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HeaterSIM

Fired Heater Simulation Results

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Simulation Results

Technical Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

ENERGY PERFORMACE
Total Absorbed DutyMW9.576
Total Heat ReleaseMW10.959
Total Efficiency%87.38
PROCESS
Process Name Dowtherm G
Heat DutyMW9.576
Flow rate (sec)kg/s40
INLET CONDITIONS
Inlet Temperature°C200
Inlet PressurekPa a750.1
OUTLET CONDITIONS
Outlet Temperature°C301.1
Outlet PressurekPa a206.755
AIR
Air Flowkg/s4.445
Air Temp.°C15.5
Excess Air%20
FUEL
Fuel Flowkg/s0.265
Fuel LHVkJ/kg41358
Fuel Mol. Wt. 7.763
STACK
Flue Gas Flowkg/s4.71
Flue Gas Temp.°C257.5
CO2mol%12.21
H2Omol%8.96
N2mol%75.42
O2 mol%3.33
SO2mol%0.08
CONVECTION
Convection Sect. No. 1
Heat DutyMW3.68
Flue Gas Flowkg/s4.71
Max Tube Temp.°C296.8
Total Press. Loss (inc. gain)mmH2O-1.18
RADIANT SECTION
Radiant Cell 1
Heat DutyMW5.896
Heat ReleaseMW10.959
Arch Temp.°C899.3
Max Tube Temp.°C340.2
Average FluxW/m²25444
Maximum FluxW/m²52620
No. of Burners 4
Arch PressuremmH2O-2.343
Floor PressuremmH2O-12.246
Carbon Emissions
ENVIRONMENTAL IMPACT
Energy Efficiency%87.38
Daily CO2 Emissionskg74844
Commercial

BID / PROJECT VALUE

Total: £ 1,038,890

SAFETY AND COMPLIANCE

Radiant cell no. 1: The Burner-to-Tube clearance seems OK (API 560)
Radiant cell no. 1: Burner Vertical Clearance seems OK (API 560)
Flame-tube impingment risk not identified
Radiant cell no. 1: API 560 Radiant height to width seems OK
Stack No. 1: Auto Stack calc. has converged OK
Radiant section 1,Coil sect. no. 1, complies with API 530
Convection section 1,Coil sect. no. 1, complies with API 530
Convection section 1,Coil sect. no. 2, complies with API 530
Convection section 1,Coil sect. no. 3, complies with API 530
COIL ARRANGEMENT
Heater Section RADIANT 1CONVECTION 1CONVECTION 1CONVECTION 1
Orientation VerticalHorizontalHorizontalHorizontal
Tube OD mm 114.3114.3114.3114.3
Tube Material 18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS
Tube Wall Thk mm Sch 40Sch 40Sch 40Sch 40
Max Tube Temperature°C340.2274.7296.8246.1
No. Tubes 64241624
Effective Length m 10.0845.8355.8355.835
Straight Length m 9.6856.2356.2356.235

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

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

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

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

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

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

Process Flow Diagram (PFD) Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

STREAM NO. 123456
Fluid Name Dowtherm GDowtherm GRadiant 1 Flue GasStack 1 Flue GasFuel No. 1Combustion Air
Flow (sec)kg/s 40404.714.710.2654.445
Flow (hr)kg/hr 144000144000169551695595416001
Temperature°C 200301.1899.3257.5Note 115.5
PressurekPa a 750.1206.755-2.343-0.999Note 2101.32

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.

P&ID

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

GA Drawing

Online API Fired Heater Software

COIL ARRANGEMENT
Heater Section RADIANT 1CONVECTION 1CONVECTION 1CONVECTION 1
Design Code API 530 API 530API 530
Orientation VerticalHorizontalHorizontalHorizontal
Tube OD mm 114.3114.3114.3114.3
Tube Material 18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS
Tube Wall Thk mm Sch 40Sch 40Sch 40Sch 40
Tube Spacing mm 203.2203.2203.2203.2
Vert. Row Spacing (Vert) mm N/A176.1176.1176.1
No. Tubes 64241624
Effective Length m 10.0845.8355.8355.835
Straight Length m 9.6856.2356.2356.235
imgGAD/Content/images/Heater560UI/VCHeaterGAD2-a.jpg
lblTopOfStackGAD36.345 m
lblTopStackPlatformGAD33.345 m
lblTopOfTransitionGAD19.345 m
lblTopOfConBoxGAD17.545 m
lblTopOfRadiantGAD13.884 m
lblTopOfMidRadStepOffGAD8.342 m
lblHearthPltfmGAD2.8 m
lblGradeGADGrade 0.00 m
lblStackDiaGAD1.27 m
lblConBoxEffLengthGAD5.835 m
lblConBoxISwidthGAD
lblRadISwidthGAD4.444 m
lblRadTCDGAD4.14 m
lblNoBurnersGAD4 Burners<br/>(Natural Draft)
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

