FLUOR PIPE STRESS ANALYST DESIGN GUIDE yewsen 3.21 DESIGN GUIDES DESIGN CRITERIA FOR FIRED HEATER PAGE lof 50 DATE 4-76 2.0 HEATER NOZZLE FORCE, MOMENT AND STRESS LIMITATION wal Pipe stress at the heater terminal shall be within the allowable stress range as designated by ANSI 831.3 (latest revision) for the material of construction. Moment on flanges shall not exceed those permitted in section 2.0 of the Stress Group Charts and Tables, to insure that leakage will not In the absence of vendors' limitations, forces shall be limited to 200 Ibs. per inch of nominal pipe size, or 2000 Ibs. which ever is jess. Cold spring may be credited in accordance with ANSI B31.3. Forces, nozzle deflections, and moments mutually agreed upon by Fluor and heater manufacturer. Forces, deflections and moments shall be transmitted to the heater vendor for their comment and approval at the earliest time possible. Preliminary layout and sketches can be used for this particular purpose. b. Supporting steel for piping from heater shell or structure shall be reviewed, designed and approved by the heater manu- facturer. The loads on supports shall also be transmitted to the heater vendor during the early stage of the job. HEATER DESIGN AND LAYOUT 2.2 ‘The most important consideration in laying out heater piping is to use the heater tube as a flexible element to minimize the amount of flexibility required in the process piping. By locating the heater tubes in the most advantageous position, the length and number. of fittings required in the process piping may be minimized. TYPES OF HEATERS Basically there are three types of heaters. They are: 1. Box-type 2. Vertical 3. Helical CoilFLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3-11 DESIGN CRITERIA FOR FIRED HEATER PAGE «2 DESIGN GUIDES DATE 4-76 3.1 Box-Type Heaters: A box-type heater is considered to be any heater in which the tubes are horizontal. There are numerous designs of box-type heaters. In this type of heater, it is possible to have locations or zones of different heat densities. The shock or shield tubes usually receive the highest heat density because they absorb both radiant and convection heat. Tubes in the radiant section of the furnace are called "radiant tubes. The heat pickup in these tubes is mainly by direct radiation from the heating flame and incandescent refractories ‘The zone of lower heat density is the convection section. The tubes in this section are called “convection tubes." The heat pickup in the convection section is obtained from the combustion gases, primarily by convection ‘The size and arrangement of tubes in a box-type heater are determined by the type of operation (crude oil distillation, cracking, etc.), the amount of heating surface required, and the flow rate through the tubes. Box-type heaters may be updraft or downdraft, with gas-or oil-fired burners located in the end or side walls, floor, roof, or any combin- ation thereof. Auxiliary tubes are often installed in the convection section after the oil convection tubes, to preheat air for the burners or to generate or superheat steam for process and other uses. 3.2 Vertical Heaters: ‘The vertical heater is either cylindrical or rec~ tangular. The entire heating coil, or major portion, consists of vertical tubes. The radiant tubes are vertical, but the upper ends of these tubes may be in a convection zone where gas velocity is increased by restricting flow area. The tubes in the convection section are always horizontal. In some installations an oil economizer section or an air-heating section, or both, are used above the main vertical heating section. ‘The auxiliary tubes in the oil economizer or air-heating sections may be either horizontal or vertical, depending on the particular design. The purpose of an oil economizer or air-heating section is to improve the economy of operation. ‘The majority of vertical tube heaters are bottom-fired, with the stack mounted directly on top of the heater. Downdraft vertical heaters have also been used. ee)FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.12 pesion DESIGN CRITERIA FOR FIRED HEATER PAGE 3 GUIDES DATE 4-76 3.3. Helical Coil Heaters: ‘The helical coil heater is cylindrical in shape, with the radiant section surface in the form of a coil which spirals up the wall of the heater. Heaters of this type usually do not have a convection section; but, if included, the convection surface is in the form of a flat spiral or bank of horizontal tubes. ‘The stack is almost always mounted directly on the heater. 4.0 THE RADIANT SECTION 4.1 Consider the vertical heater first since it is the simplest of the three. All vertical heaters have vertical tubes in the radiant section and horizontal tubes in the convection section if one is required. The tubes in the radiant section are arranged in even or odd numbers. Tubes are frequently added to reduce the height of the heater while elimination of a tube will increase the height of the heater. Even numbers of tubes will place the inlet and outlet nozzles at the same end of the heater. See Figure 4.1. 1 Pass 2 Tubes,FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.22 DESIGN CRITERIA FOR FIRED HEATER Desion pace 4 GUIDES DATE 4-76 4.2 Odd number of tubes place the inlet and outlet at opposite ends of the heater. See Figure 4.2.1. 1 Pass B. 1 Tube 3 Tubes 3 Tubes [77> [t---, —-~-—4 = ro} 1 I | | 1 x ' Figure 4.2.1 Tube & Pass Arrangements 4.3 Occasionally there is an option to increase or decrease the height of the heaters and consequently reposition the nozzles to the advantage of the piping system. (3-40' tubes = 4-30" tubes). However, when there is a convection section involved with a direct tie to the radiant section, the support and nozzle locations for the interconnecting pipe will invariable be set by the heater vendor with little option for change. see Figure 4.3.1.