2	357.3	0	141.3	3.8	136.2	138.1	140.4	155.4	1075.3	Solid	Turbulent	C.S.	21003	29529	0	0
1	16	3	7	Therminol XP	105.9	106.4	625.8	617.5	357.3	358.3	0	141.3	3.8	136.5	138.3	140.7	155.7	1079.1	Solid	Turbulent	C.S.	20939	29439	0	0
1	17	3	6	Therminol XP	106.4	107.1	617.5	609.2	358.3	360	0	141.3	3.8	152.3	155.3	158.9	173.9	1113.2	Solid	Turbulent	C.S.	32569	45671	0	0
1	18	3	6	Therminol XP	107.1	107.8	609.2	600.9	360	361.6	0	141.3	3.8	152.7	155.6	159.3	174.3	1118.5	Solid	Turbulent	C.S.	32466	45528	0	0
1	19	3	6	Therminol XP	107.8	108.5	600.9	592.5	361.6	363.2	0	141.3	3.8	153.1	156	159.6	174.6	1123.8	Solid	Turbulent	C.S.	32364	45384	0	0
1	20	3	6	Therminol XP	108.5	109.3	592.5	584.2	363.2	364.8	0	141.3	3.8	153.5	156.4	160	175	1129.2	Solid	Turbulent	C.S.	32262	45240	0	0
1	21	3	6	Therminol XP	109.3	110	584.2	575.9	364.8	366.4	0	141.3	3.8	153.8	156.7	160.3	175.3	1134.6	Solid	Turbulent	C.S.	32159	45097	0	0
1	22	3	6	Therminol XP	110	110.7	575.9	567.6	366.4	368	0	141.3	3.8	154.2	157.1	160.7	175.7	1140.1	Solid	Turbulent	C.S.	32057	44953	0	0
1	23	3	6	Therminol XP	110.7	111.4	567.6	559.3	368	369.6	0	141.3	3.8	154.6	157.5	161	176	1145.6	Solid	Turbulent	C.S.	31954	44810	0	0
1	24	3	6	Therminol XP	111.4	112.2	559.3	550.9	369.6	371.2	0	141.3	3.8	155	157.8	161.4	176.4	1151.2	Solid	Turbulent	C.S.	31852	44666	0	0
1	25	2	5	Therminol XP	112.2	113	550.9	542.6	371.2	373	0	141.3	3.8	160.8	164	168.1	183.1	1167.8	Solid	Turbulent	C.S.	36084	50596	0	0
1	26	2	5	Therminol XP	113	113.8	542.6	534.3	373	374.8	0	141.3	3.8	161.2	164.4	168.5	183.5	1174.2	Solid	Turbulent	C.S.	35994	50470	0	0
1	27	2	5	Therminol XP	113.8	114.6	534.3	525.9	374.8	376.6	0	141.3	3.8	161.6	164.8	168.9	183.9	1180.7	Solid	Turbulent	C.S.	35905	50345	0	0
1	28	2	5	Therminol XP	114.6	115.4	525.9	517.6	376.6	378.4	0	141.3	3.8	162	165.3	169.3	184.3	1187.2	Solid	Turbulent	C.S.	35816	50219	0	0
1	29	2	5	Therminol XP	115.4	116.2	517.6	509.3	378.4	380.1	0	141.3	3.8	162.5	165.7	169.7	184.7	1193.9	Solid	Turbulent	C.S.	35726	50094	0	0
1	30	2	5	Therminol XP	116.2	117	509.3	500.9	380.1	381.9	0	141.3	3.8	162.9	166.1	170.1	185.1	1200.6	Solid	Turbulent	C.S.	35637	49969	0	0
1	31	2	5	Therminol XP	117	117.8	500.9	492.6	381.9	383.7	0	141.3	3.8	163.3	166.5	170.5	185.5	1207.4	Solid	Turbulent	C.S.	35547	49843	0	0
1	32	2	5	Therminol XP	117.8	118.6	492.6	484.2	383.7	385.5	0	141.3	3.8	163.7	166.9	171	186	1214.2	Solid	Turbulent	C.S.	35458	49718	0	0
1	33	2	4	Therminol XP	118.6	119.8	484.2	475.9	385.5	388.2	0	141.3	3.8	187	192.1	198.3	213.3	1272.3	Solid	Turbulent	C.S.	54618	77579	0	0
1	34	2	4	Therminol XP	119.8	121	475.9	467.5	388.2	390.9	0	141.3	3.8	187.5	192.5	198.8	213.8	1282.7	Solid	Turbulent	C.S.	54468	77364	0	0
1	35	2	4	Therminol XP	121	122.2	467.5	459.1	390.9	393.6	0	141.3	3.8	188	193	199.3	214.3	1293.3	Solid	Turbulent	C.S.	54317	77150	0	0
1	36	2	4	Therminol XP	122.2	123.4	459.1	450.8	393.6	396.3	0	141.3	3.8	188.4	193.5	199.7	214.7	1304.1	Solid	Turbulent	C.S.	54166	76936	0	0
1	37	2	4	Therminol XP	123.4	124.6	450.8	442.4	396.3	399	0	141.3	3.8	188.9	194	200.2	215.2	1315.1	Solid	Turbulent	C.S.	54015	76722	0	0
1	38	2	4	Therminol XP	124.6	125.9	442.4	434	399	401.7	0	141.3	3.8	189.4	194.4	200.6	215.6	1326.3	Solid	Turbulent	C.S.	53864	76508	0	0
1	39	2	4	Therminol XP	125.9	127.1	434	425.6	401.7	404.4	0	141.3	3.8	189.9	194.9	201.1	216.1	1337.7	Solid	Turbulent	C.S.	53714	76294	0	0
1	40	2	4	Therminol XP	127.1	128.3	425.6	417.2	404.4	407.1	0	141.3	3.8	190.4	195.4	201.6	216.6	1349.4	Solid	Turbulent	C.S.	53563	76079	0	0
1	41	1	3	Therminol XP	128.3	128.6	417.2	408.8	407.1	407.9	0	141.3	3.8	153.3	155.1	157.4	172.4	1273.9	None	Turbulent	C.S.	16294	28461	0	0
1	42	1	3	Therminol XP	128.6	129	408.8	400.5	407.9	408.7	0	141.3	3.8	153.5	155.4	157.7	172.7	1277.7	None	Turbulent	C.S.	16283	28442	0	0
1	43	1	3	Therminol XP	129	129.4	400.5	392.1	408.7	409.5	0	141.3	3.8	153.8	155.7	157.9	172.9	1281.4	None	Turbulent	C.S.	16272	28424	0	0
1	44	1	3	Therminol XP	129.4	129.7	392.1	383.7	409.5	410.3	0	141.3	3.8	154.1	156	158.2	173.2	1285.2	None	Turbulent	C.S.	16261	28405	0	0
1	45	1	3	Therminol XP	129.7	130.1	383.7	375.3	410.3	411.1	0	141.3	3.8	154.4	156.2	158.5	173.5	1289	None	Turbulent	C.S.	16251	28386	0	0
1	46	1	3	Therminol XP	130.1	130.5	375.3	366.9	411.1	411.9	0	141.3	3.8	154.7	156.5	158.7	173.7	1292.8	None	Turbulent	C.S.	16240	28367	0	0
1	47	1	3	Therminol XP	130.5	130.8	366.9	358.5	411.9	412.8	0	141.3	3.8	154.9	156.8	159	174	1296.7	None	Turbulent	C.S.	16229	28348	0	0
1	48	1	3	Therminol XP	130.8	131.2	358.5	350.1	412.8	413.6	0	141.3	3.8	155.2	157.1	159.3	174.3	1300.6	None	Turbulent	C.S.	16218	28330	0	0
1	49	1	2	Therminol XP	131.2	131.6	350.1	341.7	413.5	414.5	0	141.3	3.8	159.5	161.7	164.3	179.3	1313.6	None	Turbulent	C.S.	19042	33262	0	0
1	50	1	2	Therminol XP	131.6	132	341.7	333.3	414.5	415.4	0	141.3	3.8	159.8	162	164.6	179.6	1318.2	None	Turbulent	C.S.	19029	33239	0	0
1	51	1	2	Therminol XP	132	132.5	333.3	324.9	415.4	416.4	0	141.3	3.8	160.1	162.3	164.9	179.9	1322.9	None	Turbulent	C.S.	19016	33216	0	0
1	52	1	2	Therminol XP	132.5	132.9	324.9	316.5	416.4	417.3	0	141.3	3.8	160.4	162.6	165.2	180.2	1327.6	None	Turbulent	C.S.	19003	33193	0	0
1	53	1	2	Therminol XP	132.9	133.3	316.5	308.1	417.3	418.3	0	141.3	3.8	160.8	162.9	165.6	180.6	1332.3	None	Turbulent	C.S.	18989	33170	0	0
1	54	1	2	Therminol XP	133.3	133.7	308.1	299.6	418.3	419.2	0	141.3	3.8	161.1	163.2	165.9	180.9	1337.1	None	Turbulent	C.S.	18976	33147	0	0
1	55	1	2	Therminol XP	133.7	134.2	299.6	291.2	419.2	420.2	0	141.3	3.8	161.4	163.6	166.2	181.2	1341.9	None	Turbulent	C.S.	18963	33124	0	0
1	56	1	2	Therminol XP	134.2	134.6	291.2	282.8	420.2	421.1	0	141.3	3.9	161.7	163.9	166.5	181.5	1346.8	None	Turbulent	C.S.	18950	33102	0	0
1	57	1	1	Therminol XP	134.5	135.1	282.8	274.4	421	422.2	0	141.3	3.9	168.2	170.9	174.2	189.2	1366.7	None	Turbulent	C.S.	23517	41080	0	0
1	58	1	1	Therminol XP	135.1	135.6	274.4	266	422.2	423.3	0	141.3	3.9	168.5	171.3	174.5	189.5	1372.8	None	Turbulent	C.S.	23501	41051	0	0
1	59	1	1	Therminol XP	135.6	136.1	266	257.6	423.3	424.5	0	141.3	3.9	168.9	171.6	174.8	189.8	1378.9	None	Turbulent	C.S.	23484	41022	0	0
1	60	1	1	Therminol XP	136.1	136.6	257.6	249.2	424.5	425.7	0	141.3	3.9	169.2	172	175.2	190.2	1385	None	Turbulent	C.S.	23467	40992	0	0
1	61	1	1	Therminol XP	136.6	137.1	249.2	240.7	425.7	426.9	0	141.3	3.9	169.6	172.3	175.5	190.5	1391.3	None	Turbulent	C.S.	23451	40963	0	0
1	62	1	1	Therminol XP	137.1	137.6	240.7	232.3	426.9	428	0	141.3	3.9	169.9	172.6	175.9	190.9	1397.6	None	Turbulent	C.S.	23434	40934	0	0
1	63	1	1	Therminol XP	137.6	138.2	232.3	223.9	428	429.2	0	141.3	3.9	170.3	173	176.2	191.2	1404	None	Turbulent	C.S.	23417	40905	0	0
1	64	1	1	Therminol XP	138.2	138.7	223.9	215.5	429.2	430.4	0	141.3	3.9	170.7	173.4	176.6	191.6	1408.2	None	Turbulent	C.S.	23401	40876	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	241.9	176.6	201.6	161.4
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	256.9	191.6	216.6	176.4
Design Tube Pressure	kPa	2000.2		2000.2	2000.2
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		36	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		1	1	1	1
Effective Length	m	12.2	4.5	4.5	4.5
Straight Length	m	12.2	4.9	4.9	4.9
No. Rows			3	2	3
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	194.96	47.92	250.64	618.28
Intermediate Supports		0 / 0	0 / 1	0 / 1	0 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.05	25.4
Fin Thickness	mm			1.27	1.27
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	256.9072	191.6194	216.5756	176.4058
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	125990.1	134224.6	131077	136143.4
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1128	1.045	1.0699	1.0304
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.11	4.05	4.07	4.03
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.7	4.62	4.65	4.61
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	20
Stack Diameter	m	1.21
Cone Diameter	m	1.211
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	189.9
Flue Gas Flow	kg/s	4.6
Steel Area	m²	76.117
Stack Entry Pressure	mmH2O	-0.522
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	741	MW Castable	74.9	0.4	ULW Castable	150.1	0.14	732.5	509.1	1400	V Y Anchors	73.3	Refrac. thickness OK
RADIANT WALL 1	516.4	Fibre (High Density)	74.9	0.1	None	0	0	732.8	398.7	1260	Twistlock Pins	59.8	Refrac. thickness OK
RADIANT ARCH 1	791	Fibre (High Density)	87.6	0.1	None	0	0	824	814.5	1260	Twistlock Pins	80.6	Refrac. thickness OK

CONVECTION SIDEWALL 1	490.4	LW Castable	74.9	0.3	ULW Castable	74.9	0.13	732.8	487.5	1100	V Y Anchors	66	Refrac. thickness OK

STACK 1	189.9	LW Castable	50	0.3	None	0	0	732.8	546.1	1100	V Y Anchors	69.5	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

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ENERGY PERFORMACE
Total Absorbed Duty	MW	9.576
Total Heat Release	MW	10.959
Total Efficiency	%	87.38

PROCESS
Process Name		Dowtherm G
Heat Duty	MW	9.576
Flow rate (sec)	kg/s	40
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
OUTLET CONDITIONS
Outlet Temperature	°C	301.1
Outlet Pressure	kPa a	206.755

AIR
Air Flow	kg/s	4.445
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.265
Fuel LHV	kJ/kg	41358
Fuel Mol. Wt.		7.763

STACK
Flue Gas Flow	kg/s	4.71
Flue Gas Temp.	°C	257.5
CO2	mol%	12.21
H2O	mol%	8.96
N2	mol%	75.42
O2	mol%	3.33
SO2	mol%	0.08

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	3.68
Flue Gas Flow	kg/s	4.71
Max Tube Temp.	°C	296.8
Total Press. Loss (inc. gain)	mmH2O	-1.18

RADIANT SECTION
Radiant Cell		1
Heat Duty	MW	5.896
Heat Release	MW	10.959
Arch Temp.	°C	899.3
Max Tube Temp.	°C	340.2
Average Flux	W/m²	25444
Maximum Flux	W/m²	52620
No. of Burners		4
Arch Pressure	mmH2O	-2.343
Floor Pressure	mmH2O	-12.246

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	87.38
Daily CO2 Emissions	kg	74844

Commercial

BID / PROJECT VALUE

Total:

£ 1,038,890

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	114.3	114.3	114.3	114.3
Tube Material		18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	340.2	274.7	296.8	246.1
No. Tubes		64	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Commercial

HeaterSIM - Fired Heater Simulation Results

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 823,817
Option items
Detail Engineering (by HeaterSIM)	£ 123,573
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£1,038,890

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Dowtherm G	Dowtherm G	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	4.71	4.71	0.265	4.445
Flow (hr)	kg/hr	144000	144000	16955	16955	954	16001
Temperature	°C	200	301.1	899.3	257.5	Note 1	15.5
Pressure	kPa a	750.1	206.755	-2.343	-0.999	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

36.345 m 19.345 m 17.545 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 1.27 m 5.835 m 4.444 m 4.14 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	114.3	114.3	114.3	114.3
Tube Material		18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	203.2	203.2	203.2	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1	176.1	176.1
No. Tubes		64	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Dowtherm G
Heat Duty	MW	9.576
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	543.345
Max. Film Temp. Calculated	°C	323.2
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	25939
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	200
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	604
OUTLET CONDITIONS
Outlet Temperature	°C	301.1
Outlet Pressure	kPa a	206.755
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	843

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type
Heat Duty	MW	5.896
Heat Release	MW	10.959
Arch Temp.	°C	899.3
Max Tube Temp.	°C	340.2
Tube Cirle Diameter	m	4.14
Average Flux	W/m²	25444
Maximum Flux	W/m²	52620
Flue Flow	kg/s	4.71
Air Flow	kg/s	4.445
Fuel Flow	kg/s	0.265
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-2.343
Floor Pressure	mmH2O	-12.246
Radiant Height	m	11.08
Radiant Width	m	4.44
Radiant Length	m	4.44
No. of Burners		4
Burner Cirle Diameter	m	1.209
Burner Design Firing	MW	3.29
Burner Normal Firing	MW	2.74
Burner Min Firing	MW	0.66
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.258
API Burner-to-Wall Dist.	m	1.165
API Burner-to-Roof/Roof Dist	m	10.455
Floor Flux	W/m²	706888

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

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Radiant Type
Flue Flow	kg/s	4.71
Air Flow	kg/s	4.445
Fuel Flow	kg/s	0.265
Fuel LHV	kJ/kg	41358
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	12.21
H2O	mol%	8.96
N2	mol%	75.42
O2	mol%	3.33
SO2	mol%	0.08
Dew Point	°C	144
Fuel Mol. Wt.		7.763
Flue Mol. Wt.		29.22
Flame Temperature	°C	1891.7
Flue Gas Emissivity		0.4

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
Heat Duty	MW	3.68
Max Tube Temp.	°C	296.8
Total Flue Press. Loss (ex. gain)	mmH2O	1.3
Total Press. Gain	mmH2O	2.47
Total Press. Loss (inc. gain)	mmH2O	-1.18
Convection Width	m	1.727
Effective Length	m	5.835
Convection Height	m	3.161
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	4.71
Flue Gas Inlet Temp.	°C	899.3
Flue Gas Outlet Temp.	°C	257.5
CO2	mol%	12.21461
H2O	mol%	8.958327
N2	mol%	75.41734
O2	mol%	3.332498
SO2	mol%	0.07723132

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.19	293.9	257.5	300	259.6	0.65	Solid	11368	13471	8	1.324	0.186	321 SS	C.S.	222.2	232.4
1	7	Coil Section 3	0.31	351.4	293.9	365.8	300	0.6	Solid	18499	21886	8	1.324	0.201	321 SS	C.S.	238	254.2
1	6	Coil Section 3	0.51	445.8	351.4	474.9	365.8	0.53	Solid	30736	36257	8	1.324	0.224	321 SS	C.S.	264.9	291.3
1	5	Coil Section 2	0.62	557	445.8	606.3	474.9	0.46	Solid	36907	44601	8	1.241	0.177	321 SS	C.S.	282	316.6
1	4	Coil Section 2	1.01	729.5	557	819.6	606.3	0.39	Solid	60143	74314	8	1.241	0.207	321 SS	C.S.	332.4	384.4
1	3	Coil Section 1	0.29	777.5	729.5	879.9	819.6	0.35	None	17727	31310	8	1.135	0.096	321 SS	None	0	0
1	2	Coil Section 1	0.34	830.3	777.5	948.2	879.9	0.33	None	21111	37287	8	1.135	0.1	321 SS	None	0	0
1	1	Coil Section 1	0.41	899.3	830.3	1026.4	948.2	0.31	None	26963	47624	8	1.135	0.106	321 SS	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.19	293.9	257.5	Dowtherm G	1	200	202	750	723	0	0	2.9	2.9	0	0	2435	2435	811877	823664
1	7	Coil Section 3	0.31	351.4	293.9	Dowtherm G	2	202	205.3	723	695	0	0	2.9	2.9	0	0	2435	2435	823695	842328
1	6	Coil Section 3	0.51	445.8	351.4	Dowtherm G	3	205.3	211.1	695	668	0	0	2.9	3	0	0	2435	2435	842346	871644
1	5	Coil Section 2	0.62	557	445.8	Dowtherm G	4	211.1	218	668	640	0	0	3	3	0	0	2435	2435	871860	908701
1	4	Coil Section 2	1.01	729.5	557	Dowtherm G	5	217.9	228.9	640	612	0	0	3	3	0	0	2435	2435	908332	967096
1	3	Coil Section 1	0.29	777.5	729.5	Dowtherm G	6	228.9	232.1	612	584	0	0	3	3	0	0	2435	2435	967097	984792
1	2	Coil Section 1	0.34	830.3	777.5	Dowtherm G	7	232.1	235.7	584	555	0	0	3	3	0	0	2435	2435	984658	1002484
1	1	Coil Section 1	0.41	899.3	830.3	Dowtherm G	8	235.7	240.1	555	527	0	0	3	3	0	0	2435	2435	1002677	1024829

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.19	293.9	257.5	Dowtherm G	1	200	202	750	723	0	0	2.9	2.9	0	0	2435	2435	811877	823664
1	7	Coil Section 3	0.31	351.4	293.9	Dowtherm G	2	202	205.3	723	695	0	0	2.9	2.9	0	0	2435	2435	823695	842328
1	6	Coil Section 3	0.51	445.8	351.4	Dowtherm G	3	205.3	211.1	695	668	0	0	2.9	3	0	0	2435	2435	842346	871644
1	5	Coil Section 2	0.62	557	445.8	Dowtherm G	4	211.1	218	668	640	0	0	3	3	0	0	2435	2435	871860	908701
1	4	Coil Section 2	1.01	729.5	557	Dowtherm G	5	217.9	228.9	640	612	0	0	3	3	0	0	2435	2435	908332	967096
1	3	Coil Section 1	0.29	777.5	729.5	Dowtherm G	6	228.9	232.1	612	584	0	0	3	3	0	0	2435	2435	967097	984792
1	2	Coil Section 1	0.34	830.3	777.5	Dowtherm G	7	232.1	235.7	584	555	0	0	3	3	0	0	2435	2435	984658	1002484
1	1	Coil Section 1	0.41	899.3	830.3	Dowtherm G	8	235.7	240.1	555	527	0	0	3	3	0	0	2435	2435	1002677	1024829

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Dowtherm G	240.1	242.1	526.9	596.1	696.1	700.7	0	114.3	3.1	266.4	274.5	284.6	299.6	2460.7	Turbulent		25939	53391	0	0
2	Wall	Dowtherm G	242.1	244.1	596.1	507.5	700.7	705.3	0	114.3	3.1	268.2	276.4	286.5	301.5	2467.9	Turbulent		25907	53342	0	0
3	Wall	Dowtherm G	244.1	246.1	507.5	576.3	705.3	709.9	0	114.3	3.1	270.1	278.2	288.3	303.3	2475.1	Turbulent		25876	53294	0	0
4	Wall	Dowtherm G	246.1	248	576.3	488	709.9	714.5	0	114.3	3.1	272	280.1	290.1	305.1	2480.7	Turbulent		25844	53245	0	0
5	Wall	Dowtherm G	248	250	488	556.4	714.5	719.1	0	114.3	3.1	273.9	282	292	307	2485.1	Turbulent		25812	53197	0	0
6	Wall	Dowtherm G	250	251.9	556.4	468.4	719.1	723.7	0	114.3	3.1	275.8	283.8	293.8	308.8	2489.4	Turbulent		25781	53147	0	0
7	Wall	Dowtherm G	251.9	253.9	468.4	536.4	723.7	728.3	0	114.3	3.1	277.7	285.7	295.7	310.7	2493.8	Turbulent		25749	53098	0	0
8	Wall	Dowtherm G	253.9	255.8	536.4	448.7	728.3	732.9	0	114.3	3.1	279.5	287.6	297.5	312.5	2498.1	Turbulent		25717	53048	0	0
9	Wall	Dowtherm G	255.8	257.8	448.7	516.4	732.9	737.5	0	114.3	3.1	281.4	289.4	299.4	314.4	2502.5	Turbulent		25684	52998	0	0
10	Wall	Dowtherm G	257.8	259.7	516.4	429	737.5	742.1	0	114.3	3.1	283.3	291.3	301.2	316.2	2506.9	Turbulent		25652	52948	0	0
11	Wall	Dowtherm G	259.7	261.6	429	496.3	742.1	746.7	0	114.3	3.1	285.2	293.1	303	318	2512.1	Turbulent		25620	52898	0	0
12	Wall	Dowtherm G	261.6	263.6	496.3	409.1	746.7	751.3	0	114.3	3.1	287	294.9	304.8	319.8	2518.7	Turbulent		25588	52848	0	0
13	Wall	Dowtherm G	263.6	265.5	409.1	476.2	751.3	756	0	114.3	3.1	288.8	296.8	306.6	321.6	2525.2	Turbulent		25557	52799	0	0
14	Wall	Dowtherm G	265.5	267.4	476.2	389.2	756	760.6	0	114.3	3.1	290.7	298.6	308.4	323.4	2531.5	Turbulent		25525	52748	0	0
15	Wall	Dowtherm G	267.4	269.3	389.2	456	760.6	765.2	0	114.3	3.1	292.5	300.4	310.2	325.2	2537.8	Turbulent		25493	52698	0	0
16	Wall	Dowtherm G	269.3	271.2	456	369.2	765.2	769.8	0	114.3	3.1	294.3	302.2	312	327	2544.1	Turbulent		25461	52648	0	0
17	Wall	Dowtherm G	271.2	273.1	369.2	435.7	769.8	774.4	0	114.3	3.1	296.2	304	313.8	328.8	2550.5	Turbulent		25429	52597	0	0
18	Wall	Dowtherm G	273.1	275	435.7	349.1	774.4	779	0	114.3	3.1	298	305.8	315.5	330.5	2556.8	Turbulent		25396	52546	0	0
19	Wall	Dowtherm G	275	276.9	349.1	415.3	779	783.6	0	114.3	3.2	299.8	307.6	317.3	332.3	2561.8	Turbulent		25364	52495	0	0
20	Wall	Dowtherm G	276.9	278.8	415.3	329	783.6	788.2	0	114.3	3.2	301.6	309.4	319.1	334.1	2566.9	Turbulent		25332	52443	0	0
21	Wall	Dowtherm G	278.8	280.7	329	394.9	788.2	792.8	0	114.3	3.2	303.4	311.2	320.9	335.9	2571.9	Turbulent		25300	52392	0	0
22	Wall	Dowtherm G	280.7	282.6	394.9	308.8	792.8	797.4	0	114.3	3.2	305.2	313	322.7	337.7	2576.8	Turbulent		25267	52340	0	0
23	Wall	Dowtherm G	282.6	284.4	308.8	374.4	797.4	802	0	114.3	3.2	307.1	314.8	324.4	339.4	2581.8	Turbulent		25235	52288	0	0
24	Wall	Dowtherm G	284.4	286.3	374.4	288.6	802	806.6	0	114.3	3.2	308.9	316.6	326.2	341.2	2586.8	Turbulent		25202	52235	0	0
25	Wall	Dowtherm G	286.3	288.2	288.6	353.8	806.6	811.2	0	114.3	3.2	310.7	318.4	328	343	2591.9	Turbulent		25169	52183	0	0
26	Wall	Dowtherm G	288.2	290.1	353.8	268.2	811.2	815.8	0	114.3	3.2	312.5	320.2	329.7	344.7	2596.8	Turbulent		25137	52130	0	0
27	Wall	Dowtherm G	290.1	291.9	268.2	333.2	815.8	820.4	0	114.3	3.2	314.3	322	331.5	346.5	2601.7	Turbulent		25104	52078	0	0
28	Wall	Dowtherm G	291.9	293.8	333.2	247.8	820.4	825.1	0	114.3	3.2	316.1	323.7	333.2	348.2	2606.6	Turbulent		25072	52026	0	0
29	Wall	Dowtherm G	293.8	295.6	247.8	312.4	825.1	829.7	0	114.3	3.2	317.8	325.5	335	350	2611.5	Turbulent		25039	51973	0	0
30	Wall	Dowtherm G	295.6	297.5	312.4	227.3	829.7	834.3	0	114.3	3.2	319.6	327.2	336.7	351.7	2616.5	Turbulent		25006	51920	0	0
31	Wall	Dowtherm G	297.5	299.3	227.3	291.6	834.3	838.9	0	114.3	3.2	321.4	329	338.5	353.5	2621.4	Turbulent		24974	51866	0	0
32	Wall	Dowtherm G	299.3	301.1	291.6	206.8	838.9	843.5	0	114.3	3.2	323.2	330.8	340.2	355.2	2626.3	Turbulent		24941	51813	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Dowtherm G	200	200.5	750.1	743.2	604.1	605.3	0	114.3	2.9	208.5	211.1	214.2	229.2	2230.9	Solid	Turbulent	321 SS	11455	15876	0	0
1	2	3	8	Dowtherm G	200.5	201	743.2	736.4	605.3	606.5	0	114.3	2.9	208.9	211.5	214.6	229.6	2232.5	Solid	Turbulent	321 SS	11376	15766	0	0
1	3	3	8	Dowtherm G	201	201.5	736.4	729.5	606.5	607.7	0	114.3	2.9	209.3	211.9	215	230	2234.1	Solid	Turbulent	321 SS	11296	15657	0	0
1	4	3	8	Dowtherm G	201.5	202	729.5	722.7	607.7	608.9	0	114.3	2.9	209.8	212.3	215.4	230.4	2235.7	Solid	Turbulent	321 SS	11217	15547	0	0
1	5	3	7	Dowtherm G	202	202.8	722.7	715.8	608.9	610.8	0	114.3	2.9	215.7	219.9	224.9	239.9	2247.9	Solid	Turbulent	321 SS	18647	25816	0	0
1	6	3	7	Dowtherm G	202.8	203.7	715.8	708.9	610.8	612.7	0	114.3	2.9	216.4	220.6	225.6	240.6	2250.7	Solid	Turbulent	321 SS	18512	25630	0	0
1	7	3	7	Dowtherm G	203.7	204.5	708.9	702	612.7	614.7	0	114.3	2.9	217.1	221.2	226.2	241.2	2253.5	Solid	Turbulent	321 SS	18378	25444	0	0
1	8	3	7	Dowtherm G	204.5	205.3	702	695.2	614.7	616.6	0	114.3	2.9	217.8	221.9	226.9	241.9	2257.4	Solid	Turbulent	321 SS	18243	25257	0	0
1	9	3	6	Dowtherm G	205.3	206.8	695.2	688.3	616.6	619.8	0	114.3	3	227.8	234.6	242.9	257.9	2278.9	Solid	Turbulent	321 SS	30997	42832	0	0
1	10	3	6	Dowtherm G	206.8	208.2	688.3	681.4	619.8	623.1	0	114.3	3	229	235.8	244	259	2285.5	Solid	Turbulent	321 SS	30757	42500	0	0
1	11	3	6	Dowtherm G	208.2	209.6	681.4	674.5	623.1	626.3	0	114.3	3	230.2	236.9	245.1	260.1	2292.2	Solid	Turbulent	321 SS	30517	42168	0	0
1	12	3	6	Dowtherm G	209.6	211.1	674.5	667.5	626.3	629.5	0	114.3	3	231.4	238.1	246.1	261.1	2298.9	Solid	Turbulent	321 SS	30276	41835	0	0
1	13	2	5	Dowtherm G	211.1	212.8	667.5	660.6	629.6	633.5	0	114.3	3	238	246.3	256.3	271.3	2314.7	Solid	Turbulent	321 SS	37175	52160	0	0
1	14	2	5	Dowtherm G	212.8	214.5	660.6	653.7	633.5	637.3	0	114.3	3	239.5	247.7	257.6	272.6	2322.6	Solid	Turbulent	321 SS	36948	51842	0	0
1	15	2	5	Dowtherm G	214.5	216.3	653.7	646.7	637.3	641.2	0	114.3	3	241	249.1	259	274	2330.5	Solid	Turbulent	321 SS	36722	51524	0	0
1	16	2	5	Dowtherm G	216.3	218	646.7	639.7	641.2	645	0	114.3	3	242.4	250.5	260.3	275.3	2338.5	Solid	Turbulent	321 SS	36495	51206	0	0
1	17	2	4	Dowtherm G	217.9	220.7	639.7	632.8	644.9	651.2	0	114.3	3	261.3	274.7	290.8	305.8	2376.4	Solid	Turbulent	321 SS	60613	86305	0	0
1	18	2	4	Dowtherm G	220.7	223.4	632.8	625.8	651.2	657.5	0	114.3	3	263.5	276.8	292.8	307.8	2391.8	Solid	Turbulent	321 SS	60207	85727	0	0
1	19	2	4	Dowtherm G	223.4	226.2	625.8	618.7	657.5	663.8	0	114.3	3	265.7	278.9	294.8	309.8	2407.4	Solid	Turbulent	321 SS	59801	85150	0	0
1	20	2	4	Dowtherm G	226.2	228.9	618.7	611.7	663.8	670.1	0	114.3	3	267.9	281	296.8	311.8	2423.1	Solid	Turbulent	321 SS	59396	84572	0	0
1	21	1	3	Dowtherm G	228.9	229.7	611.7	604.7	670.1	671.9	0	114.3	3	244.1	249	254.8	269.8	2394.1	None	Turbulent	321 SS	17381	30700	0	0
1	22	1	3	Dowtherm G	229.7	230.5	604.7	597.6	671.9	673.7	0	114.3	3	244.8	249.8	255.5	270.5	2398.9	None	Turbulent	321 SS	17355	30654	0	0
1	23	1	3	Dowtherm G	230.5	231.3	597.6	590.6	673.7	675.5	0	114.3	3	245.5	250.5	256.2	271.2	2403.8	None	Turbulent	321 SS	17330	30608	0	0
1	24	1	3	Dowtherm G	231.3	232.1	590.6	583.5	675.5	677.4	0	114.3	3	246.3	251.2	256.9	271.9	2408.6	None	Turbulent	321 SS	17304	30563	0	0
1	25	1	2	Dowtherm G	232.1	233	583.5	576.5	677.3	679.4	0	114.3	3	249.5	255.2	261.9	276.9	2416	None	Turbulent	321 SS	20198	35675	0	0
1	26	1	2	Dowtherm G	233	233.9	576.5	569.4	679.4	681.5	0	114.3	3	250.3	256.1	262.7	277.7	2419.3	None	Turbulent	321 SS	20168	35621	0	0
1	27	1	2	Dowtherm G	233.9	234.8	569.4	562.3	681.5	683.6	0	114.3	3	251.2	256.9	263.6	278.6	2422.6	None	Turbulent	321 SS	20137	35567	0	0
1	28	1	2	Dowtherm G	234.8	235.7	562.3	555.3	683.6	685.7	0	114.3	3	252.1	257.8	264.4	279.4	2425.9	None	Turbulent	321 SS	20106	35513	0	0
1	29	1	1	Dowtherm G	235.7	236.8	555.3	548.2	685.8	688.4	0	114.3	3	256.7	263.7	271.7	286.7	2435.5	None	Turbulent	321 SS	24532	43329	0	0
1	30	1	1	Dowtherm G	236.8	237.9	548.2	541.1	688.4	690.9	0	114.3	3	257.8	264.7	272.7	287.7	2439.6	None	Turbulent	321 SS	24493	43261	0	0
1	31	1	1	Dowtherm G	237.9	239	541.1	534	690.9	693.5	0	114.3	3	258.8	265.7	273.7	288.7	2443.6	None	Turbulent	321 SS	24454	43192	0	0
1	32	1	1	Dowtherm G	239	240.1	534	526.9	693.5	696.1	0	114.3	3	259.8	266.7	274.7	289.7	2447.6	None	Turbulent	321 SS	24415	43124	0	0

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Dowtherm G	Process 1: Dowtherm G	Process 1: Dowtherm G	Process 1: Dowtherm G
Tube OD	mm	114.3	114.3	114.3	114.3
Tube Material		18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	340.2	274.7	296.8	246.1
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	355.2	289.7	311.8	261.1
Design Tube Pressure	kPa	2000.2		2000.2	2000.2
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		64	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235
No. Rows			3	2	3
Tube Spacing	mm	203.2	203.2	203.2	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1	176.1	176.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	231.74	50.26	269.71	670.95
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.05	25.4
Fin Thickness	mm			1.27	1.27
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	355.2026	289.6959	311.7809	261.1343
tblTubeMaterial	Tube Material		18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS	18Cr/10Ni/Ti - 321 SS
tblTubeOD	Tube Outside Diameter		114.3	114.3	114.3	114.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.02	6.02	6.02	6.02
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	1	1	1	1
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.02	6.02	6.02	6.02
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	128083.8	133324.4	131557.6	135609.3
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	0.8856	0.851	0.8624	0.8368
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	1.89	1.85	1.86	1.84
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	2.15	2.12	2.13	2.1
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	17
Stack Diameter	m	1.27
Cone Diameter	m	1.274
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	257.5
Flue Gas Flow	kg/s	4.71
Steel Area	m²	68.067
Stack Entry Pressure	mmH2O	-0.999
CO2	mol%	12.21
H2O	mol%	8.96
N2	mol%	75.42
O2	mol%	3.33
SO2	mol%	0.08

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	849.3	MW Castable	74.9	0.4	ULW Castable	150.1	0.14	732.5	610.6	1400	V Y Anchors	80.3	Refrac. thickness OK
RADIANT WALL 1	619.7	Fibre (High Density)	74.9	0.1	None	0	0	732.8	580.9	1260	Twistlock Pins	72.3	Refrac. thickness OK
RADIANT ARCH 1	899.3	Fibre (High Density)	113	0.1	None	0	0	824	818.6	1260	Twistlock Pins	80.6	Refrac. thickness OK

CONVECTION SIDEWALL 1	578.4	LW Castable	74.9	0.3	ULW Castable	74.9	0.13	732.8	606.1	1100	V Y Anchors	73.7	Refrac. thickness OK

STACK 1	257.5	LW Castable	62.7	0.3	None	0	0	732.8	720.2	1100	V Y Anchors	80.6	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

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ENERGY PERFORMACE
Total Absorbed Duty	MW	59.993
Total Heat Release	MW	68.701
Total Efficiency	%	87.324

PROCESS
Process Name		Crude Oil 1
Heat Duty	MW	59.993
Flow rate (sec)	kg/s	200
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750.1
OUTLET CONDITIONS
Outlet Temperature	°C	484.6
Outlet Pressure	kPa a	-58043.828

AIR
Air Flow	kg/s	14.025	14.342
Air Temp.	°C	15.5	15.5
Excess Air	%	20	20

FUEL
Fuel Flow	kg/s	0.679	0.694
Fuel LHV	kJ/kg	50015	50015
Fuel Mol. Wt.		16	16

STACK
Flue Gas Flow	kg/s	29.74
Flue Gas Temp.	°C	233
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	21.024
Flue Gas Flow	kg/s	29.74
Max Tube Temp.	°C	251
Total Press. Loss (inc. gain)	mmH2O	-0.96

RADIANT SECTION
Radiant Cell		1	2
Heat Duty	MW	19.484	19.484
Heat Release	MW	33.967	34.734
Arch Temp.	°C	785.1	785.1
Max Tube Temp.	°C	496.1	496.1
Average Flux	W/m²	34292	34292
Maximum Flux	W/m²	57388	57694
No. of Burners		8	8
Arch Pressure	mmH2O	-2.582	-2.582
Floor Pressure	mmH2O	-17.497	-17.497

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	87.324
Daily CO2 Emissions	kg	327586

Commercial

BID / PROJECT VALUE

Total:

£ 1,781,252

SAFETY AND COMPLIANCE

Radiant cell no. 1: The burners to tube distance seems OK (API 560)

Radiant cell no. 2: The burners to tube distance seems OK (API 560)

Radiant cell no. 1: The burners to wall clearance seems OK (API 560)

Radiant cell no. 2: The burners to wall clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Radiant cell no. 2: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Radiant cell no. 2: API 560 Radiant height to width seems OK

Radiant cell no. 1: Single lane of burners considered

Radiant cell no. 2: Single lane of burners considered

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530#Radiant section 2,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	RADIANT 2	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	496.1	496.1	238.3	251	195.8
No. Tubes		80	80	36	24	36
Effective Length	m	16	16	15	15	15
Straight Length	m	15.5	15.5	15.4	15.4	15.4

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 1,469,350
Option items
Detail Engineering (by HeaterSIM)	£ 220,402
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£1,781,252

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	3	4	5	5	6	6
Fluid Name		Crude Oil 1	Crude Oil 1	Radiant 1 Flue Gas	Radiant 2 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Fuel No. 1	Combustion Air	Combustion Air
Flow (sec)	kg/s	200	200	14.704	15.036	29.74	0.679	0.694	14.025	14.342
Flow (hr)	kg/hr	720000	720000	52935	54130	107066	2445	2500	50490	51630
Temperature	°C	100	484.6	785.1	785.1	233	Note 1	Note 1	15.5	15.5
Pressure	kPa a	750.1	-58043.828	-2.582	-2.582	-1.597	Note 2	Note 2	101.32	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

Top of Stack Top of Transition Top of Conbox Top of Radiant Step off platform Hearth Grade Stack Dia Conbox eff Conbox IS Width I/S wall TCD No. Burners

COIL ARRANGEMENT
Heater Section		RADIANT 1	RADIANT 2	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530		API 530	API 530
Orientation		Vertical	Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	N/A	220.1	220.1	220.1
No. Tubes		80	80	36	24	36
Effective Length	m	16	16	15	15	15
Straight Length	m	15.5	15.5	15.4	15.4	15.4

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Crude Oil 1
Heat Duty	MW	59.993
Flow rate (sec)	kg/s	200
Flow rate (hr)	kg/hr	720000
Pressure drop	kPa	58793.93
Max. Film Temp. Calculated	°C	488.2
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	38153
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	135
OUTLET CONDITIONS
Outlet Temperature	°C	484.6
Outlet Pressure	kPa a	-58043.828
Outlet Vapour Fraction		1
Outlet Enthalpy	kJ/kg	435

Crude Oil 1: Calculated outlet pressure is excessively below atmospheric pressure

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1	2
Radiant Type
Heat Duty	MW	19.484	19.484
Heat Release	MW	33.967	34.734
Arch Temp.	°C	785.1	785.1
Max Tube Temp.	°C	496.1	496.1
Tube Cirle Diameter	m	N/A	N/A
Average Flux	W/m²	34292	34292
Maximum Flux	W/m²	57388	57694
Flue Flow	kg/s	14.704	15.036
Air Flow	kg/s	14.025	14.342
Fuel Flow	kg/s	0.679	0.694
Excess Air	%	20	20
Air Temp.	°C	15.5	15.5
Arch Pressure	mmH2O	-2.582	-2.582
Floor Pressure	mmH2O	-17.497	-17.497
Radiant Height	m	17	17
Radiant Width	m	7.08	7.08
Radiant Length	m	10.54	10.54
No. of Burners		8	8
Burner Cirle Diameter	m	N/A	N/A
Burner Design Firing	MW	4.67	4.78
Burner Normal Firing	MW	4.25	4.34
Burner Min Firing	MW	0.93	0.96
Burner-to-Tube Note		OK	OK
Burner-to-Wall Note		OK	OK
Burner-to-Roof Note		OK	OK
API Burner-to-Tube Dist.	m	1.668	1.71
API Burner-to-Wall Dist.	m	1.527	1.555
API Burner-to-Roof/Roof Dist	m	11.057	11.271
Floor Flux	W/m²	454989	465258

Flame-tube impingment risk not identified

Combustion

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Radiant Type
Flue Flow	kg/s	14.704	15.036
Air Flow	kg/s	14.025	14.342
Fuel Flow	kg/s	0.679	0.694
Fuel LHV	kJ/kg	50015	50015
Excess Air	%	20	20
Air Temp.	°C	15.5	15.5
CO2	mol%	8.06	8.06
H2O	mol%	16.06	16.06
N2	mol%	72.67	72.67
O2	mol%	3.21	3.21
SO2	mol%	0	0
Dew Point	°C	56	56
Fuel Mol. Wt.		16	16
Flue Mol. Wt.		27.812	27.812
Flame Temperature	°C	1805.6	1805.6
Flue Gas Emissivity		0.58	0.58

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
Heat Duty	MW	21.024
Max Tube Temp.	°C	251
Total Flue Press. Loss (ex. gain)	mmH2O	1.8
Total Press. Gain	mmH2O	2.76
Total Press. Loss (inc. gain)	mmH2O	-0.96
Convection Width	m	3.175
Effective Length	m	15
Convection Height	m	3.601
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	29.74
Flue Gas Inlet Temp.	°C	784.6
Flue Gas Outlet Temp.	°C	233
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	1.79	284.9	233	303.1	242.8	0.64	Solid	22439	26782	12	1.653	0.234	C.S.	C.S.	164.9	183.5
1	7	Coil Section 3	2.28	350	284.9	379.7	303.1	0.58	Solid	28538	33985	12	1.653	0.263	C.S.	C.S.	192.2	211.4
1	6	Coil Section 3	3.27	441.9	350	489.7	379.7	0.51	Solid	40958	48616	12	1.653	0.298	C.S.	C.S.	225.7	252.4
1	5	Coil Section 2	3.47	535.9	441.9	606.3	489.7	0.45	Solid	43387	52262	12	1.572	0.242	C.S.	C.S.	243.5	275.4
1	4	Coil Section 2	4.91	666.7	535.9	771.6	606.3	0.39	Solid	61538	75791	12	1.572	0.278	C.S.	C.S.	294.1	336.1
1	3	Coil Section 1	1.43	700.9	666.7	816.5	771.6	0.35	None	18970	33137	12	1.466	0.156	C.S.	None	0	0
1	2	Coil Section 1	1.69	738.8	700.9	865.6	816.5	0.34	None	23917	41778	12	1.466	0.162	C.S.	None	0	0
1	1	Coil Section 1	2.19	784.6	738.8	919.6	865.6	0.33	None	34768	60732	12	1.466	0.169	C.S.	None	0	0

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	1.79	284.9	233	Crude Oil 1	1	100	137.7	750	666	0	0	5.2	5.2	0	0	3874	3874	636645	649577
1	7	Coil Section 3	2.28	350	284.9	Crude Oil 1	2	137.7	147.4	666	581	0	0	5.2	5.2	0	0	3874	3874	649575	655234
1	6	Coil Section 3	3.27	441.9	350	Crude Oil 1	3	147.4	161.5	581	496	0	0	5.2	5.3	0	0	3874	3874	655235	663519
1	5	Coil Section 2	3.47	535.9	441.9	Crude Oil 1	4	161.5	176.3	496	411	0	0	5.3	5.3	0	0	3874	3874	663509	677412
1	4	Coil Section 2	4.91	666.7	535.9	Crude Oil 1	5	176.3	197.4	411	267	0	0.04	5.3	26	0	42	3874	3874	677397	719620
1	3	Coil Section 1	1.43	700.9	666.7	Crude Oil 1	6	197.3	206.7	267	-800	0.04	0.43	26	335	42	NaN	3874	3874	719596	49658332
1	2	Coil Section 1	1.69	738.8	700.9	Crude Oil 1	7	206.7	215.6	-800	-4061	0.43	1	335.1	774.7	NaN	NaN	3874	3874	49658332	49658332
1	1	Coil Section 1	2.19	784.6	738.8	Crude Oil 1	8	215.6	227.2	-4054	-15619	1	1	774.7	618.2	NaN	NaN	3874	3874	49658332	49658332

