Selection of Fired Process Heaters

DESIGN PRACTICES
FIRED HEATERS Section Page

VIII-A 1 of 24
EXXON SELECTION OF FIRED PROCESS HEATERS
Date
ENGINEERING PROPRIETARY INFORMATION — For Authorized Company Use Only December, 1996
Changes shown by
CONTENTS
Section Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Design Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
International Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Other Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Process Fired Heaters (Conventional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pyrolysis Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Types of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF FIRED HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vertical-Cylindrical Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Tube Cabin Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hoop-Tube Cabin Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Vertical Tube Box Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Horizontal Tube Box Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FIRED HEATER SELECTION AND DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fired Heater Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Return on Incremental Investment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Factors Affecting Fired Heater Selection and Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Stack Temperature (Ts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATING CONDITIONS AND FLUID CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fired Heaters in All-Liquid or Vaporizing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fired Heaters in All-Vapor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Multi-Service Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High-Pressure Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COMPUTER PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TABLES
Table 1 Checklist of Items Normally Covered in Process Fired Heater Design Specifications . . . . . . . . . . . . 14
Table 2 Checklist of Items Normally Covered in Fired Heater Duty Specifications . . . . . . . . . . . . . . . . . . . . . . 16
Table 3 Factors Affecting Fired Heater Selection and Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FIGURES
Figure 1 Vertical-Cylindrical Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 2 Vertical-Cylindrical Fired Heater with Horizontal Convection Section . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 3 Horizontal Tube Cabin Fired Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 4 Variations of Cabin Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 5 Vertical Tube Box Fired Heater Proprietary Exxon High Intensity Fired Heater . . . . . . . . . . . . . . . . . . 22
Figure 6 Single Wing Horizontal Tube Box Fired Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 7 Fired Heater Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

DESIGN PRACTICES
Section Page FIRED HEATERS
VIII-A 2 of 24
SELECTION OF FIRED PROCESS HEATERS EXXON
Date
December, 1996 PROPRIETARY INFORMATION — For Authorized Company Use Only ENGINEERING
Revision Memo
12/96 1. Consolidated English and Metric Units.

2. Updated references.
3. Revised Table 1 to reflect current practices.

DESIGN PRACTICES
VIII-A 3 of 24
Date
SCOPE
This subsection describes the different types of fired process heaters which are available and gives guidelines for selecting and
specifying the fired heater for a specific service. Fired heater design is covered in other subsections.
REFERENCES
DESIGN PRACTICES (Besides Other Subsections of this Section)

Section XIV Fluid Flow
Section XV Safety in Plant Design
INTERNATIONAL PRACTICES
IP 3-4-1 Piping for Fired Equipment
IP 7-1-1 Fired Heaters
IP 7-3-1 Sootblowers for Fired Equipment
IP 7-4-1 Burners for Fired Heaters
IP 7-5-1 Coils for Fired Heaters and Boilers
IP 7-8-1 Dampers and Guillotines for Fired Equipment
IP 7-9-1 Expansion Joints for Fired Equipment
IP 15-1-1 Instrumentation for Fired Heaters
IP 18-3-2 Statically Cast Steel and Alloy Pressure Containing Parts, and Tube Supports for Fired Heaters
IP 18-3-3 Centrifugally Cast High Alloy Tubes for Fired Heaters other than Steam Cracking Reactors
IP 19-3-3 Linings for Fired Heaters
OTHER LITERATURE
API 560, Fired Heaters for General Refinery Services
API 530, Recommended Practice for Calculation of Heater Tube Thickness in Petroleum Refineries
Report EE.70E.75, Pipestill Furnace Turndown
Guide to Boiler and Fired Heater Turndown and Excess Air Reduction
Application Technology Set Catalog (ATS CAT)
Exxon Engineering Cost Estimating Manual
Exxon Refinery Construction Materials Manual
BACKGROUND
The heating of a process fluid in a fired heater is accomplished through a combination of radiation and convection heat transfer.
The usual flow pattern of the process fluid is countercurrent to the flue gas; i.e., the process fluid passes first through the convection
section and then through the radiant section of the fired heater, whereas the flue gas travels in the other direction. This arrangement
yields a higher fired heater efficiency (lower stack gas temperature) than would be the case with concurrent flow.

DESIGN PRACTICES
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BACKGROUND (Cont)
In the radiant section, heat is transferred to the process fluid mainly by radiation from high-temperature flue gas which results from
combustion of fuel in the fire box. Some heat is also transferred here by convection. As the flue gas in the radiant section gives up
its heat and becomes cooler, heat transfer by radiation requires progressively more tube area, therefore becoming progressively
less economical. For this reason, the transition to the convection section is made while the flue gas is still relatively hot.
In the convection section, heat transfer is mainly by convection, although a small amount of radiant heat transfer occurs here also.
After all of the heat which can be economically recovered has been transferred to the process fluid, the flue gas leaves the fired
heater and passes through a stack to the atmosphere.
Fired heaters fall into two main categories: process and pyrolysis fired heaters.
PROCESS FIRED HEATERS (CONVENTIONAL)

These fired heaters provide heat which is utilized in downstream equipment. Typical examples are pipestills, reactor preheaters
(hydrofiners and POWERFORMING units), and reboilers. Indirect heating systems, such as hot oil belts, also use process
fired heaters.
PYROLYSIS FIRED HEATERS

These heaters provide the energy for endothermic chemical reactions taking place inside fired heater tubes. Steam Crackers and
Steam Reformers are the two main examples. Many considerations and problems in the design and operation of these heaters are
similar to those of conventional heaters. Pyrolysis heaters usually operate at high temperatures and have many special
considerations. Design Practice Subsection E covers the design of Exxon Steam Reformers. Steam Cracking heaters are not
covered in the Exxon Engineering Design Practices.
Some fired heaters such as visbreakers and thermal crackers, are considered to be process heaters even though they
have chemical reactions taking place inside the tubes. Their temperatures are low, compared to those of pyrolysis heaters, and
apart from the cracking calculations (consult the Heat Transfer Equipment Section of EETD), the designs closely resemble those
for process heaters.
TYPES OF SPECIFICATIONS
Two types of documents are used for specifying fired heaters: design specifications or duty specifications. In a design specification,
all of the major variables which affect performance have been determined by the designer and are specified. The fired heater vendor
must then provide the detailed mechanical design. In a duty specification, only the service requirements (e.g., heat duty and inlet
and outlet conditions) of the equipment are given. The vendor then provides both the process and mechanical designs.
Items covered in each type of specification are given in Tables 1 and 2. Fired Heater Data Sheets, ER&E developed or API 560,
may be used to present the information required by either type of specification. Most of the fired heaters specified by Exxon
Engineering are covered by a design specification. TO PROTECT PROPRIETARY TECHNOLOGY, PROCESS INFORMATION
FOR FIRED HEATERS COVERED BY DESIGN SPECIFICATIONS SHALL NOT BE DIVULGED TO THE FIRED HEATER
VENDOR BEFORE THE APPROPRIATE SECRECY AGREEMENTS HAVE BEEN EXECUTED.
DEFINITIONS
(SEE ALSO FIGURES 1 THROUGH 6)
Air Preheater. A heat exchanger which heats the air required for combustion by exchanging heat with the flue gases leaving the
convection section.
Arch. The overhead (usually flat) portion of the radiant section, supported from above.
Box. The burners and tubes are enclosed in the fire box, which consists of a structure, refractory lining and tube supports.
Breeching. The hood which collects the flue gas at the convection section exit, for transmission to the stack.
Bridgewall Temperature. The temperature of the flue gas leaving the radiant section. The term comes from the old horizontal box
heaters, where a bridgewall physically separated the radiant and convection sections.
Bulk Temperature. The average temperature of the process fluid at any tube cross-section.

