Heat Duty @ Constant Outlet Tem p.

(Btu/Hr)

Heater Load Chart

8,000,000.00

7,000,000.00

6,000,000.00

5,000,000.00

5
4,000,000.00

3,000,000.00

2,000,000.00

1,000,000.00

-
0 20 40 60 80 100 120
Inlet Temperature (Deg F)
1,000,000.00

-
0 20 40 60 80 100 120
Inlet Temperature (Deg F)
 INDIRECT FIRED HEATER
( PROCESS CALCULATION - FOR PROCESS FLUID )

Project Name : Kaji Satellite

Location : Jambi-Sumatra
Client : Medco E & P Indonesia

I PROCESS HEAT DUTY

Condition Data Gas(MMSCFD) Oil Water

Volume Flow Rate = 0.25 9,975 525 BPD
Mass Flow Rate = 0.0007283421 121,870.00 7,409.00 lb/hr
S.G. = 0.9138 0.8 1
Density = 1.732 lb/ft3
Molecular Weight = 26.5 203.4 18
Mass Heat Capacty = 0.4000 0.4764 1.0611 Btu/lb-o F
Viscosity at Inlet = 0.0110 3.97 0.85
Viscosity at Outlet = 0.0110 2.42 0.55
Thermal Conductivity at Inlet = 0.0170 0.08 0.35
Thermal Conductivity at Outlet = 0.0170 0.08 0.37
Pressure = 25 psig
Fouling Resistance = 0.0015 ft2-hr-F/btu
Pressure Drop, Allowable = 5 psig
Lower Temperature (T1) = 80 80 80 8F
Upper Temperature (T2) = 120 120 120 8F
T = 40 40 40 8F

Bath Medium = 50% Water and 50% Ethylene Glycol

Bath Medium Temperature Setting = 175 deg F

CALCULATION RESULT

LMTD = 73.19 o
F Shell Inside Diameter = 96.0 Inches
Heat Duty (calcul'd) = 2636831.37 BTU / hr Shell S/S = 26.0 Feet
Highest Heat Flux(Fire Tube) = 6557.26 BTU/Hr/ft2 Skid Length = 40.0 Feet
Heat Transfer Coeff. = 52.80 Btu / hr-ft2-oF Skid Width = 128.0 Inches
Pressure Drop Cal'd) = 2.76 psid Bath Volume = 8380.0 Gallons

II Process heat duty can be calculated using followings :

q g = M g ( T 1 −T 2 )C g =
q o = M o ( T 1 −T 2 ) Co =
q w= M w ( T 1− T 2 ) C w =
Total
0.01 Btu/hr
2,322,360.47 Btu/hr
314,470.89 Btu/hr
= 2,636,831.37 Btu/hr
= 2.64 MMBtu/hr
III HEAT DUTY FOR BURNER

For 2" thick Glass Wool insulation the standard losses to surrounding is 10 - 11% plus
20 % Safety Factor, provide the Burner Heat Duty required :

q
q B =1 . 2∗ = 3,555,278.26 Btu/hr
0 . 89
IV FIRE TUBE SIZE

Given the maximum allowable Heat Transfer 7,500 Btu/hr/Ft2, required Fire Tube
Total Surface Area is;

q
A F= = 351.578 Ft2
7,500
For 2 Burners = 175.789 Ft2

For 24 feet length, 2 passes / burner & No burners of 2

The Fire Tube Diameter is :

AF = 13.989 Inch
d F =12
πl
Taken of the 16 Inch sch. 40 inside diameter with 0.25" thick is adequate.

Actual heat Flux , q / Ao = 6557.26 Btu/hr/ft2

V PROCESS LINE TUBE

As Water / Glycol bath temperature is set at 175 o

F Coil raised from 80 o
F 120
ΔT 1 − ΔT 2
LMTD =
ΔT 1
= 73 8F -------------------- ( 5.1 )
log e
( ΔT 2 )
12 q
L= -------------------- ( 5.2 )
π−( LMTD )−Ud

1 1 L A0 -------------------- ( 5.3 )
= + R + + Ri +
U h0 0 K Ai −hi

0.4 0 .16 -------------------- ( 5.4 )

hI D C− μ e μe
) ( )
0. 8

K
=−0. 022
DG
μe ( ) ( k μe −w

Q 1 ( SG )
G=18 . 6− -------------------- ( 5.5 )
D2

0.25
 k 3  C  P3    t 
ho  116  -------------------- ( 5.6 )
   do 

To be able to solve equation ( 5.2 ) it requires to solve equation ( 5.3 ), ( 5.4),

