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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.
Section Page
INTRODUCTION............................................................................................................. 8
PRINCIPLES OF COMBUSTION.................................................................................... 8
Explosive/Flammability Limits............................................................................... 8
Heats of Combustion .......................................................................................... 10
Low Heating Value - High Heating Value............................................................ 11
Heating Value Calculation .................................................................................. 14
Example Problem 1.................................................................................. 14
Example Problem 2.................................................................................. 16
WORK AID 3: RESOURCES USED TO CALCULATE TUBE WALL THICKNESS .... 114
Work Aid 3A: Procedure to Calculate Tube Wall Thickness ............................ 114
Work Aid 3E: Graphs of Tube Material Elastic and Creep-Rupture Stresses .. 120
Work Aid 3E-4: 5Cr–½Mo Steel, ASTM A 213 T5, A 335 P5, A 200 T5 .......... 123
Work Aid 3E-5: 9Cr – 1Mo Steel, ASTM A 213 T9, A 335 P9, A 200 T9 ......... 124
REFERENCES............................................................................................................ 138
List of Figures
List of Tables
Table 10. Maximum Design Temperatures for Tube Support Materials ....................... 46
Table 13. Criteria For Lining Systems for Sulfur Containing Fuels ............................... 75
Table 16. Recommended Lower Limit on the Minimum Thickness of New Tubes ....... 96
Table 19. Heater Maximum Design Basis (SAES-F-001) and Fouling Factors .......... 137
INTRODUCTION
Furnaces combust fuel to supply heat to the process. The word
furnace and heater will be used interchangeably in this course.
PRINCIPLES OF COMBUSTION
Combustion is the process of burning (oxidation) of a flammable
material in air. The principles of combustion including limits of
flammability and heats of combustion will be reviewed first since
heaters require combustion.
Explosive/Flammability Limits
Gaseous mixtures of flammable materials, such as
hydrocarbons and air, have certain concentration ranges in
which they are combustible. A mixture that is too dilute or too
rich in the flammable material will not ignite. The limits are called
lower explosive limit (LEL) and upper explosive limit (UEL) and
are they measured at ambient temperature and pressure.
Increasing temperature or pressure reduces the LEL and raises
the UEL, widening the range in which flammability can occur.
The limits are different for different substances. Table 1 shows
typical values for LEL and UEL of various refinery components
measured as volume percent hydrocarbon in air.
Control of furnaces (including heaters) involves control of
flammability and combustion to release heat. When starting a
furnace, the furnace conditions must be below the limit of
flammability before flame is introduced into the furnace to avoid
explosions. Operation of furnaces requires maintaining furnace
conditions within the limits of flammability in order to burn fuel.
The limits of flammability of mixtures are calculated by
calculating a volumetric (molar) average flammability limits for
the mixture.
Heats of Combustion
The heating value or heat of combustion is the amount of heat
liberated when an amount of fuel is burned. The heating value
of a fuel gas or a flue gas can be calculated from the chemical
equations given in Table 2 and the composition of the gas. The
heating value is calculated using the equation and the heats of
formation for each chemical species. The heating value of a
mixture is determined by calculating the volumetric (mole)
average heating value of the mixture if the heating values are in
Btu/cf. Use weight average heating values if the heating values
are in Btu/lb.
Note that where no water is formed, the HHV and LHV are the
same. Using the composition of air as 21% O2 and 79% N2, the
above equations can be used to calculate the amount of air
required for 100% combustion by making a molar material
balance.
Example Problem 1
Calculate the lower heating value (LHV) of a refinery gas, which has the following
analysis:
Vol. %
Hydrogen, H2 = 5.1
Methane, CH4 = 86.4
Ethane, C2H6 = 8.3
Propane, C3H8 = 0.2
Total = 100.0
Answer:
Heats of Combustion can also be found in Btu/ft3 in references such as the GPSA
Engineering Databook as shown in Table 4 below.
Example Problem 2
Vol. %
Hydrogen, H2 = 5.1
Methane, CH4 = 86.4
Ethane, C2H6 = 8.3
Propane, C3H8 = 0.2
Total = 100.0
Answer:
3
Mixture LHV is 941 Btu/ft
Radiation
Radiation is a function of temperature to the fourth power as
shown in the following equation:
QR
= ke( Tf ) − ( TS )
4 4
A
TS = Temperature of surface, ºR
Q/A = Heat flux
Convection
The equation for heat transfer inside a tube is shown in the
following:
QC
= hi ( Ts − Tf )
A
Conduction
Conduction of heat through metal is usually not a controlling
factor in heat transfer because metal has good conduction (low
resistance to heat transfer). The equation for conduction is:
QM
= (k / t)( To − Ti )
A
Tm = Tb + ∆ Tf + ∆ Tc + ∆ Tw
1 Do
∆Tf = φm
hi Di − 2tc
Q kc
φm = =
A tc
(∆Tc ) - - - - - conduction
D
∆Tc = φm F o
Di
or
t Do
∆Tc = φm c
k c Di − t c
Q kw
φm = = ( ∆Tw ) - - - - - conduction
A ta
t a Do
∆Tw = φm
k w Di − t a
Example Problem 3
The following example illustrates the calculation of maximum tube metal temperature in
a furnace radiant section.
Reference: Adapted from API RP 530, Section C.5, Sample Calculation.
Given:
Tube Material = CS
Maximum Heat Flux, fm (based on 692oF TMT) Btu/hr-ft2 = 22,210
Solution:
(4.5) ºF = 124
∆Tf ′ = φm
1 Do
hi Di − 2t c
( )
= 22,210
1
[
(201) 4.0 − 2(0) ]
Coke Layer Temperature Difference:
(4.5) ºF = 37
D
( )
∆Tc = φmF o = 22,210 ( 0.0015)
Di (4.0)
Tubewall Temperature Difference:
(0.25) (4.5) ºF = 19
t
∆Tw = φm a
Do
k w Do − ta
(
= 22,210 )
(302) (4.5 − 0.25)
Total Temperature Difference = ∆Tf + ∆Tc + ∆Tw ºF = 180
0.14
Original µ w
hi′ = Original hi
Revised µ w
0.14
( 2.66 )
= ( 86.7)
2
Btu/hr-ft -ºF = 86.7
( 2.66 )
( 645 + 460)
0.5
= ( 388.6) Btu/hr-ft2-ºF = 388.8
( 644 + 460)
Original hi (2014
. ) ºF
∆Tf ′ = Original ∆Tf x = (124)
Re vised hi (2015
. ) = 124
Original k w (302) ºF
∆Tw ′ = Original ∆Tw x = (19)
Re vised k w (302) = 19
FT =
( Tg + 460) − ( Tm + 460)
4 4
=
(1650 + 460) 4 − (700 + 460) 4 = 0.966
( Tg + 460)4 − (Ta + 460)4 (1650 + 460) 4 − ( 582 + 460) 4
Maximum Radiant Heat Flux:
φm = FC FL FT φr
22140
, − 22,210
% Difference in φm: x 100 = - 0.3%
22,210
22140
,
Resulting Difference in Tm: ∆T = 180° x = 179.4° F
22,210
Furnace Radiant
FL
Section Height, ft
Up to 25 1.20
30 1.23
35 1.28
40 1.33
45 1.40
50 1.48
Duty
Plant Unit Furnace Service Type (Design)
MBtu/hr
Ras Tanura
015
Two Stage Crude
F-100 A&B Atmospheric 2 Cell Box 250.7
F-200 A&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 (R-34)
F-101 Reaction Furnace 65.0
F-102 Reaction Furnace 65.0
F-103 Reaction Furnace 65.0
VC = Vertical Cylindrical
Arbor = Box with arbor coil
Charge Heaters
Figure 7 shows Process Flow Diagram (PFD) for Ras Tanura
Refinery Crude Unit 15. This is an example of heating distillation
charge. F-100 is the atmospheric column charge heater and F-
200 is the vacuum column charge heater. Steam is added to the
F-200 charge to increase vaporization and to increase the
velocity in the tubes to minimize residence time. This minimizes
coking in the heater.
Reboilers
The Ras Tanura Naphtha Hydrotreater heater F - 202 listed in
Table 7 is an example of a reboiler application. The heater is
used to reboil (supply heat to the bottom of the column) the
desulfurized product separation column.
