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FIRED HEATERS Innovation • Performance • Value

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FIRED HEATERSInnovation • Performance • Value

THE FOSTER WHEELERADVANTAGEOur many repeat customers know that Foster Wheeler Fired Heatersdeliver value by bringing experience, expertise, innovation, technologyand cost-effectiveness to every one of our Fired Heater projects. Our low life-cycle cost approach to design and our high qualitystandards have stood the test of time with numerous fired heaters that today are operating well beyond their original design life andperformance specifications.

MODULARIZATIONCONSTRUCTABILITY

REVAMPSFIELD SERVICES

SPARE PARTS

Fired Heaters

Revamps

Studies

Services

1

MORE THAN 90 YEARS OF TURNING UP THE HEAT!

Since 1919, Foster Wheeler has developed expertise inthermal, hydraulic, structural and mechanical designnecessary to supply some of the world’s most technicallysophisticated and reliable heaters. We have a proven trackrecord of delivering projects on time and within budget whilemaintaining an exemplary safety record.

WORKING WITH US

ENGINEERING• Innovative and custom designed for specific project requirements

• Proper mass velocities and flux rates for the process service• Burner/flux profiles to fit the service and firebox profile

• Total installed cost (TIC) approach to design and supply• Robust design using the latest design tools including 3D, CFD,

and CFM• No outsourcing of engineering so lessons learned are retained

PROJECT SERVICES• Single point of contact• Accurate and timely reporting• Planned constructability reviews• Full documentation packages: drawings, installation, operation

& maintenance (IOM) manuals and data books• Pro-active approach to client communications

QUALITY & MATERIAL SERVICES• High quality and experienced sub-suppliers ensuring price

and schedule• Custom quality plans that include client requirements are

actively monitored for conformance• In-house traffic and expediting specialists to ensure delivery

of materials both onshore and offshore• ISO 9001, ISO 14001 and ISO 18001 certified

AFTER INSTALLATION COMMITMENT• Field services available for erection, commissioning and start-up• Field services available for tuning, audits, repairs or training• Studies and materials for revamps and upgrades• Original equipment manufacturer (OEM) replacement parts

COMMITMENT TO SAFETY• Zero harm culture• Active “HEART” program• Safe office behaviors• FW life critical activities

OEM Parts

Foster Wheeler’s proprietary Terrace WallTM designfeatures a vertical radiant section consisting of a firebox,containing a single row of tubes with burners on eitherside of the tubes arranged in two terrace levels. Hot fluegases flow naturally upward into the convection sectionsimilar to a conventional fired heater providing truecounter-current heat transfer for improved radiantefficiency. The convection section has several coilsections, which recover heat from the flue gas leaving the radiant section for various process and utility duties.

An air preheat system (APH) can be provided to recoverheat from the flue gas, while avoiding dew pointproblems. High fuel efficiency can also be achieved in a natural draft design through steam generation andboiler feed water (BFW) pre-heating. On hydrogen steamreformer applications an associated steam system mayalso be supplied.

The double firing on sloped firing walls and the multiplelevel burners firing upward and adjacent to the wallrefractory provide a firebox with high radiation andpredictable flue gas circulation. This assures safe, stablecombustion, even with very lean fuels such as PSA off-gas. The burners are selected to spread the flames bothhorizontally and vertically along the brick firing wall for aplanar heat flux pattern. Low BTU, low pressure PSA off-gas is stabilized against the brick firing wall preventingany instability or flame impingement.

The sloping walls also provide a uniform vertical heat fluxprofile since the distance from the tube to the radiatingwall decreases as the rising fuel gas cools while releasingheat to the tubes. Each terrace is capable of beingindependently fired to provide the particular heat fluxdesired in its zone. This allows the operator to match thevertical heat flux to the process heat demand within thetube, such as adjusting for effects of catalyst aging,thereby avoiding tube hot spots and prolonging tube andcatalyst life.

Terrace Wall units can be supplied as natural draft, APHor gas turbine exhaust configurations. Selective catalyticreduction (SCR) equipment can also be incorporated.

