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Fired heaters

Innovation. Performance. Value.


Quick insights
Amec Foster Wheeler Fired Heaters

More than a
century of
Over 2,500 fired heaters
fired heaters in over 70 countries
supporting the development
and growth of the global
refining market

Locations
In 1915, the first vegetable oil heater was supplied using Power Specialty’s technology, a founding Amec Foster Wheeler
company, and was quickly adapted for the emerging refinery industry. Since then Fired Heaters have been critical
components of all refineries, as well in petrochemical, Liquefied Natural Gas (LNG) and other facilities, which the
company still designs, builds, installs and supports a century later.

Amec Foster Wheeler’s team of approximately 150 Fired Heater specialists, located across the world, continue to provide
full life-cycle support, technically superior designs, and efficient equipment, all based on their significant pedigree
and century of experience. Since 1915, we have supplied an average of over 25 fired heaters per year in more than 70
countries, in all six inhabited continents.

“Our Fired Heaters team has a 100 years of cutting edge expertise at its fingertips and has
helped to shape today’s global refining and petrochemicals industry. Millions of people, with- 3
out even knowing it, have been transported by a product which one of our Fired Heaters has
helped to refine.”

100 years of history…

1903
Roots of fired heater equipment technology emerged when Ernest Foster invented and patented cast iron ‘gill rings’
increasing the heat transfer surface area of steam super-heaters. These cast iron ‘gill rings’ lead to the same principal
being used in the convection section of fired heaters

1915
A vegetable oil heater was the first fired heater to use Power Specialty’s technology

1919
Design and supply of the first all-convective heater to the refining industry

1920
Patent of the first tubular heater with a direct fired radiant section

1927
First vacuum distillation unit heater

1939
Firmly established as the world leader in refinery technology

1939
First double-fired visbreaker/coker heater

1953
Built the world’s biggest crude distillation heater

1954
Patent for the famous Terrace Wall design of Steam-Hydrocarbon Reforming Furnace

1960s and 1970s


Working across the globe supplying fired heaters for new build refineries of which over 200 Terrace Wall Reformers were
supplied and our compact CO Boiler developed and supplied

1990s
Growth of investment in petrochemicals, LNG, selective refinery processes such as visbreaking delayed coking,
hydrodesulphurisation, catalytic reforming, CO boilers/heaters, steam hydrocarbon reforming and EDC (ethylene
dichloride) cracking, has seen the diversification of the fired heaters technology to support the new technology

2012
The 150th delayed coker heater awarded

2015
100 year anniversary of Amec Foster Wheeler Fired Heaters
The Amec Foster Wheeler advantage

Our many repeat customers know that Amec Foster Wheeler Fired Heaters deliver value
by bringing experience, expertise, innovation, technology and cost-effectiveness to every
one of our Fired Heater projects.

Our low life-cycle cost approach to design and our high quality standards have
stood the test of time with numerous fired heaters that today are operating
well beyond their original design life and performance specifications.
5

We have a proven track record Commitment to safety Quality & material services
of delivering projects on ►► Zero harm culture ►► High quality and experienced sub-
time and within budget while ►► Active HSSE (Health, Safety, suppliers
maintaining an exemplary Security and Environment) ►► Custom quality plans that include
program client requirements are actively
safety record. monitored for conformance
►► Safe office behaviours
►► Life critical activities ►► In-house traffic and expediting
specialists to ensure delivery of
materials
Engineering
►► ISO 9001, ISO 14001 and
►► Innovative and custom designed ISO 18001 certified
for specific project requirements
► Proper mass velocities and After installation commitment
heat flux rates for the
process service ►► Field services available for
erection, commissioning and
► Burner/heat flux profiles to
start-up
fit the service and firebox
profile ►► Field services available for tuning,
audits, repairs or training
►► Total installed cost (TIC)
approach to design and supply ►► Studies and materials for revamps
and upgrades
►► Robust design using the latest
design tools including 3D, CFD ►► Original equipment manufacturer
and CFM (OEM) replacement parts
►► No outsourcing of engineering so
lessons learned are retained