Applications
Hot oil heater. Indirect fired water bath heaters (line heaters).
Regeneration gas heaters. Propane and heavier hydrocarbon vaporizers.
Amine and stabilizer reboilers. Hot oil and salt bath heaters.
Glycol and amine reboilers.
Low-pressure steam generators.
Tank heaters
Characteristics
More ancillary equipment and controls. Heat duty usually less than 10 MBtu/hr.
Higher thermal efficiency. Easily skid mounted.
Requires less plot space. Forced or natural draft combustion.
Forced or natural draft combustion. Less likely to have hot spots or tube rupture.
With permission from the Gas Processors Suppliers Association. Source: Engineering Data Book.
MBtu/hr = Million Btu/hr which is usual for heat transfer calculations.
Cylindrical/Cabin
There are two basic types of direct-fired furnaces, cylindrical
and cabin. Within each type there are many different
configurations. The furnaces can have different coil
arrangements: horizontal, vertical, helical, or serpentine. Also,
the furnace can be all-radiant (no convection section) or have a
convection section. Several configurations for the vertical
cylindrical and cabin type furnaces are shown in Figure 8 and
Figure 9.
The all-radiant cylindrical furnace is the simplest and least
expensive. Typically, an all-radiant furnace operates with about
a 60% efficiency and a stack temperature of about 1200ºF.
Adding a convection section to an all-radiant vertical cylindrical
furnace increases the overall furnace efficiency to about 80%
and drops the stack temperature to about 750ºF. Of course, the
convection section significantly increases the furnace cost.
With permission from the Gas Processors Suppliers Association. Source: Engineering Data Book.
Advantages
With permission from the Gas Processors Suppliers Association. Source: Engineering Data Book.
Legend:
1. Access door 7. Convection section 13. Header box 19. Tubesheet
2. Arch 8. Corbel 14. Radiant section 20. Pier
3. Breeching 9. Crossover 15. Shield section 21. Stack/duct
4. Center wall 10. Tubes 16. Observation door 22. Platform
5. Burner 11. Extended surface 17. Tube support
6. Casing 12. Return bend 18. Refractory lining
Source: API Standard 560, Fired Heaters for General Refinery Services,
1st Edition, January 1986. Reprinted courtesy of the American Petroleum Institute.
The radiant tube hangers (supports) are usually at the top and
the tubes are allowed to expand down. The tubes are guided so
that they maintain their position when expanding if the tubes are
30 feet or longer. The return bends (headers) are usually within
the firebox if they are welded u-bends. Plug type headers are
usually in a separate header box.
The convection tubes are usually mounted horizontally above
the radiant section. The convection section is normally shielded
from direct radiation from the firebox by either shield tubes or a
baffle shield. The return bends (headers) are often mounted in
their own header box as shown in Figure 12. The convection
tubes (except for shield tubes) have extended surfaces to
improve the heat transfer. The extended surfaces may look like
those in Figure 13. The convection section crossectional area is
smaller in than that of the radiant section to increase flue gas
velocity and thereby improve heat transfer (also increases flue
gas pressure drop). The number of coils in the convection
section is usually the same as that in the radiant section.
Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition,
January 1986. Reprinted courtesy of the American Petroleum Institute.
Radiant section tube supports are like shelf supports and allow
horizontal expansion of the tubes. Radiant section tube returns
are usually in the firebox if they are welded u-bends. Plug type
headers are usually in a separate header box.
The convection section in a cabin heater is horizontal and
mounted above the radiant section. In a box heater the
convection is also horizontal but it may be above or beside the
radiant section. The convection tubes have extended surfaces
(fins) to improve heat transfer. The convection section is smaller
in crossectional area than the radiant section to increase flue
gas velocity and thereby improve heat transfer (also increases
pressure drop). Sootblowers are installed in the convection
section if oil is fired. The number of coils in the convection
section is usually the same as that in the radiant section.
Convection section tubes supports are like a loose tubesheet.
Radiant Section:
• Walls and arches. The major lining systems used in furnaces
consist of three types of refractory linings:
− Insulating firebrick (IFB).
− Castable refractory.
− Ceramic fiber.
