heaters
TRANSCRIPT
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.1
PRESENTATION ON FIRED HEATERS OF 1265 AROMATICS
PROJECT, SHUAIBA KUWAIT Prepared by Raju Salvi (QC Inspector – Mechanical Equipments)
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.2
FIRED HEATER OR FURNACE
Device for transferring heat from the combustion of a hydrocarbon
fuel into a process stream or streams requiring heating or
vaporization
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.3
General Arrangement & Layout Of Heater
Convection
General Arrangement
Layout
Construction phases
• Radiant refractory on ground• Foundation check• Radiant section with coils• Convection section with coils• External crossovers• Hydrostatic test• Soot blower • Stack• FD & ID fan • Air preheater • Steam coil air preheater• Burners• Air duct• Flue gas duct• Platforms• Insulation• Fireproofing• Painting
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.4
Types of Heaters
1. NATURAL DRAFT HEATER
2. BALANCED DRAFT HEATER
• Radiant • Convection (optional) • Stack
• Radiant • Convection • Stack• Forced Draft Fan• Air duct• Induced Draft Fan
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.5
Types of Heaters
4. INDUCED DRAFT HEATER
3. FORCED DRAFT HEATER
• Radiant • Convection • Stack• Forced Draft Fan
• Radiant • Convection • Stack• Induced Draft Fan
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.6
Natural Draft Heaters At Aromatics
KAR-F-21005 CHARGE HEATER
KAR-F-18064 HEAVY AROMATICS COLUMN
REBOILER
KAR-F-24007CHARGE HEATER
Cylindrical Heater With Vertical Coil
Box Heater With Arbor Coil
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.7
Balanced Draft Heaters At Aromatics
KAR-F-18034 XYLENE COLUMN REBOILER
KAR-F-18035 XYLENE COLUMN REBOILER
KAR-F-21034 DEHEPTANIZER REBOILER
Twin Cylindrical Heater
With Vertical Coil
Cylindrical Heater With Vertical Coil
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.8
Typical Radiant Coil Arrangement in Heaters
KAR-F-21005 - Charge Heater
KAR-F-18034 / 18035 - Xylene Column Reboiler
KAR-F-21034 - Dehepatnizer
KAR-F-18064 - Heavy Aromatics Column Reboiler
KAR-F-24007 - Charge Heater
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.9
Typical Radiant Coil Arrangement in Heaters
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.10
Typical Burner Arrangements In Heaters
HEATERS OF AROMATICS PROJECT
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.11
Reference Procedural documents• ITP
• Radiant section erection instructions • Erection instructions APH etc• Corrosion inhibitor application • Refractory Application Procedure• Applicable WPS PQRs NDE PWHT• API 560 • ASME B31.3
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.12
Refractory Of Radiant Modules VARIOUS TEMPERATURE CONTROLS Metal < 32°C Storage < 25°C Water 5 - 32°C Dry mix < 32°C Wet mix < 25°C
CURING & DRYING Water soaked gunny bags to be kept on
refractory lining followed by sprinkling of water at every ½ an hour time interval or whenever the refractory surface can be felt warm / hot by keeping palm on it
Curing period – 24 hours Natural air drying for next 48 hours Refractory lined panels can be shifted
after 72 hours of refractory application WOODEN FORM WORK Horizontal -1.5 x 1.5 m max (Area
<3 m2) Vertical -1.5 x .5 m H Application of grease HUMIDIFYING METHODS
(Humidifying 1st layer prior to starting 2nd layer)
Sprinkling water Kaoseal Plastic sheet
POURING & TROWELLING Thickness to be built up In single
layer Finishing by wood & not by trowel
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.13
Refractory Of Radiant Modules CRACKS CRITERIA
> 3 mm to be repaired > 1.5 mm spaced at < 300 mm to be repaired > 1.5 mm & < 3 mm, vendor’s decision considering various factors: General quality of lining Zone & length of crack Conditions under which cracks 1st became apparent < 1.5 unsticking out of lining from
casing to be repaired
HAMMER TEST CRITERIA
Hammer test on curing completion Weight of hammer – 450 gms / 1