Process Conditions

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Name Dowtherm G
Heat DutyMW9.576
Flow rate (sec)kg/s40
Flow rate (hr)kg/hr144000
Pressure dropkPa543.345
Max. Film Temp. Calculated°C323.2
Max. Film Temp. Allowed°C350
Max Tube Average Flux Calculated (1)W/m²25939
Average Flux AllowedW/m²31500
INLET CONDITIONS
Inlet Temperature°C200
Inlet PressurekPa a750.1
Inlet Vapour Fraction 0
Inlet EnthalpykJ/kg604
OUTLET CONDITIONS
Outlet Temperature°C301.1
Outlet PressurekPa a206.755
Outlet Vapour Fraction 0
Outlet EnthalpykJ/kg843
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

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 DutyMW5.896
Heat ReleaseMW10.959
Arch Temp.°C899.3
Max Tube Temp.°C340.2
Tube Cirle Diameter m 4.14
Average FluxW/m²25444
Maximum FluxW/m²52620
Flue Flowkg/s4.71
Air Flowkg/s4.445
Fuel Flowkg/s0.265
Excess Air%20
Air Temp.°C15.5
Arch PressuremmH2O-2.343
Floor PressuremmH2O-12.246
Radiant Height m 11.08
Radiant Width m 4.44
Radiant Length m 4.44
No. of Burners 4
Burner Cirle Diameter m 1.209
Burner Design FiringMW3.29
Burner Normal FiringMW2.74
Burner Min FiringMW0.66
Burner-to-Tube Note Too Close (please check)
Burner-to-Wall Note N/A
Burner-to-Roof Note OK
API Burner-to-Tube Dist. m 1.258
API Burner-to-Wall Dist. m 1.165
API Burner-to-Roof/Roof Dist m 10.455
Floor FluxW/m²706888
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 Flowkg/s4.71
Air Flowkg/s4.445
Fuel Flowkg/s0.265
Fuel LHVkJ/kg41358
Excess Air%20
Air Temp.°C15.5
CO2mol%12.21
H2Omol%8.96
N2mol%75.42
O2 mol%3.33
SO2mol%0.08
Dew Point°C144
Fuel Mol. Wt. 7.763
Flue Mol. Wt. 29.22
Flame Temperature°C1891.7
Flue Gas Emissivity 0.4
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 DutyMW3.68
Max Tube Temp.°C296.8
Total Flue Press. Loss (ex. gain)mmH2O1.3
Total Press. GainmmH2O2.47
Total Press. Loss (inc. gain)mmH2O-1.18
Convection Width m 1.727
Effective Length m 5.835
Convection Height m 3.161
Total No. Rows 8
FLUE GAS DATA
Flue Gas Flowkg/s4.71
Flue Gas Inlet Temp.°C899.3
Flue Gas Outlet Temp.°C257.5
CO2mol%12.21461
H2Omol%8.958327
N2mol%75.41734
O2 mol%3.332498
SO2mol%0.07723132

Convection (Flue gas side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

ConboxRowDutyTemp InletTemp OutletEnthalpy InEnthalpy OutFlue DensityFin TypeAvg FluxMax FluxTubes per RowFG Mass Vel.Flue P dropTube MaterialFin MaterialAvg Fin TempMax Fin Temp
MW°C°CkJ/kgkJ/kgkg/m³ W/m²W/m² kg/s m²mmH2Og °C°C
180.19293.9257.5300259.60.65Solid113681347181.3240.186321 SSC.S.222.2232.4
170.31351.4293.9365.83000.6Solid184992188681.3240.201321 SSC.S.238254.2
160.51445.8351.4474.9365.80.53Solid307363625781.3240.224321 SSC.S.264.9291.3
150.62557445.8606.3474.90.46Solid369074460181.2410.177321 SSC.S.282316.6
141.01729.5557819.6606.30.39Solid601437431481.2410.207321 SSC.S.332.4384.4
130.29777.5729.5879.9819.60.35None177273131081.1350.096321 SSNone00
120.34830.3777.5948.2879.90.33None211113728781.1350.1321 SSNone00
110.41899.3830.31026.4948.20.31None269634762481.1350.106321 SSNone00