GENERAL

2

TERRACE WALLTM

Vertical tubes

Terrace firing stabilizes low BTU fuels Terrace Wall reformer – radiant modular design

STEAM REFORMINGAmmonia HydrogenMethanol

ETHYLENE CRACKING FURNACESMechanical design and supply of ethylene pyrolysisfurnaces with proprietary process design by others.

HYDROCRACKERDesigns provide a more uniform tube metaltemperature for these critical high pressure coils.

DIRECT REDUCTION IRON (DRI) PLANTSUnique geometry is well-suited for these special high temperature gas services.

APPLICATIONS

PROCESS DESIGN AND CONTROLThis distinctive double-fired design offers variousadvantages for critical services in refining andpetrochemical applications where uniform, controlled,symmetrical heat is required by the process.

Multiple terrace levels permit controlled heat input and flexibility in optimizing cracking coil configurationsor biasing heat input to account for reforming catalyst aging.

Elimination of flame impingement on the tubes provides another advantage of the upward-firingterrace configuration, increasing unit reliability and on-line performance.

Feedstock flexibility and high turndown capability areother features of the Terrace Wall design.

Special flat flame burners designed to Foster Wheelerrequirements are available in Lo-NOx designs withambient air and preheated air capability.

DRAFT OPTIONSThe Terrace Wall reformer can be designed to operateunder natural draft without the need for forced-draft(FD) or induced-draft (ID) fans.

When air preheat is selected, the Terrace Wall designdoes not require costly backup ID fans and theassociated instrumentation and maintenance.Furthermore, the reformer is designed to switch over to natural draft performance when the APH system isnot used or the ID fan fails maintaining production of syngas and steam.

LIFE CYCLE COSTSImproved life cycle costs are achieved on steamreformer services as the Terrace Wall design extendsboth tube and catalyst life.

The counter-current design significantly improvesradiant firing efficiency resulting in lower fuel use forsame product capacity.

MODULARIZATIONThe entire radiant section can be shop-modularizedand transported to site, eliminating costly high alloyfield welding and inspection requirements.

All tube and pigtail welding is performed at fabricationshop, only inlet and outlet manifold welding betweenmodules is required at site.

COMPACT PLOT AREACompact plot space due to the vertical orientation of radiant and convection coils.

Close-coupled process gas boiler for steam reformingservice eliminates long transfer lines and their maintenance issues.

FEATURES/ADVANTAGES

3

2500 MTPD MEOH reformer • Natural draftoperation • Consists of 36 radiant moduleserected in 21 days

37 MM SCFD hydrogen reformer • Air preheatoperation • Utilized radiant modularization

4

Foster Wheeler’s proprietary Terrace Wall double-fireddesign is applied to horizontal tube units to provide thesame uniformity in heat flux and predictability in gasrecirculation as utilized in the vertical tube units.

This firebox layout, along with the low peak to averageheat flux ratio, provides the optimum heat input forsensitive or severely fouling process fluids. This layout,with individual passes located in separate, isolated cellsis especially beneficial in the delayed coking process andvisbreaking. It allows precise flow and firing control forlong operational time between decoking procedures.

The burners on both sides of the tubes fire upward,adjacent to a brick wall, spreading the flame along thetube length and providing the optimal heat flux profile inthe firebox. Single and multiple burner levels (terraces)are provided, depending on specific processrequirements, to control heat input to the radiant coil.

Grade mounting of radiant sections provides easy sideaccess to view and monitor burners as well as full viewingof the tubes for optical pyrometry monitoring. The burnersare side mounted for easy access and maintenance.

The convection section is located above and/or between Terrace Wall radiant sections. The number ofconvection sections can be varied from one per heater to one convection section per pass, depending onoperational needs. In addition, they can be off-set fromthe radiant coil for ease of the entire radiant coil removaland replacement.

High thermal / fuel efficiency combustion air preheat canalso be incorporated, as well as SCR equipment.

GENERAL

TERRACE WALLTM

Horizontal tubes

Terrace firing • Uniform heat flux profile

Terrace Wall EDC cracking furnace shown withremovable radiant coil

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DELAYED COKER HEATERSOffer optimal results under special and varyingconditions including complex feedstocks, wide feedranges, turndown, and on-line decoking for maximumrun lengths.