Project services
►► Single point of contact (POC)
►► 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
Terrace Wall™
Vertical tubes

Amec Foster Wheeler’s Low BTU, low pressure PSA offgas is Direct reduction iron (DRI) plants
stabilised against the brick firing wall
proprietary Terrace Wall™ preventing any instability or flame Unique geometry is well-suited for
design features a vertical impingement. these special high temperature gas
radiant section consisting services.
of a single row of tubes with The sloping walls also provide a
uniform vertical heat flux profile since
burners on either side of the
tubes arranged in two terrace
the distance from the tube to the
radiating wall decreases as the rising
Features/advantages
levels. Hot flue gases flow flue gas cools while releasing heat to
the tubes. Each terrace is capable of Process design and control
naturally upward into the
being independently fired to provide
convection section similar to the particular heat flux desired in This distinctive double-fired design
a conventional fired heater its zone. This allows the operator to offers various advantages for critical
services in refining and petrochemical
providing true counter- match the vertical heat flux to the
process heat demand within the applications where uniform,
current heat transfer for tube, such as adjusting for effects of controlled, symmetrical heat is
improved radiant efficiency. catalyst ageing, thereby avoiding tube required by the process.
The convection section has hot spots and prolonging tube and
catalyst life. Multiple terrace levels permit
several coil sections, which controlled heat input and flexibility in
recover heat from the flue gas Terrace Wall units can be supplied optimising cracking coil configurations
leaving the radiant section as natural draft, APH or gas turbine or biasing heat input to account for
for various process and utility exhaust configurations. Selective reforming catalyst ageing.
duties. catalytic reduction (SCR) equipment
can also be incorporated. Elimination of flame impingement
on the tubes provides another
An air preheat system (APH) can be
advantage of the upward-firing terrace
provided to recover heat from the
configuration, increasing unit reliability
flue gas, while avoiding dew point Applications and on-line performance.
problems. High fuel efficiency can also
be achieved in a natural draft design Steam reforming Feedstock flexibility and high
through steam generation and boiler
►► Ammonia turndown capability are other features
feed water (BFW) pre-heating. On
of the Terrace Wall design.
hydrogen steam reformer applications ►► Hydrogen
an associated steam system may also ►► Methanol Special flat flame burners designed to
be supplied.
Amec Foster Wheeler requirements
Ethylene cracking furnaces are available in Lo-NOx designs
The double firing on sloped firing with ambient air and preheated air
walls and the multiple level burners capability.
Mechanical design and supply of
firing upward and adjacent to the wall
ethylene pyrolysis furnaces with
refractory provide a firebox with high
proprietary process design by others.
radiation and predictable flue gas Draft options
circulation. This assures safe, stable
combustion, even with very lean fuels Hydrocracker The Terrace Wall reformer can be
such as pressure swing absorption designed to operate under natural
(PSA) offgas. The burners are selected Designs provide a more uniform tube draft without the need for forced-draft
to spread the flames both horizontally metal temperature for these critical (FD) or induced-draft (ID) fans.
and vertically along the brick firing high pressure coils.
wall for a planar heat flux pattern. When air preheat is selected,
the Terrace Wall design does not
require costly backup ID fans and 7
the associated instrumentation
and maintenance. Furthermore, the
reformer is designed to switch over to
natural draft performance when the
APH system is not used or the ID fan
fails maintaining production of syngas
and steam.

Life cycle costs

Improved life cycle costs are achieved


on steam reformer services as the
Terrace Wall design extends both tube
and catalyst life.

The counter-current design


significantly improves radiant firing
efficiency resulting in lower fuel use for
same product capacity.

Modularisation

The entire radiant section can be


shop-modularised and transported to
site, minimising costly high alloy field
welding and inspection requirements.

All tube and pigtail welding is


performed at fabrication shop, only
inlet and outlet manifold welding
between modules is required at site.

Compact plot area

Compact plot space due to the


convection section mounted on
top and to the side of the vertically
oriented radiant section(s).