Convection (Process Side)

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process Inlet
Conv. BoxRowDutyFlue Temp. INFlue Temp. OUTProcessFlowBulk Temp. InBulk Temp. OutBulk Press. InBulk Press. OutVap. Fraction InVap. Fraction OutInlet VelocityInlet Crit.Vel.Outlet Crit.Vel.Inlet M Vel.Outlet M Vel.Inlet Reynolds No.Inlet Reynolds No.
MW°C°C °C°CkPa akPa a m/sm/sm/skg/s m²kg/s m²
180.19293.9257.5 Dowtherm G1200202750723002.90024352435811877823664
170.31351.4293.9 Dowtherm G2202205.3723695002.90024352435823695842328
160.51445.8351.4 Dowtherm G3205.3211.1695668002.90024352435842346871644
150.62557445.8 Dowtherm G4211.12186686400030024352435871860908701
141.01729.5557 Dowtherm G5217.9228.96406120030024352435908332967096
130.29777.5729.5 Dowtherm G6228.9232.16125840030024352435967097984792
120.34830.3777.5 Dowtherm G7232.1235.758455500300243524359846581002484
110.41899.3830.3 Dowtherm G8235.7240.1555527003002435243510026771024829
Process Outlet
Conv. BoxRowCoil SectionDutyFlue Temp. INVap. Fraction OutInlet VelocityOutlet VelocityInlet Crit.Vel.Outlet Crit.Vel.Inlet M Vel.Outlet M Vel.Inlet Reynolds No.Inlet Reynolds No.
MW°C m/sm/sm/sm/skg/s m²kg/s m²
18Coil Section 30.19293.902.92.90024352435811877823664
17Coil Section 30.31351.402.92.90024352435823695842328
16Coil Section 30.51445.802.930024352435842346871644
15Coil Section 20.625570330024352435871860908701
14Coil Section 21.01729.50330024352435908332967096
13Coil Section 10.29777.50330024352435967097984792
12Coil Section 10.34830.303300243524359846581002484
11Coil Section 10.41899.3033002435243510026771024829