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.11. DESIGN CRITERI) Fu pesict ESIGN A FOR PIRED HEATER PAGES GUIDES DATE 4-76 4.3 (Continued) stack convection Section crossover Piping mee f i £ $ ‘Tube Support inlet: ‘Tube Guide { ‘Tube Guide 4.4 Normally the supports in this case are located at the top of the radiant section to minimize growth into the crossover piping which minimizes the length and number of fittings re~ quired in the crossover piping for flexibility purposes. 4.5 The location of the nozzles has a direct bearing on the loca~ tion of the tube supports as related to the piping system. Therefore, an understanding of the type of supporting arrange~ ments available is necessary before continuing with the layout. 5.0 BOTTOM SUPPORTS 5.1 Tubes supported at the bottom of the heater have advantages which may or may not be of value in the layout of the piping system. Each must be considered on its own merit and evaluated with respect to the effect on that particular system of piping. See Figure 5.1.PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3-12 DESIGN CRITERIA FOR FIRED HEATER PAGE 6 DATE 4-76 5.1 (Continued) Arvax. exp. (#2) (pn SSS Ss ae ST = 4 f oe PW ty we ah I es | Guides tt ame fh tl Woh AP nme Ny | = tle. Support He A i S Support Nhe fe = i ST TYR le. oo RR Sect rawtet & 5.2 The long unstable tube columns require guiding to avoid buckling from their own weight and any external load applied parallel to the center line of the pipe. Columns under compressive loads are much more critical than columns in tension. To avoid eccentric column loading, the deflection " A“ of the bottom support in a horizontal direction must be minimized. The weight of the tubes is supported at a lower elevation within the heater structure. Expansion is tube movement into the piping system. Lateral dis~ placement is allowable piping movement into the heater. (L-D.) 6.0 TOP SUPPORTS 6-1 As with bottom supported tube arrangements, top supports have decided advantages which must be evaluated for each individual piping application. (1) Avin. Exp. = Tube change in length is minimum for thermal expansion growth. (2) Avax. pxp.= Tube change in length is maximum for thermal expansion growth.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.12, DESIGN CRITERIA FOR FTi Pi pees RED HEATER AGE GUIDES 4-76 6.1 (Continuea) «3) Atv. = Tube deflection is a limited dis- placement due to eccentric load, tube bending stress, and physical design of the heater compents. The ideal case would provide enough lateral displacement in the installed condition to take a cold pull equal to the piping growth from thermal expansion. Anin. Exp. (#1) te Anax . . \ sencmens is ——— re sutbee “ [a tube SS I support The long tubes are in tension and are in no danger of buckling! Horizontal displacement is limited by the stress in the tube and the limit accepted by the heater vendor. The weight of the tube is located at the top of the radiant section. See Figure 6.1. ~ 1 1 | | | LJ KY XN NA Exp. (#2) Figure 6.1 7.0 FLOATING COILS 7.1 ‘This is by far the most expensive method of absorbing displacement into the heater. There are many instances where the floating coil is the only solution to absorbing growth of the piping system and is in actuality a must because of limited pressure drop.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.11 DESIGN CR: Pact 8 a CRITERIA FOR FIRED HEATER E eae DATE 4-76 7.2 Methods of floating the coil employ either the use of spring hangers or counterweights. The most common approach used by heater vendors is the counterweighted piping system. The code demands that all counterweights are installed with fail safe devices for personnel protection in the event that the counterweight assembly fails. Usually the counterweights are attached to the headers supporting the heater tubes. The counterweight is a weight lifting the tube through a cable and pulley system or a weight lifting the tube through a cantilever beam system. See Figures 7.2.1 and 7.2.2. cable (typ) Weight (typ) tl tl rasa van —_/ | |! ws inet ty i ee ‘| BEAM SYSTEM Figure 7.2.1 Floating CoilFLUOR PIPE STRESS ANALYST DESIGN GUIDE NemseR 3.12 DESIGN DESIGN CRITERIA FOR FIRED HEATER PAGE = 9 GUIDES DATE 4-76 7.2 (Continued) Displacement limited in all directions only by heater vendor and pipe thermal expansion (displacement) . ore er zo I \ I i \ Cable (typ) 5 ! | | | | { a Weight f =) (typ) 8 Failsafe column PULLEY SYSTEM BEAM SYSTEM Figure 7.2.2 Floating Coils co — - The other method of floating the coil is with the use of spring hangers. See Figure 7.2.3. Hanger Spring Displacement limited in all directions only by heater vendor and pipe thermal expansion (displacement) Limited Horizontal Movements —e Base Spring Foundation Figure 7.2.3 Floating CoilsFLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.22 DESIGN CRITERIA FOR PAGE = 10 Seca FIRED HEATER GUIDES DATE 4-76 8.0 THE CONVECTION SECTION ‘The length of tubes in the convection section of the vertical heater are generally very short because of the limited area available on top of the radiant section. (6' to 12"). They may be controlled easily by the addition of directional anchors on the face of the convection section. Normally, the heater vendor will only supply controls on request. The standard approach is to rely on friction to provide a natural anchor in the center allowing the tube to expand outward from that point. Since the commodity in the line is heated