EDC CRACKING FURNACEA classical design, providing the requiredconfiguration for controlling heat input, residencetime, and process film temperature.

HYDROCRACKER HEATERSHorizontal tube designs provide the most uniform andpredictable heat flux to the process coil.

VACUUM HEATERSFor complex conditions requiring the benefits of lowpeak-to-average flux rates, controlling bulk fluid, filmtemperature and lower pressure drop.

APPLICATIONS

PROCESS DESIGN AND CONTROLPrecise individual pass flow control and firing control.

Uniform heat flux to process from top to bottom of coildue to the double firing and the impact of the slopedwalls; as the flue gas cools the distance from the wallsto the tubes decreases.

Stabilized flame pattern on brick walls with an increasednumber of burners used has little chance of flameimpingement.

When the process requires, multiple burner levels(terraces) for optimum control of heat flux are provided.

Special flat flame burners designed to Foster Wheelerrequirements are available in Lo-NOx designs withambient air and preheated air capability.

MAINTENANCEFull viewing of radiant tube from both sides forpyrometry measurement.

Grade mounting of radiant cell allows easy accessto burners for control and maintenance.

Delayed coker heaters have robust radiant stanchionsthat provide for individual component replacement.

Multiple convection sections on delayed coker heaters can allow individual pass on-line mechanicaldecoking (pigging).

On EDC cracking furnaces, offset convection sectionscan be provided for ease of complete radiant coilreplacement.

Radiant sections can be supplied with or without headerboxes for quick access to return bends.

MODULARIZATIONEach radiant cell can be shop-assembled with refractory,radiant coils, and manifolds.

The extent of modularization depends on transportationlimitations but can include air ducts, burners, floorrefractory, and burner piping (if within scope of supply).

EDC cracking furnaces can be designed for radiant coilreplacement complete with their support system.

Convection sections supplied fully modularized.

FEATURES/ADVANTAGES

Terrace Wall delayed coker heater • Radiantmodule with extended modularization shown

Delayed coker heater • Grade mounting =better burner monitoring/coil viewing

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GENERAL

ARBOR HEATERS

Inverted arbor heater with top mountedmanifolds using air cooled dividing walls

Wicket arbor heater •Bottom mounted manifolds

Arbor heaters are used mainly for high capacity vaporheating services since this configuration can be designedfor low pressure drops. The arbor term describes theshape of the coil. Numerous parallel passes of U-shapedtubes are collected on inlet and outlet manifolds. Twoarrangements of manifolds are used, top mountedmanifold (inverted arbor, U) and bottom mountedmanifold (arbor, wicket).

INVERTED ARBOR / U-TYPEInverted arbor or U-type with top-mounted manifolds,require side wall burner mounting and horizontal firing.Horizontal firing is limited to gas-only burners and leadsto special considerations due to opposed burner firing.This style is selected to reduce the length of the largediameter transfer line connections to stacked reactors.

ARBOR / WICKET TYPEArbor or wicket type, with bottom mounted manifolds,allows for floor fired burners and also allows for liquidfuel firing capabilities in addition to gas. Thisconfiguration is the original design used for multiplereactor heating applications. Wicket arbor units arecapable of larger capacities in a single unit than invertedarbor units, due to the limitations of sidewall-fired burnerflame coverage.

Many applications have multiple services combined intoone radiant box separated by either brick walls or semi-separate radiant cells using air cooled dividing walls.Each service can be controlled by single-fired or double-fired burner firing.

Usually these services have very high inlet/outlettemperatures such that the services are rarely used in the convection section. A convection section can belocated above the radiant cells for additional processheating or heat recovery steam generation.

Combustion air preheat and SCR can be provided oneither design.

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CATALYTIC REFORMING• Aromatics (AROMAX®) heaters• Continuous Catalytic Reforming (CCR)

Platformer heaters• Propane Dehydrogenation (OleflexTM, Catofin®)

heaters

THE FOLLOWING SERVICES ARE BEST SUITED IN THIS STYLE HEATERHigh capacity unitsLow fluid pressureVapor phase heating

Footnote:AROMAX® is owned by Chevron Phillips LLC

OleflexTM is owned by Honeywells UOP LLC

Catofin® is owned by Chicago Bridge & Iron Company

NV’s Lummus Technology

APPLICATIONS

PROCESS DESIGN AND CONTROLArbor-type heaters permit the use of many parallelprocess passes and are well-suited for high-capacityvapor-phase heating services, especially those requiringa low process-pressure drop.