• Floor. Brick and castable linings that are strong enough to
withstand maintenance turnaround traffic and scaffolding.
Convection Section:
• Sidewalls. Insulating firebrick and castable refractory linings.
• Endwalls. Single-layer castable refractory lining is used on
the flue gas side of the end tube supports.
• Header boxes. Single-layer castable refractory or ceramic
fiber lining is used on the inside surface.
Stack:
• Where required, a single-layer castable refractory lining is
used.
Burners:
• Burner blocks are constructed of high-temperature refractory
firebricks or castable refractories.
Refractory Installation
Some details of refractory installation are reviewed in the
following section.
Brick Construction
Tiebacks are used to stabilize the wall and hold it in place. Each
tieback must be designed to permit some horizontal and vertical
movement of the brick wall caused by thermal expansion. In
vertical walls, not all bricks need to be tied back. A common
practice is to tie back half the bricks in every fourth row of
bricks, which is 12.5% of the wall. Other tieback patterns are
also used. API standard 560 requires a minimum of 10% of the
bricks to be tied back (Par. 7.2.1). Typical tieback details are
illustrated in Figure 23.
For refractory brick used as the top layer of the floor in furnaces,
the allowance for thermal expansion should be about 3/32 in./ft
(unless the manufacturer's data indicate that a greater
allowance should be used). Expansion joints should be covered
with refractory bricks to keep debris out.
Castable Refractory
Notes:
1. Figures in Parentheses Indicate Spacing for Arches and Hip Sections.
2. Anchors on a Staggered Pattern, with Tines Located in a Random
Orientation.
Ceramic Fiber
In the backup layers, butt joints can be used, with the blankets
compressed at least 1 in. to allow for shrinkage. Joints in
successive layers should be staggered. This reduces the
possibility of direct heat flow back to the casing.
Corners/edges should be wrapped around to accommodate
fiber shrinkage during service and to ensure a continuous lining.
Typical details are shown Figure 28.
External Insulation
Vapor Barrier
Fuel Fired Lining Facing Back-up
Required (3)
Oil < 0.5% (wt.) sulfur or Brick, Castable
Gas < 0.5% (vol.) H2S Ceramic Fiber Any No
(4)
Brick Block Yes
Oil > 0.5% (wt.) sulfur or
Gas > 0.5% (vol.) H2S (1) Brick(4) Castable No, if t > 3 & ρ > 60(2)
Castable Block Yes
Castable Castable No, if t > 3 & ρ > 75(2)
Ceramic fiber Block Yes
Ceramic fiber Ceramic Yes
fiber
Castable
(ducts & stacks) None No, if t > 3 & ρ > 60(2)
Notes:
1. Total concentration of free alkali, MgO, and iron in the aggregate shall be less
than 10%; facing shall be a mediumweight or heavier castable, and have a
calcium binder.
2. t, is the refractory thickness in inches, and ρ is the installed fired density, lb/ft3.
3. Alternate to vapor barrier could be glass filled polyester coating of inside casing
surface.
4. IFB should be less then 2 wt % CaO. Sulfuric acid can react with CaO and
cause refractory failure.
Table 13. Criteria For Lining Systems for Sulfur Containing Fuels
If a fuel contains less than 0.5 wt% sulfur, the potential for
corrosion is small and no special materials are required.
If the fuel contains more than about 0.5 wt% sulfur, sufficient
SO2 and SO3 are produced that it can easily penetrate any fiber
structure. Provisions should be made in the design of refractory
systems to protect against potential casing corrosion and
insulation damage.
493-F-301 - 4 015-F-100A&B
Furnace
Rheniformer Atmospheric Crude
Design Fuels: Gas Gas 0.1 vol% H2S Fuel Gas – Negative. H2S
Waste Gas – 7.6 - 8.1 vol% H2S
Oil None Fuel oil – 3.9 – 5.5 wt% Sulfur
1 – 45 ppm vanadium
< 5 ppm sodium
Wall Construction: IFB/Block Dual Layer Castable
Casing/Shell
The casing/shell provides structural support for the heater. The
casing/shell of the heater should be air tight up to about 1" water
differential pressure to prevent air leakage into the heater. Air
leakage into the heater decreases the heater efficiency since all
this air must be heated to the stack temperature.
