Engineering Studies: How detailed analysis can guide difficult fired heater decisions

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By Tim Webster, Chief Operating Officer 

Engineering studies allow end users to develop ways to improve facility operations or help solve specific problems. They can also be used to help understand how custom equipment will perform in the field before installation and investment.

XRG’s team of fired equipment specialists specialize in analyzing and suggesting performance improvement opportunities, focusing heavily on eliminating bottlenecks, reducing emissions, and improving mechanical reliability. Some common areas where engineering studies can provide beneficial input prior to determining a course of action include;

  • Troubleshooting problems
    • Flame impingement
    • High emissions
    • High Tube Metal Temperatures (TMT)
    • Draft issues
    • Tube support failures
    • Coking and fouling
    • Vibration
  • Operational improvements
    • Capacity increases
    • Emissions reduction
    • Efficiency improvement
    • Feed changes
    • Fuel changes
  • CO2 reduction
    • Improve efficiency (e.g. adding air preheat)
    • Alternate fuels (e.g. hydrogen or ammonia)
    • Oxy-combustion for carbon capture and sequestration (CCS)
    • Partial or complete electrification

What does an engineering study involve?

While every study is different, they are commonly broken down into three primary phases;

Phase 1 – data gathering

Some studies can be performed through analysis of existing site data, such; as fired heater datasheets, drawings, operational data, pictures, etc. In some cases where complete data is not available, or when the current condition of equipment needs to be assessed, a detailed survey onsite is conducted for visual inspection of the heaters and auxiliary equipment, data collection, and project scope discussion with the user’s team. Data is collected for evaluation using instruments like emissions analyzers, infra-red (IR) cameras, and pyrometers to determine temperatures, pressure profiles, and flue gas constituents. The purpose of the survey is to determine exactly how the fired heater operates, inspect the overall health of the fired heater, and determine what (if any) limitations apply.

Phase 2 – detailed analysis and simulation

In the second phase, all of the documentation and data collected are analyzed and modeled to identify issues and constraints and then evaluate potential solutions. Some of the advanced analytical tools that can be used to simulate and evaluate fired heater operation include;

  • Chemical process simulation using DWSIM
  • Heater thermal rating using FRNC-5 and our proprietary in-house software Xplore
  • Computational Fluid Dynamics (CFD) modeling using Ansys Fluent
  • Pipe stress analysis using Caesar II
  • Structural analysis using RISA-3D and IdeaStatiCa
  • Finite Element Analysis (FEA) using Ansys Mechanical
  • Detailed 3D design using Tekla Structures, AutoCAD and Solidworks

These tools allow XRG engineers to troubleshoot problems, conduct feasibility studies, provide cost-benefit analyses, and perform thermal ratings.

For example, a CFD model can demonstrate flame patterns, radiant flux profile from the burners, and the resulting absorbed flux and temperature profiles on the coils. This can be used to solve heat transfer problems in the fired heater caused by non-optimal burner layouts or flue gas patterns in the furnace.

The detailed heat flux data that is generated through the CFD model can then be used as an input into our thermal rating software to provide more accurate modeling results and heater performance predictions.

Phase 3 – conclusions and recommendations

XRG will work closely with your engineering, operations and maintenance staff to discuss options and determine the solution that accomplishes your goals in the most cost effective manner. Each solution is custom-developed from real world analysis and modeled to provide options for achieving the desired outcome. When it comes to solving complex issues, trust XRG engineers to evaluate all potential options with actionable solutions and guaranteed results.

Once a solution is chosen, XRG can prepare any equipment proposals, budgets and schedules needed to help you completely understand the impact of any recommended changes. Our expert team can procure all equipment, provide technical support, manage vendors, supervise installation and provide commissioning oversight and support.

Why choose XRG for your next engineering study?

  • Objective: XRG is not tied to any specific burner vendor or technology. We neutrally assess the problem and suggest the best solutions for the specific case.
  • Experience: We have years of experience as combustion and heat transfer experts with field installation experience that gives the confidence that we can not only solve the problem but implement that solution in the field.
  • Advanced Tools: a wide suite of advanced analytical and design tools to ensure that every step, from analysis to implementation, is studied thoroughly and any risks are identified and mitigated up front.
  • Value: XRG puts customer goals first and develops solutions that take into account safety, reliability, fired heater efficiency, fuel savings, longer equipment life, and reductions in emissions like CO2, NOx and CO. We are so confident we can develop a solution for you that we offer a “no cure no pay” study option allowing you to be confident in your investment! 

 

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ERWIN PLATVOET
As CTO of XRG, Erwin is a true innovator, whose career spans more than three decades in heat transfer and combustion industries. Erwin is a graduate of Twente University in the Netherlands with a MS in Chemical Engineering. Erwin has served the industry around the globe in a variety of roles including Research and Development Engineer, Cracking Furnace Specialist, and Director of Engineering, and now CTO. Erwin holds eight patents in fired heat transfer and emissions control technology, has published numerous papers, and co-authored the John Zink Combustion handbook and Industrial Combustion Testing book. Erwin has been an active member of the API 560 and API 535 subcommittees and taken an active role in revising these standards.
BAILEY HENDRIX
Bailey graduated from Oklahoma State University with a Bachelor of Science in Mechanical Engineering. Upon graduation, she joined the private sector as an Applications Engineer in Tulsa, OK at a local combustion company where she managed the sales activities for the process burner refining market. She quickly accelerated her career, becoming the Refining Account Manager responsible for all business development and sales of process burners in North and South America. Her strong leadership skills and interpersonal qualities led her to a position as the Western Hemisphere Sales Director for the process burner business, leading a group of sales engineers in the areas of new equipment, retrofits and burner management systems. Her financial and commercial acumen drives the success of XRG Technologies’ business development.
ALLEN BURRIS
Allen’s background includes 10 years of experience in designing and selling process burners. Allen is a graduate of Oklahoma State University with a BS in Mechanical Engineering and is a licensed professional mechanical engineer in the State of Oklahoma. His knowledge and superior customer focus led him to a career change to process design, custom-engineered fired heater sales, and associated sub-systems for the petrochemical, refining and NGL industries. With more than two decades of experience in the combustion and fired heater industry, Allen has what it takes to overcome challenges associated with complex projects and possesses.
TIM WEBSTER
With over 25 years of experience in the combustion industry, Tim brings a wealth of industry experience and technical expertise to XRG. Tim graduated with a Bachelor of Science in Mechanical Engineering from San Jose State University and received a Master of Engineering from the University of Wisconsin. Tim began his career engineering custom combustion systems for a wide range of applications including boilers, heaters, furnaces, kilns, and incinerators. Tim is a licensed professional mechanical engineer in the states of California, Texas, Louisiana and Oklahoma, has authored numerous articles and papers, and has co-authored several combustion handbooks.
matt martin
As the Lead Scientist at XRG, Matt has over 30 years of experience in the combustion industry. He specializes in CFD of fired equipment, including UOP platforming heaters, burners in process heaters, thermal oxidizers and flares with over 300 simulations of installed, field-proven equipment. Matt received a Bachelor of Science in Computer Science with a minor in Mathematics from the University of Tulsa. He has written numerous publications, is listed as inventor or co-inventor on 27 patents and was awarded the title of Honeywell Fellow in 2011 for technical excellence and leadership.
gina briggs
Gina is a native Oklahoman and attended the University of Tulsa, graduating with a BSBA in Accounting. She is a Certified Public Accountant and Chartered Global Management Accountant. Gina began her career with the Tulsa office of Deloitte Haskins and Sells, providing audit and tax services. Since leaving Deloitte, she has held CFO positions with privately held companies in the manufacturing, construction and distribution industries. In 2013, she began a consulting practice providing contract CFO services to companies, one of which was XRG and joined XRG as CFO in 2019. Gina has always enjoyed working in the small business arena, helping business owners to profitably grow and manage their businesses.