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	1.79	284.9	233	Crude Oil 1	1	100	137.7	750	666	0	0	5.2	5.2	0	0	3874	3874	636645	649577
1	7	Coil Section 3	2.28	350	284.9	Crude Oil 1	2	137.7	147.4	666	581	0	0	5.2	5.2	0	0	3874	3874	649575	655234
1	6	Coil Section 3	3.27	441.9	350	Crude Oil 1	3	147.4	161.5	581	496	0	0	5.2	5.3	0	0	3874	3874	655235	663519
1	5	Coil Section 2	3.47	535.9	441.9	Crude Oil 1	4	161.5	176.3	496	411	0	0	5.3	5.3	0	0	3874	3874	663509	677412
1	4	Coil Section 2	4.91	666.7	535.9	Crude Oil 1	5	176.3	197.4	411	267	0	0.04	5.3	26	0	42	3874	3874	677397	719620
1	3	Coil Section 1	1.43	700.9	666.7	Crude Oil 1	6	197.3	206.7	267	-800	0.04	0.43	26	335	42	NaN	3874	3874	719596	49658332
1	2	Coil Section 1	1.69	738.8	700.9	Crude Oil 1	7	206.7	215.6	-800	-4061	0.43	1	335.1	774.7	NaN	NaN	3874	3874	49658332	49658332
1	1	Coil Section 1	2.19	784.6	738.8	Crude Oil 1	8	215.6	227.2	-4054	-15619	1	1	774.7	618.2	NaN	NaN	3874	3874	49658332	49658332

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Crude Oil 1	227.2	232.4	-15618.8	-18789.9	240.1	244.9	1	141.3	542	237.7	239.8	247.1	262.1	13116.5	Turbulent		38153	63038	0	0
2	Wall	Crude Oil 1	232.4	237.6	-18789.9	-21596.8	244.9	249.8	1	141.3	483.8	242.8	244.9	252.2	267.2	13209.9	Turbulent		38007	62836	0	0
3	Wall	Crude Oil 1	237.6	242.8	-21596.8	-24120.1	249.8	254.7	1	141.3	437.7	247.9	250	257.3	272.3	13301.2	Turbulent		37860	62632	0	0
4	Wall	Crude Oil 1	242.8	247.9	-24120.1	-26416.4	254.7	259.5	1	141.3	400.4	253.1	255.2	262.4	277.4	13390.5	Turbulent		37712	62424	0	0
5	Wall	Crude Oil 1	247.9	253.1	-26416.4	-28524.6	259.5	264.4	1	141.3	367.4	258.2	260.3	267.5	282.5	13478.9	Turbulent		37561	62212	0	0
6	Wall	Crude Oil 1	253.1	258.3	-28524.6	-30459.9	264.4	269.3	1	141.3	338.7	263.3	265.4	272.6	287.6	13574.5	Turbulent		37409	61997	0	0
7	Wall	Crude Oil 1	258.3	263.4	-30459.9	-32251.2	269.3	274.2	1	141.3	314.6	268.4	270.5	277.7	292.7	13668.1	Turbulent		37254	61778	0	0
8	Wall	Crude Oil 1	263.4	268.6	-32251.2	-33920.7	274.2	279	1	141.3	294.1	273.6	275.6	282.9	297.9	13759.7	Turbulent		37098	61555	0	0
9	Wall	Crude Oil 1	268.6	273.8	-33920.7	-35485.8	279	283.9	1	141.3	276.5	278.7	280.7	288	303	13849.6	Turbulent		36940	61329	0	0
10	Wall	Crude Oil 1	273.8	279	-35485.8	-36960.5	283.9	288.8	1	141.3	261.1	283.8	285.8	293.1	308.1	13937.7	Turbulent		36780	61099	0	0
11	Wall	Crude Oil 1	279	285.4	-36960.5	-38343.3	288.8	293.6	1	141.3	242.9	290.2	291.6	299.5	314.5	14005.9	Turbulent		36597	60816	0	0
12	Wall	Crude Oil 1	285.4	292.2	-38343.3	-39630.5	293.6	298.5	1	141.3	226.5	297	298.2	306.2	321.2	14050.5	Turbulent		36385	60502	0	0
13	Wall	Crude Oil 1	292.2	299	-39630.5	-40834.5	298.5	303.4	1	141.3	212.5	303.7	304.9	312.9	327.9	14097.1	Turbulent		36163	60179	0	0
14	Wall	Crude Oil 1	299	305.8	-40834.5	-41967	303.4	308.3	1	141.3	200.3	310.5	311.7	319.7	334.7	14142.7	Turbulent		35939	59848	0	0
15	Wall	Crude Oil 1	305.8	312.6	-41967	-43037.2	308.3	313.1	1	141.3	189.4	317.2	318.4	326.4	341.4	14187.2	Turbulent		35710	59511	0	0
16	Wall	Crude Oil 1	312.6	319.4	-43037.2	-44048.2	313.1	318	1	141.3	179.2	324	325.2	333.1	348.1	14234.1	Turbulent		35478	59165	0	0
17	Wall	Crude Oil 1	319.4	326.2	-44048.2	-45006.8	318	322.9	1	141.3	170.2	330.8	331.9	339.9	354.9	14280.4	Turbulent		35241	58812	0	0
18	Wall	Crude Oil 1	326.2	333	-45006.8	-45919	322.9	327.7	1	141.3	162.2	337.5	338.6	346.6	361.6	14325.7	Turbulent		35000	58451	0	0
19	Wall	Crude Oil 1	333	339.8	-45919	-46789.9	327.7	332.6	1	141.3	155.1	344.3	345.4	353.3	368.3	14370.2	Turbulent		34755	58082	0	0
20	Wall	Crude Oil 1	339.8	346.7	-46789.9	-47612.6	332.6	337.5	1	141.3	144.8	351.1	352.2	360.1	375.1	14409.6	Turbulent		34504	57699	0	0
21	Wall	Crude Oil 1	346.7	353.6	-47612.6	-48382.1	337.5	342.4	1	141.3	135.8	358	359	366.9	381.9	14445	Turbulent		34247	57308	0	0
22	Wall	Crude Oil 1	353.6	360.5	-48382.1	-49105.7	342.4	347.2	1	141.3	128	364.8	365.8	373.8	388.8	14479.7	Turbulent		33985	56907	0	0
23	Wall	Crude Oil 1	360.5	367.4	-49105.7	-49789.3	347.2	352.1	1	141.3	121.2	371.7	372.7	380.6	395.6	14513.7	Turbulent		33718	56497	0	0
24	Wall	Crude Oil 1	367.4	374.3	-49789.3	-50437.7	352.1	357	1	141.3	115.1	378.5	379.5	387.4	402.4	14547.1	Turbulent		33447	56078	0	0
25	Wall	Crude Oil 1	374.3	381.2	-50437.7	-51054.9	357	361.8	1	141.3	109.8	385.4	386.4	394.2	409.2	14579.9	Turbulent		33170	55650	0	0
26	Wall	Crude Oil 1	381.2	388.1	-51054.9	-51644.4	361.8	366.7	1	141.3	105	392.3	393.2	401	416	14612.1	Turbulent		32889	55212	0	0
27	Wall	Crude Oil 1	388.1	395	-51644.4	-52208.8	366.7	371.6	1	141.3	100.7	399.1	400	407.8	422.8	14643.7	Turbulent		32602	54764	0	0
28	Wall	Crude Oil 1	395	401.9	-52208.8	-52750.7	371.6	376.5	1	141.3	96.8	406	406.8	414.6	429.6	14674.7	Turbulent		32310	54307	0	0
29	Wall	Crude Oil 1	401.9	408.8	-52750.7	-53272	376.5	381.3	1	141.3	93.2	412.8	413.7	421.4	436.4	14705.2	Turbulent		32013	53839	0	0
30	Wall	Crude Oil 1	408.8	415.7	-53272	-53774.7	381.3	386.2	1	141.3	89.9	419.7	420.5	428.2	443.2	14735.2	Turbulent		31711	53361	0	0
31	Wall	Crude Oil 1	415.7	422.6	-53774.7	-54260.3	386.2	391.1	1	141.3	87	426.5	427.3	435	450	14764.7	Turbulent		31403	52872	0	0
32	Wall	Crude Oil 1	422.6	429.5	-54260.3	-54730.1	391.1	395.9	1	141.3	84.2	433.4	434.2	441.8	456.8	14793.8	Turbulent		31089	52373	0	0
33	Wall	Crude Oil 1	429.5	436.4	-54730.1	-55185.4	395.9	400.8	1	141.3	81.7	440.2	441	448.6	463.6	14822.3	Turbulent		30770	51862	0	0
34	Wall	Crude Oil 1	436.4	443.3	-55185.4	-55627.3	400.8	405.7	1	141.3	79.3	447.1	447.8	455.4	470.4	14850.4	Turbulent		30445	51341	0	0
35	Wall	Crude Oil 1	443.3	450.2	-55627.3	-56056.7	405.7	410.6	1	141.3	77.1	453.9	454.6	462.2	477.2	14878.1	Turbulent		30113	50808	0	0
36	Wall	Crude Oil 1	450.2	457.1	-56056.7	-56474.5	410.6	415.4	1	141.3	75.1	460.8	461.4	469	484	14905.3	Turbulent		29776	50264	0	0
37	Wall	Crude Oil 1	457.1	464	-56474.5	-56881.4	415.4	420.3	1	141.3	73.2	467.6	468.2	475.8	490.8	14932.2	Turbulent		29433	49708	0	0
38	Wall	Crude Oil 1	464	470.9	-56881.4	-57278.2	420.3	425.2	1	141.3	71.4	474.5	475.1	482.5	497.5	14958.6	Turbulent		29083	49141	0	0
39	Wall	Crude Oil 1	470.9	477.8	-57278.2	-57665.5	425.2	430	1	141.3	69.7	481.3	481.9	489.3	504.3	14984.7	Turbulent		28727	48561	0	0
40	Wall	Crude Oil 1	477.8	484.6	-57665.5	-58043.8	430	434.9	1	141.3	68.1	488.2	488.7	496.1	511.1	15010.3	Turbulent		28365	47969	0	0
1	Wall	Crude Oil 1	227.2	232.4	-15618.8	-18789.9	240.1	244.9	1	141.3	542	237.7	239.8	247.1	262.1	13116.5	Turbulent		38153	63038	0	0
2	Wall	Crude Oil 1	232.4	237.6	-18789.9	-21596.8	244.9	249.8	1	141.3	483.8	242.8	244.9	252.2	267.2	13209.9	Turbulent		38007	62836	0	0
3	Wall	Crude Oil 1	237.6	242.8	-21596.8	-24120.1	249.8	254.7	1	141.3	437.7	247.9	250	257.3	272.3	13301.2	Turbulent		37860	62632	0	0
4	Wall	Crude Oil 1	242.8	247.9	-24120.1	-26416.4	254.7	259.5	1	141.3	400.4	253.1	255.2	262.4	277.4	13390.5	Turbulent		37712	62424	0	0
5	Wall	Crude Oil 1	247.9	253.1	-26416.4	-28524.6	259.5	264.4	1	141.3	367.4	258.2	260.3	267.5	282.5	13478.9	Turbulent		37561	62212	0	0
6	Wall	Crude Oil 1	253.1	258.3	-28524.6	-30459.9	264.4	269.3	1	141.3	338.7	263.3	265.4	272.6	287.6	13574.5	Turbulent		37409	61997	0	0
7	Wall	Crude Oil 1	258.3	263.4	-30459.9	-32251.2	269.3	274.2	1	141.3	314.6	268.4	270.5	277.7	292.7	13668.1	Turbulent		37254	61778	0	0
8	Wall	Crude Oil 1	263.4	268.6	-32251.2	-33920.7	274.2	279	1	141.3	294.1	273.6	275.6	282.9	297.9	13759.7	Turbulent		37098	61555	0	0
9	Wall	Crude Oil 1	268.6	273.8	-33920.7	-35485.8	279	283.9	1	141.3	276.5	278.7	280.7	288	303	13849.6	Turbulent		36940	61329	0	0
10	Wall	Crude Oil 1	273.8	279	-35485.8	-36960.5	283.9	288.8	1	141.3	261.1	283.8	285.8	293.1	308.1	13937.7	Turbulent		36780	61099	0	0
11	Wall	Crude Oil 1	279	285.4	-36960.5	-38343.3	288.8	293.6	1	141.3	242.9	290.2	291.6	299.5	314.5	14005.9	Turbulent		36597	60816	0	0
12	Wall	Crude Oil 1	285.4	292.2	-38343.3	-39630.5	293.6	298.5	1	141.3	226.5	297	298.2	306.2	321.2	14050.5	Turbulent		36385	60502	0	0
13	Wall	Crude Oil 1	292.2	299	-39630.5	-40834.5	298.5	303.4	1	141.3	212.5	303.7	304.9	312.9	327.9	14097.1	Turbulent		36163	60179	0	0
14	Wall	Crude Oil 1	299	305.8	-40834.5	-41967	303.4	308.3	1	141.3	200.3	310.5	311.7	319.7	334.7	14142.7	Turbulent		35939	59848	0	0
15	Wall	Crude Oil 1	305.8	312.6	-41967	-43037.2	308.3	313.1	1	141.3	189.4	317.2	318.4	326.4	341.4	14187.2	Turbulent		35710	59511	0	0
16	Wall	Crude Oil 1	312.6	319.4	-43037.2	-44048.2	313.1	318	1	141.3	179.2	324	325.2	333.1	348.1	14234.1	Turbulent		35478	59165	0	0
17	Wall	Crude Oil 1	319.4	326.2	-44048.2	-45006.8	318	322.9	1	141.3	170.2	330.8	331.9	339.9	354.9	14280.4	Turbulent		35241	58812	0	0
18	Wall	Crude Oil 1	326.2	333	-45006.8	-45919	322.9	327.7	1	141.3	162.2	337.5	338.6	346.6	361.6	14325.7	Turbulent		35000	58451	0	0
19	Wall	Crude Oil 1	333	339.8	-45919	-46789.9	327.7	332.6	1	141.3	155.1	344.3	345.4	353.3	368.3	14370.2	Turbulent		34755	58082	0	0
20	Wall	Crude Oil 1	339.8	346.7	-46789.9	-47612.6	332.6	337.5	1	141.3	144.8	351.1	352.2	360.1	375.1	14409.6	Turbulent		34504	57699	0	0
21	Wall	Crude Oil 1	346.7	353.6	-47612.6	-48382.1	337.5	342.4	1	141.3	135.8	358	359	366.9	381.9	14445	Turbulent		34247	57308	0	0
22	Wall	Crude Oil 1	353.6	360.5	-48382.1	-49105.7	342.4	347.2	1	141.3	128	364.8	365.8	373.8	388.8	14479.7	Turbulent		33985	56907	0	0
23	Wall	Crude Oil 1	360.5	367.4	-49105.7	-49789.3	347.2	352.1	1	141.3	121.2	371.7	372.7	380.6	395.6	14513.7	Turbulent		33718	56497	0	0
24	Wall	Crude Oil 1	367.4	374.3	-49789.3	-50437.7	352.1	357	1	141.3	115.1	378.5	379.5	387.4	402.4	14547.1	Turbulent		33447	56078	0	0
25	Wall	Crude Oil 1	374.3	381.2	-50437.7	-51054.9	357	361.8	1	141.3	109.8	385.4	386.4	394.2	409.2	14579.9	Turbulent		33170	55650	0	0
26	Wall	Crude Oil 1	381.2	388.1	-51054.9	-51644.4	361.8	366.7	1	141.3	105	392.3	393.2	401	416	14612.1	Turbulent		32889	55212	0	0
27	Wall	Crude Oil 1	388.1	395	-51644.4	-52208.8	366.7	371.6	1	141.3	100.7	399.1	400	407.8	422.8	14643.7	Turbulent		32602	54764	0	0
28	Wall	Crude Oil 1	395	401.9	-52208.8	-52750.7	371.6	376.5	1	141.3	96.8	406	406.8	414.6	429.6	14674.7	Turbulent		32310	54307	0	0
29	Wall	Crude Oil 1	401.9	408.8	-52750.7	-53272	376.5	381.3	1	141.3	93.2	412.8	413.7	421.4	436.4	14705.2	Turbulent		32013	53839	0	0
30	Wall	Crude Oil 1	408.8	415.7	-53272	-53774.7	381.3	386.2	1	141.3	89.9	419.7	420.5	428.2	443.2	14735.2	Turbulent		31711	53361	0	0
31	Wall	Crude Oil 1	415.7	422.6	-53774.7	-54260.3	386.2	391.1	1	141.3	87	426.5	427.3	435	450	14764.7	Turbulent		31403	52872	0	0
32	Wall	Crude Oil 1	422.6	429.5	-54260.3	-54730.1	391.1	395.9	1	141.3	84.2	433.4	434.2	441.8	456.8	14793.8	Turbulent		31089	52373	0	0
33	Wall	Crude Oil 1	429.5	436.4	-54730.1	-55185.4	395.9	400.8	1	141.3	81.7	440.2	441	448.6	463.6	14822.3	Turbulent		30770	51862	0	0
34	Wall	Crude Oil 1	436.4	443.3	-55185.4	-55627.3	400.8	405.7	1	141.3	79.3	447.1	447.8	455.4	470.4	14850.4	Turbulent		30445	51341	0	0
35	Wall	Crude Oil 1	443.3	450.2	-55627.3	-56056.7	405.7	410.6	1	141.3	77.1	453.9	454.6	462.2	477.2	14878.1	Turbulent		30113	50808	0	0
36	Wall	Crude Oil 1	450.2	457.1	-56056.7	-56474.5	410.6	415.4	1	141.3	75.1	460.8	461.4	469	484	14905.3	Turbulent		29776	50264	0	0
37	Wall	Crude Oil 1	457.1	464	-56474.5	-56881.4	415.4	420.3	1	141.3	73.2	467.6	468.2	475.8	490.8	14932.2	Turbulent		29433	49708	0	0
38	Wall	Crude Oil 1	464	470.9	-56881.4	-57278.2	420.3	425.2	1	141.3	71.4	474.5	475.1	482.5	497.5	14958.6	Turbulent		29083	49141	0	0
39	Wall	Crude Oil 1	470.9	477.8	-57278.2	-57665.5	425.2	430	1	141.3	69.7	481.3	481.9	489.3	504.3	14984.7	Turbulent		28727	48561	0	0
40	Wall	Crude Oil 1	477.8	484.6	-57665.5	-58043.8	430	434.9	1	141.3	68.1	488.2	488.7	496.1	511.1	15010.3	Turbulent		28365	47969	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Crude Oil 1	100	112.6	750.1	722	135	138	0	141.3	5.2	128.9	125	133.7	148.7	2265.8	Solid	Turbulent	C.S.	24104	33541	0	0
1	2	3	8	Crude Oil 1	112.6	125.1	722	693.8	138	141	0	141.3	5.2	140	135.9	144.4	159.4	2274.6	Solid	Turbulent	C.S.	22056	30692	0	0
1	3	3	8	Crude Oil 1	125.1	137.7	693.8	665.7	141	144	0	141.3	5.2	151.1	146.8	155.1	170.1	2284	Solid	Turbulent	C.S.	20002	27833	0	0
1	4	3	7	Crude Oil 1	137.7	140.9	665.7	637.4	144	147.8	0	141.3	5.2	160.2	161.5	166.1	181.1	2295.5	Solid	Turbulent	C.S.	28953	40228	0	0
1	5	3	7	Crude Oil 1	140.9	144.2	637.4	609.2	147.8	151.6	0	141.3	5.2	163.1	164.3	168.8	183.8	2300.4	Solid	Turbulent	C.S.	28410	39474	0	0
1	6	3	7	Crude Oil 1	144.2	147.4	609.2	581	151.6	155.4	0	141.3	5.2	166	167.1	171.6	186.6	2305.2	Solid	Turbulent	C.S.	27867	38720	0	0
1	7	3	6	Crude Oil 1	147.4	152.1	581	552.7	155.4	160.8	0	141.3	5.3	179.6	181.4	188	203	2315.4	Solid	Turbulent	C.S.	41572	57640	0	0
1	8	3	6	Crude Oil 1	152.1	156.8	552.7	524.4	160.8	166.3	0	141.3	5.3	183.6	185.4	191.9	206.9	2321.9	Solid	Turbulent	C.S.	40762	56516	0	0
1	9	3	6	Crude Oil 1	156.8	161.5	524.4	496.1	166.3	171.7	0	141.3	5.3	187.7	189.4	195.8	210.8	2328.3	Solid	Turbulent	C.S.	39951	55392	0	0
1	10	2	5	Crude Oil 1	161.5	166.4	496.1	467.7	171.7	177.5	0	141.3	5.3	195.4	197.4	204.4	219.4	2336.7	Solid	Turbulent	C.S.	43941	61474	0	0
1	11	2	5	Crude Oil 1	166.4	171.4	467.7	439.4	177.5	183.2	0	141.3	5.3	199.8	201.8	208.7	223.7	2344.9	Solid	Turbulent	C.S.	43261	60523	0	0
1	12	2	5	Crude Oil 1	171.4	176.3	439.4	411	183.2	189	0	141.3	5.3	204.2	206.1	213	228	2352.8	Solid	Turbulent	C.S.	42581	59572	0	0
1	13	2	4	Crude Oil 1	176.3	183.3	411	382.6	189	197.2	0	141.3	5.3	224.6	227.7	237.8	252.8	2363	Solid	Turbulent	C.S.	62385	88556	0	0
1	14	2	4	Crude Oil 1	183.3	190.3	382.6	354.2	197.2	205.4	0	141.3	5.3	230.7	233.7	243.7	258.7	2374.7	Solid	Turbulent	C.S.	61327	87053	0	0
1	15	2	4	Crude Oil 1	190.3	197.4	354.2	266.8	205.4	213.6	0.0422	141.3	26	238.3	241.1	251	266	2305.3	Solid	Bubble	C.S.	60268	85551	15288.12	10870.17
1	16	1	3	Crude Oil 1	197.3	200.4	266.8	75	213.6	215.9	0.139	141.3	112.3	216.1	216.9	220.7	235.7	2205.6	None	Bubble	C.S.	17947	31349	15040.16	26910.24
1	17	1	3	Crude Oil 1	200.4	203.6	75	-444.4	215.9	218.3	0.305	141.3	239.9	218.9	219.7	223.5	238.5	2233.6	None	Mist	C.S.	17839	31160	13357.52	107073.8
1	18	1	3	Crude Oil 1	203.6	206.7	-444.4	-799.7	218.3	220.7	0.4286	141.3	335	213.4	214.2	218	233	5032.5	None	Mist	C.S.	17731	30972	10800.19	232530
1	19	1	2	Crude Oil 1	206.7	209.6	-800.1	-1386.2	220.7	223.5	0.629	141.3	489.2	215.8	217.1	221.3	236.3	6598.8	None	Mist	C.S.	21202	37036	8891.784	326055
1	20	1	2	Crude Oil 1	209.6	212.6	-1386.2	-2350.6	223.5	226.3	0.9552	141.3	740.3	217.2	218.4	222.6	237.6	8968.8	None	Mist	C.S.	21095	36848	5774.438	477563.1
1	21	1	2	Crude Oil 1	212.6	215.6	-2350.6	-4060.9	226.3	229.1	1	141.3	774.7	218.8	220.1	224.3	239.3	12532.8	None	Annular & Mist	C.S.	20988	36661	665.4189	724486.6
1	22	1	1	Crude Oil 1	215.6	219.5	-4053.8	-8191.2	229.1	232.8	1	141.3	774.7	223.6	225.2	230.7	245.7	12957.8	None	Turbulent	C.S.	27581	48178	0	0
1	23	1	1	Crude Oil 1	219.5	223.4	-8191.2	-12130.6	232.8	236.4	1	141.3	692.6	227.4	229	234.5	249.5	12985.4	None	Turbulent	C.S.	27437	47926	0	0
1	24	1	1	Crude Oil 1	223.4	227.2	-12130.6	-15618.8	236.4	240.1	1	141.3	618.2	231.3	232.9	238.3	253.3	13058.4	None	Turbulent	C.S.	27292	47673	0	0

Coil Configuration

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Heater Section		RADIANT 1	RADIANT 2	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Crude Oil 1	Process 1: Crude Oil 1	Process 1: Crude Oil 1	Process 1: Crude Oil 1	Process 1: Crude Oil 1
Tube OD	mm	141.3	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	496.1	496.1	238.3	251	195.8
Tube Temperature Margin	°C	15	15	15	15	15
Design Tube Temperature	°C	511.1	511.1	253.3	266	210.8
Design Tube Pressure	kPa	2000.2	2000.2		2000.2	2000.2
Design Code		API 530	API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		80	80	36	24	36
No. Tubes Per Row				12	12	12
No. Passes		2	2	4	4	4
Effective Length	m	16	16	15	15	15
Straight Length	m	15.5	15.5	15.4	15.4	15.4
No. Rows				3	2	3
Tube Spacing	mm	254	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	N/A	220.1	220.1	220.1
Coil Alignment				Staggered	Staggered	Staggered
Orientation		Vertical	Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	568.2	568.2	239.59	1253.19	3091.42
Intermediate Supports		0 / 0	0 / 0	3 / 3	3 / 3	3 / 3
Corbel Width	m			1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type				None	Solid	Solid
Fin Material				None	Carbon Steel	Carbon Steel
Fin Height	mm				19.05	25.4
Fin Thickness	mm				1.27	1.27
Serrated Fin Wn
Fin Density	fins/m				157	197

Radiant section 1,Coil sect. no. 1, complies with API 530#Radiant section 2,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	511.0971	511.0971	253.3483	266.0134	210.785
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	84244.3	84244.3	126439	124841.6	131807.3
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.6578	1.6578	1.1089	1.123	1.0641
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.66	4.66	4.11	4.12	4.06
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	5.32	5.32	4.7	4.71	4.64
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		31211.2	31211.2	0	0	0
RuptureNfactor,resultref0	Rupture n factor		4.520613	4.520613	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	1.6778	1.6778	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	4.68	4.68	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	5.35	5.35	0	0	0
RuptureBfactor,resultref0	B factor		1.788087	1.788087	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		1	1	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Thickness is OK	Thickness is OK	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	16
Stack Diameter	m	3.15
Cone Diameter	m	3.052
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	233
Flue Gas Flow	kg/s	29.74
Steel Area	m²	158.438
Stack Entry Pressure	mmH2O	-1.597
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	735.1	MW Castable	74.9	0.4	ULW Castable	150.1	0.14	732.5	503.9	1400	V Y Anchors	73.3	Refrac. thickness OK
RADIANT WALL 1	640.6	Fibre (High Density)	74.9	0.1	None	0	0	732.8	618.9	1260	Twistlock Pins	74.4	Refrac. thickness OK
RADIANT ARCH 1	785.1	Fibre (High Density)	87.6	0.1	None	0	0	824	800.8	1260	Twistlock Pins	80.6	Refrac. thickness OK

RADIANT FLOOR 2	735.1	MW Castable	74.9	0.4	ULW Castable	150.1	0.14	732.5	503.9	1400	V Y Anchors	73.3	Refrac. thickness OK
RADIANT WALL 2	640.6	Fibre (High Density)	74.9	0.1	None	0	0	732.8	618.9	1260	Twistlock Pins	74.4	Refrac. thickness OK
RADIANT ARCH 2	785.1	Fibre (High Density)	87.6	0.1	None	0	0	824	800.8	1260	Twistlock Pins	80.6	Refrac. thickness OK

CONVECTION SIDEWALL 1	508.8	LW Castable	74.9	0.3	ULW Castable	74.9	0.13	732.8	512.8	1100	V Y Anchors	68.1	Refrac. thickness OK

STACK 1	233	LW Castable	62.7	0.3	None	0	0	732.8	616.6	1100	V Y Anchors	74.4	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

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ENERGY PERFORMACE
Total Absorbed Duty	MW	12.497
Total Heat Release	MW	14.758
Total Efficiency	%	84.681

PROCESS
Process Name		Therminol 66
Heat Duty	MW	12.497
Flow rate (sec)	kg/s	114
INLET CONDITIONS
Inlet Temperature	°C	190
Inlet Pressure	kPa a	750
OUTLET CONDITIONS
Outlet Temperature	°C	242.5
Outlet Pressure	kPa a	780.437

AIR
Air Flow	kg/s	5.802
Air Temp.	°C	15.5
Excess Air	%	15

FUEL
Fuel Flow	kg/s	0.302
Fuel LHV	kJ/kg	48846.3
Fuel Mol. Wt.		20.2

STACK
Flue Gas Flow	kg/s	6.104
Flue Gas Temp.	°C	311.2
CO2	mol%	8.93
H2O	mol%	15.75
N2	mol%	72.79
O2	mol%	2.52
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	3.94
Flue Gas Flow	kg/s	6.104
Max Tube Temp.	°C	313.4
Total Press. Loss (inc. gain)	mmH2O	-1.08

RADIANT SECTION
Radiant Cell		1
Heat Duty	MW	8.558
Heat Release	MW	14.758
Arch Temp.	°C	822.4
Max Tube Temp.	°C	300.9
Average Flux	W/m²	30866
Maximum Flux	W/m²	52297
No. of Burners		4
Arch Pressure	mmH2O	-3.542
Floor Pressure	mmH2O	-13.367

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	84.681
Daily CO2 Emissions	kg	74169

Commercial

BID / PROJECT VALUE

Total:

£ 795,536

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	300.9	263	313.4	269.4
No. Tubes		52	24	16	24
Effective Length	m	10.084	3.5	3.5	3.5
Straight Length	m	9.685	3.9	3.9	3.9

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 612,205
Option items
Detail Engineering (by HeaterSIM)	£ 91,831
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£795,536

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol 66	Therminol 66	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	114	114	6.104	6.104	0.302	5.802
Flow (hr)	kg/hr	144000	144000	21975	21975	1088	20887
Temperature	°C	190	242.5	822.4	311.2	Note 1	15.5
Pressure	kPa a	750	780.437	-3.542	-2.426	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

35.225 m 20.225 m 18.425 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 1.53 m 3.5 m 5.503 m 5.045 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	304.8	304.8	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1	264.1
No. Tubes		52	24	16	24
Effective Length	m	10.084	3.5	3.5	3.5
Straight Length	m	9.685	3.9	3.9	3.9

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Therminol 66
Heat Duty	MW	12.497
Flow rate (sec)	kg/s	114
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	-30.437
Max. Film Temp. Calculated	°C	298.4
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	31147
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	190
Inlet Pressure	kPa a	750
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	452
OUTLET CONDITIONS
Outlet Temperature	°C	242.5
Outlet Pressure	kPa a	780.437
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	562

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type
Heat Duty	MW	8.558
Heat Release	MW	14.758
Arch Temp.	°C	822.4
Max Tube Temp.	°C	300.9
Tube Cirle Diameter	m	5.045
Average Flux	W/m²	30866
Maximum Flux	W/m²	52297
Flue Flow	kg/s	6.104
Air Flow	kg/s	5.802
Fuel Flow	kg/s	0.302
Excess Air	%	15
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-3.542
Floor Pressure	mmH2O	-13.367
Radiant Height	m	11.08
Radiant Width	m	5.5
Radiant Length	m	5.5
No. of Burners		4
Burner Cirle Diameter	m	1.28
Burner Design Firing	MW	4.43
Burner Normal Firing	MW	3.69
Burner Min Firing	MW	0.89
Burner-to-Tube Note		OK
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.585
API Burner-to-Wall Dist.	m	1.464
API Burner-to-Roof/Roof Dist	m	10.564
Floor Flux	W/m²	620823

Flame-tube impingment risk not identified

Combustion

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Radiant Type
Flue Flow	kg/s	6.104
Air Flow	kg/s	5.802
Fuel Flow	kg/s	0.302
Fuel LHV	kJ/kg	48846.3
Excess Air	%	15
Air Temp.	°C	15.5
CO2	mol%	8.93
H2O	mol%	15.75
N2	mol%	72.79
O2	mol%	2.52
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		20.2
Flue Mol. Wt.		27.955
Flame Temperature	°C	1880.4
Flue Gas Emissivity		0.458

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
Heat Duty	MW	3.94
Max Tube Temp.	°C	313.4
Total Flue Press. Loss (ex. gain)	mmH2O	2.13
Total Press. Gain	mmH2O	3.21
Total Press. Loss (inc. gain)	mmH2O	-1.08
Convection Width	m	2.591
Effective Length	m	3.5
Convection Height	m	4.041
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	6.104
Flue Gas Inlet Temp.	°C	822.4
Flue Gas Outlet Temp.	°C	311.2
CO2	mol%	8.93492
H2O	mol%	15.75452
N2	mol%	72.79327
O2	mol%	2.517298
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.31	354.5	311.2	383.9	333.2	0.56	Solid	20895	25222	8	1.766	0.288	C.S.	C.S.	245.3	257.8
1	7	Coil Section 3	0.43	412.9	354.5	454	383.9	0.52	Solid	28864	34758	8	1.766	0.312	C.S.	C.S.	266.5	283.4
1	6	Coil Section 3	0.61	494.7	412.9	553.5	454	0.47	Solid	40999	49672	8	1.766	0.344	C.S.	C.S.	298.3	321.5
1	5	Coil Section 2	0.67	582	494.7	662.7	553.5	0.42	Solid	44971	55742	8	1.694	0.276	C.S.	C.S.	309.9	338.6
1	4	Coil Section 2	0.93	701.3	582	816.2	662.7	0.37	Solid	63172	79694	8	1.694	0.31	C.S.	C.S.	356.2	393.7
1	3	Coil Section 1	0.28	736.7	701.3	861.5	816.2	0.34	None	19743	34230	8	1.597	0.191	C.S.	None	0	0
1	2	Coil Section 1	0.32	773.8	736.7	911.4	861.5	0.33	None	23192	40210	8	1.597	0.198	C.S.	None	0	0
1	1	Coil Section 1	0.39	822.4	773.8	966.9	911.4	0.32	None	29631	51375	8	1.597	0.206	C.S.	None	0	0

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.31	354.5	311.2	Therminol 66	1	190	191.2	750	747	0	0	1.7	1.7	0	0	1528	1528	242709	246130
1	7	Coil Section 3	0.43	412.9	354.5	Therminol 66	2	191.2	192.8	747	744	0	0	1.7	1.7	0	0	1528	1528	246114	250963
1	6	Coil Section 3	0.61	494.7	412.9	Therminol 66	3	192.8	195.2	744	741	0	0	1.7	1.7	0	0	1528	1528	250978	258128
1	5	Coil Section 2	0.67	582	494.7	Therminol 66	4	195.2	197.7	741	738	0	0	1.7	1.7	0	0	1528	1528	258081	266297
1	4	Coil Section 2	0.93	701.3	582	Therminol 66	5	197.7	201.5	738	735	0	0	1.7	1.7	0	0	1528	1528	266216	277179
1	3	Coil Section 1	0.28	736.7	701.3	Therminol 66	6	201.5	202.7	735	732	0	0	1.7	1.7	0	0	1528	1528	277139	279927
1	2	Coil Section 1	0.32	773.8	736.7	Therminol 66	7	202.7	204.1	732	729	0	0	1.7	1.7	0	0	1528	1528	279855	283077
1	1	Coil Section 1	0.39	822.4	773.8	Therminol 66	8	204.2	205.9	729	726	0	0	1.7	1.7	0	0	1528	1528	283169	287102

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.31	354.5	311.2	Therminol 66	1	190	191.2	750	747	0	0	1.7	1.7	0	0	1528	1528	242709	246130
1	7	Coil Section 3	0.43	412.9	354.5	Therminol 66	2	191.2	192.8	747	744	0	0	1.7	1.7	0	0	1528	1528	246114	250963
1	6	Coil Section 3	0.61	494.7	412.9	Therminol 66	3	192.8	195.2	744	741	0	0	1.7	1.7	0	0	1528	1528	250978	258128
1	5	Coil Section 2	0.67	582	494.7	Therminol 66	4	195.2	197.7	741	738	0	0	1.7	1.7	0	0	1528	1528	258081	266297
1	4	Coil Section 2	0.93	701.3	582	Therminol 66	5	197.7	201.5	738	735	0	0	1.7	1.7	0	0	1528	1528	266216	277179
1	3	Coil Section 1	0.28	736.7	701.3	Therminol 66	6	201.5	202.7	735	732	0	0	1.7	1.7	0	0	1528	1528	277139	279927
1	2	Coil Section 1	0.32	773.8	736.7	Therminol 66	7	202.7	204.1	732	729	0	0	1.7	1.7	0	0	1528	1528	279855	283077
1	1	Coil Section 1	0.39	822.4	773.8	Therminol 66	8	204.2	205.9	729	726	0	0	1.7	1.7	0	0	1528	1528	283169	287102

Radiant Tube Profile

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol 66	205.9	208.8	725.8	810.3	486.8	492.5	0	168.3	1.7	265.6	268.5	274.2	289.2	1012.7	Turbulent		31147	52700	0	0
2	Wall	Therminol 66	208.8	211.6	810.3	721.3	492.5	498.3	0	168.3	1.7	267.9	270.8	276.5	291.5	1022.7	Turbulent		31099	52632	0	0
3	Wall	Therminol 66	211.6	214.5	721.3	805.4	498.3	504.1	0	168.3	1.7	270.2	273	278.8	293.8	1032.8	Turbulent		31051	52563	0	0
4	Wall	Therminol 66	214.5	217.4	805.4	716.8	504.1	509.8	0	168.3	1.8	272.4	275.3	281	296	1043.1	Turbulent		31003	52493	0	0
5	Wall	Therminol 66	217.4	220.3	716.8	800.4	509.8	515.6	0	168.3	1.8	274.7	277.5	283.3	298.3	1053.6	Turbulent		30954	52423	0	0
6	Wall	Therminol 66	220.3	223.2	800.4	712.2	515.6	521.4	0	168.3	1.8	277	279.8	285.5	300.5	1064.3	Turbulent		30906	52352	0	0
7	Wall	Therminol 66	223.2	226.1	712.2	795.4	521.4	527.2	0	168.3	1.8	279.2	282.1	287.8	302.8	1075.3	Turbulent		30857	52281	0	0
8	Wall	Therminol 66	226.1	229	795.4	707.7	527.2	532.9	0	168.3	1.8	281.5	284.3	290.1	305.1	1086	Turbulent		30807	52209	0	0
9	Wall	Therminol 66	229	231.9	707.7	790.5	532.9	538.7	0	168.3	1.8	283.8	286.6	292.4	307.4	1096.6	Turbulent		30756	52135	0	0
10	Wall	Therminol 66	231.9	234.7	790.5	703.1	538.7	544.5	0	168.3	1.8	286.1	288.9	294.7	309.7	1107.5	Turbulent		30706	52061	0	0
11	Wall	Therminol 66	234.7	237.6	703.1	785.4	544.5	550.3	0	168.3	1.8	288.4	291.2	297	312	1118.6	Turbulent		30655	51987	0	0
12	Wall	Therminol 66	237.6	240.4	785.4	698.4	550.3	556	0	168.3	1.8	290.6	293.5	299.1	314.1	1129.7	Turbulent		30604	51914	0	0
13	Wall	Therminol 66	240.4	242.5	698.4	780.4	556	561.8	0	168.3	1.8	292.4	295.5	300.9	315.9	1137.6	Turbulent		30558	51853	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Therminol 66	190	190.6	750	748.5	452.3	453.7	0	168.3	1.7	225.6	227.6	230.3	245.3	915.7	Solid	Turbulent	C.S.	20926	29317	0	0
1	2	3	8	Therminol 66	190.6	191.2	748.5	747	453.7	455	0	168.3	1.7	225.9	228	230.6	245.6	918.2	Solid	Turbulent	C.S.	20837	29192	0	0
1	3	3	7	Therminol 66	191.2	192	747	745.5	455	456.9	0	168.3	1.7	239.2	242	245.7	260.7	936.3	Solid	Turbulent	C.S.	28908	40437	0	0
1	4	3	7	Therminol 66	192	192.8	745.5	744	456.9	458.7	0	168.3	1.7	239.6	242.5	246.1	261.1	939.9	Solid	Turbulent	C.S.	28782	40260	0	0
1	5	3	6	Therminol 66	192.8	194	744	742.5	458.8	461.4	0	168.3	1.7	259.5	263.6	268.9	283.9	961.9	Solid	Turbulent	C.S.	41063	57669	0	0
1	6	3	6	Therminol 66	194	195.2	742.5	741	461.4	464.1	0	168.3	1.7	260.1	264.1	269.4	284.4	966.9	Solid	Turbulent	C.S.	40875	57404	0	0
1	7	2	5	Therminol 66	195.2	196.5	741	739.4	464	467	0	168.3	1.7	268	272.6	278.5	293.5	979.4	Solid	Turbulent	C.S.	45035	64152	0	0
1	8	2	5	Therminol 66	196.5	197.7	739.4	737.9	467	469.9	0	168.3	1.7	268.6	273.2	279.1	294.1	985.2	Solid	Turbulent	C.S.	44864	63908	0	0
1	9	2	4	Therminol 66	197.7	199.6	737.9	736.4	469.8	473.9	0	168.3	1.7	297.7	304.2	312.7	327.7	1016.5	Solid	Turbulent	C.S.	63273	91176	0	0
1	10	2	4	Therminol 66	199.6	201.5	736.4	734.9	473.9	478	0	168.3	1.7	298.4	304.9	313.4	328.4	1024.2	Solid	Turbulent	C.S.	62999	90780	0	0
1	11	1	3	Therminol 66	201.5	202.1	734.9	733.4	478	479.2	0	168.3	1.7	239.5	241.9	244.9	259.9	973.6	None	Turbulent	C.S.	19233	33347	0	0
1	12	1	3	Therminol 66	202.1	202.7	733.4	731.9	479.2	480.5	0	168.3	1.7	240	242.4	245.4	260.4	975.7	None	Turbulent	C.S.	19211	33307	0	0
1	13	1	2	Therminol 66	202.7	203.4	731.9	730.4	480.4	481.8	0	168.3	1.7	245.6	248.4	251.8	266.8	982.5	None	Turbulent	C.S.	21904	37977	0	0
1	14	1	2	Therminol 66	203.4	204.1	730.4	728.8	481.8	483.3	0	168.3	1.7	246.2	248.9	252.3	267.3	984.8	None	Turbulent	C.S.	21877	37931	0	0
1	15	1	1	Therminol 66	204.2	205	728.8	727.3	483.3	485	0	168.3	1.7	255	258.3	262.4	277.4	995.2	None	Turbulent	C.S.	26266	45540	0	0
1	16	1	1	Therminol 66	205	205.9	727.3	725.8	485	486.8	0	168.3	1.7	255.7	258.9	263	278	998	None	Turbulent	C.S.	26233	45483	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol 66	Process 1: Therminol 66	Process 1: Therminol 66	Process 1: Therminol 66
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	300.9	263	313.4	269.4
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	315.9	278	328.4	284.4
Design Tube Pressure	kPa	2000		2000	2000
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		4	4	4	4
Effective Length	m	10.084	3.5	3.5	3.5
Straight Length	m	9.685	3.9	3.9	3.9
No. Rows			3	2	3
Tube Spacing	mm	304.8	304.8	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1	264.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	277.25	44.39	228.71	559.4
Intermediate Supports		0 / 0	0 / 0	0 / 0	0 / 0
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.1	25.4
Fin Thickness	mm			1.3	1.3
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000	2000	2000	2000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750	750	750	750
tblDesignTemp,calcref0	Design Temperature	°C	315.8961	278.0457	328.394	284.394
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		168.3	168.3	168.3	168.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	7.11	7.11	7.11	7.11
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	7.11	7.11	7.11	7.11
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	117865.3	123324	116279.5	122523.3
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.4159	1.3537	1.435	1.3625
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.42	4.35	4.44	4.36
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	5.05	4.98	5.07	4.99
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	15
Stack Diameter	m	1.53
Cone Diameter	m	1.534
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	311.2
Flue Gas Flow	kg/s	6.104
Steel Area	m²	72.299
Stack Entry Pressure	mmH2O	-2.426
CO2	mol%	8.93
H2O	mol%	15.75
N2	mol%	72.79
O2	mol%	2.52
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	772.4	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	538.2	1400	V Y Anchors	76.1	Refrac. thickness OK
RADIANT WALL 1	561.7	Fibre (High Density)	75	0.1	Fibre (Low Density)	75	0.06	732.8	239.4	1260	Twistlock Pins	48.7	Refrac. thickness OK
RADIANT ARCH 1	822.4	Fibre (High Density)	87.7	0.2	Fibre (High Density)	75	0.07	824	486.2	1260	Twistlock Pins	62.6	Refrac. thickness OK

CONVECTION SIDEWALL 1	566.8	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	589.7	1100	V Y Anchors	72.3	Refrac. thickness OK

STACK 1	311.2	LW Castable	88.1	0.3	None	0	0	732.8	679.8	1100	V Y Anchors	77.8	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

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ENERGY PERFORMACE
Total Absorbed Duty	MW	9.575
Total Heat Release	MW	10.521
Total Efficiency	%	91.015

PROCESS
Process Name		Therminol XP
Heat Duty	MW	9.575
Flow rate (sec)	kg/s	40
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750
OUTLET CONDITIONS
Outlet Temperature	°C	200
Outlet Pressure	kPa a	590.72

AIR
Air Flow	kg/s	4.344
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.21
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

STACK
Flue Gas Flow	kg/s	4.554
Flue Gas Temp.	°C	171.4
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

CONVECTION
Convection Sect. No.		1
Heat Duty	MW	3.393
Flue Gas Flow	kg/s	4.554
Max Tube Temp.	°C	217.1
Total Press. Loss (inc. gain)	mmH2O	-2.05

Radiant Cell		1
Arch Temp.	°C	768.9
Max Tube Temp.	°C	260.1
Average Flux	W/m²	26560
Arch Pressure	mmH2O	-2.49

Carbon Emissions

ENVIRONMENTAL IMPACT
Energy Efficiency	%	91.015
Daily CO2 Emissions	kg	50166

Commercial

BID / PROJECT VALUE

Total:

£ 763,559

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	260.1	189.2	217.1	169.4
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 584,399
Option items
Detail Engineering (by HeaterSIM)	£ 87,660
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£763,559

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	4.554	4.554	0.21	4.344
Flow (hr)	kg/hr	144000	144000	16396	16396	757	15639
Temperature	°C	100	200	768.9	171.4	Note 1	15.5
Pressure	kPa a	750	590.72	-2.49	0.065	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

40.785 m 19.785 m 17.985 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 1.18 m 5.835 m 4.584 m 4.204 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Name		Therminol XP
Heat Duty	MW	9.575
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	159.28
Max. Film Temp. Calculated	°C	252.1
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	26928
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	344
OUTLET CONDITIONS
Outlet Temperature	°C	200
Outlet Pressure	kPa a	590.72
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	583

