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	9.628
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

Total:	£ 813,264

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

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	£ 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

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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).

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

Online API Fired Heater Software

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

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

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	4.819
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

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	3.386
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)

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	0.19	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

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	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

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	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

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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

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

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

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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	1.32
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

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.

imgGAD	/Content/images/Heater560UI/CabinHeaterGAD-a.jpg
lblTopOfStackGAD	33.141 m
lblTopStackPlatformGAD	30.141 m
lblTopOfTransitionGAD	18.141 m
lblTopOfConBoxGAD	16.341 m
lblTopOfRadiantGAD	11.8 m
lblTopOfMidRadStepOffGAD	7.3 m
lblHearthPltfmGAD	2.8 m
lblGradeGAD	Grade 0.00 m
lblStackDiaGAD	1.32 m
lblConBoxEffLengthGAD
lblConBoxISwidthGAD	2.591 m
lblRadISwidthGAD	3.75 m
lblRadTCDGAD	0 m
lblNoBurnersGAD	4 Burners<br/>(Natural Draft)

Process:	Crude Oil 1
Flow rate:	40 kg/s
Temperature:	200 °C
Pressure:	750.1 kPa a
Liquid Flow:	40 kg/s
Vapour Flow:	0 kg/s

Process:	Crude Oil 1
Flow rate:	40 kg/s
Temperature:	516.4 °C
Pressure:	359.3 kPa a
Liquid Flow:	18.17 kg/s
Vapour Flow:	21.83 kg/s

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Fired Heater Simulation Results

Simulation Results

Technical Summary

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GA Drawing

GENERAL ARRANGEMENT DRAWINGAPI 560 FIRED HEATER PROPOSAL

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NOTE

Process Conditions

Process Inlet

Process Outlet

Radiant Section

Combustion

Convection Section

Convection (Flue gas side)

Convection (Process Side)

Process Inlet

Process Outlet

Radiant Tube Profile

Process fluid side

Tube side

Convection Tube Profile

Process fluid side

Tube side

Coil Configuration

API 530

ResultsMainTitle,resultref0

TUBE DESIGN RESULTS

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GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL