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FURNACE and FLARE

FURNACE EFFICIENCY IMPROVEMENTS • NOx REDUCTION • FLARE GAS RECOVERY • EFFICIENCY SEMINARS • CEMS
A DIVISION OF BHP ENGINEERING AND CONSTRUCTION, L.P. 715 Oak Park Ave Corpus Christi, TX 78408, USA Voice: (361) 693-6200 Fax: (361) 884-3522

FURNACE EFFICIENCY IMPROVEMENTS FLARE GAS RECOVERY EFFICIENCY SEMINARS NOx REDUCTION CONTINUOUS EMISSION MONITORING SYSTEM FEA STRESS ANALYSIS

CORPUS CHRISTI
715 OAK PARK AVENUE CORPUS CHRISTI TEXAS 78408 361-693-6200

VICTORIA
11202 US HWY. 59 NORTH, SUITE B VICTORIA TEXAS 77905 361-572-8039

BAYPORT
11837 FAIRMONT PARKWAY LA PORTE TEXAS 77571 979-429-6807

LAGOS
Plot 28 Block 93 Awkuzu Street Lekki 1 Lagos Nigeria 234-1-270-1581

www.bhpeng.com

....................................FURNACE and FLARE FURNACE EFFICIENCY IMPROVEMENTS • NOx REDUCTION • FLARE GAS RECOVERY • EFFICIENCY SEMINARS • CEMS A DIVISION OF BHP ENGINEERING AND CONSTRUCTION. 5 B............................................................................................... USA Voice: (361) 693-6200 Fax: (361) 884-3522 REDUCE ENERGY COST UP TO 5 PERCENT ............................................................4 FURNACE and FLARE ......................... FLARE GAS RECOVERY...................................................................................................................................................................................................12 PROJECT PROFILE ...13 CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 2 ........................ 715 Oak Park Ave Corpus Christi..................... DATA COLLECTION AND REPORTS...................... 8 F........................................................................................................ 7 D.................................................................................... 8 E............................................................4 BENEFITS.... TX 78408...................10 FEA STRESS ANALYSIS ......................................... L...........................FURNACES ......................................................................................P............................................. 9 CEMS..................................3 ENERGY SERVICES ................................................................................ 6 C.............................................................. ENERGY LOSS SURVEY.................................................. FURNACE EFFICIENCY IMPROVEMENTS ....................................................................... PERSONNEL TRAINING......5 A....................................... NOx REDUCTION .................................................................................

000 $1 00. and analysis of combustion equipment.REDUCE ENERGY COST UP TO 5 PERCENT Let our combustion experts give you timely.000 A nnual Savings. cost effective support and solutions for your combustion equipment problems. $ per M M B TU 5 % E xc e s s A ir 1 0 % E xc e s s A ir Furnace Efficiency S ta c k T e m p e ra tu re CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 3 . Furnace and Flare Engineers are experienced in design. $ 600. troubleshooting. operation.000 $ 400.000 $ 500. The charts below illustrate the savings possible from small efficiency improvements to a medium size heater (100MM BTU/Hr) using fuel valued at $5 to $10 per MM BTU. $ /Yr $ 300.000 $0 5 6 7 8 9 1 0 Fuel Co st. startup.000 @5% Impro vement $ 200.

ENERGY LOSS SURVEYS E. A. PERSONNEL TRAINING FOR BETTER OPERATION F. CALCULATIONS AND REPORTS BENEFITS Most improvements may be implemented with little capital investment. DATA COLLECTION. and results can be realized with minimum cost. FURNACE EFFICIENCY IMPROVEMENTS B. FLARE GAS RECOVERY D. NOx REDUCTION C.ENERGY SERVICES Furnace and Flare offers the services of experienced engineers to improve the efficiency of your combustion equipment. Improvements to your combustion equipment can yield the following benefits. • REDUCED ENERGY COST • LOWERED EMISSIONS • MAXIMIZED EFFICIENCIES • EXTENDED EQUIPMENT SERVICE LIFE CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 4 .

These services cover the complete range of client needs from heater efficiency surveys and operator/ supervisor training to the recovery of products and fuel from flare gas. • STACK GAS ANALYSIS • HEATER DRAFT PROFILE • HEATER TEMPERATURE PROFILE • OBSERVATION OF FLAME PATTERN • MECHANICAL CONDITION OF EQUIPMENT • PROCESS FLOW AND TEMPERATURE PROFILE • TUNING THE FURNACE FOR OPTIMUM EFFICIENCY CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 5 .FURNACE and FLARE offers the following technical services to improve the efficiency of your combustion equipment. A. FURNACE EFFICIENCY IMPROVEMENTS The following investigation steps will be taken to develop a plan that will outline corrective action and issue a report of equipment and operating changes needed with an estimate of potential savings.

