FIS Company Brochure


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FIS Company Brochure

  1. 1. Furnace Improvements Services Low Cost Value Added Solutions for Fired Heaters Increased Capacity Higher Efficiency Longer Run Lengths Lower NOx EmissionsFurnace Improvements Services Inc. A.G. Furnace Improvements Pvt. Ltd. 1600 Highway 6, Suite 480 K-33, Kalkaji Sugar Land, TX 77478 New Delhi – 110019 Tel: (281)980-0325 Tel 1: 91-11-405 8 8696 Fax: 1-877-395-0760 Tel 2: 91-11-262-8 6775 Email: Web:
  2. 2. Furnace Improvements Global AUSTRALIA, SINGAPORE, NEWZEALAND, INDONESIA & TAIWAN MALASYA Douglas Chang Kate Gimblett Tel: 886-2-2706-1544 Tel: +61 (0) 7 5435 2205 Mobile:886-921-069-827 Mobile: +61 (0) 417 087 129 BAHRAIN UNITED ARAB EMIRATES George Mathew Sarwar Ali Tel: 00 973 17 785757 Tel: ++971 6 742 50 35 (M): 00973 36683942 Mobile:++971 50 6317452 VENEZUELA, ARUBA, ARGENTINA, BRAZIL COLOMBIA, Jose Fleischmann Carlos Alarcon Tel: (+55) 11-5641-4361 Tel: 58-4416-6093444 Fax: (+55) 11-5641-4361 Fax: 58-414-3668406 CANADA CALIFORNIA, USA Paul Henry David P. Diggins Tel: 450-676-3222 Tel: (949)497-6551 Fax: 450-676-5997 Mobile: (949) 463-8591 INDIA LOUISIANA, USAR. Rajamani Ajai Agarwal Charles H. ThatcherTel: + 91 94483 79108 Tel: (+9111) 421-43751 Tel: 985-892-4224Tel2: +91 80 65971113 Mobile:(+91) 981-01-59901 Mobile: KUWAIT SOUTHEAST, USA Alex Ambi David Gangle Tel: (965) 248-29160 ext.126 Tel: 205 437-1702 Mobile: (965) 338-41712 Mobile: 205 542-7006 MEXICO TEXAS, USA Jorge Ruiz Silva Stan McHugh Tel: (713)839-8788 Cel: 1+52 55 54 62 04 09 Mobile: (713) 703-8907 UTAH, MONTANA, NEVADA, IDAHO, SAUDI ARABIA WYOMING Azfar Mahmood Tel: +966-3-899-6333 Allan Woodbury Mobile: +966-5-3451-2635 Tel: + 801 274-3333 Mobile: + 801 918-4826 Revamping – Training – Troubleshooting
  3. 3. Furnace ImprovementsLow Cost Solutions for Fired HeatersFurnace Improvements Services (FIS) was started in March 1996 in Sugar Land, TX. Ourmission is to provide services for improving the performance of existing fired heaters inrefineries and petrochemical plants. FIS started with conducting engineering studies for firedheaters and provided solutions to customers to overcome operational problems. FIS also saw aneed for training young engineers and operators on how to operate fired heaters and startedoffering heater training courses.For over 15 years, FIS has been helping end users and owners with design and engineeringservices to improve the performance and efficiency of their fired heaters, boilers and reducerefinery NOx emissions.After handling more than 300 studies and projects for CITGO, Valero, ConocoPhillips, Alon,Frontier and other refineries, FIS has developed into a full service engineering and consultingcompany. FIS started supplying new heaters on a turnkey basis in 2002.FIS currently has a team of forty-five people employed, with offices in Sugar Land, TX and inNew Delhi, India. We have been growing at the rate of 35% per year with a vision to be theultimate technology provider for fired heaters and boilers.Our ExpertiseFIS can design and revamp all refinery fired heaters including Crude, Vacuum, CatalyticReformer, Hot Oil, Coker Heater and CO Boilers. Our skilled group of engineers has a combinedexperience of over 300 years.FIS also provides design of new fired heaters to end users. Our designs are the most economical,efficient, and reliable. We ensure that key design parameters are not compromised and heatersperform to their full capacity from day one.We are the only heater company that has developed expertise in rating of industrial boilers andCO boilers. FIS has rated boilers for:• Exxon Beaumont (TX) – CO Boiler• Citgo Corpus Christi (TX) – CO Boiler• Valero Port Arthur (TX) – Boiler NOx Reduction• ConocoPhillips Borger (TX) – Boiler NOx Reduction• ConocoPhillips Wood River (IL) - Boiler NOx Reduction• Targa HRSG Boiler (TX) – Performance Improvement• ConocoPhillips Bayway (TX) – Performance Improvement of Economaizer Revamping – Training – Troubleshooting
