Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Furnaces - Equipment Description

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 Aramcos
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.

Chapter : Vessels
File Reference: MEX10505

For additional information on this subject, contact

J.H. Thomas on 875-2230

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Furnaces - Equipment Description

MODULE COMPONENT

PAGE

FURNACE CHARACTERISTICS .......................................................................... 1

Types and Terminology................................................................................ 1
Burner Arrangements........................................................................ 6
Sulfur Furnace .................................................................................. 7
Furnaces in Use in Saudi Aramco..................................................... 9
Major Furnace Components ....................................................................... 10
DOCUMENTS USED BY SAUDI ARAMCO...................................................... 14
Standards and Codes .................................................................................. 14
AES-F-001 Process Fired Heaters .................................................. 14
AES-A-005 Safety Instruction Sheets............................................. 14
Fired Heater Data Sheets ............................................................................ 15
Saudi Aramco Equipment Files.................................................................. 15
Plant Record Books ........................................................................ 15
Drawing Files.................................................................................. 15
Inspection Record Books ................................................................ 15
WORK AID 1 ........................................................................................................ 16
REFERENCES....................................................................................................... 17
GLOSSARY .......................................................................................................... 18

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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.
Types and Terminology
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).

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Furnaces - Equipment Description

TYPICAL FURNACE TYPES

Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.

FIGURE 1

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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.
SAUDI ARAMCO VERTICAL CYLINDRICAL FURNACES

Stack
Flue Gas Crossover
Convection
Section
Coils

F-102

F-101
Inspection

Damper
Control

Doors

Radiant
Section

Burner

Draft
Gauge

Snuffing
Steam
Header

FIGURE 2

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VERTICAL CYLINDRICAL FURNACE - INTERNAL VIEW

Draft Gauge

Stack
Stack
Temperature
Indicator

Damper
Draft Gauge

Header Box

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

FIGURE 3

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Most vertical cylindrical furnaces have a horizontal convection section located above the
radiant section. Flue gases flow upwards through the convection bank and then to the stack.
Some vertical cylindrical furnaces do not have convection sections. These all-radiant
furnaces are very inefficient and usually are used only for very small furnaces or when the
furnace is operated very infrequently.
Box type furnaces are used for larger duties. In box furnaces with horizontal radiant tubes,
the tubes are located on the radiant section sidewalls and roof. The convection section, also
containing horizontal tubes, extends over the entire length of the radiant section. Larger box
furnaces can have two radiant boxes with one common convection section, as shown in
Figure 1f. Cabin furnaces are very similar to box furnaces. An internal view of a cabin
furnace is shown in Figure 4.
CABIN FURNACE - INTERNAL VIEW
Stack

Draft Gauges

Breeching

Tube Supports

Damper
Stack Temperature
Indicator

Sootblower
Locations

Header Box

Coil Inlet

Corbelling
Convection
Section
Shield Tubes

Draft Gauge
Radiant
Section

Coil
Outlet
Burners

End View

Side View

FIGURE 4

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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.
TYPICAL BURNER ARRANGEMENTS - ELEVATION VIEW

Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.

FIGURE 5

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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.

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TYPICAL SULFUR FURNACE

20'-0 3/4" Length

7/8" End Plate

4 1/2" Thk. Insulating

Castable
9" Thk. Firebrick
A

Detail 1

Waste
Heat Boiler

1/2" Shell
Reaction Furnace

Elevation
Refractory Anchor
Refractory

(Waste Heat
Boiler)

Air Inlet

Shell

Reaction
Furnace
Tubes
Tube Sheet

Detail 1

Acid Gas Inlet

Section A-A

FIGURE 6

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Furnaces in Use in Saudi Aramco

A partial list of the furnaces in Saudi Aramco plants is contained in Figure 7.
SAUDI ARAMCO FURNACES
Plant
/
Unit

Furnace

Service

Duty
(Design)
MBtu/hr

Type

Ras Tanura
015
Two Stage Crude
F-100A&B
Atmospheric
F-200A&B
Vacuum
493
Prefractionator
F-101
Lt Ends Reboiler
F-102
Hvy Ends Reboiler
Naphtha
Hydrotreater
F-201
Hydrotreater Charge
F-202
Desulfurizer Reboiler
Rheniformer
F-301
No. 1 Reactor Heater
F-302
No. 2 Reactor Heater
F-303
No. 3 Reactor Heater
F-304
No. 4 Reactor Heater
Convection Section
Superheater
Steam Generation
Boiler Feedwater
Total for
Rheniformer

2 Cell Box
2 Cell Box

250.7
124.6

VC
VC

45.2
64.4

VC
VC

32.0
27.0

Arbor
Arbor
Arbor
Arbor

84.0
47.0
28.0
14.0

13.0
79.8
17.2
283.0

Uthmaniyah
R34
F-101
F-102
F-103

Reaction Furnace
Reaction Furnace
Reaction Furnace

65.0
65.0
65.0

FIGURE 7
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Major Furnace Components

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.
FURNACE COMPONENTS

21

18

Process In

13
11

12
8
19

15

14

2
9

17

18
13

16

Process Out

22

10

1
5
20

Legend:
1.
2.
3.
4.
5.
6.