Draft
The pressure at the top of the stack is the same inside and
outside the stack. The pressure at the bottom of a column of
fluid is a function of the density and the height. The pressure at
the bottom of the stack is:
Draft/Stack Height
1 1
SE = 7.61 (H) −
Ta + 460 Tg + 460
Ta = Air temperature, °F
The net draft available at the top of the furnace firebox is the
stack effect minus pressure drop in the stack, damper, ducting,
and convection section as illustrated in Figure 31. The stack
effect is calculated separately for each section because the
average temperature is significantly different. A typical total
pressure drop is about 0.1 – 0.5 in. H2O. A typical draft at the
top or arch of the firebox is about 0.1 – 0.2 in. H2O.
There is also a stack effect over the firebox so that the available
draft at the burners is greater than that at the top of the firebox.
The typical pressure drop across a burner (draft) is 0.2 to 0.5 in.
H2O.
The draft across a burner controls and the area of air flow
controls the airflow into a burner. The area of airflow is adjusted
by the burner air register but this adjustment can also affect the
draft.
Draft Control
(Natural Draft)
Draft is the negative pressure within the furnace. A positive draft
is a pressure below atmospheric. The amount of draft available
in the firebox depends on the pressure drop in the flue gas
system, the pressure drop across the burners and the stack
draft. Draft is controlled by both the stack damper and the
burner air registers. Figure 31, on the next page shows a draft
profile through a natural draft heater.
The minimum draft occurs near the top of the radiant section
and is the point where the heater draft is usually measured. The
top of the radiant section is also called the arch or bridgewall. It
is essential that there be a draft at this point for all operating
conditions. A positive pressure (negative draft) can permit hot
gases to escape through small openings and damage the
furnace structure. When opening an observation door, it is
important to stand to the side out of the way of escaping hot flue
gases in case the heater is under positive pressure. It is also a
good idea to use goggles when using an observation door on a
natural draft furnace.
Air Preheater
The purposes of combustion air heating or air preheating are to
improve combustion of fuels that are difficult, such as steam
cracker tar and vacuum still bottoms; to recover flue gas heat for
efficiency improvement; and to absorb excess low-pressure
steam. Air preheaters can take several forms including tubular
exchangers and rotary regenerative.
33 and Figure
34 have the problem that soot deposited on the heating surface
may catch fire in the presence of air. Fire detection systems are
a requirement when using this type of air preheater in services
that fire liquid fuels.
Figure 33.
Air Preheaters – Elements of a
Rotary Regenerative Air Heater
Figure 34.
Air Preheaters – Diagrammatic
Illustration of Rotary Regenerative Air
Heater (Vertical Shaft Arrangement)
With Gas and Air Counterflow
Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January
1986. Reprinted courtesy of the American Petroleum Institute.
Material Requirements
Radiant tube support materials are chosen for their high
temperature strength and resistance to oxidation. The materials
commonly used are:
Example Problem 4
Answer:
Refer to Work Aid 2 and plot the point 800ºF and 1400 psia
hydrogen partial pressure. The plotted point falls above the
carbon steel line and the 1.25 Cr, 0.5 Mo steel lines. These
materials are not adequate. The point is below the 2.0 Cr, 0.5
Mo steel line. The carbon steel tubes must be replaced with 2.0
Cr, 0.5 Mo steel as a minimum.
Tube/Pipe
Specifications
Minimum Thickness
Tube Outside Diamete
(inches)r Ferritic Steel Tubes Austenitic Steel Tubes
(inches) (inches)
2.375 0.135 0.095
2.875 0.178 0.105
3.50 0.189 0.105
4.00 0.198 0.105
4.50 0.207 0.105
5.563 0.226 0.117
6.625 0.245 0.117
8.625 0.282 0.130
10.75 0.319 0.144
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Design Conditions
Furnace tube design is based on the following design
conditions:.
Elastic design pressure (Pe), psig, is the maximum pressure that
the furnace coil could be exposed to for short periods of time (a
few hours or days). This pressure is usually related to safety
valve settings, maximum pump pressures, etc. This pressure is
higher than the normal operating pressure. This pressure is
used with the Elastic Design Procedure to ensure that the tube
does not burst when at its maximum pressure.