DESIGN PRACTICES
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DEFINITIONS (Cont)
Burner. A device for mixing fuel and air for combustion.
Casing. A steel sheathing which encloses the heater box and makes it essentially air-tight.
Cell. A portion of the radiant section, separated from other cells by tubes or a refractory wall. Also called a “zone”.
Center Wall. A refractory wall in the radiant section, which divides it into two separate cells.
Coil. A series of straight tube lengths connected by 180_ return bends, forming a continuous path through which the process fluid
passes and is heated.
Convection Section. The portion of a heater, consisting of a bank of tubes, which receives heat from the hot flue gases, mainly
by convection.
Conversion. The fraction of feed converted into a desired product, usually expressed as LV%. Applied mainly to Visbreaker and
Thermal Cracker Fired Heaters.
Corbelling. Narrow ledges extending from the convection section side walls to prevent flue gas from flowing preferentially up the
side of the convection section, between the wall and the nearest tubes, thereby bypassing the tube bank.
Critical Velocity. A fluid velocity equal to the velocity of sound through the fluid at its temperature and pressure. Also called
“sonic velocity”.
Crossover. Piping which transfers the process fluid either externally or internally from one section of the heater to another.
Damper. A device to regulate flow of gas through a stack or duct and to control draft in a heater. A typical damper consists of one
or more flat plates connected to a shaft(s) which can be rotated.
Draft. The negative pressure (vacuum) at a given point inside the heater, usually expressed in inches of water.
Excess Air. The percentage of air in the heater in excess of the stoichiometric amount required for combustion.
Extended Surface. Surface added to the outside of bare tubes in the convection section to provide more heat transfer area. This
may consist of cylindrical studs butt-welded to the tube or fins continuously wound around and welded to the tube.
Film. A thin fluid layer adjacent to a pipe wall which remains in laminar flow, even when the bulk flow is turbulent. The velocity profile
in the film is approximately linear, with zero velocity existing at the wall.
Film Coefficient. The convective heat transfer coefficient of the film.
Film Temperature. The maximum temperature in the film, at the tube wall.
Fire Box. A term used to describe the structure which surrounds the radiant coils and into which the burners protrude.
Flue Gas. A mixture of gaseous products resulting from combustion of the fuel.
Fouling. The building up of a film of dirt, ash, soot or coke on heat transfer surfaces, resulting in increased resistance to heat flow.
Forced Draft. Use of a fan to supply combustion air to the burners and to overcome the pressure drop through the burners. This
is in contrast to natural draft, where the buoyancy of the column of hot flue gas in the stack and heater provides the “suction” to pull
combustion air into the burners.
Fired Heater Efficiency. The ratio of heat absorbed to heat fired, on a lower heating value basis.
Gross Fuel. The total fuel fired in the heater, including all losses (usually expressed in lb/hr or kg / hr).
Gross Heating Value. See higher heating value.
Header. The fitting which connects two tubes in a coil. In common usage, “header” refers to cast or forged 180_ “U-bends” (“return bends”).

DESIGN PRACTICES
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DEFINITIONS (Cont)
Header Box. The compartment at the end of the convection section where the headers are located. There is no flue gas flow in
the header box, since it is separated from the inside of the heater by an insulated tube sheet. Header boxes are sometimes also
used in the radiant section.
Heat Available. The heat absorbed from the products of combustion (flue gas) as they are cooled from the flame temperature to
a given flue gas temperature.
Heat Density. The rate of heat transfer per unit area to a tube, usually based on total outside surface area. Typical units are
Btu/hr-sq. ft (w/m2). Also called “heat flux”.
Heat Duty. The total heat absorbed by the process fluid, usually expressed in MBtu/hr (MW). Total fired heater duty is the sum of
heat transferred to all process streams, including auxiliary services such as steam superheaters and drier coils.
Heat Fired. The total heat released in the heater, equal to gross fuel times lower heating value (LHV) of the fuel. Usually expressed
in MBtu/hr (MW).
Higher Heating Value (HHV). The theoretical heat of combustion of a fuel, when the water formed is considered as a liquid (credit
taken for its heat of condensation). Also called “gross heating value”.
Hip Section. The transition zone at the top of the radiant section in cabin type heaters. The wall of this section is usually at a
45 degree angle.
Induced Draft. Use of a fan to provide the additional draft required over that supplied by the stack, to draw the flue gas through the
convection section, and any downstream heat recovery equipment (i.e., air preheater).
Inspection Doors. Openings in the convection section sidewalls to allow inspection of tubes, extended surfaces and supports,
when the heater is out of service.
Lower Heating Value (LHV). The theoretical heat of combustion of a fuel, when no credit is taken for the heat of condensation of
water in the flue gas. Also called “net heating value”. Usually expressed in Btu/lb (kJ/kg).
Manifold. A pipe connected to several parallel passes and used to distribute or collect fluid from these passes.
Mass Velocity. The mass flow rate per unit of flow area through the coil. Typical units are lb/s-sq. ft (kg/s-m2).
Natural Draft. System in which the draft required to move combustion air into the heater and flue gas through the heater and out
the stack is provided by stack effect alone.
Net Fuel. The fuel which would be required in the heater if there were no radiation losses. Usually expressed in lb/hr (kg/hr).
NPS. Abbreviation for “Nominal Pipe Size”.
Observation Doors. Openings in the radiant section floor and at selected points along the walls, to permit viewing of tubes,
supports, and burners.
One-Side Fired Tubes. Radiant section tubes located adjacent to a heater wall have only one side directly exposed to a burner
flame. Radiation to the back side of the tubes is by reflection/reradiation from the refractory wall.
Pass. A coil which transports the process fluid from fired heater inlet to outlet. The total process fluid can be transported through
the heater by one or more parallel passes.
Peepholes. Small observation ports usually placed in the radiant section floor and/or arch to permit viewing of tubes, supports and
burners. They are usually glass covered.
Radiant Section. The section of the fired heater in which heat is transferred to the heater tubes primarily by radiation from
high-temperature flue gas.
Service Factor. A measure of the continuity of operation, generally expressed as the ratio of total running days for a given time
period to the total calendar days in the period.