as it flows from one end of the tube to the other, the tube metal will generally be hotter at the outlet end than on the inlet end and the metal temperature is 100°F to 200°F hotter than the flowing commodity. See Figure 8.1. Convection Section Tubes Vertical Supports pee Lye, [Ye cusses € HEATER Figure 6.1 eFLUOR PIPE STRESS ANALYST DESIGN GUIDE NuMBER 3.21 DESIGN CRITERIA FOR FIRED HEATER foo PAGE LL GUIDES DATE 4-76 8.2 The same phenomena will occur regardless of the number of passes or the length of the tube although to a lesser degree on shorter tubes. See Figure 8.2.1. convection Section Tubes « 7 Vertical Supports ¢ eater Figure 8.2.1 8.3 A reliable frictional restraint such as is described is a figment of the imagination. There are too many factors which tend to control the direction of the expansion if positive methods are not utilized; i-e., weld splatter, crooked supports, crooked guides, etc. The correct approach is to add restraints to the tube. This action will have the additional benefit of providing effective wind and seismic stops which is definitely lacking in the frictionally restrained state. The three locations available for providing control on the tube are the front face of the convection section, the rear face of the convection section and the internal supports for the tubes. Any one of these locations may be selected. Never more than one. Furthermore, the stop may only be provided ‘on the first or the last pass only because of the difference in the metal temperature of the tubes. See Figure 8.3.1.PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER 8.3 (Continuea) b= 10-0" stop Gxiald cane M_ _rones oe __ ans B00°F Le #2 Outlet Tube eee a ee A, - 26 € Heater J——convection Section Stop (Axial) Heater Figure 8.3.1PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER 3.11 PAGE = 13 DATE 4-76 8.3 (Continued) Assuming linear heat buildup and a tube metal temperature 00°F higher than the conmodity-321SS tubes. See calculations below: Calculations For Figure 8. Temp. @ inlet = 100°F + 600°F = 700°F Temp. @ return bend = 800°F (avg.) Temp. @ outlet = 100°F + 00°F = 900°F Average temperature of tube fone = 750°R (e @ 750°F = .0815"/Ft.) Average temperature of tube #two = 850°F (e @ 850°F = .0941"/Ft.) Ay [no x .0815) - (20 x .0941]) .126" our (Direction Due To A, . fac x .0815) - Go x -0941)] = .126" IN} Location of Stop See Figure 8.3.1. stop s stop 815 Ay us 4, —_— NN _ i 5 ar = Fe oo Ng Ay 940 7-7 : ~~ >A Stub Through Wall 4a 10 x -0815 = .815"; 2 a Tube Bend Through Wall. 10 x -0941 = .941"FLUOR DESIGN GUIDES PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER PAGE DATE 3.11 14 4-76 Installation of internal guides and anchors is not desireable because the support steel and piping attachment are exposed to the direct heat in the section and have no flowing commodity to cool then. |. See Figure 8.4.1. -3915" 70°F sto" —— bab -5175" 900°F| H 750° Fa _ 50°F Figure 8.4.1 stop nor Allowed G wearer Large forces must be restrained by face of plates. Temp. Inlet ‘Temp. Stop ‘Temp. Return Bend = 800° ‘Temp. certer ‘Temp. Outlet 700° = 750° 850° 900° Avg = 725° Avg = 775° Avg = 825° avg -S x .0848 45 x .0911 5 x .0972 Floating coils in the convection section are not considered because of the extreme difficulty in supporting the long horizontal tubes on springs or counter-weights. ‘The coils may be displaced normal to the centerline of the tube with only the tube stress level as a limit. ment of the coil parallel to the centerline of the tube is not allowed. Vertical displacement is limited to the upward direc- tion so that the tube is lifted off of the pipe support. The 2426" +.4555" 486" Displace-FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.12 DESIGN CRITERIA FOR FIRED HEATER a PAGE 15 GuIpes DATE 4-76 8.6 (Continued) additional weight from loss of the supports must be absorbed by the first internal and external support that is effective. See Figure 8.5.1. 8.7 Tf a directional control is required at the center of the tube (Fig. 8.4.1) the same effect can be achieved by placing a stop at both ends of the tube and providing a gap equal to half the thermal expansion of the tube Maximum Displacement A " Displacemen 4a 4a ae : Maximum Displacenent —¥| Operating Position - Pipe is Hor Me ‘Thermal exp. is directed from vert. supt. @ "A" |__ a7 Tube is lifted off support* Tgeate cellar eee Tesupt's_ 4 4 First Effective Support Installed Position - Pipe is COLD }—— “a” vertical support Figure 8 ‘The amount of lift of€ is proportional to vert. exp., which is dependent on: Line Temp., Pipe Mat'l & Dim. “L", to first vertical support.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.12 pesien DESIGN CRITERIA FOR FIRED HEATER PAGE 16 GUIDES DATE 4-76 8.7. The weight resting on the first four supports inside the con~ vection section must now be added as additional load on the third internal support and on the external support. The new unsupported span must also be considered. See Figure 8.6.1. 