Further, when required, a close-


coupled process gas boiler eliminates
long transfer lines and their
maintenance issues.
Terrace Wall™
Horizontal tubes

Amec Foster Wheeler’s


proprietary Terrace Wall
double-fired design is applied
to horizontal tube units to
provide the same uniformity
in heat flux and predictability
in flue gas recirculation as
utilised in the vertical tube
units.

This firebox layout, along


with the low peak to average
heat flux ratio, provides
the optimum heat input for
sensitive or severely fouling
process fluids. This layout,
with individual passes located
in separate, isolated cells is
especially beneficial in the
delayed coking process and
visbreaking. It allows precise
flow and firing control for long
operational time between
decoking procedures.
The burners on both sides of the
tubes fire upward, adjacent to a brick
wall, spreading the flame along the
tube length and providing the optimal
heat flux profile in the firebox. Single
and multiple burner levels (terraces)
are provided, depending on specific
process requirements, to control heat
input to the radiant coil.

Grade mounting of radiant sections


provides easy side access to view
and monitor burners as well as full
viewing of the tubes for optical
pyrometry monitoring. The burners
are side mounted for easy access and
maintenance.
The convection section is located Features/advantages Radiant sections can be supplied with 9
above and/or between Terrace Wall or without header boxes for quick
radiant sections. The number of access to return bends.
convection sections can be varied Process design and control
from one per heater to one convection
section per pass, depending on Precise individual pass flow control Modularisation
operational needs. In addition, they and firing control.
can be off-set from the radiant coil for Each radiant cell can be shop-
ease of the entire radiant coil removal Uniform heat flux to process from assembled with refractory, radiant
and replacement. top to bottom of coil due to the coils, and manifolds.
double firing and the impact of the
sloped walls; as the flue gas cools the The extent of modularisation depends
High thermal/fuel efficiency distance from the walls to the tubes on transportation limitations but
combustion air preheat can also decreases. can include air ducts, burners, floor
be incorporated, as well as SCR refractory, and burner piping (if within
equipment. Stabilised flame pattern on brick scope of supply).
walls with an increased number of
burners used has little chance of flame Convection section supplied fully
impingement. modularised.
Applications
When the process requires, multiple
Delayed coker heaters burner levels (terraces) for optimum
control of heat flux are provided.
Offer optimal results under special
and varying conditions including Special flat flame burners designed to
complex feedstocks, wide feed ranges, Amec Foster Wheeler requirements
turndown, and on-line decoking for are available in ultra Lo-NOx designs
maximum run lengths. with ambient air and preheated air
capability.

EDC cracking furnace


Maintenance
A design, providing the required
configuration for controlling heat Full viewing of radiant tube from both
input, residence time, and process film sides for pyrometry measurement.
temperature.
Grade mounting of radiant cell allows
easy access to burners for control and
Hydrocracker heaters maintenance.

Horizontal tube designs provide the Delayed coker heaters have robust
most uniform and predictable heat flux radiant stanchions that provide for
to the process coil. individual component replacement.

Multiple convection sections on


Vacuum and Visbreaker heaters delayed coker heaters can allow
individual pass on-line mechanical
For complex conditions requiring decoking (pigging).
the benefits of low peak-to-average
flux rates, controlling bulk fluid, film
temperature and lower pressure drop.
Arbor heaters

Inverted arbor/U-type Applications


Inverted arbor or U-type with top-
mounted manifolds, require side Catalytic reforming
wall burner mounting and horizontal ►► Aromatics (AROMAX®) heaters
firing. Horizontal firing is limited to ►► Continuous Catalytic Reforming
gas-only burners and leads to special (CCR) Platformer heaters
considerations due to opposed burner
firing. This style is selected to reduce ►► Propane Dehydrogenation
the length of the large diameter (OleflexTM, Catofin®) heaters
transfer line connections to stacked
The following services are best suited
reactors.
in this style heater
►► High capacity units
Arbor/wicket type ►► Low fluid pressure

