HINDUSTAN PETROLEUM

CORPORATION LTD
Mumbai Refinery

ENERGY CONSERVATION
HANDBOOK – Fired

ENCON SECTION

TECHNICAL DEPARTMENT
 Energy Conservation Hand Book-2010

INDEX
Sr. No. Subject Page No.

1 Introduction 3

2 Classification of Furnaces 6

3 Furnaces Efficiency Calculations 9

3 Furnace Design Data 11

4 Furnace Tuning 12

5 Factors affecting Furnace Parameters 14

6 Burner Management 16

Industrial Fired Heaters

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 Energy Conservation Hand Book-2010

An industrial furnace or direct fired heater is equipment used to provide heat for a
process. Furnace designs vary as to its function, heating duty, type of fuel and method of
introducing combustion air. However, most process furnaces have some common features.

1. Introduction:
Fuel flows into the burner and is burnt
with air provided from an air blower. There can
be more than one burner in a particular furnace
which can be arranged in cells which heat a
particular set of tubes. The flames heat up the
tubes, which in turn heat the fluid inside in the
first part of the furnace known as the radiant
section or firebox (Fig 1.1).
In this chamber where combustion takes
place, the heat is transferred mainly by radiation
to tubes around the fire in the chamber. The
heating fluid passes through the tubes and is
thus heated to the desired temperature. Fig 1.1 The gases
from the combustion are known as flue gas. After
the flue gas leaves the firebox, most furnace designs include a convection section where more
heat is recovered before venting to the atmosphere through the flue gas stack.

 Radiant Section:
The radiant section is where the tubes receive almost all its heat by radiation from the
flame. In a vertical, cylindrical furnace, the tubes are vertical. Tubes can be vertical or
horizontal, placed along the refractory wall, in the middle, etc., or arranged in cells. Studs are
used to hold the insulation together and on the wall of the furnace. They are placed about 1 ft
(300 mm) apart in this picture of the inside of a furnace. The tubes, shown below, which are
reddish brown from corrosion, are carbon steel tubes and run the height of the radiant section;
The tubes are a distance away from the insulation so radiation can be reflected to the back of
the tubes to maintain a uniform tube wall temperature. Tube guides at the top, middle and
bottom hold the tubes in place.

 Convection section:
The convection section is located above the radiant section where it is cooler to recover
additional heat. Heat transfer takes place by convection here, and the tubes are finned to
increase heat transfer. The first two tube rows in the bottom of the convection section and at
the top of the radiant section is an area of bare tubes (without fins) and are known as the
shield section, so named because they are still exposed to plenty of radiation from the firebox
and they also act to shield the convection section tubes, which are normally of less resistant
material from the high temperatures in the firebox. The area of the radiant section just before
flue gas enters the shield section and into the convection section called the bridge zone.
Crossover is the term used to describe the tube that connects from the convection section
outlet to the radiant section inlet. The crossover piping is normally located outside so that the
temperature can be monitored and the efficiency of the convection section can be calculated.
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The sight glass at the top allows personnel to see the flame shape and pattern from above and
visually inspect if flame impingement is occurring. Flame impingement happens when the
flame touches the tubes and causes small isolated spots of very high temperature.

 Burner
The burner in the vertical, cylindrical furnace as above is located in the floor and fires
upward (Fig 1.2). Some furnaces have side
fired burners, such as in train
locomotives. The burner tile is made of high
temperature refractory and is where the flame
is contained in. Air registers located below
the burner and at the outlet of the air
blower are devices with movable flaps or
vanes that control the shape and pattern
of the flame, whether it spreads out or even
swirls around. Flames should not spread
out too much, as this will cause flame
impingement. Air registers can be classified
as primary, secondary and if Fig 1.2 applicable,
tertiary, depending on when their air is introduced. The primary air register supplies primary
air, which is the first to be introduced in the burner. Secondary air is added to supplement
primary air. Burners may include a pre-mixer to mix the air and fuel for better combustion
before introducing into the burner. Some burners even use steam as premix to preheat the air
and create better mixing of the fuel and heated air. The floor of the furnace is mostly made of a
different material from that of the wall, typically hard cast-able refractory to allow technicians
to walk on its floor during maintenance.
A furnace can be lit by a small pilot flame or in some older models, by hand. Most pilot
flames nowadays are lit by an ignition transformer (much like a car's spark plugs). The pilot
flame in turn lights up the main flame. The pilot flame uses natural gas while the main flame
can use both diesel and natural gas. When using liquid fuels, an atomizer is used; otherwise,
the liquid fuel will simply pour onto the furnace floor and become a hazard. Using a pilot flame
for lighting the furnace increases safety and ease compared to using a manual ignition method
(like a match).
 Soot blower:
Soot blowers are found in the convection section. As this section is above the radiant
section and air movement is slower because of the fins, soot tends to accumulate here. Soot
blowing is normally done when the efficiency of the convection section is decreased. This can
be calculated by looking at the temperature change from the crossover piping and at the
convection section exit. Soot blowers utilize flowing media such as water, air or steam to
remove deposits from the tubes. This is typically done during maintenance with the air blower
turned on. There are several different types of soot blowers used. Wall blowers of the rotary
type are mounted on furnace walls protruding between the convection tubes. The lances are
connected to a steam source with holes drilled into it at intervals along its length. When it is
turned on, it rotates and blows the soot off the tubes and out through the stack.