DESIGN PRACTICES
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DEFINITIONS (Cont)
Setting. The refractory insulation on the inside of the heater box.
Shield Section. The first two tube rows of the convection section. These tubes are exposed to direct radiation from the radiant
section and usually receive about half of their heat in this manner. They are usually made of more resistant material than the rest
of the tubes in the convection section. Extended surfaces are not used in this section.
Sootblower. A steam lance (usually movable) in the convection section for blowing soot and ash from the tubes using
high-pressure steam.
Stack. A cylindrical steel, concrete or brick shell which carries flue gas to the atmosphere and provides necessary draft.
Stack Effect. The difference (buoyancy) between the weight of a column of high-temperature gases inside the heater and/or stack
and the weight of an equivalent column of external air, usually expressed in inches of water per foot of height.
Stack Temperature. The temperature of the flue gas as it leaves the convection section, or air preheater directly upstream of the stack.
Transfer Line. Piping used to connect the fired heater outlet to downstream processing equipment (tower, reactor, etc.).
Tube Guide. Device used to guide thermal movement of tubes.
Tube Sheet. A large tube support plate located in the convection section and supporting a number of tubes. The end supports are
usually carbon steel or low-alloy steel and make up one side of the header box. The inside of the end supports, which is exposed
to the flue gas, is insulated. Intermediate supports are exposed to flue gas on both sides and are fabricated of a suitable alloy
material, usually castings.
Tube Support. A metal part which supports the weight of the tube.
Turndown. Reduced operating conditions compared to design conditions. This usually refers to reduced heat duty, which may be
the result of reduced throughput and/or reduced enthalpy requirements.
Two-Side Fired Tubes. Radiant section tubes which are exposed on both sides to direct radiation from the burners.
TYPES OF FIRED HEATERS
Many fired heater types, or arrangements, are available and have been used over the years. These heaters are all made up of four
basic components: box, burners, coil and stack. The fired process heaters described below are currently the types most commonly
found in Exxon refineries and chemical plants.
VERTICAL-CYLINDRICAL FIRED HEATERS

Figures 1 and 2 show cross-sectional views of typical vertical-cylindrical (VC) fired heaters. These heaters are probably the most
common in use today and are used for heat duties up to about 150 MBtu/hr (45 MW). In the radiant section, tubes stand or hang
vertically in a circle around the floor-mounted burners. Thus, firing is parallel to the radiant section tubes.
Vertical-cylindrical heaters are designed both with and without a convection section. The all-radiant heater (Figure 1A) is
inexpensive, but since the temperature of flue gases leaving the heater is high, 1500 – 1800_F (815 – 980_C), it has a very low
efficiency. A convection section can usually be justified, except for the very smallest heaters less than about 5 MBtu/hr (1.5 MW),
heaters infrequently operated, or in locations where fuel costs are extremely low.
Most vertical-cylindrical fired heaters now built have a horizontal convection section located above the radiant section (Figure 2).
Flue gases flow upwards through the convection bank and then to the stack. The shield section consists of the bottom two rows
of tubes in the convection section.
Some older vertical-cylindrical fired heaters have vertical convection sections (Figure 1B). Often the same tube is used for both
radiant and convection service (integral convection section). The convection portion of the tube usually has some form of extended
surface to increase the convection heat transfer rate. Only gas or distillate fuels should be fired in this type heater, since the
convection section is almost impossible to clean. This type of fired heater has not been built since the mid-1960’s.

DESIGN PRACTICES
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TYPES OF FIRED HEATERS (Cont)
HORIZONTAL TUBE CABIN FIRED HEATERS

Figure 3 shows end and side views of a typical cabin fired heater. The radiant section includes horizontal tube surface on the side walls
and the sloping roof of the cabin. The convection section extends over the entire length of the radiant section. Burners are floor-mounted
in a row down the center of the cabin and are fired vertically. Thus, firing is normal to both radiant and convection tubes.
Horizontal tube cabin fired heaters have been built in sizes up to about 500 MBtu/hr (145 MW) heat absorbed. However, in small sizes
under about 120 MBtu/hr (35 MW), vertical cylindrical fired heaters are usually more economical, and in sizes larger than about
150 MBtu/hr (45 MW), the vertical tube box fired heater is generally more economical. Also, both vertical tube type fired heaters require
less plot area. Therefore, except in special cases, horizontal tube cabin fired heaters are no longer being designed by Exxon Engineering.
Variations of the cabin fired heater arrangements are made for certain applications, as illustrated in Figure 4. Cabin fired heaters
with a center wall (Figures 4A and B) can be used for the following services:
1. For large fired heaters, the use of an air-cooled center wall permits about twice the surface for a given tube length. This configuration
is usually used when tubes in a single radiant zone would be over about 80 ft (24 m) long, or the radiant zone over 40 ft (12 m) high.
2. Where two separate heating zones (i.e., two or more separately controlled services) are required in the radiant section.
Depending upon the heater size, the center wall may or may not be covered with tubes. The different services must be
compatible, since to some extent the firing in one section will affect heater transfer in the other section. The maximum turndown
of one service is to about 75% of design with the other service at full capacity, if both services use the convection section
(or to about 50% of design if one is in all-radiant service). If one service is taken off stream, the heater must be completely shut
down or some other fluid circulated through the off-stream section to prevent tube burnout.
HOOP-TUBE CABIN FIRED HEATERS
In all-vapor flow, non-coking services where low coil pressure drop is desired (such as POWERFORMING units), cabin fired heaters
with vertically oriented, bent, or “hoop”, tubes offer considerable savings in investment (Figures 4C and D). This arrangement
permits a low process mass velocity to be used, because of the many parallel flow passes, without maldistribution of flow.
For POWERFORMING heaters, the radiant section consists of separate zones for preheat and for each reheat duty. These zones
are separated by free-standing brick walls. Flue gases from all of the radiant zones pass through a common convection section,
which in the past has been utilized for preheat service only. In such a heater, variations in operating conditions of the individual
services should be carefully considered, since the reheat zones are also providing heat to the preheat convection coil. More recently,
with low pressure POWERFORMING, the entire process duty will be absorbed in the radiant section and the convection section
used for a separate service(s). This is due to the relatively high/costly pressure drop of the convection coil. POWERFORMING
heaters of the hoop tube type have been built in sizes from about 70 to 400 MBtu/hr (20 to 120 MW) total heat absorbed.
VERTICAL TUBE BOX FIRED HEATERS

The Exxon High Intensity Heater is a proprietary vertical tube box fired heater design and has substantial advantages over the
designs of our competitors. TO PROTECT THIS PROPRIETARY TECHNOLOGY, CARE MUST BE TAKEN TO INSURE THAT
ONLY CONTRACTORS AND FIRED HEATER VENDORS WHO HAVE SIGNED APPROPRIATE CONFIDENTIALITY
AGREEMENTS ARE GIVEN INFORMATION ON THE VERTICAL TUBE BOX FIRED HEATER.
Figure 5 shows a typical vertical tube box fired heater. In the radiant section, tubes stand vertically along all four walls. These tubes
are fired from one side, the same as in vertical-cylindrical and cabin fired heaters. In addition, rows of standing vertical tubes running
across the box are fired on both sides by the floor-mounted burners. These two-side fired tubes have a 50% greater heat input than
the wall tubes, although the peak heat density is the same as for the wall tubes.
The addition of the two-side fired tubes shortens the radiant coil and results in a significant decrease in radiant box volume,
compared to horizontal tube cabin heaters. Each tube pass has an equal number of both wall and center tubes, so that heat
distribution between passes is uniform. This heater is particularly well suited for the large forced-draft burners now in general usage.
Two to four burners provide the required heat input to each cell and usually set the box dimensions. A horizontal convection section
running the entire length of the heater is located above the radiant section.
Variations of the vertical tube box fired heater arrangement are occasionally used. The most common variation consists of installing
only the two-side fired center tubes. These tubes are usually installed in a number of rows across the box, normal to the convection
section. They may also be installed in two rows parallel to the convection section, extending the entire length of the heater. The latter
arrangement is like that used in steam reformer fired heaters.