Access door
Arch
Breeching
Bridgewall
Burner
Casing

7.
8.
9.
10.
11.
12.

Convection section
Corbel
Crossover
Tubes
Extended surface
Return bend

13.
14.
15.
16.
17.
18.

Header box
Radiant section
Shield section
Observation door
Tube support
Refractory lining

19.
20.
21.
22.

Tubesheet
Pier
Stack/duct
Platform

Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.

FIGURE 8

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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.
TYPES OF EXTENDED SURFACES

a) Serrated Fins

b) Solid Fins

c) Studs

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.

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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.

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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.
AIR PREHEAT SYSTEMS

Source: API Standard 560, Fired Heaters for General Refinery Services , 1st Edition, January 1986. Reprinted
courtesy of the American Petroleum Institute.

FIGURE 10
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.

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DOCUMENTS USED BY SAUDI ARAMCO

Standards and Codes
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.
AES-F-001 Process Fired Heaters
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:

Basic process and mechanical design considerations.

Mechanical design requirements, including the design of tubes and tube supports,
refractory, burners and fans, structure, platforms, stacks and ducts.

Inspection and testing.

Required connections and auxiliary equipment.

This standard also references other documents that cover specific aspects of the furnace
supply and design. The most important are listed below:

API Recommended Practice 530, Calculation of Heater-Tube Thickness in Petroleum

Refineries. This document covers procedures for the design of furnace tubes.
Application of these procedures is covered in MEX 105.06.

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.

AES-A-005 Safety Instruction Sheets

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.

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Fired Heater Data Sheets

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.
Saudi Aramco Equipment Files
Details of the furnace and its auxiliary equipment are contained in several sources.
Plant Record Books
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
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.

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WORK AID 1

USE PHOTOSTAT OF SAUDI ARAMCO 2731-ENG

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REFERENCES
Saudi Aramco Standards
AES-A-005: Safety Instruction Sheets - Form 2731 Fired Heaters
AES-F-001: Process Fired Heaters
AES-J-600: Process Heater Burner Safety System
AES-J-603: Process Heater Burner Safety System
API Publications
Recommended Practice 530: Calculation of Heater-Tube Thickness in Petroleum Refineries
Standard 560: Fired Heaters for General Refinery Services
ASTM Publications
Material Specifications
Other Publications
Chemical Engineering Magazine, Fired Heaters, H. L. Berman, June-September 1978
issues.

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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.

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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.

crossover

The interconnecting piping, either internal or external,

between any two heater coil sections.

damper

A device to regulate flow of gas through a stack or duct

and to control draft in a heater. A typical damper consists
of a flat plate connected to a shaft which can be rotated,
similar to a butterfly valve.

draft

The negative pressure (vacuum) at a given point inside

the heater, usually expressed in inches of water.

excess air

The percentage of air in the heater in excess of the

stoichiometric amount required for combustion.

extended service

Surface added to the outside of bare tubes in the

convection section to provide more heat transfer area.
This may consist of cylindrical studs butt welded to the
tube, or fins continuously wound around and welded to
the tube.

fire box

A term used to describe the structure which surrounds the

radiant coils and into which the burners protrude.

flue gas

A mixture of gaseous products resulting from combustion

of the fuel.

forced draft

Use of a fan to supply combustion air to the burners and

to overcome the pressure drop through the burners.

header

The fitting which connects two tubes in a coil. In

common usage, header refers to cast or forged 180
U-bends (return bends).

header box

The compartment at the end of the convection section

where the headers are located. There is no flue gas flow
in the header box, since it is separated from the inside of
the furnace by an insulated tubesheet. Header boxes are
sometimes also used in the radiant section.

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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.
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.

one-side fired tubes

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.

radiant section

The section of the furnace in which heat is transferred to

the furnace tubes primarily by radiation from hightemperature flue gas.

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setting

The furnace casing, brickwork, refractory, and insulation,

including the tiebacks or anchors.

shield section

The first two tube rows of the convection section. These

tubes shield the balance of the convection section from
direct radiation.

sootblower

A steam lance (usually movable) in the convection

section for blowing soot and ash from the tubes, using
high-pressure steam.

stack

A cylindrical steel, concrete, or brick shell which carries

flue gas to the atmosphere and provides necessary draft.

stack effect

The difference (buoyancy) between the weight of a

column of high-temperature gases inside the furnace
and/or stack, and the weight of an equivalent column of
external air, usually expressed in inches of water per foot
of height.

stack temperature

The temperature of the flue gas as it leaves the

convection section, or air preheater, directly upstream of
the stack.

tube guide

Device used to restrict the movement of tubes.

tubesheet

A large tube support plate supporting a number of tubes.

tube support

A metal part which supports the weight of one or more

tubes.

two-side fired tubes

Radiant section tubes which are exposed on both sides to

direct radiation from the burners.

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