Radiant Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process fluid side
Tube No.Loc.ProcessBulk Temp In.Bulk Temp Out.Bulk Press In.Bulk Press. OutEnth. InEnth. OutVapour OutTube ODVelocity OutFilm TempAvg Tube Temp.Max Tube Temp.API Design Temp.Avg HTCFlow RegimeAvg FluxMax Flux
°C°CkPa akPa akJ/kgkJ/kg m/s°C°C°C°CW/m² °C W/m²W/m²
1WallDowtherm G240.1242.1526.9596.1696.1700.70114.33.1266.4274.5284.6299.62460.7Turbulent2593953391
2WallDowtherm G242.1244.1596.1507.5700.7705.30114.33.1268.2276.4286.5301.52467.9Turbulent2590753342
3WallDowtherm G244.1246.1507.5576.3705.3709.90114.33.1270.1278.2288.3303.32475.1Turbulent2587653294
4WallDowtherm G246.1248576.3488709.9714.50114.33.1272280.1290.1305.12480.7Turbulent2584453245
5WallDowtherm G248250488556.4714.5719.10114.33.1273.92822923072485.1Turbulent2581253197
6WallDowtherm G250251.9556.4468.4719.1723.70114.33.1275.8283.8293.8308.82489.4Turbulent2578153147
7WallDowtherm G251.9253.9468.4536.4723.7728.30114.33.1277.7285.7295.7310.72493.8Turbulent2574953098
8WallDowtherm G253.9255.8536.4448.7728.3732.90114.33.1279.5287.6297.5312.52498.1Turbulent2571753048
9WallDowtherm G255.8257.8448.7516.4732.9737.50114.33.1281.4289.4299.4314.42502.5Turbulent2568452998
10WallDowtherm G257.8259.7516.4429737.5742.10114.33.1283.3291.3301.2316.22506.9Turbulent2565252948
11WallDowtherm G259.7261.6429496.3742.1746.70114.33.1285.2293.13033182512.1Turbulent2562052898
12WallDowtherm G261.6263.6496.3409.1746.7751.30114.33.1287294.9304.8319.82518.7Turbulent2558852848
13WallDowtherm G263.6265.5409.1476.2751.37560114.33.1288.8296.8306.6321.62525.2Turbulent2555752799
14WallDowtherm G265.5267.4476.2389.2756760.60114.33.1290.7298.6308.4323.42531.5Turbulent2552552748
15WallDowtherm G267.4269.3389.2456760.6765.20114.33.1292.5300.4310.2325.22537.8Turbulent2549352698
16WallDowtherm G269.3271.2456369.2765.2769.80114.33.1294.3302.23123272544.1Turbulent2546152648
17WallDowtherm G271.2273.1369.2435.7769.8774.40114.33.1296.2304313.8328.82550.5Turbulent2542952597
18WallDowtherm G273.1275435.7349.1774.47790114.33.1298305.8315.5330.52556.8Turbulent2539652546
19WallDowtherm G275276.9349.1415.3779783.60114.33.2299.8307.6317.3332.32561.8Turbulent2536452495
20WallDowtherm G276.9278.8415.3329783.6788.20114.33.2301.6309.4319.1334.12566.9Turbulent2533252443
21WallDowtherm G278.8280.7329394.9788.2792.80114.33.2303.4311.2320.9335.92571.9Turbulent2530052392
22WallDowtherm G280.7282.6394.9308.8792.8797.40114.33.2305.2313322.7337.72576.8Turbulent2526752340
23WallDowtherm G282.6284.4308.8374.4797.48020114.33.2307.1314.8324.4339.42581.8Turbulent2523552288
24WallDowtherm G284.4286.3374.4288.6802806.60114.33.2308.9316.6326.2341.22586.8Turbulent2520252235
25WallDowtherm G286.3288.2288.6353.8806.6811.20114.33.2310.7318.43283432591.9Turbulent2516952183
26WallDowtherm G288.2290.1353.8268.2811.2815.80114.33.2312.5320.2329.7344.72596.8Turbulent2513752130
27WallDowtherm G290.1291.9268.2333.2815.8820.40114.33.2314.3322331.5346.52601.7Turbulent2510452078
28WallDowtherm G291.9293.8333.2247.8820.4825.10114.33.2316.1323.7333.2348.22606.6Turbulent2507252026
29WallDowtherm G293.8295.6247.8312.4825.1829.70114.33.2317.8325.53353502611.5Turbulent2503951973
30WallDowtherm G295.6297.5312.4227.3829.7834.30114.33.2319.6327.2336.7351.72616.5Turbulent2500651920
31WallDowtherm G297.5299.3227.3291.6834.3838.90114.33.2321.4329338.5353.52621.4Turbulent2497451866
32WallDowtherm G299.3301.1291.6206.8838.9843.50114.33.2323.2330.8340.2355.22626.3Turbulent2494151813
Tube side
Flame-tube impingment risk not identified