NOx REDUCTION Troubleshooting and installation of modern burners is important for optimum fuel efficiency and LoNOx performance.B. FURNACE and FLARE has the experience to solve your burner problems. • BURNER REGISTER OPERATION • BURNER FLAME PATTERN DIAGNOSTICS • TURNAROUND MAINTENANCE SUPERVISION • BURNER TIP ALIGNMENT AND TOLERANCE ADJUSTMENTS • AIR PREHEAT AND DUCT SYSTEM DIAGNOSTICS • FUEL FILTRATION SYSTEMS DESIGN CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 6 .

• PSV SIZING WITH INLET AND OUTLET PIPE SIZING PER API 520 • RELIEF SYSTEM DESIGN AND HYDRAULIC CALCULATIONS • KNOCKOUT DRUM AND SEAL DRUM DESIGN • FLARE TIP DIAMETER AND ELEVATION ESTIMATION PER API 521 • FLARE GAS RECOVERY SYSTEM DESIGN AND INSTALLATION CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 7 .C. FLARE GAS RECOVERY FURNACE and FLARE can assist you with any flare system problems from relief valve sizing to tip replacement to product recovery from flare gas.

• BURNER AND HEATER SEMINARS • BOILER OPERATION AND TROUBLESHOOTING • NOx FORMATION CHEMISTRY • HAND'S ON PROBLEM SOLVING CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 8 . ENERGY LOSS SURVEY The energy transmission and exchanger train will be investigated to develop a plan of action to reduce steam and heat transfer losses.D. • STEAM SYSTEM SURVEYS • BOILER EFFICIENCY INVESTIGATION • HEAT EXCHANGER EFFICIENCY INVESTIGATION E. PERSONNEL TRAINING FURNACE and FLARE can provide tools and understanding your operators and supervisors need to continuously monitor and adjust your combustion equipment for optimum efficiency.

Reports will be issued in a timely manner.F. • TIMELY REPORT OF FINDINGS • SUGGESTIONS FOR ENERGY SAVINGS • COST ESTIMATES FOR ANY EQUIPMENT CHANGES • RESULTS OF EQUIPMENT MECHANICAL CONDITION • PHOTOGRAPHS OF EXISTING EQUIPMENT • CALCULATIONS INCLUDED WITH RAW OPERATING DATA CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 9 . DATA COLLECTION AND REPORTS All aspects of furnace and boiler operation can be captured for resolution of efficiency problems or stack gas compliance investigation.

installation. SO2 SO2. budget estimates.000. O2 NOx. inspection and start up. O2 H2S. CO. O2 NOx. O2 H2S Plus numerous other on-line process analyzer projects. O2 NOx. CO. CO. O2 NOx. CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 10 . CO. O2 H2S NOx.CEMS (Continuous Emission Monitoring System) BHP provided all phases of engineering including front end engineering. The analyzer projects included: • Sample System • Analyzer Specifications & Purchase • Analyzer / Control System Interface Design The following is a list of recent CEMS projects with cost range up to $500. CO. O2 NOx. BHP Heater Analyzer Projects Year Client Project Description Analyzed 2005 CITGO 2003 CITGO 2000 CITGO 1998 CITGO 2005 FHR 2004 FHR 2004 FHR 2003 FHR 2002 FHR 2001 FHR 2003 Valero #4 Platformer Heater CEMS SRU Claus Air Demand Analyzers SRU Tail Gas Incinerator CEMS #2 FCCU CEMS MIO Crude Boiler CEMS #2 Parex Heater CEMS Toluene Heater CEMS Thermal Oxider CEMS MSTDP Heater CEMS BTX Heaters CEMS (4 Stack System) Three Rivers Fuel Gas H2S Analyzer NOx. detailed engineering. CO.

O2 Dual Stream Monitoring Single Stream Monitoring Firing Efficiency Analyzer O2 & Combustibles Manual Operation Automatic Operation CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 11 .Continuous Emission Monitoring System FHR BTX Heaters CEMS (4 Stack System) NOx. CO.

CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 12 .FEA STRESS ANALYSIS Before Revision Over Stress After Revision Over Stress Removed Stress contour views of heater stack for a heater upgrades project Structural design capabilities utilizing FEA improves structural design economy & saves T/A time.