9.0 REGENERATION 9-1 During catalyst regeneration and especially during decoking operations the line temperature may increase considerably. ‘The effect on the line expansion, whether the decoking-regen- eration system is independent of the process system or not, must be taken into account in the design of the heater. The decoking temperature generally is in the vicinity of 1300°F, and will affect the displacement required at the heater tube nozzles. See Figure 9.1. Pipe Mat‘l: Stainless Steel Temp. : Normal oper. Des. = 800°F, /\ , 130°. /\, Temp. + Decoking Anchor --4 --4 1.056" Doe ‘Thermal exp. is from the anchor point to the heater, thus deflecting the tubesFLUOR DESIGN GUIDES otch at joint cx PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER 3.11 PAGE 17 DATE 4-76 ‘The heater tube in the decoking operation is displaced nearly twice as much as in the design condition. The allowable,pipe spans and the pipe material are severely limited at 1300°F. Because of these factors, water quenches are introduced into the lines to reduce the temperature. Invariably these quenches require mixing gees to recude the temperature rapidly to a maximum of 1000°F or less. See Figure 9.2.1 \q—"Mixing Tee" (Designed by Stress Eng.) Pipe may require “Liner” to reduce thermal shock, fatigue & erosion Erosion Point Hivy. wall because RETICAL LENGTH Figure 9.2.1 , Critical length determined by Process Eng. & Mechanical Eng. Consultant. The critical length shown is a factor of the injected material, temperature and velocity. It is required to prevent wear (erosion) on the elbow from the effect of the injected material striking the elbow at high velocity. The length must be sufficient so that the injected material is thoroughly mixed with the flowing commodity before the elbow. Using the weld reducer to attach the injection line removes the thermal shock from the crotch and allows the injection to be made without weld cracking and bowing at the junction point. The connection at the junction point will be designed by stress.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.22. DESIGN CRITERIA FOR FIRED HEATER PAGE 18 DESIGN GUIDES DATE 4-76 9.4 0.8.H.A. has had a drastic effect on Fluor's attitude toward “throw away" or “expendable” piping in decoking systems. Fluor is now obligated to recommend material which is within the temperature limits established by the Refinery Piping Code or be in a position to prove the suitability of the material at higher temperatures ~ even though this piping is used infrequently. At temperatures above 1100°F (the Code limiting temperature of carbon steel) Fluor will recommend alloy or stainless steel pipe for these installations. In the event that the client insists on using carbon steel pipe he must indicate in writing that his decision is to override Fluor's recommendation. He must also provide allowable stress for computing wall thicknesses, pipe spans and thermal expansion for all temperatures beyond the range of the code. Fluor will then design to the specific parameters dictated by the client ‘This approach is mandatory for all plants which fall under the jurisdiction of United States federal regulations. Note- In determining design temperatures, consider the temperature derating allowances permitted by Code for uninsulated piping. 20.0 RING HEADERS 10.1 ‘The ring header must always be supplied by the heater vendor. Tube connections are difficult to locate on the header, also, the support and tube movements from the ring header expansion are removed from the area of responsibility of the vendor when hhe does not design and fabricate the ring. Since there is no flexibility between the ring and the tube, the tube must absorb the expansion of the ring header. The weight of the header is on the tube support. 11.0 STRESS CHARTFLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER. 3.21 DESIGN CRITERIA FOR FIRED HEATER DESIGN PAGE 19 GUIDES DATE 4-76 12.0 VERPICAL HEATER SAMPLE PROBLEM #1 20" @ Inlet from V-101 20" g outlet to pipeway Stainless Tubes 253 Gr-B Pipe Figure 12.1 Plan Layout: (a) (B) (c) options 1-40 Tube, 2-20 Tubes, 3-13" Tubes, o Fe ae Inlet 600°F 20 Req'd 20 Sets Req'd 20 Sets Req'd outlet 800°F 42' Height 22" Height: 15" Height Tube Metal = 900°F 6'-6" @ utr. 11'-6" @ Htr. 16'-6" Htr. Commodity Avg. = 700°F 5'-6" g Ring 10'-6" g Ring 15'-6" ¢ RingFLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.22 DESIGN CRITERIA FOR FIRED HEATER PAGE 20 DESIGN DATE 4-76. aA 1B 2a 2B 2D 3a 3B Figure 12.2 Tube and Support Arrangement Sample Problem 12.1 The thermal expansion between V-101 and H-101 is 50 x .046 = 2.30" in the east-west direction which must be absorbed by additional piping in the north-south and vertical direction or by the heater tubes. By the Table 11.0 a 4" tube of minimum 18" length is required and would be top supported to handle the large displacement. ‘This eliminates scheme 3A and 3B because of the short tube length unless the coil is floated (too expen- sive unless other schemes fail). Schemes 2D, 2B and 1B are eliminated because bottom supported tubes allow limited dis placement. Schemes 1A, 2A and 2C are best suited for the layout to accommodate the horizontal displacement. However, the top supported units impose vertical displacement into ‘the piping system. Obviously scheme 1A is the worse offender, and it is eliminated. See Figure 12.1.1.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.31 fee DESIGN CRITERIA FOR FIRED HEATER PAGE = 22 GUIDES DATE 4-76 12.1 (continued) pats Thea 12.2 The bottom inlet and outlet may require less piping but requires a higher supporting structure for the heater. Ring headers on the bottom must be raised to allow 7'-6" clearance under the pipe. Use the bottom inlet and outlet connections. 12.3 The piping system must now be arranged and anchored to control the movements and forces on the heater nozzle. Supports are added to the system and loading is calculated for each. All pertinent information is then transmitted to the heater manu- facturer. See Figure 12.3.1.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3-11 DESIGN CRITERIA FOR FIRED HEATER DESIGN PAGE = 22 Guipes DATE 4-76 12.3 (Continued) Dummy Support Directional Anchor a Transmit load to vendor Transmit loads and movements to heater vendor Ring Header ERE Figure 12.3.1 12.4 Information to be transmitted to heater vendor. 