( 5.5 ) & (5.6 )
 Finding hi :

Viscousity of fluid takes control and for the Equation :

- At average temperature = ( 120 + 80 ) /2 = 100 oF e = 3.195 cP

- At wall side ( 175 oF )  ew = 2.755 cP

- Conductivity Fluid, k = 0.094 BTU/hr - ft2 - oF

- Heat Capacity, C = 0.4 BTU/lb - oF

- Average Heat Capacity, C = 0.7687561455 BTU/lb - oF

- Inside Diameter, D = 4.026 In. 25.3999006

0.336 ft.
Thus,

G = W/A = 205,677.84
0. 4 0. 16

][ ] [ ] [ ]
0 .8 Cμe μe
hi =[ 0 .022 . k DG
D
.
μe k μ ew
= 68.318 BTU/hr - ft2 - oF

Finding ho :
At bath temperature = 175o F from Hysys (Eglycol : Water = 50% Vol : 50% Vol)

r = 64.08 ;  = 4,95 ; k = 0.312 ; C = 0.8381

r = 64.08 = 4.95 k= 0.3120263395 C = 0.83811237
 0.0024 1/ oF do = 3.5 Dt = 175 - 100 = 75 8 F

0. 25
ho =116− [
k 3−C−ρ2− β− Δt
μ− ]
= 161.97 BTU/hr - ft2 - oF

Finding : U

1 1 L A0
= + R0 + + R i + ; Ro + Ri = 0.0015
U h0 K Ai hi k = 30

= 0.0189378271

U = 52.804368344 Btu/hr-ft2- oF

12 q
L=
π ( LMTD )Ud

Thus, L = 744.63 Ft.

Line Tube Surface Area = 682.30 Ft2

Since each pass is selected for : 24 feet long thus the coil requires : 31
rounded up to : 31
Passes and selected number passes : 32
in parralel of : 2

Maximum heat - flux, through tubes : 3,865 BTU/Hr/Ft 2 lower than 7,500 BTU/Hr/Ft 2
( max allowed )

Therefore,
To maintain bath temperature no less than : 175 o
F
And getting pressure drop less than : 5 Psi
The number of pass is selected for : 32 passes in series.
To Determine Pressure Drop:

SG = 0.90
W = 129,279 lb/hr

d = 4.026 in 2.649E-03

R = 23.81 cu.ft /bbl

12 , 409 ( S .G .) P  2 . 7 RSP
rm  = 22.254 Lb/Ft3
198 . 7 P  RTZ

P1 = 39.7 Psia
T1 = 580 8 R

For 4" steel pipe e/d = 0.001

Z = 0.8791

As per GPSA Engineering Data Book:

−6 2
3. 4 x 10 fLW
ΔP= = 2.76 Psid
ρ m D5
f= 2.649E-03 (new steel pipe)

Therefore the pressure drop is still lower than

maximum allowable pressure drop of = 5 psid

To Determine Shell Diameter and Length:

Coil Pitch ( Long R ) = 8 inch

Total Area required for Coils (min.) 1995.04 Sqin

Total Area required for Fire-tube (min.) 2116.00 Sqin

Total Area required for H/Shell (min.) 4111.04 Sqin

Shell Diameter required (w/ 20% safety) 84.06 Inch

Rounded Diameter 96.00 Inch

Total Seam to Seam Length 26.00 Feet

Skid Length 40.00 Feet

Skid Width 128.00 Inch

WATER / GLYCOL BATH VOLUME.