Fuel gases are readily fired in either the sidewall-firedor floor-fired configurations. State-of-the-art low-NOxburners can be provided if required.

The conventional bottom manifold design is also well-suited for firing liquid fuels and can be designed to handle heavy oil fuels.

Control of tube metal temperatures or process outlettemperatures is provided by use of single-fired ordouble-fired burner firing.

MAINTENANCEAdequate space and platforms are provided alongmanifolds and penetration seals for proper monitoringand maintenance.

The large size of these heaters and coils requires a significant amount of access platforms oftenoverlooked in budgeting but always provided by Foster Wheeler.

AIR COOLED WALL DESIGNPermits the radiant cell structural columns to be locatedat strategic points for convection section and stacksupport (simpler and less costly structures) andfacilitates larger scale modularization than the brick-wall design.

CRITICAL PIPING INTERFACEThe movement of large high temperature transfer linesmust be accommodated with a properly designedsupport system, using counterweights or springs. Foster Wheeler’s specialists work with the client’s pipingengineers to perform the combined system stressanalysis for each coil and transfer line. This approachassures a proper, cost-effective system design,eliminating potentially costly pipe supports that would otherwise be needed.

MODULARIZATIONThe air-cooled wall design approach permits large-scale modularization of the radiant sections, with shop-installed casing, lining, and structural steel.

Radiant coils can be supplied in arbors welded tomanifolds for truck shipment.

Convection sections are supplied in modules.

FEATURES/ADVANTAGES

Arbor coil with extruded manifolds shop-fabricated for overland transportation

Fully modularized inverted arbor •Radiant section on left

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VERTICAL CYLINDRICALThe vertical cylindrical (VC) design is the most widelyused design in the industry. The radiant section, a vertical cylinder, has floor-mounted burners with verticaltubes arranged in a circle. Sometimes the radiant tubesare in a helix, resembling a large coil spring.

Flue gas flows upward from the radiant section to thehorizontal tube convection section. Process preheatservices and/or steam generation services are usuallylocated here. A top-mounted stack provides natural draft operation.

CELLULAR VERTICAL TUBE BOX“Cellular” describes the appearance of this heater’sradiant section as viewed from a top cutaway. The tubesare arranged around the walls, forming a rectangle. This rectangle is further divided by several single rows oftubes arranged across the heater, plus another single rowof tubes located along the center axis. The subdivisionsare called “cells” or “modules”. The size and number of cells are determined by the heater capacity and burner arrangement.

Heat transfer to the tubes is achieved by a combinationof single firing and double firing floor mounted burners.The wall tubes are single-fired, the transverse tubes are double-fired. The critical element in this design isbalancing the pass arrangement. Careful design andlayout is important to ensure each pass has symmetricalflow and heat transfer. With the process outlet in thedouble-fired tubes, the high inside film temperature iswhere the peak to average heat flux is the lowest.

DOUBLE-FIRED VERTICAL TUBE BOXThe double-fired design consists of single vertical rows of radiant tubes arranged centrally between two rows offloor-mounted burners. This arrangement provides nearlyuniform heating around the tube circumference, andoptimizes average heat input rates within limits of tubeskin temperature and process film temperature.

Vertical tube design can be used in most all non-foulingservices. Although these units are not drainable, withconstant diameter tubes they can be pigged to removefluids. Foster Wheeler will select not only the most cost-effective style, but will also provide reliable service basedon the intended process conditions.

Combustion-air preheat and SCR equipment can also be integrated.

