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	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

Total:	£ 854,035

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

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	£ 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).

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	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

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	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

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	3.943
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

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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	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

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	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

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	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

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

Online API Fired Heater Software

Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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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

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/NoneGAD.jpg
lblTopOfStackGAD
lblTopStackPlatformGAD
lblTopOfTransitionGAD
lblTopOfConBoxGAD
lblTopOfRadiantGAD
lblTopOfMidRadStepOffGAD
lblHearthPltfmGAD
lblGradeGAD
lblStackDiaGAD
lblConBoxEffLengthGAD
lblConBoxISwidthGAD
lblRadISwidthGAD
lblRadTCDGAD
lblNoBurnersGAD

Process:	Therminol XP
Flow rate:	40 kg/s
Temperature:	200 °C
Pressure:	750.1 kPa a
Liquid Flow:	40 kg/s
Vapour Flow:	0 kg/s

Process:	Therminol XP
Flow rate:	40 kg/s
Temperature:	306.9 °C
Pressure:	410.9 kPa a
Liquid Flow:	40 kg/s
Vapour Flow:	0 kg/s

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Fired Heater Simulation Results

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GENERAL ARRANGEMENT DRAWINGAPI 560 FIRED HEATER PROPOSAL

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GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL