Professional Documents
Culture Documents
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Contents Pages
INTRODUCTION................................................................................................................ 1
GLOSSARY........................................................................................................................18
INTRODUCTION
This module provides an introduction to the furnaces used by Saudi Aramco in petroleum
processing plants.
The types of documents used by Saudi Aramco to specify furnaces for design and purchase, and
to record their inspection and maintenance history, will be presented.
FURNACE CHARACTERISTICS
Furnaces are used mainly to heat process fluids and usually are parts of specific process units.
Process furnaces consist of an internally-insulated enclosure, in which heat is liberated by the
combustion of fuel and is transferred to fluids contained in tubular coils. Since the composition of
the fluids being processed and the operating conditions vary widely between units, many furnace
arrangements are used to satisfy the individual process unit requirements. Furnace size is almost
always denoted by the amount of heat absorbed.
Furnaces are also referred to as “fired heaters.” These two terms are used interchangeably.
Furnaces consist of a radiant section and a convection section. In the radiant section, heat is
transferred to the process fluid in the tubes primarily by radiation from high-temperature flue gas.
In the convection section, heat is transferred from the flue gas to a bank of tubes, mainly by
convection.
Furnaces are generally classified by the type of structural configuration and radiant coil
arrangement used. The choice of furnace type depends mainly on the furnace size and the process
coil requirements. Figure 1 illustrates typical furnace types in use today. The main types of
furnaces used by Saudi Aramco are vertical cylindrical and box furnaces (Figures 1a, e, f).
Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.
Vertical cylindrical furnaces are the most common type in use in the petroleum processing
industry. They are usually used for heat duties up to about 100 M Btu/hr, although larger ones
are sometimes used. Figure 2 shows two vertical cylindrical furnaces at the Ras Tanura refinery.
The interior of a typical vertical cylindrical furnace is shown in Figure 3. 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.
Stack
Flue Gas Crossover
Convection
Section
Coils
F-102
F-101
Damper Inspection
Control Doors
Radiant
Section
Burner
Draft Snuffing
Steam
Gauge Header
Draft Gauge
Stack Stack
Damper Header Box
Temperature
Draft Gauge Indicator
Breeching
Coil Inlet
Convection Section
Shield Section
Crossover TI
Crossover
Piping
Draft
Gauge Side View
Radiant Section
Radiant
Tubes
Burners
Coil Outlet
Radiant Tube Circle
Elevation Plan View
Stack
Breeching
Draft Gauges Damper Tube Supports
Stack Temperature
Sootblower Header Box
Indicator
Locations
Coil Inlet
Corbelling
Convection
Section
Shield Tubes
Draft Gauge
Radiant
Section
Coil
Outlet
Burners
Burner Arrangements
Several burner arrangements can be used with box furnaces, as shown in Figure 5. In Saudi
Aramco's furnaces, the burners are located in the furnace floor, firing upward, or in the sidewalls
below the tubes, firing horizontally against a center wall (Figures 5a and c). In either case, firing
is perpendicular to the tubes.
Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.
Arbor, or “hoop” tube, coils are also used in box furnaces (Figure 1a). These coils consist of a
series of vertical tubes located on each side of a radiant section, connected at the top by a large
semicircular tube section. This arrangement permits the use of a large number of parallel flow
paths. It is used in noncoking, all-vapor process flow services, where a low pressure drop is
desired.
Arbor coils are used in the Plant 488 and 493 Rheniformer furnaces. In this furnace, separate
radiant zones are provided for the preheat and each reheat service. These zones are separated by
free-standing brick walls. The flue gases from all the radiant zones pass through a common
convection section.
Sulfur Furnace
A sulfur furnace is a different type of furnace, which is used in a sulfur recovery plant. It consists
of a refractory-lined combustion chamber, in which the H2S in the acid gas feed stream is partially
combusted with air under carefully controlled conditions. The effluent from the combustor flows
directly through a fire-tube waste heat boiler, where steam is generated, and then to the remainder
of the unit for sulfur recovery and further processing. A sketch of a typical sulfur combustor
furnace is shown in Figure 6.
A Detail 1
Waste
Heat Boiler
A 1/2" Shell
Reaction Furnace
Elevation
Refractory Anchor
(Waste Heat
Boiler)
Refractory
Air Inlet
Shell
Reaction
Furnace
Tubes
Tube Sheet
Detail 1
Section A-A
Ras Tanura
015
Two Stage Crude
F-100A&B Atmospheric 2 Cell Box 250.7
F-200A&B Vacuum 2 Cell Box 124.6
493
Prefractionator
F-101 Lt Ends Reboiler VC 45.2
F-102 Hvy Ends Reboiler VC 64.4
Naphtha Hydrotreater
F-201 Hydrotreater Charge VC 32.0
F-202 Desulfurizer Reboiler VC 27.0
Rheniformer
F-301 No. 1 Reactor Heater Arbor 84.0
F-302 No. 2 Reactor Heater Arbor 47.0
F-303 No. 3 Reactor Heater Arbor 28.0
F-304 No. 4 Reactor Heater Arbor 14.0
Convection Section
Superheater 13.0
Steam Generation 79.8
Boiler Feedwater 17.2
Total for Rheniformer = 283.0
Uthmaniyah
R34
F-101 Reaction Furnace 65.0
F-102 Reaction Furnace 65.0
F-103 Reaction Furnace 65.0
The major components of a typical furnace are shown in Figure 8, which is an illustration of a
horizontal tube box furnace. These components comprise the three major elements of the
furnace: the process coil, the combustion/flue gas system, and the structure.
21
18
13
Process In
11 3
12
8
7
19 15
14
2
9
4 6
17
18
13
16 22
10
Process Out 1
20
Legend:
Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.
The process coil consists of a series of tubes which are connected at the ends by headers. The
process fluid usually enters the furnace at the top of the convection section, where both the
process and flue gas temperatures are the lowest. It passes down through the convection section,
following several parallel flow paths (passes), and exiting at the bottom of the convection section.
The convection section tube bank consists of several tube rows, with each row consisting of
several tubes. In the upper rows, the tubes have an external extended surface to improve heat
transfer with the flue gas. This extended surface can be either fins or studs, and these are
illustrated in Figure 9.
The headers which connect the tubes are located in header boxes at each end of the convection
section. Headers can be either return bends or plug-type headers. Plug-type headers are used
only in cases where access to the inside of the coil is required for inspection or cleaning. This
access is not required in most cases.
The shield section consists of the bottom two rows of tubes in the convection section. These
tubes shield the next rows of tubes from direct radiation.
After leaving the convection section, the fluid passes through crossover pipes to the radiant
section. In most furnaces, the radiant tubes are arranged in single rows that are located a few
inches from refractory walls.
In some furnaces, an auxiliary coil is included in the convection section to provide heat to a
secondary process service. In addition to heat required by the process services, more heat can
often be recovered from the flue gas by adding a steam generating section to the convection
section. In the case of the Plant 488 and 493 Rheniformer furnaces, the process coils are located
only in the radiant section, and the entire convection section is used for steam generation.
Throughout the furnace, the tubes are supported by tube supports, which are attached to the
furnace structure. In the convection section, large supports which extend across the width of the
convection section are used to support several rows of tubes. In the radiant section, horizontal
tubes are supported by small supports which resemble fingers. These are discussed in greater
detail in another module. Arbor coils are supported by the inlet and outlet manifolds which are
usually located below the furnace floor. Tube guides are also provided to restrict movement of
the tubes.
Most of Saudi Aramco's furnaces are designed to fire either gas or oil fuel, although some are
designed to fire only gas. Oil fired furnaces usually require sootblowers to periodically clean the
convection section tubes, particularly when extended surface tubes are used. Sootblowers direct
a blast of steam at the tubes to clean the surface and increase heat transfer.
Combustion air is supplied to the burners, where it is mixed with the fuel. This flow of air is
caused by the natural draft in the furnace, which is caused by the difference in temperature
between the flue gas inside the furnace and stack, and the outside air. The rate of air flow is
adjusted so that only the amount of air required for good combustion is admitted to the furnace.
Greater quantities of air-flow waste energy. Combustion takes place in the furnace radiant
section. Heat is transferred from the burning fuel and hot flue gases to the radiant tubes by direct
radiation. The radiant section is sized to ensure that there is no direct flame impingement on the
radiant tubes.
The flue gases then flow through the convection section around the tube bank. Corbels are
provided in the convection section sidewalls to prevent flue gas from bypassing the tube bank.
The flue gas then flows from the convection section, through the breeching and ducting, to the
stack. In some cases, the flue gases from two or more furnaces are combined and exit through a
common stack. Dampers are provided in the ducting or stack to regulate the available draft in the
furnace.
Some furnaces use a combustion air preheater to improve efficiency. The most common type of
air preheater system is shown in Figure 10a. This system uses a heat exchanger to transfer heat
from the flue gas leaving the furnace to the air to be used for combustion. Because of the
increased combustion air, and flue gas pressure drops, forced and induced-draft fans are needed.
Another type of air preheat system is shown in Figure 10b. In this system, waste heat from
another source is used to heat the furnace combustion air.
Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.
The furnace enclosure consists of a metal casing plate with an internal refractory-lining. An
external structure supports all the furnace components. The furnace casing is designed for
minimum air infiltration, since any air entering the furnace, except through the burners, does not
contribute to good combustion. However, since the furnace normally operates with a slight
negative pressure (draft) inside, the structure is not subject to the same internal pressures as
boilers. Therefore, an expensive pressure-tight structure is not required. Observation doors are
provided in the casing to permit viewing the burners, the combustion process, and all the radiant
section tubes.
Several Standards and Codes are used to cover the minimum requirements of new equipment
purchased by Saudi Aramco. Additional documents are used to record details of the equipment
actually purchased and installed, and to record the furnace's history during its operating life.
This Engineering Standard is mainly used for the purchase of new process furnaces (fired heaters).
It is based on and includes API Standard 560, Fired Heaters for General Refinery Services, which
contains the minimum requirements for the design and fabrication of process furnaces. AES-F-
001 also includes specific additions and revisions to API 560 to meet Saudi Aramco's specific
requirements. Included in these standards are:
• Mechanical design requirements, including the design of tubes and tube supports, refractory,
burners and fans, structure, platforms, stacks and ducts.
This standard also references other documents that cover specific aspects of the furnace supply
and design. The most important are listed below:
• AES-J-600, 603 Process Heater Burner Safety System. These standards cover the
instruments and controls required for safe operation of the furnace combustion system.
The purpose of the Safety Instruction Sheets (SIS) is to provide operating, maintenance, and
inspection personnel with important information about certain pressure-containing and rotating
equipment in the plants. This information is presented in a consistent format and includes safe
operating limits for the equipment, protective devices, and any special safety precautions required.
SIS are initially prepared for new equipment, and then revised when existing equipment is re-
rated.
For furnaces, SIS are required for the furnace tubes, using Saudi Aramco Form 2731 - Fired
Heaters which is presented in Work Aid 1. Use of the SIS is covered in MEX 105.06.
This document is provided by the furnace manufacturer and includes a summary of the furnace's
physical characteristics and its predicted operating performance. It is usually part of the
manufacturer's original proposal and is subsequently modified to incorporate any changes that
occur as the furnace detail design progresses. The final issue should reflect the as-built furnace.
Data sheets are contained in Saudi Aramco Form 8009 (6 pages). This form is equivalent to a
general form for the data sheets contained in the Appendix of API Standard 560. Unless the use
of Saudi Aramco Form 8009 is insisted upon, manufacturers will often use their own data sheets,
which are very similar to this.
Details of the furnace and its auxiliary equipment are contained in several sources.
The contractor prepares a plant record book for the furnace. This contains details of the furnace
design and construction, including many of the manufacturer's drawings. Adequate information
should be included to permit necessary inspection and maintenance of the furnace. The plant
record book should also contain information on components purchased by the manufacturer from
subsuppliers, such as burners, fans and drivers, sootblowers, safety valves, and instruments.
Drawing Files
Drawings covering furnace details should be available for reference and to permit furnace
inspection and maintenance. These should be available in the plant record books and/or in the
inspection record books. As modifications are made to the furnace over its life, these changes
should be recorded on the original drawings or on new drawings.
Inspection Record Books should include inspection results and a record of past maintenance and
repairs. Any modifications made to the boiler should also be documented in this file. This file
should provide a valuable history of furnace performance and assist in determining future
maintenance requirements.
REFERENCE
API Publications
ASTM Publications
Material Specifications
Other Publications
GLOSSARY
air preheater A heat exchanger which heats the air required for
combustion by exchanging heat with the flue gases
leaving the convection section, or with another fluid
of higher temperature.
arch The flat or sloped portion of the radiant section
opposite the floor.
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
or the outlet duct work.
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.
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.
corbel A projection from the convection section sidewall to
prevent flue gas from flowing up the side of the
convection section, between the wall and the nearest
tubes, thereby bypassing the tube bank.
heat duty The total heat absorbed by the process fluid, usually
expressed in MBtu/hr (million Btu per hour). Total
furnace duty is the sum of heat transferred to all
process streams, including auxiliary services such as
stream superheaters and drier coils.
heat fired The total heat released in the furnace, equal to gross
fuel times lower heating value (LHV) of the fuel.
Usually expressed in MBtu/hr.
hip section The transition zone at the top of the radiant section
in cabin type furnaces. The wall of this section is
usually at a 45° angle.
induced-draft Use of a fan to provide the additional draft required,
in addition to that supplied by the stack, to draw the
flue gas through the convection section, and any
downstream heat recovery equipment (i.e., air
pressure).
inspection doors Openings in the convection section sidewalls to
allow inspection of tubes, extended surfaces, and
supports.
manifold A pipe connected to several parallel passes and used
to distribute or collect fluid from these passes.
natural draft System in which the draft required to move
combustion air into the furnace, and flue gas through
the furnace and out the stack, is provided by stack
effect alone.
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 furnace
wall have only one side directly exposed to a burner
flame. Radiation to the backside of the tubes is by
reflection/radiation from the refractory wall.
pass A coil which transports the process fluid from
furnace inlet to outlet. The total process fluid can
be transported through the furnace by one or more
parallel passes.