DESIGN PRACTICES
VIII-A 9 of 24
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TYPES OF FIRED HEATERS (Cont)
For a given heat duty, the use of all two-side fired radiant tubes requires less tube surface (and a shorter coil length) than in a
conventional heater. As mentioned above, the two-side fired tubes pick up 50% more heat than the one-side fired wall tubes.
However, the advantage of a shorter coil is offset by the need for a larger radiant section box. The use of two-side fired tubes only
is advantageous in the following cases:
1. Where tube materials are very expensive; e.g., thick-wall stainless steel tubes.
2. Where short residence time is required.
3. Where allowable coil pressure drop is low.
4. Where preinvestment for future increased capacity is required. (Wall tubes can be added later.)
HORIZONTAL TUBE BOX FIRED HEATERS
Figure 6 shows the side view of a typical horizontal tube box fired heater. The radiant and convection sections are separated by
a wall called the bridge wall. Larger box heaters have two radiant sections, with a common convection section located between
them. Although these heaters were commonly built until about 1955, they are now obsolete because of their high initial cost.
FIRED HEATER SELECTION AND DESIGN
FIRED HEATER PERFORMANCE

A fundamental requirement for achieving good fired heater performance is a sound design. The design requirements must be
properly spelled out and interpreted. This basis must include all recognizable process and mechanical factors that will have a
bearing on the design. Special requirements that may apply to a specific situation must be considered. Satisfactory fired heater
performance can be measured by a combination of the following:
1. Operability – The ability of the fired heater to safely meet the process requirements with an acceptable service factor is
undoubtedly the most important single measure of performance.
2. Maintenance – Costs and manpower required to maintain the fired heater in a condition to meet process requirements must
be considered. Incremental investment to reduce maintenance costs must be judged against these savings. In most cases, this
is largely based on judgment, refinery experience and project investment philosophy.
RETURN ON INCREMENTAL INVESTMENT
This factor affects mainly the fired heater tube area; i.e., adding heat transfer surface to increase efficiency and save fuel. This is
probably the only type of fired heater investment that can be readily broken out and evaluated on its own.
FACTORS AFFECTING FIRED HEATER SELECTION AND DESIGN

Factors which must be considered in the design of a fired heater are discussed below and summarized in Table 3. These
considerations will affect the type and size of fired heater, the number of tubes and passes, the materials used and the heater
efficiency.
Heat Duty andType of Service – The main considerations in selecting the specific fired heater type are the heat duty and the type
of fluid flow (all-liquid or vaporizing flow vs. all-vapor flow). Since the radiant heat density (flux rate) is largely fixed for any given
service, the physical size of the heater is proportional to duty. Thus, except for borderline cases, the selection of the best heater
type is usually clear-cut. A fired heater selection guide is given in Figure 7. Note that in some cases requiring very small fired heaters
(duties < 25 MBtu/hr or 7.5 MW), commercially available packages may be appropriate and can result in significant investment
savings vs. a custom designed fired heater.
Type of Fuel – The fuel to be fired in a fired heater has a marked effect on the design. It is therefore extremely important to decide
what fuel or fuels are to be fired before beginning any detailed design work. Factors affected by the type of fuel are:
1. Fired Heater Efficiency – Fuel value will affect the incremental heater investment that can be justified to increase efficiency.
2. Fired Heater Cost – In general, a heater designed to fire heavy liquid fuel requires 10 to 20% greater investment than for the
same duty heater designed to fire only gas. This is due largely to sootblower investment.

DESIGN PRACTICES
VIII-A 10 of 24
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FIRED HEATER SELECTION AND DESIGN (Cont)
3. Type of Convection Section Extended Surface – Tubes with thin, closely spaced fins are easily fouled and therefore
should be used only with gas firing (or very light liquid fuels). Thick finned or studded tubes must be used if the fuel is heavier
than 25_ API.
' 4. Convection Section Cleaning – If the fuel oil contains more than 0.01 wt% ash, sootblowers must be provided to keep the
convection tubes clean. This is nearly always the case with heavy liquid fuels. Sootblowers should also be provided for dirty
gaseous fuels producing more than 5 wppm (5 mg/kg) particulates in the flue gas.
5. Type of Burners – Gas firing is usually done with natural-draft burners of the raw gas or inspirating type. These burners are
easy to operate and maintain, combustion is good and noise attenuation is easily accomplished by primary mufflers and plenum
chambers.
Oil firing is more difficult than gas firing due to plugging of oil guns by solids in the fuel. Natural-draft oil burners require higher
operating and maintenance attention. Noise attenuation is accomplished by plenum chambers, but oil dripping back into these
plenums may cause a serious maintenance problem.
To reduce these problems, forced-draft burners are often used for oil firing. Combustion is better than in natural-draft burners
due to better fuel and air mixing, maintenance and operator attention are reduced and noise in the forced-draft system is easily
attenuated. The forced-draft system provides an efficiency credit when either fuel oil or a combination of gas and oil is fired, due
to lower excess air requirements, and is also readily adaptable to computer control.
Forced draft burners or natural draft burners, adapted for forced draft service, are usually required for fired heaters equipped
with air preheaters.
6. Radiant and Convection Section Layout – Greater clearances between burners and tubes are usually required for firing of
oil fuels, compared to gaseous fuels, because of the larger flames produced from oil firing. When heater stack height is
determined by draft requirements, flue gas mass velocities in the convection section should be designed lower for oil firing than
for gas firing, because of the greater fouling potential of oil fuels. When stack height is set by environmental/pollution
considerations or when induced draft systems are employed, sufficient draft may be available to overcome pressure losses in
fouled convection sections. Higher design mass velocities may then be used for oil firing installations. These higher mass
velocities increase convection heat transfer coefficients and therefore, may reduce the amount of convection surface required.
7. Design Excess Air – A higher combustion air rate is necessary than that theoretically required for complete combustion of the
fuel. This is caused by variations in the distribution of air and fuel to the individual burners, as well as by imperfect mixing of air
and fuel in the burner and the flame. Consequently, extra air must be supplied to obtain satisfactory combustion. However, no
more excess air should be furnished than that actually required, since any additional air must be heated up to the stack exit
temperature, wasting fuel.
All fired heaters designed for forced-draft firing (regardless of fuel) or for natural draft firing of gas fuel should be based on 15%
excess air. Heaters designed for natural draft fuel oil firing, or combination gas/oil firing, encounter greater mixing difficulties and
should be designed for 20% excess air.
8. Corrosive Materials – Special construction materials may be required for refractory and tube supports if the fuel contains high
concentrations of corrosive materials, such as vanadium, sodium or sulfur. See IP 7-1-1.
Design tube metal temperature should be kept below 1200_F if the fuel contains more than about 150 ppm vanadium plus sodium.
9. “Cold-End” Corrosion – Special consideration should be given to services with tube metal temperatures, or coil inlet
temperatures, below about 250 to 300_F (120_C to 150_C) to avoid “cold-end” corrosion. When fuels containing sulfur are
burned, part of the sulfur is converted to sulfur trioxide (SO3), which combines with water vapor to form sulfuric acid. This sulfuric
acid remains in the vapor state as long as the temperature is above the dew point of the gas, but condenses out on relatively
cool surfaces, below about 250 to 300_F (120_C to 150_C) and causes metal corrosion. The surfaces most likely to be affected
are the last rows of convection section tubes, and the cold end of air preheaters where metal temperatures are close to the flue
gas dew point temperature.
Flue gas dew points can be determined from the Exxon Refinery Construction Materials Manual.