Arbor or wicket type, with bottom ►► Vapour phase heating


mounted manifolds, allows for floor
fired burners and also allows for liquid
fuel firing capabilities in addition to
gas. This configuration is the original
design used for multiple reactor
heating applications. Wicket arbor
units are capable of larger capacities in
a single unit than inverted arbor units,
due to the limitations of sidewall-fired
burner flame coverage.
Arbor heaters are used mainly
Many applications have multiple
for high capacity vapour services combined into one radiant
heating services since this box separated either by brick walls or
configuration can be designed semi-separate radiant cells using air
for low pressure drops. The cooled dividing walls. Each service can
be controlled by single-fired or double-
arbor term describes the fired burner firing.
shape of the coil. Numerous
parallel passes of U-shaped Usually these services have very
tubes are collected on inlet high inlet/outlet temperatures such
that the services are rarely used in
and outlet manifolds. Two the convection section. A convection
arrangements of manifolds section can be located above the
are used, top mounted radiant cells for additional process
heating or heat recovery steam
manifold (inverted arbor, generation.
U) and bottom mounted
manifold (arbor, wicket). Combustion air preheat and SCR can
be provided on either design.
Features/advantages Air cooled wall design Modularisation

Permits the radiant cell structural The air-cooled wall design approach
Process design and control columns to be located at strategic permits large-scale modularisation
points for convection section and of the radiant sections, with shop- 11
Arbor-type heaters permit the use of stack support (simpler and less costly installed casing, lining, and structural
many parallel process passes and are structures) and facilitates larger scale steel.
well-suited for high-capacity vapour- modularisation than the brick-wall
phase heating services, especially design. Radiant coils can be supplied in
those requiring a low process-pressure arbors welded to manifolds for truck
drop. shipment.
Critical piping interface
Fuel gases are readily fired in either Convection sections are supplied in
the sidewall-fired or floor-fired The movement of large high modules.
configurations. State-of-the-art ultra temperature transfer lines must
Lo-NOx burners can be designed to be accommodated with a properly
handle heavy oil fuels. designed support system, using
counterweights or springs. Amec
The conventional bottom manifold Foster Wheeler’s specialists work
design is also well-suited for firing with the client’s piping engineers to
liquid fuels and can be designed to perform the combined system stress
handle heavy oil fuels. analysis for each coil and transfer line.
This approach assures a proper, cost-
Control of tube metal temperatures effective system design, eliminating
or process outlet temperatures is potentially costly pipe supports that
provided by use of single-fired or would otherwise be needed.
double-fired burner firing.

Maintenance

Adequate space and platforms


are provided along manifolds
and penetration seals for proper
monitoring and maintenance.

The large size of these heaters and


coils requires a significant amount of
access platforms often overlooked
in budgeting but always provided by
Amec Foster Wheeler.
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

Continuous Catalytic Reforming (CCR)


Platformer heaters is owned by Axens
13

connected excellence
in all we do
Vertical tube box and cylindrical heaters

Vertical cylindrical Double-fired vertical tube ►► High temperature process heating