GENERAL

VERTICAL TUBE BOX ANDCYLINDRICAL HEATERS

Vertical cylindrical heater is the most common,versatile design for a wide variety of services

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CYLINDRICALMost services

CELLULARCrudeVacuumAtmosphericBitumenCharge heatingHot oil

DOUBLE FIREDHydrocracker chargeHydrotreater chargeStyrene steam superheatersPyrolysisHigh temperature process heatingHigh temperature steam/gas heating

APPLICATIONS

PROCESS DESIGN AND CONTROLFoster Wheeler has the skills and experience to selectthe best vertical tube design to optimize the heat inputrates, adding dividing walls for additional control anddetermining the proper radiant height/length ratio forthe process service.

The cellular type reduces residence time toward theprocess outlet in double-fired tubes, especiallybeneficial in critical services.

The cellular design is especially cost-effective for high-capacity units, such as atmospheric (crude/bitumen)service as multiple passes are easily accommodated.

COST SAVING DESIGNDependable and cost-effective design minimizes plot surface and material costs. Double firing reduces radiant surface area without raising tube metal temperatures.

MINIMUM PLOT AREAVertical tube designs with top-mounted convectionsections typically require less plot space than theirhorizontal-tube counterparts. Tube pull space isminimized as radiant tubes are pulled vertically.

MINIMUM NUMBER OF BURNERSWith forced-draft or combustion-air preheat, thesedesigns can be tailored to require fewer burners.

These arrangements are often well-suited for firingliquid fuels.

MANIFOLD PIPING INTERFACESprings or counterweights are used as required toaccommodate expansions or applied external loads on large diameter inlet and outlet manifolds.

A coordinated effort with client’s piping engineersminimizes the piping interface requirements.

MODULARIZATIONVertical cylindrical heaters are well-suited for full radiantmodularization, either as full cans on smaller units topanels complete with radiant coils shop installed forlarge heaters.

Vertical tube box designs are typically supplied in full-height lined panels with radiant coils in bundles to minimize field work.

Convection sections are fully modularized.

FEATURES/ADVANTAGES

Twin cell vertical box heater

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The radiant section tubes are horizontal and arranged ina rectangular box-shaped enclosure with a convectionsection above or between the radiant section(s).

The most popular design consists of tubes located on theradiant sidewalls and roof with a row of upward-firingburners centrally located in the floor, or a single-fireddesign. Smaller units, often called “cabin” heaters, haveone radiant firebox with a sloped roof resembling a cabinshape. Larger units have two or more radiant fireboxes,with an essentially flat roof.

On the single-fired design, the flexibility to adjust theradiant tube length to maintain proper height to widthdimensions for well-stirred box design practice makes the horizontal tube box a practical design for manycritical services.

Our widely used “classic” single-fired delayed cokerfeatures a central divider wall (bridgewall) in each radiantsection. Burners are located in rows on each side of thebridgewall. This arrangement provides independent firingcontrol for each process pass and enhances heat transferto the firebox tubes.

Multiple passes on a wall can provide even heat flux and similar hydraulics by use of nested pass designs that is alternating passes down the radiant wall.

Double-fired versions are used in many critical services such as EDC cracking furnaces and hydrocracker heaters.

For EDC cracking furnace application, radiant wallburners are placed at multi-levels on both side wallsproviding uniform heat to the horizontal tubes located in the middle. Foster Wheeler is experienced in offering this design in accordance with all licensor design requirements.

Other options, such as combustion-air preheat and SCR equipment can also be integrated.

GENERAL

HORIZONTAL TUBEBOX HEATERS

Nested pass arrangement provides uniformflux and pressure drop • Recommended forvacuum heaters

Horizontal tubebox heaters •EDC crackingfurnaces •Radiant wallburner design

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REFININGAtmospheric (crude/bitumen)Delayed cokerVacuumVisbreakerHydrocrackerHydrotreater chargeSingle-phase chargeReboilersTwo-phase charge

PETROCHEMICALEDC cracking furnacesHot oil heatingReboilingSingle-phase chargeTwo-phase charge

APPLICATIONS

PROCESS DESIGN AND CONTROLAchieves better control of heat input to the tube with proper design of the firebox height to width ratioand if needed, use of bridgewalls.

Tube length can be increased over vertical tube designswithout compromising flow stability or mechanicaldesign. This benefits large-capacity units.

Tube layout facilitates thermal and hydraulic symmetryfor each pass.

