Fired Heater Design & Performance Calculations

Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

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

Total:	£ 736,084

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

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	£ 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

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)	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).

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	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

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	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

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	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

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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

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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
					°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

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	2000.2	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

HeaterSIM - Fired Heater Simulation Results

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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

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/VCHeaterGAD2-a.jpg
lblTopOfStackGAD	134 Ft
lblTopStackPlatformGAD	124 Ft
lblTopOfTransitionGAD	65 Ft
lblTopOfConBoxGAD	59 Ft
lblTopOfRadiantGAD	46 Ft
lblTopOfMidRadStepOffGAD	27 Ft
lblHearthPltfmGAD	9 Ft
lblGradeGAD	Grade 0.00 Ft
lblStackDiaGAD	4 Ft
lblConBoxEffLengthGAD	19 Ft
lblConBoxISwidthGAD
lblRadISwidthGAD	15 Ft
lblRadTCDGAD	14 Ft
lblNoBurnersGAD	4 Burners<br/>(Natural Draft)

Process:	Therminol XP
Flow rate:	88.2 lb/s
Temperature:	212 °F
Pressure:	108.8 psi a
Liquid Flow:	88.2 lb/s
Vapour Flow:	0 lb/s

Process:	Therminol XP
Flow rate:	88.2 lb/s
Temperature:	391.8 °F
Pressure:	85.7 psi a
Liquid Flow:	88.2 lb/s
Vapour Flow:	0 lb/s

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GENERAL ARRANGEMENT DRAWINGAPI 560 FIRED HEATER PROPOSAL

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ResultsMainTitle,resultref0

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GENERAL ARRANGEMENT DRAWING
API 560 FIRED HEATER PROPOSAL