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type
Heat Duty	MW	6.182
Heat Release	MW	10.521
Arch Temp.	°C	768.9
Max Tube Temp.	°C	260.1
Tube Cirle Diameter	m	4.204
Average Flux	W/m²	26560
Maximum Flux	W/m²	54321
Flue Flow	kg/s	4.554
Air Flow	kg/s	4.344
Fuel Flow	kg/s	0.21
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-2.49
Floor Pressure	mmH2O	-12.161
Radiant Height	m	11.08
Radiant Width	m	4.58
Radiant Length	m	4.58
No. of Burners		4
Burner Cirle Diameter	m	1.209
Burner Design Firing	MW	3.16
Burner Normal Firing	MW	2.63
Burner Min Firing	MW	0.63
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.262
API Burner-to-Wall Dist.	m	1.13
API Burner-to-Roof/Roof Dist	m	7.984
Floor Flux	W/m²	637803

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Type
Flue Flow	kg/s	4.554
Air Flow	kg/s	4.344
Fuel Flow	kg/s	0.21
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°C	1805.6
Flue Gas Emissivity		0.443

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Convection Sect. No.		1
Heat Duty	MW	3.393
Max Tube Temp.	°C	217.1
Total Flue Press. Loss (ex. gain)	mmH2O	0.63
Total Press. Gain	mmH2O	2.68
Total Press. Loss (inc. gain)	mmH2O	-2.05
Convection Width	m	2.159
Effective Length	m	5.835
Convection Height	m	3.601
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	4.554
Flue Gas Inlet Temp.	°C	768.9
Flue Gas Outlet Temp.	°C	171.4
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.2	210.1	171.4	216.5	172.7	0.73	Solid	9643	11934	8	0.979	0.084	C.S.	C.S.	135.6	144.4
1	7	Coil Section 3	0.31	268.1	210.1	283.6	216.5	0.66	Solid	14734	18209	8	0.979	0.092	C.S.	C.S.	154.8	168.1
1	6	Coil Section 3	0.48	358.1	268.1	388.7	283.6	0.58	Solid	23106	28442	8	0.979	0.105	C.S.	C.S.	184.6	205.1
1	5	Coil Section 2	0.55	458.5	358.1	509.9	388.7	0.5	Solid	26631	32790	8	0.93	0.087	C.S.	C.S.	198.8	226.3
1	4	Coil Section 2	0.85	607.6	458.5	696.4	509.9	0.42	Solid	41025	51120	8	0.93	0.103	C.S.	C.S.	244.4	283.7
1	3	Coil Section 1	0.27	652.9	607.6	754.6	696.4	0.38	None	13628	23805	8	0.866	0.051	C.S.	None	0	0
1	2	Coil Section 1	0.33	704.3	652.9	821.2	754.6	0.36	None	16766	29287	8	0.866	0.054	C.S.	None	0	0
1	1	Coil Section 1	0.41	768.9	704.3	898.7	821.2	0.34	None	22510	39320	8	0.866	0.057	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.2	210.1	171.4	Therminol XP	1	100	102.2	750	740	0	0	1.9	1.9	0	0	1549	1549	56942	58968
1	7	Coil Section 3	0.31	268.1	210.1	Therminol XP	2	102.2	105.7	740	731	0	0	1.9	1.9	0	0	1549	1549	58966	62257
1	6	Coil Section 3	0.48	358.1	268.1	Therminol XP	3	105.7	111.1	731	721	0	0	1.9	1.9	0	0	1549	1549	62264	67972
1	5	Coil Section 2	0.55	458.5	358.1	Therminol XP	4	111.1	117.3	721	712	0	0	1.9	1.9	0	0	1549	1549	67973	75551
1	4	Coil Section 2	0.85	607.6	458.5	Therminol XP	5	117.3	126.8	712	702	0	0	1.9	1.9	0	0	1549	1549	75573	90048
1	3	Coil Section 1	0.27	652.9	607.6	Therminol XP	6	126.8	129.9	702	693	0	0	1.9	1.9	0	0	1549	1549	89990	95589
1	2	Coil Section 1	0.33	704.3	652.9	Therminol XP	7	129.9	133.5	693	683	0	0	1.9	1.9	0	0	1549	1549	95569	102998
1	1	Coil Section 1	0.41	768.9	704.3	Therminol XP	8	133.5	138.1	683	673	0	0	1.9	1.9	0	0	1549	1549	102947	113605

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.2	210.1	171.4	Therminol XP	1	100	102.2	750	740	0	0	1.9	1.9	0	0	1549	1549	56942	58968
1	7	Coil Section 3	0.31	268.1	210.1	Therminol XP	2	102.2	105.7	740	731	0	0	1.9	1.9	0	0	1549	1549	58966	62257
1	6	Coil Section 3	0.48	358.1	268.1	Therminol XP	3	105.7	111.1	731	721	0	0	1.9	1.9	0	0	1549	1549	62264	67972
1	5	Coil Section 2	0.55	458.5	358.1	Therminol XP	4	111.1	117.3	721	712	0	0	1.9	1.9	0	0	1549	1549	67973	75551
1	4	Coil Section 2	0.85	607.6	458.5	Therminol XP	5	117.3	126.8	712	702	0	0	1.9	1.9	0	0	1549	1549	75573	90048
1	3	Coil Section 1	0.27	652.9	607.6	Therminol XP	6	126.8	129.9	702	693	0	0	1.9	1.9	0	0	1549	1549	89990	95589
1	2	Coil Section 1	0.33	704.3	652.9	Therminol XP	7	129.9	133.5	693	683	0	0	1.9	1.9	0	0	1549	1549	95569	102998
1	1	Coil Section 1	0.41	768.9	704.3	Therminol XP	8	133.5	138.1	683	673	0	0	1.9	1.9	0	0	1549	1549	102947	113605

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol XP	138.1	140.5	673.3	749.4	428.9	434.8	0	141.3	1.9	210.8	213.6	218.9	233.9	860.4	Turbulent		26928	54896	0	0
2	Wall	Therminol XP	140.5	142.9	749.4	667.1	434.8	440.8	0	141.3	1.9	212.4	215.2	220.5	235.5	870	Turbulent		26899	54852	0	0
3	Wall	Therminol XP	142.9	145.3	667.1	742.8	440.8	446.7	0	141.3	1.9	214	216.8	222	237	879.9	Turbulent		26870	54808	0	0
4	Wall	Therminol XP	145.3	147.7	742.8	660.8	446.7	452.7	0	141.3	1.9	215.5	218.4	223.6	238.6	889.9	Turbulent		26842	54763	0	0
5	Wall	Therminol XP	147.7	150.1	660.8	736.2	452.7	458.6	0	141.3	2	217.1	220	225.2	240.2	900.1	Turbulent		26813	54718	0	0
6	Wall	Therminol XP	150.1	152.6	736.2	654.6	458.6	464.6	0	141.3	2	218.7	221.5	226.8	241.8	910.6	Turbulent		26784	54672	0	0
7	Wall	Therminol XP	152.6	155	654.6	729.5	464.6	470.5	0	141.3	2	220.3	223.1	228.4	243.4	921.3	Turbulent		26754	54627	0	0
8	Wall	Therminol XP	155	157.4	729.5	648.3	470.5	476.5	0	141.3	2	221.9	224.7	230	245	932.3	Turbulent		26725	54581	0	0
9	Wall	Therminol XP	157.4	159.8	648.3	722.9	476.5	482.4	0	141.3	2	223.5	226.3	231.6	246.6	943.5	Turbulent		26696	54534	0	0
10	Wall	Therminol XP	159.8	162.2	722.9	642	482.4	488.3	0	141.3	2	225.1	227.9	233.2	248.2	955	Turbulent		26666	54488	0	0
11	Wall	Therminol XP	162.2	164.6	642	716.2	488.3	494.3	0	141.3	2	226.7	229.5	234.8	249.8	966.8	Turbulent		26636	54441	0	0
12	Wall	Therminol XP	164.6	167	716.2	635.6	494.3	500.2	0	141.3	2	228.4	231.2	236.5	251.5	978.5	Turbulent		26604	54390	0	0
13	Wall	Therminol XP	167	169.4	635.6	709.6	500.2	506.2	0	141.3	2	230	232.8	238.1	253.1	990.3	Turbulent		26574	54342	0	0
14	Wall	Therminol XP	169.4	171.9	709.6	629.3	506.2	512.1	0	141.3	2	231.6	234.5	239.7	254.7	1002.4	Turbulent		26543	54293	0	0
15	Wall	Therminol XP	171.9	174.3	629.3	702.9	512.1	518.1	0	141.3	2	233.3	236.1	241.3	256.3	1014.9	Turbulent		26512	54244	0	0
16	Wall	Therminol XP	174.3	176.7	702.9	622.9	518.1	524	0	141.3	2	234.9	237.7	242.9	257.9	1027.7	Turbulent		26482	54195	0	0
17	Wall	Therminol XP	176.7	179.1	622.9	696.2	524	530	0	141.3	2	236.5	239.3	244.6	259.6	1040.9	Turbulent		26451	54146	0	0
18	Wall	Therminol XP	179.1	181.5	696.2	616.5	530	535.9	0	141.3	2	238.1	240.9	246.2	261.2	1054.5	Turbulent		26420	54096	0	0
19	Wall	Therminol XP	181.5	183.8	616.5	689.5	535.9	541.8	0	141.3	2	239.7	242.6	247.8	262.8	1066.9	Turbulent		26388	54046	0	0
20	Wall	Therminol XP	183.8	186.1	689.5	610.1	541.8	547.8	0	141.3	2	241.5	244.4	249.5	264.5	1076.3	Turbulent		26354	53991	0	0
21	Wall	Therminol XP	186.1	188.4	610.1	682.8	547.8	553.7	0	141.3	2	243.2	246.1	251.3	266.3	1085.8	Turbulent		26320	53936	0	0
22	Wall	Therminol XP	188.4	190.7	682.8	603.6	553.7	559.7	0	141.3	2	245	247.9	253.1	268.1	1095.5	Turbulent		26285	53881	0	0
23	Wall	Therminol XP	190.7	193	603.6	676	559.7	565.6	0	141.3	2	246.8	249.6	254.8	269.8	1105.3	Turbulent		26251	53825	0	0
24	Wall	Therminol XP	193	195.3	676	597.2	565.6	571.6	0	141.3	2	248.5	251.4	256.6	271.6	1115.3	Turbulent		26216	53769	0	0
25	Wall	Therminol XP	195.3	197.6	597.2	669.2	571.6	577.5	0	141.3	2	250.3	253.2	258.3	273.3	1125.4	Turbulent		26181	53712	0	0
26	Wall	Therminol XP	197.6	200	669.2	590.7	577.5	583.5	0	141.3	2	252.1	254.9	260.1	275.1	1135.7	Turbulent		26146	53655	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Therminol XP	100	100.6	750	747.6	344.2	345.4	0	141.3	1.9	126.7	127.4	128.7	143.7	583.3	Solid	Turbulent	C.S.	9715	13844	0	0
1	2	3	8	Therminol XP	100.6	101.1	747.6	745.2	345.4	346.7	0	141.3	1.9	127	127.7	129	144	585.6	Solid	Turbulent	C.S.	9652	13756	0	0
1	3	3	8	Therminol XP	101.1	101.7	745.2	742.8	346.7	347.9	0	141.3	1.9	127.3	128	129.3	144.3	587.9	Solid	Turbulent	C.S.	9590	13667	0	0
1	4	3	8	Therminol XP	101.7	102.2	742.8	740.4	347.9	349.2	0	141.3	1.9	127.6	128.3	129.5	144.5	590.2	Solid	Turbulent	C.S.	9528	13578	0	0
1	5	3	7	Therminol XP	102.2	103.1	740.4	738.1	349.2	351.1	0	141.3	1.9	141.1	142.2	144.1	159.1	613.7	Solid	Turbulent	C.S.	14845	21137	0	0
1	6	3	7	Therminol XP	103.1	104	738.1	735.7	351.1	353	0	141.3	1.9	141.5	142.6	144.5	159.5	617	Solid	Turbulent	C.S.	14749	20999	0	0
1	7	3	7	Therminol XP	104	104.8	735.7	733.3	353	354.9	0	141.3	1.9	141.9	143	144.9	159.9	620.4	Solid	Turbulent	C.S.	14652	20862	0	0
1	8	3	7	Therminol XP	104.8	105.7	733.3	730.9	354.9	356.8	0	141.3	1.9	142.3	143.4	145.3	160.3	623.8	Solid	Turbulent	C.S.	14556	20725	0	0
1	9	3	6	Therminol XP	105.7	107	730.9	728.5	356.8	359.8	0	141.3	1.9	163.2	164.9	168	183	649.9	Solid	Turbulent	C.S.	23285	33066	0	0
1	10	3	6	Therminol XP	107	108.4	728.5	726.1	359.8	362.8	0	141.3	1.9	163.7	165.4	168.4	183.4	655.4	Solid	Turbulent	C.S.	23128	32844	0	0
1	11	3	6	Therminol XP	108.4	109.7	726.1	723.7	362.8	365.8	0	141.3	1.9	164.2	165.9	168.9	183.9	661.1	Solid	Turbulent	C.S.	22971	32622	0	0
1	12	3	6	Therminol XP	109.7	111.1	723.7	721.3	365.8	368.8	0	141.3	1.9	164.7	166.4	169.4	184.4	666.8	Solid	Turbulent	C.S.	22815	32399	0	0
1	13	2	5	Therminol XP	111.1	112.6	721.3	718.9	368.8	372.2	0	141.3	1.9	173.9	175.9	179.4	194.4	684	Solid	Turbulent	C.S.	26805	38044	0	0
1	14	2	5	Therminol XP	112.6	114.2	718.9	716.5	372.2	375.7	0	141.3	1.9	174.5	176.5	180	195	691	Solid	Turbulent	C.S.	26663	37841	0	0
1	15	2	5	Therminol XP	114.2	115.7	716.5	714.1	375.7	379.1	0	141.3	1.9	175.1	177.1	180.6	195.6	698.3	Solid	Turbulent	C.S.	26520	37638	0	0
1	16	2	5	Therminol XP	115.7	117.3	714.1	711.7	379.1	382.6	0	141.3	1.9	175.7	177.7	181.2	196.2	705.6	Solid	Turbulent	C.S.	26377	37435	0	0
1	17	2	4	Therminol XP	117.3	119.7	711.7	709.3	382.6	387.9	0	141.3	1.9	206.9	210.1	215.6	230.6	746.3	Solid	Turbulent	C.S.	41317	59102	0	0
1	18	2	4	Therminol XP	119.7	122	709.3	706.9	387.9	393.2	0	141.3	1.9	207.5	210.6	216.1	231.1	758	Solid	Turbulent	C.S.	41074	58754	0	0
1	19	2	4	Therminol XP	122	124.4	706.9	704.5	393.2	398.5	0	141.3	1.9	208	211.1	216.6	231.6	770.1	Solid	Turbulent	C.S.	40830	58406	0	0
1	20	2	4	Therminol XP	124.4	126.8	704.5	702.1	398.5	403.8	0	141.3	1.9	208.6	211.7	217.1	232.1	782.6	Solid	Turbulent	C.S.	40587	58058	0	0
1	21	1	3	Therminol XP	126.8	127.6	702.1	699.7	403.8	405.5	0	141.3	1.9	162.2	163.5	165.5	180.5	736.5	None	Turbulent	C.S.	13234	23118	0	0
1	22	1	3	Therminol XP	127.6	128.3	699.7	697.3	405.5	407.2	0	141.3	1.9	162.7	164	166	181	740.9	None	Turbulent	C.S.	13215	23083	0	0
1	23	1	3	Therminol XP	128.3	129.1	697.3	694.9	407.2	408.9	0	141.3	1.9	163.2	164.5	166.5	181.5	745.5	None	Turbulent	C.S.	13195	23049	0	0
1	24	1	3	Therminol XP	129.1	129.9	694.9	692.5	408.9	410.6	0	141.3	1.9	163.7	165	167	182	750	None	Turbulent	C.S.	13176	23015	0	0
1	25	1	2	Therminol XP	129.9	130.8	692.5	690.1	410.6	412.6	0	141.3	1.9	170.5	172	174.5	189.5	763.6	None	Turbulent	C.S.	15747	27507	0	0
1	26	1	2	Therminol XP	130.8	131.7	690.1	687.7	412.6	414.6	0	141.3	1.9	171	172.6	175	190	769.3	None	Turbulent	C.S.	15723	27464	0	0
1	27	1	2	Therminol XP	131.7	132.6	687.7	685.3	414.6	416.7	0	141.3	1.9	171.6	173.1	175.6	190.6	775	None	Turbulent	C.S.	15698	27421	0	0
1	28	1	2	Therminol XP	132.6	133.5	685.3	682.9	416.7	418.7	0	141.3	1.9	172.2	173.7	176.1	191.1	780.9	None	Turbulent	C.S.	15674	27378	0	0
1	29	1	1	Therminol XP	133.5	134.6	682.9	680.5	418.7	421.2	0	141.3	1.9	182.2	184.2	187.3	202.3	802	None	Turbulent	C.S.	19816	34614	0	0
1	30	1	1	Therminol XP	134.6	135.8	680.5	678.1	421.2	423.8	0	141.3	1.9	182.9	184.8	187.9	202.9	809.3	None	Turbulent	C.S.	19783	34557	0	0
1	31	1	1	Therminol XP	135.8	136.9	678.1	675.7	423.8	426.3	0	141.3	1.9	183.5	185.4	188.5	203.5	816.9	None	Turbulent	C.S.	19751	34500	0	0
1	32	1	1	Therminol XP	136.9	138.1	675.7	673.3	426.3	428.9	0	141.3	1.9	184.1	186.1	189.2	204.2	824.5	None	Turbulent	C.S.	19718	34443	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	260.1	189.2	217.1	169.4
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	275.1	204.2	232.1	184.4
Design Tube Pressure	kPa	2000		2000	2000
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235
No. Rows			3	2	3
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	232.77	62.13	325.88	801.84
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.1	25.4
Fin Thickness	mm			1.3	1.3
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000	2000	2000	2000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750	750	750	750
tblDesignTemp,calcref0	Design Temperature	°C	275.1136	204.1628	232.1274	184.3701
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	123693.8	132642.5	129115.5	135138.9
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1332	1.0573	1.086	1.0379
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.13	4.06	4.09	4.04
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.72	4.64	4.67	4.61
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	21
Stack Diameter	m	1.18
Cone Diameter	m	1.184
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	171.4
Flue Gas Flow	kg/s	4.554
Steel Area	m²	78.09
Stack Entry Pressure	mmH2O	0.065
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	718.9	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	490.1	1400	V Y Anchors	71.9	Refrac. thickness OK
RADIANT WALL 1	514.5	Fibre (High Density)	75	0.1	None	0	0	732.8	395.2	1260	Twistlock Pins	59.8	Refrac. thickness OK
RADIANT ARCH 1	768.9	Fibre (High Density)	87.7	0.1	None	0	0	824	765.9	1260	Twistlock Pins	77.8	Refrac. thickness OK

CONVECTION SIDEWALL 1	470.2	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	459.4	1100	V Y Anchors	63.9	Refrac. thickness OK

STACK 1	171.4	LW Castable	50	0.3	None	0	0	732.8	450.2	1100	V Y Anchors	63.9	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	3.721
Flue Gas Temp.	°C	155.7
CO2	mol%	8.5
H2O	mol%	15.28
N2	mol%	72.93
O2	mol%	3.29
SO2	mol%	0

AIR
Air Flow	kg/s	3.532
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.189
Fuel LHV	kJ/kg	46766.8
Fuel Mol. Wt.		19.817

Radiant Cell		1
Arch Temp.	°C	895.4
Max Tube Temp.	°C	393.1
Average Flux	W/m²	32132
Arch Pressure	mmH2O	3.25

No. of Burners		4
Floor Pressure	mmH2O	-2.955

ENERGY PERFORMACE
Total Absorbed Duty	MW	8.196
Total Heat Release	MW	8.861
Total Efficiency	%	92.494

ENVIRONMENTAL IMPACT
Energy Efficiency	%	92.494
Daily CO2 Emissions	kg	43012

Total:

£ 918,218

HR	MW	8.861
Arch	°C	895.4
Tube	°C	393.1
Flux	W/m²	32132

No. Burners		4
Fuel Flow	kg/s	0.189
Air Flow	kg/s	3.532
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/s	3.721
Temp.	°C	155.7
CO2	mol%	8.5
H2O	mol%	15.28
N2	mol%	72.93
O2	mol%	3.29
SO2	mol%	0

Process Inlet------->

RATED , 100 °C, 7481.32 kPa a

Water , 210 °C, 1911.33 kPa a

Fuel m.w.		19.817
Fuel LHV	kJ/kg	46766.8

Process Outlet------->

RATED , 343.9 °C, 7353.167 kPa a, 7.171 MW

Water , 327.9 °C, 1824.878 kPa a, 1.025 MW

Firing MW
8.86
Duty MW
8.2
Efficiency %
92.49
CO2 Ton/day
43

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner vertical clearance is NOT satisfied (API 560)

Flame-tube impingment risk identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Stack design seems OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with ASME I

Convection section 1,Coil sect. no. 2, complies with ASME I

Convection section 1,Coil sect. no. 3, complies with ASME I

Convection section 1,Coil sect. no. 4, complies with ASME I

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 718,885
Option items
Detail Engineering (by HeaterSIM)	£ 107,833
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£918,218

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

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STREAM NO.		1	1A	2	2A	3	4	5	6
Fluid Name		RATED	Water	RATED	Water	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	4.604	3.712	4.604	3.712	3.721	3.721	0.189	3.532
Flow (hr)	kg/hr	16574	13362	16574	13362	13397	13397	682	12715
Temperature	°C	100	210	343.9	327.9	895.4	155.7	Note 1	15.5
Pressure	kPa a	7481.32	1911.33	7353.167	1824.878	3.25	-2.412	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

45.317 m 17.317 m 15.517 m 9.655 m 6.227 m 2.8 m Grade 0.00 m 1.39 m 3.813 m 4.305 m 3.881 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	ASME I	ASME I
Orientation		Vertical	Horizontal	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3	141.3
Tube Material		18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H
Tube Wall Thk	mm	Sch 40	Sch 80	Sch 40	Sch 40	Sch 80
Tube Spacing	mm	254	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1	220.1
No. Tubes		48	12	4	8	40
Effective Length	m	7	3.813	3.813	3.813	3.813
Straight Length	m	6.6	3.976	3.976	3.976	3.976

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		RATED	Water
Heat Duty	MW	7.171	1.025
Flow rate (sec)	kg/s	4.604	3.712
Flow rate (hr)	kg/hr	16574	13362
Pressure drop	kPa	128.153	86.452
Max. Film Temp. Calculated	°C	375.7	497.7
Max. Film Temp. Allowed	°C	Not specified	Not specified
Max Tube Average Flux Calculated (1)	W/m²	33225	0
Average Flux Allowed	W/m²	31500	31500
INLET CONDITIONS
Inlet Temperature	°C	100	210
Inlet Pressure	kPa a	7481.32	1911.33
Inlet Vapour Fraction		1	1
Inlet Enthalpy	kJ/kg	740	2800
OUTLET CONDITIONS
Outlet Temperature	°C	343.9	327.9
Outlet Pressure	kPa a	7353.167	1824.878
Outlet Vapour Fraction		1	1
Outlet Enthalpy	kJ/kg	2296	3075

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type
Heat Duty	MW	4.793
Heat Release	MW	8.861
Arch Temp.	°C	895.4
Max Tube Temp.	°C	393.1
Tube Cirle Diameter	m	3.881
Average Flux	W/m²	32132
Maximum Flux	W/m²	53834
Flue Flow	kg/s	3.721
Air Flow	kg/s	3.532
Fuel Flow	kg/s	0.189
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	3.25
Floor Pressure	mmH2O	-2.955
Radiant Height	m	6.86
Radiant Width	m	4.3
Radiant Length	m	4.3
No. of Burners		4
Draft Type		Natural
Burner Cirle Diameter	m	1.209
Burner Design Firing	MW	2.66
Burner Normal Firing	MW	2.22
Burner Min Firing	MW	0.53
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		Too Close (please check)
API Burner-to-Tube Dist.	m	1.132
API Burner-to-Wall Dist.	m	1
API Burner-to-Roof/Roof Dist	m	6.974
Floor Flux	W/m²	609165

Flame-tube impingment risk identified

Combustion

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Radiant Cell		1
Radiant Type
No. of Burners		4
Flue Flow	kg/s	3.721
Air Flow	kg/s	3.532
Fuel Flow	kg/s	0.189
Fuel LHV	kJ/kg	46766.8
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	8.5
H2O	mol%	15.28
N2	mol%	72.93
O2	mol%	3.29
SO2	mol%	0
Dew Point	°C	55
Fuel Mol. Wt.		19.817
Flue Mol. Wt.		27.964
Flame Temperature	°C	1861.7
Flue Gas Emissivity		0.404

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
Heat Duty	MW	3.404
Max Tube Temp.	°C	530.2
Total Flue Press. Loss (ex. gain)	mmH2O	1.71
Total Press. Gain	mmH2O	4.15
Total Press. Loss (inc. gain)	mmH2O	-2.44
Convection Width	m	1.651
Effective Length	m	3.813
Convection Height	m	5.362
Total No. Rows		16
FLUE GAS DATA
Flue Gas Flow	kg/s	3.721
Flue Gas Inlet Temp.	°C	895.4
Flue Gas Outlet Temp.	°C	155.7
CO2	mol%	8.501945
H2O	mol%	15.28267
N2	mol%	72.92802
O2	mol%	3.287358
SO2	mol%	0

Convection (Flue gas side)

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Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	16	Coil Section 4	0.06	170.3	155.7	170.6	154.4	0.78	Solid	8898	10904	4	0.943	0.075	347H SS	C.S.	116.5	125
1	15	Coil Section 4	0.07	188	170.3	190.2	170.6	0.75	Solid	10777	13221	4	0.943	0.078	347H SS	C.S.	122.1	132.4
1	14	Coil Section 4	0.09	208.6	188	214	190.2	0.72	Solid	13071	16040	4	0.943	0.082	347H SS	C.S.	128.8	141.3
1	13	Coil Section 4	0.11	233.8	208.6	242.8	214	0.69	Solid	15871	19472	4	0.943	0.086	347H SS	C.S.	137	152.1
1	12	Coil Section 4	0.13	264.8	233.8	278.2	242.8	0.65	Solid	19420	23807	4	0.943	0.091	347H SS	C.S.	147.1	165.5
1	11	Coil Section 4	0.16	302.5	264.8	321.8	278.2	0.61	Solid	23930	29293	4	0.943	0.098	347H SS	C.S.	159.7	182.1
1	10	Coil Section 4	0.2	347.9	302.5	375.7	321.8	0.57	Solid	29640	36204	4	0.943	0.106	347H SS	C.S.	175.4	202.6
1	9	Coil Section 4	0.25	404.5	347.9	443	375.7	0.53	Solid	36975	45040	4	0.943	0.116	347H SS	C.S.	195.3	228.4
1	8	Coil Section 4	0.32	474.7	404.5	527.8	443	0.48	Solid	46629	56607	4	0.943	0.129	347H SS	C.S.	220.7	261.2
1	7	Coil Section 4	0.42	565.1	474.7	639.6	527.8	0.43	Solid	61410	75814	4	0.943	0.145	347H SS	C.S.	257.4	308.1
1	6	Coil Section 3	0.41	652.6	565.1	749.8	639.6	0.39	Solid	60501	78052	4	0.943	0.169	347H SS	C.S.	455	491.2
1	5	Coil Section 3	0.49	755	652.6	882.7	749.8	0.35	Solid	73113	96395	4	0.943	0.191	347H SS	C.S.	543.7	583.3
1	4	Coil Section 2	0.12	779.5	755	915.2	882.7	0.33	None	17835	34136	4	1.018	0.081	347H SS	None	0	0
1	3	Coil Section 1	0.17	812.5	779.5	959.7	915.2	0.32	None	25528	44591	4	1.018	0.084	347H SS	None	0	0
1	2	Coil Section 1	0.19	848.7	812.5	1007.6	959.7	0.31	None	29030	50709	4	1.018	0.086	347H SS	None	0	0
1	1	Coil Section 1	0.22	895.4	848.7	1059.8	1007.6	0.3	None	35593	62173	4	1.018	0.09	347H SS	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	16	Coil Section 4	0.06	170.3	155.7	RATED	1	100	102.1	7481	7477	1	1	15.2	15.3	653.9	656.1	196	196	7992274	7992274
1	15	Coil Section 4	0.07	188	170.3	RATED	2	102.1	104.6	7477	7473	1	1	15.3	15.4	656.1	658.6	196	196	7992274	7992274
1	14	Coil Section 4	0.09	208.6	188	RATED	3	104.6	107.6	7473	7470	1	1	15.4	15.5	658.6	661.7	196	196	7992274	7992274
1	13	Coil Section 4	0.11	233.8	208.6	RATED	4	107.6	111.3	7470	7465	1	1	15.5	15.7	661.7	665.4	196	196	7992274	7992274
1	12	Coil Section 4	0.13	264.8	233.8	RATED	5	111.3	115.9	7465	7461	1	1	15.7	15.9	665.4	669.8	196	196	7992274	7992274
1	11	Coil Section 4	0.16	302.5	264.8	RATED	6	115.9	121.5	7461	7457	1	1	15.9	16.2	669.8	675.2	196	196	7992274	7992274
1	10	Coil Section 4	0.2	347.9	302.5	RATED	7	121.4	128.4	7457	7453	1	1	16.2	16.5	675.2	681.7	196	196	7992274	7992274
1	9	Coil Section 4	0.25	404.5	347.9	RATED	8	128.4	137	7453	7449	1	1	16.5	16.9	681.7	689.6	196	196	7992274	7992273
1	8	Coil Section 4	0.32	474.7	404.5	RATED	9	137	147.9	7449	7444	1	1	16.9	17.4	689.6	699.2	196	196	7992274	7992274
1	7	Coil Section 4	0.42	565.1	474.7	RATED	10	147.8	162.2	7444	7440	1	1	17.4	18	699.1	711.4	196	196	7992274	7992274
1	6	Coil Section 3	0.41	652.6	565.1	Water	101	210	265.1	1911	1885	1	1	33.6	37.9	406.2	428.8	288	288	2247746	1981670
1	5	Coil Section 3	0.49	755	652.6	Water	102	264.8	314.3	1885	1856	1	1	37.9	42	428.7	447.9	288	288	1982536	1791993
1	4	Coil Section 2	0.12	779.5	755	Water	103	314	327.9	1856	1825	1	1	42	43.7	447.8	453.1	288	288	1793021	1745775
1	3	Coil Section 1	0.17	812.5	779.5	RATED	11	162.2	168	7440	7435	1	1	18	18.3	711.4	716.2	196	196	7992273	7992274
1	2	Coil Section 1	0.19	848.7	812.5	RATED	12	167.9	174.4	7435	7430	1	1	18.3	18.6	716.2	721.5	196	196	7992274	7992274
1	1	Coil Section 1	0.22	895.4	848.7	RATED	13	174.3	181.8	7430	7426	1	1	18.6	18.9	721.3	727.4	196	196	7992274	4502850

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	16	Coil Section 4	0.06	170.3	155.7	RATED	1	100	102.1	7481	7477	1	1	15.2	15.3	653.9	656.1	196	196	7992274	7992274
1	15	Coil Section 4	0.07	188	170.3	RATED	2	102.1	104.6	7477	7473	1	1	15.3	15.4	656.1	658.6	196	196	7992274	7992274
1	14	Coil Section 4	0.09	208.6	188	RATED	3	104.6	107.6	7473	7470	1	1	15.4	15.5	658.6	661.7	196	196	7992274	7992274
1	13	Coil Section 4	0.11	233.8	208.6	RATED	4	107.6	111.3	7470	7465	1	1	15.5	15.7	661.7	665.4	196	196	7992274	7992274
1	12	Coil Section 4	0.13	264.8	233.8	RATED	5	111.3	115.9	7465	7461	1	1	15.7	15.9	665.4	669.8	196	196	7992274	7992274
1	11	Coil Section 4	0.16	302.5	264.8	RATED	6	115.9	121.5	7461	7457	1	1	15.9	16.2	669.8	675.2	196	196	7992274	7992274
1	10	Coil Section 4	0.2	347.9	302.5	RATED	7	121.4	128.4	7457	7453	1	1	16.2	16.5	675.2	681.7	196	196	7992274	7992274
1	9	Coil Section 4	0.25	404.5	347.9	RATED	8	128.4	137	7453	7449	1	1	16.5	16.9	681.7	689.6	196	196	7992274	7992273
1	8	Coil Section 4	0.32	474.7	404.5	RATED	9	137	147.9	7449	7444	1	1	16.9	17.4	689.6	699.2	196	196	7992274	7992274
1	7	Coil Section 4	0.42	565.1	474.7	RATED	10	147.8	162.2	7444	7440	1	1	17.4	18	699.1	711.4	196	196	7992274	7992274
1	6	Coil Section 3	0.41	652.6	565.1	Water	101	210	265.1	1911	1885	1	1	33.6	37.9	406.2	428.8	288	288	2247746	1981670
1	5	Coil Section 3	0.49	755	652.6	Water	102	264.8	314.3	1885	1856	1	1	37.9	42	428.7	447.9	288	288	1982536	1791993
1	4	Coil Section 2	0.12	779.5	755	Water	103	314	327.9	1856	1825	1	1	42	43.7	447.8	453.1	288	288	1793021	1745775
1	3	Coil Section 1	0.17	812.5	779.5	RATED	11	162.2	168	7440	7435	1	1	18	18.3	711.4	716.2	196	196	7992273	7992274
1	2	Coil Section 1	0.19	848.7	812.5	RATED	12	167.9	174.4	7435	7430	1	1	18.3	18.6	716.2	721.5	196	196	7992274	7992274
1	1	Coil Section 1	0.22	895.4	848.7	RATED	13	174.3	181.8	7430	7426	1	1	18.6	18.9	721.3	727.4	196	196	7992274	4502850

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	RATED	181.8	188.7	7425.7	7423.1	1254.6	1297.9	1	141.3	17.4	215.9	223.1	237.2	252.2	2240.5	Turbulent		33225	55382	0	0
2	Wall	RATED	188.7	195.6	7423.1	7420.5	1297.9	1341.3	1	141.3	17.7	226.3	233.4	247.3	262.3	1977.3	Turbulent		33045	55136	0	0
3	Wall	RATED	195.6	202.5	7420.5	7417.8	1341.3	1384.7	1	141.3	18	235.9	242.8	256.7	271.7	1810.3	Turbulent		32875	54903	0	0
4	Wall	RATED	202.5	209.4	7417.8	7415.1	1384.7	1428.1	1	141.3	18.2	244.9	251.8	265.5	280.5	1693	Turbulent		32711	54676	0	0
5	Wall	RATED	209.4	216.2	7415.1	7412.4	1428.1	1471.4	1	141.3	18.5	253.6	260.4	274	289	1605.4	Turbulent		32551	54452	0	0
6	Wall	RATED	216.2	223.1	7412.4	7409.6	1471.4	1514.8	1	141.3	18.8	262	268.6	282.2	297.2	1537.2	Turbulent		32393	54230	0	0
7	Wall	RATED	223.1	230	7409.6	7406.8	1514.8	1558.2	1	141.3	19	269.3	275.8	289.2	304.2	1517.5	Turbulent		32254	54034	0	0
8	Wall	RATED	230	236.9	7406.8	7404	1558.2	1601.5	1	141.3	19.3	275.6	282.1	295.5	310.5	1532.5	Turbulent		32130	53857	0	0
9	Wall	RATED	236.9	243.8	7404	7401.1	1601.5	1644.9	1	141.3	19.5	282	288.4	301.7	316.7	1547	Turbulent		32004	53677	0	0
10	Wall	RATED	243.8	250.7	7401.1	7398.2	1644.9	1688.3	1	141.3	19.8	288.5	294.8	308	323	1561.1	Turbulent		31876	53492	0	0
11	Wall	RATED	250.7	257.3	7398.2	7395.2	1688.3	1731.7	1	141.3	20.1	294.6	301	313.9	328.9	1575.3	Turbulent		31749	53312	0	0
12	Wall	RATED	257.3	263.8	7395.2	7392.2	1731.7	1775	1	141.3	20.3	300.6	307	319.8	334.8	1589.8	Turbulent		31624	53131	0	0
13	Wall	RATED	263.8	270.3	7392.2	7389.2	1775	1818.4	1	141.3	20.6	306.7	312.9	325.7	340.7	1603.8	Turbulent		31497	52947	0	0
14	Wall	RATED	270.3	276.8	7389.2	7386.1	1818.4	1861.8	1	141.3	20.8	312.7	318.9	331.6	346.6	1617.4	Turbulent		31369	52758	0	0
15	Wall	RATED	276.8	283.4	7386.1	7383	1861.8	1905.2	1	141.3	21.1	318.9	325	337.7	352.7	1630.7	Turbulent		31237	52563	0	0
16	Wall	RATED	283.4	290.1	7383	7379.8	1905.2	1948.5	1	141.3	21.3	325.2	331.1	343.8	358.8	1644.8	Turbulent		31101	52361	0	0
17	Wall	RATED	290.1	296.9	7379.8	7376.6	1948.5	1991.9	1	141.3	21.6	331.5	337.4	349.9	364.9	1658.7	Turbulent		30961	52154	0	0
18	Wall	RATED	296.9	303.6	7376.6	7373.4	1991.9	2035.3	1	141.3	21.9	337.8	343.6	356.1	371.1	1672.2	Turbulent		30819	51942	0	0
19	Wall	RATED	303.6	310.3	7373.4	7370.1	2035.3	2078.7	1	141.3	22.1	344.2	349.8	362.3	377.3	1685.4	Turbulent		30675	51726	0	0
20	Wall	RATED	310.3	317.1	7370.1	7366.8	2078.7	2122	1	141.3	22.4	350.5	356.1	368.4	383.4	1699.1	Turbulent		30528	51506	0	0
21	Wall	RATED	317.1	323.8	7366.8	7363.4	2122	2165.4	1	141.3	22.6	356.8	362.3	374.6	389.6	1712.9	Turbulent		30379	51281	0	0
22	Wall	RATED	323.8	330.5	7363.4	7360.1	2165.4	2208.8	1	141.3	22.9	363.1	368.6	380.8	395.8	1726.3	Turbulent		30228	51051	0	0
23	Wall	RATED	330.5	337.3	7360.1	7356.6	2208.8	2252.2	1	141.3	23.1	369.5	374.8	386.9	401.9	1739.4	Turbulent		30074	50817	0	0
24	Wall	RATED	337.3	343.9	7356.6	7353.2	2252.2	2295.5	1	141.3	23.4	375.7	381.1	393.1	408.1	1752.7	Turbulent		29918	50580	0	0

Flame-tube impingment risk identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	4	16	RATED	100	101	7481.3	7479.4	740.3	746.8	1	141.3	15.2	106.2	109.7	114.2	129.2	2832	Solid	Turbulent	347H SS	8956	12680	0	0
1	2	4	16	RATED	101	102.1	7479.4	7477.4	746.8	753.4	1	141.3	15.3	107.2	110.6	115	130	2842	Solid	Turbulent	347H SS	8806	12467	0	0
1	3	4	15	RATED	102.1	103.3	7477.4	7475.5	753.3	761.2	1	141.3	15.3	109.6	113.8	119.2	134.2	2847.8	Solid	Turbulent	347H SS	10847	15369	0	0
1	4	4	15	RATED	103.3	104.6	7475.5	7473.5	761.2	769.1	1	141.3	15.4	110.7	114.8	120.2	135.2	2859.9	Solid	Turbulent	347H SS	10667	15113	0	0
1	5	4	14	RATED	104.6	106.1	7473.5	7471.5	769	778.7	1	141.3	15.5	113.6	118.7	125.3	140.3	2866.9	Solid	Turbulent	347H SS	13157	18645	0	0
1	6	4	14	RATED	106.1	107.6	7471.5	7469.5	778.7	788.3	1	141.3	15.5	115	119.9	126.4	141.4	2881.6	Solid	Turbulent	347H SS	12939	18336	0	0
1	7	4	13	RATED	107.6	109.5	7469.5	7467.5	788.2	799.9	1	141.3	15.6	118.5	124.6	132.6	147.6	2890.1	Solid	Turbulent	347H SS	15975	22636	0	0
1	8	4	13	RATED	109.5	111.3	7467.5	7465.5	799.9	811.6	1	141.3	15.7	120.2	126.2	134	149	2907.7	Solid	Turbulent	347H SS	15710	22260	0	0
1	9	4	12	RATED	111.3	113.6	7465.5	7463.5	811.5	825.8	1	141.3	15.8	124.6	132	141.7	156.7	2917.5	Solid	Turbulent	347H SS	19548	27683	0	0
1	10	4	12	RATED	113.6	115.9	7463.5	7461.4	825.8	840	1	141.3	15.9	126.6	133.8	143.4	158.4	2938.5	Solid	Turbulent	347H SS	19220	27220	0	0
1	11	4	11	RATED	115.9	118.7	7461.4	7459.4	840.1	857.6	1	141.3	16.1	132	141.1	152.9	167.9	2949.9	Solid	Turbulent	347H SS	24090	34082	0	0
1	12	4	11	RATED	118.7	121.5	7459.4	7457.3	857.6	875.2	1	141.3	16.2	134.5	143.3	155	170	2975.1	Solid	Turbulent	347H SS	23681	33504	0	0
1	13	4	10	RATED	121.4	124.9	7457.3	7455.2	875.1	896.9	1	141.3	16.4	141.2	152.3	166.8	181.8	2988	Solid	Turbulent	347H SS	29842	42161	0	0
1	14	4	10	RATED	124.9	128.4	7455.2	7453.1	896.9	918.7	1	141.3	16.5	144.2	155.1	169.3	184.3	3017.9	Solid	Turbulent	347H SS	29325	41430	0	0
1	15	4	9	RATED	128.4	132.7	7453.1	7451	918.9	946.1	1	141.3	16.7	152.7	166.3	184.3	199.3	3032.7	Solid	Turbulent	347H SS	37232	52506	0	0
1	16	4	9	RATED	132.7	137	7451	7448.8	946.1	973.2	1	141.3	16.9	156.5	169.7	187.3	202.3	3068.1	Solid	Turbulent	347H SS	36570	51573	0	0
1	17	4	8	RATED	137	142.5	7448.8	7446.6	973.1	1007.4	1	141.3	17.2	167.2	184.1	206.3	221.3	3083.6	Solid	Turbulent	347H SS	46963	66081	0	0
1	18	4	8	RATED	142.5	147.9	7446.6	7444.4	1007.4	1041.6	1	141.3	17.4	171.9	188.3	210.2	225.2	3125.6	Solid	Turbulent	347H SS	46101	64867	0	0
1	19	4	7	RATED	147.8	155	7444.4	7442.1	1041	1086.1	1	141.3	17.7	187.4	209.4	238.5	253.5	3136.5	Solid	Turbulent	347H SS	61876	88036	0	0
1	20	4	7	RATED	155	162.2	7442.1	7439.8	1086.1	1131.2	1	141.3	18	193.5	214.8	243.3	258.3	3188.1	Solid	Turbulent	347H SS	60656	86301	0	0
1	21	1	3	RATED	162.2	165.1	7439.8	7437.5	1131.3	1149.6	1	141.3	18.2	180.5	191.9	206.2	221.2	3283.5	None	Turbulent	347H SS	25049	43755	0	0
1	22	1	3	RATED	165.1	168	7437.5	7435.2	1149.6	1168	1	141.3	18.3	183.3	194.6	208.8	223.8	3301.9	None	Turbulent	347H SS	24935	43557	0	0
1	23	1	2	RATED	167.9	171.2	7435.2	7432.8	1167.6	1188	1	141.3	18.4	188.1	200.6	216.4	231.4	3313.5	None	Turbulent	347H SS	27760	48490	0	0
1	24	1	2	RATED	171.2	174.4	7432.8	7430.4	1188	1208.4	1	141.3	18.6	191.2	203.6	219.3	234.3	3333.3	None	Turbulent	347H SS	27630	48264	0	0
1	25	1	1	RATED	174.3	178	7430.5	7428.1	1207.3	1230.9	1	141.3	18.7	197.6	212	230.2	245.2	3312.7	None	Turbulent	347H SS	32203	56251	0	0
1	26	1	1	RATED	178	181.8	7428.1	7425.7	1230.9	1254.6	1	141.3	18.9	204.6	218.9	236.9	251.9	2829.9	None	Turbulent	347H SS	32048	55980	0	0
1	1	3	6	Water	210	223.8	1911.3	1905.1	2800.3	2827.9	1	141.3	34.6	407.2	415.9	438.4	453.4	559.2	Solid	Turbulent	347H SS	63554	93121	0	0
1	2	3	6	Water	223.8	237.5	1905.1	1898.7	2827.9	2855.5	1	141.3	35.7	410	418.1	440	455	573	Solid	Turbulent	347H SS	61297	89814	0	0
1	3	3	5	Water	237.5	251.3	1898.7	1892.1	2855.5	2883.1	1	141.3	36.8	413.7	421.2	442.5	457.5	586.4	Solid	Turbulent	347H SS	59039	86505	0	0
1	4	3	5	Water	251.3	265.1	1892.1	1885.3	2883.1	2910.6	1	141.3	37.9	417.8	424.8	445.5	460.5	599.6	Solid	Turbulent	347H SS	56780	83195	0	0
1	5	3	5	Water	264.8	277.2	1885.3	1878.3	2910.2	2943.6	1	141.3	38.9	490.6	502.3	526.4	541.4	583.6	Solid	Turbulent	347H SS	76037	113057	0	0
1	6	3	5	Water	277.2	289.6	1878.3	1871.1	2943.6	2976.9	1	141.3	39.9	492.6	503.8	527.3	542.3	595.7	Solid	Turbulent	347H SS	73840	109790	0	0
1	7	3	4	Water	289.6	301.9	1871.1	1863.7	2976.9	3010.2	1	141.3	41	495.1	505.7	528.7	543.7	607.7	None	Turbulent	347H SS	71641	106522	0	0
1	8	3	4	Water	301.9	314.3	1863.7	1856.1	3010.2	3043.5	1	141.3	42	497.7	507.8	530.2	545.2	619.6	None	Turbulent	347H SS	69442	103252	0	0
1	9	2	4	Water	314	317.5	1856.1	1848.4	3042.9	3051	1	141.3	42.4	373	377.2	384.8	399.8	685.5	None	Turbulent	347H SS	18039	34526	0	0
1	10	2	4	Water	317.5	320.9	1848.4	1840.7	3051	3059.1	1	141.3	42.9	375.8	380	387.6	402.6	688	None	Turbulent	347H SS	17900	34260	0	0
1	11	2	3	Water	320.9	324.4	1840.7	1832.8	3059.1	3067.2	1	141.3	43.3	378.7	382.8	390.3	405.3	690.4	None	Turbulent	347H SS	17761	33994	0	0
1	12	2	3	Water	324.4	327.9	1832.8	1824.9	3067.2	3075.4	1	141.3	43.7	381.5	385.5	393	408	693	None	Turbulent	347H SS	17622	33728	0	0

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3	Coil Section 4
Process Name		Process 1: RATED	Process 1: RATED	Process 2: Water	Process 2: Water	Process 1: RATED
Tube OD	mm	141.3	141.3	141.3	141.3	141.3
Tube Material		18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H	18Cr/10Ni/Nb - 347H
Tube Wall Thk	mm	Sch 40	Sch 80	Sch 40	Sch 40	Sch 80
Max Tube Temperature	°C	393.1	236.9	393	530.2	243.3
Tube Temperature Margin	°C	15	15	15	15	15
Design Tube Temperature	°C	408.1	251.9	408	545.2	258.3
Design Tube Pressure	kPa	8500		8500	3200	3200
Design Code		API 530		API 530	ASME I	ASME I
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (ASME VIII)	Tube Thk. OK (ASME VIII)	Tube Thk. OK (ASME VIII)	Tube Thk. OK (ASME VIII)
No. Tubes		48	12	4	8	40
No. Tubes Per Row			4	4	4	4
No. Passes		2	2	1	1	2
Effective Length	m	7	3.813	3.813	3.813	3.813
Straight Length	m	6.6	3.976	3.976	3.976	3.976
No. Rows			3	1	2	10
Tube Spacing	mm	254	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1	220.1
Coil Alignment			Staggered	Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal	Horizontal
Tube Area	m²	149.15	20.3	6.77	171.77	858.84
Intermediate Supports		0 / 0	0 / 0	0 / 0	0 / 0	0 / 0
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	None	None
Fin Type			None	None	Solid	Solid
Fin Material			None	None	Carbon Steel	Carbon Steel
Fin Height	mm				25	25
Fin Thickness	mm				1.3	1.3
Serrated Fin Wn
Fin Density	fins/m				197	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with ASME I

Convection section 1,Coil sect. no. 2, complies with ASME I

Convection section 1,Coil sect. no. 3, complies with ASME I

Convection section 1,Coil sect. no. 4, complies with ASME I

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT
tblCoilSectName	Coil/Piping Section		Coil Section 1
tblDesignPress,calcref0	Design Pressure	kPa g	8500
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	7481.3
tblDesignTemp,calcref0	Design Temperature	°C	408.0611
tblTubeMaterial	Tube Material		18Cr/10Ni/Nb - 347H
tblTubeOD	Tube Outside Diameter		141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	1
tblDesignLifeHrs,calcref0	Design Life	hours	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	126442.4
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	4.595
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	5.59
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	6.39
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0
RuptureNfactor,resultref0	Rupture n factor		0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0
RuptureBfactor,resultref0	B factor		0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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CalcType		0	0	0	0
Units		0	0	0	0
Heater Section		Convection	Convection	Convection	Convection
Coil/Piping Section		Coil Section 1	Coil Section 2	Coil Section 3	Coil Section 4
Tube Outside diameter	mm	141.3	141.3	141.3	141.3
Tube Inside Radius	mm	61.12	64.1	64.1	61.12
Design Pressure	kPa g	3200	3200	3200	3200
Design Temperature	°C	251.9	408	545.2	258.3
Tube Material		Not Found	Not Found	Not Found	Not Found
Allowable Stress at Td	kPa g	119888.8	115920.1	113190.3	119502.9
Joint Efficiency		1	1	1	1
Temperature Coefficient Y		0.4	0.4	0.4	0.4
Efficiency Factor		1	1	1	1
Quality Factor		0.8	0.8	0.8	0.8
Stress Thickness	mm	1.87	1.93	1.98	1.87
Corrosion Allowance	mm	1	1	1	1
Minimum Wall Thickness Required	mm	2.87	2.93	2.98	2.87
Average Wall Thickness Required	mm	3.28	3.35	3.4	3.28
Actual Tube Thickness	mm	9.53	6.55	6.55	9.53
Stress Suitability		Tube Thk. OK (ASME VIII)	Tube Thk. OK (ASME VIII)	Tube Thk. OK (ASME VIII)	Tube Thk. OK (ASME VIII)
Corroded State Suitability		Tube thickness is adequate for calculated stress.<br/>The corroded state tube thickness is also compliant with ASME code.	Tube thickness is adequate for calculated stress.<br/>The corroded state tube thickness is also compliant with ASME code.	Tube thickness is adequate for calculated stress.<br/>The corroded state tube thickness is also compliant with ASME code.	Tube thickness is adequate for calculated stress.<br/>The corroded state tube thickness is also compliant with ASME code.
TUBE TEST CONDITIONS
Actual Min. Tube Thickness	mm	8.34	5.73	5.73	8.34
Min. Yield Stress (Ambient)	kPa	205000	205000	205000	205000
Allowable Test Stress	kPa	184500	184500	184500	184500
Max Allowable Test Pressure	kPa	19995.7	12695.57	12695.57	19995.71

ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

HeaterSIM - Fired Heater Simulation Results

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	28
Stack Diameter	m	1.39
Cone Diameter	m	0.854
Cone Height	m	0.5
Actual Exit Velocity	m/s	10.5
Design Exit Velocity	m/s	12.6
Flue Gas Temp.	°C	155.7
Flue Gas Flow	kg/s	3.721
Steel Area	m²	122.623
Stack Entry Pressure	mmH2O	-2.412
CO2	mol%	8.5
H2O	mol%	15.28
N2	mol%	72.93
O2	mol%	3.29
SO2	mol%	0

Draft at Stack Base	mmH2Og	2.5
Draft at Arch	mmH2Og	2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Stack design seems OK

Refractory

HeaterSIM - Fired Heater Simulation Results

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	845.4	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	607.1	1400	V Y Anchors	80.3	Refrac. thickness OK
RADIANT WALL 1	644.2	Fibre (High Density)	75	0.1	None	0	0	732.8	625.8	1260	Twistlock Pins	75.1	Refrac. thickness OK
RADIANT ARCH 1	895.4	Fibre (High Density)	113.1	0.1	None	0	0	824	811.1	1260	Twistlock Pins	80.6	Refrac. thickness OK

CONVECTION SIDEWALL 1	525.6	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	534.5	1100	V Y Anchors	69.5	Refrac. thickness OK

STACK 1	155.7	LW Castable	50	0.3	None	0	0	732.8	369.5	1100	V Y Anchors	57.7	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	4.489
Flue Gas Temp.	°C	146.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

AIR
Air Flow	kg/s	4.282
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.207
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

Radiant Cell		1
Arch Temp.	°C	765
Max Tube Temp.	°C	259.3
Average Flux	W/m²	26275
Arch Pressure	mmH2O	-2.577

No. of Burners		4
Floor Pressure	mmH2O	-12.234

ENERGY PERFORMACE
Total Absorbed Duty	MW	9.575
Total Heat Release	MW	10.369
Total Efficiency	%	92.341

ENVIRONMENTAL IMPACT
Energy Efficiency	%	92.341
Daily CO2 Emissions	kg	49444

Total:

£ 763,559

HR	MW	10.369
Arch	°C	765
Tube	°C	259.3
Flux	W/m²	26275

No. Burners		4
Fuel Flow	kg/s	0.207
Air Flow	kg/s	4.282
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/s	4.489
Temp.	°C	146.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Process Inlet------->

Therminol XP , 100 °C, 750 kPa a

Fuel m.w.		16
Fuel LHV	kJ/kg	50015

Process Outlet------->

Therminol XP , 199.8 °C, 590.693 kPa a, 9.575 MW

Firing MW
10.37
Duty MW
9.58
Efficiency %
92.34
CO2 Ton/day
49

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

HeaterSIM - Fired Heater Simulation Results

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 584,399
Option items
Detail Engineering (by HeaterSIM)	£ 87,660
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£763,559

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	4.489	4.489	0.207	4.282
Flow (hr)	kg/hr	144000	144000	16160	16160	746	15413
Temperature	°C	100	199.8	765	146.5	Note 1	15.5
Pressure	kPa a	750	590.693	-2.577	0.015	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

34.785 m 19.785 m 17.985 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 1.35 m 5.835 m 4.584 m 4.204 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530		API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
No. Tubes		52	24	16	24
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Therminol XP
Heat Duty	MW	9.575
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	159.307
Max. Film Temp. Calculated	°C	251.4
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	26620
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	344
OUTLET CONDITIONS
Outlet Temperature	°C	199.8
Outlet Pressure	kPa a	590.693
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	583

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type
Heat Duty	MW	6.116
Heat Release	MW	10.369
Arch Temp.	°C	765
Max Tube Temp.	°C	259.3
Tube Cirle Diameter	m	4.204
Average Flux	W/m²	26275
Maximum Flux	W/m²	53676
Flue Flow	kg/s	4.489
Air Flow	kg/s	4.282
Fuel Flow	kg/s	0.207
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-2.577
Floor Pressure	mmH2O	-12.234
Radiant Height	m	11.08
Radiant Width	m	4.58
Radiant Length	m	4.58
No. of Burners		4
Draft Type		Natural
Burner Cirle Diameter	m	1.209
Burner Design Firing	MW	3.11
Burner Normal Firing	MW	2.59
Burner Min Firing	MW	0.62
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.244
API Burner-to-Wall Dist.	m	1.119
API Burner-to-Roof/Roof Dist	m	7.892
Floor Flux	W/m²	628620

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type
No. of Burners		4
Flue Flow	kg/s	4.489
Air Flow	kg/s	4.282
Fuel Flow	kg/s	0.207
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flame Temperature	°C	1805.6
Flue Gas Emissivity		0.444

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

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Convection Sect. No.		1
Heat Duty	MW	3.459
Max Tube Temp.	°C	220.6
Total Flue Press. Loss (ex. gain)	mmH2O	0.58
Total Press. Gain	mmH2O	2.65
Total Press. Loss (inc. gain)	mmH2O	-2.08
Convection Width	m	2.159
Effective Length	m	5.835
Convection Height	m	3.601
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	4.489
Flue Gas Inlet Temp.	°C	765
Flue Gas Outlet Temp.	°C	146.5
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.16	178.2	146.5	180.2	144.1	0.78	Solid	7874	9745	8	0.965	0.077	C.S.	C.S.	127.9	134.3
1	7	Coil Section 3	0.27	229.7	178.2	239.2	180.2	0.71	Solid	12877	15944	8	0.965	0.083	C.S.	C.S.	145.8	156.3
1	6	Coil Section 3	0.45	315.1	229.7	338.4	239.2	0.62	Solid	21663	26746	8	0.965	0.093	C.S.	C.S.	175.5	193.1
1	5	Coil Section 2	0.55	417.7	315.1	461.1	338.4	0.53	Solid	26687	32966	8	0.917	0.077	C.S.	C.S.	193.8	218.6
1	4	Coil Section 2	0.9	578.7	417.7	659.9	461.1	0.44	Solid	43218	53425	8	0.917	0.092	C.S.	C.S.	242.6	280.6
1	3	Coil Section 1	0.3	630.3	578.7	725.1	659.9	0.39	None	14928	26076	8	0.853	0.049	C.S.	None	0	0
1	2	Coil Section 1	0.37	690.1	630.3	801.9	725.1	0.36	None	18671	32614	8	0.853	0.052	C.S.	None	0	0
1	1	Coil Section 1	0.47	765	690.1	893.6	801.9	0.34	None	25256	44117	8	0.853	0.055	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.16	178.2	146.5	Therminol XP	1	100	101.8	750	740	0	0	1.9	1.9	0	0	1549	1549	56942	58589
1	7	Coil Section 3	0.27	229.7	178.2	Therminol XP	2	101.7	104.7	740	731	0	0	1.9	1.9	0	0	1549	1549	58501	61332
1	6	Coil Section 3	0.45	315.1	229.7	Therminol XP	3	104.7	109.8	731	721	0	0	1.9	1.9	0	0	1549	1549	61339	66555
1	5	Coil Section 2	0.55	417.7	315.1	Therminol XP	4	109.6	115.9	721	712	0	0	1.9	1.9	0	0	1549	1549	66397	73728
1	4	Coil Section 2	0.9	578.7	417.7	Therminol XP	5	116.1	126.1	712	702	0	0	1.9	1.9	0	0	1549	1549	73997	88846
1	3	Coil Section 1	0.3	630.3	578.7	Therminol XP	6	126	129.4	702	693	0	0	1.9	1.9	0	0	1549	1549	88696	94734
1	2	Coil Section 1	0.37	690.1	630.3	Therminol XP	7	129.9	134	693	683	0	0	1.9	1.9	0	0	1549	1549	95679	104095
1	1	Coil Section 1	0.47	765	690.1	Therminol XP	8	133.5	138.6	683	673	0	0	1.9	1.9	0	0	1549	1549	102897	114318

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.16	178.2	146.5	Therminol XP	1	100	101.8	750	740	0	0	1.9	1.9	0	0	1549	1549	56942	58589
1	7	Coil Section 3	0.27	229.7	178.2	Therminol XP	2	101.7	104.7	740	731	0	0	1.9	1.9	0	0	1549	1549	58501	61332
1	6	Coil Section 3	0.45	315.1	229.7	Therminol XP	3	104.7	109.8	731	721	0	0	1.9	1.9	0	0	1549	1549	61339	66555
1	5	Coil Section 2	0.55	417.7	315.1	Therminol XP	4	109.6	115.9	721	712	0	0	1.9	1.9	0	0	1549	1549	66397	73728
1	4	Coil Section 2	0.9	578.7	417.7	Therminol XP	5	116.1	126.1	712	702	0	0	1.9	1.9	0	0	1549	1549	73997	88846
1	3	Coil Section 1	0.3	630.3	578.7	Therminol XP	6	126	129.4	702	693	0	0	1.9	1.9	0	0	1549	1549	88696	94734
1	2	Coil Section 1	0.37	690.1	630.3	Therminol XP	7	129.9	134	693	683	0	0	1.9	1.9	0	0	1549	1549	95679	104095
1	1	Coil Section 1	0.47	765	690.1	Therminol XP	8	133.5	138.6	683	673	0	0	1.9	1.9	0	0	1549	1549	102897	114318

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol XP	138.6	141	673.3	749.3	430.3	436.2	0	141.3	1.9	210.4	213.2	218.4	233.4	861.7	Turbulent		26620	54213	0	0
2	Wall	Therminol XP	141	143.4	749.3	667.1	436.2	442	0	141.3	1.9	211.9	214.7	219.9	234.9	871.2	Turbulent		26591	54169	0	0
3	Wall	Therminol XP	143.4	145.8	667.1	742.7	442	447.9	0	141.3	1.9	213.5	216.3	221.5	236.5	881	Turbulent		26563	54125	0	0
4	Wall	Therminol XP	145.8	148.2	742.7	660.8	447.9	453.8	0	141.3	1.9	215.1	217.9	223.1	238.1	890.9	Turbulent		26534	54080	0	0
5	Wall	Therminol XP	148.2	150.6	660.8	736.1	453.8	459.7	0	141.3	2	216.7	219.5	224.6	239.6	901.1	Turbulent		26506	54036	0	0
6	Wall	Therminol XP	150.6	153	736.1	654.6	459.7	465.6	0	141.3	2	218.2	221	226.2	241.2	911.5	Turbulent		26477	53990	0	0
7	Wall	Therminol XP	153	155.4	654.6	729.5	465.6	471.5	0	141.3	2	219.8	222.6	227.8	242.8	922.1	Turbulent		26448	53945	0	0
8	Wall	Therminol XP	155.4	157.7	729.5	648.3	471.5	477.3	0	141.3	2	221.4	224.2	229.4	244.4	933	Turbulent		26419	53899	0	0
9	Wall	Therminol XP	157.7	160.1	648.3	722.9	477.3	483.2	0	141.3	2	223	225.8	231	246	944.1	Turbulent		26389	53853	0	0
10	Wall	Therminol XP	160.1	162.5	722.9	641.9	483.2	489.1	0	141.3	2	224.6	227.4	232.5	247.5	955.6	Turbulent		26360	53807	0	0
11	Wall	Therminol XP	162.5	164.9	641.9	716.2	489.1	495	0	141.3	2	226.1	228.9	234.1	249.1	967.3	Turbulent		26330	53760	0	0
12	Wall	Therminol XP	164.9	167.3	716.2	635.6	495	500.9	0	141.3	2	227.8	230.6	235.8	250.8	979.1	Turbulent		26299	53711	0	0
13	Wall	Therminol XP	167.3	169.7	635.6	709.6	500.9	506.7	0	141.3	2	229.4	232.2	237.4	252.4	990.8	Turbulent		26269	53663	0	0
14	Wall	Therminol XP	169.7	172.1	709.6	629.2	506.7	512.6	0	141.3	2	231.1	233.9	239	254	1002.8	Turbulent		26238	53614	0	0
15	Wall	Therminol XP	172.1	174.4	629.2	702.9	512.6	518.5	0	141.3	2	232.7	235.5	240.6	255.6	1015.1	Turbulent		26208	53566	0	0
16	Wall	Therminol XP	174.4	176.8	702.9	622.9	518.5	524.4	0	141.3	2	234.3	237.1	242.3	257.3	1027.8	Turbulent		26177	53517	0	0
17	Wall	Therminol XP	176.8	179.2	622.9	696.2	524.4	530.3	0	141.3	2	235.9	238.7	243.9	258.9	1040.9	Turbulent		26146	53468	0	0
18	Wall	Therminol XP	179.2	181.6	696.2	616.4	530.3	536.1	0	141.3	2	237.5	240.3	245.5	260.5	1054.3	Turbulent		26115	53419	0	0
19	Wall	Therminol XP	181.6	183.9	616.4	689.5	536.1	542	0	141.3	2	239.1	241.9	247.1	262.1	1066.5	Turbulent		26084	53369	0	0
20	Wall	Therminol XP	183.9	186.2	689.5	610.1	542	547.9	0	141.3	2	240.9	243.7	248.8	263.8	1075.8	Turbulent		26050	53315	0	0
21	Wall	Therminol XP	186.2	188.5	610.1	682.8	547.9	553.8	0	141.3	2	242.6	245.4	250.6	265.6	1085.2	Turbulent		26016	53260	0	0
22	Wall	Therminol XP	188.5	190.7	682.8	603.6	553.8	559.7	0	141.3	2	244.4	247.2	252.3	267.3	1094.7	Turbulent		25982	53205	0	0
23	Wall	Therminol XP	190.7	193	603.6	676	559.7	565.5	0	141.3	2	246.1	248.9	254.1	269.1	1104.4	Turbulent		25948	53150	0	0
24	Wall	Therminol XP	193	195.3	676	597.2	565.5	571.4	0	141.3	2	247.9	250.7	255.8	270.8	1114.3	Turbulent		25913	53094	0	0
25	Wall	Therminol XP	195.3	197.6	597.2	669.2	571.4	577.3	0	141.3	2	249.6	252.4	257.6	272.6	1124.3	Turbulent		25879	53038	0	0
26	Wall	Therminol XP	197.6	199.8	669.2	590.7	577.3	583.2	0	141.3	2	251.4	254.2	259.3	274.3	1134.5	Turbulent		25844	52982	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	Therminol XP	100	100.5	750	747.6	344.2	345.2	0	141.3	1.9	122.1	122.7	123.7	138.7	576.1	Solid	Turbulent	C.S.	7939	11315	0	0
1	2	3	8	Therminol XP	100.5	100.9	747.6	745.2	345.2	346.2	0	141.3	1.9	122.3	122.9	123.9	138.9	577.9	Solid	Turbulent	C.S.	7878	11227	0	0
1	3	3	8	Therminol XP	100.9	101.4	745.2	742.8	346.2	347.2	0	141.3	1.9	122.6	123.1	124.1	139.1	579.7	Solid	Turbulent	C.S.	7816	11140	0	0
1	4	3	8	Therminol XP	101.4	101.8	742.8	740.4	347.2	348.2	0	141.3	1.9	122.8	123.3	124.4	139.4	581.5	Solid	Turbulent	C.S.	7755	11052	0	0
1	5	3	7	Therminol XP	101.7	102.5	740.4	738.1	348	349.7	0	141.3	1.9	136.2	137.2	138.9	153.9	605.5	Solid	Turbulent	C.S.	12983	18510	0	0
1	6	3	7	Therminol XP	102.5	103.2	738.1	735.7	349.7	351.4	0	141.3	1.9	136.5	137.5	139.2	154.2	608.6	Solid	Turbulent	C.S.	12883	18367	0	0
1	7	3	7	Therminol XP	103.2	104	735.7	733.3	351.4	353	0	141.3	1.9	136.8	137.8	139.5	154.5	611.8	Solid	Turbulent	C.S.	12783	18225	0	0
1	8	3	7	Therminol XP	104	104.7	733.3	730.9	353	354.7	0	141.3	1.9	137.2	138.1	139.8	154.8	614.9	Solid	Turbulent	C.S.	12683	18082	0	0
1	9	3	6	Therminol XP	104.7	106	730.9	728.5	354.7	357.5	0	141.3	1.9	159.4	161	163.9	178.9	642.1	Solid	Turbulent	C.S.	21847	31086	0	0
1	10	3	6	Therminol XP	106	107.3	728.5	726.1	357.5	360.3	0	141.3	1.9	159.8	161.4	164.3	179.3	647.1	Solid	Turbulent	C.S.	21674	30840	0	0
1	11	3	6	Therminol XP	107.3	108.5	726.1	723.7	360.3	363.1	0	141.3	1.9	160.3	161.9	164.7	179.7	652.3	Solid	Turbulent	C.S.	21501	30594	0	0
1	12	3	6	Therminol XP	108.5	109.8	723.7	721.3	363.1	365.9	0	141.3	1.9	160.7	162.3	165.1	180.1	657.5	Solid	Turbulent	C.S.	21328	30348	0	0
1	13	2	5	Therminol XP	109.6	111.2	721.3	718.9	365.6	369.1	0	141.3	1.9	173.4	175.4	178.9	193.9	677.7	Solid	Turbulent	C.S.	26882	38234	0	0
1	14	2	5	Therminol XP	111.2	112.7	718.9	716.5	369.1	372.5	0	141.3	1.9	173.9	175.9	179.4	194.4	684.5	Solid	Turbulent	C.S.	26715	37995	0	0
1	15	2	5	Therminol XP	112.7	114.3	716.5	714.1	372.5	376	0	141.3	1.9	174.5	176.4	180	195	691.6	Solid	Turbulent	C.S.	26547	37757	0	0
1	16	2	5	Therminol XP	114.3	115.9	714.1	711.7	376	379.4	0	141.3	1.9	175	177	180.5	195.5	698.7	Solid	Turbulent	C.S.	26379	37518	0	0
1	17	2	4	Therminol XP	116.1	118.6	711.7	709.3	379.9	385.5	0	141.3	1.9	210.3	213.6	219.5	234.5	744.4	Solid	Turbulent	C.S.	43558	61981	0	0
1	18	2	4	Therminol XP	118.6	121.1	709.3	706.9	385.5	391.1	0	141.3	1.9	210.7	214	219.8	234.8	756.5	Solid	Turbulent	C.S.	43261	61558	0	0
1	19	2	4	Therminol XP	121.1	123.6	706.9	704.5	391.1	396.7	0	141.3	1.9	211.2	214.5	220.2	235.2	769	Solid	Turbulent	C.S.	42964	61136	0	0
1	20	2	4	Therminol XP	123.6	126.1	704.5	702.1	396.7	402.3	0	141.3	1.9	211.7	214.9	220.6	235.6	782	Solid	Turbulent	C.S.	42667	60713	0	0
1	21	1	3	Therminol XP	126	126.9	702.1	699.7	402.1	404	0	141.3	1.9	164.9	166.3	168.6	183.6	736.6	None	Turbulent	C.S.	14547	25411	0	0
1	22	1	3	Therminol XP	126.9	127.7	699.7	697.3	404	405.8	0	141.3	1.9	165.4	166.9	169.1	184.1	741.4	None	Turbulent	C.S.	14522	25367	0	0
1	23	1	3	Therminol XP	127.7	128.6	697.3	694.9	405.8	407.7	0	141.3	1.9	166	167.4	169.7	184.7	746.3	None	Turbulent	C.S.	14497	25323	0	0
1	24	1	3	Therminol XP	128.6	129.4	694.9	692.5	407.7	409.6	0	141.3	1.9	166.5	167.9	170.2	185.2	751.3	None	Turbulent	C.S.	14472	25280	0	0
1	25	1	2	Therminol XP	129.9	130.9	692.5	690.1	410.7	413	0	141.3	1.9	175.1	176.8	179.6	194.6	770.9	None	Turbulent	C.S.	17676	30876	0	0
1	26	1	2	Therminol XP	130.9	132	690.1	687.7	413	415.3	0	141.3	1.9	175.7	177.4	180.2	195.2	777.3	None	Turbulent	C.S.	17644	30820	0	0
1	27	1	2	Therminol XP	132	133	687.7	685.3	415.3	417.6	0	141.3	1.9	176.3	178	180.8	195.8	783.8	None	Turbulent	C.S.	17612	30764	0	0
1	28	1	2	Therminol XP	133	134	685.3	682.9	417.6	419.8	0	141.3	1.9	176.9	178.6	181.3	196.3	790.4	None	Turbulent	C.S.	17579	30707	0	0
1	29	1	1	Therminol XP	133.5	134.8	682.9	680.5	418.6	421.5	0	141.3	1.9	188.6	190.9	194.4	209.4	808.6	None	Turbulent	C.S.	22613	39500	0	0
1	30	1	1	Therminol XP	134.8	136.1	680.5	678.1	421.5	424.4	0	141.3	1.9	189.3	191.5	195	210	816.9	None	Turbulent	C.S.	22569	39424	0	0
1	31	1	1	Therminol XP	136.1	137.3	678.1	675.7	424.4	427.4	0	141.3	1.9	189.9	192.1	195.7	210.7	825.4	None	Turbulent	C.S.	22526	39348	0	0
1	32	1	1	Therminol XP	137.3	138.6	675.7	673.3	427.4	430.3	0	141.3	1.9	190.6	192.8	196.3	211.3	834.2	None	Turbulent	C.S.	22482	39272	0	0

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	mm	141.3	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	259.3	196.3	220.6	165.1
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	274.3	211.3	235.6	180.1
Design Tube Pressure	kPa	2000		2000	2000
Design Code		API 530		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	m	10.084	5.835	5.835	5.835
Straight Length	m	9.685	6.235	6.235	6.235
No. Rows			3	2	3
Tube Spacing	mm	254	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1	220.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	232.77	62.13	325.88	801.84
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	mm			19.1	25.4
Fin Thickness	mm			1.3	1.3
Serrated Fin Wn
Fin Density	fins/m			157	197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000	2000	2000	2000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750	750	750	750
tblDesignTemp,calcref0	Design Temperature	°C	274.3071	211.3035	235.6328	180.1001
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	123795.5	131741.9	128673.4	135677.5
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1323	1.0645	1.0897	1.0338
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.13	4.06	4.09	4.03
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.72	4.65	4.67	4.61
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

HeaterSIM - Fired Heater Simulation Results

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	15
Stack Diameter	m	1.35
Cone Diameter	m	1.145
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	146.5
Flue Gas Flow	kg/s	4.489
Steel Area	m²	63.396
Stack Entry Pressure	mmH2O	0.015
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Draft at Stack Base	mmH2Og	-2.5
Draft at Arch	mmH2Og	-2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

HeaterSIM - Fired Heater Simulation Results

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	715	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	486.8	1400	V Y Anchors	71.9	Refrac. thickness OK
RADIANT WALL 1	512.2	Fibre (High Density)	75	0.1	None	0	0	732.8	391.8	1260	Twistlock Pins	59.8	Refrac. thickness OK
RADIANT ARCH 1	765	Fibre (High Density)	87.7	0.1	None	0	0	824	757.1	1260	Twistlock Pins	77.8	Refrac. thickness OK

CONVECTION SIDEWALL 1	455.8	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	439.9	1100	V Y Anchors	62.6	Refrac. thickness OK

STACK 1	146.5	LW Castable	50	0.2	None	0	0	732.8	322.4	1100	V Y Anchors	54.9	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	6.531
Flue Gas Temp.	°C	639.2
CO2	mol%	8.32
H2O	mol%	16.21
N2	mol%	72.6
O2	mol%	2.86
SO2	mol%	0

AIR
Air Flow	kg/s	5.524
Air Temp.	°C	15.5
Excess Air	%	15

FUEL
Fuel Flow	kg/s	0.325
Fuel LHV	kJ/kg	43123.5
Fuel Mol. Wt.		18.19

Radiant Cell		1
Arch Temp.	°C	696.6
Max Tube Temp.	°C	235.4
Average Flux	W/m²	22013
Arch Pressure	mmH2O	-2.497

No. of Burners		4
Floor Pressure	mmH2O	-9.623

ENERGY PERFORMACE
Total Absorbed Duty	MW	9.067
Total Heat Release	MW	13.998
Total Efficiency	%	64.774

ENVIRONMENTAL IMPACT
Energy Efficiency	%	64.774
Daily CO2 Emissions	kg	74248

Total:

£ 799,164

HR	MW	13.998
Arch	°C	696.6
Tube	°C	235.4
Flux	W/m²	22013

No. Burners		4
Fuel Flow	kg/s	0.325
Air Flow	kg/s	5.524
Air Temp.	°C	15.5
Excess Air	%	15

STACK
Flow	kg/s	6.531
Temp.	°C	639.2
CO2	mol%	8.32
H2O	mol%	16.21
N2	mol%	72.6
O2	mol%	2.86
SO2	mol%	0

Process Inlet------->

H2N2 , 50 °C, 10870 kPa a

Fuel m.w.		18.19
Fuel LHV	kJ/kg	43123.5

Process Outlet------->

H2N2 , 240.1 °C, 10786.586 kPa a, 9.067 MW

Firing MW
14
Duty MW
9.07
Efficiency %
64.77
CO2 Ton/day
74

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

HeaterSIM - Fired Heater Simulation Results

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Stack design seems OK

Radiant section 1,Coil sect. no. 1, does not satisfy API 530 requirements

Convection section 1,Coil sect. no. 1, does not satisfy API 530 requirements

Commercial

HeaterSIM - Fired Heater Simulation Results

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 615,360
Option items
Detail Engineering (by HeaterSIM)	£ 92,304
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£799,164

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

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STREAM NO.		1	2	3	4	5	6
Fluid Name		H2N2	H2N2	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	15.5	15.5	5.848	6.531	0.325	5.524
Flow (hr)	kg/hr	55800	55800	21054	23512	1169	19885
Temperature	°C	50	240.1	696.6	639.2	Note 1	15.5
Pressure	kPa a	10870	10786.586	-2.497	-28.195	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

54.76 m 19.76 m 17.96 m 16.8 m 9.8 m 2.8 m Grade 0.00 m 2.46 m 0 m 6 m 6.986 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1
Design Code		API 530
Orientation		Arbour Bend	Horizontal
Tube OD	mm	168.3	141.3
Tube Material		18Cr/8Ni - 304SS	Carbon Steel
Tube Wall Thk	mm	20	Sch 120
Tube Spacing	mm	304.8	254
Vert. Row Spacing (Vert)	mm	N/A	220.1
No. Tubes		72	24
Effective Length	m	10.82	0
Straight Length	m	10.5	0

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

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Process Name		H2N2
Heat Duty	MW	9.067
Flow rate (sec)	kg/s	15.5
Flow rate (hr)	kg/hr	55800
Pressure drop	kPa	83.414
Max. Film Temp. Calculated	°C	235.4
Max. Film Temp. Allowed	°C	250
Max Tube Average Flux Calculated (1)	W/m²	22013
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	50
Inlet Pressure	kPa a	10870
Inlet Vapour Fraction		1
Inlet Enthalpy	kJ/kg	164
OUTLET CONDITIONS
Outlet Temperature	°C	240.1
Outlet Pressure	kPa a	10786.586
Outlet Vapour Fraction		1
Outlet Enthalpy	kJ/kg	749

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type
Heat Duty	MW	9.067
Heat Release	MW	13.998
Arch Temp.	°C	696.6
Max Tube Temp.	°C	235.4
Tube Cirle Diameter	m	6.986
Average Flux	W/m²	22013
Maximum Flux	W/m²	41500
Flue Flow	kg/s	5.848
Air Flow	kg/s	5.524
Fuel Flow	kg/s	0.325
Excess Air	%	15
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-2.497
Floor Pressure	mmH2O	-9.623
Radiant Height	m	14
Radiant Width	m	6
Radiant Length	m	6
No. of Burners		4
Draft Type		Natural
Burner Cirle Diameter	m	1.209
Burner Design Firing	MW	4.2
Burner Normal Firing	MW	3.5
Burner Min Firing	MW	0.84
Burner-to-Tube Note		OK
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API Burner-to-Tube Dist.	m	1.54
API Burner-to-Wall Dist.	m	1.404
API Burner-to-Roof/Roof Dist	m	10.101
Floor Flux	W/m²	495343

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type
No. of Burners		4
Flue Flow	kg/s	5.848
Air Flow	kg/s	5.524
Fuel Flow	kg/s	0.325
Fuel LHV	kJ/kg	43123.5
Excess Air	%	15
Air Temp.	°C	15.5
CO2	mol%	8.58
H2O	mol%	16.37
N2	mol%	72.53
O2	mol%	2.52
SO2	mol%	0
Dew Point	°C	57
Fuel Mol. Wt.		18.19
Flue Mol. Wt.		27.837
Flame Temperature	°C	1857.7
Flue Gas Emissivity		0.494

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

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Convection Sect. No.		1
Heat Duty	MW	0.201
Max Tube Temp.	°C	101.5
Total Flue Press. Loss (ex. gain)	mmH2O	0.02
Total Press. Gain	mmH2O	1.85
Total Press. Loss (inc. gain)	mmH2O	-1.84
Convection Width	m	0
Effective Length	m	0
Convection Height	m	0.66
Total No. Rows		3
FLUE GAS DATA
Flue Gas Flow	kg/s	0.683
Flue Gas Inlet Temp.	°C	330.8
Flue Gas Outlet Temp.	°C	100.4
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	3	Coil Section 1	0	0	0	0	0	0.71	Solid	1393	2432	8	0.13	0.001	C.S.	C.S.	0	0
1	2	Coil Section 1	0	0	0	0	0	0.66	Solid	2046	3574	8	0.13	0.001	C.S.	C.S.	0	0
1	1	Coil Section 1	0	0	0	0	0	0.59	Solid	3167	5532	8	0.13	0.001	C.S.	C.S.	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	3	Coil Section 1	0	0	0	H2N2	1	100.9	101.2	700	690	0	0	1.9	1.9	0	0	1588	1588	59142	59422
1	2	Coil Section 1	0	0	0	H2N2	2	101.2	101.6	690	680	0	0	1.9	1.9	0	0	1588	1588	59425	59827
1	1	Coil Section 1	0	0	0	H2N2	3	101.6	102.2	680	670	0	0	1.9	1.9	0	0	1588	1588	59827	60425

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	3	Coil Section 1	0	0	0	H2N2	1	100.9	101.2	700	690	0	0	1.9	1.9	0	0	1588	1588	59142	59422
1	2	Coil Section 1	0	0	0	H2N2	2	101.2	101.6	690	680	0	0	1.9	1.9	0	0	1588	1588	59425	59827
1	1	Coil Section 1	0	0	0	H2N2	3	101.6	102.2	680	670	0	0	1.9	1.9	0	0	1588	1588	59827	60425

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	H2N2	50	78.4	10870	10867.6	164.5	197	1	168.3	4.9	64.2	64.2	64.2	79.2	2			22013	41594	0	0
2	Wall	H2N2	78.4	87.9	10867.6	10864.9	197	229.5	1	168.3	5.1	83.2	83.2	83.2	98.2	2.6			22013	41555	0	0
3	Wall	H2N2	87.9	97.4	10864.9	10862.1	229.5	262	1	168.3	5.3	92.7	92.7	92.7	107.7	2.9			22013	41562	0	0
4	Wall	H2N2	97.4	106.9	10862.1	10859.1	262	294.5	1	168.3	5.6	102.2	102.2	102.2	117.2	3.1			22013	41568	0	0
5	Wall	H2N2	106.9	116.5	10859.1	10856	294.5	327	1	168.3	5.9	111.7	111.7	111.7	126.7	3.4			22013	41576	0	0
6	Wall	H2N2	116.5	126	10856	10852.8	327	359.5	1	168.3	6.2	121.2	121.2	121.2	136.2	3.7			22013	41584	0	0
7	Wall	H2N2	126	135.5	10852.8	10849.3	359.5	392	1	168.3	6.6	130.7	130.7	130.7	145.7	4.1			22013	41593	0	0
8	Wall	H2N2	135.5	145	10849.3	10845.6	392	424.5	1	168.3	6.9	140.2	140.2	140.2	155.2	4.4			22013	41603	0	0
9	Wall	H2N2	145	154.5	10845.6	10841.7	424.5	457	1	168.3	7.4	149.8	149.8	149.8	164.8	4.8			22013	41613	0	0
10	Wall	H2N2	154.5	164	10841.7	10837.5	457	489.5	1	168.3	7.9	159.3	159.3	159.3	174.3	5.1			22013	41623	0	0
11	Wall	H2N2	164	173.5	10837.5	10833	489.5	522	1	168.3	8.5	168.8	168.8	168.8	183.8	5.5			22013	41633	0	0
12	Wall	H2N2	173.5	183.1	10833	10828.1	522	554.5	1	168.3	9.2	178.3	178.3	178.3	193.3	5.8			22013	41643	0	0
13	Wall	H2N2	183.1	192.6	10828.1	10822.8	554.5	587	1	168.3	10	187.8	187.8	187.8	202.8	6.2	Laminar		22013	41654	0	0
14	Wall	H2N2	192.6	202.1	10822.8	10817	587	619.5	1	168.3	10.9	197.3	197.3	197.3	212.3	6.5	Laminar		22013	41665	0	0
15	Wall	H2N2	202.1	211.6	10817	10810.7	619.5	652	1	168.3	12.1	206.9	206.9	206.9	221.9	6.9	Laminar		22013	41676	0	0
16	Wall	H2N2	211.6	221.1	10810.7	10803.5	652	684.5	1	168.3	13.4	216.4	216.4	216.4	231.4	7.3	Laminar		22013	41687	0	0
17	Wall	H2N2	221.1	230.6	10803.5	10795.6	684.5	717	1	168.3	15	225.9	225.9	225.9	240.9	7.6	Laminar		22013	41698	0	0
18	Wall	H2N2	230.6	240.1	10795.6	10786.6	717	749.5	1	168.3	17	235.4	235.4	235.4	250.4	8	Laminar		22013	41709	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	1	3	H2N2	100	100	750	747.5	344.2	344.2	0	141.3	1.9	100.2	100.2	100.2	115.2	557.5	Solid	Turbulent	C.S.	60	89	0	0
1	2	1	3	H2N2	100	100	747.5	745	344.2	344.2	0	141.3	1.9	100.2	100.2	100.2	115.2	557.5	Solid	Turbulent	C.S.	59	89	0	0
1	3	1	3	H2N2	100	100	745	742.5	344.2	344.2	0	141.3	1.9	100.2	100.2	100.2	115.2	557.5	Solid	Turbulent	C.S.	59	89	0	0
1	4	1	3	H2N2	100	100	742.5	740	344.2	344.2	0	141.3	1.9	100.2	100.2	100.2	115.2	557.5	Solid	Turbulent	C.S.	59	88	0	0
1	5	1	2	H2N2	100	100	740	737.5	344.2	344.2	0	141.3	1.9	100.5	100.5	100.5	115.5	558	Solid	Turbulent	C.S.	161	244	0	0
1	6	1	2	H2N2	100	100	737.5	735	344.2	344.2	0	141.3	1.9	100.5	100.5	100.5	115.5	558	Solid	Turbulent	C.S.	161	242	0	0
1	7	1	2	H2N2	100	100	735	732.5	344.2	344.3	0	141.3	1.9	100.5	100.5	100.6	115.6	558	Solid	Turbulent	C.S.	160	241	0	0
1	8	1	2	H2N2	100	100.1	732.5	729.9	344.3	344.3	0	141.3	1.9	100.5	100.5	100.6	115.6	558.1	Solid	Turbulent	C.S.	159	240	0	0
1	9	1	1	H2N2	100.1	100.1	729.9	727.4	344.3	344.3	0	141.3	1.9	101.3	101.4	101.4	116.4	559.1	Solid	Turbulent	C.S.	424	646	0	0
1	10	1	1	H2N2	100.1	100.1	727.4	724.9	344.3	344.4	0	141.3	1.9	101.4	101.4	101.5	116.5	559.2	Solid	Turbulent	C.S.	422	644	0	0
1	11	1	1	H2N2	100.1	100.1	724.9	722.4	344.4	344.4	0	141.3	1.9	101.4	101.4	101.5	116.5	559.3	Solid	Turbulent	C.S.	420	641	0	0
1	12	1	1	H2N2	100.1	100.1	722.4	719.9	344.4	344.5	0	141.3	1.9	101.4	101.4	101.5	116.5	559.4	Solid	Turbulent	C.S.	418	638	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1
Process Name		Process 1: H2N2	Process 1: H2N2
Tube OD	mm	168.3	141.3
Tube Material		18Cr/8Ni - 304SS	Carbon Steel
Tube Wall Thk	mm	20	Sch 120
Max Tube Temperature	°C	23577.2	112.2
Tube Temperature Margin	°C	15	15
Design Tube Temperature	°C	23592.2	127.2
Design Tube Pressure	kPa	23000
Design Code		API 530
Tube Thk. Comment		Tube Thk. Too Low (API 530)	Tube Thk. Too Low (API 530)
No. Tubes		72	24
No. Tubes Per Row			8
No. Passes		4	2
Effective Length	m	10.82	0
Straight Length	m	10.5	0
No. Rows			3
Tube Spacing	mm	304.8	254
Vert. Row Spacing (Vert)	mm	N/A	220.1
Coil Alignment			Staggered
Orientation		Arbour Bend	Horizontal
Tube Area	m²	411.9	62.13
Intermediate Supports		1 / 2	-1 / -1
Corbel Width	m		1/2 Tube Space
Fin Type			Solid
Fin Material			Carbon Steel
Fin Height	mm		25.4
Fin Thickness	mm		1.3
Serrated Fin Wn
Fin Density	fins/m		197

Radiant section 1,Coil sect. no. 1, does not satisfy API 530 requirements

Convection section 1,Coil sect. no. 1, does not satisfy API 530 requirements

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1
tblDesignPress,calcref0	Design Pressure	kPa g	23000	23000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	10870	10870
tblDesignTemp,calcref0	Design Temperature	°C	23592.16	127.2213
tblTubeMaterial	Tube Material		18Cr/8Ni - 304SS	Carbon Steel
tblTubeOD	Tube Outside Diameter		168.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	20	12.7
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	0	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	20	12.7
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	0	142346.9
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	168.3	10.5621
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	168.3	13.56
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	192.34	15.5
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Not sufficient	Not sufficient
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0
RuptureNfactor,resultref0	Rupture n factor		0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0
RuptureBfactor,resultref0	B factor		0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	35
Stack Diameter	m	2.46
Cone Diameter	m	1.3
Cone Height	m	0.5
Actual Exit Velocity	m/s	15.6
Design Exit Velocity	m/s	1.6
Flue Gas Temp.	°C	639.2
Flue Gas Flow	kg/s	6.531
Steel Area	m²	270.491
Stack Entry Pressure	mmH2O	-28.195
CO2	mol%	8.32
H2O	mol%	16.21
N2	mol%	72.6
O2	mol%	2.86
SO2	mol%	0

Draft at Stack Base	mmH2Og	2.5
Draft at Arch	mmH2Og	2.5
Draft at Floor	mmH2Og	0

Stack No. 1: Stack design seems OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	646.6	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	426	1400	V Y Anchors	67.1	Refrac. thickness OK
RADIANT WALL 1	466	Fibre (High Density)	75	0.1	None	0	0	732.8	324.9	1260	Twistlock Pins	54.9	Refrac. thickness OK
RADIANT ARCH 1	696.6	Fibre (High Density)	87.7	0.1	None	0	0	824	623	1260	Twistlock Pins	70.2	Refrac. thickness OK


STACK 1	639.2	LW Castable	227.8	0.3	None	0	0	732.8	701.6	1100	V Y Anchors	79.2	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	3.13
Flue Gas Temp.	°C	156.2
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0

AIR
Air Flow	kg/s	2.969
Air Temp.	°C	47
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.161
Fuel LHV	kJ/kg	44896.5
Fuel Mol. Wt.		18.65

Radiant Cell		1
Arch Temp.	°C	757.1
Max Tube Temp.	°C	255.1
Average Flux	W/m²	27720
Arch Pressure	mmH2O	-2.519

No. of Burners		3
Floor Pressure	mmH2O	-8.525

ENERGY PERFORMACE
Total Absorbed Duty	MW	6.648
Total Heat Release	MW	7.217
Total Efficiency	%	92.118

ENVIRONMENTAL IMPACT
Energy Efficiency	%	92.118
Daily CO2 Emissions	kg	35581

Total:

£ 873,559

HR	MW	7.217
Arch	°C	757.1
Tube	°C	255.1
Flux	W/m²	27720

No. Burners	m	3
Fuel Flow	kg/s	0.161
Air Flow	kg/s	2.969
Air Temp.	°C	47
Excess Air	%	20

STACK
Flow	kg/s	3.13
Temp.	°C	156.2
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0

Process Inlet------->

TORADA TC , 145 °C, 987.3 kPa a

Fuel m.w.		18.65
Fuel LHV	kJ/kg	44896.5

Process Outlet------->

TORADA TC , 177.1 °C, 955.269 kPa a, 6.648 MW

Firing MW
7.22
Duty MW
6.65
Efficiency %
92.12
CO2 Ton/day
36

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 680,051
Option items
Detail Engineering (by HeaterSIM)	£ 102,008
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£873,559

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		TORADA TC	TORADA TC	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	94.17	94.17	3.13	3.13	0.161	2.969
Flow (hr)	kg/hr	339012	339012	11267	11267	579	10688
Temperature	°C	145	177.1	757.1	156.2	Note 1	47
Pressure	kPa a	987.3	955.269	-2.519	1.218	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

47.67 m 44.67 m 17.67 m 15.87 m 10.8 m 6.8 m 2.8 m Grade 0.00 m 1.85 m 5.835 m 4.75 m 4.14 m 3 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530	API 530
Orientation		Vertical	Horizontal	Horizontal
Tube OD	mm	219.1	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	406.4	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1
No. Tubes		32	32	48
Effective Length	m	7	5.835	5.835
Straight Length	m	6.723	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		TORADA TC
Heat Duty	MW	6.648
Flow rate (sec)	kg/s	94.17
Flow rate (hr)	kg/hr	339012
Pressure drop	kPa	32.031
Max. Film Temp. Calculated	°C	247.3
Max. Film Temp. Allowed	°C	240
Max Tube Average Flux Calculated (1)	W/m²	25648
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	145
Inlet Pressure	kPa a	987.3
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	108
OUTLET CONDITIONS
Outlet Temperature	°C	177.1
Outlet Pressure	kPa a	955.269
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	179

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type		Vertical Cylindrical
Heat Duty	MW	4.274
Heat Release	MW	7.217
Arch Temp.	°C	757.1
Max Tube Temp.	°C	255.1
Tube Cirle Diameter	m	4.14
Average Flux	W/m²	27720
Maximum Flux	W/m²	44702
Flue Flow	kg/s	3.13
Air Flow	kg/s	2.969
Fuel Flow	kg/s	0.161
Excess Air	%	20
Air Temp.	°C	47
Arch Pressure	mmH2O	-2.519
Floor Pressure	mmH2O	-8.525
DIMENSIONS
Radiant Height	m	8
Radiant Width	m	4.75
Radiant Length	m	4.75
No. of Burners		3
Draft Type		Natural
BURNERS
Burner Cirle Diameter	m	0.987
Burner Design Firing	MW	2.89
Burner Normal Firing	MW	2.41
Burner Min Firing	MW	0.58
Burner-to-Tube Note		OK
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API 560 COMPLIANCE
API Burner-to-Tube Dist.	m	1.177
API Burner-to-Wall Dist.	m	1.06
API Burner-to-Roof/Roof Dist	m	7.437
Floor Flux	W/m²	407448

Flame-tube impingment risk not identified

Combustion

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Radiant Cell		1
Radiant Type
AIR & FUEL
Flue Flow	kg/s	3.13
Air Flow	kg/s	2.969
Fuel Flow	kg/s	0.161
Fuel LHV	kJ/kg	44896.5
Excess Air	%	20
Air Temp.	°C	47
BURNERS
No. of Burners	m	3
Burner Cirle Diameter	m
Burner Design Firing	MW	2.89
Burner Normal Firing	MW	2.41
Burner Min Firing	MW	0.58
Flame Temperature	°C	1807.7
EMISSIONS
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		18.65
Flue Mol. Wt.		27.907
Flue Gas Emissivity		0.443

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MW	2.374
Max Tube Temp.	°C	202.7
DIMENSIONS
Convection Width	m	2.591
Effective Length	m	5.835
Convection Height	m	4.57
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH2O	0.23
Total Press. Gain	mmH2O	2.83
Total Press. Loss (inc. gain)	mmH2O	-2.6
Total No. Rows		10
FLUE GAS DATA
Flue Gas Flow	kg/s	3.13
Flue Gas Inlet Temp.	°C	757.1
Flue Gas Outlet Temp.	°C	156.2
CO2	mol%	8.346025
H2O	mol%	15.56667
N2	mol%	72.86749
O2	mol%	3.219826
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	10	Coil Section 2	0.03	164.7	156.2	164.3	154.8	0.78	Solid	1204	1568	8	0.532	0.024	C.S.	C.S.	151.1	153.4
1	9	Coil Section 2	0.05	178.7	164.7	179.9	164.3	0.76	Solid	1973	2575	8	0.532	0.025	C.S.	C.S.	155	157.7
1	8	Coil Section 2	0.09	203.2	178.7	208	179.9	0.73	Solid	3571	4666	8	0.532	0.026	C.S.	C.S.	160.4	165.3
1	7	Coil Section 2	0.16	247.3	203.2	258.7	208	0.68	Solid	6441	8418	8	0.532	0.027	C.S.	C.S.	170	178.8
1	6	Coil Section 2	0.29	327.6	247.3	352.3	258.7	0.61	Solid	11880	15475	8	0.532	0.03	C.S.	C.S.	187.4	203.3
1	5	Coil Section 2	0.57	478.6	327.6	533.1	352.3	0.51	Solid	22973	29663	8	0.532	0.035	C.S.	C.S.	219.6	249.3
1	4	Coil Section 1	0.19	526.4	478.6	592.3	533.1	0.44	None	7510	14298	8	0.491	0.014	C.S.	None	0	0
1	3	Coil Section 1	0.24	584.7	526.4	665.7	592.3	0.41	None	10134	17570	8	0.491	0.015	C.S.	None	0	0
1	2	Coil Section 1	0.32	658.4	584.7	758.9	665.7	0.38	None	13851	24014	8	0.491	0.016	C.S.	None	0	0
1	1	Coil Section 1	0.45	757.1	658.4	880.8	758.9	0.35	None	20759	35993	8	0.491	0.018	C.S.	None	0	0

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	10	Coil Section 2	0.03	164.7	156.2	TORADA TC	1	145	148.5	987	984	0	0	1.6	1.6	0	0	1263	1263	144106	151127
1	9	Coil Section 2	0.05	178.7	164.7	TORADA TC	2	148.5	148.7	984	982	0	0	1.6	1.6	0	0	1263	1263	151128	151653
1	8	Coil Section 2	0.09	203.2	178.7	TORADA TC	3	148.7	149	982	979	0	0	1.6	1.6	0	0	1263	1263	151654	152611
1	7	Coil Section 2	0.16	247.3	203.2	TORADA TC	4	149	149.7	979	976	0	0	1.6	1.6	0	0	1263	1263	152614	154365
1	6	Coil Section 2	0.29	327.6	247.3	TORADA TC	5	149.7	151	976	973	0	0	1.6	1.6	0	0	1263	1263	154370	157686
1	5	Coil Section 2	0.57	478.6	327.6	TORADA TC	6	151	153.4	973	970	0	0	1.6	1.6	0	0	1263	1263	157691	163805
1	4	Coil Section 1	0.19	526.4	478.6	TORADA TC	7	153.5	154.3	970	967	0	0	1.6	1.6	0	0	1263	1263	163822	165825
1	3	Coil Section 1	0.24	584.7	526.4	TORADA TC	8	154.3	155.3	967	964	0	0	1.6	1.6	0	0	1263	1263	165836	168639
1	2	Coil Section 1	0.32	658.4	584.7	TORADA TC	9	155.3	156.7	964	961	0	0	1.6	1.7	0	0	1263	1263	168687	173010
1	1	Coil Section 1	0.45	757.1	658.4	TORADA TC	10	156.7	158.6	961	958	0	0	1.7	1.7	0	0	1263	1263	173061	179362

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	10	Coil Section 2	0.03	164.7	156.2	TORADA TC	1	145	148.5	987	984	0	0	1.6	1.6	0	0	1263	1263	144106	151127
1	9	Coil Section 2	0.05	178.7	164.7	TORADA TC	2	148.5	148.7	984	982	0	0	1.6	1.6	0	0	1263	1263	151128	151653
1	8	Coil Section 2	0.09	203.2	178.7	TORADA TC	3	148.7	149	982	979	0	0	1.6	1.6	0	0	1263	1263	151654	152611
1	7	Coil Section 2	0.16	247.3	203.2	TORADA TC	4	149	149.7	979	976	0	0	1.6	1.6	0	0	1263	1263	152614	154365
1	6	Coil Section 2	0.29	327.6	247.3	TORADA TC	5	149.7	151	976	973	0	0	1.6	1.6	0	0	1263	1263	154370	157686
1	5	Coil Section 2	0.57	478.6	327.6	TORADA TC	6	151	153.4	973	970	0	0	1.6	1.6	0	0	1263	1263	157691	163805
1	4	Coil Section 1	0.19	526.4	478.6	TORADA TC	7	153.5	154.3	970	967	0	0	1.6	1.6	0	0	1263	1263	163822	165825
1	3	Coil Section 1	0.24	584.7	526.4	TORADA TC	8	154.3	155.3	967	964	0	0	1.6	1.6	0	0	1263	1263	165836	168639
1	2	Coil Section 1	0.32	658.4	584.7	TORADA TC	9	155.3	156.7	964	961	0	0	1.6	1.7	0	0	1263	1263	168687	173010
1	1	Coil Section 1	0.45	757.1	658.4	TORADA TC	10	156.7	158.6	961	958	0	0	1.7	1.7	0	0	1263	1263	173061	179362

Radiant Tube Profile

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	TORADA TC	158.6	160.9	958.3	1010.2	133.5	139.2	0	219.1	1	239.3	242	247	262	580.3	Turbulent		25648	42023	0	0
2	Wall	TORADA TC	160.9	163.2	1010.2	957.6	139.2	144.9	0	219.1	1	240.6	243.4	248.4	263.4	586.6	Turbulent		25620	41984	0	0
3	Wall	TORADA TC	163.2	165.5	957.6	1009.2	144.9	150.5	0	219.1	1	241.6	244.3	249.3	264.3	596.7	Turbulent		25601	41958	0	0
4	Wall	TORADA TC	165.5	167.8	1009.2	956.8	150.5	156.2	0	219.1	1	242.8	245.6	250.6	265.6	604.5	Turbulent		25576	41923	0	0
5	Wall	TORADA TC	167.8	170.1	956.8	1008.2	156.2	161.9	0	219.1	1	244	246.8	251.8	266.8	612.9	Turbulent		25552	41889	0	0
6	Wall	TORADA TC	170.1	172.4	1008.2	956	161.9	167.6	0	219.1	1	244.9	247.6	252.6	267.6	625	Turbulent		25535	41865	0	0
7	Wall	TORADA TC	172.4	174.8	956	1007.3	167.6	173.2	0	219.1	1	246.1	248.8	253.8	268.8	634.2	Turbulent		25511	41831	0	0
8	Wall	TORADA TC	174.8	177.1	1007.3	955.3	173.2	178.9	0	219.1	1	247.3	250	255.1	270.1	643.4	Turbulent		25485	41795	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	2	10	TORADA TC	145	146.7	987.3	985.9	108.2	108.4	0	168.3	1.6	149.6	148.9	149.9	164.9	696.8	Solid	Turbulent	C.S.	1239	1826	0	0
1	2	2	10	TORADA TC	146.7	148.5	985.9	984.4	108.4	108.5	0	168.3	1.6	150.9	150.2	151.2	166.2	705	Solid	Turbulent	C.S.	1077	1587	0	0
1	3	2	9	TORADA TC	148.5	148.6	984.4	983	108.5	108.8	0	168.3	1.6	153	153.2	153.5	168.5	711.7	Solid	Turbulent	C.S.	1975	2913	0	0
1	4	2	9	TORADA TC	148.6	148.7	983	981.5	108.8	109	0	168.3	1.6	153.1	153.3	153.6	168.6	712.3	Solid	Turbulent	C.S.	1965	2899	0	0
1	5	2	8	TORADA TC	148.7	148.9	981.5	980.1	109	109.5	0	168.3	1.6	156.9	157.2	157.7	172.7	719.3	Solid	Turbulent	C.S.	3574	5277	0	0
1	6	2	8	TORADA TC	148.9	149	980.1	978.6	109.5	110	0	168.3	1.6	157	157.3	157.8	172.8	720.3	Solid	Turbulent	C.S.	3557	5252	0	0
1	7	2	7	TORADA TC	149	149.4	978.6	977.2	110	110.8	0	168.3	1.6	163.6	164.1	165.1	180.1	733.9	Solid	Turbulent	C.S.	6447	9520	0	0
1	8	2	7	TORADA TC	149.4	149.7	977.2	975.7	110.8	111.7	0	168.3	1.6	163.8	164.4	165.3	180.3	735.9	Solid	Turbulent	C.S.	6417	9474	0	0
1	9	2	6	TORADA TC	149.7	150.4	975.7	974.3	111.7	113.2	0	168.3	1.6	175.4	176.5	178.2	193.2	764.9	Solid	Turbulent	C.S.	11892	17520	0	0
1	10	2	6	TORADA TC	150.4	151	974.3	972.8	113.2	114.8	0	168.3	1.6	175.8	176.8	178.5	193.5	768.8	Solid	Turbulent	C.S.	11834	17434	0	0
1	11	2	5	TORADA TC	151	152.2	972.8	971.4	114.8	117.8	0	168.3	1.6	196.1	198.1	201.4	216.4	839.9	Solid	Turbulent	C.S.	22996	33681	0	0
1	12	2	5	TORADA TC	152.2	153.4	971.4	969.9	117.8	120.8	0	168.3	1.6	196.7	198.7	202	217	846.6	Solid	Turbulent	C.S.	22877	33506	0	0
1	13	1	4	TORADA TC	153.5	153.9	969.9	968.5	120.8	121.8	0	168.3	1.6	174	175	176.3	191.3	774.5	None	Turbulent	C.S.	7514	14305	0	0
1	14	1	4	TORADA TC	153.9	154.3	968.5	967	121.8	122.8	0	168.3	1.6	174.4	175.3	176.6	191.6	776.5	None	Turbulent	C.S.	7506	14289	0	0
1	15	1	3	TORADA TC	154.3	154.8	967	965.6	122.8	124.1	0	168.3	1.6	178.2	179.3	180.8	195.8	787.7	None	Turbulent	C.S.	9732	16873	0	0
1	16	1	3	TORADA TC	154.8	155.3	965.6	964.1	124.1	125.3	0	168.3	1.6	178.6	179.7	181.2	196.2	790.4	None	Turbulent	C.S.	9720	16852	0	0
1	17	1	2	TORADA TC	155.3	156	964.1	962.7	125.4	127.1	0	168.3	1.6	185.8	187.2	189.3	204.3	815	None	Turbulent	C.S.	12841	22264	0	0
1	18	1	2	TORADA TC	156	156.7	962.7	961.2	127.1	128.7	0	168.3	1.7	186.3	187.7	189.8	204.8	820.2	None	Turbulent	C.S.	12824	22234	0	0
1	19	1	1	TORADA TC	156.7	157.7	961.2	959.8	128.8	131.2	0	168.3	1.7	197.2	199.2	202.2	217.2	868.1	None	Turbulent	C.S.	18127	31428	0	0
1	20	1	1	TORADA TC	157.7	158.6	959.8	958.3	131.2	133.5	0	168.3	1.7	197.7	199.8	202.7	217.7	876.3	None	Turbulent	C.S.	18100	31381	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2
Process Name		Process 1: TORADA TC	Process 1: TORADA TC	Process 1: TORADA TC
Tube OD	mm	219.1	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	255.1	202.7	202
Tube Temperature Margin	°C	15	15	15
Design Tube Temperature	°C	270.1	217.7	217
Design Tube Pressure	kPa	2000	2000	2000
Design Code		API 530	API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		32	32	48
No. Tubes Per Row			8	8
No. Passes		4	4	4
Effective Length	m	7	5.835	5.835
Straight Length	m	6.723	6.235	6.235
No. Rows			4	6
Tube Spacing	mm	406.4	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1
Coil Alignment			Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal
Tube Area	m²	154.18	98.67	1516.54
Intermediate Supports		0 / 0	0 / 1	0 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid
Fin Material			None	Carbon Steel
Fin Height	mm			25.4
Fin Thickness	mm			1.3
Serrated Fin Wn
Fin Density	fins/m			157

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2
tblDesignPress,calcref0	Design Pressure	kPa g	2000	2000	2000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	987.3	987.3	987.3
tblDesignTemp,calcref0	Design Temperature	°C	270.0781	217.7247	217.0165
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		219.1	168.3	168.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	8.18	7.11	7.11
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	8.18	7.11	7.11
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	124328.9	130932	131021.4
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.7482	1.2757	1.2748
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.75	4.28	4.27
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	5.43	4.89	4.89
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	30
Stack Diameter	m	1.85
Cone Diameter	m	0.749
Cone Height	m	0.5
Actual Exit Velocity	m/s	12
Design Exit Velocity	m/s	14.4
Flue Gas Temp.	°C	156.2
Flue Gas Flow	kg/s	3.13
Steel Area	m²	174.285
Stack Entry Pressure	mmH2O	1.218
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	707.1	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	480	1400	V Y Anchors	71.2	Refrac. thickness OK
RADIANT WALL 1	506.1	Fibre (High Density)	75	0.1	None	0	0	732.8	382.3	1260	Twistlock Pins	59.1	Refrac. thickness OK
RADIANT ARCH 1	757.1	Fibre (High Density)	87.7	0.1	None	0	0	824	740.5	1260	Twistlock Pins	76.4	Refrac. thickness OK

CONVECTION SIDEWALL 1	456.6	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	440.9	1100	V Y Anchors	62.6	Refrac. thickness OK

STACK 1	156.2	LW Castable	50	0.3	None	0	0	732.8	372	1100	V Y Anchors	58.4	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	3.13
Flue Gas Temp.	°C	156.2
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0

AIR
Air Flow	kg/s	2.969
Air Temp.	°C	47
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.161
Fuel LHV	kJ/kg	44896.5
Fuel Mol. Wt.		18.65

Radiant Cell		1
Arch Temp.	°C	757.1
Max Tube Temp.	°C	255.1
Average Flux	W/m²	27720
Arch Pressure	mmH2O	-2.519

No. of Burners		3
Floor Pressure	mmH2O	-8.525

ENERGY PERFORMACE
Total Absorbed Duty	MW	6.648
Total Heat Release	MW	7.217
Total Efficiency	%	92.118

ENVIRONMENTAL IMPACT
Energy Efficiency	%	92.118
Daily CO2 Emissions	kg	35581

Total:

£ 873,559

HR	MW	7.217
Arch	°C	757.1
Tube	°C	255.1
Flux	W/m²	27720

No. Burners	m	3
Fuel Flow	kg/s	0.161
Air Flow	kg/s	2.969
Air Temp.	°C	47
Excess Air	%	20

STACK
Flow	kg/s	3.13
Temp.	°C	156.2
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0

Process Inlet------->

TORADA TC , 145 °C, 987.3 kPa a

Fuel m.w.		18.65
Fuel LHV	kJ/kg	44896.5

Process Outlet------->

TORADA TC , 177.1 °C, 955.269 kPa a, 6.648 MW

Firing MW
7.22
Duty MW
6.65
Efficiency %
92.12
CO2 Ton/day
36

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 680,051
Option items
Detail Engineering (by HeaterSIM)	£ 102,008
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£873,559

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		TORADA TC	TORADA TC	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	94.17	94.17	3.13	3.13	0.161	2.969
Flow (hr)	kg/hr	339012	339012	11267	11267	579	10688
Temperature	°C	145	177.1	757.1	156.2	Note 1	47
Pressure	kPa a	987.3	955.269	-2.519	1.218	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

47.67 m 44.67 m 17.67 m 15.87 m 10.8 m 6.8 m 2.8 m Grade 0.00 m 1.85 m 5.835 m 4.75 m 4.14 m 3 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530	API 530
Orientation		Vertical	Horizontal	Horizontal
Tube OD	mm	219.1	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	406.4	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1
No. Tubes		32	32	48
Effective Length	m	7	5.835	5.835
Straight Length	m	6.723	6.235	6.235

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Name		TORADA TC
Heat Duty	MW	6.648
Flow rate (sec)	kg/s	94.17
Flow rate (hr)	kg/hr	339012
Pressure drop	kPa	32.031
Max. Film Temp. Calculated	°C	247.3
Max. Film Temp. Allowed	°C	240
Max Tube Average Flux Calculated (1)	W/m²	25648
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	145
Inlet Pressure	kPa a	987.3
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	108
OUTLET CONDITIONS
Outlet Temperature	°C	177.1
Outlet Pressure	kPa a	955.269
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	179

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type		Vertical Cylindrical
Heat Duty	MW	4.274
Heat Release	MW	7.217
Arch Temp.	°C	757.1
Max Tube Temp.	°C	255.1
Tube Cirle Diameter	m	4.14
Average Flux	W/m²	27720
Maximum Flux	W/m²	44702
Flue Flow	kg/s	3.13
Air Flow	kg/s	2.969
Fuel Flow	kg/s	0.161
Excess Air	%	20
Air Temp.	°C	47
Arch Pressure	mmH2O	-2.519
Floor Pressure	mmH2O	-8.525
DIMENSIONS
Radiant Height	m	8
Radiant Width	m	4.75
Radiant Length	m	4.75
No. of Burners		3
Draft Type		Natural
BURNERS
Burner Cirle Diameter	m	0.987
Burner Design Firing	MW	2.89
Burner Normal Firing	MW	2.41
Burner Min Firing	MW	0.58
Burner-to-Tube Note		OK
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API 560 COMPLIANCE
API Burner-to-Tube Dist.	m	1.177
API Burner-to-Wall Dist.	m	1.06
API Burner-to-Roof/Roof Dist	m	7.437
Floor Flux	W/m²	407448

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type
AIR & FUEL
Flue Flow	kg/s	3.13
Air Flow	kg/s	2.969
Fuel Flow	kg/s	0.161
Fuel LHV	kJ/kg	44896.5
Excess Air	%	20
Air Temp.	°C	47
BURNERS
No. of Burners	m	3
Burner Cirle Diameter	m
Burner Design Firing	MW	2.89
Burner Normal Firing	MW	2.41
Burner Min Firing	MW	0.58
Flame Temperature	°C	1807.7
EMISSIONS
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		18.65
Flue Mol. Wt.		27.907
Flue Gas Emissivity		0.443

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MW	2.374
Max Tube Temp.	°C	202.7
DIMENSIONS
Convection Width	m	2.591
Effective Length	m	5.835
Convection Height	m	4.57
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH2O	0.23
Total Press. Gain	mmH2O	2.83
Total Press. Loss (inc. gain)	mmH2O	-2.6
Total No. Rows		10
FLUE GAS DATA
Flue Gas Flow	kg/s	3.13
Flue Gas Inlet Temp.	°C	757.1
Flue Gas Outlet Temp.	°C	156.2
CO2	mol%	8.346025
H2O	mol%	15.56667
N2	mol%	72.86749
O2	mol%	3.219826
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	10	Coil Section 2	0.03	164.7	156.2	164.3	154.8	0.78	Solid	1204	1568	8	0.532	0.024	C.S.	C.S.	151.1	153.4
1	9	Coil Section 2	0.05	178.7	164.7	179.9	164.3	0.76	Solid	1973	2575	8	0.532	0.025	C.S.	C.S.	155	157.7
1	8	Coil Section 2	0.09	203.2	178.7	208	179.9	0.73	Solid	3571	4666	8	0.532	0.026	C.S.	C.S.	160.4	165.3
1	7	Coil Section 2	0.16	247.3	203.2	258.7	208	0.68	Solid	6441	8418	8	0.532	0.027	C.S.	C.S.	170	178.8
1	6	Coil Section 2	0.29	327.6	247.3	352.3	258.7	0.61	Solid	11880	15475	8	0.532	0.03	C.S.	C.S.	187.4	203.3
1	5	Coil Section 2	0.57	478.6	327.6	533.1	352.3	0.51	Solid	22973	29663	8	0.532	0.035	C.S.	C.S.	219.6	249.3
1	4	Coil Section 1	0.19	526.4	478.6	592.3	533.1	0.44	None	7510	14298	8	0.491	0.014	C.S.	None	0	0
1	3	Coil Section 1	0.24	584.7	526.4	665.7	592.3	0.41	None	10134	17570	8	0.491	0.015	C.S.	None	0	0
1	2	Coil Section 1	0.32	658.4	584.7	758.9	665.7	0.38	None	13851	24014	8	0.491	0.016	C.S.	None	0	0
1	1	Coil Section 1	0.45	757.1	658.4	880.8	758.9	0.35	None	20759	35993	8	0.491	0.018	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	10	Coil Section 2	0.03	164.7	156.2	TORADA TC	1	145	148.5	987	984	0	0	1.6	1.6	0	0	1263	1263	144106	151127
1	9	Coil Section 2	0.05	178.7	164.7	TORADA TC	2	148.5	148.7	984	982	0	0	1.6	1.6	0	0	1263	1263	151128	151653
1	8	Coil Section 2	0.09	203.2	178.7	TORADA TC	3	148.7	149	982	979	0	0	1.6	1.6	0	0	1263	1263	151654	152611
1	7	Coil Section 2	0.16	247.3	203.2	TORADA TC	4	149	149.7	979	976	0	0	1.6	1.6	0	0	1263	1263	152614	154365
1	6	Coil Section 2	0.29	327.6	247.3	TORADA TC	5	149.7	151	976	973	0	0	1.6	1.6	0	0	1263	1263	154370	157686
1	5	Coil Section 2	0.57	478.6	327.6	TORADA TC	6	151	153.4	973	970	0	0	1.6	1.6	0	0	1263	1263	157691	163805
1	4	Coil Section 1	0.19	526.4	478.6	TORADA TC	7	153.5	154.3	970	967	0	0	1.6	1.6	0	0	1263	1263	163822	165825
1	3	Coil Section 1	0.24	584.7	526.4	TORADA TC	8	154.3	155.3	967	964	0	0	1.6	1.6	0	0	1263	1263	165836	168639
1	2	Coil Section 1	0.32	658.4	584.7	TORADA TC	9	155.3	156.7	964	961	0	0	1.6	1.7	0	0	1263	1263	168687	173010
1	1	Coil Section 1	0.45	757.1	658.4	TORADA TC	10	156.7	158.6	961	958	0	0	1.7	1.7	0	0	1263	1263	173061	179362

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	10	Coil Section 2	0.03	164.7	156.2	TORADA TC	1	145	148.5	987	984	0	0	1.6	1.6	0	0	1263	1263	144106	151127
1	9	Coil Section 2	0.05	178.7	164.7	TORADA TC	2	148.5	148.7	984	982	0	0	1.6	1.6	0	0	1263	1263	151128	151653
1	8	Coil Section 2	0.09	203.2	178.7	TORADA TC	3	148.7	149	982	979	0	0	1.6	1.6	0	0	1263	1263	151654	152611
1	7	Coil Section 2	0.16	247.3	203.2	TORADA TC	4	149	149.7	979	976	0	0	1.6	1.6	0	0	1263	1263	152614	154365
1	6	Coil Section 2	0.29	327.6	247.3	TORADA TC	5	149.7	151	976	973	0	0	1.6	1.6	0	0	1263	1263	154370	157686
1	5	Coil Section 2	0.57	478.6	327.6	TORADA TC	6	151	153.4	973	970	0	0	1.6	1.6	0	0	1263	1263	157691	163805
1	4	Coil Section 1	0.19	526.4	478.6	TORADA TC	7	153.5	154.3	970	967	0	0	1.6	1.6	0	0	1263	1263	163822	165825
1	3	Coil Section 1	0.24	584.7	526.4	TORADA TC	8	154.3	155.3	967	964	0	0	1.6	1.6	0	0	1263	1263	165836	168639
1	2	Coil Section 1	0.32	658.4	584.7	TORADA TC	9	155.3	156.7	964	961	0	0	1.6	1.7	0	0	1263	1263	168687	173010
1	1	Coil Section 1	0.45	757.1	658.4	TORADA TC	10	156.7	158.6	961	958	0	0	1.7	1.7	0	0	1263	1263	173061	179362

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	TORADA TC	158.6	160.9	958.3	1010.2	133.5	139.2	0	219.1	1	239.3	242	247	262	580.3	Turbulent		25648	42023	0	0
2	Wall	TORADA TC	160.9	163.2	1010.2	957.6	139.2	144.9	0	219.1	1	240.6	243.4	248.4	263.4	586.6	Turbulent		25620	41984	0	0
3	Wall	TORADA TC	163.2	165.5	957.6	1009.2	144.9	150.5	0	219.1	1	241.6	244.3	249.3	264.3	596.7	Turbulent		25601	41958	0	0
4	Wall	TORADA TC	165.5	167.8	1009.2	956.8	150.5	156.2	0	219.1	1	242.8	245.6	250.6	265.6	604.5	Turbulent		25576	41923	0	0
5	Wall	TORADA TC	167.8	170.1	956.8	1008.2	156.2	161.9	0	219.1	1	244	246.8	251.8	266.8	612.9	Turbulent		25552	41889	0	0
6	Wall	TORADA TC	170.1	172.4	1008.2	956	161.9	167.6	0	219.1	1	244.9	247.6	252.6	267.6	625	Turbulent		25535	41865	0	0
7	Wall	TORADA TC	172.4	174.8	956	1007.3	167.6	173.2	0	219.1	1	246.1	248.8	253.8	268.8	634.2	Turbulent		25511	41831	0	0
8	Wall	TORADA TC	174.8	177.1	1007.3	955.3	173.2	178.9	0	219.1	1	247.3	250	255.1	270.1	643.4	Turbulent		25485	41795	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	2	10	TORADA TC	145	146.7	987.3	985.9	108.2	108.4	0	168.3	1.6	149.6	148.9	149.9	164.9	696.8	Solid	Turbulent	C.S.	1239	1826	0	0
1	2	2	10	TORADA TC	146.7	148.5	985.9	984.4	108.4	108.5	0	168.3	1.6	150.9	150.2	151.2	166.2	705	Solid	Turbulent	C.S.	1077	1587	0	0
1	3	2	9	TORADA TC	148.5	148.6	984.4	983	108.5	108.8	0	168.3	1.6	153	153.2	153.5	168.5	711.7	Solid	Turbulent	C.S.	1975	2913	0	0
1	4	2	9	TORADA TC	148.6	148.7	983	981.5	108.8	109	0	168.3	1.6	153.1	153.3	153.6	168.6	712.3	Solid	Turbulent	C.S.	1965	2899	0	0
1	5	2	8	TORADA TC	148.7	148.9	981.5	980.1	109	109.5	0	168.3	1.6	156.9	157.2	157.7	172.7	719.3	Solid	Turbulent	C.S.	3574	5277	0	0
1	6	2	8	TORADA TC	148.9	149	980.1	978.6	109.5	110	0	168.3	1.6	157	157.3	157.8	172.8	720.3	Solid	Turbulent	C.S.	3557	5252	0	0
1	7	2	7	TORADA TC	149	149.4	978.6	977.2	110	110.8	0	168.3	1.6	163.6	164.1	165.1	180.1	733.9	Solid	Turbulent	C.S.	6447	9520	0	0
1	8	2	7	TORADA TC	149.4	149.7	977.2	975.7	110.8	111.7	0	168.3	1.6	163.8	164.4	165.3	180.3	735.9	Solid	Turbulent	C.S.	6417	9474	0	0
1	9	2	6	TORADA TC	149.7	150.4	975.7	974.3	111.7	113.2	0	168.3	1.6	175.4	176.5	178.2	193.2	764.9	Solid	Turbulent	C.S.	11892	17520	0	0
1	10	2	6	TORADA TC	150.4	151	974.3	972.8	113.2	114.8	0	168.3	1.6	175.8	176.8	178.5	193.5	768.8	Solid	Turbulent	C.S.	11834	17434	0	0
1	11	2	5	TORADA TC	151	152.2	972.8	971.4	114.8	117.8	0	168.3	1.6	196.1	198.1	201.4	216.4	839.9	Solid	Turbulent	C.S.	22996	33681	0	0
1	12	2	5	TORADA TC	152.2	153.4	971.4	969.9	117.8	120.8	0	168.3	1.6	196.7	198.7	202	217	846.6	Solid	Turbulent	C.S.	22877	33506	0	0
1	13	1	4	TORADA TC	153.5	153.9	969.9	968.5	120.8	121.8	0	168.3	1.6	174	175	176.3	191.3	774.5	None	Turbulent	C.S.	7514	14305	0	0
1	14	1	4	TORADA TC	153.9	154.3	968.5	967	121.8	122.8	0	168.3	1.6	174.4	175.3	176.6	191.6	776.5	None	Turbulent	C.S.	7506	14289	0	0
1	15	1	3	TORADA TC	154.3	154.8	967	965.6	122.8	124.1	0	168.3	1.6	178.2	179.3	180.8	195.8	787.7	None	Turbulent	C.S.	9732	16873	0	0
1	16	1	3	TORADA TC	154.8	155.3	965.6	964.1	124.1	125.3	0	168.3	1.6	178.6	179.7	181.2	196.2	790.4	None	Turbulent	C.S.	9720	16852	0	0
1	17	1	2	TORADA TC	155.3	156	964.1	962.7	125.4	127.1	0	168.3	1.6	185.8	187.2	189.3	204.3	815	None	Turbulent	C.S.	12841	22264	0	0
1	18	1	2	TORADA TC	156	156.7	962.7	961.2	127.1	128.7	0	168.3	1.7	186.3	187.7	189.8	204.8	820.2	None	Turbulent	C.S.	12824	22234	0	0
1	19	1	1	TORADA TC	156.7	157.7	961.2	959.8	128.8	131.2	0	168.3	1.7	197.2	199.2	202.2	217.2	868.1	None	Turbulent	C.S.	18127	31428	0	0
1	20	1	1	TORADA TC	157.7	158.6	959.8	958.3	131.2	133.5	0	168.3	1.7	197.7	199.8	202.7	217.7	876.3	None	Turbulent	C.S.	18100	31381	0	0

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2
Process Name		Process 1: TORADA TC	Process 1: TORADA TC	Process 1: TORADA TC
Tube OD	mm	219.1	168.3	168.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	255.1	202.7	202
Tube Temperature Margin	°C	15	15	15
Design Tube Temperature	°C	270.1	217.7	217
Design Tube Pressure	kPa	2000	2000	2000
Design Code		API 530	API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		32	32	48
No. Tubes Per Row			8	8
No. Passes		4	4	4
Effective Length	m	7	5.835	5.835
Straight Length	m	6.723	6.235	6.235
No. Rows			4	6
Tube Spacing	mm	406.4	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1
Coil Alignment			Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal
Tube Area	m²	154.18	98.67	1516.54
Intermediate Supports		0 / 0	0 / 1	0 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid
Fin Material			None	Carbon Steel
Fin Height	mm			25.4
Fin Thickness	mm			1.3
Serrated Fin Wn
Fin Density	fins/m			157

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2
tblDesignPress,calcref0	Design Pressure	kPa g	2000	2000	2000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	987.3	987.3	987.3
tblDesignTemp,calcref0	Design Temperature	°C	270.0781	217.7247	217.0165
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		219.1	168.3	168.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	8.18	7.11	7.11
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	8.18	7.11	7.11
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	124328.9	130932	131021.4
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.7482	1.2757	1.2748
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.75	4.28	4.27
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	5.43	4.89	4.89
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	30
Stack Diameter	m	1.85
Cone Diameter	m	0.749
Cone Height	m	0.5
Actual Exit Velocity	m/s	12
Design Exit Velocity	m/s	14.4
Flue Gas Temp.	°C	156.2
Flue Gas Flow	kg/s	3.13
Steel Area	m²	174.285
Stack Entry Pressure	mmH2O	1.218
CO2	mol%	8.35
H2O	mol%	15.57
N2	mol%	72.87
O2	mol%	3.22
SO2	mol%	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	707.1	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	480	1400	V Y Anchors	71.2	Refrac. thickness OK
RADIANT WALL 1	506.1	Fibre (High Density)	75	0.1	None	0	0	732.8	382.3	1260	Twistlock Pins	59.1	Refrac. thickness OK
RADIANT ARCH 1	757.1	Fibre (High Density)	87.7	0.1	None	0	0	824	740.5	1260	Twistlock Pins	76.4	Refrac. thickness OK

CONVECTION SIDEWALL 1	456.6	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	440.9	1100	V Y Anchors	62.6	Refrac. thickness OK

STACK 1	156.2	LW Castable	50	0.3	None	0	0	732.8	372	1100	V Y Anchors	58.4	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	8.423
Flue Gas Temp.	°C	223.3
CO2	mol%	8.25
H2O	mol%	15.74
N2	mol%	72.8
O2	mol%	3.22
SO2	mol%	0

AIR
Air Flow	kg/s	7.982
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.441
Fuel LHV	kJ/kg	43920.9
Fuel Mol. Wt.		18.144

Radiant Cell		1
Arch Temp.	°C	844.4
Max Tube Temp.	°C	152.8
Average Flux	W/m²	36814
Arch Pressure	mmH2O	5.326

No. of Burners		8
Floor Pressure	mmH2O	-5.84

ENERGY PERFORMACE
Total Absorbed Duty	MW	16.99
Total Heat Release	MW	19.377
Total Efficiency	%	87.677

ENVIRONMENTAL IMPACT
Energy Efficiency	%	87.677
Daily CO2 Emissions	kg	94734

Total:

£ 946,784

HR	MW	19.377
Arch	°C	844.4
Tube	°C	152.8
Flux	W/m²	36814

No. Burners	m	8
Fuel Flow	kg/s	0.441
Air Flow	kg/s	7.982
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/s	8.423
Temp.	°C	223.3
CO2	mol%	8.25
H2O	mol%	15.74
N2	mol%	72.8
O2	mol%	3.22
SO2	mol%	0

Process Inlet------->

Water , 103.1 °C, 900 kPa a

Fuel m.w.		18.144
Fuel LHV	kJ/kg	43920.9

Process Outlet------->

Water , 130.5 °C, 823.625 kPa a, 16.99 MW

Firing MW
19.38
Duty MW
16.99
Efficiency %
87.68
CO2 Ton/day
95

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Stack design seems OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 743,725
Option items
Detail Engineering (by HeaterSIM)	£ 111,559
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£946,784

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Water	Water	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	145.96	145.96	8.423	8.423	0.441	7.982
Flow (hr)	kg/hr	525456	525456	30323	30323	1588	28735
Temperature	°C	103.1	130.5	844.4	223.3	Note 1	15.5
Pressure	kPa a	900	823.625	5.326	6.266	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

32.38 m 19.88 m 18.08 m 15.3 m 9.05 m 2.8 m Grade 0.00 m 1.9 m 3.8 m 5.5 m 4.657 m 8 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1
Design Code		API 530	API 530
Orientation		Vertical	Horizontal
Tube OD	mm	168.3	114.3
Tube Material		Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40
Tube Spacing	mm	304.8	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1
No. Tubes		48	54
Effective Length	m	11.3	3.8
Straight Length	m	11	4.2

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Water
Heat Duty	MW	16.99
Flow rate (sec)	kg/s	145.96
Flow rate (hr)	kg/hr	525456
Pressure drop	kPa	76.375
Max. Film Temp. Calculated	°C	141.8
Max. Film Temp. Allowed	°C	175
Max Tube Average Flux Calculated (1)	W/m²	36921
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	103.1
Inlet Pressure	kPa a	900
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	438
OUTLET CONDITIONS
Outlet Temperature	°C	130.5
Outlet Pressure	kPa a	823.625
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	555

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type		Vertical Cylindrical
Heat Duty	MW	10.558
Heat Release	MW	19.377
Arch Temp.	°C	844.4
Max Tube Temp.	°C	152.8
Tube Cirle Diameter	m	4.657
Average Flux	W/m²	36814
Maximum Flux	W/m²	70917
Flue Flow	kg/s	8.423
Air Flow	kg/s	7.982
Fuel Flow	kg/s	0.441
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	5.326
Floor Pressure	mmH2O	-5.84
DIMENSIONS
Radiant Height	m	12.5
Radiant Width	m	5.5
Radiant Length	m	5.5
No. of Burners		8
Draft Type		Natural
BURNERS
Burner Cirle Diameter	m	2.104
Burner Design Firing	MW	2.91
Burner Normal Firing	MW	2.42
Burner Min Firing	MW	0.58
Burner-to-Tube Note		OK
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API 560 COMPLIANCE
API Burner-to-Tube Dist.	m	1.181
API Burner-to-Wall Dist.	m	1.065
API Burner-to-Roof/Roof Dist	m	7.478
Floor Flux	W/m²	816022

Flame-tube impingment risk not identified

Combustion

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Radiant Cell		1
Radiant Type
AIR & FUEL
Flue Flow	kg/s	8.423
Air Flow	kg/s	7.982
Fuel Flow	kg/s	0.441
Fuel LHV	kJ/kg	43920.9
Excess Air	%	20
Air Temp.	°C	15.5
BURNERS
No. of Burners	m	8
Burner Cirle Diameter	m
Burner Design Firing	MW	2.91
Burner Normal Firing	MW	2.42
Burner Min Firing	MW	0.58
Flame Temperature	°C	1802.4
EMISSIONS
CO2	mol%	8.25
H2O	mol%	15.74
N2	mol%	72.8
O2	mol%	3.22
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		18.144
Flue Mol. Wt.		27.874
Flue Gas Emissivity		0.453

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MW	6.432
Max Tube Temp.	°C	159.2
DIMENSIONS
Convection Width	m	3.759
Effective Length	m	3.8
Convection Height	m	2.28
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH2O	0.95
Total Press. Gain	mmH2O	1.78
Total Press. Loss (inc. gain)	mmH2O	-0.83
Total No. Rows		3
FLUE GAS DATA
Flue Gas Flow	kg/s	8.423
Flue Gas Inlet Temp.	°C	844.4
Flue Gas Outlet Temp.	°C	223.3
CO2	mol%	8.246462
H2O	mol%	15.73672
N2	mol%	72.79999
O2	mol%	3.216844
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	3	Coil Section 1	0.9	315.7	223.3	338.2	231.2	0.63	Solid	36689	42162	18	1.667	0.253	C.S.	C.S.	135.5	157.9
1	2	Coil Section 1	1.72	485.1	315.7	542	338.2	0.51	Solid	69920	80089	18	1.667	0.303	C.S.	C.S.	166.5	207.2
1	1	Coil Section 1	3.81	844.4	485.1	995.4	542	0.38	Solid	155398	180828	18	1.667	0.393	C.S.	C.S.	246.3	330.4

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	3	Coil Section 1	0.9	315.7	223.3	Water	1	103.1	104.6	900	879	0	0	3.1	3.1	0	0	2962	2962	1109359	1126890
1	2	Coil Section 1	1.72	485.1	315.7	Water	2	104.6	107.4	879	858	0	0	3.1	3.1	0	0	2962	2962	1126879	1158870
1	1	Coil Section 1	3.81	844.4	485.1	Water	3	107.4	113.6	858	836	0	0	3.1	3.1	0	0	2962	2962	1158865	1230156

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	3	Coil Section 1	0.9	315.7	223.3	Water	1	103.1	104.6	900	879	0	0	3.1	3.1	0	0	2962	2962	1109359	1126890
1	2	Coil Section 1	1.72	485.1	315.7	Water	2	104.6	107.4	879	858	0	0	3.1	3.1	0	0	2962	2962	1126879	1158870
1	1	Coil Section 1	3.81	844.4	485.1	Water	3	107.4	113.6	858	836	0	0	3.1	3.1	0	0	2962	2962	1158865	1230156

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Water	113.6	115.8	836.4	939.7	482.5	491.5	0	168.3	1.4	127.8	132.2	138.8	153.8	6436	Turbulent		36921	71062	0	0
2	Wall	Water	115.8	117.7	939.7	833.2	491.5	500.5	0	168.3	1.4	129.7	134.2	140.7	155.7	6494.3	Turbulent		36891	71023	0	0
3	Wall	Water	117.7	120	833.2	936.1	500.5	509.6	0	168.3	1.4	131.9	136.2	142.8	157.8	6557.4	Turbulent		36860	70979	0	0
4	Wall	Water	120	122	936.1	830	509.6	518.6	0	168.3	1.4	133.7	138.2	144.7	159.7	6615.8	Turbulent		36828	70937	0	0
5	Wall	Water	122	124.3	830	932.5	518.6	527.7	0	168.3	1.4	135.9	140.2	146.9	161.9	6677.8	Turbulent		36797	70893	0	0
6	Wall	Water	124.3	126.2	932.5	826.8	527.7	536.7	0	168.3	1.4	137.7	142.2	148.7	163.7	6735	Turbulent		36765	70851	0	0
7	Wall	Water	126.2	128.5	826.8	928.9	536.7	545.8	0	168.3	1.4	139.9	144.3	150.9	165.9	6795.9	Turbulent		36733	70805	0	0
8	Wall	Water	128.5	130.5	928.9	823.6	545.8	554.8	0	168.3	1.4	141.8	146.3	152.8	167.8	6851.8	Turbulent		36701	70763	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	1	3	Water	103.1	103.6	900	893	438.4	440.5	0	114.3	3.1	108	111	114.6	129.6	12599.4	Solid	Turbulent	C.S.	36764	49739	0	0
1	2	1	3	Water	103.6	104.1	893	885.9	440.5	442.5	0	114.3	3.1	108.5	111.5	115	130	12632.4	Solid	Turbulent	C.S.	36644	49577	0	0
1	3	1	3	Water	104.1	104.6	885.9	878.9	442.5	444.6	0	114.3	3.1	109	112	115.5	130.5	12665.4	Solid	Turbulent	C.S.	36525	49415	0	0
1	4	1	2	Water	104.6	105.6	878.9	871.8	444.6	448.5	0	114.3	3.1	113.8	119.6	126.3	141.3	12782.6	Solid	Turbulent	C.S.	70064	94616	0	0
1	5	1	2	Water	105.6	106.5	871.8	864.7	448.5	452.4	0	114.3	3.1	114.7	120.5	127.1	142.1	12841.6	Solid	Turbulent	C.S.	69829	94300	0	0
1	6	1	2	Water	106.5	107.4	864.7	857.7	452.4	456.3	0	114.3	3.1	115.6	121.3	128	143	12900.4	Solid	Turbulent	C.S.	69595	93983	0	0
1	7	1	1	Water	107.4	109.5	857.7	850.6	456.3	465	0	114.3	3.1	127.5	140.6	155.7	170.7	13164.7	Solid	Turbulent	C.S.	155748	212226	0	0
1	8	1	1	Water	109.5	111.5	850.6	843.5	465	473.8	0	114.3	3.1	129.3	142.3	157.4	172.4	13290.6	Solid	Turbulent	C.S.	155127	211380	0	0
1	9	1	1	Water	111.5	113.6	843.5	836.4	473.8	482.5	0	114.3	3.1	131.1	144.1	159.2	174.2	13415.6	Solid	Turbulent	C.S.	154505	210533	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1
Process Name		Process 1: Water	Process 1: Water
Tube OD	mm	168.3	114.3
Tube Material		Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40
Max Tube Temperature	°C	152.8	159.2
Tube Temperature Margin	°C	15	15
Design Tube Temperature	°C	167.8	174.2
Design Tube Pressure	kPa	1840	1840
Design Code		API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		48	54
No. Tubes Per Row			18
No. Passes		6	6
Effective Length	m	11.3	3.8
Straight Length	m	11	4.2
No. Rows			3
Tube Spacing	mm	304.8	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1
Coil Alignment			Staggered
Orientation		Vertical	Horizontal
Tube Area	m²	286.78	984.63
Intermediate Supports		0 / 0	0 / 1
Corbel Width	m		1/2 Tube Space
Fin Type			Solid
Fin Material			Carbon Steel
Fin Height	mm		25.4
Fin Thickness	mm		1.5
Serrated Fin Wn
Fin Density	fins/m		197

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1
tblDesignPress,calcref0	Design Pressure	kPa g	1840	1840
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	900	900
tblDesignTemp,calcref0	Design Temperature	°C	167.769	174.1501
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		168.3	114.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	7.11	6.02
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	7.11	6.02
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	137232.8	136427.9
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1208	0.7656
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.12	3.77
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.71	4.3
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0
RuptureNfactor,resultref0	Rupture n factor		0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0
RuptureBfactor,resultref0	B factor		0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	12.5
Stack Diameter	m	1.9
Cone Diameter	m	1.17
Cone Height	m	0.5
Actual Exit Velocity	m/s	13.7
Design Exit Velocity	m/s	16.5
Flue Gas Temp.	°C	223.3
Flue Gas Flow	kg/s	8.423
Steel Area	m²	74.613
Stack Entry Pressure	mmH2O	6.266
CO2	mol%	8.25
H2O	mol%	15.74
N2	mol%	72.8
O2	mol%	3.22
SO2	mol%	0