1. Inlet tube movement for all tubes. + at] 016 = 2 13/16" west tay [fston + es0'-0 toy [fst-an] woes = 1/4" nacen and south Sree ere ore eres rites Bg ese eee fore ta pec en ne fcaes 13.0 VERTICAL HEATER SAMPLE PROBLEM #2 13.1 Another type installation is the vertical heater with a convection section. In this case, consider the convection section a preheater with crossover piping between the convection section and theFLUOR PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER Desicx GUIDES 13.1 (Continued) a pi 153'=0" ‘ EL : “4 fH | 2 13.2 Material Piping Inlet = S00°F, a53 Gr-B Piping Outlet = 700°F, 53 Gr-B Sp Heater Tube = 800°F, ss EL. 100'-0" Figure 1 ‘The vertical expansion in the inlet line is (153.0' - 101.5") x 0362 = 1.864". From the stress chart (Table 11.0) the 6" tube 12'-0 long can only be bent 5/8", therefore, the line cannot be supported at grade. Supporting will be in the form of spring hangers at any elevation or a solid support from the heater structure. The maximum distance from the nozzle to. the solid support is 0.625/.0362 = 17'-3 Support the inlet line at elevation 135'-9". The support must be designed to absorb the thermal force to bend the 12'-0" leg plus half the weight of the 12'-0" leg plus the weight of the entire vertical line and half the weight of the lower horizontal run to the first support. The inlet nozzles must absorb the horizontal movement of the intet line.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.22 DESIGN DESIGN CRITERIA FOR FIRED HEATER GUIDES 13.2 (Continued) 5 x .0362 = .181 = 3/16" North and South; and 11 x .0362 West; and the vertical expansion of 17.25 x .0362 13.3 The lower 12" manifold will grow down from the upper pipe sup- port (135.75' - 101.5') x .0362 = 1.24" which must be absorbed by bending the pipe between the manifold and the first solid support. Springs may be required on the 12" line. 13.4 The outlet ring header grows down (151' - 108") x .088 = 3.78". Location of the first solid support must be at least 38 linear horizontal feet from the ring header (see Table 11.0). 13.5 Maximum horizontal expansion which can be absorbed by the 51" long inlet lines is more than 8 7/8" per Table 11. 13.6 Maximum horizontal expansion which can be absorbed by the 43 Jong outlet tubes is more than 16 3/16" per chart. 13.7 Tube movenents of large magnitudes such as these present prob lems of heat loss* to the heater vendor, however, they are not insurmountable. The best example for large magnitudes of move- (0 ments into heater tubes are applications in hydrogen and reformer heaters. 14.0 Other typical layouts are piping arrangements to reactors and drums, See Figure 14.1. ‘Heat loss problems in this case is concerned with the closure of gap between the outside of the tube and the wall or floor of the heater.PIPE STRESS ANALYST DESIGN GUIDE wumeeR 3.22 DESIGN CRITERIA FOR FIRED HEATER PAGE 25 DATE = 4-76 14.0 (Continued) ar 800°F, A53-GrB a EL 147'-0" El. 144'-0" Avg, Commodity Tem I} 8758s tube = 975¢e pap Tubes 950°F, A53-GrB EL.__107'~0 Figure 14.1 14.1 In order to minimize the vertical expansion difference, the tube support should be located as near to the reactor support as poss- ible. When the lower tangent line of the reactor is close to the bottom of the heater the tubes should be bottom supported. When the lower tangent line of the reactor is near the top of the heater, the tubes should be top supported. 14.2 Example of vertical expansion difference. Example #1 a. Bottom supported heater tubes. Elevation H = 107'-0" Are fasr-on = caor-or) x 0698 = 2.792" a: " [a47+-o7) = aoo-or} x sana Net = 1.441" 4.2332"FLUOR PIPE STRESS ANALYST DESIGN GUIDE nai ert P, 26 prin DESIGN CRITERIA FOR FIRED HEATER AGE GUIDES DATE 4-76 14.2 (Continued) b. Top supported heater tubes Elevation H = 107'-0" A a2 [aa7'-0") = ao7'-o"] x .0698 = fuar'-or) = aaron] x canta = Net = 2.458" ‘a. Bottom supported heater tubes Elevation H = 124'-0" Ai = [far = a2at-o"] x .0698 = 1.6054" Az = [aar'-o%) = og'-orj} x 1114 = 4.2332" Net = 2.6278" b. Top supported heater tubes Elevation H = 124"-0" Ax = [f147!-0") - (124'-o"j] x .0698 = 1.6054" @ Qa = [aa7t-or) - aaat-onmy) x .1114 = 23342" Net = 1.2712" 14.3 In order to evaluate the heater as a whole, the lower ring header and attached piping must be considered. Example #3 a. Bottom supported heater tubes Elevation # = 107" A3 = fost-o") = ao7'-on]} x a= fao'-07) ~ 207'-0")] x 0835 = .0277* up Example #4 b. Top supported heater tubes Elevation # = 107'-0" As = [ase-o" = aor-o4) x ana faro'-0%) = (207'-0%)) x .0835 = 3.8713" down 14.4 When large piping is involved, a floating coil may be preferred to use the flexibility in both the inlet and outlet piping and to absorb the heater tube expansion.FLUOR PIPE STRESS-ANALYST DESIGN GUIDE 14.4 DESIGN GuIDes NUMBER 3-11. DESIGN CRITERIA FOR FIRED HEATER PAGE = 27 DATE 4-76 (Continued) Example #5 H = Lo7*~ + Reactor = [(247'-0") - (107!-0"]] x -0698 ~ eater = [247'-0") ~ co7!-0"] x ana + tower Pipe = [(1i0'-0") ~ c07*-or]] x .0835 Net = 1eava" Example #6 H = 124'-0" + reactor = [f247'-0") - (22at-o"j] x 0698 = 1.605" = eater = [(247'-0") ~ (ao7'0"] x uaad = = 4.456" + Lower Pipe = [(110'=0") - (2o7!