DESIGN PRACTICES
VIII-A 11 of 24
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FIRED HEATER SELECTION AND DESIGN (Cont)
STACK TEMPERATURE (T S)
The economical stack temperature is a function of fuel value, process inlet temperature, cost of incremental convection section or
air preheater capacity and the required rate of return on incremental investment. For heaters that include air preheat facilities the
economical stack temperature is normally set by cold end corrosion considerations and is discussed more fully in Subsection VIII-K
on Air Preheaters. For heaters without air preheat, an approach temperature of 25 – 50_F (15 – 30_C) between stack temperature
and inlet process stream temperature can visually be justified. The situation where this would not be true will usually have one or
more of the following characteristics:
1. Require a high DCF rate of return.

2. Have access to relatively low value fuel.
3. Require a large number of expensive finned alloy tubes to achieve the low approach temperature.
4. Require incremental sootblowers for the additional surface.
5. Result in flue gas or tube metal temperatures below the acid dew point.
The economics of each case can be calculated by using Equation 1.
% Return before tax is = S C0.12 C 100 Eq. (1)
= C
S
0.12 100
where: C = Incremental Investment

S = Annual fuel savings obtained from the incremental investment (based on 8000 hr/yr operation)
The quantity (0.12 C) represents 12% maintenance and depreciation charges on the incremental investment.
When calculating investment for convection section surface, care must be taken to consider step changes which are occasionally
necessary. For example, the return on incremental investment for the last two or three rows of tubes would be much lower if an
additional row of sootblowers is required than if it were not.
Another factor which will enter into the calculation of incremental investment is the change in the radiant section investment due
to the increased heat transferred in the convection section. The increased investment in the convection section and stack is
sometimes partly offset by a reduction in investment in the radiant section. For heaters in which the radiant heat duty is essentially
constant (steam crackers and steam reformers), the savings due to increased convection heat duty will take the form of reduced
investment or fuel savings for other equipment such as offsite steam generation.
OPERATING CONDITIONS AND FLUID CHARACTERISTICS
FIRED HEATERS IN ALL-LIQUID OR VAPORIZING SERVICE

Fired process heaters should be designed to minimize coking. Hydrocarbon cracking and resulting coke formation occurs in the
film layer on the inside tube wall surface at varying temperatures depending on the residence time at temperature and the fluid being
heated. Some of the coke thus formed adheres to the tube wall, resulting in increased coil pressure drop and higher tube metal
temperatures, both of which must be considered in the design. Eventually, all fired heaters in coking services will develop some
internal tube coke deposition and must be decoked as described in Subsection VIII-I.
Typically, in process heaters designed for non-cracking services such as atmospheric and vacuum pipestills, incipient coke begins
to form at a film temperature above about 660_F (350_C), usually equivalent to a bulk fluid temperature of about 600_F (315_C).
In other services such as Visbreaking and Thermal Cracking, where fluid cracking is an inherent characteristic of the process,
acceptable coke formation and run length can usually be attained if film temperatures do not exceed 910_F (490_C), equivalent
to a bulk fluid temperature of about 880_F (470_C).
In order to directionally mitigate the formation of coke, a high inside film coefficient is necessary to minimize the difference between
bulk fluid and film temperature. This high film coefficient is obtained largely by maintaining adequately turbulent flow conditions
inside the tube. The higher the mass velocity the better the heat transfer coefficient will be.

DESIGN PRACTICES
VIII-A 12 of 24
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OPERATING CONDITIONS AND FLUID CHARACTERISTICS (Cont)
However, too high a mass velocity will cause a high coil pressure drop, resulting in high pumping costs, increased design pressure
of upstream equipment, and sometimes, erosion of return bends. Therefore, the design mass velocity is usually kept in a range of
250 to 300 lb/s ft2 (1220 to 1465 kg/s-m2) for most conventional, non-cracking liquid or vaporizing hydrocarbon services. For
cracking services, such as Visbreaking and Thermal Cracking, mass velocities in a range of 550 – 600 lb/s ft2 (2700 – 2930 kg/s-m2)
are usually used. These target velocities have been found satisfactory for either horizontal or vertical flow tubes. More specific
recommendations for mass velocity in different services are given in Subsection VIII-B.
In addition to these mass velocity criteria, special services such as lube plant vacuum pipestill fired heaters must also meet
residence time/temperature criteria to avoid color degradation of the lube product. These special requirements are frequently
provided by the Process Designer in the Design Basis memorandum covering the heater or may be discussed with fired heater
design specialists in the Heat Transfer Equipment Section of EETD.
During the design of fired heaters consideration must be given to unit performance during anticipated turndown operations. Earlier
Design Practices guidelines required that mass velocity during maximum turndown should not be permitted to drop below
150 – 180 lb/s ft2 (730 – 880 kg/s-m2). However, more recent information, based on simulation studies and extensive field data,
strongly support the position that most fired heaters in non-cracking services can be satisfactorily operated at substantially lower
mass velocity during turndown. Also, the bases for establishing permissible turndown criteria must account for changes in other
parameters such as coil inlet temperature, firing patterns, air preheat and excess air levels and radiant vs. convection section duty
shifts. The inter-relationships of these parameters are discussed in considerable detail in Report EE.70E.75, Pipestill Furnace
Turndown, dated August, 1975; and, in a more comprehensive manual, Guide to Boiler and Fired Heater Turndown and Excess
Air Reduction. The substantive conclusion of these studies is that most conventional all liquid and vaporizing service fired heaters
will be more tolerant of turndown operations than once considered prudent.
Even at full design throughput conditions a high film coefficient by itself will not necessarily guarantee a satisfactory design. If the
rate of heat transfer to any point is too great, vaporization on the surface will be so rapid that the area will become vapor-blanketed.
The surface is then essentially covered with vapor bubbles and liquid cannot move in to replace the bubbles. Thus, the effective
film coefficient becomes very low, resulting in excessive tube and film temperatures and rapid coke buildup. For typical vaporizing
hydrocarbon services, about 35,000 Btu/hr-sq. ft (110 kW/m2) is the maximum possible heat transfer rate before a “burn-out”
condition is encountered (assuming adequate mass velocities as discussed above).
The rate of heat transfer is not uniform to all radiant tube surfaces. For typical one-side fired tubes the overall average heat density
is only about 40 to 50% of the maximum point heat flux. For two-side fired tubes this average is improved to about 60 to 75% of
maximum. Therefore, the heater design and operation must be based on average heat densities low enough to assure a satisfactory
maximum density. Detailed recommendations for average radiant heat densities are listed in Subsection VIII-B. Following these
recommendations, as well as all other recommended heater design criteria, will insure that the maximum radiant heat density will
be satisfactory.
One condition that must usually be avoided is going through the dry point in the coil, since this may cause a coking or fouling problem.
Material that does not vaporize may plate out on the tube at the dry point and cause a heavy buildup. This may be a foreign material,
such as corrosion products, or a polymer that was formed in tankage. Such heaters should be designed to get the dry point out of
the heated zone. Maximum vaporization in the coil should be limited to about 80 wt%.
On the other hand, when a distillate, such as a pipestill sidestream, is fed directly into a fired heater (with no intermediate storage),
the risk associated with going through the dry point is minimal, since the distillate has just been completely vaporized and
condensed.
The normal design criteria for vaporizing services may not be applicable to single-component fluids in horizontal tubes. Stratified
flow, leading to excessive tube metal temperatures, has been found in heaters operating near the interface between slug flow and
bubble or froth flow (see Section XIV-C). In such cases, the Heat Transfer Equipment Section of EETD should be consulted.
FIRED HEATERS IN ALL-VAPOR SERVICE