pound 610 x 610 mm grid area for arch 920 x 920 mm grid area for walls Hollow areas of 150 x 150 mm to be
repaired
REPAIR CRITERIA
Stripping repair area down to casing Edge of stripped area like dovetail profile Smaller dimension of dovetail profile on lining surface
side Vibration apparatus not to be used Minimum area 300 x 300 mm to be removed for
repair work Minimum 3 anchors to be exposed
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.14
Construction Phase
Sample Size in mm100 x 100 x
100 100 x 100 x 100250 x 100 x
100
Mixing Water
%
§ Apparent Density
± 15 %Kg / mc
§ Compressive Strength
(- 20 %)N / mm2
Linear
Shrinkage mm
Refractory PC 105 8 7 - 9 3 7 0 8 1 . 5 - 0 . 3%
Refractory PC 124 I 3 5 – 3 9 9 8 0 3 . 5 - 0 . 2 5%
Preinstallation Test Of Insulating Castable Refractory:
Samples preferably to be casted in metal case
SERVICE TEMPERATURE OF REFRACTORY MATERIAL : 1100°C
§ Samples are tested after drying in oven at 110°C
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.15
Refractory Of Radiant Modules
Surface Preparation
Anchor orientation & tectyl application
Inspection ActivitiesSurface free from oil grease & mill scales.
Inspection Activities• Anchor type • Anchor material SS 304 / 310 (Color coding to avoid intermixing)• Anchor dimensions & orientation• Anchor tightness• Temperature 10 - 32°C• DFT / WFT – 250 / 100
Radiant floor panel
Radiant module 2
Problems faced• Surface found rusting at inspection time • KN & TCM mutually agreed for inspection as & when it is ready against witness point as per ITP
Problems faced• Shop welded nuts breaking on anchor tightness• Re-welding nuts • 250 micron DFT not achievable with one coat• TCM advised 100 WFT
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.16
Refractory Of Radiant Modules
Radiant module 2 & 3
Radiant module 4
Problems faced
• Even though all the three methods of humidifying refractory used, still cracks observed in the second layer of refractory application
• It was summer season so water in the second layer of refractory was getting evaporated faster as well as traveling into 1st layer leading to cracks
• Winter season arrived so cracks were under control as 1st layer of refractory was humidified by sprinkling of water
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.17
After application of refractory layers
Progressive sampling testingof refractory per 20 tonnes
Radiant module 2 with single layer refractoryPC 105
Radiant module 2 with double layer refractoryPC 105 & PC 124 I
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.18
REFRACTORY DATAHEATER ITEM
THK mm PC 105
PC 124 I
PC 105
PC 124 I
KAR-F-18034 A
M-I 75 75 1.55 2.3
M-II 75 75 10.235 14.98
M-III 75 75 10.33 14.95
M-IV 75 75 0.75 2.175
ROOF 75 125 3.45 7.78
CON BRID 75 125 2.78 6.56
FLOOR 200 7.95
Tons 29.095 56.695
HEATER ITEMTHK mm PC
105PC
124 IPC 105
PC 124 I
KAR-F-18034 B
M-I 75 75 1.52 2.35
M-II 75 75 10.36 14.88
M-III 75 75 10.54 14.98
M-IV 75 75 0.745 2.405
ROOF 75 125 3.48 7.825
FLOOR 200 7.95
Tons 26.645 50.39
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.19
REFRACTORY DATAHEATER ITEM
THK mm PC 105
PC 124 I
PC 105
PC 124 I
KAR-F-21034
M-I 75 75 2.85
M-II 75 75 2 26.695
M-III 75 75 13.36 25.32
M-IV 75 75 13.45 12
ROOF 110 90 8.52 10
FLOOR 75 125 4.72 8.395
Tons 42.05 85.26
HEATER ITEM
THK mm PC 105
PC 124 I
PC 105
PC 124 I
KAR-F-21005
M-I SW 75 75 1.78 2.405
M-I EW 125 75 0.77 0.93
M-II SW 75 75 11.2 15.965
M-II EW 125 75 4.455 6.43
M-III SW 75 75 14.45 20.88
M-III EW 125 75 5.8 6.72
ROOF 125 75 9.82 8.67
FLOOR 160 75 5.9 4
Tons 54.175 66
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.20
REFRACTORY DATA
HEATER ITEMTHK mm PC
105PC
124 I
PC 105
PC 124 I
KAR-F-24007 FLOOR 120 75 1.04 1
KAR-F-18064 FLOOR 215 3.35
Refractory PC 105
209 TONS
Refractory PC 124 I
367.925 TONS
TOTAL CONSUMPTION
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.21
Radiant Module 1& Floor
Radiant Module 1 – 4 nos.