=0"] x .0835 250" Net = 2.601" 15.0 BOX-TYPE HEATERS 16.0 15.1 15.2 Box heaters are generally much larger than the vertical type heaters and present more varied and complex problems with respect to stress analysis. The radiant section tubes can be vertical or horizontal with connecting headers in varied forms welded directly or with flexible “pigtails.” Rather than discuss the radiant section as a general form, specific units will be analyzed with the most effective layouts presented and the reasons for their selection. CRUDE HEATER OUTLET TO VACUUM TOWER 16.2 Do not arrange radiant tubes parallel to the major pipe run. Heater tubes may not be moved parallel to themselves because of the large number of tubes which are interconnected. Flex- ibility would then be required in the piping arrangement. See Figure 16.1.FLUOR PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER DESIGN GUIDES NUMBER 3.11. PAGE = 28 DATE = 4-76 a 16.1 (Continued) Required Loop Alloy Piping 36" DIA P-101 ar Supt. by vendor vacuum a) —<—_ eared Stop Tube 4 ee Expansion Tangential aaa Nozzle Cold Spring Riser 100 crude Heater (Box-Type) Figure 16.1 An arrangement such as this requires about a 50' deep loop with four extra elbows.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.21 DESIGN GUIDES DESIGN CRITERIA FOR FIRED HEATER PAGE 29 DATE 4-76, Hanger spring Required 6"-alloy ‘ube Leads ™ yy Alloy Pipe 36" DIA 16.2 Eigure_ 16.2.2 An arrangenent such as this requires about 30' minimum of vertical 6" alloy pipe per lead, two extra elbows as shown, plus a spring support for each lead. See Figure 16.2.1.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NumBeR 3.22 DESIGN CRITERIA FOR FIRED HEATER PASE DESIGN ou Gulpes DATE 4-76 Sup't by vendor stop Tube Expansion 20"-0" Figure 16.3.1 wed 16.3 An arrangement such as this requires about a 70' offset in the 36" B alloy pipe plus two elbows. See Figure 16.3.1.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.12 fe DESIGN CRITERIA FOR FIRED HEATER PAGE = 31 GUIDES DATE 4-76 16.4 Yo minimize piping costs and maintain a tight professional layout the heater tubes should be perpendicular to the longest length of pipe. See Figure 16.4.1 thru 16.4.4. stop Nobil Joliet Layout a T-101 60" DIA es + Inclined Plane Sup't (typ) Trt trite Cold Spring Risers 100%, to grow — down on the tube support when oper. I>} — z Transmit loads & sup't by vendor. movements to vessels early ee 70'~0" ‘Tube Movement Figure 16.4.1 Transmit tube movement and loads on heater structure to heater vendor before purchase 36" DIA Vendor sup't Cold Spring —+ | Risers 1008 Val 1 (| Miia Tubes 50' long Figure 16.4.2PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER 3.11 PAGE = 32 16.4 (Continued) Sup't by vendor NN Hanger Roa a 1 special Inclined 4 Plane on cold sprin Roller Bearings Cold Spring Stop Tube 1-101 Expansion NTOC Layout (tehran) Two Units Installed 48" Lines oo Figure 16.4.3 cold Spring —~| Risers 100% Stop Tube Expansion NIOC Abadan 36" @ tine Figure _FLUOR PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER 3.11 P DESIGN ‘AGE 33 GUIDES DATE 4-76 17.0 The lines from the tube nozzle to the upper header are to have 100% cold spring so that they will be supported in the operating position. In order for the tubes to be straight and relatively stress free in the operating position, the main pipe header should have 100% cold spring. See Figure 17.1. Cold spring 1008 = 6" OOO a a x Support —” 7 5 2 S z caer . 90000 tt es s 7 Support Elev. a L F istaitea Operating ‘Tube Positions in Heater Figure 17.1FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3-21 DESIG F pEsicn SN CRITERIA FOR FIRED HEATER PAGE «34 cuines DATE 4-76 ot 14.0 ‘The inlet to the heater is in the convection section and the piping is usually in the form of a water fall. See Figure 18.1. A-o Stop movement in and out Sup't by vendor Do not 9 Cold Spring ADD weight of DROP, weight of tube to first effective support, weight of pipe to first support and thermal. Figure 1FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUBER 3.12 DESIGN DESIGN CRITERIA FOR FIRED HEATER PAGE 35 GuIDes DATE 4-76 18.0 (Continued) Supports should be located on the heater structure at a point where springs are not necessary. Vertical expansion is mini~ mized in the lower piping system and absorbed by the convection section. 19.0 In addition to plot arrangement, there are a mumber of items to be con- sidered in designing the line 19.1 During start up the outlet line is filled with liguid and will weigh several times more than in the normal operating condition when it is in a vapor state. Consequently, a solid support is preferred whenever possible. Where springs are required, the piping should be arranged to sit on solid supports at installa~ tion and as they grow off the support in the operating condition the spring hanger will handle the load in the vapor state. 19.2 Since the line has a vacuum design, the dead load at each sup- port adds to the external pressure at that point. This condition makes the use of a stiffening ring mandatory at the support regardless of the stiffening requirements of the vacuum condition! (Very Important) 19.3 Forces, loads and moments must be transmitted to the vessel department as early as possible. (Extremely Important) 19.4 Forces, loads and moments must be transmitted to the vendor as early as possible. 19.5 Soil conditions where settlement is a problem will force the use ‘of springs in the piping system. Because of the two phase flow, and the vibration problems in these systems, springs are not desireable. Exert every effort to pile the heater, vessel and pipe supports. Do not depend on hydrotest settlement to elimi- nate the problem. Spring back of the soil will occur and the equipment will settle again. 