Fired Heater Mechanical Components

1-radiant section – portion of the heater in which heat is transferred to

the tubes primarily by radiation

2-arch – flat or sloped portion of the heater radiant section opposite

the floor

3-convection section – portion of the heater in which the heat is

transferred to the tubes primarily by convection

4-crossover – inter-connecting piping between any two heater-coil

sections

5-breeching – heater section where flue gases are collected after the
last convection coil for transmission to the stack or the outlet ductwork

6-stack – vertical conduit used to discharge flue gas to the atmosphere

7-damper – device for introducing a variable resistance in order to

regulate the flow of flue gas or air. In some cases, like smaller forced-
draft systems, a damper is not used.
8-burner – device that introduces fuel and air into a heater at the
desired velocities, turbulence and concentration to establish and
maintain proper ignition and combustion. Burners are classified by the
type of fuel fired, such as oil, gas, or combination (also called dual fuel).

9-pilot – small burner that provides ignition energy to light the main
burner

10-terminal – flanged or welded connection to or from the coil

providing for inlet and outlet of fluids

11-pass/stream – flow circuit consisting of one or more tubes in series

Fired HeaterMechanical Components- Convection Section
1-Convection section: Bank of coils which receives the heat form hot
flue gases mainly by convection.

 Finned/studded tubes are often used in convection coils due to

lower flue gas temperature. Finned tubes ( 1.3 mm thick strip
200turn/meter) are difficult to clean when compared to
studded (12.7 mm dia)
 The rate of heat absorption tends to be high at the entrance to
the convection section in heaters, where the convection section is
right above the radiant section. Tubes at this section are called
shock / shield tubes .Normally first two rows absorb half of their
heat in this section.
 Consists of a large tube support plate located in the
convection section and supports number of End supports &
intermediate supports are usually low alloy steels.
 Replacing /Repair of Convection tube support sheet is difficult &
calls for removal of all convection coils or it is necessary to lower
the entire module.

2-Plug header: A bend, provided with one or more openings for the
purpose of inspection,initial measurement of coke before cleaning.

 Ensure proper depressurization before opening the plug.

 Ensure Arrow mark is maintained on plug to ensure plug nut is
guiding
 After repair /replacement of plug hydro test of the coil pass is
recommended.
3-Tube supports:

 Tube supports are metal devices which supports the weight of

the
 Tube guide is used to direct movement of tubes in one particular
direction.
 These are metallic members able to withstand high temperatures
used to prevent sagging/ bowing / buckling/ swaying of tubes
 Tube supports are more prone to high temperature oxidation and
fuel ash corrosion.
 Horizontal roof tubes of box type heaters are supported by means
of hangers
 Tube supports must be aligned perfectly in one straight line.
 The use of fillers of any kind is prohibited.
 Ensure perfect contact between supports and tubes.
 Coils shall rest uniformly all over the supports.
 Failure of tube supports may take place due to mechanical
overloading caused by bowing of tubes, loss of strength of
supports and tube vibration.
 The tube support / hangers / guides shall be examined for cracks,
oxidation, missing sections and missing/broken or oxidised bolts.
Figure shows typical tube supports

4-shield section/shock section – tubes that shield the remaining

convection-section tubes from direct radiation

5-extended surface – heat-transfer surface in the form of fins or studs

attached to the heat-absorbing surface

6-tube support/tube sheet – device used to support tubes

7-header (return bend) – cast or wrought fitting shaped in a 180°bend

and used to connect two or more tubes
8-header box – internally insulated structural compartment, separated
from the flue-gas stream, which is used to enclose a number of headers
or manifolds
Heater Mechanical Components – Refractory
Refractory is used throughout the inside of the heater to shield the
heater casing from excess temperatures. It is typically designed to
reduce the outside temperature of the metal casing to 180°F (per API
560 specification). There are many different types of refractory, but the
most common types are castable and ceramic fiber.

1-ceramic fiber – fibrous refractory insulation which can be in the form

of refractory ceramic fiber (RCF) or man-made vitreous fiber (MMVF).
Common forms include bulk, blanket, board, and modules. It is not
recommended because it may remain loose even with fixing systems or
tongue and groove. It has difficult interface.
2-castable – insulating concrete of good strength poured or gunned in
place to form a rigid refractory shape or structure. It is suitable for
modularization. It may need dry-out. The interface is easy.

3-multi-component lining – refractory system consisting of two or more

layers of different refractory types

4-hot-face layer– refractory layer exposed to the highest temperatures

in a multilayer or multicomponent lining