Potentially high turndown is especially critical for two-phase flow applications.

Multiple passes on each wall with nested pass designallows uniform heat input to each pass, critical forvacuum heater service (refer to details on facing page).

EDC cracking furnace design with multiple level side fired burners allows fine tuning of heat flux for optimal EDC conversion.

Roof tubes can be provided depending on process, to increase radiant surface area.

MAINTENANCERadiant tubes can be individually pulled and replacedalong with their tube supports if needed.

Radiant section can be supplied with or without headerboxes for quick access to return bends. Mechanicalcleanout (plug) headers, if desired, must be in header boxes.

Burners are centrally located for proper operation and maintenance.

MODULARIZATIONThese heaters offer a high degree of modularization, in which radiant cells can be shop assembled withrefractory, supports and coils installed.

Convection sections are supplied in modules.

FEATURES/ADVANTAGES

Horizontal tube box heater • Visbreakerheater service with air preheat system

Horizontal tube box heater •Vacuum heater service

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CO boilers or CO heaters are primarily found in fluidcatalytic cracking units (FCCU), residue fluid catalyticcracking units (RFCCU) or fluid cokers in refineries.Foster Wheeler’s equipment can also be used to combust any low-BTU off-gas stream for process heating or steam generation.

Our CO boiler/heater uses our proprietary adiabatictoroidal combustor design, a refractory lined chamberwith no heat-absorbing surface followed by a heatrecovery section. This combustor design ensurescomplete, dependable combustion of the CO or low-BTUoffgas by thoroughly mixing the offgas, combustion airand supplemental fuel. In many cases the CO fuelcontent in the offgas is sufficient for combustion and the need for supplemental fuel firing is minimized.

FORCED CIRCULATION HEAT RECOVERYThe toroidal combustor and forced-circulation convectiveheat recovery sections are designed for high flue gasvelocities to keep any catalyst particles entrained andflowing through the unit. There is no need for hoppers or other catalyst fines collection devices prevalent in other designs.

Heat recovery coils are arranged in horizontal tube rows,with flue gas flowing upward, similar to fired heaterconvection sections. Steam generation or process heatingcan be accommodated in these heat recovery coils. Ourdesign experience allows use of tubes with low densitythick fins, that is proven by years of successful operation.

NATURAL CIRCULATION HEAT RECOVERYThe toroidal combustor can also be paired with a vertical tube natural circulation heat recovery section.This style is restricted to heat recovery of steamgeneration applications.

Foster Wheeler engineers and supplies the entirecombustor and heat recovery system including circulation pumps, interconnecting piping/valves and the steam drum.

GENERAL

CO BOILER/HEATER

CO boiler combustor style withconvection section style heat recovery

CO boiler combustor with naturalcirculation steam system includinga SCR system

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COMBUSTOR SOURCESFCCU regenerator gas heat recoveryRFCCU regenerator gas heat recoveryFluid coker off-gas heat recoveryLow-BTU off-gas heat recovery

WITH HEAT RECOVERY TOBFW/steam servicesCrude heating servicesHC preheat servicesVacuum heating services

APPLICATIONS

PROCESS DESIGN AND CONTROLToroidal combustor assures full combustion whileentraining the catalyst or other particles so they passthrough the unit.

Adiabatic combustor can reduce the amount ofsupplemental firing for the same heat recovery thussaving operating costs.

Conventional heater convection section design is used in the forced-circulation design for convenientmaintenance and operations planning.

Robust pipe materials that handle erosive catalyst fines service are used for forced-circulation heat recovery coils.

Forced-circulation steam systems respond better to loadchanges and start-up fluctuations and have higher fluegas velocities to keep catalyst entrained and notdeposited in the combustor.

For forced-circulation applications low-density finned tubes are used in FCCU applications for more cost-effective designs.

COMPACT PLOT AREASHorizontal convection bank mounted directly over theadiabatic combustor with vertical flue gas flow offersthe smallest plot footprint and is an excellent choice for limited space (retrofit) applications.