19.6 To eliminate ‘thermal forces horizontally perpendicular to the line, the center line of the heater should be in line with the irectional anchors on the tubes at the face of the heater.FLUOR PIPE STRESS ANALYST DESIGN GUIDE HUMBER 3.22 36 neseN DESIGN CRITERIA FOR FIRED HEATER PAGE Guipes DATE = 4-76 20.0 REFORMERS 20.1 Catalytic reformers generally have a heater-reactor system with vertical tube heaters located opposite a series of reactors. The interconnecting piping is most frequently large enough that the entire heater coil must be floating. ‘The following figures show typical heater tube arrangements: ‘Tube (typ) Inlet Har. —e ja outlet Har. Figure 20.1.1FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.21 8: pEsicn DESIGN CRITERIA FOR FIRED HEATER PAGE 37 GUIDES DATE 4-76 20.1 (Continued) outlet Har Inlet Hér. ee Figure 20.1.2 Inlet Har. outlet Har. ™ ooFLUOR PIPE STRESS ANALYST DESIGN GUIDE DESIGN GUIDES NUMBER 3.11. DESIGN CRITERIA FOR FIRED HEATER PAGE (38 pate = 4°76 20-1 (Continued) 20.2 20.3 Inlet Hare A xO Fit 2 20. the tubes are stubbed into the headers at close intervals (6"¢ to ¢ for 4"@ tubes) and usually consist of 80 to 120 tubes for each header. Since the headers are large diameter pipe (28" # to 36" ) there is no flexibility in the inlet and outlet piping systens. ‘The heater tubes must then be floating to accommodate the thermal expansion if the plot is to be minimized and pipe plus fitting costs held down. A typical heater reactor train is the Mobil Joliet Reformer, Union 0i1 Reformer and Puerto Rican Reformer Reactors. See Figure 20.3.1.FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3-12 DESIGN CRITERIA FOR FIRED HEATER an PAGE 39 GUIDES DATE 4-76 20.3 (Continued) Reactors 25" or Min. 36" 6 Pipe 1000°F ' [>_< Q HE eddddt-}-—. KD Vertical Ef€luent Exchangers 2 8 - Seismic & Wind Stop Oy (+ zi 7 WD OD 20.4 All horizontal and vertical pipe expansion is absorbed by allow- ing the heater tubes to move freely in the vertical direction and to slide across the counterweights and through the heater horizontally. The piping system provides little if any flexi~ bility and all differential thermal expansion is abosrbed by the heater tubes. Pipe supporting is critical and should be arranged so that the heater tubes and headers are balanced independently of the piping system. Responsibility for proper support of theFLUOR PIPE STRESS ANALYST DESIGN GUIDE numer 3.12 DESIGN GuIDes DESIGN CRITERIA FOR FIRED HEATER PAGE = 40 DATE 4-76 20.4 (Continued) 20.5 20.6 20.7 20.8 20.9 heater loads is then clearly left to the heater vendor while the piping system is the responsibility of the pipe stress engineer. Reactor piping must be capable of standing independently when the elbows on top of the reactor are removed (catalyst loading conditions) . The piping system is, however, supported from the heater structure and must be guided so that the wind and seism‘c loads are trans- mitted to the main heater structure. These loads must be sub- mitted to the heater vendor along with terminal movements as early as possible. Stress analysis should include effects of the heater header, tubes, guides and frictional forces to move the heater headers. In most cases the frictional effects will exceed the thermal effect in magnitude and will be the determining factor in design of the reactor foundation, flanges, structure, etc. Whenever possible the heater headers should have limit stops in the form of horizontal guides parallel and perpendicular to the heater header and vertical stops. The counterweights provided by the heater vendor must be adjustable to afford a margin for od error in erection. See Figure 20.7.1. Flanges in the line and on the reactor are not standard rated flanges. They must be designed to withstand the forces and moments developed from thermal, friction, wind, seismic, dead- weight and hydrotest loads. These loads must be transmitted to the vessel department for incorporation in vessel design and to the selected flange vendor -designer to be used along with pressure considerations in the flange design. See Figure 20.8.1. Effects of settlement will also be a determining factor in establishing clearance and movements required in the heater and the support structure.BK) 1 -76 3 4 4 NUMBER PAGE DATE LOE eanbra PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER DESIGN GUIDES FLUOR ‘aubromre3un09 eraessatpy ain sped uotzon woxa peoT peed on TS borate | saqny Teoy3300, uhzFLUOR DESIGN GUIDES PIPE STRESS ANALYST DESIGN GUIDE NUMBER DESIGN CRITERIA FOR FIRED HEATER PAGE DATE 3.1 42 4-76 20.8 (Continued) Heater Removable Elbow Seismic & Wind stop Friction Moment NN Hanger Spring for Upper Line Hanger Spring on Lower Line Grade Friction Friction Force RIFE £ —1 Figure 20.8.1FLUOR PIPE STRESS ANALYST DESIGN GUIDE HUMBER 3.22 DESIGN GUIDES DESIGN CRITERIA FOR FIRED HEATER PAGE «43 DATE = 4-76 21-0 OP PLATFORMER 21.1 21.2 21.3 21.4 ‘The major difference between the normal Reformer layout and the UOP Platformer is that the reactors are stacked on top of each other as a huge vertical vessel. A structure is built around the reactor and the piping drops are supported from the struc- ture. The piping from the reactors to and from the heater has long drops which are sufficiently flexible so that the horizontal expansion need not be taken into the heater. Vertical expansion must be accommodated by floating the heater tubes and headers similar to the reformer unit. Since the pipe is not required to slide across the supports, the frictional forces are not major design considerations. When supporting the piping from the structure, it is adviseable to position the spring supports in two separate locations for drops over 100". Seismic stops will be required on the long drops. Flanges are specially designed to accommodate piping forces and moments as well as the internal or external pressures. All loads must be transmitted to the heater vender, reactor and those responsible for flange design. ‘The same