Convection Tube Profile

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Process fluid side
Conv. BoxTube No.Coil Sect.RowProcessBulk Temp. InBulk Temp. OutPress. InPress. OutEnth. InEnth. OutVapour FractionTube ODVelocityFilmAvg Tube Temp.Max Tube Temp.API Design Temp.Avg HTCFin TypeFlow RegimeTube Mat.Avg FluxMax Flux
°C°CkPa akPa akJ/kgkJ/kg m/s°C°C°C°CW/m² °C W/m²W/m²
1138Dowtherm G200200.5750.1743.2604.1605.30114.32.9208.5211.1214.2229.22230.9SolidTurbulent321 SS1145515876
1238Dowtherm G200.5201743.2736.4605.3606.50114.32.9208.9211.5214.6229.62232.5SolidTurbulent321 SS1137615766
1338Dowtherm G201201.5736.4729.5606.5607.70114.32.9209.3211.92152302234.1SolidTurbulent321 SS1129615657
1438Dowtherm G201.5202729.5722.7607.7608.90114.32.9209.8212.3215.4230.42235.7SolidTurbulent321 SS1121715547
1537Dowtherm G202202.8722.7715.8608.9610.80114.32.9215.7219.9224.9239.92247.9SolidTurbulent321 SS1864725816
1637Dowtherm G202.8203.7715.8708.9610.8612.70114.32.9216.4220.6225.6240.62250.7SolidTurbulent321 SS1851225630
1737Dowtherm G203.7204.5708.9702612.7614.70114.32.9217.1221.2226.2241.22253.5SolidTurbulent321 SS1837825444
1837Dowtherm G204.5205.3702695.2614.7616.60114.32.9217.8221.9226.9241.92257.4SolidTurbulent321 SS1824325257
1936Dowtherm G205.3206.8695.2688.3616.6619.80114.33227.8234.6242.9257.92278.9SolidTurbulent321 SS3099742832
11036Dowtherm G206.8208.2688.3681.4619.8623.10114.33229235.82442592285.5SolidTurbulent321 SS3075742500
11136Dowtherm G208.2209.6681.4674.5623.1626.30114.33230.2236.9245.1260.12292.2SolidTurbulent321 SS3051742168
11236Dowtherm G209.6211.1674.5667.5626.3629.50114.33231.4238.1246.1261.12298.9SolidTurbulent321 SS3027641835
11325Dowtherm G211.1212.8667.5660.6629.6633.50114.33238246.3256.3271.32314.7SolidTurbulent321 SS3717552160
11425Dowtherm G212.8214.5660.6653.7633.5637.30114.33239.5247.7257.6272.62322.6SolidTurbulent321 SS3694851842
11525Dowtherm G214.5216.3653.7646.7637.3641.20114.33241249.12592742330.5SolidTurbulent321 SS3672251524
11625Dowtherm G216.3218646.7639.7641.26450114.33242.4250.5260.3275.32338.5SolidTurbulent321 SS3649551206
11724Dowtherm G217.9220.7639.7632.8644.9651.20114.33261.3274.7290.8305.82376.4SolidTurbulent321 SS6061386305
11824Dowtherm G220.7223.4632.8625.8651.2657.50114.33263.5276.8292.8307.82391.8SolidTurbulent321 SS6020785727
11924Dowtherm G223.4226.2625.8618.7657.5663.80114.33265.7278.9294.8309.82407.4SolidTurbulent321 SS5980185150
12024Dowtherm G226.2228.9618.7611.7663.8670.10114.33267.9281296.8311.82423.1SolidTurbulent321 SS5939684572
12113Dowtherm G228.9229.7611.7604.7670.1671.90114.33244.1249254.8269.82394.1NoneTurbulent321 SS1738130700
12213Dowtherm G229.7230.5604.7597.6671.9673.70114.33244.8249.8255.5270.52398.9NoneTurbulent321 SS1735530654
12313Dowtherm G230.5231.3597.6590.6673.7675.50114.33245.5250.5256.2271.22403.8NoneTurbulent321 SS1733030608
12413Dowtherm G231.3232.1590.6583.5675.5677.40114.33246.3251.2256.9271.92408.6NoneTurbulent321 SS1730430563
12512Dowtherm G232.1233583.5576.5677.3679.40114.33249.5255.2261.9276.92416NoneTurbulent321 SS2019835675
12612Dowtherm G233233.9576.5569.4679.4681.50114.33250.3256.1262.7277.72419.3NoneTurbulent321 SS2016835621
12712Dowtherm G233.9234.8569.4562.3681.5683.60114.33251.2256.9263.6278.62422.6NoneTurbulent321 SS2013735567
12812Dowtherm G234.8235.7562.3555.3683.6685.70114.33252.1257.8264.4279.42425.9NoneTurbulent321 SS2010635513
12911Dowtherm G235.7236.8555.3548.2685.8688.40114.33256.7263.7271.7286.72435.5NoneTurbulent321 SS2453243329
13011Dowtherm G236.8237.9548.2541.1688.4690.90114.33257.8264.7272.7287.72439.6NoneTurbulent321 SS2449343261
13111Dowtherm G237.9239541.1534690.9693.50114.33258.8265.7273.7288.72443.6NoneTurbulent321 SS2445443192
13211Dowtherm G239240.1534526.9693.5696.10114.33259.8266.7274.7289.72447.6NoneTurbulent321 SS2441543124
Tube side