Rupture design pressure (Pr), psig is the normal operating
pressure that the furnace coil is exposed to over long periods of
operation. If the operating pressure changes during an
operating run, the highest operating pressure should be used.
This pressure is used with the Rupture Design Procedure to
prevent failure during the design life of the tube.
In most situations, both elastic and rupture design pressures will
vary through the coil due to the coil pressure drop. For low-
pressure or low-pressure-drop coils, it is common practice to
use a constant elastic or rupture design pressure for the entire
coil. However, in high-pressure, high-pressure-drop, or high-
temperature coils, it may be advantageous to establish different
design pressures for several sections of the coil. This may
permit the use of less expensive tubes than would otherwise be
required.
Tubewall Thickness
Furnace tubes are designed using the mean-diameter equation
for stress in a tube. This equation gives good results for thin-
walled tubes (tubes with a thickness/outside diameter ratio of
less than 0.15). All tubes in Saudi Aramco's furnaces are in this
category.
P Do
S= − 1 (Eqn. 1)
2 t
Pe Do
ts = (Eqn. 2)
2 Se + Pe
tm = ts + CA (Eqn.3)
Stress Rupture
Design
The following equations are used for the design of furnace tubes
using the Rupture Design Basis:
Pr Do
ts = (Eqn.4)
2S r + Pr
tm = t s + f CA (Eqn. 5)
where: ts = Minimum tubewall thickness to meet the
stress conditions, in.
tm = Minimum required tubewall thickness for a
new tube, including corrosion allowances,
in.
Pr = Rupture design pressure, (operating
pressure as discussed above), psig.
Do = Outside diameter of the tube, in.
Sr = Rupture allowable stress, psi. This is a
function of Td, the design tube metal
temperature, and the tube design life. This
stress is obtained from the table in Work Aid
3B or from the graphs in Work Aids 3E-1 to
3E-7.
For Saudi Aramco furnace tubes, Sr is
based on a design tube life of 100,000
hours, using the minimum rupture strength
of the material. (SAES-F-001, Par. 3.1)
CA = Corrosion allowance, as discussed above,
in.
f = Corrosion fraction. This is the fraction of the
design corrosion allowance that must be
added to the stress thickness to obtain the
design tube life of a tube with no corrosion.
This fraction takes credit for the reduction in
stress in a new tube caused by the addition
of a corrosion allowance. At these lower
stresses, rupture tube life is increased. As
the corrosion allowance is used, the
stresses increase. When the entire
corrosion allowance has been used, the
stresses are equal than the rupture design
stress.
Example Problem 5
Pe Do
ts = (Eqn. 2)
2 Se + Pe
(550) (6.625)
= 0.1323 in.
2 (13,500) + 550
Since the tube has only 0.258 in. thickness and 0.2623 in. is
required, the tube should be replaced.
Example Problem 6
The following sample problem illustrates the use of Work Aid 3A to calculate the
required thickness of furnace tubes.
Reference: API RP 530, Section 4.3 Sample Problem
Material Type 347 ASTM Spec A213
Use Work Aid 3B or 3E-7.
Given:
Outside diameter Do = 6.625 in.
Corrosion fraction:
n = 4.4
B = 0.264
f = 0.558
tm (rupture) = ts(rupture) + f CA [0.558 (0.125)] tmr = 0.544 in.
0.474 + 0.070
Example Problem 7
The following example illustrates the procedure for estimating the remaining life of a
furnace tube.
Given: Material: Type 347 Stainless Steel
Outside diameter: 6.625 in.
Initial minimum thickness: 0.268 in.
Approximate Operating History
Step 1. Calculate stress at beginning and end of period using equation 1. Calculate
average stress.
For Period 1:
P Do
S= − 1 (Eqn. 1) from pg. 92
2 t
575 6.625
= − 1
2 t
Step 2: Use Work Aid 3E-7 and average stress to find minimum and average Larson-
Miller (LM) values
Enter Work Aid 3E-7 with stress of 7045 on left and go to diagonal line
labeled “Minimum rupture strength” and then read LM value of 34.3 at top.
Enter Work Aid 3E-7 with stress of 7045 on left and go to diagonal line
labeled “Average rupture strength” and then read LM value of 33.1 at top.