SOOT BLOWER SELECTIONMany services are dust laden, including catalyst fines.Foster Wheeler’s experience provides robust sootblowerdesigns and layouts to entrain the particles and prevent depositing on the heat transfer surfaces, even low-density finned tube surfaces.

MODULARIZATIONHeat recovery coils can be fully assembled in modularsections, with lining coils, and supports installed.

Combustor sections of CO boilers can be shop-assembled.

Steam drums, piping, and duct work, are typically shopassembled to maximum extent possible to minimize fielderection time and cost.

FEATURES/ADVANTAGES

CO Fired Heaters • One for crudeservice and one for vacuum service

Proprietary Toroidal CO bustle that providesturbulence and mixing for CO destruction

14

GENERAL

MODULARIZATION

Extended radiant module for Terrace Wall delayedcoker heater • Minimal overseas packing required

Fully modularizedTerrace Wall steamreformer furnace

When building a new heater, the degree of shopassembly is undoubtedly an important element of anyoffering. The low initial cost of lower shop prefabricationcan easily double the total installed cost (TIC). FosterWheeler designs consider the TIC approach early in theproposal phase of the project where it is most critical foroptimal TIC.

Regardless of the type or size of a fired heater or heat recovery unit, the proper assembly of its manycomponents is critical for the successful performance of the unit. The steel casing and structure, refractories,radiant and convection coils, alloy supports, stacks andducts can each be pre-assembled prior to shipment fromfabrication shops, limited only by the shipping and liftinglimits of the project.

Modularization typically refers to large-scale pre-assembly, which combines the assembly of the variouscomponents into complete, integral units or sub-units.Probably the most frequent application of modularizationis the convection section of a fired heater or heatrecovery unit. This comprises a large number of tubeswith associated manifolds and return fittings, tubesheets,refractories and steel casing with structural members.

Even on panel designs it is important to consider how the panels are supplied and erected. Full-height verticalpanels allow structural members to be included in thepanels and eliminate column welding. Horizontal panelswith structural members included will require structuralfield welds and increase field assembly time and cost.

Modularization can be extended to virtually any level,even to complete heaters, with burners, piping and ductwork installed.

Generally, the only items which need to be shippedseparately are stacks and large equipment items such as fans and air preheaters. These items themselves aresupplied as complete assemblies or sub-assemblies forefficient field installation.

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PROJECT TAILOREDThe heater design can be tailored to modularization, to best match the site’s needs assuring the optimal TICapproach to the heater design and shop supply.

Several levels of modularization are availabledepending on heater type, heater size, shippingclearances and site labor conditions. Foster Wheelercan develop a project modularization plan for:

Coil bundlesFully assembled heatersLarge modulesLined and unlined panelsOverland transportable modules

Foster Wheeler’s Terrace Wall steam reformer furnaces and delayed coker heaters are well-suited to modularization and are very cost-effective on total installed cost (TIC) evaluation. As anotherexample, the use of separate radiant cells (air-cooledwall design) for a catalytic reformer may permit the cells to be modularized.

QUALITYA controlled shop environment provides skilled,specialized work forces and facilitates inspection andmonitoring to assure quality products, minimizing fieldwork and fit-up problems.

SHIPPING AND HANDLINGFoster Wheeler’s project and logistics team carefullyevaluates each design to assure proper clearances,structural integrity and protection in shipment and handling.

Modules are structurally integrated and packaged toresist damage in shipping and handling, and to provideease of installation in the field.

COST AND TIME EFFECTIVENESSField erection cost and time can be greatly reduced.This aspect is especially important for projects built inareas of limited work force, plot space or facilities.

CONSTRUCTABILITYModules provide better ability to construct componentsto each other as compared to numerous similar-lookingpanels requiring accurate match marking andsequencing.

Close cooperation with the field erector will optimizethe use of any heavy-lift rigging needed on the job site.