  4. 4. Furnace ImprovementsLow Cost Solutions for Fired HeatersNew HeatersFIS provides these services for design, engineering and supply of fired heaters: 1. Engineering • Thermal Design and Modeling of New Fired Heaters • Development of API Data Sheets • Mechanical Design • CFD Modeling • Pressure Parts Design • Intermediate Tube Sheets, Hangers Design • Structural Analysis and Design (STAAD) • GA, Fabrication and Erection Drawings 2. Procurement • Material Requisitions and Engineering Specifications. • Vendor Bid Evaluation • Purchase Requisitions 3. Project Management • Planning and Scheduling • Project Monitoring • Project Progress Report • Vendor Coordination/Follow Up with Client 4. Fabrication • Fabrication Sub-contracted to Renowned Shops • Shop Inspection and Quality Control 5. Site Services • Job Walk with Erection Contractors • Erection Supervision • Heater Start-Up/CommissioningNew Heater SupplyFurnace Improvements has supplied the following heaters:• Citgo Corpus Christi - GHT Heater• Devon Energy - Hot Oil Heater• ConocoPhillips - Hot Oil Heater• ConocoPhillips - Vacuum Heater Revamping – Training – Troubleshooting
  5. 5. Furnace ImprovementsLow Cost Solutions for Fired HeatersRevamping ServicesRevamping fired heaters is a practical and effective way to improve heater performance. Thisfocuses on working with existing components and as a result, investment and downtime isminimized. FIS projects are accessed in the following areas: • Capacity Increase • Efficiency Improvement • NOx ReductionA fired heater revamping project typically has the following phases:Phase I → Engineering Study +/- 30% Cost Estimates.Phase II → Project Design Basis Report with +/- 10% Cost Estimates.Phase III → Detailed Engineering, Project Services, ExecutionFurnace Improvements’ scope of services includes but is not limited to: • Design • Engineering • Project Management • Procurement • Fabrication • Site ServicesHere are some revamp projects FIS has carried out:• Valero, Wilmington Refinery - Platformer Heater, Capacity Improvement• Citgo, Corpus Christi, TX - Platformer Heater, Efficiency Improvement and NOx Reduction• ConocoPhillips, Borger, TX - U40 Boiler NOx ReductionFIS office in Delhi carries out Mechanical Design and Detailed Engineering. Due to the timedifference, work is performed on a 24 hour basis and at much lower cost kept schedules. Revamping – Training – Troubleshooting
  6. 6. Furnace ImprovementsLow Cost Solutions for Fired HeatersComputational Fluid Dynamics (CFD) ModelingComputational Fluid Dynamics (CFD) involves the solution of mass, momentum and heattransfer equations in a particular domain, which is comprised of the geometry of interest. CFDwas developed during the past two decades. Its accuracy in predicting real world problems hasimproved with the present age computers and better models.At Furnace Improvements we utilize CFD to study the design and operating conditions ofheaters, analyze problems and provide solutions.The following are a few areas of concern where FIS has applied this tool: 1. Flow Maldistribution 2. Mixing (Ammonia Injection Grid & Flue Gas Recirculation Mix Box Design) 3. Combustion (Burner & Heater Design) 4. Tube Failures 5. Heat TransferNote: The CFD applications are not limited to the listed items. Furnace Improvements is making every effort toexplore its varied applications and use this powerful tool if and when it is required.CFD gives a competitive edge over other analysis due to its visual presentation of the observations.FIS has applied the CFD studies in the following cases: • ConocoPhillips, Roxana, IL - CO Emission Reduction • ConocoPhillips, Alliance Refinery - NOx Reduction of Crude Heater • ConocoPhillips, Borger, TX - U40 Boiler NOx Reduction • ConocoPhillips – Economizer Flow Modeling • Citgo Lake Charles – Modeling of Combustion Air Ducts Revamping – Training – Troubleshooting
  7. 7. Furnace ImprovementsLow Cost Solutions for Fired HeatersFIS TechnologiesFIS has realized that many heaters present common problems such as: • Low Capacity • High Tube Skin Temperature • Coking Issues • Bad Burner FlameFIS developed and patented three different technologies to eliminate these issues Flue GasInjection, Split Flow and the Inclined Firing System.Flue Gas Injection *Furnace Improvements has developed Flue GasInjection (FGI) as a remedy to: • High tube skin temperatures • Coking issues • Increasing capacity but not increasing radiant flux.This new technology reduces the fireboxtemperature by taking a part of the flue gas from thestack and injecting it near the radiant tubes throughspecially designed nozzles in the heater floor.This technology requires the following additionalhardware: • FGI Fan (Induced Draft Fan) • Cold Flue Gas Ducting to Heater Floor Flue Gas Injection Scheme*Patent # US 7,484,478 B2 Revamping – Training – Troubleshooting
  8. 8. Furnace Improvements Low Cost Solutions for Fired Heaters Split Flow Technology* Furnace Improvements has developed a new approach to increase the capacity of fired heaters without increasing the process side pressure drop. “Split Flow” aims at improved utilization of thermal energy for process heating. This is achieved by splitting the process fluid into two parallel streams: Main Stream – The fluid in the first stream is heated predominantly by the convection and radiant heat transfer mechanism. Split Stream – The fluid in the second stream is heated predominantly by the convective heat transfer mechanism. The streams are combined at the heater outlet. This technology has been very successful for capacity increase revamps in Platformer Heaters. It is extremely efficient and a low cost process. It is very suitable for an increasing capacity by 15- 30%. We have implemented this technology at: • Alon - H2 Heater • ConocoPhillips - ReformerCatalytic Heater • Alon - DHT Heater • Valero Texas City Refinery • Citgo Corpus Christi Refinery • Valero Wilmington Refinery Typical Reformer Heater Split Flow Reformer Heater*Patent # US 7,204,966 B2 Revamping – Training – Troubleshooting
  9. 9. Furnace Improvements Low Cost Solutions for Fired Heaters Inclined Firing System * Most tube failures in fired heaters occur due to high tube skin temperatures. Bad burner flames could lead to high tube skin temperatures through flame impingement in the tubes. Furnace Improvements developed the Inclined Firing System technology in order to avoid flame impingement on tubes. The burners are installed at 5-10° angles. With this arrangement the heater will have the following advantages: • Elimination of flame impingement • Increase of tube life • Increase run length 12-9" TCD 44 ½" 44 ½" 4 BCD Original Firing Scheme Inclined Firing System*Patent # US 7,484,478 B2 Revamping – Training – Troubleshooting
  10. 10. Revamping – Training – Troubleshooting
  11. 11. New Heater Case Studies Revamping – Training – Troubleshooting
  12. 12. Revamping – Training – Troubleshooting
  13. 13. Furnace ImprovementsLow Cost Solutions for Fired Heaters Combined Feed HeaterThe first new heater job by Furnace Improvements(FIS) was for a Corpus Christi refinery. This heater jobwas executed through Jacobs Engineering Group.The new vertical cylindrical heater was a combined feedheater with a natural draft. It is used to heat a mixture ofhydrocarbon and hydrogen.The heater was designed for a heat duty of49MMBtu/hr and an efficiency of 82%.FIS’ scope of services included: • Design • Engineering • Fabrication • Supply The heater was successfully commissioned in August2005. … Revamping – Training – Troubleshooting
  14. 14. Furnace ImprovementsLow Cost Solutions for Fired Heaters Hot Oil HeaterFurnace Improvements (FIS) was employed to supply a new Hot Oil Heater (HT-501) for a gasplant in Wyoming.FIS executed the following activities: The total • Process Design duration • Mechanical Design of this project • Structural Analysis from • Material Procurement and Supply start to end was • Field Installation of the Hot Oil 12 Heater months. This • Piping heater • Instrumentation was successf • Foundation ully commissFIS supplied the burner management system ioned inand procured all the instrumentation controls Augustof the heater. 2007.This hot oil heater is designed for a heatduty of 25.0 MMBtu/hr. The heater has anefficiency of 85.3%. … Revamping – Training – Troubleshooting