Step 3: Calculate life at this condition using equation at the top of Work Aid 3E-7 for
both minimum strength and average strength.
Solving:
log Lr = 5.67
Lr = 473,000 hr = 54 yr
Step 4: Calculate life fraction for both minimum and average strength
Step 5: Calculate “Estimated accumulated damage” which equals sum of life fraction.
PART 1: Solution:
Using Eqn. (1), calculate the stress at the beginning and end of each operating period.
Use the average of these stresses with the Larson-Miller parameter to estimate the life
fraction expended in each period.
Time Based on
Average Larson-Miller Values Time Based on
Average
Stress (LM) Minimum Strength
Strength
Operating psi Minimum Average yr Life Fraction yr Life
Period Fraction
PART 2: Is the tube suitable for one additional year of operation at the following
conditions?
Operating pressure = 620 psig
Metal temperature = 1200ºF
Corrosion rate = 0.013 in./yr
Step 4: Calculate rupture time (Lr) from equation at top of Work Aid 3E-7.
PART 2: Solution:
Pe Do (620)(6.625)
t se = = = 0.116 in.
2Se + Pe 2(17,400) + (620)
Conclusion: Based on the estimated operating conditions over the life of the tube, it is
adequate for the proposed operation. Note that these calculations were
based on minimum rupture strengths.
Vol. %
Hydrogen, H2 = 5.1
Methane, CH4 = 86.4
Ethane, C2H6 = 8.3
Propane, C3H8 = 0.2
Total = 100.0
Answer:
Given:
Outside diameter Do = in.
Rupture Pr = psig
Solution:
tse = in.
Rupture Design
tsr = in.
Corrosion fraction:
Rupture exponent (Work Aid 3C and 3E-1 to 3E-7) n =
B = CA/ts(rupture) = ( )/( ) B =
A-213, 271,
A-53 Gr. B A-213 T11 A-213 T22 A-213 TS A-213 T9 312, 316
A-106 Gr. B A-161 T1 A-335 P11 A-335 P22 A-335 PS A-335 P9 Types 304,
Med. Carbon A-335 T1 A-200 T11* A-200 T22* A-200 T5* A-200 T9* 304H
Steel C-1/2 Mo 1 1/4Cr-1/2Mo 2 1/4Cr-1Mo 5Cr-1/2 Mo 9Cr-1 Mo 18Cr-8Ni
Temp. Elastic Creep Elastic Creep Elastic Creep Elastic Creep Elastic Creep Elastic Creep Elastic Creep
ºF(1) Stress Stress Stress Stress Stress Stress Stress Stress Stress Stress Stress Stress Stress Stress
* Elastic stresses for A200 materials are approximately 83% of stresses listed.
Notes:
1. For intermediate temperatures, stresses can be obtained by interpolation. For
higher temperatures, see Work Aids 3E-1 to 3E-7.
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Tube Thickness in Petroleum Refineries, 3rd Edition, September 1988. Reprinted courtesy of the
American Petroleum Institute.
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Work Aid 3E-2: 1¼Cr – ½MO Steel, ASTM A 213 T11, A 335 P11,
A200 T11
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Figure 41. 1¼Cr – ½Mo Steel, ASTM A 213 T11, A 335 P11, A200 T11
Work Aid 3E-3: 2¼CR – 1MO Steel, ASTM A 213 T22, A 335 P22,
A 200 T22
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Figure 42. 2¼Cr - 1Mo Steel, ASTM A 213 T22, A 335 P22, A 200 T22
Work Aid 3E-4: 5CR–½MO Steel, ASTM A 213 T5, A 335 P5, A 200 T5
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Figure 43. 5Cr-½Mo Steel, ASTM A 213 T5, A 335 P5, A 200 T5
Work Aid 3E-5: 9CR – 1MO Steel, ASTM A 213 T9, A 335 P9, A 200 T9
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Figure 44. 9Cr - 1Mo Steel, ASTM A 213 T9, A 335 P9, A 200 T9
Work Aid 3E-6: Types 304 and 304H Stainless Steel, ASTM A 213,
A 271, A 312, A 376
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Figure 45. Types 304 and 304H Stainless Steel, ASTM A 213, A 271, A312, A 376
Work Aid 3E-7: Types 347 AND 347H Stainless Steel, ASTM A 213,
A 271, A 312, A 376
Source: API Recommended Practice 530, Calculation of Heater Tube Thickness in Petroleum
Refineries, 3rd Edition, September 1988. Reprinted courtesy of the American Petroleum Institute.