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 Stack
The flue gas stack is a
cylindrical structure at the top of all the
heat transfer chambers. The
breeching directly below it collects
the flue gas and brings it up high into
the atmosphere where it will not
endanger personnel (Fig 1.3).
The stack damper
contained within works like a butterfly
valve and regulates draft (pressure
difference between air intake and air
exit) in the furnace, which is what
pulls the flue gas through the Fig 1.3
convection section. The stack damper also regulates the heat lost through the stack. As the
damper closes, the amount of heat escaping the furnace through the stack decreases, but the
pressure or draft in the furnace increases which poses risks to those working around it if there
are air leakages in the furnace, the flames can then escape out of the firebox or even explode if
the pressure is too great.

2. Classification of Furnace

 Classification based on furnace draft

Natural Draft:
In this the buoyancy of the hot flue in the stack & furnace provides the suction to pull
combustion air into the furnace (Fig. 2.2 C)

MR Natural Draft Furnaces

Sr. No. Furnace Service

1 LR VPS RCO
(F101)

2 SEU I Extract/Raffinate
(F201/02)

3 SEU II Extract/Raffinate
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(F3201/02)

4 SEU III Extract/Raffinate

(F4201/02)

5 IOH Hydrofiner
(F401)

6 DHDS Raw Diesel & Hydrogen

(71F1)

7 NHT CCR Charge Heater Naphtha & Hydrogen

(102F1001)

8 CCR Charge Heater Naphtha & Hydrogen

(102F2001)

9 CCR No. 1 Inter Heater Naphtha & Hydrogen

(102F2002)

10 CCR No. 2 Inter Heater Naphtha & Hydrogen

(102F2003)

11 CCR No. 3 Inter Heater Naphtha & Hydrogen

(102F2004)

12 NHT ISOM Naphtha & Hydrogen

(103F1001)

13 Prime G+ Naphtha & Hydrogen

(105F1001)

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 buoyancies of the column of
hot flue in the stack and furnace provide the “suction” to pull combustion air into the furnace.
(Fig. 2.2 B)

MR Forced Draft Furnaces

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Sr. No. Furnace Service

1 NSU Naphtha
(101F1001)

Balanced/Induced Draft:
Use of a fan on the flue gas side of the furnace, to provide the additional draft required over
that supplied by the stack to draw the flue gas through the convection section. (Fig. 2.2 A)

MR Balance Draft Furnaces

Sr. No. Furnace Service

1 FR APS Crude
(11F1/11F2)

2 FR VPS RCO
(12F1)

3 FRE APS Crude

(31F1)

4 FRE VPS RCO

(32F1)

5 FCCU CAT Feed

(14F1X)

6 PDA Asphalt Heater

(F4101)

 Classification based on furnace size

Vertical-Cylindrical furnace (Fig. 2.1 A)
These furnaces are probably most commonly used furnaces with heat duties up to about
150 MM BTU/hr. 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. These furnaces are
designed either with or without a convection section. Most of vertical cylindrical furnace is
being provided with a horizontal convection section located above radiant section. In small sizes
under about 120 MM BTU/hr, these furnace are more economical& in sizes larger than about

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150 MMBTU/hr the vertical tube box furnaces is more economical . Also these furnaces require
less plot area.

Horizontal tube cabin furnace (Fig. 2.1 B)

These furnaces have been built with the heat duties up to about 500 MM BTU/hr. The
radiant section includes horizontal tube surface on the side walls &the slopping 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 & are fired vertically. This firing is normal
to both radiant &convection tubes.
Horizontal tube box furnace (Fig. 2.1 C)
The radiant & convection section
are separated by a wall called bridge
wall. Larger box furnaces have two radiant
sections with a common
convection section located between
them. Burners are usually located in the
end walls & fired towards the bridge
wall. The furnace tubes all lie Fig 2.1
horizontally &firing is normal to the
tubes.

Fig 2.2

3. Furnace Efficiency calculation

 There are two methods to calculate furnace efficiency.