►► High temperature steam/gas
The vertical cylindrical (VC) design box heating
is the most widely used design in the
The double-fired design consists
industry. The radiant section, a vertical
of single vertical rows of radiant
cylinder, has floor-mounted burners
with vertical tubes arranged in a circle.
tubes arranged centrally between Features/advantages
two rows of floor-mounted burners.
Sometimes the radiant tubes are in a
This arrangement provides nearly Process design and control
helix, resembling a large coil spring.
uniform heating around the tube
circumference, and optimises average Amec Foster Wheeler has the skills
Flue gas flows upward from the
heat input rates within limits of tube and experience to select the best
radiant section to the horizontal tube
skin temperature and process film vertical tube design to optimise the
convection section. Process preheat
temperature. heat input rates, adding dividing walls
services and/or steam generation
services are usually located here. A for additional control and determining
Vertical tube design can be used in the proper radiant height/length ratio
top-mounted stack provides natural
most all non-fouling services. Although for the process service.
draft operation.
these units are not drainable, with
constant diameter tubes they can The cellular type reduces residence
be pigged to remove fluids. Amec time toward the process outlet
Cellular vertical tube box Foster Wheeler will select not only the in double-fired tubes, especially
“Cellular” describes the appearance of most cost effective style, but will also beneficial in severe services.
this heater’s radiant section as viewed provide reliable service based on the
from a top cutaway. The tubes are intended process conditions. The cellular design is especially cost-
arranged around the walls, forming effective for high capacity units, such
a rectangle. This rectangle is further Combustion-air preheat and SCR as atmospheric (crude/bitumen)
divided by several single rows of tubes equipment can also be integrated. service as multiple passes are easily
arranged across the heater, plus accommodated.
another single row of tubes located
along the center axis. The subdivisions Applications
are called “cells” or “modules”. Cost saving design
The size and number of cells are Cylindrical
determined by the heater capacity and Dependable and cost-effective design
burner arrangement. ►► Most services minimises plot surface and material
costs. Double firing reduces radiant
Heat transfer to the tubes is achieved surface area without raising tube
Cellular
by a combination of single firing and metal temperatures.
double firing floor mounted burners. ►► Atmospheric/Crude
The wall tubes are single-fired, the ►► Vacuum
Minimum plot area
transverse tubes are double-fired. ►► Bitumen
The critical element in this design
►► Charge heating Vertical tube designs with top-
is balancing the pass arrangement.
Careful design and layout is important ►► Hot oil mounted convection sections typically
to ensure each pass has symmetrical require less plot space than their
flow and heat transfer. With the horizontal-tube counterparts. Tube
Double-fired pull space is minimised as radiant
process outlet in the double-fired
tubes, the high inside film temperature ►► Hydrocracker charge tubes are pulled vertically.
is where the peak to average heat flux ►► Hydrotreater charge
is the lowest.
►► Styrene steam superheaters
►► Pyrolysis
Minimum number of burners 15

With forced-draft or combustion-air


preheat, these designs can be tailored
to require fewer burners.

These arrangements are often well-


suited for firing liquid fuels.

Manifold piping interface

Springs or counterweights are used as


required to accommodate expansions
or applied external loads on large
diameter inlet and outlet manifolds
and transfer lines.

A coordinated effort with clients


piping engineers minimises the piping
interface requirements.

Modularisation

Vertical cylindrical heaters are well-


suited for full radiant modularisation,
either as full cans on smaller units to
panels complete with radiant coils
shop installed for large heaters.

Vertical tube box designs are typically


supplied in full-height lined panels with
radiant coils in bundles to minimise
field work.