Stack No. 1: Stack design seems OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	794.4	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	558.7	1400	V Y Anchors	77.5	Refrac. thickness OK
RADIANT WALL 1	498.6	Fibre (High Density)	75	0.1	None	0	0	732.8	371.7	1260	Twistlock Pins	58.4	Refrac. thickness OK
RADIANT ARCH 1	844.4	Fibre (High Density)	100.4	0.1	None	0	0	824	813.5	1260	Twistlock Pins	80.6	Refrac. thickness OK

CONVECTION SIDEWALL 1	533.9	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	545.6	1100	V Y Anchors	69.5	Refrac. thickness OK

STACK 1	223.3	LW Castable	50	0.3	None	0	0	732.8	722.5	1100	V Y Anchors	80.6	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	5.227
Flue Gas Temp.	°C	403.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

AIR
Air Flow	kg/s	4.986
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.241
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

Radiant Cell		1
Arch Temp.	°C	799
Max Tube Temp.	°C	267.9
Average Flux	W/m²	29053
Arch Pressure	mmH2O	-2.582

No. of Burners		4
Floor Pressure	mmH2O	-12.608

ENERGY PERFORMACE
Total Absorbed Duty	MW	9.576
Total Heat Release	MW	12.076
Total Efficiency	%	79.301

ENVIRONMENTAL IMPACT
Energy Efficiency	%	79.301
Daily CO2 Emissions	kg	57580

Total:

£ 832,473

HR	MW	12.076
Arch	°C	799
Tube	°C	267.9
Flux	W/m²	29053

No. Burners	m	4
Fuel Flow	kg/s	0.241
Air Flow	kg/s	4.986
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/s	5.227
Temp.	°C	403.5
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Process Inlet------->

Therminol XP , 100 °C, 750 kPa a

Fuel m.w.		16
Fuel LHV	kJ/kg	50015

Process Outlet------->

Therminol XP , 200 °C, 641.977 kPa a, 9.576 MW

Firing MW
12.08
Duty MW
9.58
Efficiency %
79.3
CO2 Ton/day
58

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 644,324
Detailed Engineering (by HeaterSIM)	£ 96,649
Option items
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£832,473

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	40	40	5.227	5.227	0.241	4.986
Flow (hr)	kg/hr	144000	144000	18819	18819	869	17950
Temperature	°C	100	200	799	403.5	Note 1	15.5
Pressure	kPa a	750	641.977	-2.582	-5.644	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

34.637 m 19.637 m 17.837 m 14.176 m 8.488 m 2.8 m Grade 0.00 m 1.63 m 3.958 m 4.584 m 4.204 m 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530	API 530
Orientation		Vertical	Horizontal	Horizontal
Tube OD	mm	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1
No. Tubes		52	12	12
Effective Length	m	10.376	3.958	3.958
Straight Length	m	9.978	4.458	4.458

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Therminol XP
Heat Duty	MW	9.576
Flow rate (sec)	kg/s	40
Flow rate (hr)	kg/hr	144000
Pressure drop	kPa	108.023
Max. Film Temp. Calculated	°C	329.3
Max. Film Temp. Allowed	°C	350
Max Tube Average Flux Calculated (1)	W/m²	29430
Average Flux Allowed	W/m²	31500
INLET CONDITIONS
Inlet Temperature	°C	100
Inlet Pressure	kPa a	750
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	344
OUTLET CONDITIONS
Outlet Temperature	°C	200
Outlet Pressure	kPa a	641.977
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	584

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type		Vertical Cylindrical
Heat Duty	MW	6.959
Heat Release	MW	12.076
Arch Temp.	°C	799
Max Tube Temp.	°C	267.9
Tube Cirle Diameter	m	4.204
Average Flux	W/m²	29053
Maximum Flux	W/m²	61635
Flue Flow	kg/s	5.227
Air Flow	kg/s	4.986
Fuel Flow	kg/s	0.241
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH2O	-2.582
Floor Pressure	mmH2O	-12.608
DIMENSIONS
Radiant Height	m	11.38
Radiant Width	m	4.58
Radiant Length	m	4.58
No. of Burners		4
Draft Type		Natural
BURNERS
Burner Cirle Diameter	m	1.209
Burner Design Firing	MW	3.62
Burner Normal Firing	MW	3.02
Burner Min Firing	MW	0.72
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API 560 COMPLIANCE
API Burner-to-Tube Dist.	m	1.425
API Burner-to-Wall Dist.	m	1.253
API Burner-to-Roof/Roof Dist	m	8.931
Floor Flux	W/m²	732064

Flame-tube impingment risk not identified

Combustion

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Radiant Cell		1
Radiant Type
AIR & FUEL
Flue Flow	kg/s	5.227
Air Flow	kg/s	4.986
Fuel Flow	kg/s	0.241
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
BURNERS
No. of Burners	m	4
Burner Cirle Diameter	m
Burner Design Firing	MW	3.62
Burner Normal Firing	MW	3.02
Burner Min Firing	MW	0.72
Flame Temperature	°C	1805.6
EMISSIONS
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flue Gas Emissivity		0.439

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MW	2.618
Max Tube Temp.	°C	354.2
DIMENSIONS
Convection Width	m	1.143
Effective Length	m	3.958
Convection Height	m	3.161
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH2O	4.45
Total Press. Gain	mmH2O	2.57
Total Press. Loss (inc. gain)	mmH2O	1.88
Total No. Rows		6
FLUE GAS DATA
Flue Gas Flow	kg/s	5.227
Flue Gas Inlet Temp.	°C	799
Flue Gas Outlet Temp.	°C	403.5
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	6	Coil Section 2	0.46	475.8	403.5	531.7	443.5	0.48	Solid	65664	76855	4	3.148	0.73	C.S.	C.S.	283.1	307.2
1	5	Coil Section 2	0.6	568.2	475.8	646.5	531.7	0.43	Solid	85420	100482	4	3.148	0.815	C.S.	C.S.	331.7	361.9
1	4	Coil Section 2	0.81	689.4	568.2	801.2	646.5	0.38	Solid	115125	137507	4	3.148	0.922	C.S.	C.S.	398.9	438
1	3	Coil Section 1	0.22	721.7	689.4	843.2	801.2	0.35	None	32218	56277	4	2.93	0.638	C.S.	None	0	0
1	2	Coil Section 1	0.25	756.3	721.7	888.5	843.2	0.33	None	36132	63115	4	2.93	0.66	C.S.	None	0	0
1	1	Coil Section 1	0.28	799	756.3	937.7	888.5	0.32	None	42861	74869	4	2.93	0.685	C.S.	None	0	0

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	6	Coil Section 2	0.46	475.8	403.5	Therminol XP	1	100	105.2	750	746	0	0	1.9	1.9	0	0	1549	1549	56942	61773
1	5	Coil Section 2	0.6	568.2	475.8	Therminol XP	2	105.2	111.9	746	742	0	0	1.9	1.9	0	0	1549	1549	61776	68970
1	4	Coil Section 2	0.81	689.4	568.2	Therminol XP	3	111.9	121	742	738	0	0	1.9	1.9	0	0	1549	1549	68967	80786
1	3	Coil Section 1	0.22	721.7	689.4	Therminol XP	4	121	123.5	738	734	0	0	1.9	1.9	0	0	1549	1549	80795	84601
1	2	Coil Section 1	0.25	756.3	721.7	Therminol XP	5	123.5	126.3	734	730	0	0	1.9	1.9	0	0	1549	1549	84611	89136
1	1	Coil Section 1	0.28	799	756.3	Therminol XP	6	126.3	129.4	730	726	0	0	1.9	1.9	0	0	1549	1549	89150	94784

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	6	Coil Section 2	0.46	475.8	403.5	Therminol XP	1	100	105.2	750	746	0	0	1.9	1.9	0	0	1549	1549	56942	61773
1	5	Coil Section 2	0.6	568.2	475.8	Therminol XP	2	105.2	111.9	746	742	0	0	1.9	1.9	0	0	1549	1549	61776	68970
1	4	Coil Section 2	0.81	689.4	568.2	Therminol XP	3	111.9	121	742	738	0	0	1.9	1.9	0	0	1549	1549	68967	80786
1	3	Coil Section 1	0.22	721.7	689.4	Therminol XP	4	121	123.5	738	734	0	0	1.9	1.9	0	0	1549	1549	80795	84601
1	2	Coil Section 1	0.25	756.3	721.7	Therminol XP	5	123.5	126.3	734	730	0	0	1.9	1.9	0	0	1549	1549	84611	89136
1	1	Coil Section 1	0.28	799	756.3	Therminol XP	6	126.3	129.4	730	726	0	0	1.9	1.9	0	0	1549	1549	89150	94784

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Therminol XP	129.4	132.4	725.7	804.4	409.7	416.3	0	141.3	1.9	216.1	219.2	225.3	240.3	819.5	Turbulent		29430	62239	0	0
2	Wall	Therminol XP	132.4	135.5	804.4	719.3	416.3	423	0	141.3	1.9	217.2	220.3	226.4	241.4	838.4	Turbulent		29410	62207	0	0
3	Wall	Therminol XP	135.5	138.4	719.3	797.8	423	429.7	0	141.3	1.9	218.2	221.3	227.4	242.4	858.2	Turbulent		29391	62176	0	0
4	Wall	Therminol XP	138.4	141.1	797.8	713	429.7	436.4	0	141.3	1.9	219.6	222.8	228.8	243.8	872.5	Turbulent		29364	62135	0	0
5	Wall	Therminol XP	141.1	143.8	713	791	436.4	443.1	0	141.3	1.9	221.3	224.5	230.5	245.5	883.5	Turbulent		29333	62086	0	0
6	Wall	Therminol XP	143.8	146.6	791	706.7	443.1	449.8	0	141.3	1.9	222.9	226.2	232.1	247.1	894.8	Turbulent		29302	62036	0	0
7	Wall	Therminol XP	146.6	149.3	706.7	784.3	449.8	456.5	0	141.3	2	224.6	227.9	233.8	248.8	906.3	Turbulent		29271	61986	0	0
8	Wall	Therminol XP	149.3	152	784.3	700.3	456.5	463.2	0	141.3	2	226.3	229.6	235.5	250.5	918.1	Turbulent		29239	61936	0	0
9	Wall	Therminol XP	152	154.7	700.3	777.5	463.2	469.9	0	141.3	2	228	231.3	237.2	252.2	929.9	Turbulent		29207	61884	0	0
10	Wall	Therminol XP	154.7	157.4	777.5	693.9	469.9	476.6	0	141.3	2	229.8	233	239	254	941.6	Turbulent		29174	61831	0	0
11	Wall	Therminol XP	157.4	160.1	693.9	770.7	476.6	483.3	0	141.3	2	231.5	234.8	240.7	255.7	953.7	Turbulent		29142	61778	0	0
12	Wall	Therminol XP	160.1	162.9	770.7	687.5	483.3	489.9	0	141.3	2	233.3	236.5	242.5	257.5	966.1	Turbulent		29109	61725	0	0
13	Wall	Therminol XP	162.9	165.6	687.5	763.9	489.9	496.6	0	141.3	2	235	238.2	244.2	259.2	978.9	Turbulent		29076	61671	0	0
14	Wall	Therminol XP	165.6	168.3	763.9	681.1	496.6	503.3	0	141.3	2	236.7	240	245.9	260.9	992	Turbulent		29043	61617	0	0
15	Wall	Therminol XP	168.3	171	681.1	757.1	503.3	510	0	141.3	2	238.5	241.7	247.7	262.7	1005.5	Turbulent		29010	61563	0	0
16	Wall	Therminol XP	171	173.7	757.1	674.6	510	516.7	0	141.3	2	240.2	243.4	249.4	264.4	1019.5	Turbulent		28976	61508	0	0
17	Wall	Therminol XP	173.7	176.4	674.6	750.3	516.7	523.4	0	141.3	2	241.9	245.2	251.1	266.1	1033.8	Turbulent		28943	61453	0	0
18	Wall	Therminol XP	176.4	179.2	750.3	668.1	523.4	530.1	0	141.3	2	243.7	246.9	252.9	267.9	1048.7	Turbulent		28910	61398	0	0
19	Wall	Therminol XP	179.2	181.9	668.1	743.5	530.1	536.8	0	141.3	2	245.5	248.7	254.7	269.7	1064.2	Turbulent		28874	61340	0	0
20	Wall	Therminol XP	181.9	184.5	743.5	661.6	536.8	543.5	0	141.3	2	247.2	250.5	256.4	271.4	1077.5	Turbulent		28839	61283	0	0
21	Wall	Therminol XP	184.5	187.1	661.6	736.6	543.5	550.2	0	141.3	2	249.1	252.4	258.3	273.3	1088.2	Turbulent		28802	61221	0	0
22	Wall	Therminol XP	187.1	189.7	736.6	655.1	550.2	556.9	0	141.3	2	251.1	254.4	260.2	275.2	1099	Turbulent		28764	61158	0	0
23	Wall	Therminol XP	189.7	192.2	655.1	729.7	556.9	563.5	0	141.3	2	253	256.3	262.1	277.1	1110	Turbulent		28726	61095	0	0
24	Wall	Therminol XP	192.2	194.8	729.7	648.6	563.5	570.2	0	141.3	2	254.9	258.2	264.1	279.1	1121.3	Turbulent		28688	61031	0	0
25	Wall	Therminol XP	194.8	197.4	648.6	722.7	570.2	576.9	0	141.3	2	256.8	260.1	266	281	1132.7	Turbulent		28650	60967	0	0
26	Wall	Therminol XP	197.4	200	722.7	642	576.9	583.6	0	141.3	2	258.7	262	267.9	282.9	1144.4	Turbulent		28611	60902	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	2	6	Therminol XP	100	102.6	750	748	344.2	349.9	0	141.3	1.9	243.4	248.9	256.9	271.9	707.2	Solid	Turbulent	C.S.	65864	90448	0	0
1	2	2	6	Therminol XP	102.6	105.2	748	746	349.9	355.7	0	141.3	1.9	243	248.4	256.4	271.4	717.2	Solid	Turbulent	C.S.	65356	89749	0	0
1	3	2	5	Therminol XP	105.2	108.6	746	743.9	355.7	363.2	0	141.3	1.9	279.7	287	297.6	312.6	760.5	Solid	Turbulent	C.S.	85694	118061	0	0
1	4	2	5	Therminol XP	108.6	111.9	743.9	741.9	363.2	370.7	0	141.3	1.9	278.6	285.8	296.4	311.4	774.5	Solid	Turbulent	C.S.	84992	117094	0	0
1	5	2	4	Therminol XP	111.9	116.5	741.9	739.9	370.7	380.8	0	141.3	1.9	329.3	339.4	354.2	369.2	833.3	Solid	Turbulent	C.S.	115520	160733	0	0
1	6	2	4	Therminol XP	116.5	121	739.9	737.9	380.8	390.9	0	141.3	1.9	326.7	336.7	351.3	366.3	854.4	Solid	Turbulent	C.S.	114490	159299	0	0
1	7	1	3	Therminol XP	121	122.3	737.9	735.8	390.9	393.7	0	141.3	1.9	203	206.5	211.2	226.2	757.3	None	Turbulent	C.S.	31771	55496	0	0
1	8	1	3	Therminol XP	122.3	123.5	735.8	733.8	393.7	396.5	0	141.3	1.9	203.4	206.9	211.6	226.6	763.8	None	Turbulent	C.S.	31703	55379	0	0
1	9	1	2	Therminol XP	123.5	124.9	733.8	731.8	396.5	399.6	0	141.3	1.9	211.4	215.2	220.4	235.4	778.5	None	Turbulent	C.S.	34971	61087	0	0
1	10	1	2	Therminol XP	124.9	126.3	731.8	729.7	399.6	402.7	0	141.3	1.9	211.8	215.6	220.8	235.8	785.9	None	Turbulent	C.S.	34895	60954	0	0
1	11	1	1	Therminol XP	126.3	127.9	729.7	727.7	402.7	406.2	0	141.3	1.9	222.9	227.2	233.2	248.2	806.1	None	Turbulent	C.S.	39791	69506	0	0
1	12	1	1	Therminol XP	127.9	129.4	727.7	725.7	406.2	409.7	0	141.3	1.9	223.2	227.6	233.5	248.5	815	None	Turbulent	C.S.	39702	69351	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	mm	141.3	141.3	141.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	267.9	233.5	351.3
Tube Temperature Margin	°C	15	15	15
Design Tube Temperature	°C	282.9	248.5	366.3
Design Tube Pressure	kPa	2000	2000	2000
Design Code		API 530	API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	12	12
No. Tubes Per Row			4	4
No. Passes		2	2	2
Effective Length	m	10.376	3.958	3.958
Straight Length	m	9.978	4.458	4.458
No. Rows			3	3
Tube Spacing	mm	254	254	254
Vert. Row Spacing (Vert)	mm	N/A	220.1	220.1
Coil Alignment			Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal
Tube Area	m²	239.51	21.07	165.79
Intermediate Supports		0 / 0	0 / 0	0 / 0
Corbel Width	m		1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid
Fin Material			None	Carbon Steel
Fin Height	mm			19.1
Fin Thickness	mm			1.3
Serrated Fin Wn
Fin Density	fins/m			157

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2
tblDesignPress,calcref0	Design Pressure	kPa g	2000	2000	2000
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750	750	750
tblDesignTemp,calcref0	Design Temperature	°C	282.901	248.486	366.3296
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	122711.6	127052.2	109558.7
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1422	1.1035	1.2781
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.14	4.1	4.28
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.73	4.69	4.89
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	15
Stack Diameter	m	1.63
Cone Diameter	m	1.532
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	403.5
Flue Gas Flow	kg/s	5.227
Steel Area	m²	76.898
Stack Entry Pressure	mmH2O	-5.644
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	749	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	516.3	1400	V Y Anchors	74	Refrac. thickness OK
RADIANT WALL 1	533.4	Fibre (High Density)	75	0.1	None	0	0	732.8	424.3	1260	Twistlock Pins	61.9	Refrac. thickness OK
RADIANT ARCH 1	799	Fibre (High Density)	100.4	0.1	None	0	0	824	726.1	1260	Twistlock Pins	76.4	Refrac. thickness OK

CONVECTION SIDEWALL 1	601.2	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	638.2	1100	V Y Anchors	75.1	Refrac. thickness OK

STACK 1	403.5	LW Castable	126.2	0.3	None	0	0	732.8	683.9	1100	V Y Anchors	77.8	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Back

Matched Case Results

Table Result 1

Table Result 2

Table Result 3

Table Result 4

Notes More Data

Audit Report

HeaterSIM Technology | Artificial Intelligence Report

Energy Performance Forecast

Matched & Optimum Case Results

STACK
Flue Gas Flow	kg/hr	4669
Flue Gas Temp.	°C	175.3
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

AIR
Air Flow	kg/hr	4454
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/hr	216
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

Radiant Cell		1
Arch Temp.	°C	750.5
Max Tube Temp.	°C	296.3
Average Flux	W/m²	29948
Arch Pressure	mmH₂Og	-1.481

No. of Burners		1
Floor Pressure	mmH₂Og	-6.047

ENERGY PERFORMACE
Total Absorbed Duty	MW	2.721
Total Heat Release	MW	2.996
Total Efficiency	%	90.82

ENVIRONMENTAL IMPACT
Total Duty	%	2.721193
Energy Release	%	2.996245
Energy Efficiency	%	90.82
Daily CO₂ Emissions	kg	14287

Total:

£ 721,897

HR	MW	2.996
Arch	°C	750.5
Tube	°C	296.3
Flux	W/m²	29948

No. Burners	m	1
Fuel Flow	kg/hr	216
Air Flow	kg/hr	4454
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/hr	4669
Temp.	°C	175.3
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

Process Inlet------->

Kerosene , 40 °C, 750.1 kPa a

Fuel m.w.		16
Fuel LHV	kJ/kg	50015

Process Outlet------->

Kerosene , 259.8 °C, 725.2 kPa a, 2.721 MW

Firing MW
3
Duty MW
2.72
Efficiency %
90.82
CO2 Ton/day
14

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

HeaterSIM - Fired Heater Simulation Results

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

API Burner Layout Rad. Sect 1: OK

Burner Vertical Clearance Rad. Sect 1: VTA

Radiant Cell 1 Floor Flux (API 560): OK

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 548,171
Option items
Detail Engineering (by HeaterSIM)	£ 82,226
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£721,897

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Kerosene	Kerosene	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	5.92	5.92	1.297	1.297	0.06	1.237
Flow (hr)	kg/hr	21320	21320	4669	4669	216	4454
Temperature	°C	40	259.8	750.5	175.3	Note 1	15.5
Pressure	kPa a	750.1	725.2	-1.481	-2.779	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

30.528 m 13.528 m 11.728 m 8.067 m 5.434 m 2.8 m Grade 0.00 m 0.88 m 1.7 m 4.124 m 1.358 m 1 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530	API 530
Orientation		Horizontal	Horizontal	Horizontal
Tube OD	mm	114.3	114.3	114.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	304.8	203.2	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1	176.1
No. Tubes		14	12	20
Effective Length	m	12	1.7	1.7
Straight Length	m	12	2.1	2.1

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Kerosene
Heat Duty	MW	2.721
Flow rate (sec)	kg/s	5.92
Flow rate (hr)	kg/hr	21320
Pressure drop	kPa	24.9
Max. Film Temp. Calculated	°C	290.5
Max. Film Temp. Allowed	°C	290
Max Tube Average Flux Calculated (1)	W/m²	31228
Average Flux Allowed	W/m²	31499
INLET CONDITIONS
Inlet Temperature	°C	40
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	100
OUTLET CONDITIONS
Outlet Temperature	°C	259.8
Outlet Pressure	kPa a	725.2
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	560

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type		Vertical Cylindrical
Heat Duty	MW	1.807
Heat Release	MW	2.996
Arch Temp.	°C	750.5
Max Tube Temp.	°C	296.3
Tube Cirle Diameter	m	1.358
Average Flux	W/m²	29948
Maximum Flux	W/m²	42610
Flue Flow	kg/hr	4669
Air Flow	kg/hr	4454
Fuel Flow	kg/hr	216
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH₂Og	-1.481
Floor Pressure	mmH₂Og	-6.047
Exchange Factor		0.537
DIMENSIONS
Radiant Height	m	5.27
Radiant Width	m	4.12
Radiant Length	m	4.12
No. of Burners		1
Draft Type		Natural
BURNERS
Burner Design Firing	MW	3.6
Burner Normal Firing	MW	3
Burner Min Firing	MW	0.72

API 560 COMPLIANCE
Burner Spacing		OK
Burner Circle Diameter	m	0
Adjusted BCD (for BCD-TCD API limits)	m	0
BCD/TCD		0
Flame height suitability		VTA
BTB value	m	1.265
BTC value	m	1.25
BTW	m	0.569
Floor Flux	W/m²	224425
Floor Flux Suitability		OK

Flame-tube impingment risk not identified

Combustion

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Radiant Cell		1
Radiant Type		Vertical Cylindrical
AIR & FUEL
Flue Flow	kg/hr	4669
Air Flow	kg/hr	4454
Fuel Flow	kg/hr	216
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
BURNERS
No. of Burners	m	1
Burner Cirle Diameter	m
Burner Design Firing	MW	3.6
Burner Normal Firing	MW	3
Burner Min Firing	MW	0.72
Flame Temperature	°C	1793
EMISSIONS
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flue Gas Emissivity		0.417

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MW	0.915
Max Tube Temp.	°C	217.8
DIMENSIONS
Convection Width	m	0.914
Effective Length	m	1.7
Convection Height	m	3.161
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH₂O	3
Total Press. Gain	mmH₂O	2.34
Total Press. Loss (inc. gain)	mmH₂O	0.66
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/hr	4669
Flue Gas Inlet Temp.	°C	750.5
Flue Gas Outlet Temp.	°C	175.3
CO₂	mol%	8.058337
H₂O	mol%	16.05639
N₂	mol%	72.674
O₂	mol%	3.211277
SO₂	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 2	0.07	222	175.3	230.7	177	0.72	Solid	28496	33377	4	2.352	0.302	C.S.	C.S.	94.2	108.8
1	7	Coil Section 2	0.09	283.6	222	301.6	230.7	0.65	Solid	37704	44122	4	2.352	0.336	C.S.	C.S.	117.4	136.5
1	6	Coil Section 2	0.12	365.2	283.6	397.6	301.6	0.57	Solid	50958	59507	4	2.352	0.382	C.S.	C.S.	150	175.2
1	5	Coil Section 2	0.17	474	365.2	529.7	397.6	0.49	Solid	70187	81713	4	2.352	0.446	C.S.	C.S.	196.7	229.7
1	4	Coil Section 2	0.24	624.6	474	717.9	529.7	0.42	Solid	99942	117028	4	2.352	0.532	C.S.	C.S.	267.5	311.8
1	3	Coil Section 1	0.06	662	624.6	765.5	717.9	0.37	None	26121	46135	4	2.146	0.32	C.S.	None	0	0
1	2	Coil Section 1	0.07	701.9	662	817.6	765.5	0.35	None	29685	52431	4	2.146	0.334	C.S.	None	0	0
1	1	Coil Section 1	0.08	750.5	701.9	874.9	817.6	0.34	None	35645	62958	4	2.146	0.349	C.S.	None	0	0

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 2	0.07	222	175.3	Kerosene	1	40	45.6	750	749	0	0	0.9	0.9	0	0	721	721	737100	737100
1	7	Coil Section 2	0.09	283.6	222	Kerosene	2	45.6	53	749	747	0	0	0.9	0.9	0	0	721	721	737100	737100
1	6	Coil Section 2	0.12	365.2	283.6	Kerosene	3	53	63	747	746	0	0	0.9	0.9	0	0	721	721	737100	737100
1	5	Coil Section 2	0.17	474	365.2	Kerosene	4	63	76.9	746	744	0	0	0.9	0.9	0	0	721	721	737100	737100
1	4	Coil Section 2	0.24	624.6	474	Kerosene	5	76.8	96.5	744	743	0	0	0.9	0.9	0	0	721	721	737100	737100
1	3	Coil Section 1	0.06	662	624.6	Kerosene	6	96.5	101.6	743	741	0	0	0.9	0.9	0	0	721	721	737100	737100
1	2	Coil Section 1	0.07	701.9	662	Kerosene	7	101.6	107.3	741	740	0	0	0.9	0.9	0	0	721	721	737100	737100
1	1	Coil Section 1	0.08	750.5	701.9	Kerosene	8	107.4	113.9	740	739	0	0	0.9	0.9	0	0	721	721	737100	737100

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 2	0.07	222	175.3	Kerosene	1	40	45.6	750	749	0	0	0.9	0.9	0	0	721	721	737100	737100
1	7	Coil Section 2	0.09	283.6	222	Kerosene	2	45.6	53	749	747	0	0	0.9	0.9	0	0	721	721	737100	737100
1	6	Coil Section 2	0.12	365.2	283.6	Kerosene	3	53	63	747	746	0	0	0.9	0.9	0	0	721	721	737100	737100
1	5	Coil Section 2	0.17	474	365.2	Kerosene	4	63	76.9	746	744	0	0	0.9	0.9	0	0	721	721	737100	737100
1	4	Coil Section 2	0.24	624.6	474	Kerosene	5	76.8	96.5	744	743	0	0	0.9	0.9	0	0	721	721	737100	737100
1	3	Coil Section 1	0.06	662	624.6	Kerosene	6	96.5	101.6	743	741	0	0	0.9	0.9	0	0	721	721	737100	737100
1	2	Coil Section 1	0.07	701.9	662	Kerosene	7	101.6	107.3	741	740	0	0	0.9	0.9	0	0	721	721	737100	737100
1	1	Coil Section 1	0.08	750.5	701.9	Kerosene	8	107.4	113.9	740	739	0	0	0.9	0.9	0	0	721	721	737100	737100

Radiant Tube Profile

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Kerosene	113.9	124.3	738.5	737.6	254.5	276.3	0	114.3	0.9	158.2	155.9	164.1	179.1	1458.7	Turbulent		31228	44221	0	0
2	Wall	Kerosene	124.3	134.7	737.6	736.6	276.3	298.1	0	114.3	0.9	168.4	166.1	174.3	189.3	1459.9	Turbulent		31044	43994	0	0
3	Wall	Kerosene	134.7	145.1	736.6	735.7	298.1	319.9	0	114.3	0.9	178.6	176.3	184.5	199.5	1461	Turbulent		30856	43760	0	0
4	Wall	Kerosene	145.1	155.5	735.7	734.7	319.9	341.7	0	114.3	0.9	188.8	186.5	194.7	209.7	1462.2	Turbulent		30662	43518	0	0
5	Wall	Kerosene	155.5	166	734.7	733.8	341.7	363.5	0	114.3	0.9	199	196.7	204.9	219.9	1463.3	Turbulent		30464	43267	0	0
6	Wall	Kerosene	166	176.4	733.8	732.8	363.5	385.3	0	114.3	0.9	209.2	206.9	215	230	1464.5	Turbulent		30259	43008	0	0
7	Wall	Kerosene	176.4	186.8	732.8	731.9	385.3	407.1	0	114.3	0.9	219.4	217.1	225.2	240.2	1465.6	Turbulent		30049	42740	0	0
8	Wall	Kerosene	186.8	197.2	731.9	730.9	407.1	428.9	0	114.3	0.9	229.6	227.3	235.4	250.4	1466.8	Turbulent		29833	42461	0	0
9	Wall	Kerosene	197.2	207.7	730.9	730	428.9	450.7	0	114.3	0.9	239.8	237.5	245.6	260.6	1468	Turbulent		29611	42173	0	0
10	Wall	Kerosene	207.7	218.1	730	729	450.7	472.5	0	114.3	0.9	249.9	247.6	255.7	270.7	1469.1	Turbulent		29382	41875	0	0
11	Wall	Kerosene	218.1	228.5	729	728.1	472.5	494.3	0	114.3	0.9	260.1	257.8	265.9	280.9	1470.4	Turbulent		29147	41567	0	0
12	Wall	Kerosene	228.5	238.9	728.1	727.1	494.3	516.1	0	114.3	0.9	270.2	267.9	276	291	1471.6	Turbulent		28905	41248	0	0
13	Wall	Kerosene	238.9	249.4	727.1	726.2	516.1	537.9	0	114.3	0.9	280.4	278.1	286.1	301.1	1472.8	Turbulent		28656	40917	0	0
14	Wall	Kerosene	249.4	259.8	726.2	725.2	537.9	559.7	0	114.3	0.9	290.5	288.2	296.3	311.3	1473.9	Turbulent		28400	40574	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	2	8	Kerosene	40	41.4	750.1	749.7	100	102.9	0	114.3	0.9	72	73.8	77	92	1449.6	Solid	Turbulent	C.S.	28824	39622	0	0
1	2	2	8	Kerosene	41.4	42.8	749.7	749.4	102.9	105.9	0	114.3	0.9	73.1	74.9	78.1	93.1	1449.8	Solid	Turbulent	C.S.	28564	39264	0	0
1	3	2	8	Kerosene	42.8	44.2	749.4	749	105.9	108.8	0	114.3	0.9	74.2	76	79.2	94.2	1450	Solid	Turbulent	C.S.	28304	38907	0	0
1	4	2	8	Kerosene	44.2	45.6	749	748.7	108.8	111.7	0	114.3	0.9	75.3	77.1	80.3	95.3	1450.2	Solid	Turbulent	C.S.	28044	38549	0	0
1	5	2	7	Kerosene	45.6	47.5	748.7	748.3	111.7	115.6	0	114.3	0.9	87.8	90.3	94.6	109.6	1450.4	Solid	Turbulent	C.S.	38144	52401	0	0
1	6	2	7	Kerosene	47.5	49.3	748.3	747.9	115.6	119.5	0	114.3	0.9	89.3	91.7	96	111	1450.6	Solid	Turbulent	C.S.	37795	51922	0	0
1	7	2	7	Kerosene	49.3	51.2	747.9	747.6	119.5	123.4	0	114.3	0.9	90.8	93.2	97.4	112.4	1450.8	Solid	Turbulent	C.S.	37446	51442	0	0
1	8	2	7	Kerosene	51.2	53	747.6	747.2	123.4	127.3	0	114.3	0.9	92.3	94.7	98.9	113.9	1451	Solid	Turbulent	C.S.	37097	50963	0	0
1	9	2	6	Kerosene	53	55.5	747.2	746.8	127.2	132.5	0	114.3	0.9	110	113.3	119.2	134.2	1451.3	Solid	Turbulent	C.S.	51570	70749	0	0
1	10	2	6	Kerosene	55.5	58	746.8	746.5	132.5	137.7	0	114.3	0.9	112	115.3	121.1	136.1	1451.5	Solid	Turbulent	C.S.	51083	70081	0	0
1	11	2	6	Kerosene	58	60.5	746.5	746.1	137.7	143	0	114.3	0.9	114	117.2	123	138	1451.8	Solid	Turbulent	C.S.	50596	69412	0	0
1	12	2	6	Kerosene	60.5	63	746.1	745.8	143	148.2	0	114.3	0.9	116	119.2	124.9	139.9	1452	Solid	Turbulent	C.S.	50109	68744	0	0
1	13	2	5	Kerosene	63	66.5	745.8	745.4	148.2	155.4	0	114.3	0.9	141.4	146	154.1	169.1	1452.3	Solid	Turbulent	C.S.	71070	97308	0	0
1	14	2	5	Kerosene	66.5	70	745.4	745	155.4	162.7	0	114.3	0.9	144.1	148.6	156.6	171.6	1452.7	Solid	Turbulent	C.S.	70366	96344	0	0
1	15	2	5	Kerosene	70	73.4	745	744.7	162.7	169.9	0	114.3	0.9	146.8	151.3	159.2	174.2	1453.2	Solid	Turbulent	C.S.	69662	95380	0	0
1	16	2	5	Kerosene	73.4	76.9	744.7	744.3	169.9	177.1	0	114.3	0.9	149.5	153.9	161.8	176.8	1453.6	Solid	Turbulent	C.S.	68957	94415	0	0
1	17	2	4	Kerosene	76.8	81.8	744.3	743.9	177.1	187.4	0	114.3	0.9	188.8	195.5	207.1	222.1	1454	Solid	Turbulent	C.S.	101286	139202	0	0
1	18	2	4	Kerosene	81.8	86.7	743.9	743.6	187.4	197.7	0	114.3	0.9	192.5	199.1	210.7	225.7	1454.6	Solid	Turbulent	C.S.	100204	137716	0	0
1	19	2	4	Kerosene	86.7	91.6	743.6	743.2	197.7	208	0	114.3	0.9	196.3	202.8	214.2	229.2	1455.1	Solid	Turbulent	C.S.	99123	136229	0	0
1	20	2	4	Kerosene	91.6	96.5	743.2	742.9	208	218.3	0	114.3	0.9	200	206.4	217.8	232.8	1455.7	Solid	Turbulent	C.S.	98041	134742	0	0
1	21	1	3	Kerosene	96.5	97.8	742.9	742.5	218.3	220.9	0	114.3	0.9	132.8	135.2	138.8	153.8	1456.1	None	Turbulent	C.S.	25805	45578	0	0
1	22	1	3	Kerosene	97.8	99.1	742.5	742.1	220.9	223.6	0	114.3	0.9	134	136.3	140	155	1456.3	None	Turbulent	C.S.	25746	45473	0	0
1	23	1	3	Kerosene	99.1	100.3	742.1	741.8	223.6	226.2	0	114.3	0.9	135.2	137.5	141.1	156.1	1456.4	None	Turbulent	C.S.	25687	45369	0	0
1	24	1	3	Kerosene	100.3	101.6	741.8	741.4	226.2	228.9	0	114.3	0.9	136.3	138.7	142.3	157.3	1456.6	None	Turbulent	C.S.	25628	45265	0	0
1	25	1	2	Kerosene	101.6	103	741.4	741	228.9	231.9	0	114.3	0.9	142	144.7	148.7	163.7	1456.7	None	Turbulent	C.S.	28780	50833	0	0
1	26	1	2	Kerosene	103	104.5	741	740.7	231.9	234.8	0	114.3	0.9	143.4	146	150	165	1456.9	None	Turbulent	C.S.	28712	50713	0	0
1	27	1	2	Kerosene	104.5	105.9	740.7	740.3	234.8	237.8	0	114.3	0.9	144.7	147.3	151.4	166.4	1457.1	None	Turbulent	C.S.	28645	50594	0	0
1	28	1	2	Kerosene	105.9	107.3	740.3	740	237.8	240.7	0	114.3	0.9	146	148.6	152.7	167.7	1457.2	None	Turbulent	C.S.	28577	50474	0	0
1	29	1	1	Kerosene	107.4	109	740	739.6	240.9	244.3	0	114.3	0.9	153.9	156.9	161.6	176.6	1457.4	None	Turbulent	C.S.	33154	58558	0	0
1	30	1	1	Kerosene	109	110.6	739.6	739.2	244.3	247.7	0	114.3	0.9	155.4	158.5	163.1	178.1	1457.6	None	Turbulent	C.S.	33073	58416	0	0
1	31	1	1	Kerosene	110.6	112.2	739.2	738.9	247.7	251.1	0	114.3	0.9	156.9	160	164.6	179.6	1457.8	None	Turbulent	C.S.	32993	58273	0	0
1	32	1	1	Kerosene	112.2	113.9	738.9	738.5	251.1	254.5	0	114.3	0.9	158.4	161.5	166.1	181.1	1458	None	Turbulent	C.S.	32912	58131	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2
Process Name		Process 1: Kerosene	Process 1: Kerosene	Process 1: Kerosene
Tube OD	mm	114.3	114.3	114.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	296.3	166.1	217.8
Tube Temperature Margin	°C	15	15	15
Design Tube Temperature	°C	311.3	181.1	232.8
Design Tube Pressure	kPa	2000.2	2000.2	2000.2
Design Code		API 530	API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		14	12	20
No. Tubes Per Row			4	4
No. Passes		1	1	1
Effective Length	m	12	1.7	1.7
Straight Length	m	12	2.1	2.1
No. Rows			3	5
Tube Spacing	mm	304.8	203.2	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1	176.1
Coil Alignment			Staggered	Staggered
Orientation		Horizontal	Horizontal	Horizontal
Tube Area	m²	60.33	7.32	98.5
Intermediate Supports		2 / 3	0 / 0	0 / 0
Corbel Width	m		1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid
Fin/Stud Material			None	Carbon Steel
Fin/Stud Height	mm			19.1
Fin/Stud Thickness	mm			1.3
Serrated Fin Wn
Fin/Stud Density	fins/m			157
No. Studs per ring				12

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	311.2501	181.1315	232.8154
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		114.3	114.3	114.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.02	6.02	6.02
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.02	6.02	6.02
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	118715.6	135547.4	129028.7
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	0.9549	0.8372	0.8791
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	3.95	3.84	3.88
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.52	4.39	4.43
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

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Stack Height	m	17
Stack Diameter	m	0.88
Cone Diameter	m	0.682
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	175.3
Flue Gas Flow	kg/hr	4669
Steel Area	m²	47.083
Stack Entry Pressure	mmH₂O	-2.779
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	700.5	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	474.3	1400	V Y Anchors	70.6	Refrac. thickness OK
RADIANT WALL 1	523.4	Fibre (High Density)	75	0.1	None	0	0	732.8	408.8	1260	Twistlock Pins	60.5	Refrac. thickness OK
RADIANT ARCH 1	750.5	Fibre (High Density)	87.7	0.1	None	0	0	824	726.7	1260	Twistlock Pins	76.4	Refrac. thickness OK

CONVECTION SIDEWALL 1	462.9	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	449.4	1100	V Y Anchors	63.3	Refrac. thickness OK

STACK 1	175.3	LW Castable	50	0.3	None	0	0	732.8	470.4	1100	V Y Anchors	64.6	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Back

Matched Case Results

Table Result 1

Table Result 2

Table Result 3

Table Result 4

Notes More Data

Audit Report

HeaterSIM Technology | Artificial Intelligence Report

Energy Performance Forecast

Matched & Optimum Case Results

STACK
Flue Gas Flow	kg/hr	4684
Flue Gas Temp.	°C	180.6
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

AIR
Air Flow	kg/hr	4468
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/hr	216
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

Radiant Cell		1
Arch Temp.	°C	761.9
Max Tube Temp.	°C	302.5
Average Flux	W/m²	30937
Arch Pressure	mmH₂Og	-2.897

No. of Burners		1
Floor Pressure	mmH₂Og	-7.304

ENERGY PERFORMACE
Total Absorbed Duty	MW	2.721
Total Heat Release	MW	3.006
Total Efficiency	%	90.513

ENVIRONMENTAL IMPACT
Total Duty	%	2.720519
Energy Release	%	3.005655
Energy Efficiency	%	90.513
Daily CO₂ Emissions	kg	14332

Total:

£ 758,237

HR	MW	3.006
Arch	°C	761.9
Tube	°C	302.5
Flux	W/m²	30937

No. Burners	m	1
Fuel Flow	kg/hr	216
Air Flow	kg/hr	4468
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/hr	4684
Temp.	°C	180.6
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

Process Inlet------->

Kerosene , 40 °C, 750.1 kPa a

Fuel m.w.		16
Fuel LHV	kJ/kg	50015

Process Outlet------->

Kerosene , 259.8 °C, 719.114 kPa a, 2.721 MW

Firing MW
3.01
Duty MW
2.72
Efficiency %
90.51
CO2 Ton/day
14

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

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Radiant cell no. 1: The burners to tube distance seems OK (API 560)

Radiant cell no. 1: The burners to wall clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Radiant cell no. 1: Two lanes of burners considered

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

API Burner Layout Rad. Sect 1: OK

Burner Vertical Clearance Rad. Sect 1: VTA

Radiant Cell 1 Floor Flux (API 560): OK

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 579,771
Option items
Detail Engineering (by HeaterSIM)	£ 86,966
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£758,237

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Kerosene	Kerosene	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	5.92	5.92	1.301	1.301	0.06	1.241
Flow (hr)	kg/hr	21320	21320	4684	4684	216	4468
Temperature	°C	40	259.8	761.9	180.6	Note 1	15.5
Pressure	kPa a	750.1	719.114	-2.897	-0.832	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

27.973 m 12.973 m 11.173 m 7.864 m 5.332 m 2.8 m Grade 0.00 m 0.79 m 0.914 m 2.11 m 0 m 1 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530	API 530
Orientation		Horizontal	Horizontal	Horizontal
Tube OD	mm	114.3	114.3	114.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	203.2	203.2	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1	176.1
No. Tubes		40	12	12
Effective Length	m	4	4	4
Straight Length	m	4	4.4	4.4

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

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Process Name		Kerosene
Heat Duty	MW	2.721
Flow rate (sec)	kg/s	5.92
Flow rate (hr)	kg/hr	21320
Pressure drop	kPa	30.986
Max. Film Temp. Calculated	°C	295.8
Max. Film Temp. Allowed	°C	290
Max Tube Average Flux Calculated (1)	W/m²	32586
Average Flux Allowed	W/m²	31499
INLET CONDITIONS
Inlet Temperature	°C	40
Inlet Pressure	kPa a	750.1
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	100
OUTLET CONDITIONS
Outlet Temperature	°C	259.8
Outlet Pressure	kPa a	719.114
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	560

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

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Radiant Cell		1
Radiant Type		Cabin
Heat Duty	MW	1.777
Heat Release	MW	3.006
Arch Temp.	°C	761.9
Max Tube Temp.	°C	302.5
Tube Cirle Diameter	m
Average Flux	W/m²	30937
Maximum Flux	W/m²	50174
Flue Flow	kg/hr	4684
Air Flow	kg/hr	4468
Fuel Flow	kg/hr	216
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH₂Og	-2.897
Floor Pressure	mmH₂Og	-7.304
Exchange Factor		0.626
DIMENSIONS
Radiant Height	m	5.06
Radiant Width	m	2.11
Radiant Length	m	5
No. of Burners		1
Draft Type		Natural
BURNERS
Burner Design Firing	MW	3.61
Burner Normal Firing	MW	3.01
Burner Min Firing	MW	0.72

API 560 COMPLIANCE
Burner Spacing		OK
Burner Circle Diameter	m
Adjusted BCD (for BCD-TCD API limits)	m	N/A
BCD/TCD		N/A
Flame height suitability		VTA
BTB value	m	1.279
BTC value	m	1.25
BTW	m	0.576
Floor Flux	W/m²	284896
Floor Flux Suitability		OK

Flame-tube impingment risk not identified

Combustion

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Radiant Cell		1
Radiant Type		Cabin
AIR & FUEL
Flue Flow	kg/hr	4684
Air Flow	kg/hr	4468
Fuel Flow	kg/hr	216
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
BURNERS
No. of Burners	m	1
Burner Cirle Diameter	m
Burner Design Firing	MW	3.61
Burner Normal Firing	MW	3.01
Burner Min Firing	MW	0.72
Flame Temperature	°C	1793
EMISSIONS
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flue Gas Emissivity		0.417

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

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Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MW	0.943
Max Tube Temp.	°C	154.1
DIMENSIONS
Convection Width	m	0.914
Effective Length	m	4
Convection Height	m	2.809
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH₂O	0.45
Total Press. Gain	mmH₂O	2.1
Total Press. Loss (inc. gain)	mmH₂O	-1.65
Total No. Rows		6
FLUE GAS DATA
Flue Gas Flow	kg/hr	4684
Flue Gas Inlet Temp.	°C	761.9
Flue Gas Outlet Temp.	°C	180.6
CO₂	mol%	8.058337
H₂O	mol%	16.05639
N₂	mol%	72.674
O₂	mol%	3.211277
SO₂	mol%	0

Convection (Flue gas side)

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	6	Coil Section 2	0.12	259.7	180.6	273.4	182.9	0.69	Solid	20475	24851	4	1.003	0.072	C.S.	C.S.	84.9	104.6
1	5	Coil Section 2	0.18	379.8	259.7	415.5	273.4	0.58	Solid	32111	38801	4	1.003	0.087	C.S.	C.S.	119.8	149.5
1	4	Coil Section 2	0.3	571.1	379.8	649.8	415.5	0.46	Solid	52867	63398	4	1.003	0.109	C.S.	C.S.	179.9	225.8
1	3	Coil Section 1	0.09	624.4	571.1	717.6	649.8	0.39	None	16262	28723	4	0.915	0.055	C.S.	None	0	0
1	2	Coil Section 1	0.11	686.1	624.4	796.6	717.6	0.37	None	20111	35521	4	0.915	0.059	C.S.	None	0	0
1	1	Coil Section 1	0.14	761.9	686.1	889.5	796.6	0.34	None	26879	47476	4	0.915	0.063	C.S.	None	0	0