Radiant Floor Panels & Module 2
Inspection ActivitiesFoundation check, orientation, elevation, leveling, verticality, joint fit up, bolting
•Inspection ActivitiesOrientation, elevation, floor panel to panel joint fit up, Weld visual of: Gusset plates Floor panel to panel joints
Problem faced• Gusset plates of floor support columns mismatching
• Removed & re-welded gusset plates
Problem faced• Base plate’s holes mismatching
• Holes enlarged by machining • Joint inspection at the time of pouring concrete
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.22
Radiant Module 2 & 3
Radiant Module 2 – 10 nos.Inspection Activities
Orientation, elevation, leveling, verticality, joint fit up, boltingWeld visual of inside seal welding of bolted joints including module 1
Radiant Module 3 – 10 nos.
Problem faced• Gap of 5 to 20 mm observed in the joint fit up • Shim provided• Coil support holes not as per drawing• Drilled new holes with additional stiffening plates
Splice joint
Interlocking arrangement to be considered while erecting radiant
panels
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.23
Splice Joints Of Radiant M 1, 2 & 3
Inspection Activities
Refractory of vertical & horizontal field splice bolted joints of radiant module 1 2 3
• Surface preparation
• Anchor fixing & orientation
• Tectyl application DFT
• Single layer refractory
• Visual inspection & hammer test
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.24
Radiant Coils
ASTM A297 Gr HK to ASTM Gr 304Jump overs to be welded at site
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.25
Radiant Coils
Radiant coils – 4 passes
Inspection Activities• Orientation • Elevation & leveling • Verticality • Freeness in tube guides, resting on • Coils resting on supports without any gap• Fit up, weld visual, RT – 100%• Weld visual of bar & pin• Weld visual of socket & tube guide• External coil supports bolting & weld visual Problem faced• Gap of maximum 25+ mm observed between bottom of return bend elbow of coil & coil support top
• Coil shop weld joints were cut & length reduced of coil to rest properly on coil support
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.26
Radiant Module 4
• Orientation
• Elevation & leveling
• Joint fit up & bolting
• Weld visual of inside seal welding of bolted joints
Inspection Activities
Problem faced• Holes mismatching between M3 & M4 • Preassembly of M4 carried out to assess: a) Field splice joint’s b) Correct pitch of holes
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.27
Splice Joints Of Radiant M 4 Inspection Activities
Refractory of vertical & horizontal field splice bolted joints of radiant module 4
• Surface preparation
• Anchor fixing & orientation
• Tectyl application DFT
• Single layer refractory
• Visual inspection & hammer test
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.28
Convection section
Convection Bottom Module (54 tons) Convection Middle Module (89.5 tons)
Convection Top Module (63 tons)
Inspection activities
• Orientation
• Elevation & leveling
• Verticality
• Joint fit up & bolting
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.29
Convection coils
Jump over to be installed & welded at site after removal of convection header boxes
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.30
External Crossovers
Inspection Activities For Convection Coils & External CrossoversLeveling, fit up, weld visual, RT,
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.31
External Crossover Supports
Inspection Activities:• Gap between guide & shoe• Weld visual of support structure