Fired Heaters with all-vapor flow are generally not susceptible to the same severe coking problems as those in vaporizing services,
because of the lighter nature of the process fluid. Satisfactory film coefficients usually can be obtained with a mass velocity at design
conditions in the range of 15 to 100 lb/s ft2 (73 to 490 kg/s-m2). Higher mass velocities, such as those used in vaporizing services,
would cause extraordinarily high pressure drops in all-vapor flow. These high P’s would be particularly uneconomical in
compressor circuits.

DESIGN PRACTICES
VIII-A 13 of 24
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OPERATING CONDITIONS AND FLUID CHARACTERISTICS (Cont)
MULTI-SERVICE FIRED HEATERS

In some cases, two or more services can be placed in one fired heater, with substantial investment savings. This applies to both
cabin and vertical-cylindrical type designs. The services must contain radiant surface and be separated by an internal refractory
wall, if each is to be controlled independently.
A reduction in capacity to about 75% of design is possible on any service with the other service operating at full capacity. This
assumes that the services are properly integrated in the convection section design. All-radiant services can be turned down to as
low as about 50% of the design. Vertical box heaters can also be used for two services. In this case, an internal refractory wall is
not required between the two services.
HIGH-PRESSURE FIRED HEATERS

The design criteria for fired heaters with high pressure services (1000 psig, 6900 kPa and higher) must be more conservative than
for those with low pressure services, because of the potential for extensive damage from a tube failure. The following minimum
requirements should be observed, to reduce the probability of a tube failure and minimize damage in the event of a failure. Consult
the Heat Transfer Equipment Section of EETD for additional details.
1. Minimize the risk of local flame impingement and local high tube metal temperature by liberal firebox dimensions. Two-side firing
and avoidance of liquid fuel firing should also be considered.
2. Use small diameter tubes (maximum of 4 in., 100 mm I.D.) to limit the discharge rate in event of a tube failure.
3. Incorporate a firebox pressure relief system, to keep pressure buildup within the structural capability of the heater enclosure
in event of a tube failure.
4. Provide remotely operated valves (inlet and outlet) to isolate the heater from the process in event of a tube failure. For a more
complete definition of heater isolation requirements see DP Section XV-F.
COMPUTER PROGRAMS
Program 3558, the Fired Heater Simulation Program, is available to aid engineers design new heaters and simulate existing ones.
Program 3660, the Fired Heater Pressure Drop Program, is available for the calculation of pressure drop in fired heater coils and
transfer lines. The program can be used to calculate pressure drops for single phase liquid or vapor processes, as well as mixed
phase processes.
For an up-to-date listing and description of heat transfer programs, personnel should access the Application Technology Set Catalog
(ATS CAT) maintained by ER&E.

DESIGN PRACTICES
VIII-A 14 of 24
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TABLE 1
CHECKLIST OF ITEMS NORMALLY COVERED IN PROCESS FIRED HEATER DESIGN SPECIFICATIONS
Notes Notes
OPERATING CONDITIONS HEADERS

a. Process fluid a. Type
(1) Throughput b. Materials: same as tubes (convection headers may
(2) Percent vaporization at inlet and outlet be lower grade material when higher grade tubes
are used based on extended surface)
(3) Heat duty
c. Location: inside or outside of firebox (radiant
b. Steam superheater (if any) normally inside firebox, convection outside firebox)
(1) Throughput DIMENSIONS (1)
(2) Heat duty a. Radiant section
c. Total heat duty and heat fired (LHV) b. Convection section (include corbelling)
d. Percent excess air at stack c. Approximate elevation of heater floor above grade
e. Efficiency (based on LHV) (bottom firing requires 6 ft – 6 in., 2000 mm) clear
headroom)
f. Conditions for each tube section: radiant,
convection (shield, bare, each extended surface) d. Sootblower spacings in convection section
(1) Average heat density (extended surface e. Locations of observation doors
sections based on total outside surface BURNERS (see International Practice IP 7-1-1 and
(2) Section inlet and outlet temperatures IP 7-4-1)
(3) Section inlet and outlet pressures a. Manufacturer (only if required)
(4) Section maximum tube metal temperatures b. Type (forced or natural draft; raw gas or inspirator;
combination gas/oil)
(5) Flue gas temperature leaving each section.
Temperature leaving last section is stack c. Model number (optional)
temperature. These temperatures are also d. Size (optional)
used for design of convection section tube
supports e. Number (1)
(6) No flow conditions, if applicable (e.g., steam f. Location (1)

superheat coil) g. Maximum and normal firing rate per burner
g. Refractory hot face design temperatures h. Minimum firebox draft at burner level
TUBES i. Burner flameout protection (pilots and flame rods) (4)
a. Number and OD: radiant, shield convection (bare), (1) j. Plenum chambers, if required
convection (each type of extended surface), and FUEL OIL
steam
(1) a. Total requirement
b. Number of passes: radiant, shield, convection, and
steam b. API gravity
c. Number of tubes per row: shield, convection and (1) c. Temperature of oil at burner
steam d. Viscosity of oil at burner
d. Average (or minimum) wall thickness e. Pressure at burners
e. Exposed length f. Pressure and temperature of atomizing steam at
f. Exposed surface, including extended surface burners
g. Center-to-center spacing (1) g. Solids content and/or corrosive compounds (4)
(V, Na, S, ash)
h. Center-to-wall spacing (1)
h. Lower heating values (2)
i. Center-to-burner center spacing (1)
FUEL GAS
j. Materials
a. Composition
k. Stud details (length, diameter, number per row,
spacing of rows, material) b. Pressure and temperature at burners
l. Fin details (height, thickness, pitch, material) c. Lower heating values
m. Design pressure (4) d. Corrosive compounds (S) (4)
n. Design pressure and temperature for crossover e. Molecular weight
piping and external manifolds