- Shell Volume = 1362.19 CUFT

- Fire Tube = 144.09 CUFT

- Coils Volume = 111.18 CUFT

- Water Pod Volume = 13.40 CUFT

Thus, Total Water Bath Shell + Head +Water Pod - Fire Tube - Coils

= 1120.33 CUFT = 8,380 Gallons = 31,718 Litres

69,926
VI ESTIMATED TIME REQUIRED FOR START-UP

Total Heat Required to Raise Water Temperature to 175 °F

W = Heat Capacity x Total Weight x Temperature Increament

= 9.41 MMBTU

Total Heat Required to Raise Shell/Tank Temp. to 175 ° F, Total Shell/Tank Weight 26954 kg
59422.398589
W = Heat Capacity x Total Weight x Temperature Increament
= 7.99 MMBTU

Burner design capacity / ea = 3.200 MMBTU/Hr

Total estimated time required for start-up the Heater, include correction for Stack & Radiation losses ( 30 %)

Wt = 22.622 MMBTU
t= 7.069 Hours = 424.163 menit
 PATERN RE- ALIGNMENT OPTIMIZED WATER FLOOD PROJECT

KAJI SATELLlTE

DATA SHEET

INDIRECT FIRED HEATER

KJS-NAP-111

ASME VIII Div. 1

B 1/28/2008 Revised ISU/HWP HNV SSH

A 2/8/2007 issued for approval ISU/HWP HNV SSH
REV DATE DESCRIPTION PREPARED CHECKED APPROVED COMPANY
STATUS CODE : A= Issued for Comments - B= Issued for Approval - C= Approved for Construction - D= As Built
Info = For Information
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN
WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER
PT MEDCO E & P INDONESIA
PATERN REALIGNMENT OPTIMIZE WATERFLOOD PROJECT

CLASS REVISION STATUS

A D
 PATERN REALIGNMENT OPTIMIZED WATERFLOOD PROJECT - PT. MEDCO E&P INDONESIA

DATA SHEET INDIRECT FIRED HEATER

KJS-NAP-111

Tag No. : KJS-NAP-111 Type : Horizontal Doc. No. : KJS-M-DS-109

Service : INDIRECT FIRED HEATER No. of Unit : 1 (One) Rev : B
Size by : PT. SURYATEGUH CEMERLANGPERKASA Location : 0 Page : 1 of 4

PERFORMANCE OF ONE UNIT

Fluid Allocation Tube Side Shell Side
Fluid Name Crude Oil + 5% vol water Water Bath (Glycol and Water)
In Out Composition (% Vol)
Fluid Quantity, Total lb/hr 129353 (note 3) - Water 50
- Vapor, lb/hr ( @ 80 0 F ) 46.8 159 - Glycol 50
- Oil, lb/hr ( @ 80 0 F ) 122620 122530 Pressure, Psig 0
- Water, lb/hr ( @ 80 0 F ) 7409 7386.8 Temperature, 0 F ( Note 2 ) 175

Temperature ( min / nor / max) 0 F ) 70/80/120 110/120/135 Density, lb/ft 3 63.7

Mixed Density, Liquid, lb/ft3 @ 80 0 F in & 120 0 F Out 46.8 36.11 Viscocity, cP 4.949
Viscocity, Vapor, cP @ 80 0 F in & 120 0 F Out 0.011 0.011 Molecular Weight 27.9
Viscocity ( Oil/Water), cP @ 80 0 F in & 120 0 F Out 3.97/0.85 2.42/0.55 Spec Heat
Molecular Weight, Vapor 22.1 26.1 Thermal Cond, btu/hr-ft- 0 F 0.3
Molecular Weight ( Oil / Water ), cP @ 80 0 F in & 120 0 F 213.9/18 214.9/18
Spec. Heat, Vapor, btu / lb mole 0 F 10.6 12.4
Spec. Heat (Oil/Water), btu / lb mole 0 F 96.9/19.1 102/19.1
Thermal Cond. Vapor, btu / hr-ft - 0 F 0.017 0.017
Thermal Conductivity (Oil/Water) btu/hr-ft- 0 F 0.08/0.35 0.08/0.37
Pressure psig 25 20
Pressure Drop, Allow/Calc. psi 5.00
Fouling Resistante ft2-hr- 0 F/btu 0.0015
Heat Exchanged 2,595,000 btu/hr MTD / CMTD ( 0 F )
Transfer Rate, Serv/Clean/Calc, btu/hr-ft3-0 F /
NOTES

(1). The Indirect Fired Heater shall be commont prectical design of indirect water bath heater, the vessel/shell is filled with water or mixture of water and glycol.
A fire tube and process coil are submerged in the bath, which transfers heat to the process stream in the coll. A liquid bath vessel is heated by one of several
firetubes into which a process coll is immersed. The liquid bath fluid is ussually water with anti freeze and corosion inhibitor.

(2). The Mix Glycol-water bath is designed for atmospheric condition PT.SURYATEGUH CP to confirm actual composition and whether atmospheric bath
can be used For this temperature.
(3). PT.SURYATEGUH CP. scope of supply is a Skid mounted Indirect Fired Heater, Include the following equipment as minimum.
1.1. Process Coll
1.2. Firebox with one or more tube bundles.
1.3. Two or more burners c/w Burner Management System (PLC Based)
1.4. Fuel Control System
1.5. Stack
1.6. Structure
1.7. Piping and Valves
1.8. Instrument accessories
1.9. Burner

(4). Heater shall have design capacity 10,500 BPD crude oil (5% WC) and capable of handling 0.25 MMSCFD and design duty of 3,000,000 btu/hr
PT.SURYATEGUH CEMERLANGPERKASA shall ensure no contract between fuel gas coil and fire tube to avoid potential hot spots.
 PATERN REALIGNMENT OPTIMIZED WATERFLOOD PROJECT - PT. MEDCO E&P INDONESIA

DATA SHEET INDIRECT FIRED HEATER

KJS-NAP-111

Tag No. : KJS-NAP-111 Type : Horizontal Doc. No. : KJS-M-DS-109

Service : INDIRECT FIRED HEATER No. of Unit : 1 (One) Rev : B
Size : 96" ID x 26' S/S Location : 0 Page : 2 of 4

Applicable Specifications : ASME Boller & Press. Vessel Code Section I/V/VIII Div 1 /Section IX, API Spec 12K
ANSI B16.5/B31.3/14.2, ASTM A36, AWS D1.1.