Convection (Process Side)

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Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	6	Coil Section 2	0.12	259.7	180.6	Kerosene	1	40	49.5	750	748	0	0	0.9	0.9	0	0	721	721	737100	737100
1	5	Coil Section 2	0.18	379.8	259.7	Kerosene	2	49.5	64.3	748	746	0	0	0.9	0.9	0	0	721	721	737100	737100
1	4	Coil Section 2	0.3	571.1	379.8	Kerosene	3	64.3	88.8	746	744	0	0	0.9	0.9	0	0	721	721	737100	737100
1	3	Coil Section 1	0.09	624.4	571.1	Kerosene	4	88.7	96	744	742	0	0	0.9	0.9	0	0	721	721	737100	737100
1	2	Coil Section 1	0.11	686.1	624.4	Kerosene	5	96.2	105	742	740	0	0	0.9	0.9	0	0	721	721	737100	737100
1	1	Coil Section 1	0.14	761.9	686.1	Kerosene	6	105.1	116.2	740	738	0	0	0.9	0.9	0	0	721	721	737100	737100

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	6	Coil Section 2	0.12	259.7	180.6	Kerosene	1	40	49.5	750	748	0	0	0.9	0.9	0	0	721	721	737100	737100
1	5	Coil Section 2	0.18	379.8	259.7	Kerosene	2	49.5	64.3	748	746	0	0	0.9	0.9	0	0	721	721	737100	737100
1	4	Coil Section 2	0.3	571.1	379.8	Kerosene	3	64.3	88.8	746	744	0	0	0.9	0.9	0	0	721	721	737100	737100
1	3	Coil Section 1	0.09	624.4	571.1	Kerosene	4	88.7	96	744	742	0	0	0.9	0.9	0	0	721	721	737100	737100
1	2	Coil Section 1	0.11	686.1	624.4	Kerosene	5	96.2	105	742	740	0	0	0.9	0.9	0	0	721	721	737100	737100
1	1	Coil Section 1	0.14	761.9	686.1	Kerosene	6	105.1	116.2	740	738	0	0	0.9	0.9	0	0	721	721	737100	737100

Radiant Tube Profile

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Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	Kerosene	116.2	119.8	738.1	737.6	259.4	266.9	0	114.3	0.9	159.9	161.6	166.9	181.9	1458.6	Turbulent		32586	52307	0	0
2	Wall	Kerosene	119.8	123.4	737.6	737.2	266.9	274.4	0	114.3	0.9	163.4	165.1	170.4	185.4	1459	Turbulent		32506	52206	0	0
3	Wall	Kerosene	123.4	127	737.2	736.7	274.4	281.9	0	114.3	0.9	166.9	168.6	173.9	188.9	1459.4	Turbulent		32425	52104	0	0
4	Wall	Kerosene	127	130.6	736.7	736.2	281.9	289.5	0	114.3	0.9	170.4	172.1	177.4	192.4	1459.8	Turbulent		32343	52001	0	0
5	Wall	Kerosene	130.6	134.2	736.2	735.7	289.5	297	0	114.3	0.9	173.9	175.6	180.9	195.9	1460.2	Turbulent		32261	51897	0	0
6	Wall	Kerosene	134.2	137.8	735.7	735.3	297	304.5	0	114.3	0.9	177.4	179.1	184.4	199.4	1460.5	Turbulent		32178	51792	0	0
7	Wall	Kerosene	137.8	141.3	735.3	734.8	304.5	312	0	114.3	0.9	180.9	182.6	187.9	202.9	1460.9	Turbulent		32095	51686	0	0
8	Wall	Kerosene	141.3	144.9	734.8	734.3	312	319.5	0	114.3	0.9	184.4	186.1	191.3	206.3	1461.4	Turbulent		32012	51579	0	0
9	Wall	Kerosene	144.9	148.5	734.3	733.8	319.5	327	0	114.3	0.9	187.9	189.6	194.8	209.8	1461.8	Turbulent		31927	51471	0	0
10	Wall	Kerosene	148.5	152.1	733.8	733.4	327	334.5	0	114.3	0.9	191.4	193	198.3	213.3	1462.2	Turbulent		31843	51362	0	0
11	Wall	Kerosene	152.1	155.7	733.4	732.9	334.5	342	0	114.3	0.9	194.8	196.5	201.8	216.8	1462.6	Turbulent		31757	51252	0	0
12	Wall	Kerosene	155.7	159.3	732.9	732.4	342	349.5	0	114.3	0.9	198.3	200	205.3	220.3	1463	Turbulent		31671	51140	0	0
13	Wall	Kerosene	159.3	162.9	732.4	731.9	349.5	357	0	114.3	0.9	201.8	203.5	208.8	223.8	1463.3	Turbulent		31585	51028	0	0
14	Wall	Kerosene	162.9	166.5	731.9	731.5	357	364.5	0	114.3	0.9	205.3	207	212.3	227.3	1463.7	Turbulent		31498	50914	0	0
15	Wall	Kerosene	166.5	170	731.5	731	364.5	372	0	114.3	0.9	208.8	210.5	215.7	230.7	1464.2	Turbulent		31410	50799	0	0
16	Wall	Kerosene	170	173.6	731	730.5	372	379.5	0	114.3	0.9	212.3	214	219.2	234.2	1464.6	Turbulent		31322	50684	0	0
17	Wall	Kerosene	173.6	177.2	730.5	730	379.5	387	0	114.3	0.9	215.8	217.4	222.7	237.7	1465	Turbulent		31233	50567	0	0
18	Wall	Kerosene	177.2	180.8	730	729.6	387	394.5	0	114.3	0.9	219.3	220.9	226.2	241.2	1465.4	Turbulent		31144	50448	0	0
19	Wall	Kerosene	180.8	184.4	729.6	729.1	394.5	402	0	114.3	0.9	222.8	224.4	229.7	244.7	1465.7	Turbulent		31054	50329	0	0
20	Wall	Kerosene	184.4	188	729.1	728.6	402	409.6	0	114.3	0.9	226.2	227.9	233.1	248.1	1466.1	Turbulent		30963	50208	0	0
21	Wall	Kerosene	188	191.6	728.6	728.1	409.6	417.1	0	114.3	0.9	229.7	231.4	236.6	251.6	1466.5	Turbulent		30872	50086	0	0
22	Wall	Kerosene	191.6	195.2	728.1	727.7	417.1	424.6	0	114.3	0.9	233.2	234.9	240.1	255.1	1466.9	Turbulent		30780	49962	0	0
23	Wall	Kerosene	195.2	198.8	727.7	727.2	424.6	432.1	0	114.3	0.9	236.7	238.3	243.6	258.6	1467.4	Turbulent		30687	49838	0	0
24	Wall	Kerosene	198.8	202.4	727.2	726.7	432.1	439.6	0	114.3	0.9	240.2	241.8	247.1	262.1	1467.7	Turbulent		30594	49712	0	0
25	Wall	Kerosene	202.4	206	726.7	726.2	439.6	447.1	0	114.3	0.9	243.7	245.3	250.5	265.5	1468.1	Turbulent		30500	49584	0	0
26	Wall	Kerosene	206	209.5	726.2	725.8	447.1	454.6	0	114.3	0.9	247.2	248.8	254	269	1468.5	Turbulent		30405	49456	0	0
27	Wall	Kerosene	209.5	213.1	725.8	725.3	454.6	462.1	0	114.3	0.9	250.6	252.3	257.5	272.5	1468.9	Turbulent		30309	49326	0	0
28	Wall	Kerosene	213.1	216.7	725.3	724.8	462.1	469.6	0	114.3	0.9	254.1	255.7	261	276	1469.4	Turbulent		30213	49195	0	0
29	Wall	Kerosene	216.7	220.3	724.8	724.3	469.6	477.1	0	114.3	0.9	257.6	259.2	264.4	279.4	1469.8	Turbulent		30117	49062	0	0
30	Wall	Kerosene	220.3	223.9	724.3	723.9	477.1	484.6	0	114.3	0.9	261.1	262.7	267.9	282.9	1470.2	Turbulent		30019	48928	0	0
31	Wall	Kerosene	223.9	227.5	723.9	723.4	484.6	492.1	0	114.3	0.9	264.5	266.2	271.3	286.3	1470.7	Turbulent		29921	48793	0	0
32	Wall	Kerosene	227.5	231.1	723.4	722.9	492.1	499.6	0	114.3	0.9	268	269.6	274.8	289.8	1471.1	Turbulent		29823	48656	0	0
33	Wall	Kerosene	231.1	234.7	722.9	722.4	499.6	507.1	0	114.3	0.9	271.5	273.1	278.3	293.3	1471.5	Turbulent		29723	48518	0	0
34	Wall	Kerosene	234.7	238.2	722.4	722	507.1	514.6	0	114.3	0.9	275	276.6	281.7	296.7	1471.9	Turbulent		29623	48379	0	0
35	Wall	Kerosene	238.2	241.8	722	721.5	514.6	522.1	0	114.3	0.9	278.4	280	285.2	300.2	1472.3	Turbulent		29522	48237	0	0
36	Wall	Kerosene	241.8	245.4	721.5	721	522.1	529.6	0	114.3	0.9	281.9	283.5	288.7	303.7	1472.7	Turbulent		29420	48095	0	0
37	Wall	Kerosene	245.4	249	721	720.5	529.6	537.2	0	114.3	0.9	285.4	287	292.1	307.1	1473.1	Turbulent		29317	47950	0	0
38	Wall	Kerosene	249	252.6	720.5	720.1	537.2	544.7	0	114.3	0.9	288.9	290.4	295.6	310.6	1473.5	Turbulent		29213	47805	0	0
39	Wall	Kerosene	252.6	256.2	720.1	719.6	544.7	552.2	0	114.3	0.9	292.3	293.9	299	314	1473.9	Turbulent		29109	47657	0	0
40	Wall	Kerosene	256.2	259.8	719.6	719.1	552.2	559.7	0	114.3	0.9	295.8	297.3	302.5	317.5	1474.2	Turbulent		29004	47509	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	2	6	Kerosene	40	42.4	750.1	749.6	100	105	0	114.3	0.9	64.9	65.6	68.7	83.7	1449.7	Solid	Turbulent	C.S.	20802	29270	0	0
1	2	2	6	Kerosene	42.4	44.7	749.6	749.1	105	109.9	0	114.3	0.9	67	67.7	70.7	85.7	1450	Solid	Turbulent	C.S.	20516	28868	0	0
1	3	2	6	Kerosene	44.7	47.1	749.1	748.6	109.9	114.9	0	114.3	0.9	69.1	69.7	72.7	87.7	1450.3	Solid	Turbulent	C.S.	20230	28465	0	0
1	4	2	6	Kerosene	47.1	49.5	748.6	748.1	114.9	119.9	0	114.3	0.9	71.1	71.7	74.7	89.7	1450.6	Solid	Turbulent	C.S.	19944	28063	0	0
1	5	2	5	Kerosene	49.5	53.2	748.1	747.6	119.8	127.6	0	114.3	0.9	88.5	89.6	94.4	109.4	1450.9	Solid	Turbulent	C.S.	32646	45802	0	0
1	6	2	5	Kerosene	53.2	56.9	747.6	747.1	127.6	135.4	0	114.3	0.9	91.7	92.7	97.5	112.5	1451.3	Solid	Turbulent	C.S.	32177	45143	0	0
1	7	2	5	Kerosene	56.9	60.6	747.1	746.6	135.4	143.1	0	114.3	0.9	94.9	95.9	100.6	115.6	1451.7	Solid	Turbulent	C.S.	31707	44484	0	0
1	8	2	5	Kerosene	60.6	64.3	746.6	746.1	143.1	150.9	0	114.3	0.9	98.1	99	103.7	118.7	1452.1	Solid	Turbulent	C.S.	31237	43825	0	0
1	9	2	4	Kerosene	64.3	70.4	746.1	745.6	150.8	163.7	0	114.3	0.9	128.2	130.1	138	153	1452.6	Solid	Turbulent	C.S.	53812	75121	0	0
1	10	2	4	Kerosene	70.4	76.6	745.6	745.1	163.7	176.5	0	114.3	0.9	133.4	135.2	143.1	158.1	1453.4	Solid	Turbulent	C.S.	52971	73946	0	0
1	11	2	4	Kerosene	76.6	82.7	745.1	744.6	176.5	189.3	0	114.3	0.9	138.6	140.3	148.1	163.1	1454.1	Solid	Turbulent	C.S.	52129	72771	0	0
1	12	2	4	Kerosene	82.7	88.8	744.6	744.1	189.3	202.1	0	114.3	0.9	143.8	145.4	153.2	168.2	1454.7	Solid	Turbulent	C.S.	51286	71595	0	0
1	13	1	3	Kerosene	88.7	90.5	744.1	743.6	201.9	205.7	0	114.3	0.9	112.1	113	115.7	130.7	1455.1	None	Turbulent	C.S.	15894	28073	0	0
1	14	1	3	Kerosene	90.5	92.3	743.6	743.1	205.7	209.5	0	114.3	0.9	113.8	114.7	117.5	132.5	1455.4	None	Turbulent	C.S.	15838	27974	0	0
1	15	1	3	Kerosene	92.3	94.2	743.1	742.6	209.5	213.4	0	114.3	0.9	115.6	116.5	119.2	134.2	1455.6	None	Turbulent	C.S.	15782	27875	0	0
1	16	1	3	Kerosene	94.2	96	742.6	742.1	213.4	217.2	0	114.3	0.9	117.3	118.2	121	136	1455.8	None	Turbulent	C.S.	15726	27777	0	0
1	17	1	2	Kerosene	96.2	98.4	742.1	741.6	217.5	222.1	0	114.3	0.9	124.3	125.4	128.7	143.7	1456.1	None	Turbulent	C.S.	19094	33724	0	0
1	18	1	2	Kerosene	98.4	100.6	741.6	741.1	222.1	226.7	0	114.3	0.9	126.4	127.5	130.8	145.8	1456.4	None	Turbulent	C.S.	19022	33598	0	0
1	19	1	2	Kerosene	100.6	102.8	741.1	740.6	226.7	231.3	0	114.3	0.9	128.5	129.6	132.9	147.9	1456.7	None	Turbulent	C.S.	18951	33473	0	0
1	20	1	2	Kerosene	102.8	105	740.6	740.1	231.3	235.9	0	114.3	0.9	130.6	131.7	135	150	1456.9	None	Turbulent	C.S.	18880	33347	0	0
1	21	1	1	Kerosene	105.1	107.9	740.1	739.6	236.2	242	0	114.3	0.9	140.6	142	146.2	161.2	1457.2	None	Turbulent	C.S.	24107	42580	0	0
1	22	1	1	Kerosene	107.9	110.7	739.6	739.1	242	247.8	0	114.3	0.9	143.2	144.6	148.8	163.8	1457.5	None	Turbulent	C.S.	24012	42411	0	0
1	23	1	1	Kerosene	110.7	113.5	739.1	738.6	247.8	253.6	0	114.3	0.9	145.8	147.2	151.4	166.4	1457.9	None	Turbulent	C.S.	23916	42241	0	0
1	24	1	1	Kerosene	113.5	116.2	738.6	738.1	253.6	259.4	0	114.3	0.9	148.5	149.9	154.1	169.1	1458.2	None	Turbulent	C.S.	23820	42072	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2
Process Name		Process 1: Kerosene	Process 1: Kerosene	Process 1: Kerosene
Tube OD	mm	114.3	114.3	114.3
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	302.5	154.1	153.2
Tube Temperature Margin	°C	15	15	15
Design Tube Temperature	°C	317.5	169.1	168.2
Design Tube Pressure	kPa	2000.2	2000.2	2000.2
Design Code		API 530	API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		40	12	12
No. Tubes Per Row			4	4
No. Passes		1	1	1
Effective Length	m	4	4	4
Straight Length	m	4	4.4	4.4
No. Rows			3	3
Tube Spacing	mm	203.2	203.2	203.2
Vert. Row Spacing (Vert)	mm	N/A	176.1	176.1
Coil Alignment			Staggered	Staggered
Orientation		Horizontal	Horizontal	Horizontal
Tube Area	m²	57.45	17.23	139.06
Intermediate Supports		0 / 1	0 / 1	0 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid
Fin/Stud Material			None	Carbon Steel
Fin/Stud Height	mm			19.1
Fin/Stud Thickness	mm			1.3
Serrated Fin Wn
Fin/Stud Density	fins/m			157
No. Studs per ring				12

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	317.4938	169.0511	168.1987
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		114.3	114.3	114.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.02	6.02	6.02
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.02	6.02	6.02
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	117678.2	137071	137178.6
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	0.9632	0.8279	0.8273
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	3.96	3.83	3.83
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.53	4.37	4.37
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	m	15
Stack Diameter	m	0.79
Cone Diameter	m	0.686
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	180.6
Flue Gas Flow	kg/hr	4684
Steel Area	m²	37.035
Stack Entry Pressure	mmH₂O	-0.832
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	711.9	MW Castable	75	0.4	ULW Castable	150	0.14	732.5	484.1	1400	V Y Anchors	71.9	Refrac. thickness OK
RADIANT WALL 1	532.2	Fibre (High Density)	75	0.1	None	0	0	732.8	422.5	1260	Twistlock Pins	61.9	Refrac. thickness OK
RADIANT ARCH 1	761.9	Fibre (High Density)	87.7	0.1	None	0	0	824	751.4	1260	Twistlock Pins	77.8	Refrac. thickness OK

CONVECTION SIDEWALL 1	471.2	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	460.8	1100	V Y Anchors	63.9	Refrac. thickness OK

STACK 1	180.6	LW Castable	50	0.3	None	0	0	732.8	498	1100	V Y Anchors	66.7	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

Audit Report

HeaterSIM Technology | Artificial Intelligence Report

Audit Report

HeaterSIM Technology | Artificial Intelligence Report

Energy Performance Forecast

Efficiency

CO₂ Emissions

Matched & Optimum Case Results

STACK
Flue Gas Flow	kg/s	19411
Flue Gas Temp.	°C	385.5
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

AIR
Air Flow	kg/s	18514
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	897
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

Radiant Cell		1
Arch Temp.	°C	855.2
Max Tube Temp.	°C	445.4
Average Flux	W/m²	26747
Arch Pressure	mmH₂Og	-7.808

No. of Burners		3
Floor Pressure	mmH₂Og	-17.747

ENERGY PERFORMACE
Total Absorbed Duty	MW	10.003
Total Heat Release	MW	12.465
Total Efficiency	%	80.245

ENVIRONMENTAL IMPACT
Total Duty	%	10.00279
Energy Release	%	12.46535
Energy Efficiency	%	80.245
Daily CO₂ Emissions	kg	59438

Total:

£ 951,983

HR	MW	12.465
Arch	°C	855.2
Tube	°C	445.4
Flux	W/m²	26747

No. Burners	m	3
Fuel Flow	kg/s	897
Air Flow	kg/s	18514
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/s	19411
Temp.	°C	385.5
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

Process Inlet------->

AR-HVS-MPS , 356 °C, 13099.999 kPa a

, °C, kPa a

Fuel m.w.		16
Fuel LHV	kJ/kg	50015

Process Outlet------->

AR-HVS-MPS , 406.7 °C, 12976.369 kPa a, 10.003 MW

, °C, kPa a, MW

Air Flow		18514
Air Temp.	°C	15.5

Firing MW
12.47
Duty MW
10
Efficiency %
80.24
CO2 Ton/day
59

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

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•Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

•Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

•Flame-tube impingment risk not identified

•Radiant cell no. 1: API 560 Radiant height to width seems OK

•Stack No. 1: Stack design seems OK

•Radiant section 1,Coil sect. no. 1, complies with API 530

•Convection section 1,Coil sect. no. 1, complies with API 530

•Convection section 1,Coil sect. no. 2, complies with API 530

•Convection section 1,Coil sect. no. 3, complies with API 530

•API Burner Layout Rad. Sect 1: OK

•Burner Vertical Clearance Rad. Sect 1: OK

•Radiant Cell 1 Floor Flux (API 560): OK

•Slug flow detected for AR-HVS-MPS. Coil vibration & damage is possible. Increase process flowrate is possible

Commercial

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 748,246
Option items
Detail Engineering (by HeaterSIM)	£ 112,237
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£951,983

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		AR-HVS-MPS	AR-HVS-MPS	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	30	30	5.396	5.396	0.249	5.147
Flow (hr)	kg/s	144000	144000	19426	19426	897	18529
Temperature	°C	356	406.7	855.2	385.5	Note 1	15.5
Pressure	kPa a	13099.999	12976.369	-7.808	-4.292	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

35.225 m 20.225 m 18.425 m 13.884 m 8.342 m 2.8 m Grade 0.00 m 1.54 m 5.84 m 5.018 m 4.56 m 3 Burners
(Forced Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530	API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		9Cr/1.0Mo - P9	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	mm	304.8	304.8	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1	264.1
No. Tubes		47	24	16	24
Effective Length	m	10.084	5.84	5.84	5.84
Straight Length	m	9.685	6.24	6.24	6.24

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

Cost Estimate

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Name		AR-HVS-MPS
Heat Duty	MW	10.003
Flow rate (sec)	kg/s	30
Flow rate (hr)	kg/s
Pressure drop	kPa	123.63
Max. Film Temp. Calculated	°C	461
Max. Film Temp. Allowed	°C	436
Average Flux Allowed	W/m²	60176
Avg. Rad. Flux	W/m²	26361
Max Rad. Flux	W/m²	49521
Max Conv. Flux	W/m²	37024
Mass Velocity (Rad.)	kg/s m²	1609
Mass Velocity (Conv.)	kg/s m²	804


INLET CONDITIONS
Inlet Temperature	°C	356
Inlet Pressure	kPa a	13099.999
Inlet Vapour Fraction		0.032
Inlet Enthalpy	kJ/kg	100
Inlet Velocity	m/s	0.93
Inlet Mass Velocity	kg/s m²	804


OUTLET CONDITIONS
Outlet Temperature	°C	406.7
Outlet Pressure	kPa a	12976.369
Outlet Vapour Fraction		0.465
Outlet Enthalpy	kJ/kg	433
Outlet Velocity	m/s	235.48
Outlet Mass Velocity	kg/s m²	1609

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type		Vertical Cylindrical
Heat Duty	MW	6.703
Heat Release	MW	12.465
Arch Temp.	°C	855.2
Max Tube Temp.	°C	445.4
Tube Cirle Diameter	m	4.56
Average Flux	W/m²	26747
Maximum Flux	W/m²	50164
Flue Flow	kg/s	19411
Air Flow	kg/s	18514
Fuel Flow	kg/s	897
Excess Air	%	20
Air Temp.	°C	15.5
Arch Pressure	mmH₂Og	-7.808
Floor Pressure	mmH₂Og	-17.747
Exchange Factor		0.412
DIMENSIONS
Radiant Height	m	11.08
Radiant Width	m	5.02
Radiant Length	m	5.02
No. of Burners		3
Draft Type		Forced
BURNERS
Burner Design Firing	MW	4.99
Burner Normal Firing	MW	4.16
Burner Min Firing	MW	1

API 560 COMPLIANCE
Burner Spacing		OK
Burner Circle Diameter	m	1.394
Adjusted BCD (for BCD-TCD API limits)	m	1.394
BCD/TCD		0.31
Flame height suitability		OK
BTB value	m	0.697
BTC value	m	1.346
BTW	m	0.314
Floor Flux	W/m²	630629
Floor Flux Suitability		OK

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Radiant Cell		1
Radiant Type		Vertical Cylindrical
AIR & FUEL
Flue Flow	kg/s	19411
Air Flow	kg/s	18514
Fuel Flow	kg/s	897
Fuel LHV	kJ/kg	50015
Excess Air	%	20
Air Temp.	°C	15.5
BURNERS
No. of Burners	m	3
Burner Cirle Diameter	m
Burner Design Firing	MW	4.99
Burner Normal Firing	MW	4.16
Burner Min Firing	MW	1
Flame Temperature	°C	1793
EMISSIONS
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0
Dew Point	°C	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flue Gas Emissivity		0.392

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MW	3.3
Max Tube Temp.	°C	469.9
DIMENSIONS
Convection Width	m	2.59
Effective Length	m	5.84
Convection Height	m	4.041
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH₂O	0.74
Total Press. Gain	mmH₂O	3.31
Total Press. Loss (inc. gain)	mmH₂O	-2.57
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	kg/s	19411
Flue Gas Inlet Temp.	°C	855.2
Flue Gas Outlet Temp.	°C	385.5
CO₂	mol%	8.058337
H₂O	mol%	16.05639
N₂	mol%	72.674
O₂	mol%	3.211277
SO₂	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MW	°C	°C	kJ/kg	kJ/kg	kg/m³		W/m²	W/m²		kg/s m²	mmH2Og			°C	°C
1	8	Coil Section 3	0.13	405.2	385.5	445.4	421.8	0.51	Solid	5161	6638	8	0.936	0.118	C.S.	C.S.	375.5	379.4
1	7	Coil Section 3	0.22	438	405.2	485.3	445.4	0.49	Solid	8716	11282	8	0.936	0.122	C.S.	C.S.	389.6	396.1
1	6	Coil Section 3	0.37	494.9	438	554.6	485.3	0.46	Solid	15149	19805	8	0.936	0.128	C.S.	C.S.	414.9	426
1	5	Coil Section 2	0.49	567.8	494.9	646.1	554.6	0.42	Solid	19998	26658	8	0.898	0.099	C.S.	C.S.	435.7	451.5
1	4	Coil Section 2	0.83	688.3	567.8	799.9	646.1	0.38	Solid	33648	45548	8	0.898	0.108	C.S.	C.S.	485.1	510.4
1	3	Coil Section 1	0.33	733.1	688.3	858.4	799.9	0.34	None	13731	23808	8	0.847	0.054	C.S.	None	0	0
1	2	Coil Section 1	0.4	785.3	733.1	927.7	858.4	0.33	None	17526	30386	8	0.847	0.056	C.S.	None	0	0
1	1	Coil Section 1	0.53	855.2	785.3	1011.5	927.7	0.31	None	24484	42451	8	0.847	0.06	C.S.	None	0	0

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.13	405.2	385.5	AR-HVS-MPS	1	356	356.6	13100	13097	0.03	0.04	1	1	14.8	16.1	804	804	250915	253520
1	7	Coil Section 3	0.22	438	405.2	AR-HVS-MPS	2	356.6	357.7	13097	13095	0.04	0.05	1	1	16.1	18.2	804	804	253520	258002
1	6	Coil Section 3	0.37	494.9	438	AR-HVS-MPS	3	357.7	359.6	13095	13092	0.05	0.06	1	1	18.2	21.5	804	804	257996	266037
1	5	Coil Section 2	0.49	567.8	494.9	AR-HVS-MPS	4	359.6	362.1	13092	13090	0.06	0.08	1	1	21.5	25.5	804	804	266032	276490
1	4	Coil Section 2	0.83	688.3	567.8	AR-HVS-MPS	5	362.1	366.3	13090	13088	0.08	0.12	1	0.9	25.5	31.9	804	804	276481	292134
1	3	Coil Section 1	0.33	733.1	688.3	AR-HVS-MPS	6	366.3	368	13088	13085	0.12	0.13	0.9	0.9	31.9	34.3	804	804	292152	300012
1	2	Coil Section 1	0.4	785.3	733.1	AR-HVS-MPS	7	368	370	13085	13083	0.13	0.15	0.9	0.9	34.3	37.4	804	804	299995	310930
1	1	Coil Section 1	0.53	855.2	785.3	AR-HVS-MPS	8	370	372.7	13083	13080	0.15	0.18	0.9	0.9	37.4	41.5	804	804	311001	325655

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MW	°C	°C			°C	°C	kPa a	kPa a			m/s	m/s	m/s	m/s	kg/s m²	kg/s m²
1	8	Coil Section 3	0.13	405.2	385.5	AR-HVS-MPS	1	356	356.6	13100	13097	0.03	0.04	1	1	14.8	16.1	804	804	250915	253520
1	7	Coil Section 3	0.22	438	405.2	AR-HVS-MPS	2	356.6	357.7	13097	13095	0.04	0.05	1	1	16.1	18.2	804	804	253520	258002
1	6	Coil Section 3	0.37	494.9	438	AR-HVS-MPS	3	357.7	359.6	13095	13092	0.05	0.06	1	1	18.2	21.5	804	804	257996	266037
1	5	Coil Section 2	0.49	567.8	494.9	AR-HVS-MPS	4	359.6	362.1	13092	13090	0.06	0.08	1	1	21.5	25.5	804	804	266032	276490
1	4	Coil Section 2	0.83	688.3	567.8	AR-HVS-MPS	5	362.1	366.3	13090	13088	0.08	0.12	1	0.9	25.5	31.9	804	804	276481	292134
1	3	Coil Section 1	0.33	733.1	688.3	AR-HVS-MPS	6	366.3	368	13088	13085	0.12	0.13	0.9	0.9	31.9	34.3	804	804	292152	300012
1	2	Coil Section 1	0.4	785.3	733.1	AR-HVS-MPS	7	368	370	13085	13083	0.13	0.15	0.9	0.9	34.3	37.4	804	804	299995	310930
1	1	Coil Section 1	0.53	855.2	785.3	AR-HVS-MPS	8	370	372.7	13083	13080	0.15	0.18	0.9	0.9	37.4	41.5	804	804	311001	325655

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C			W/m²	W/m²
1	Wall	AR-HVS-MPS	372.7	373.4	13080.4	13268.2	210.1	214.8	0.181	168.3	1.8	428.6	434.9	442	457	979.6	Bubble		26290	49400	0.08314553	1186236
2	Wall	AR-HVS-MPS	373.4	374.2	13268.2	13167.2	214.8	219.6	0.187	168.3	1.8	429	435.4	442.4	457.4	984.3	Bubble		26278	49378	0.08732186	1186236
3	Wall	AR-HVS-MPS	374.2	374.9	13167.2	13348.5	219.6	224.3	0.194	168.3	1.8	429.5	435.8	442.8	457.8	989.4	Bubble		26266	49358	0.09163508	1186237
4	Wall	AR-HVS-MPS	374.9	375.6	13348.5	13248.3	224.3	229.1	0.2	168.3	1.8	429.8	436.1	443.2	458.2	995	Bubble		26254	49338	0.09609371	1186237
5	Wall	AR-HVS-MPS	375.6	376.3	13248.3	13423.2	229.1	233.8	0.206	168.3	1.8	430.2	436.5	443.5	458.5	1001	Slug		26243	49319	0.1007057	1186236
6	Wall	AR-HVS-MPS	376.3	377.1	13423.2	13323.8	233.8	238.6	0.212	168.3	1.8	430.6	436.9	443.9	458.9	1007.4	Slug		26233	49302	0.1054795	1186237
7	Wall	AR-HVS-MPS	377.1	377.8	13323.8	13492.3	238.6	243.3	0.218	168.3	1.8	430.9	437.2	444.2	459.2	1014.2	Slug		26223	49284	0.1104258	1186236
8	Wall	AR-HVS-MPS	377.8	378.5	13492.3	13393.8	243.3	248.1	0.224	168.3	1.8	431.2	437.5	444.5	459.5	1022.1	Slug		26214	49270	0.1156134	1186237
9	Wall	AR-HVS-MPS	378.5	379.2	13393.8	13555.8	248.1	252.8	0.231	168.3	1.8	431.5	437.7	444.8	459.8	1031.1	Slug		26207	49257	0.121053	1186236
10	Wall	AR-HVS-MPS	379.2	379.9	13555.8	13458.1	252.8	257.6	0.237	168.3	1.8	431.7	438	445	460	1040.3	Slug		26199	49245	0.1267094	1186237
11	Wall	AR-HVS-MPS	379.9	380.7	13458.1	13613.6	257.6	262.4	0.243	168.3	1.8	431.9	438.2	445.2	460.2	1050	Slug		26193	49234	0.132596	1186236
12	Wall	AR-HVS-MPS	380.7	381.4	13613.6	13516.9	262.4	267.1	0.249	168.3	1.8	432.2	438.4	445.4	460.4	1059.9	Slug		26186	49222	0.1387295	1186237
13	Wall	AR-HVS-MPS	381.4	382.1	13516.9	13665.9	267.1	271.9	0.255	168.3	1.8	414.2	420.6	427.7	442.7	1707	Slug		26707	50105	0.1451266	1186237
14	Wall	AR-HVS-MPS	382.1	382.8	13665.9	13570	271.9	276.6	0.261	168.3	1.8	414.3	420.7	427.8	442.8	1739.1	Slug		26703	50099	0.1518058	1186237
15	Wall	AR-HVS-MPS	382.8	383.6	13570	13712.6	276.6	281.4	0.268	168.3	1.8	414.4	420.9	428	443	1770.9	Slug		26699	50092	0.1587841	1186236
16	Wall	AR-HVS-MPS	383.6	384.3	13712.6	13617.6	281.4	286.1	0.274	168.3	1.8	414.6	421	428.1	443.1	1804.9	Slug		26695	50085	0.166133	1186237
17	Wall	AR-HVS-MPS	384.3	385	13617.6	13753.6	286.1	290.9	0.28	168.3	1.8	414.7	421.1	428.3	443.3	1838.7	Slug		26690	50078	0.1738332	1186237
18	Wall	AR-HVS-MPS	385	385.7	13753.6	13659.6	290.9	295.6	0.286	168.3	1.8	414.9	421.3	428.5	443.5	1872.2	Slug		26685	50069	0.1819192	1186237
19	Wall	AR-HVS-MPS	385.7	386.4	13659.6	13789.1	295.6	300.4	0.292	168.3	1.8	415.1	421.5	428.7	443.7	1905.5	Slug		26679	50059	0.1904234	1186237
20	Wall	AR-HVS-MPS	386.4	387.2	13789.1	13696.1	300.4	305.1	0.298	168.3	1.8	415.3	421.8	428.9	443.9	1938.6	Slug		26673	50048	0.1993833	1186237
21	Wall	AR-HVS-MPS	387.2	387.9	13696.1	13818.9	305.1	309.9	0.305	168.3	1.8	415.6	422	429.1	444.1	1971.6	Slug		26666	50037	0.2088415	1186237
22	Wall	AR-HVS-MPS	387.9	388.6	13818.9	13727.1	309.9	314.6	0.311	168.3	1.8	415.9	422.3	429.4	444.4	2004.3	Slug		26659	50024	0.2188449	1186236
23	Wall	AR-HVS-MPS	388.6	389.3	13727.1	13843.2	314.6	319.4	0.317	168.3	1.8	416.1	422.5	429.6	444.6	2037.1	Slug		26651	50011	0.2295657	1186237
24	Wall	AR-HVS-MPS	389.3	390	13843.2	13752.6	319.4	324.2	0.323	168.3	1.8	416.4	422.8	429.9	444.9	2069.9	Slug		26643	49997	0.2411135	1186237
25	Wall	AR-HVS-MPS	390	390.8	13752.6	13867.8	324.2	328.9	0.329	168.3	1.8	416.7	423.1	430.2	445.2	2102.6	Slug		26634	49982	0.2534348	1186236
26	Wall	AR-HVS-MPS	390.8	391.5	13867.8	13772.9	328.9	333.7	0.336	168.3	1.8	417	423.4	430.5	445.5	2135.1	Slug		26625	49967	0.2666202	1186237
27	Wall	AR-HVS-MPS	391.5	392.2	13772.9	13879.8	333.7	338.4	0.342	168.3	1.8	417.4	423.8	430.9	445.9	2167.4	Slug		26615	49951	0.2807751	1186237
28	Wall	AR-HVS-MPS	392.2	392.9	13879.8	13788.4	338.4	343.2	0.348	168.3	1.9	417.7	424.1	431.2	446.2	2199.6	Slug		26606	49934	0.2960292	1186237
29	Wall	AR-HVS-MPS	392.9	393.7	13788.4	13886.8	343.2	347.9	0.354	168.3	1.9	418.1	424.5	431.6	446.6	2231.6	Slug		26595	49917	0.3125342	1186237
30	Wall	AR-HVS-MPS	393.7	394.4	13886.8	13799.2	347.9	352.7	0.36	168.3	1.9	418.5	424.8	431.9	446.9	2263.4	Slug		26585	49899	0.3304737	1186237
31	Wall	AR-HVS-MPS	394.4	395.1	13799.2	13888.9	352.7	357.4	0.366	168.3	1.9	418.9	425.2	432.3	447.3	2293	Slug		26573	49880	0.3502289	1186237
32	Wall	AR-HVS-MPS	395.1	395.8	13888.9	13805.1	357.4	362.2	0.373	168.3	2	419.3	425.6	432.7	447.7	2322.3	Slug		26561	49860	0.3719897	1186237
33	Wall	AR-HVS-MPS	395.8	396.5	13805.1	13885.8	362.2	366.9	0.379	168.3	2	419.7	426.1	433.2	448.2	2351.3	Slug		26549	49839	0.396113	1186237
34	Wall	AR-HVS-MPS	396.5	397.3	13885.8	13806.2	366.9	371.7	0.385	168.3	2.1	420.1	426.5	433.6	448.6	2380.1	Annular		26537	49818	0.4230813	1186237
35	Wall	AR-HVS-MPS	397.3	398	13806.2	13877.3	371.7	376.4	0.391	168.3	2.2	420.6	426.9	434	449	2408.6	Annular		26524	49797	0.4535256	1186237
36	Wall	AR-HVS-MPS	398	398.7	13877.3	13802.5	376.4	381.2	0.397	168.3	2.3	421	427.4	434.5	449.5	2437	Annular		26511	49775	0.4883105	1186236
37	Wall	AR-HVS-MPS	398.7	399.4	13802.5	13863.5	381.2	386	0.403	168.3	2.4	421.5	427.8	434.9	449.9	2465.1	Annular		26498	49753	0.5286321	1186236
38	Wall	AR-HVS-MPS	399.4	400.2	13863.5	13794.1	386	390.7	0.41	168.3	2.6	421.9	428.3	435.4	450.4	2494.3	Annular		26485	49730	0.5765904	1186236
39	Wall	AR-HVS-MPS	400.2	400.9	13794.1	13844.1	390.7	395.5	0.416	168.3	2.8	422.4	428.7	435.8	450.8	2525.4	Annular		26472	49708	0.6352871	1186237
40	Wall	AR-HVS-MPS	400.9	401.6	13844.1	13781.6	395.5	400.2	0.422	168.3	3.2	422.8	429.2	436.2	451.2	2556.3	Annular		26459	49686	0.7086913	1186237
41	Wall	AR-HVS-MPS	401.6	402.3	13781.6	13818.6	400.2	405	0.428	168.3	3.7	423.3	429.6	436.7	451.7	2587	Annular		26446	49664	0.8046253	1186236
42	Wall	AR-HVS-MPS	402.3	403	13818.6	13765.6	405	409.7	0.434	168.3	4.6	423.8	430.1	437.2	452.2	2617.6	Annular		26432	49641	0.9385071	1186237
43	Wall	AR-HVS-MPS	403	403.8	13765.6	13785.6	409.7	414.5	0.44	168.3	6.4	424.2	430.6	437.6	452.6	2648.1	Annular		26418	49617	1.146653	1186237
44	Wall	AR-HVS-MPS	403.8	404.5	13785.6	13745.4	414.5	419.2	0.447	168.3	12.7	424.7	431	438.1	453.1	2678.4	Annular		26404	49594	1.547229	1186236
45	Wall	AR-HVS-MPS	404.5	405.2	13745.4	13708.3	419.2	424	0.453	168.3	229.3	425.2	431.5	438.6	453.6	2708.6	Mist		26390	49570	3.093204	1186237
46	Wall	AR-HVS-MPS	405.2	405.9	13708.3	13380.6	424	428.7	0.459	168.3	232.4	425.7	432	439.1	454.1	2738.7	Mist		26376	49545	9.029726	1186237
47	Wall	AR-HVS-MPS	405.9	406.7	13380.6	12976.4	428.7	433.5	0.465	168.3	235.5	426.2	432.5	439.6	454.6	2768.6	Mist		26361	49521	9.23555	1186237

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

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Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°C	°C	kPa a	kPa a	kJ/kg	kJ/kg			m/s	°C	°C	°C	°C	W/m² °C				W/m²	W/m²
1	1	3	8	AR-HVS-MPS	356	356.2	13100	13099.4	100	101.1	0.0334	168.3	1	371.5	372.1	372.8	387.8	538.3	Solid	Stratified	C.S.	5185	7574	2.359085	157.8938
1	2	3	8	AR-HVS-MPS	356.2	356.3	13099.4	13098.7	101.1	102.1	0.0348	168.3	1	371.6	372.2	372.9	387.9	537.6	Solid	Stratified	C.S.	5163	7542	2.392047	164.8901
1	3	3	8	AR-HVS-MPS	356.3	356.5	13098.7	13098.1	102.1	103.2	0.0362	168.3	1	371.8	372.3	373	388	536.9	Solid	Stratified	C.S.	5141	7509	2.425596	171.9079
1	4	3	8	AR-HVS-MPS	356.5	356.6	13098.1	13097.5	103.2	104.2	0.0376	168.3	1	371.9	372.4	373.1	388.1	536.2	Solid	Stratified	C.S.	5118	7477	2.459743	178.9476
1	5	3	7	AR-HVS-MPS	356.6	356.9	13097.5	13096.8	104.2	106	0.0399	168.3	1	382.9	383.8	385.1	400.1	540.1	Solid	Stratified	C.S.	8758	12848	2.506617	188.4457
1	6	3	7	AR-HVS-MPS	356.9	357.2	13096.8	13096.2	106	107.8	0.0422	168.3	1	383.1	384.1	385.3	400.3	539	Solid	Stratified	C.S.	8719	12791	2.567131	200.4359
1	7	3	7	AR-HVS-MPS	357.2	357.5	13096.2	13095.6	107.8	109.6	0.0446	168.3	1	383.3	384.3	385.5	400.5	537.9	Solid	Stratified	C.S.	8681	12735	2.629513	212.4902
1	8	3	7	AR-HVS-MPS	357.5	357.7	13095.6	13095	109.6	111.4	0.0469	168.3	1	383.5	384.5	385.7	400.7	536.8	Solid	Stratified	C.S.	8642	12678	2.693833	224.6093
1	9	3	6	AR-HVS-MPS	357.7	358.2	13095	13094.3	111.4	114.5	0.051	168.3	1	403.3	405	407.1	422.1	544.9	Solid	Stratified	C.S.	15223	22481	2.784803	241.2419
1	10	3	6	AR-HVS-MPS	358.2	358.7	13094.3	13093.7	114.5	117.6	0.055	168.3	1	403.7	405.4	407.5	422.5	543.3	Solid	Stratified	C.S.	15153	22378	2.906471	262.6188
1	11	3	6	AR-HVS-MPS	358.7	359.2	13093.7	13093.1	117.6	120.8	0.0591	168.3	1	404.1	405.7	407.9	422.9	541.9	Solid	Stratified	C.S.	15083	22275	3.034992	284.2045
1	12	3	6	AR-HVS-MPS	359.2	359.6	13093.1	13092.5	120.8	123.9	0.0631	168.3	1	404.4	406.1	408.3	423.3	540.6	Solid	Stratified	C.S.	15013	22172	3.170801	305.9979
1	13	2	5	AR-HVS-MPS	359.6	360.3	13092.5	13091.9	123.9	128	0.0684	168.3	1	419.9	422.2	425.1	440.1	550.3	Solid	Stratified	C.S.	20084	30017	3.337827	331.4975
1	14	2	5	AR-HVS-MPS	360.3	360.9	13091.9	13091.3	128	132.1	0.0737	168.3	1	420.4	422.7	425.6	440.6	548.9	Solid	Stratified	C.S.	20009	29904	3.542183	360.9376
1	15	2	5	AR-HVS-MPS	360.9	361.5	13091.3	13090.7	132.1	136.2	0.0791	168.3	1	420.9	423.2	426.1	441.1	547.7	Solid	Stratified	C.S.	19933	29791	3.762705	390.7745
1	16	2	5	AR-HVS-MPS	361.5	362.1	13090.7	13090.1	136.2	140.3	0.0844	168.3	1	421.4	423.7	426.6	441.6	546.8	Solid	Stratified	C.S.	19858	29678	4.005133	421.2971
1	17	2	4	AR-HVS-MPS	362.1	363.2	13090.1	13089.4	140.3	147.2	0.0934	168.3	1	458.8	462.8	467.8	482.8	582.2	Solid	Stratified	C.S.	33803	51042	4.365259	463.045
1	18	2	4	AR-HVS-MPS	363.2	364.2	13089.4	13088.8	147.2	154.2	0.1024	168.3	1	459.6	463.6	468.6	483.6	581.3	Solid	Stratified	C.S.	33664	50833	4.878654	516.7249
1	19	2	4	AR-HVS-MPS	364.2	365.3	13088.8	13088.3	154.2	161.1	0.1114	168.3	1	460.3	464.3	469.3	484.3	580.9	Solid	Stratified	C.S.	33525	50623	5.470936	571.7672
1	20	2	4	AR-HVS-MPS	365.3	366.3	13088.3	13087.7	161.1	168	0.1204	168.3	0.9	461	464.9	469.9	484.9	580.9	Solid	Stratified	C.S.	33386	50413	6.157171	628.2441
1	21	1	3	AR-HVS-MPS	366.3	366.8	13087.7	13087.1	168	170.8	0.1239	168.3	0.9	413.4	415.2	417.4	432.4	539	None	Stratified	C.S.	13278	23022	6.704411	668.7589
1	22	1	3	AR-HVS-MPS	366.8	367.2	13087.1	13086.4	170.8	173.5	0.1275	168.3	0.9	413.7	415.5	417.7	432.7	539.5	None	Stratified	C.S.	13263	22995	7.039266	691.9253
1	23	1	3	AR-HVS-MPS	367.2	367.6	13086.4	13085.8	173.5	176.2	0.1311	168.3	0.9	414	415.8	418	433	540.1	None	Stratified	C.S.	13247	22968	7.396738	715.6275
1	24	1	3	AR-HVS-MPS	367.6	368	13085.8	13085.2	176.2	178.9	0.1346	168.3	0.9	414.3	416.1	418.3	433.3	540.8	None	Stratified	C.S.	13232	22941	7.777658	739.6002
1	25	1	2	AR-HVS-MPS	368	368.5	13085.2	13084.6	178.9	182.3	0.139	168.3	0.9	425	427.2	430	445	548.4	None	Stratified	C.S.	16367	28377	8.229455	766.4888
1	26	1	2	AR-HVS-MPS	368.5	369	13084.6	13084	182.3	185.6	0.1433	168.3	0.9	425.4	427.6	430.3	445.3	549.4	None	Stratified	C.S.	16347	28342	8.771743	796.7934
1	27	1	2	AR-HVS-MPS	369	369.5	13084	13083.4	185.6	189	0.1477	168.3	0.9	425.7	427.9	430.6	445.6	550.5	None	Stratified	C.S.	16327	28308	9.360255	827.538
1	28	1	2	AR-HVS-MPS	369.5	370	13083.4	13082.8	189	192.4	0.1521	168.3	0.9	426	428.2	430.9	445.9	551.7	None	Stratified	C.S.	16307	28273	9.999845	858.7363
1	29	1	1	AR-HVS-MPS	370	370.7	13082.8	13082.2	192.5	196.9	0.1579	168.3	0.9	442.6	445.5	449.1	464.1	565.3	None	Stratified	C.S.	21436	37167	10.82771	896.1517
1	30	1	1	AR-HVS-MPS	370.7	371.4	13082.2	13081.6	196.9	201.3	0.1636	168.3	0.9	442.9	445.9	449.4	464.4	567.1	None	Stratified	C.S.	21409	37119	11.85138	938.4774
1	31	1	1	AR-HVS-MPS	371.4	372.1	13081.6	13081	201.3	205.7	0.1693	168.3	0.9	443.3	446.2	449.8	464.8	569.1	None	Stratified	C.S.	21382	37072	13.00111	981.6729
1	32	1	1	AR-HVS-MPS	372.1	372.7	13081	13080.4	205.7	210.1	0.175	168.3	0.9	443.6	446.5	450.1	465.1	571.2	None	Stratified	C.S.	21354	37024	14.29967	1025.859