Coil Configuration

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Heater Section RADIANT 1CONVECTION 1CONVECTION 1CONVECTION 1
Coil Section Coil Section 1Coil Section 1Coil Section 2Coil Section 3
Process Name Process 1: Dowtherm GProcess 1: Dowtherm GProcess 1: Dowtherm GProcess 1: Dowtherm G
Tube OD mm 114.3114.3114.3114.3
Tube Material 18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS
Tube Wall Thk mm Sch 40Sch 40Sch 40Sch 40
Max Tube Temperature°C340.2274.7296.8246.1
Tube Temperature Margin°C15151515
Design Tube Temperature°C355.2289.7311.8261.1
Design Tube PressurekPa2000.2 2000.22000.2
Design Code API 530 API 530API 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 64241624
No. Tubes Per Row 888
No. Passes 2222
Effective Length m 10.0845.8355.8355.835
Straight Length m 9.6856.2356.2356.235
No. Rows 323
Tube Spacing mm 203.2203.2203.2203.2
Vert. Row Spacing (Vert) mm N/A176.1176.1176.1
Coil Alignment StaggeredStaggeredStaggered
Orientation VerticalHorizontalHorizontalHorizontal
Tube Aream²231.7450.26269.71670.95
Intermediate Supports 0 / 01 / 11 / 11 / 1
Corbel Width m 1/2 Tube Space1/2 Tube Space1/2 Tube Space
Fin Type NoneSolidSolid
Fin Material NoneCarbon SteelCarbon Steel
Fin Height mm 19.0525.4
Fin Thickness mm 1.271.27
Serrated Fin Wn
Fin Densityfins/m 157197
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.

API 530

Calculation of Heater-tube Thickness in Petroleum Refineries

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Location RADIANTCONVECTIONCONVECTIONCONVECTION
Coil/Piping Section Coil Section 1Coil Section 1Coil Section 2Coil Section 3
Design PressurekPa g2000.22000.22000.22000.2
Max Operating PressurekPa g750.1750.1750.1750.1
Design Temperature°C355.2026289.6959311.7809261.1343
Tube Material 18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS18Cr/10Ni/Ti - 321 SS
Tube Outside Diameter 114.3114.3114.3114.3
Tube Thickness mm 6.026.026.026.02
Corrosion Allowance mm 1111
Design Lifehours100000100000100000100000

TUBE DESIGN RESULTS
Specified Tube Thickness mm 6.026.026.026.02
ELASTIC DESIGN
Elastic Allowable StresskPa128083.8133324.4131557.6135609.3
Elastic Stress Thickness mm 0.88560.8510.86240.8368
Elastic Min. Tube Thickness mm 1.891.851.861.84
Elastic Average Tube Thickness mm 2.152.122.132.1
Elastic Design Comment Thickness is OKThickness is OKThickness is OKThickness is OK
RUPTURE DESIGN
Rupture Allowable Stress 0000
Rupture n factor 0000
Rupture Stress Thickness mm 0000
Rupture Min. Tube Thickness mm 0000
Rupture Avg. Tube Thickness mm 0000
B factor 0000
Corrosion Factor Fcorr 0000
Rupture Design Comment Not applicableNot applicableNot applicableNot applicable

Stack & Draft Summary

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Stack Height m 17
Stack Diameter m 1.27
Cone Diameter m 1.274
Cone Height m 0.5
Actual Exit Velocitym/s6.5
Design Exit Velocitym/s7.8
Flue Gas Temp.°C257.5
Flue Gas Flowkg/s4.71
Steel Aream²68.067
Stack Entry PressuremmH2O-0.999
CO2mol%12.21
H2Omol%8.96
N2mol%75.42
O2 mol%3.33
SO2mol%0.08
Draft at Stack BasemmH2Og-2.5
Draft at ArchmmH2Og-2.5
Draft at FloormmH2Og0
heater560, fired heater draft calculation, api 560 fired heater draft profile, draft, profile, draft simulation, heater simulation
Stack No. 1: Auto Stack calc. has converged OK

Refractory

HeaterSIM - Fired Heater Simulation Results

Online API Fired Heater Software

Hot-FaceHot-FaceHot-FaceBack-UpBack-UpBack-UpMaterial
Flue Temp.MaterialThicknessConductivityMaterialThicknessConductivityAllowable FluxActual FluxDesign Temp.Anchor TypeCasing Temp.Comment
°C mmW/mK mmW/mKW/m²W/m²°C
RADIANT FLOOR 1 849.3MW Castable74.90.4ULW Castable150.10.14732.5610.61400V Y Anchors80.3Refrac. thickness OK
RADIANT WALL 1 619.7Fibre (High Density)74.90.1None00732.8580.91260Twistlock Pins72.3Refrac. thickness OK
RADIANT ARCH 1 899.3Fibre (High Density)1130.1None00824818.61260Twistlock Pins80.6Refrac. thickness OK
CONVECTION SIDEWALL 1 578.4LW Castable74.90.3ULW Castable74.90.13732.8606.11100V Y Anchors73.7Refrac. thickness OK
STACK 1 257.5LW Castable62.70.3None00732.8720.21100V Y Anchors80.6Refrac. 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.

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