DESIGN DATA HEATING UNIT

Design Capacity : 0.25 MMSCFD, 10,500BLPD Type Fire Tube Burner Type OILON GP-80P
Design Duty 3,400,000 btu/hr Nozzle Size/Ring N/A
Design Press/Temperature : Shell 20 / 250 0 F Heat Transfer Coeff 52.8043683442 BTU/ hr-FT2 - oF Burner Turndown 5:1
Tube 20 psig @ 500 0 F Efficiency 70% Flame Arrester Yes
Fire Tube 20 / 500 0 F Eff.Surf.Area (Fire Tube) 6,557 BTU/Hr/Ft2 Fuel Pressure 70 Psi Min.
Eff.Surf.Area (Line Tube) 3,865 BTU/Hr/Ft2 Fuel Gas Composition (% mole)
Vessel Size 96" ID x 26' S/S Tube Wall Te Max 250 o
F - Methane (C1) 83.8
Tube Size NPS 4" / Sch Std Fuel Gas Temp. 100 o
F - Ethane (C2) 5.56
Fire Tube Size / Thk 16" OD x 24 ' S/S / 3/8" Thk Excess Air (%) 30% - Propane (C3) 5.27
Fire Tube Supports Yes ( Rail Type ) - C4 1.83
Corrosion Allowance - Shell/Head 3.175 mm Tube No./Dia. 34 / NPS 4" - Carbondioxide (CO2) 0.37
Registration Yes Stack Height 22 FT - Nitrogen (N2) 2.15
Code Stamp Yes / No - Water (H2O) 1.02
Post Weld Heat Treatment No CONNECTION SCHEDULE (note 3)
Allowable Stress @ Design Temperature 137,996 kPa Size Rating Facing Out
No Nozzle
Ambient Temperature (Operating) 70 -100 0
F NPS No. Service
Minimum Metal Design Temperature -20 0
F N1 8" 1 Inlet 150# RF
MATERIALS N2 8" 1 Outlet 150# RF
Shell/Heads SA 516 Gr 70 N3 1-1/2" 1 TI 150# RF
Tube A 106 B N4 1-1/2" 1 TT 150# RF
Supports As Plate N5 2" 1 Water Inlet 150# RF
Trays N/A N6A/B 4" 2 Water Pod 150# RF
Bolts 304 SS (Internal) / SA 193 Gr B7 (External) N7 6" 1 Vent 150# RF
Flanges SA 105 N8 2" 1 PT 150# RF
Nozzle-Neck SA 106 Gr B N9 2" 1 PI 150# RF
Structural Attachments-External As Plate N10A/B 2" 2 Briddle Conn. 150# RF
Structural Attachments-Internal As Plate N11A/B 2" 2 LS Conn 150# RF
Gaskets Spiral Wound, 304SS Outer Liner Ring, Thickness 1/8" N12A/B 2" 2 Drain 150# RF
N13 2" 1 Drain 150# RF
MH 20" 1 Man Hole w/Flg&D 150# RF
BI.A/B 8.1/2" 2 Burner Inlet - -
MECHANICAL BO.A/B 12" 2 Burner Outlet 150# RF
Vessel Size 96" ID x 26' S/S
Shell Thickness 0.5118 Inches PAINTING AND INSULATION
Head Thickness 0.375 Inches ( Minimum After Forming ) External Surface Preparation Yes
Joint Efficiency Shell : 1.00 Internal Surface Preparation Yes
Head : 1.00 Structural Surface Preparation Yes
Capacity 23 m3 Vessel External (Coat/Int. Coat) Inorganic Zinc / Modified Silicon
Weight - Empty 25,924 kg Vessel External Finish Modified Silicon
Weight - Internal 11,572 kg Structural Prime (Coat/Int. Coat) Zinc Chromate Epoxy
Weight - Operating 61,603 kg Highbuild Catalyzed Epoxy
Weight - Hydrotest 67,204 kg Vessel Internal Prime No
Q/A Shipping Dimension 11 L x 2.75 W x 3H m Vessel Internal Finish No
F.O.B. Point Structural Finish Highbuild Catalyzed Epoxy
Nozzle Covers/Connection Plugs Yes External Insulation - Shell No
Shipping Cradles Yes External Insulation - Heads No
Ocean Transport Protection Yes External Cladding No
Insulation - Bottom Head No
Insulation - Skirt No
ACCESSORIES BY FABRICATOR Fireproofing - Skirt No
Manway Davits/Hinge No Fireproofing - Saddles Yes
Ladder and Platform Clips Yes Fireproofing - Saddles
Pipe Support and Guide Clips Yes QUALITY CONTROL / INSPECTING / TESTING
Insulation Support Yes Hydro Pressure 1.3 x MAWP
Insulation Support Bottom Head Hydro Medium Water
Fireproofing Supports Hydrotest Duration (hrs) Per Code
Ladders Yes Radiographic Inspection Per Code
Platforms No Ultrasonic Inspection 100%
Lifting Lugs Yes Magnetic Partical Inspection Per Code
Grounding Lugs Yes Dye Penetrant Inspection Per Code
Pipe Coil Yes Material Mill Test Reports No
Lugs/Saddles Saddle Post Weld Heat Treatment & Records N/A
Syphon Drain N/A Hydrotest Reports Yes
Vortex Breaker N/A Radiographic Inspection Reports Yes
Mist Eliminator N/A Ultrasonic Inspection Reports (If UI crried out)
Tray/Packing Supports N/A Magnetic Partical Inspection Reports (If MPI carried out)
Dye Penetrant Inspection Reports (If DPI carried out)
Fabricator Quality Control Manual Required
Shop Inspection by Owner Required
Welding Procedure Review / Approval Required
INDIRECT FIRED HEATER

Tag No. : KJS-NAP-111 Type : Horizontal Doc No. : KJS-M-DS-109

Service : INDIRECT FIRED HEATER No. of Unit : 1 (One) Rev. : B

Size 96" ID x 26' S/S Mfr : Page : 3 of 4

:
VESSEL SKETCH

N8 N5 N14

N7 N10A

BO.A/
B
N6A N6B
N1
B

96" ID
N2
BI.A/ FIRE TUBE B
B
MH
BURNER&FLARE
ARRESTER ASSY.

N10B
N9 N4 N3
N12B N13 N11
A N12A
A A
A

26 FT S/S
INDIRECT FIRED HEATER

Tag No. : KJS-NAP-111 Type : Horizontal Doc No. : KJS-M-DS-109

Service : Indirect Fired Heater No. of Unit : : 1(One) Rev. : B
Mfr : Page : 4 of 4
NOTES:

1 PT.SURYATEGUH CEMERLANGPERKASA to confirmed

2 Vessel head shall be 2:1 semi elliptical
3 PT.SURYATEGUH CEMERLANGPERKASA proposed the nozzle orientation and arrangeent with refern to P&ID attached

PT. SURYATEGUH CEMERLANGPERKASA.

Director