DESIGN PRACTICES
VIII-A 15 of 24
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TABLE 1 (Cont)
CHECKLIST OF ITEMS NORMALLY COVERED IN PROCESS FIRED HEATER DESIGN SPECIFICATIONS
Notes Notes
INSTRUMENTS (3) (5) DECOKING (if specified)

a. Coil outlet temperature controls Steam-Air Decoking:
b. Tube metal temperature points (if required) a. Provide for thermal expansion of coil (4)
c. Fluid temperature and pressure points b. Design of decoking system (3)
d. Draft gauges (special gauges usually specified in Pig Decoking:
furnace notes)
a. Specify spool piece connections in each coil pass
e. O2 /Combustibles Analyzer (usually specified in inlet and outlet
instruments section)
b. General location of spool piece connections (3)
f. Forced draft controls (if required)
SOOTBLOWERS (if used) (see IP 7-1-1 and IP 7-3-1)
g. Emergency shutdown system (if provided)
a. Type (retractable)
h. Air preheater controls (if required)
b. Number
i. Flue gas temperature points
c. Where located (1)
STACK (1)
d. Steam pressure and amount (note in fired heater (2)
a. Location section if less than 250 psig, 1725 KPa)
b. Inside diameter at exit PLATFORMS (see IP 7-1-1)
c. Height above convection section (or above grade) All platforms and access in addition to those required by (4)
d. Cross-sectional area and arrangement of duct work IP should be specified
to stack and air preheater FORCED DRAFT SYSTEM
e. Breeching (see Design Practices: Forced Draft Systems – Section
f. Draft required above convection section, if vendor VIII-G, Air Preheaters – Section VIII-K)
has to size or design any part of duct and stack
system
SAFETY AND MISCELLANEOUS (see International
Practices IP 3-4-1, 7-1-1, 15-1-1 and Design Practices
Section XV)
a. Provisions against loss of feed
b. Provisions against loss of pilot gas and/or
combustion air when applicable.
c. Provisions for firebox purging (3)
d. Special refractory and tube support requirements
Notes:
(1) Items normally shown on fired heater sketch.
(2) Normally covered in utility section of Design Specification.
(3) Normally covered in flow plan section of Design Specification.
(4) Information required by IP 7-1-1.
(5) Instruments are normally shown on the flow plan. They are usually located on the fired heater sketch so that the proper
connections may be provided.

DESIGN PRACTICES
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TABLE 2
CHECKLIST OF ITEMS NORMALLY COVERED IN FIRED HEATER DUTY SPECIFICATIONS
Heat to Oil. BURNERS

Include any required duty for flexibility. a. Type.
b. Pilot and flame rod required.
Heat Fired, Stack Temperature and LHV Efficiency, or factors by c. Type of noise control required.
which manufacturer can develop economical design. FUEL(s)
Maximum Allowable Average Heat Density for each section on bare a. Rate.
tube basis.
b. Characteristics (HHV, LHV, *gravity, etc.).
Design % Excess Air.
c. Operating conditions at burners (fuel temperature and pressure,
Feed Characteristics (Type, Gravity, Viscosity, Temperature-Enthalpy atomizing steam pressure, etc.).
Curve, etc.).
d. Pilot fuel characteristics.
OPERATING CONDITIONS
*e. Quantities of V, Na, S, ash in fuel.
a. Feed rate.
INSTRUMENTS REQUIRED (not covered by IP 7-1-1, IP 15-1-1)
b. Coil inlet temperature and pressure.
a. Thermowells, TI’s, etc.
c. Coil outlet temperature and pressure.
DECOKING (if required)
d. Vaporization at coil outlet.
Steam – Air Decoking:
e. Coil pressure drop clean or coked (minimum and maximum).
*a. Clearances for thermal expansion to be provided.
f. Minimum mass velocity.
Pig Decoking:
TUBES
a. Specify spool piece connections in each coil pass inlet and outlet
a. OD (if important in stock considerations).
b. Material(s) if preferences known. CONVECTION SECTION CLEANING
c. Corrosion allowance and/or life required. *a. Sootblowers required if fuel oil contains more than 0.01 wt% ash or
fuel gas produces more than 5 wppm (5 mg/kg) particulates in the
STACK flue gas.
a. Height (minimum height only from considerations of air pollution (1) Type of sootblower (retractable).
or clearing nearby structures.).
(2) Steam pressure for sootblowers.
b. Design summer air temperature.
INTERNATIONAL PRACTICES (normally specified in Job Spec)
a. IP 7-1-1, Fired Heaters.
b. Other related IP’s.
FORCED AND INDUCED DRAFT SYSTEMS
a. Type of air preheater, if used.
b. Maximum preheated air temperature to burners.
c. Fan operating temperatures.
d. Flue gas dew point temperature.
* Information required IP 7-1-1.

DESIGN PRACTICES
VIII-A 17 of 24
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TABLE 3
FACTORS AFFECTING FIRED HEATER SELECTION AND DESIGN
DESIGN CONSIDERATION REMARKS
Type of Service (Fluid being heated)
1. All-Liquid
2. Vaporizing Requires adequate mass velocity to minimize coking/fouling.
3. All-Vapor Usually not coking; lower mass velocity to minimize P.
Heat Duty Determines type of fired heater.
Operating Conditions:
1. Feed Rate Affects tube size and number of passes.
2. Process Conditions:
a. Properties
b. Temperature
c. Pressure High pressure ( 1000 psig), requires special considerations.
d. Vaporization Maximum vaporization in the coil should be limited to about 80 wt%.
Minimize vapor at inlet of multi-pass fired heaters.
e. Composition Single-component fluids require special considerations in
vaporizing services.
3. Flue Gas Conditions:
a. Stack Temperature 1. High temperatures increase incentives for air
preheaters/additional waste heat recovery.
b. Composition 2. Low temperatures may result in acid dew point problems.
Fluid Characteristics:
1. Coking Residence time/temperature important.
2. Color Stability
3. Corrosivity
4. H2 / H2S Content Affects tube materials required.
5. Viscosity High viscosity gives poor film coefficient.
Fuels
1. Gas and/or Liquids Affects convection section extended surface, convection section
cleaning, type of burners.
2. Corrosive Compounds Affects tube supports, refractory materials.
3. Cost 1. Affects design fired heater efficiency.
2. Affects air preheater justification.
Special Requirements:
1. High Turndown Fired heater geometry, mass velocity, P.
2. Pre-Investment Two sets of conditions to be covered.
3. Space Limitations Type of fired heater.
4. Special Refinery Requirements Maintenance and operating experience.
5. Air Pollution, SO2 Ground Level Concentration Stack height.
6. Noise Mufflers, forced-draft burners.
7. NOx Low NOx burners.