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: AR-HVS-MPS	Process 1: AR-HVS-MPS	Process 1: AR-HVS-MPS	Process 1: AR-HVS-MPS
Tube OD	mm	168.3	168.3	168.3	168.3
Tube Material		9Cr/1.0Mo - P9	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	mm	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°C	445.4	450.1	469.9	408.3
Tube Temperature Margin	°C	15	15	15	15
Design Tube Temperature	°C	460.4	465.1	484.9	423.3
Design Tube Pressure	kPa	3030	3030	3030	3030
Design Code		API 530	API 530	API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		47	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		1	2	2	2
Effective Length	m	10.084	5.84	5.84	5.84
Straight Length	m	9.685	6.24	6.24	6.24
No. Rows			3	2	3
Tube Spacing	mm	304.8	304.8	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1	264.1	264.1
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	m²	250.59	74.07	381.62	933.39
Intermediate Supports		0 / 0	0 / 1	0 / 1	0 / 1
Corbel Width	m		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin/Stud Material			None	Carbon Steel	Carbon Steel
Fin/Stud Height	mm			19.1	25.4
Fin/Stud Thickness	mm			1.3	1.3
Serrated Fin Wn
Fin/Stud Density	fins/m			157	197
No. Studs per ring				12	12
Avg Fin Temperature	°C			485.1	414.9
Max Fin Temperature	°C			510.4	426


PROCESS DATA
Process Temp. In	°C	372.7	366.3	359.6	356
Process Temp. Out	°C	406.7	372.7	366.3	359.6
Process Press. In	°C	13080.4	13087.7	13092.5	13100
Process Press. Out	°C	12976.4	13080.4	13087.7	13092.5
Process Vap. Fract In		0	0.12	0.063	0.032
Process Vap. Fract Out		0.465	0.175	0.12	0.063
Process Max. Velocity	m/s	235.48	0.93	0.97	1
Process Max. Mass Velocity	kg/s m²	1608.94	804.47	804.47	804.47
Process Flow Regime In		Bubble	Stratified	Stratified	Stratified
Process Flow Regime Out		Mist	Stratified	Stratified	Stratified


FLUE GAS DATA
Flue Temp. In	°C	855.2	855.2	688.3	494.9
Flue Temp. Out	°C	855.2	688.3	494.9	385.5
Flue Enthalpy In	kJ/kg	1011.5	1012	800	555
Flue Enthalpy Out	kJ/kg	1011.5	800	555	422
Conv. Flue Mass Velocity	kg/s m²		0.85	0.9	0.94

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	3030	3030	3030	3030
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	13100	13100	13100	13100
tblDesignTemp,calcref0	Design Temperature	°C	460.4437	465.0589	484.9034	423.2567
tblTubeMaterial	Tube Material		9Cr/1.0Mo - P9	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		168.3	168.3	168.3	168.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	7.11	7.11	7.11	7.11
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	2	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	7.11	7.11	7.11	7.11
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	104048	92461.9	89188.5	99951.4
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	2.4154	2.7132	2.8111	2.5129
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.42	5.71	5.81	5.51
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	5.05	6.53	6.64	6.3
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	57617.2	44690	92412.3
RuptureNfactor,resultref0	Rupture n factor		0	5.663273	5.226935	6.793061
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	17.1796	21.5138	11.1392
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	20.18	24.51	14.14
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	23.06	28.02	16.16
RuptureBfactor,resultref0	B factor		0	0.1746261	0.1394456	0.2693181
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	1	1	1
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Thickness is OK	Thickness is OK	Thickness is OK

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

HeaterSIM - Fired Heater Simulation Results

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

HeaterSIM - Fired Heater Simulation Results

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Stack Height	m	15
Stack Diameter	m	1.54
Cone Diameter	m	1.535
Cone Height	m	0.5
Actual Exit Velocity	m/s	6.5
Design Exit Velocity	m/s	7.8
Flue Gas Temp.	°C	385.5
Flue Gas Flow	kg/s	19411
Steel Area	m²	72.571
Stack Entry Pressure	mmH₂O	-4.292
CO₂	mol%	8.06
H₂O	mol%	16.06
N₂	mol%	72.67
O₂	mol%	3.21
SO₂	mol%	0

Stack No. 1: Stack design seems OK

Refractory

HeaterSIM - Fired Heater Simulation Results

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°C		mm	W/mK		mm	W/mK	W/m²	W/m²	°C
RADIANT FLOOR 1	805.2	MW Castable	75	0.4	ULW Castable	150	0.13	732.5	543.9	1400	V Y Anchors	76.1	Refrac. thickness OK
RADIANT WALL 1	650.3	Fibre (High Density)	75	0.1	None	0	0	732.8	636.9	1260	Twistlock Pins	75.1	Refrac. thickness OK
RADIANT ARCH 1	855.2	Fibre (High Density)	100.4	0.1	None	0	0	824	954.7	1260	Twistlock Pins	87.6	Refrac.thickness NOT sufficient

CONVECTION SIDEWALL 1	620.4	LW Castable	75	0.3	ULW Castable	75	0.13	732.8	666.2	1100	V Y Anchors	77.8	Refrac. thickness OK

STACK 1	385.5	LW Castable	62.7	0.3	None	0	0	732.8	1621.2	1100	V Y Anchors	126.4	Refrac.thickness NOT sufficient

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	lb/s	9.897
Flue Gas Temp.	°F	295.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

AIR
Air Flow	lb/s	9.44
Air Temp.	°F	59.9
Excess Air	%	20

FUEL
Fuel Flow	lb/s	0.457
Fuel LHV	BTU/lb	21517
Fuel Mol. Wt.		16

Radiant Cell		1
Arch Temp.	°F	1409
Max Tube Temp.	°F	498.6
Average Flux	BTU/hr ft²	8330
Arch Pressure	mmH2O	-0.104

No. of Burners		4
Floor Pressure	mmH2O	-0.49

ENERGY PERFORMACE
Total Absorbed Duty	MMBTU/hr	32.669
Total Heat Release	MMBTU/hr	35.383
Total Efficiency	%	92.33

ENVIRONMENTAL IMPACT
Energy Efficiency	%	92.33
Daily CO2 Emissions	kg	49446

Total:

£ 879,974

HR	MMBTU/hr	35.383
Arch	°F	1409
Tube	°F	498.6
Flux	BTU/hr ft²	8330

No. Burners	Ft	4
Fuel Flow	lb/s	0.457
Air Flow	lb/s	9.44
Air Temp.	°F	59.9
Excess Air	%	20

STACK
Flow	lb/s	9.897
Temp.	°F	295.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Process Inlet------->

Therminol XP , 212 °F, 108.8 psi a

Fuel m.w.		16
Fuel LHV	BTU/lb	21517

Process Outlet------->

Therminol XP , 391.7 °F, 85.687 psi a, 32.669 MMBTU/hr

Firing MMBTU/hr
35.38
Duty MMBTU/hr
32.67
Efficiency %
92.33
CO2 Ton/day
49

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

HeaterSIM - Fired Heater Simulation Results

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Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

Commercial

HeaterSIM - Fired Heater Simulation Results

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 685,630
Option items
Detail Engineering (by HeaterSIM)	£ 102,844
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£879,974

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Therminol XP	Therminol XP	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	lb/s	88.2	88.2	9.897	9.897	0.457	9.44
Flow (hr)	lb/hr	317520	317520	35628	35628	1646	33983
Temperature	°F	212	391.7	1409	295.9	Note 1	15.5
Pressure	psi a	108.8	85.687	-0.104	0	Note 2	14.7

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

114 Ft 65 Ft 59 Ft 46 Ft 27 Ft 9 Ft Grade 0.00 Ft 4 Ft 19 Ft 15 Ft 14 Ft 4 Burners
(Natural Draft)

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Design Code		API 530	API 530	API 530	API 530
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Tube Spacing	inch	10	10	10	10
Vert. Row Spacing (Vert)	inch	N/A	8.7	8.7	8.7
No. Tubes		52	24	16	24
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

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Process Name		Therminol XP
Heat Duty	MMBTU/hr	32.669
Flow rate (sec)	lb/s	88.2
Flow rate (hr)	lb/hr	317520
Pressure drop	psi	23.113
Max. Film Temp. Calculated	°F	484.3
Max. Film Temp. Allowed	°F	662
Max Tube Average Flux Calculated (1)	BTU/hr ft²	8438
Average Flux Allowed	BTU/hr ft²	9986
INLET CONDITIONS
Inlet Temperature	°F	212
Inlet Pressure	psi a	108.8
Inlet Vapour Fraction		0
Inlet Enthalpy	BTU/lb	148
OUTLET CONDITIONS
Outlet Temperature	°F	391.7
Outlet Pressure	psi a	85.687
Outlet Vapour Fraction		0
Outlet Enthalpy	BTU/lb	251

If the specified or calculated fluid temperature(s) and pressure(s) are outside of the defined property grid the program will use extrapolation. Significant extrapolation may introduce inaccuracies.

1) The max flux calculated on a individual tube basis (see tube profile results data).

Typical Schematic

Radiant Section

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type		Vertical Cylindrical
Heat Duty	MMBTU/hr	20.87
Heat Release	MMBTU/hr	35.383
Arch Temp.	°F	1409
Max Tube Temp.	°F	498.6
Tube Cirle Diameter	Ft	13.793
Average Flux	BTU/hr ft²	8330
Maximum Flux	BTU/hr ft²	17015
Flue Flow	lb/s	9.897
Air Flow	lb/s	9.44
Fuel Flow	lb/s	0.457
Excess Air	%	20
Air Temp.	°F	59.9
Arch Pressure	mmH2O	-0.104
Floor Pressure	mmH2O	-0.49
DIMENSIONS
Radiant Height	Ft	36.37
Radiant Width	Ft	15.04
Radiant Length	Ft	15.04
No. of Burners		4
Draft Type		Natural
BURNERS
Burner Cirle Diameter	Ft	3.967
Burner Design Firing	MMBTU/hr	10.62
Burner Normal Firing	MMBTU/hr	8.85
Burner Min Firing	MMBTU/hr	2.12
Burner-to-Tube Note		Too Close (please check)
Burner-to-Wall Note		N/A
Burner-to-Roof Note		OK
API 560 COMPLIANCE
API Burner-to-Tube Dist.	Ft	4.083
API Burner-to-Wall Dist.	Ft	3.67
API Burner-to-Roof/Roof Dist	Ft	25.894
Floor Flux	BTU/hr ft²	199266

Flame-tube impingment risk not identified

Combustion

HeaterSIM - Fired Heater Simulation Results

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Radiant Cell		1
Radiant Type
AIR & FUEL
Flue Flow	lb/s	9.897
Air Flow	lb/s	9.44
Fuel Flow	lb/s	0.457
Fuel LHV	BTU/lb	21517
Excess Air	%	20
Air Temp.	°F	59.9
BURNERS
No. of Burners	Ft	4
Burner Cirle Diameter	Ft
Burner Design Firing	MMBTU/hr	10.62
Burner Normal Firing	MMBTU/hr	8.85
Burner Min Firing	MMBTU/hr	2.12
Flame Temperature	°F	3282
EMISSIONS
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0
Dew Point	°F	56
Fuel Mol. Wt.		16
Flue Mol. Wt.		27.812
Flue Gas Emissivity		0.444

Notes
1. One UV scanner per burner is recommended (if total no. burners < 20)
2. One Pilot per burner is recommended
3. Electric spark ignition is recommended for each pilot
4. Forced draft system

Convection Section

HeaterSIM - Fired Heater Simulation Results

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Convection Sect. No.		1
DUTY & TUBE TEMP.
Heat Duty	MMBTU/hr	11.8
Max Tube Temp.	°F	428.9
DIMENSIONS
Convection Width	Ft	4.76
Effective Length	Ft	12.864
Convection Height	Ft	11.815
PRESSURE LOSSES
Total Flue Press. Loss (ex. gain)	mmH2O	0.02
Total Press. Gain	mmH2O	0.11
Total Press. Loss (inc. gain)	mmH2O	-0.08
Total No. Rows		8
FLUE GAS DATA
Flue Gas Flow	lb/s	9.897
Flue Gas Inlet Temp.	°F	1409
Flue Gas Outlet Temp.	°F	295.9
CO2	mol%	8.058337
H2O	mol%	16.05639
N2	mol%	72.674
O2	mol%	3.211277
SO2	mol%	0

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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Conbox	Row	Coil Section	Duty	Temp Inlet	Temp Outlet	Enthalpy In	Enthalpy Out	Flue Density	Fin Type	Avg Flux	Max Flux	Tubes per Row	FG Mass Vel.	Flue P drop	Tube Material	Fin Material	Avg Fin Temp	Max Fin Temp
			MMBTU/hr	°F	°F	BTU/lb	BTU/lb	lb/ft³		BTU/hr ft²	BTU/hr ft²		lb/s ft²	inchH2Og			°F	°F
1	8	Coil Section 3	0.56	353.1	295.9	77.6	62	0.05	Solid	2498	3093	8	0.197	0.003	C.S.	C.S.	262.4	273.9
1	7	Coil Section 3	0.91	446	353.1	103	77.6	0.04	Solid	4085	5060	8	0.197	0.003	C.S.	C.S.	294.6	313.6
1	6	Coil Section 3	1.53	599.6	446	145.7	103	0.04	Solid	6864	8479	8	0.197	0.004	C.S.	C.S.	348.3	380
1	5	Coil Section 2	1.89	784.3	599.6	198.5	145.7	0.03	Solid	8457	10450	8	0.187	0.003	C.S.	C.S.	381.1	425.8
1	4	Coil Section 2	3.05	1073.6	784.3	283.9	198.5	0.03	Solid	13686	16924	8	0.187	0.004	C.S.	C.S.	469.4	537.6
1	3	Coil Section 1	1.03	1166.6	1073.6	311.9	283.9	0.02	None	4732	8266	8	0.175	0.002	C.S.	None	32	32
1	2	Coil Section 1	1.25	1274.1	1166.6	345	311.9	0.02	None	5919	10338	8	0.175	0.002	C.S.	None	32	32
1	1	Coil Section 1	1.59	1409	1274.1	384.4	345	0.02	None	8006	13985	8	0.175	0.002	C.S.	None	32	32

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MMBTU/hr	°F	°F			°F	°F	psi a	psi a			ft/s	ft/s	ft/s	ft/s	lb/s ft²	lb/s ft²
1	8	Coil Section 3	0.56	353.1	295.9	Therminol XP	1	212	215.3	109	107	0	0	6.2	6.2	0	0	317	317	56952	58602
1	7	Coil Section 3	0.91	446	353.1	Therminol XP	2	215.1	220.5	107	106	0	0	6.2	6.2	0	0	317	317	58516	61354
1	6	Coil Section 3	1.53	599.6	446	Therminol XP	3	220.6	229.7	106	105	0	0	6.2	6.2	0	0	317	317	61368	66591
1	5	Coil Section 2	1.89	784.3	599.6	Therminol XP	4	229.4	240.6	105	103	0	0	6.2	6.2	0	0	317	317	66458	73806
1	4	Coil Section 2	3.05	1073.6	784.3	Therminol XP	5	241	259.1	103	102	0	0	6.2	6.3	0	0	317	317	74077	88956
1	3	Coil Section 1	1.03	1166.6	1073.6	Therminol XP	6	258.9	265	102	100	0	0	6.3	6.3	0	0	317	317	88785	94841
1	2	Coil Section 1	1.25	1274.1	1166.6	Therminol XP	7	265.9	273.3	100	99	0	0	6.3	6.3	0	0	317	317	95755	104194
1	1	Coil Section 1	1.59	1409	1274.1	Therminol XP	8	272.3	281.6	99	98	0	0	6.3	6.3	0	0	317	317	102994	114387

Conv. Box	Row	Coil Section	Duty	Flue Temp. IN	Flue Temp. OUT	Process	Flow	Bulk Temp. In	Bulk Temp. Out	Bulk Press. In	Bulk Press. Out	Vap. Fraction In	Vap. Fraction Out	Inlet Velocity	Outlet Velocity	Inlet Crit.Vel.	Outlet Crit.Vel.	Inlet M Vel.	Outlet M Vel.	Inlet Reynolds No.	Inlet Reynolds No.
			MMBTU/hr	°F	°F			°F	°F	psi a	psi a			ft/s	ft/s	ft/s	ft/s	lb/s ft²	lb/s ft²
1	8	Coil Section 3	0.56	353.1	295.9	Therminol XP	1	212	215.3	109	107	0	0	6.2	6.2	0	0	317	317	56952	58602
1	7	Coil Section 3	0.91	446	353.1	Therminol XP	2	215.1	220.5	107	106	0	0	6.2	6.2	0	0	317	317	58516	61354
1	6	Coil Section 3	1.53	599.6	446	Therminol XP	3	220.6	229.7	106	105	0	0	6.2	6.2	0	0	317	317	61368	66591
1	5	Coil Section 2	1.89	784.3	599.6	Therminol XP	4	229.4	240.6	105	103	0	0	6.2	6.2	0	0	317	317	66458	73806
1	4	Coil Section 2	3.05	1073.6	784.3	Therminol XP	5	241	259.1	103	102	0	0	6.2	6.3	0	0	317	317	74077	88956
1	3	Coil Section 1	1.03	1166.6	1073.6	Therminol XP	6	258.9	265	102	100	0	0	6.3	6.3	0	0	317	317	88785	94841
1	2	Coil Section 1	1.25	1274.1	1166.6	Therminol XP	7	265.9	273.3	100	99	0	0	6.3	6.3	0	0	317	317	95755	104194
1	1	Coil Section 1	1.59	1409	1274.1	Therminol XP	8	272.3	281.6	99	98	0	0	6.3	6.3	0	0	317	317	102994	114387

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Tube No.	Loc.	Process	Bulk Temp In.	Bulk Temp Out.	Bulk Press In.	Bulk Press. Out	Enth. In	Enth. Out	Vapour Out	Tube OD	Velocity Out	Film Temp	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
			°F	°F	psi a	psi a	BTU/lb	BTU/lb			ft/s	°F	°F	°F	°F	BTU/hr ft² °F			BTU/hr ft²	BTU/hr ft²
1	Wall	Therminol XP	281.6	285.9	97.7	108.7	185.1	187.7	0	5.56	6.4	410.8	415.9	425.2	452.2	151.7	Turbulent		8438	17184	0	0
2	Wall	Therminol XP	285.9	290.2	108.7	96.8	187.7	190.2	0	5.56	6.4	413.6	418.7	428	455	153.4	Turbulent		8429	17171	0	0
3	Wall	Therminol XP	290.2	294.5	96.8	107.7	190.2	192.7	0	5.56	6.4	416.4	421.5	430.8	457.8	155.1	Turbulent		8420	17157	0	0
4	Wall	Therminol XP	294.5	298.8	107.7	95.9	192.7	195.2	0	5.56	6.4	419.2	424.3	433.6	460.6	156.9	Turbulent		8411	17143	0	0
5	Wall	Therminol XP	298.8	303.1	95.9	106.8	195.2	197.8	0	5.56	6.4	422	427.1	436.4	463.4	158.7	Turbulent		8402	17129	0	0
6	Wall	Therminol XP	303.1	307.4	106.8	95	197.8	200.3	0	5.56	6.4	424.9	429.9	439.2	466.2	160.6	Turbulent		8393	17114	0	0
7	Wall	Therminol XP	307.4	311.7	95	105.8	200.3	202.8	0	5.56	6.4	427.7	432.7	442.1	469.1	162.5	Turbulent		8384	17100	0	0
8	Wall	Therminol XP	311.7	315.9	105.8	94	202.8	205.4	0	5.56	6.4	430.5	435.5	444.9	471.9	164.4	Turbulent		8375	17086	0	0
9	Wall	Therminol XP	315.9	320.2	94	104.9	205.4	207.9	0	5.56	6.5	433.3	438.4	447.7	474.7	166.4	Turbulent		8366	17071	0	0
10	Wall	Therminol XP	320.2	324.5	104.9	93.1	207.9	210.4	0	5.56	6.5	436.2	441.2	450.5	477.5	168.5	Turbulent		8356	17057	0	0
11	Wall	Therminol XP	324.5	328.8	93.1	103.9	210.4	212.9	0	5.56	6.5	439	444	453.4	480.4	170.6	Turbulent		8347	17042	0	0
12	Wall	Therminol XP	328.8	333.1	103.9	92.2	212.9	215.5	0	5.56	6.5	442	447	456.4	483.4	172.7	Turbulent		8337	17027	0	0
13	Wall	Therminol XP	333.1	337.4	92.2	102.9	215.5	218	0	5.56	6.5	444.9	449.9	459.2	486.2	174.8	Turbulent		8328	17011	0	0
14	Wall	Therminol XP	337.4	341.7	102.9	91.3	218	220.5	0	5.56	6.5	447.8	452.8	462.1	489.1	176.9	Turbulent		8318	16996	0	0
15	Wall	Therminol XP	341.7	346	91.3	102	220.5	223.1	0	5.56	6.5	450.6	455.7	465	492	179.1	Turbulent		8309	16981	0	0
16	Wall	Therminol XP	346	350.3	102	90.4	223.1	225.6	0	5.56	6.6	453.5	458.6	467.9	494.9	181.4	Turbulent		8299	16965	0	0
17	Wall	Therminol XP	350.3	354.6	90.4	101	225.6	228.1	0	5.56	6.6	456.4	461.4	470.8	497.8	183.7	Turbulent		8289	16950	0	0
18	Wall	Therminol XP	354.6	358.8	101	89.4	228.1	230.7	0	5.56	6.6	459.3	464.3	473.6	500.6	186.1	Turbulent		8279	16935	0	0
19	Wall	Therminol XP	358.8	363	89.4	100	230.7	233.2	0	5.56	6.6	462.2	467.3	476.5	503.5	188.3	Turbulent		8270	16919	0	0
20	Wall	Therminol XP	363	367.1	100	88.5	233.2	235.7	0	5.56	6.6	465.3	470.4	479.7	506.7	189.9	Turbulent		8259	16902	0	0
21	Wall	Therminol XP	367.1	371.2	88.5	99	235.7	238.2	0	5.56	6.6	468.5	473.6	482.8	509.8	191.5	Turbulent		8248	16884	0	0
22	Wall	Therminol XP	371.2	375.3	99	87.6	238.2	240.8	0	5.56	6.6	471.7	476.8	486	513	193.2	Turbulent		8237	16867	0	0
23	Wall	Therminol XP	375.3	379.4	87.6	98.1	240.8	243.3	0	5.56	6.6	474.8	479.9	489.1	516.1	194.9	Turbulent		8226	16849	0	0
24	Wall	Therminol XP	379.4	383.5	98.1	86.6	243.3	245.8	0	5.56	6.7	478	483.1	492.3	519.3	196.6	Turbulent		8215	16831	0	0
25	Wall	Therminol XP	383.5	387.6	86.6	97.1	245.8	248.4	0	5.56	6.7	481.2	486.3	495.5	522.5	198.3	Turbulent		8204	16814	0	0
26	Wall	Therminol XP	387.6	391.7	97.1	85.7	248.4	250.9	0	5.56	6.7	484.3	489.4	498.6	525.6	200.1	Turbulent		8193	16796	0	0

Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Conv. Box	Tube No.	Coil Sect.	Row	Process	Bulk Temp. In	Bulk Temp. Out	Press. In	Press. Out	Enth. In	Enth. Out	Vapour Fraction	Tube OD	Velocity	Film	Avg Tube Temp.	Max Tube Temp.	API Design Temp.	Avg HTC	Fin Type	Flow Regime	Tube Mat.	Avg Flux	Max Flux	Regime X	Regime Y
					°F	°F	psi a	psi a	BTU/lb	BTU/lb			ft/s	°F	°F	°F	°F	BTU/hr ft² °F				BTU/hr ft²	BTU/hr ft²
1	1	3	8	Therminol XP	212	212.8	108.8	108.5	148.1	148.5	0	5.56	6.2	251.6	252.7	254.7	538.8	102	Solid	Turbulent	C.S.	2519	3591	0	0
1	2	3	8	Therminol XP	212.8	213.7	108.5	108.1	148.5	149	0	5.56	6.2	252.1	253	255	539.5	102.3	Solid	Turbulent	C.S.	2499	3563	0	0
1	3	3	8	Therminol XP	213.7	214.5	108.1	107.8	149	149.4	0	5.56	6.2	252.5	253.6	255.4	540.2	102.6	Solid	Turbulent	C.S.	2480	3535	0	0
1	4	3	8	Therminol XP	214.5	215.3	107.8	107.4	149.4	149.8	0	5.56	6.2	252.9	253.9	255.7	540.9	102.9	Solid	Turbulent	C.S.	2460	3507	0	0
1	5	3	7	Therminol XP	215.1	216.5	107.4	107.1	149.8	150.5	0	5.56	6.2	277	278.8	281.8	587.8	107.1	Solid	Turbulent	C.S.	4119	5874	0	0
1	6	3	7	Therminol XP	216.5	217.8	107.1	106.7	150.5	151.2	0	5.56	6.2	277.5	279.3	282.4	588.8	107.7	Solid	Turbulent	C.S.	4087	5828	0	0
1	7	3	7	Therminol XP	217.8	219.2	106.7	106.4	151.2	151.9	0	5.56	6.2	278.2	279.9	282.9	589.8	108.2	Solid	Turbulent	C.S.	4055	5783	0	0
1	8	3	7	Therminol XP	219.2	220.5	106.4	106	151.9	152.6	0	5.56	6.2	278.8	280.4	283.5	590.8	108.8	Solid	Turbulent	C.S.	4023	5738	0	0
1	9	3	6	Therminol XP	220.6	222.8	106	105.7	152.6	153.8	0	5.56	6.2	318.7	321.6	326.8	668.8	113.5	Solid	Turbulent	C.S.	6922	9853	0	0
1	10	3	6	Therminol XP	222.8	225.1	105.7	105.3	153.8	155	0	5.56	6.2	319.5	322.3	327.6	670.1	114.4	Solid	Turbulent	C.S.	6868	9775	0	0
1	11	3	6	Therminol XP	225.1	227.4	105.3	105	155	156.3	0	5.56	6.2	320.2	323.1	328.3	671.4	115.3	Solid	Turbulent	C.S.	6813	9698	0	0
1	12	3	6	Therminol XP	227.4	229.7	105	104.6	156.3	157.5	0	5.56	6.2	321.1	323.8	329	672.7	116.2	Solid	Turbulent	C.S.	6758	9620	0	0
1	13	2	5	Therminol XP	229.4	232.2	104.6	104.3	157.3	158.8	0	5.56	6.2	343.8	347.4	353.8	717.5	119.8	Solid	Turbulent	C.S.	8519	12118	0	0
1	14	2	5	Therminol XP	232.2	235	104.3	103.9	158.8	160.3	0	5.56	6.2	344.8	348.4	354.7	719.2	120.9	Solid	Turbulent	C.S.	8466	12043	0	0
1	15	2	5	Therminol XP	235	237.8	103.9	103.6	160.3	161.8	0	5.56	6.2	345.9	349.3	355.8	720.9	122.2	Solid	Turbulent	C.S.	8413	11967	0	0
1	16	2	5	Therminol XP	237.8	240.6	103.6	103.2	161.8	163.3	0	5.56	6.2	346.8	350.4	356.7	722.7	123.4	Solid	Turbulent	C.S.	8359	11891	0	0
1	17	2	4	Therminol XP	241	245.5	103.2	102.9	163.5	165.9	0	5.56	6.2	410.2	416.1	426.7	848.6	131.4	Solid	Turbulent	C.S.	13794	19632	0	0
1	18	2	4	Therminol XP	245.5	250.1	102.9	102.6	165.9	168.3	0	5.56	6.3	411.1	417	427.5	850	133.5	Solid	Turbulent	C.S.	13700	19499	0	0
1	19	2	4	Therminol XP	250.1	254.6	102.6	102.2	168.3	170.7	0	5.56	6.3	412	417.7	428.2	851.4	135.7	Solid	Turbulent	C.S.	13606	19365	0	0
1	20	2	4	Therminol XP	254.6	259.1	102.2	101.9	170.7	173.1	0	5.56	6.3	412.9	418.6	428.9	852.8	137.9	Solid	Turbulent	C.S.	13512	19231	0	0
1	21	1	3	Therminol XP	258.9	260.5	101.9	101.5	173	173.8	0	5.56	6.3	328.8	331.5	335.5	684.6	129.9	None	Turbulent	C.S.	4611	8055	0	0
1	22	1	3	Therminol XP	260.5	262	101.5	101.2	173.8	174.6	0	5.56	6.3	329.9	332.4	336.6	686.3	130.7	None	Turbulent	C.S.	4603	8041	0	0
1	23	1	3	Therminol XP	262	263.5	101.2	100.8	174.6	175.4	0	5.56	6.3	330.8	333.3	337.5	688	131.5	None	Turbulent	C.S.	4596	8027	0	0
1	24	1	3	Therminol XP	263.5	265	100.8	100.5	175.4	176.2	0	5.56	6.3	331.9	334.4	338.4	689.7	132.4	None	Turbulent	C.S.	4588	8013	0	0
1	25	1	2	Therminol XP	265.9	267.7	100.5	100.1	176.7	177.7	0	5.56	6.3	347.4	350.4	355.3	720.2	135.8	None	Turbulent	C.S.	5603	9788	0	0
1	26	1	2	Therminol XP	267.7	269.6	100.1	99.8	177.7	178.7	0	5.56	6.3	348.3	351.5	356.4	722.1	136.9	None	Turbulent	C.S.	5593	9770	0	0
1	27	1	2	Therminol XP	269.6	271.4	99.8	99.4	178.7	179.6	0	5.56	6.3	349.3	352.6	357.4	724	138.1	None	Turbulent	C.S.	5583	9752	0	0
1	28	1	2	Therminol XP	271.4	273.3	99.4	99.1	179.6	180.6	0	5.56	6.3	350.4	353.5	358.5	725.9	139.2	None	Turbulent	C.S.	5573	9734	0	0
1	29	1	1	Therminol XP	272.3	274.6	99.1	98.7	180.1	181.4	0	5.56	6.3	371.7	375.6	382.1	768.3	142.4	None	Turbulent	C.S.	7168	12521	0	0
1	30	1	1	Therminol XP	274.6	277	98.7	98.4	181.4	182.6	0	5.56	6.3	372.7	376.9	383.2	770.4	143.8	None	Turbulent	C.S.	7154	12497	0	0
1	31	1	1	Therminol XP	277	279.3	98.4	98	182.6	183.9	0	5.56	6.3	374	378	384.4	772.5	145.3	None	Turbulent	C.S.	7140	12473	0	0
1	32	1	1	Therminol XP	279.3	281.6	98	97.7	183.9	185.1	0	5.56	6.3	375.3	379.2	385.5	774.6	146.8	None	Turbulent	C.S.	7127	12449	0	0

Coil Configuration

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Heater Section		RADIANT 1	CONVECTION 1	CONVECTION 1	CONVECTION 1
Coil Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
Process Name		Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP	Process 1: Therminol XP
Tube OD	inch	5.56	5.56	5.56	5.56
Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
Tube Wall Thk	inch	Sch 40	Sch 40	Sch 40	Sch 40
Max Tube Temperature	°F	498.6	385.5	429	329
Tube Temperature Margin	°F	59	59	59	59
Design Tube Temperature	°F	525.6	412.5	456	356
Design Tube Pressure	psi	290.1	290.1	290.1	290.1
Design Code		API 530	API 530	API 530	API 530
Tube Thk. Comment		Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)	Tube Thk. OK (API 530)
No. Tubes		52	24	16	24
No. Tubes Per Row			8	8	8
No. Passes		2	2	2	2
Effective Length	Ft	33.084	19.144	19.144	19.144
Straight Length	Ft	31.775	20.456	20.456	20.456
No. Rows			3	2	3
Tube Spacing	inch	10	10	10	10
Vert. Row Spacing (Vert)	inch	N/A	8.7	8.7	8.7
Coil Alignment			Staggered	Staggered	Staggered
Orientation		Vertical	Horizontal	Horizontal	Horizontal
Tube Area	ft²	2505.52	668.81	3507.59	8623.6
Intermediate Supports		0 / 0	1 / 1	1 / 1	1 / 1
Corbel Width	Ft		1/2 Tube Space	1/2 Tube Space	1/2 Tube Space
Fin Type			None	Solid	Solid
Fin Material			None	Carbon Steel	Carbon Steel
Fin Height	inch			0.75	1
Fin Thickness	inch			0.05	0.05
Serrated Fin Wn
Fin Density	fins/ft			48	60

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 2, complies with API 530

Convection section 1,Coil sect. no. 3, complies with API 530

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API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

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tblCalcType,calcref999	Calculation Ref Type		0
tblUnits,calcref999	Units selection		0
tblHeaterSection	Location		RADIANT	CONVECTION	CONVECTION	CONVECTION
tblCoilSectName	Coil/Piping Section		Coil Section 1	Coil Section 1	Coil Section 2	Coil Section 3
tblDesignPress,calcref0	Design Pressure	kPa g	2000.2	2000.2	2000.2	2000.2
tblMaxOpPress,calcref0	Max Operating Pressure	kPa g	750.1	750.1	750.1	750.1
tblDesignTemp,calcref0	Design Temperature	°C	274.2419	211.4063	235.5491	179.9751
tblTubeMaterial	Tube Material		Carbon Steel	Carbon Steel	Carbon Steel	Carbon Steel
tblTubeOD	Tube Outside Diameter		141.3	141.3	141.3	141.3
tblTubeThk,calcref0,calcref2,calcref3	Tube Thickness	mm	6.55	6.55	6.55	6.55
tblCorrosionAllowance,calcref0	Corrosion Allowance	mm	3	3	3	3
tblDesignLifeHrs,calcref0	Design Life	hours	100000	100000	100000	100000

ResultsMainTitle,resultref0	TUBE DESIGN RESULTS
UserSpecifiedThk,resultref0	Specified Tube Thickness	mm	6.55	6.55	6.55	6.55
ResultsElasticTitle,resultref0	ELASTIC DESIGN
AllowableElasticStress,resultref0	Elastic Allowable Stress	kPa	123803.7	131728.9	128683.9	135693.3
ElasticStressThk,resultref0	Elastic Stress Thickness	mm	1.1323	1.0647	1.0897	1.0338
ElasticMinTubeThk,resultref0	Elastic Min. Tube Thickness	mm	4.13	4.06	4.09	4.03
ElasticAvgTubeThk,resultref0	Elastic Average Tube Thickness	mm	4.72	4.65	4.67	4.61
ElasticDesignCalcResultComment,resultref0	Elastic Design Comment		Thickness is OK	Thickness is OK	Thickness is OK	Thickness is OK
ResultsRuptureTitle,resultref0	RUPTURE DESIGN
RuptureStress,resultref0	Rupture Allowable Stress		0	0	0	0
RuptureNfactor,resultref0	Rupture n factor		0	0	0	0
RuptureStressThk,resultref0	Rupture Stress Thickness	mm	0	0	0	0
RuptureMinTubeThk,resultref0	Rupture Min. Tube Thickness	mm	0	0	0	0
RuptureAvgTubeThk,resultref0	Rupture Avg. Tube Thickness	mm	0	0	0	0
RuptureBfactor,resultref0	B factor		0	0	0	0
RuptureFcorrfactor,resultref0	Corrosion Factor Fcorr		0	0	0	0
RuptureDesignCalcResultComment,resultref0	Rupture Design Comment		Not applicable	Not applicable	Not applicable	Not applicable

btnRUN,calcref0,calcref1,calcref2,calcref3
btnRESET,resultref0,resultref1,resultref2,resultref3

ASME I

BPVC Section I Rules for Construction of Power Boilers

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ASME VIII

BPVC Section VIII Rules for Construction of Pressure Vessels

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Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

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Stack Height	Ft	49.213
Stack Diameter	Ft	4.429
Cone Diameter	Ft	3.76
Cone Height	Ft	1.64
Actual Exit Velocity	ft/s	21.3
Design Exit Velocity	ft/s	25.6
Flue Gas Temp.	°F	295.9
Flue Gas Flow	lb/s	9.897
Steel Area	ft²	682.781
Stack Entry Pressure	mmH2O	0
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Stack No. 1: Auto Stack calc. has converged OK

Refractory

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		Hot-Face	Hot-Face	Hot-Face	Back-Up	Back-Up	Back-Up	Material
	Flue Temp.	Material	Thickness	Conductivity	Material	Thickness	Conductivity	Allowable Flux	Actual Flux	Design Temp.	Anchor Type	Casing Temp.	Comment
	°F		inch	BTU/hr ft F		inch	BTU/hr ft F	BTU/hr ft²	BTU/hr ft²	°F
RADIANT FLOOR 1	1319	MW Castable	2.95	2.6744	ULW Castable	5.91	0.9546	232.2	154.2337	161.5	2552	V Y Anchors	161.5	Refrac. thickness OK
RADIANT WALL 1	953.8	Fibre (High Density)	2.95	0.4736	None	0	0	232.3	124.2919	139.6	2300	Twistlock Pins	139.6	Refrac. thickness OK
RADIANT ARCH 1	1409	Fibre (High Density)	3.45	0.674	None	0	0	261.2	240.1784	172.1	2300	Twistlock Pins	172.1	Refrac. thickness OK

CONVECTION SIDEWALL 1	852.4	LW Castable	2.95	2.0308	ULW Castable	2.95	0.876	232.3	139.579	144.6	2012	V Y Anchors	144.6	Refrac. thickness OK

STACK 1	295.9	LW Castable	1.97	1.7328	None	0	0	232.3	102.2968	130.85	2012	V Y Anchors	130.85	Refrac. thickness OK

No thermal calc. carried out for Convection End Wall (Tubesheets) or Headerbox sections

Simulation Results

STACK
Flue Gas Flow	kg/s	12.368
Flue Gas Temp.	°C	596.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

AIR
Air Flow	kg/s	11.797
Air Temp.	°C	15.5
Excess Air	%	20

FUEL
Fuel Flow	kg/s	0.571
Fuel LHV	kJ/kg	50015
Fuel Mol. Wt.		16

Radiant Cell		1
Arch Temp.	°C	534.3
Max Tube Temp.	°C	455
Average Flux	W/m²	9909
Arch Pressure	mmH2O	-8.608

No. of Burners		15
Floor Pressure	mmH2O	-25.993

ENERGY PERFORMACE
Total Absorbed Duty	MW	84.723
Total Heat Release	MW	28.572
Total Efficiency	%	296.528

ENVIRONMENTAL IMPACT
Energy Efficiency	%	296.528
Daily CO2 Emissions	kg	136235

Total:

£ 165,311,712

HR	MW	28.572
Arch	°C	534.3
Tube	°C	455
Flux	W/m²	9909

No. Burners	m	15
Fuel Flow	kg/s	0.571
Air Flow	kg/s	11.797
Air Temp.	°C	15.5
Excess Air	%	20

STACK
Flow	kg/s	12.368
Temp.	°C	596.9
CO2	mol%	8.06
H2O	mol%	16.06
N2	mol%	72.67
O2	mol%	3.21
SO2	mol%	0

Process Inlet------->

Ck , 320 °C, 925.748 kPa a

Fuel m.w.		16
Fuel LHV	kJ/kg	50015

Process Outlet------->

Ck , 404 °C, -61854.93 kPa a, 84.723 MW

Air Flow		11.797
Air Temp.	°C	15.5

Firing MW
28.57
Duty MW
84.72
Efficiency %
296.53
CO2 Ton/day
136

Carbon Emissions

Commercial

BID / PROJECT VALUE

SAFETY AND COMPLIANCE

Safety & Compliance

HeaterSIM - Fired Heater Simulation Results

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Process 1: Ck difficult to converge at row no. 1 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 2 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 3 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 4 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 5 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 6 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 7 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 8 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 9 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 10 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Process 1: Ck difficult to converge at row no. 11 in Con. box no. 1. Process temp. may be hotter than flue at this row. Please check all related inputs and try again.

Radiant cell no. 1: The burners to tube distance seems OK (API 560)

Radiant cell no. 1: The burners to wall clearance seems OK (API 560)

Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)

Flame-tube impingment risk not identified

Radiant cell no. 1: API 560 Radiant height to width seems OK

Radiant cell no. 1: Single lane of burners considered

Stack No. 1: Auto Stack calc. has converged OK

Radiant section 1,Coil sect. no. 1, complies with API 530

Convection section 1,Coil sect. no. 1, complies with API 530

Commercial

HeaterSIM - Fired Heater Simulation Results

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Materials & Equipment Supply Steelwork & Fabrication Painting, Refractory & Anchors Ladders & Platforms, Tubes & Fittings Finning, Tube Supports Coil Fabrication (inc. Radiography) BMS, Instrumentation & Fuel Skid Burners	Detail Engineering Process & Thermal Design, Mechanical Design Piping Stress Analysis, Stuctural Design 3D Modelling, Detailed Design Drawings Fabrication, Shipping & Transport Drawings
Shipping & Delivery 1. Radiant Section - fully modulurised 2. Convection Section - fully modulurised 3. Stack - fully modulurised sections 4. Fuel Skid - fully modulurised	Terms 1. Delivery: 54 weeks (28 weeks Detailed Eng. only) 2. Validity: 14 days 3. Warranty: 3 years

Our Partners & Vendors

Heater companies:
Birwelco
FEI
GasTech
KT-Technology
Thermax

Burner Vendors:
Callidus (UOP)
Greens Combustion
ICE
John Zink Hamworthy
Zeeco

Fabricators:
Vatana Phisal (VPE)
Vipco
Steelcon Malaysia
AD Demirel
Polimex

Refractory:
Morgan
Linco Baxo
Insulcon B.V.
Zibo Luzhong

Summary

Main items
Material & Equipment Supply	£ 153,600,200
Option items
Detail Engineering (by HeaterSIM)	£ 11,620,010
Performance Guarantee	£35000
Third Party Design Check	£29500
Burner Performance Test	£27000
Total	£165,311,712

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

Process Flow Diagram (PFD) Summary

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STREAM NO.		1	2	3	4	5	6
Fluid Name		Ck	Ck	Radiant 1 Flue Gas	Stack 1 Flue Gas	Fuel No. 1	Combustion Air
Flow (sec)	kg/s	371.875	371.875	12.369	12.368	0.571	11.797
Flow (hr)	kg/hr	1338750	1338750	44527	44526	2057	42471
Temperature	°C	320	404	534.3	596.9	Note 1	15.5
Pressure	kPa a	925.748	-61854.93	-8.608	-7.65	Note 2	101.32

1. Fuel Temperature as per project specifications. This value is not reported here.
2. Fuel Pressure typically ~2 barg (29 psig) at maximum burner heat release. This value is not reported here.

GA Drawing

Stack Top Platform

Online API Fired Heater Software

COIL ARRANGEMENT
Heater Section		RADIANT 1	CONVECTION 1
Design Code		API 530	API 530
Orientation		Vertical	Horizontal
Tube OD	mm	168.3	168.3
Tube Material		5.0 Cr / 0.5 Mo - P5	5.0 Cr / 0.5 Mo - P5
Tube Wall Thk	mm	Sch 120	Sch 120
Tube Spacing	mm	304.8	304.8
Vert. Row Spacing (Vert)	mm	N/A	264.1
No. Tubes		16	88
Effective Length	m	17.574	7960
Straight Length	m	17.095	7960.4

Notes

1. DIMENSIONS TO BE CONFIRMED DURING DETAILED ENGINEERING PHASE

2. LADDERS AND PLATFORMS SHALL BE IN ACCORDANCE WITH API 56O REQUIREMENTS MINIMUM AND PROJECT SPECIFICATIONS

3. THIS PROPOSAL DRAWING SHOULD BE CONSIDERED AS A SKETCH AND MAY NOT BE ENTIRELY DRAWN TO SCALE

4. REFRACTORY MATERIAL AND THICKNESSES SHALL BE AS PER PROJECT HEATER DATASHEET

5. PLEASE REFER TO COIL CONFIGURATION AND MATERIAL WITHIN THE TABLE BELOW

6. DOORS SHALL BE PROVIDED IN ACCORDANCE WITH PROJECT HEATER DATASHEET

REV	DATE	DRAWING DESCRIPTION	BY	CHK

GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL

TAG NO. / PROJECT REF. HS

PROJECT TITLE

CLIENT

PROJECT LOCATION

EmissionsLow NOx burners

Carbon Dioxide
Sulphur Dioxide
Carbon Monoxide	<100 ppm
N2 Oxides (NOx)	<150 ppm

NOTE

The ability to view full results and modify the model is not availble on the screen size that you're currently using

Process Conditions

HeaterSIM - Fired Heater Simulation Results

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Process Name		Ck
Heat Duty	MW	84.723
Flow rate (sec)	kg/s	371.875
Flow rate (hr)	kg/hr	1338750
Pressure drop	kPa	62780.676
Max. Film Temp. Calculated	°C	448.3
Max. Film Temp. Allowed	°C	415
Max Tube Average Flux Calculated (1)	W/m²	9971
Average Flux Allowed	W/m²	22500
INLET CONDITIONS
Inlet Temperature	°C	320
Inlet Pressure	kPa a	925.748
Inlet Vapour Fraction		0
Inlet Enthalpy	kJ/kg	100
OUTLET CONDITIONS
Outlet Temperature	°C	404
Outlet Pressure	kPa a	-61854.93
Outlet Vapour Fraction		0
Outlet Enthalpy	kJ/kg	328

Ck: Calculated outlet pressure is excessively below atmospheric pressure