Convection sections are supplied fully


modularised.
Horizontal tube box heaters

The radiant section tubes For EDC cracking furnace application, compromising flow stability or 17
radiant wall burners are placed mechanical design. This benefits
are horizontal and arranged at multi-levels on both side walls large-capacity units.
in a rectangular box-shaped providing uniform heat to the
enclosure with a convection horizontal tubes located in the middle. Tube layout facilitates thermal and
section above or between the Amec Foster Wheeler is experienced in hydraulic symmetry for each pass.
offering the visbreaker heater with air
radiant section(s). preheat system design in accordance Potentially high turndown is
with all licensor design requirements. especially critical for two-phase flow
The most popular design applications.
is single-fired, consisting of Other options, such as combustion-air
tubes located on the radiant preheat and SCR equipment can also Multiple passes on each wall with
be integrated. nested pass design allows uniform
sidewalls and roof with a heat input to each pass, critical for
row of upward-firing burners vacuum heater service (refer to details
centrally located in the floor. Applications on facing page).
Smaller units, often called
EDC cracking furnace design with
“cabin” heaters, have one Refining
multiple level side fired burners allows
radiant firebox with a sloped ►► Atmospheric (crude/bitumen) fine tuning of heat flux for optimal EDC
roof resembling a cabin ►► Delayed coker conversion.
shape. Larger units have two ►► Vacuum
Roof tubes can be provided depending
or more radiant fireboxes, ►► Visbreaker on process, to increase radiant surface
with an essentially flat roof. ►► Hydrocracker area.
►► Hydrotreater charge
On the single-fired design, the
►► Single-phase charge Maintenance
flexibility to adjust the radiant tube
length to maintain proper height to ►► Reboilers
width dimensions for well-stirred box ►► Two-phase charge Radiant tubes can be individually
design practice makes the horizontal pulled and replaced along with their
tube box a practical design for many tube supports if needed.
Petrochemical
critical services.
►► EDC cracking furnaces Radiant section can be supplied with
Our widely used “classic” single-fired or without header boxes for quick
►► Hot oil heating
delayed coker features a central access to return bends. Mechanical
►► Reboiling cleanout (plug) headers, if desired,
divider wall (bridgewall) in each radiant
section. Burners are located in rows ►► Single-phase charge must be in header boxes.
on each side of the bridgewall. This ►► Two-phase charge
arrangement provides independent Floor mounted burners are centrally
firing control for each process pass located for proper operation and
and enhances heat transfer to the Features/advantages maintenance.
firebox tubes.
Process design and control Modularisation
Multiple passes on a wall can provide
even heat flux and similar hydraulics
Achieves better control of heat input These heaters offer a high degree
by use of nested pass designs that is
to the tube with proper design of the of modularisation, in which radiant
alternating passes down the radiant
firebox height to width ratio and if cells can be shop assembled with
wall.
needed, use of bridgewalls. refractory, supports and coils
Double-fired versions are used in many installed.
Tube length can be increased
critical services such as EDC cracking
over vertical tube designs without Convection sections are supplied fully
furnaces and hydrocracker heaters.
modularised .
CO boiler/heater – flue gas cooler

CO boilers or CO heaters are primarily found in fluid catalytic cracking units


(FCCU), residue fluid catalytic cracking units (RFCCU) or fluid cokers in
refineries. Amec 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 and heat recovery system including Forced-circulation steam systems 19
proprietary adiabatic toroidal circulation pumps, interconnecting respond better to load changes and
combustor design, a refractory lined piping/valves and the steam drum. start-up fluctuations and have higher
chamber with no heat-absorbing flue gas velocities to keep catalyst
surface followed by a heat recovery fines entrained and not deposited in
section. This combustor design Applications the combustor.
ensures complete, dependable
combustion of the CO or low-BTU Combustor sources For forced-circulation applications low-
offgas by thoroughly mixing the offgas, density finned tubes are used in FCCU
combustion air and supplemental fuel. ►► FCCU regenerator gas heat applications for more cost-effective
In many cases the CO fuel content in recovery designs.
the offgas is sufficient for combustion ►► RFCCU regenerator gas heat
and the need for supplemental fuel recovery
firing is minimised. Compact plot areas
►► Fluid coker off-gas heat recovery
►► Low-BTU off-gas heat recovery Horizontal convection bank mounted
Forced circulation heat recovery directly over the adiabatic combustor
With heat recovery to with vertical flue gas flow offers the
The toroidal combustor and forced- smallest plot footprint and is an
circulation convective heat recovery ►► BFW/steam services excellent choice for limited space
sections are designed for high flue ►► Crude heating services (retrofit) applications.
gas velocities to keep any catalyst ►► HC preheat services
particles entrained and flowing
►► Vacuum heating services Soot blower selection
through the unit. There is no need
for hoppers or other catalyst fines ►► Hot oil heating services
collection devices prevalent in other Many services are dust laden,
designs. including catalyst fines. Amec Foster
Features/advantages Wheeler has experience with robust
Heat recovery sections are arranged sootblower designs and layouts that
in horizontal tube rows, with flue Process design and control can entrain particles and prevent their
gas flowing upward, similar to fired deposition on heat transfer surfaces,
heater convection sections. Steam Toroidal combustor assures full including those with low density
generation or process heating can be combustion while entraining the finning.
accommodated in these heat recovery catalyst fines or other particles so they
coils. Our design experience allows use pass through the unit.
of tubes with low density thick fins, Modularisation
that is proven by years of successful Adiabatic combustor can reduce the
operation. Heat recovery convection sections
amount of supplemental firing for
can be fully assembled in modules,
the same heat recovery thus saving
with lining coils, and supports
operating costs.
Natural circulation heat recovery installed.
Conventional heater convection
The toroidal combustor can also be Combustor sections of CO boilers can
section design is used in the forced-
paired with a vertical tube natural be shop-assembled.
circulation design for convenient
circulation heat recovery section. This maintenance and operations planning.
style is restricted to heat recovery of Steam drums, piping, and duct work,
steam generation applications. are typically shop assembled to
Robust pipe materials designed to
maximum extent possible to minimise
handle erosive catalyst fines services
Amec Foster Wheeler engineers field erection time and cost.
in forced-circulation heat recovery
and supplies the entire combustor coils.
Modularisation