DESIGN PRACTICES
VIII-A 18 of 24
Date
FIGURE 1
VERTICAL-CYLINDRICAL FIRED HEATERS
Draft Gage
Damper Draft Stack

Gage
Top Headers
Top Header
Draft Gage Box
Damper Finned Convection

Baffle
Convection Sleeve Section
Tubes
Stack
Draft Gage
Draft Gage
Reradiating
Cone
Radiant
Section
Radiant
Radiant Tubes
Section Combustion
Zone
Draft Gage
Draft Gage
Coil Inlet Coil

Outlet
Burners Bottom Burners
Headers
(A) ALL-RADIANT FIRED HEATER (B) INTEGRAL CONVECTION SECTION

DESIGN PRACTICES
VIII-A 19 of 24
Date
FIGURE 2
VERTICAL-CYLINDRICAL FIRED HEATER WITH HORIZONTAL CONVECTION SECTION
Draft Gage Stack

Damper
Stack Header Box
Draft Gage
TI
ÉÉ É
ÉÉ É
Breeching
Coil Inlet
Convection
ÉÉ É
ÉÉ É
Section
Crossover TI Shield Section

ÉÉ É
Crossover
Piping
Draft Gage
SIDE VIEW
Radiant
Section
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
ÇÇÇÇÇÇÇÇÇ
ÉÉÉÉÉÉÉÉÉ
ÇÇÇÇÇÇÇÇÇ
ÉÉÉÉÉÉÉÉÉ
ÇÇÇÇÇÇÇÇÇ
Radiant
ÉÉÉÉÉÉÉÉÉ
ÇÇÇÇÇÇÇÇÇ
ÉÉÉÉÉÉÉÉÉ
Tubes
Draft Gage
ÏÏÏ ÇÇÇÇÇÇÇÇÇ
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
Burners
Coil Outlet
ÉÉÉÉÉÉÉÉÉ
Radiant Tube Circle
ELEVATION PLAN VIEW

DESIGN PRACTICES
VIII-A 20 of 24
Date
FIGURE 3
HORIZONTAL TUBE CABIN FIRED HEATER
Header Box
+
Breeching
+
+
SIDE VIEW
+
+
Sootblower
Tube Supports
Locations
+
Convection
Radiant
Section
Section
Stack TI
Damper
END VIEW
Draft Gage
Burners
Draft Gages
Shield Tubes
Corbelling
Stack
Coil Inlet
Draft Gage
Outlet
Coil

DESIGN PRACTICES
VIII-A 21 of 24
Date
FIGURE 4
VARIATIONS OF CABIN FIRED HEATERS
(a) AIR-COOLED CENTER WALL (b) FREE STANDING CENTER WALL
(c) HOOP-TUBE (d) DOUBLE HOOP-TUBE

DESIGN PRACTICES
VIII-A 22 of 24
Date
FIGURE 5
VERTICAL TUBE BOX FIRED HEATER
PROPRIETARY EXXON HIGH INTENSITY FIRED HEATER
To Stack
1-Side Fired
Wall Tubes
2-Side Fired
Center Tubes
Burners
Forced Air
Supply Duct

DESIGN PRACTICES
VIII-A 23 of 24
Date
FIGURE 6
SINGLE WING HORIZONTAL TUBE BOX FIRED HEATER
Stack
Draft Gages Damper
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ Coil Inlet
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ Coil Outlet
Corbelling
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ Convection
Section
Shield Tubes
Radiant Section
Burners
Self-Supporting
Bridge wall
Draft Gage Draft Gage

DESIGN PRACTICES
VIII-A 24 of 24
Date
FIGURE 7
FIRED HEATER SELECTION GUIDE
ALL-LIQUID OR VAPORIZING SERVICES

Heat Duty Absorbed, MW
20 40 60 80 100 120 140 160
Vertical Cylindrical
Horizontal Cabin
Vertical Tube Box
0 100 200 300 400 500 600

Heat Duty Absorbed, MBtu/hr
Type of Fired Heater
ALL-VAPOR SERVICES
Heat Duty Absorbed, MW
20 40 60 80 100 120 140 160
Vertical Cylinder
Hoop Tube Cabin
Multiservice V.C.
Multiservice Hoop Tube Cabin (Powerformers)
0 100 200 300 400 500 600

Heat Duty Absorbed, MBtu/hr

Selection of Fired Process Heaters

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DESIGN PRACTICES

FIRED HEATERS Section Page

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

12/96 1. Consolidated English and Metric Units.

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

DESIGN PRACTICES (Besides Other Subsections of this Section)

Section XV Safety in Plant Design

IP 7-1-1 Fired Heaters

IP 7-3-1 Sootblowers for Fired Equipment

IP 7-4-1 Burners for Fired Heaters

IP 7-5-1 Coils for Fired Heaters and Boilers

IP 7-8-1 Dampers and Guillotines for Fired Equipment

IP 7-9-1 Expansion Joints for Fired Equipment

IP 15-1-1 Instrumentation for Fired Heaters

IP 19-3-3 Linings for Fired Heaters

Report EE.70E.75, Pipestill Furnace Turndown

Application Technology Set Catalog (ATS CAT)

Exxon Engineering Cost Estimating Manual

Exxon Refinery Construction Materials Manual

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

PROCESS FIRED HEATERS (CONVENTIONAL)

PYROLYSIS FIRED HEATERS

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

Burner. A device for mixing fuel and air for combustion.

Film Coefficient. The convective heat transfer coefficient of the film.

Gross Heating Value. See higher heating value.

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

NPS. Abbreviation for “Nominal Pipe Size”.

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

Setting. The refractory insulation on the inside of the heater box.

Tube Guide. Device used to guide thermal movement of tubes.

TYPES OF FIRED HEATERS

VERTICAL-CYLINDRICAL FIRED HEATERS

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

TYPES OF FIRED HEATERS (Cont)

HORIZONTAL TUBE CABIN FIRED HEATERS

VERTICAL TUBE BOX FIRED HEATERS

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

TYPES OF FIRED HEATERS (Cont)

FIRED HEATER SELECTION AND DESIGN

FIRED HEATER PERFORMANCE

FACTORS AFFECTING FIRED HEATER SELECTION AND DESIGN

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

FIRED HEATER SELECTION AND DESIGN (Cont)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

FIRED HEATER SELECTION AND DESIGN (Cont)

1. Require a high DCF rate of return.

% Return before tax is = S C0.12 C 100 Eq. (1)

where: C = Incremental Investment

OPERATING CONDITIONS AND FLUID CHARACTERISTICS

FIRED HEATERS IN ALL-LIQUID OR VAPORIZING SERVICE

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

OPERATING CONDITIONS AND FLUID CHARACTERISTICS (Cont)

FIRED HEATERS IN ALL-VAPOR SERVICE

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

OPERATING CONDITIONS AND FLUID CHARACTERISTICS (Cont)

MULTI-SERVICE FIRED HEATERS

HIGH-PRESSURE FIRED HEATERS

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

OPERATING CONDITIONS HEADERS

(6) No flow conditions, if applicable (e.g., steam f. Location (1)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.