Direct method
 Heat absorbed by Process Fluid = m * cp * (COT-CIT)
 Heat Fired by Fuel = m FO/FG * Calorific value of FO/FG

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 Efficiency =
( HeatHeatAbsorbed
Fired )
∗100
Indirect Method
 Heat Release by FG mmkcal/hr = m FG * LHV FG
 Heat Release by FO mmkcal/hr = m FO * LHV FO
 Total Heat Release mmkcal/hr = Heat Release by FG + Heat Release by FO
 Total CO2 kg moles =

C / H FO∗m FO C /H FG∗m FG ❑
+
C / H FO +1 C/ H FG+1
(C/ H FO∗3)∗1000
 Theoretical air FO kgmoles =
(C / H FO +1 )∗12∗0.21
(C /H FG∗3)∗1000
 Theoretical air FG kgmoles =
(C / H FG +1 )∗12∗0.21
 Total theoretical air Kgmoles =(Theoretical air FO kgmoles * m FO )
+ (Theoretical air FG kgmoles * m FG)
 Total H2O kgmoles =

m FO m FG❑
( +
C/ H FO+1 C / H FG +1
∗1000/12 )
 Total N2 kgmole = (Total theoretical air ) * 0.79
 Total flue gas O2 kgmole = O2%*

( Total CO 2+Total H 2 O+ Total N 2

100−O 2 /0.21
 Actual air kgmole
 Total Air Nm3/hr
 Total air T/D
 Total air m3/hr
)
= Total theoretical air + (Total O2 kgmole /0.21)
= Actual air kgmole *(22.4/24)
= Actual air kgmole * 29/1000
= Total Air Nm3/hr *((273+35)/273)

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 Excess air % =

( Actual airTheoretical
kgmole−Theoretical air kgmole
air kgmole )
 H2O kgmole due to humidity = Actual air kgmole * 0.022 *29/18
 Total flue gas kgmoles =(Total CO2 + Total H2O + Total N2
+ Total O2/0.21 + Atm steam*1000/18
+ H2O kgmole due to humidity)
 Flue Gas avg molecular weight =
Total H

(Total CO 2∗44 +(¿ humidity )∗18+ ¿ Total N 2∗28+Total

( ¿¿ To
 Total Flue Gas Nm3/hr = Total flue gas kgmoles * 22.4/24
 Total Flue Gas T/D =

( Total flue gas kgmoles∗Flue

1000
Gas avg molwt
)
 Total Flue Gas m3/hr = Total Flue Gas Nm3/hr *((273+ T)/273)
 Flue Gas Heat loss mmkcal/hr =

Total Flue GasT /D∗1000∗0.245∗( ¿ – Am

 % Heat loss to flue gas

( =
24∗106

Flue Gas Heat loss MMKcal/hr

( Total Heat Release MMKcal/hr )
*100

 Setting loss mmkcal/hr = (Radiation loss * Total heat release)/100

 Actual furnace efficiency = 100 – (% Heat loss to flue gas) – (%Setting loss) – (%
loss due to APH) – (%Setting loss) – (% loss due to APH)

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4. Furnace Design Data

 FR/FRE Block

Temperature profile O2 Profile &

Efficiency

Furnace CIT °C COT °C BWT °C HAT °C Stack °C O2 % η %

11F1 262 361 830 333 160 2.5-3.0 90.7

11F2 262 361 830 333 160 2.5-3.0 90.7

12F1 340 416 800 388 221 2.5-3.0 87.7

31F1 270 355 940 354 160 2.5-3.0 90.7

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32F1 318 410 951 230 160 2.5-3.0 90.7

14F1X 270 390 694 280 165 2.5-3.0 90.0

 LR/LRE Block

Temperature profile O2 Profile &

Efficiency

Furnace CIT °C COT °C BWT °C HAT °C Stack °C O2 η

% %

F101 238 410 993 NA 329 4.5-5.0 83.5

225 327 858 4.5-5.0

F201/02 NA 330 84.0

210 357 782 4.5-5.0

225 327 841 4.5-5.0

F3201/02 NA 330 84.0

210 357 782 4.5-5.0

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225 327 858 4.5-5.0

F4201/02 NA 330 84.0

210 357 782 4.5-5.0

F4101 81 260 550 204 180 4.5-5.0 90.0

 GFEC Block

Temperature profile O2 Profile &

Efficiency

Furnace CIT °C COT °C BWT HAT Stack O2 η

°C °C °C % %

101F1001 147.1 151.1 766 154 200 2.5-3.0 89.8

102F1001 279 341 765 NA 685 4.5-5.0 64.3

102F2001/02 464/437 549/549 758 NA 206 4.5-5.0 89.3

102F2003/04 481/498 549/549 760 NA 215 4.5-5.0 92.1

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103F1001 258 310 630 NA 325 4.5-5.0 82.5

105F1001 285 345 730 NA 335 4.5-5.0 82.4

5. Furnaces Tuning

 Natural Draft Heater Tuning Guide

Check flame characteristic

 Open all peepholes then check flame pattern.
 If there is bad flame then increase air flow.
 Then see whether flame is OK if it is No then shut down burner, clean burner and then light
up.
 Recheck flame pattern.
 If it is Good flame a)Check arch draft b)Check Excess O2
 Close all peep holes.