Figure 46. Types 347 and 347H Stainless Steel, ASTM A 213, A 271, A 312, A 376
Step 1. Calculate stress at beginning and end of period using equation 1. Calculate
average stress.
For Period 1:
P Do
S= − 1 (Eqn. 1) from pg. 93
2 t
575 6.625
= − 1
2 t
Step 2: Use Work Aid 3E-7 and average stress to find minimum and average
Larson-Miller (LM) values
Enter Work Aid 3E-7 with stress of 7045 on left and go to diagonal line
labeled “Minimum rupture strength” and then read LM value of 34.3 at top.
Enter Work Aid 3E-7 with stress of 7045 on left and go to diagonal line
labeled “Average rupture strength” and then read LM value of 33.1 at top.
Step 3: Calculate life at this condition using equation at the top of Work Aid 3E-7 for
both minimum strength and average strength.
Solving:
log Lr = 5.67
Lr = 473,000 hr = 54 yr
Step 4: Calculate life fraction for both minimum and average strength
Step 5: Calculate “Estimated accumulated damage” which equals sum of life fraction.
PART 1: Solution:
Using Eqn. (1), calculate the stress at the beginning and end of each operating period.
Use the average of these stresses with the Larson-Miller parameter to estimate the life
fraction expended in each period.
Time Based on
Average Larson-Miller Values Time Based on Average
Stress (LM) Minimum Strength Strength
PART 2: Is the tube suitable for one additional year of operation at the following
conditions?
PART 2: Solution:
Pe Do (620)(6.625)
t se = = = 0.116 in.
2Se + Pe 2(17,400) + (620)
Conclusion: Based on the estimated operating conditions over the life of the tube, it is
adequate for the proposed operation. Note that these calculations were
based on minimum rupture strengths.
GLOSSARY
air preheater Heat exchanger that heats the air required for combustion
by exchanging heat with the flue gases leaving the
convection section, or with another fluid of higher
temperature.
breeching Hood that collects flue gas at the convection section exit, for
transmission to the stack or the outlet ductwork.
casing Steel sheathing that encloses the heater box and makes it
essentially airtight.
center wall Refractory wall in the radiant section, which divides it into
two separate cells.
corrosion allowance Corrosion rate times the design life, expressed in inches.
corrosion fraction The fraction of the design corrosion allowance that must be
added to the stress thickness to obtain design tube life of a
tube with no corrosion.
design life Operating time used as a basis for tube design. Design life
is not necessarily the same as the retirement or
replacement life. Expressed in hours.
design metal temperature Tube metal, or skin, temperature used for design. Normally
determined by calculating maximum tube metal temperature
and adding appropriate temperature allowance. Expressed
in ºF.
elastic allowable stress Allowable stress for the elastic range, expressed in psi.
elastic design pressure Maximum pressure that the heater coil will sustain for short
periods of time, expressed in psig.
forced draft Use of a fan to supply combustion air to the burners and to
overcome the pressure drop through the burners.
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.
pass A coil that transports the process fluid from furnace inlet to
outlet. Total process fluid can be transported through the
furnace by one or more parallel passes.
plug-type header Return bend, normally cast, that is provided with one or
more openings for the purpose of inspection, mechanical
cleaning, or draining. A variety of closure devices can be
used.
rupture allowable stress Allowable stress for the creep-rupture range, expressed in
psi.
rupture design pressure Maximum operating pressure that the coil section will
sustain during normal operation, expressed in psig.
stack Cylindrical steel, concrete, or brick shell that carries flue gas
to the atmosphere and provides necessary draft and
description of flue gases.
tube support Metal part that supports the weight of one or more tubes.
Table 19. Heater Maximum Design Basis (SAES-F-001) and Fouling Factors
REFERENCES
SAES-A-005 Safety Instruction Sheets