FEATURES/ADVANTAGES

Terrace Wall delayed coker heater half-height radiant module • Moduleoverland transportable

Fully modularized convection section

The extent of shop fabrication or degree ofmodularization should be carefully evaluated prior toaward to consider the following points to achievelowest total installed costs (TIC):• Purchase price• Shipping costs• Shipping weights and dimensions (to plant and

inside plant)• Shipping time• Lifting requirements• Field erection costs• Field erection time

CONSIDERATIONS

16

Do you have a fired heater that is 20 to 40 or more years old and still performing well? If so, it’s probably a FosterWheeler fired heater. Since many Foster Wheeler fired heaters perform well beyond their original design life, OEM partsand services are critical to keep these units operational. We continue to support the operation, maintenance and partsrequests of fired heaters that remain in service.

GENERAL

AFTERMARKET PARTSAND SERVICES

WHEN INQUIRINGFor Foster Wheeler units, knowing the contract number or serial number (located on the nameplate) or general arrangement drawing number will help us provide you with a quick response to your inquiry. If your inquiry concerns other manufacturers please provide appropriate drawings or descriptions.

Convection sectionintermediate tubesheet

Radiant section tube hangers • Many otherdesigns available

Sight door ceramic-formedsurround affords betterviewing of radiant section

Bottom-hinged sightdoor • Tighter sealingto prevent air leakage

Catalyst cone

Foster Wheeler offers several services to keep your oldfired heater reliable and working longer.

REVAMP SERVICESMany of our design improvements, some of which arelisted below, can provide benefits of lower maintenancecosts, higher availability, better operating limits, lowerNOx or improved fuel efficiency.

Air preheat additionCapacity upgradingChanging process servicesConvection section replacementEmissions upgrading – burners and SCR equipmentStack extension assessmentSteam reformer furnaces

Capacity increasesFeedstock upgradesProcess gas boilersSingle row conversionsSteam drums

FIELD SERVICESOur experienced service staff can provide an audit of the current operation for correct mechanicalinstallation, burner operation, and general operations.

Emergency field repairEnergy auditsSteam reformer auditsHeater tuning/balancingBurner tuning/replacementTraining

METALLURGICAL CONSULTING SERVICESNew and existing fired heaters need careful review and selection of the proper materials forconstruction, due to heavier and sourer new crudesalong with chemical process improvements. Foster Wheeler has expertise to provide solutions for the following technical services:

Coating specificationsCorrosion control and preventionFabrication specifications and recommendationsFailure analysisMaterial selection and design reviewMetallurgical assessmentsPrevention and repair strategiesProblem resolution assistanceRepair recommendations

SERVICES

Emergencyprocess gas boilerreplacementbeing loaded forairfreight as clientrequired quickdelivery

OEM PARTS

If your fired heater has a turnaround in the futurecontact us, as we can assist you with your fired heaterturnaround planning needs. We can also supportunexpected shutdowns and warehouse stocking.

We provide spare parts for our fired heaters, includingmany older ones. This is important since thesecomponents are custom-designed and of specialtyconstruction. Our replacement parts are specified,tested and inspected prior to shipment to meet OEMstandards. We recognize the importance of a quickresponse, price competitiveness, and expedited delivery.

REPRESENTATIVE PARTS LISTING• Sight doors – tighter fitting doors for modern

burners• Sight doors ceramic-formed surround – better

pyrometry viewing• Tube hangers• Tube sheets• Steam reformer parts

Arch/floor sealsCatalyst support conesCatalyst tube assembliesPigtailsPusher barsStress collars

• Coil hairpin assemblies• Finned tubes• Studded tubes

Whether your requirements for parts are an immediateneed or you’re stocking your warehouse for normalheater maintenance, and/or unforseen emergencies,you can depend on Foster Wheeler to meet your needs.

contact us at:email: [email protected] website: www.fwc.com

www.fwc.com/firedheaters

CanadaCalgary, AlbertaT +1 403-255-3447 F +1 403-259-4558E [email protected] / [email protected]

ItalyMilanT +39 (02) 4486-3216 / +39 (02) 4486-2382 F +39 (02) 4486-3473E [email protected]

SpainLas Rozas (Madrid)T +34 91 336 2760 F +34 91 336 2842E [email protected]

United KingdomReadingT +44 (0) 118-913-1234 F +44 (0) 118-913-2333E [email protected]

United States of AmericaHampton, New JerseyT +1 908-713-3030 F +1 908-713-3033E [email protected] / [email protected]

© 2013 Foster Wheeler