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.32
QUANTITY OF FIELD WELD COIL JOINTS HEATER COIL MATERIAL SPECIFICATION RADIANT CONVECTION CROSSOVER
Size(OD x Thk) Inch X mm Qty
Size(OD x Thk) Inch X mm Qty
Size(OD x Thk) Inch X mm Qty
18034 A ASTM 106 Gr B 8 x 8.18 56 6 x 7.11 48 6 x 7.11 27
8 x 8.18 4
18034 B ASTM 106 Gr B 8 x 8.18 56 6 x 7.11 48 6 x 7.11 25
8 x 8.18 4
18035 A ASTM 106 Gr B 8 x 8.18 56 6 x 7.11 48 6 x 7.11 27
8 x 8.18 4
18035 B ASTM 106 Gr B 8 x 8.18 56 6 x 7.11 48 6 x 7.11 25
8 x 8.18 4
18064 ASTM 106 Gr B 5 x 6.55 12
21034 ASTM 106 Gr B 8 x 8.18 36 6 x 7.11 18 6 x 7.11 36
21005 ASTM 106 Gr B 5 x 6.55 24
SA 335 Gr P11 TO P22 4 x 6.02 120
SA 335 Gr P11 42 x 16 2
24007 ASTM A 335 Gr P9 6 x 10.97 2
8 x 12.7 3
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.33
DISSIMILAR WELDINGSERIAL HEATER MATERIAL 1 MATERIAL 2
1 KAR-F-18034 A / BKAR-F-18035 A / B
KAR-F-21034
ASTM A 106 Gr B SS TP 304 / 310 / 316
2 KAR-F-18034 A / BKAR-F-18035 A / B
ASTM A 297 Gr HK ASTM A 182 Gr 304
3 KAR-F-24007 ASTM A 335 Gr P9 SS TP 316 L
KAR-F-18034 A / BKAR-F-18035 A / B
KAR-F-21034
ASTM A 297 Gr HK ASTM A 297 Gr HK
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.34
Hydrostatic Test Schematic Sketch
Test Pack Activities• Test pack documentation• Approval of test pack• Hydrostatic test
Design Pressure / Test Pressure (Kg/cm2)KAR-F-18034 A / B, KAR-F-18035 A / B - 16 / 31.8KAR-F-21034, KAR-F-21005 - 17 / 33.8 KAR-F-18064 - 10.5 / 20.9KAR-F-24007 - 40 / 79.1
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.35
Floor Refractory & BurnersInspection Activities• Surface preparation • DFT of tectyl • Visual inspection
• Hammer test
Floor of KAR-F-18034 / 35 Floor of KAR-F-24007
HEATER PC 105 PC 124 I FIRE BRICK
KAR - F -18034 / 35
0 200 65
KAR - F -18064
0 215 65
KAR - F -21005
160 75 65
KAR - F -21034
75 125 65
KAR - F -24007
100 75 65
Detail of refractory thickness used in floorGA of floor refractory
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.36
Stack
Stack Support Structure
Stack Module 1 2 3 (63, 15, 23 tons)
Stack Module 4 5 & Off take duct (24.5 tons)
Inspection Activities
Orientation, elevation, leveling, verticality Joint fit up & bolting
Problem faced• Stack refractory damaged during transportation
• Repair identified & repaired
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.37
Auxiliaries
Soot Blowers
Forced Draft Fan
APH
Induced Draft Fan, APH, SAPH
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.38
Air Duct (FD Fan To Plenum)Bypass air
Plan View
Elevation
71 0C
227
0 C
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.39
Air Duct (Plenum To Burners)
Plan View
Elevation
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.40
Flue Gas Duct
Stack to APH
ID F
an t
o St
ack
Plan
Elevation
Elevation
APH to ID Fan
318 0C
179 0C
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.41
Flue
Gas
Duc
tID
Fan
to
Stac
k
Flue
Gas
Duc
tSt
ack
to A
PH
Flue Gas Duct APH to ID Fan
Stack
ID Fan
APH
Flue Gas Duct
Air Duct
APH Bypass
FD Fan
Assembled Heater
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.42
Other Jobs Insulation From steam coil air preheater upto
burner duct including air heater bypass duct
Fireproofing Main radiant structure columns & Radiant floor structure columns Painting
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.43
PROCESS FLOW DIAGRAMS
KAR-F-18034 / 18035
KAR-F-24007
AWI 106 Att. 8 Rev. 1 22 Sep. 2007
Date/ Rev.44
PROCESS FLOW DIAGRAMS
KAR-F-18064
KAR-F-21005 &
KAR-F-21034