general design philosophy has been used for the Champlin Oil Refinery, Corpus Christi, Texas; Coastal States Refiner, Corpus Christi, Texas; BPOC Refinery, Marcus Hooke Penna; and is being considered for the Pertamina Aromatics plant in Indonesia. See Figure 21.4.1 and Figure 21.4.2.DESIGN GUIDES 21.4 Fa FLUOR PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER 3.12 PAGE = 44 DATE 4-76 (continued) Har. . Har. Upper Htr. @-spring Ranger Figure 21.4.1FLUOR PIPE STRESS ANALYST DESIGN GUIDE NUMBER 3.22 45 peaen DESIGN CRITERIA FOR FIRED HEATER PAGE GuIDes DATE 4-76 21.4 (Continued) 14" vertical Growth 4 — Exchanger Hanger Spring ——>| Hydraulic —_— ‘Snubber Box Heater la Hanger Spring—*" Bottom Heater Har. EE Figure 21FLUOR PIPE STRESS ANALYST DESIGN GUIDE umen 3.21 pean DESIGN CRITERIA FOR FIRED HEATER PAGE 46, uipes DATE = 4-76 stop all directions except vertical. i) pe Rs \E vertical stop (failsafe) with clearance SE «typ) Figure 21.5-1 Vertical stop Typ. With Clearance 21-5 The most critical lines to be considered are the bottom line out of the reactor and the naptha charge to the heater both entering and leaving the same exchanger. Since the bottom line out of the reactor has no provision for flexibility the exchangers are on slide pads, rollers, rod hangers or spring hangers. Analysis is made utilizing all line to and from the exchangers and the entire heater coil including the heater outlet line. ‘The entire unit is compact with a minimum number of elbows in each line. No loops or dog legs are required for flexibility if the system is given proper analysis during layout. See Figure 21.5.1 and Figure 21.5.2.FLUOR PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER 3-12. PAGE = 47 DATE DESIGN GUIDES 4-76 21.5 (Continued) Reactor Heater Tubes: 80 Tubes @ DIA 36" DIA \ 36" DIA Counterweights (typ) lame Exchanger - Rod Hung Figure 21FLUOR PIPE STRESS ANALYST DESIGN GUIDE DESIGN GuiDes NUMBER 3.11 DESIGN CRITERIA FOR FIRED HEATER PAGE = 48 DATE 4-76 4 22.0 ULTRAFORMER ~ POWERFORMER 22.1 22.2 ‘The most complex piping system found in refinery applications today are in the ultra or powerformer units. They generally consist of four or five reactors operating in conjunction with three or four heaters which make up the reactor train. The complexity of the system is caused by the necessity of using one reactor as a swing reactor for catalyst regeneration. Each reactor has the capability of being the swing reactor so that a network of bypass lines is required enabling the remaining re~ actors to perform independently of the swing reactor. The re- actors are set opposite the heaters and a structure is pro~ vided in the center to support the weight of the piping and valves. On large diameter piping (24" +), each valve will weigh between 10,000 and 20,000 pounds. Sprinas are usually installed on both sides of each valve to minimize the bending moment in the piping system. Since the valve and piping loads are so mass~ ive, the entire structural design is meaningless until the piping design is firm and all springs and valves are located. At that time, loads will be provided to structural department by stress. Heaters should be positioned so that the maximum thermal expan- sion is perpendicular to the heater tube. In most cases the tubes in the heaters are not vertical. Attempting to slide them oa through the heater is difficult. 23.0 HYDROGEN HEATERS 23.1 23.2 ‘The major problem with hydrogen heaters is the extreme tempera~ ture in the outlet line to the waste heat boiler, and in the heater tubes themselves. The outlet stream is about 1800°F and the header under the heater is generally refactory lined. Since the tubes are so hot, the heater manufacturer prefers t~ Keep the stress level as low as possible and will insist on fixing these headers at the center of the heater. There is no available flexibility in the refactory lined header so that the waste heat boiler must then be mounted on slide pads or hung by means of rods or spring heangers. The other alternate is to make the outlet line Inconel which creates problems with expansion into the heater tubes. First we will explore the refactory lined header arrangement. Initially a layout was dictated by a customer which was not a good design but will serve as an example of poor layout. See Figure 23.2.1.FLUOR DESIGN GUIDES PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER NUMBER 3-11, PAGE 49 DATE 4-76 23.2 (Continued) 40" pia/e" 0.0004, Refractory Directional Anchor @ canter of Her. (typ) Tubes (oPeN 300,000 ft-# (Heesesss tec] 23.3 23.4 23.5 on Teflon Slide Pads 35.0008 wom —[ rn Waste Heat Boiler Figure 23.2.1 The thrust required to move the waste heat boiler creates a large bending moment on the pipe which could crack the refac~ tory and introduce hot spots on the carbon steel pipe. Cal~ culated pipe shell temperature was 300°F. Fluor's recommendation to hang the waste heat boiler or reposition it to a better location were not accepted. Since that time, rumors of numerous hot spots have been heard and in a more recent project the waste heat boiler has been repositioned by the same customer to a location which minimizes the bending moment on the pipe. ‘The horizontal expansion is absorbed by the piping between the waste heat boiler and the steam drum mounted above it. See Figure 23.5.1. 12,500# Sliding or Hung Boiler Dir. anch. (typ)PIPE STRESS ANALYST DESIGN GUIDE DESIGN CRITERIA FOR FIRED HEATER FLUOR DESIGN GUIDES NUMBER PAGE = 50 DATE 4-76 3. 23.6 Another approach to the problem is to locate the waste heat boilers under the heater and route the outlet piping in a flexible manner to the steam drum. See Figure 23.6.1. Figure 23.6.1