When building a new heater, Even on panel designs it is important Features/advantages


to consider how the panels are
the degree of shop assembly supplied and erected. Full-height
is undoubtedly an important vertical panels allow structural Project tailored
element of any offering. The members to be included in the
panels and eliminate column welding. The heater design can be tailored to
low initial cost of lower shop modularisation, to best match the
Horizontal panels with structural
prefabrication can easily members included will require site’s needs assuring the optimal TIC
double the TIC. Amec Foster structural field welds and increase approach to the heater design and
shop supply.
Wheeler designs consider field assembly time and cost.
the TIC approach early in the Several levels of modularisation are
Modularisation can be extended to
proposal phase of the project virtually any level, even to complete available depending on heater type,
where it is most critical for heaters, with burners, piping and duct heater size, shipping clearances
and site labor conditions. Amec
optimal TIC. work installed.
Foster Wheeler can develop a project
Generally, the only items which need modularisation plan for:
Regardless of the type or size of
a fired heater or heat recovery to be shipped separately are stacks ►► Coil bundles
unit, the proper assembly of its and large equipment items such as
►► Fully assembled heaters
many components is critical for fans and air preheaters. These items
themselves are supplied as complete ►► Large modules
the successful performance of the
unit. The steel casing and structure, assemblies or sub-assemblies for ►► Lined and unlined panels
refractories, radiant and convection efficient field installation. ►► Overland transportable modules
coils, alloy supports, stacks and ducts
can each be pre-assembled prior to Amec Foster Wheeler’s Terrace
shipment from fabrication shops, Considerations Wall steam reformer furnaces and
limited only by the shipping and lifting delayed coker heaters are well-suited
limits of the project. The extent of shop fabrication or to modularisation and are very cost-
degree of modularisation should be effective on TIC evaluation. As another
Modularisation typically refers to carefully evaluated prior to award example, the use of separate radiant
large-scale preassembly, which to consider the following points to cells (air-cooled wall design) for a
combines the assembly of the various achieve lowest TIC: catalytic reformer may permit the cells
components into complete, integral ►► Purchase price to be modularised.
units or sub-units. Probably the most ►► Shipping costs
frequent application of modularisation
is the convection section of a fired ►► Shipping weights and dimensions Quality
heater or heat recovery unit. This (to plant and inside plant)
comprises a large number of tubes ►► Shipping time A controlled shop environment
with associated manifolds and return provides skilled, specialised work
►► Lifting requirements
fittings, tubesheets, refractories and forces and facilitates inspection and
►► Field erection costs monitoring to assure quality products,
steel casing with structural members.
►► Field erection time minimising field work and fit-up
problems.
21

Shipping and handling Cost and time effectiveness Constructability

Amec Foster Wheeler’s project and Field erection cost and time can Modules provide better ability to
logistics team carefully evaluates each be greatly reduced. This aspect is construct components to each other
design to assure proper clearances, especially important for projects built as compared to numerous similar-
structural integrity and protection in in areas of limited work force, plot looking panels requiring accurate
shipment and handling. space or facilities. match marking and sequencing.