  15. 15. Furnace ImprovementsLow Cost Solutions for Fired Heaters Hot Oil HeaterFurnace Improvements (FIS) was employed to supply a new hot oil heater (H-3) in Illinois. The heater was designed for a total heat duty of 165 MMBtu/hr. The design efficiency of this heater is 88%. This heater is fitted with 18 Ultra Low NOx Burners. FIS executed the heater process, mechanical design, structural analysis, material procurement and fabrication. This heater was supplied in 12 months from the date of award of the contract. The heater was designed in parts and modules to minimize work at the site. All the connections were designed to be bolted connections. This is a 6 pass heater and radiant panels were designed for each pass to fit in each radiant panel. The stack outside diameter is 11’ 3 5/8” and the height is 97’ 2”. This stack was shipped in two pieces which would be bolted at the site. The installation of the hot oil heater has been completed in 2009. … Revamping – Training – Troubleshooting
  16. 16. Furnace Improvements Low Cost Solutions for Fired Heaters Vacuum Heater A refinery was facing coking problems in their Vacuum Heater. In addition, they also wanted to revamp the heater to handle Canadian Crude and reduce NOx emissions. FIS did the process study and as a result of the study, the client decided to build a new Vacuum heater with an existing heater foundation. The new heater is 4 ft wider. This vacuum heater is a horizontal tube box with a convection section. It is designed for a heat duty of 43MMBtu/hr. FIS’ scope involves design, engineering, structural analysis and supply of this heater to the site. The heater has an efficiency of 90%. It was successfully commissioned in March 2009. The heater was delivered within 7 months of starting the job. A few months after the start up, FIS received the following feedback from the client.“.. we talked about the performance of the VF4H28 heater since startup. It has been fantastic!The stack temperature is 370-380°F and the fuelgas usage has dropped about 40% from the oldheater. This is one of the most efficient heatersin the refinery. The NOx stack testing cameback 0.026 lb NOx/MMBtu, which is alsooutstanding. They are even trying to reduce theO2 even lower, from 4% to 3%. Its a lotdifferent when you have a tight firebox. Greatjob!!!” -Client … Revamping – Training – Troubleshooting
  17. 17. Revamping – Training – Troubleshooting
  18. 18. Revamping Case Studies Revamping – Training – Troubleshooting
  19. 19. Revamping – Training – Troubleshooting
  20. 20. Furnace ImprovementsLow Cost Solutions for Fired Heaters NHT and Platformer Heater Capacity Increase ProjectFurnace Improvements (FIS) was employed todevelop the best capacity improvement schemefor a #2 Platformer Heater and NHT Heaters.The Platformer Heater (H-20/21/22) wasoriginally designed for 12,000 BPD operation andrated for 119.6 MMBtu/hr process heat duty. Thedesign thermal efficiency of the heater is ~ 88%and was operating at 80 – 81%.Three all radiant heaters (H-18/19/23) along with a3-cell Platformer Heater, share a commonconvection section and a stack.The heaters were running at 13,000 to 15,000BPD charge rate. The client wished to revamp theheaters to 18,000 BPD capacity.The conventional revamp option was to extend the existing radiant cells. The other option was toinstall a new heater for the extra duty required. Extending radiant cells has the followingdisadvantages: • Space limitation • Higher firing rates • Very high costFIS’ recommendation was to increase the capacity of the heater with our patented “Split FlowTechnology”. Based on this, the convection section was replaced with a new one. The existingconvection section was used for steam generation. The new convection section is being used forheating split flow streams for all NHT heaters (H-18/19/23) and Platformer Heaters (H-20/21), inaddition to steam generation.The heaters were revamped for 18,000 BPD capacity and a design heat duty of 150.4 MMBtu/hr.The revamp cost was one fourth of the alternate design. The heater firing was limited to thedesign firing rate. The thermal efficiency of the heaters was increased from 80% to 89%. Theheater was successfully revamped in January 2006, not only for increased capacity but also forimproved thermal efficiency and improved reliability. In addition, the Platformer Heater burnerswere replaced with new Ultra Low NOx flat flame burners. … Revamping – Training – Troubleshooting