Provided initial process evaluation. complete engineering.Corpus Christi.Burner Cost $1. equipment specification and selection.Corpus Christi. P&ID's. burner controls and air ducts.5 million CITGO Refining Company .P. and mechanical specifications to retrofit the # 4 Platformer furnace with LoNOx burners. P&ID's. Refinery LoNOx Burners . Tie-ins. and mechanical specifications to retrofit the West Crude furnace with LoNOx burners. TX A Duct Burner system was added to the existing Cogeneration/Steam Generation Unit in the East Plant to provide supplemental firing to increase steam generation. L. TX Provided engineering with PFD's.Corpus Christi. Notable Burner and Heater Projects: Refinery LoNOx Burners . Instrument Loop drawings. TX Provided engineering with PFD's.Burner Installed Cost $1.FURNACE and FLARE FURNACE EFFICIENCY IMPROVEMENTS • NOx REDUCTION • FLARE GAS RECOVERY • EFFICIENCY SEMINARS A DIVISION OF BHP ENGINEERING AND CONSTRUCTION. TX 78408.3 million CITGO Refining Company . CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 13 . Co-Gen Auxiliary Burners Valero Refining .FURNACES Furnace and Flare Engineers have completed many projects to upgrade Heaters and Boilers for LoNOx requirements and improve energy conservation. Electrical One-lines. Instrument Loop drawings. 715 Oak Park Ave Corpus Christi. Tie-ins. air preheater. Electrical One-lines. Instrument Loop drawings.Corpus Christi. and mechanical specifications to retrofit the # 5 Platformer furnace with LoNOx burners. Electrical One-lines. Refinery LoNOx Burners . USA (361) 693-6200 PROJECT PROFILE . construction management and start-up assistance for this project. This project included new fuel gas coalescing filters. P&ID's. scope definition. TX Provided engineering with PFD's.0 million Flint Hills Resources .Burner Installed Cost $1. Tie-ins.

This increased product recovery was achieved while meeting desired product specifications. heater. LP . drums. Major new equipment included a reactor. instrument/electrical and Triconex programming update. Provided initial process simulations and evaluations.Corpus Christi.0 Million Valero Refining . TX Provided a 25% increased flow rate to the Gas Oil Treater Stabilizer Heat with heat integration. complete engineering. The pre-outage construction portion of this project was accomplished in six weeks. SRU Waste Heat Boilers and Superheater . This project converted 4 boilers from natural gas to heavy waste oil fuel firing. construction management and start-up assistance for this project. Gas Oil HDS Unit Revamp . and piping design.0 Million Celanese Chemical Provided project management and complete project design for full discipline Waste Liquid Boiler and 600# Steam Turbo-Generator Set.Corpus Christi. CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 14 . air-cooled exchangers. while the unit outage portion o the effort was accomplished in twenty days. Assisted in construction inspection. Peak workforce for this project was 300 men. trayed vessel. equipment specification and selection.Total Project Cost $8.Total Project Cost $5. TX Provided complete detail process and project engineering including mechanical. shell & tube exchangers. Set .6-Oil System Reactivation Equistar Chemicals. structural. I&E. including mechanical /piping.Total Project Cost $1. Waste Liquid Boiler and Turbo-Gen.6 Million Valero Refining . scope definition. numerous pumps and instrumentation.Corpus Christi. TX Complete detail design for the reactivation of the 6-Oil facilities for the “A” Boilers at the Equistar Corpus Christi Plant. Partial issues of drawings were required to expedite construction. definitive project estimate. This project was performed on a crash basis. improved preheat capabilities and energy conservation.

structural steel drawings and mechanical specifications to retrofit three (3) #1 Crude Unit furnace with added convection sections with steam coils and addition stack high to provide required draft to recover waste heat. Piping isometrics. Electrical One-lines. Furnace Efficiency Improvements .000 Valero Refining –Three Rivers. TX Provided engineering with PFD's. Piping isometrics and mechanical specifications to retrofit the Vacuum Unit furnace with LoNOx burners. P&ID's. Instrument Loop drawings. Tie-ins. CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS 15 .000 Valero Refining –Three Rivers. P&ID's. Instrument Loop drawings. Electrical One-lines. Piping isometrics and mechanical specifications to retrofit the two (2) furnaces in the #1 Reformer Unit with LoNOx burners. Tie-ins. Piping isometrics. P&ID's. Refinery LoNOx Burners . Instrument Loop drawings.Burner Installed Cost $450. Electrical One-lines.Burner Installed Cost $250. Piping isometrics and mechanical specifications to retrofit the HF Alky Unit furnace with LoNOx burners. Tie-ins. Tie-ins. Electrical One-lines. Tie-ins. Instrument Loop drawings.Burner Installed Cost $550.500. Instrument Loop drawings.Refinery LoNOx Burners .Installed Cost $750. Furnace Efficiency Improvements. TX Provided engineering with PFD's. FEA analysis of existing and modified structure. TX Provided engineering with PFD's. Electrical One-lines. P&ID's. structural steel drawings and mechanical specifications to retrofit the #1 Reformer Unit furnace with added convection section with steam coils and addition stack high to provide required draft to recover waste heat. Refinery LoNOx Burners . TX Provided engineering with PFD's. P&ID's. FEA analysis of existing and modified structure.000 Valero Refining –Three Rivers.000 Valero Refining –Three Rivers. TX Provided engineering with PFD's.000 Valero Refining –Three Rivers.Installed Cost $ 2.