Modules are structurally integrated Close cooperation with the field


and packaged to resist damage in erector will optimise the use of any
shipping and handling, and to provide heavy-lift rigging needed on the job
ease of installation in the field. site.
Aftermarket parts and services

Do you have a fired heater OEM parts Representative parts listing


that is 20 to 40 or more If your fired heater has a turnaround in ►► Sight doors – tighter fitting doors
years old and still performing the future contact us, as we can assist for modern burners
well? If so, it’s probably an you with your fired heater turnaround ►► Sight doors ceramic-formed
planning needs. We can also support surround – better pyrometry
Amec Foster Wheeler fired viewing
unexpected shutdowns and warehouse
heater. Since many Amec stocking. ►► Tube hangers
Foster Wheeler fired heaters ►► Tube sheets
perform well beyond their We provide spare parts for our
►► Steam reformer parts
original design life, OEM parts fired heaters, including many older
ones. This is important since these ► Arch/floor seals
and services are critical to components are custom-designed ► Catalyst support cones
keep these units operational. and of specialty construction. Our ► Catalyst tube assemblies
We continue to support the replacement parts are specified,
tested and inspected prior to shipment ► Pigtails
operation, maintenance to meet OEM standards. We recognise ► Pusher bars
and parts requests of fired the importance of a quick response, ► Stress collars
heaters that remain in price competitiveness, and expedited
►► Coil hairpin assemblies
service. delivery.
►► Finned tubes
►► Studded tubes

Whether your requirements for parts


are an immediate need or you’re
stocking your warehouse for normal
heater maintenance, and/or unforseen
emergencies, you can depend on
Amec Foster Wheeler to meet your
needs.
23
Services
Amec Foster Wheeler offers several
services to keep your old fired heater
reliable and working longer.

Revamp services Metallurgical consulting services

Many of our design improvements, New and existing fired heaters need
some of which are listed below, can careful review and selection of the
provide benefits of lower maintenance proper materials for construction,
costs, higher availability, better due to heavier and sourer new
operating limits, lower NOx or crudes along with chemical process
improved fuel efficiency. improvements. Amec Foster Wheeler
has expertise to provide solutions for
►► Air preheat addition
the following technical services:
►► Capacity upgrading
►► Coating specifications
►► Changing process services
►► Corrosion control and prevention
►► Convection section replacement
►► Fabrication specifications and
►► Emissions upgrading – burners
recommendations
and SCR equipment
►► Failure analysis
►► Stack extension assessment
►► Material selection and design
►► Steam reformer furnaces
review
► Capacity increases
►► Metallurgical assessments
► Feedstock upgrades
►► Prevention and repair strategies
► Process gas boilers
►► Problem resolution assistance
► Single row conversions
►► Repair recommendations
► Steam drums

Field services
When enquiring
For Amec Foster Wheeler units,
Our experienced service staff can knowing the contract number or serial
provide an audit of the current number (located on the nameplate) or
operation for correct mechanical general arrangement drawing number
installation, burner operation, and will help us provide you with a quick
general operations. response to your enquiry. If your
inquiry concerns other manufacturers
►► Emergency field repair please provide appropriate drawings
►► Energy audits or descriptions.
►► Steam reformer audits
►► Heater tuning/balancing
►► Burner tuning/replacement
►► Training
Amec Foster Wheeler designs, delivers and maintains strategic and complex assets for its customers
across the global energy and related sectors.

Employing around 36,000 people in more than 55 countries, the company operates across the oil and
gas industry – from production through to refining, processing and distribution of derivative products
– and in the mining, power and process, pharma, environment and infrastructure markets.

Amec Foster Wheeler offers full life-cycle services to offshore and onshore oil and gas projects
(conventional and unconventional, upstream, midstream and downstream) for greenfield, brownfield
and asset support projects, plus leading refining technology.

Amec Foster Wheeler shares are publicly traded on the London Stock Exchange and its American
Depositary Shares are traded on the New York Stock Exchange. Both trade under the ticker AMFW.

connected excellence in all we do


amecfw.com/fired-heaters
heater.sales@amecfw.com

To find out more


amecfw.com

@amec_fw
linkedin.com/company/amecfw
youtube.com/amecfw
facebook.com/amecfw

© Amec Foster Wheeler 2017