Check arch draft

 Read arch draft
 If ok then Arch draft = 0.1’wc
 If high then close stack damper check flame characteristic & check Excess O2.
 If low then open stack damper, then check flame characteristic & check excess O2.

Excess O2
 Read Excess O2.
 If Ok then Excess O2=3% & Heater is tuned.
 If low then open burner registers. Check flame characteristic.
 Then check Arch Draft & then Excess O2 =3%.
 If excess O2 is high close burner air registers.
 Check flame characteristic & then Check Arch draft then Excess O2 = 3%.
 Heater is tuned

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 Balanced Draft Heater Tuning Guide

Check flame characteristic

 Open all peepholes then check flame pattern.
 If there is bad flame then increase air flow.
 Then see whether flame is OK if it is No then shut down burner, clean burner and then light
up.
 Recheck flame pattern.
 If it is Good flame a)Check arch draft b)Check Excess O 2
 Close all peep holes.

Check arch draft

 Read arch draft
 If ok then Arch draft = 0.1’wc
 If high then close ID fan damper & check flame characteristic & check Excess O 2.
 If low then open stack open ID fan damper & then check flame characteristic & check excess
O2.

Excess O2
 Read Excess O2
 If Ok then Excess O2=3% & Heater is tuned
 If low then open FD fan damper. Check flame characteristic
 Then check Arch Draft & then Excess O2 =3%.
 If excess O2 is high close the FD fan damper.
 Check flame characteristic & then Check Arch draft then Excess O2 = 3%.
 Heater is tuned

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6. Factors affecting Furnace Parameters

 Excess Air (high/low):

Effect: Excess air in the heater will result in poor heater efficiency. With a constant stack temp
of 530oC the heat loss @20% excess air is 3 times of that at 10% excess air.
Measures taken: Adjust dampers, Adjust air registers maintain optimum air/fuel ratio.
Results: 10% drop in excess air amounts to 1% saving on fuel fired.

 Deposits on convection tubes:

Effect: Less Heat transfer
Measures taken: Regular soot blowing
Results: 3 mm spot deposit increase fuel consumption by 2.5%

 Open peep hole doors:

Measures taken: Close peep hole doors when not in use.
Results: Unwanted air entry reduces excess air

 Low oil temp to burners:-

Measures taken: Maintain correct oil temperature.
Results: Normally in the range of 110-120 C ensures proper atomisation and complete
combustion of oil.

 Oil Dripping from burners:-

Measures taken: attend leaks at joints and clean burners.
Results: Ensures good housekeeping and saves oil.

 Wet steam and condensate to burners:-

Measures taken: Check steam superheat.
Results: Results in steady flame and proper fuel atomization.

 Damage to burner tips & plugs

Measure taken: Use proper wire brush & maintain correct alignment during installation.
Results: Well maintained tips will ensure good combustion and flame pattern.

 Liquid Condensate To Gas Burner:

Measure taken: Proper draining of condensate in fuel gas line.
Results: Avoids backfires, ensures steady pattern and safe conditions in furnace.

 Incomplete Combustion In Furnace Box

Ways to be ensured: Maintain proper flame pattern, Maintain correct excess air, Maintain
proper atomisation for oil Burners.
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Results: Results in high efficiency & reduced fuel consumption.

 Air Preheater Bypass Open

Ways to be ensured: Keep always closed.
Results: Reduces heat loss. Entry 22C drop in air preheat temperature amounts to 1% loss in
efficiency.

 Non Uniform Firing In Furnace

Ways to be ensured: Adjust burners for uniform firing.
Results: Avoids localized heating resulting in faster coking in tubes and / or failure of tubes.

7. Burner Management

The following practice is being followed in our refinery with regard to burner management
system

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 Energy Conservation Hand Book-2010

Daily Weekly Monthly Semi Annually

annually
Check Check fuel and Inspect Check oil Clean
combustion air linkage burner preheater fireside
visually surface

Check Check indicating Analyze Inspect Clean

general lights ad alarms combustion refractory breaching
burner
operation

Check operating Inspect for Clean oil Check oil

and limit fuel gas pump storage
controls leaks strainer & tanks.
filter

Check safety and Inspect for Reset Check fluid

interlock hot spots combustion level and
controls hydraulic
valves

Check for leaks, Check Remove

noise,vibration combustion and
unusual air supply recondition
conditions safety
Check valves.
operations of all
motors.

Check general Check all

burner operation filter
elements

Check flame Check fuel

scanner system.
assembly.

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