  21. 21. Furnace ImprovementsLow Cost Solutions for Fired Heaters Alky Heater (H-2) NOx Reduction and Efficiency Improvement Project Furnace Improvements (FIS) was hired to perform aturnkey NOx Reduction revamp on an Alky Unit Heater(H-2). The target NOx emission rate was 0.035 lb/MMBtu(HHV). The Alky Heater is a vertical cylindrical heaterwith a design heat duty of 55 MMBtu/hr. The heaterefficiency was very low at 66%.Excess oxygen in the firebox was very high at 8.5%. Theheater floor was in bad shape. The heater did not have anystack damper for draft control.FIS’ scope included finalization of thermal design andengineering, procurement of material, fabrication, supplyand field installation of the heater.FIS’ scope of services included:• Modification of Existing Floor• Install Eight New Ultra Low NOx Burners (ULNB)• Install New Convection Module• Installation of New Stack and DamperAfter the revamp, the efficiency increased by 20%. The total cost of the project for the designservices, engineering services, fabrication and installation was $1,560,000. The project payoutwas estimated to be less than 2 years. This heater was successfully commissioned in March2008. … Revamping – Training – Troubleshooting
  22. 22. Furnace ImprovementsLow Cost Solutions for Fired Heaters Convection Section Modifications in CO Heater for SCR InstallationFurnace Improvements (FIS) was contacted to help with a carbon monoxide (CO) heater (CCU-1) in a fluid catalytic cracking (FCC) unit. It is used to combust the FCC off gas (mainly CO gas)from the spent catalyst regenerator unit.The hot flue gases generated from combustion of FCC off gas are used to preheat the oil andgenerate super heated steam @ 600 psig / 700 °F. The client was installing a new SCR unitdownstream of the CO Heater as a part of their consent decree agreement to reduce the NOXemissions.The new SCR requires a flue gas inlet temperature in the range of 680-700 °F, which requiredreconfiguring the heat transfer surface in the convection section.Furnace Improvements modeled theconvection section for five proposed casesand provided a revised design. The clientapproved FIS design and we have completedthe detail engineering of the revampconvection section.They also had CO slippage problems andpost combustion in the convection sections.FIS analyzed this issue as well and came upwith a practical solution.FIS developed a computational fluiddynamic (CFD) model of the existingcombustion chamber and found out thatmixing of FCC off gas and air was very poorin the combustion chamber leading toincomplete combustion in the firebox andpost combustion in the convection section.All modifications to CO Heater (CCU-1) were successfully executed during the February 2008turnaround. … Revamping – Training – Troubleshooting
  23. 23. Furnace ImprovementsLow Cost Solutions for Fired Heaters CDHDS Reboiler Heater (H-60) Efficiency Improvement ProjectFurnace Improvements (FIS) was employed by a Texas refinery to develop an efficiencyimprovement scheme for CDHDS reboiler heater (H-60).The CDHDS reboiler heater is a vertical cylindrical natural draft heater built in 2002. The CDHDSreboiler heater (H-60) was designed for a process duty of 72 MMBtu/hr. With the help of FurnaceImprovements it now has a design efficiency of 81%. The heater was operating at an efficiency of79%, with the flue gas stack temperature of 780°F.FIS reviewed the design and proposed the followingchanges to improve the efficiency: • Adding six rows of steam generation coil in convection section • New stack transition cone • 25 ft of stack extensionIn this scheme, 71,000 lb/hr of 450 # steam condensate isflashed to 150 # 2 phase, vapor-liquid stream. Flashing iscompleted before it enters the convection section.The total heat duty of the heater was increased to 82MMBtu/hr. The extra 10 MMBtu/hr is absorbed in steamgeneration coil. Flue gas temperature leaving the stackwas reduced at 400°F. The efficiency of the heater wasincreased to 90%, which brought energy savings ofapproximately USD $ 590,550 per year. The paybackperiod is 1 year 3 months.This project has been successfully commissioned inOctober 2007. … Revamping – Training – Troubleshooting
  24. 24. Revamping – Training – Troubleshooting
  25. 25. Technical ArticlesRevamping – Training – Troubleshooting
  26. 26. Revamping – Training – Troubleshooting