1.
0 American Petroleum Institute (API):
The American Petroleum Institute (API) is the primary trade association and standard-setting
organization for the oil, natural gas, and petrochemical sectors. API, which was established in
1919, plays a key role in the promotion of safe work practices, safe operations,
environmental stewardship, and uniform equipment standards. API was the originator of,
and still develops and maintains, over 700 standards, recommended practices (RPs), and
specifications that are recognized internationally.
API standards are used in both U.S. industrial projects and around the world, encouraging
interoperability, reliability and regulatory compliance.
API standards appear in various places around the world and are typically reviewed and
referenced in project specifications, regulatory compliance, and/or procurement. Following
are several API standards on equipment:
API 610 - Centrifugal pumps for petroleum and petrochemical service
API 676 - Positive displacement rotary pumps
API 661 - Air-cooled heat exchangers for refinery service
API 660 - Shell-and-tube heat exchangers for process applications
API 520/521/526 - Pressure-relieving systems (valves, safety devices)
API 560 - Fired heaters for general refinery service
2.0 API Fired Heaters:
An API fired heater is an industrial heater designed and manufactured in accordance with
API Standard 560 with specific emphasis on traditional use in refineries and petrochemical
plants to heat process fluids (such as crude oil, hydrocarbons, and gases) at high
temperatures to be further processed.
The API 560 standard provides that fired heaters are heat transfer devices that can comply
with stringent specifications for safety, reliability, heat transfer efficiency, combustion
quality, and emissions control.
2.1 Main Features of fired heaters:
Casing: The casing of a fired heater is the outer protective casing; the casing encloses and
protects the heater within. The primary function of the casing is to provide structural
support and insulation to minimize heat loss to the environment.
Tubes: In a fired heater, tubes are hollow transfer lines that filled with hot gases that convey
heat to the process fluid. These pipes are essential for heat transfer, allowing combustion
gases transfer their energy to whatever substance is being processed to improve the
efficiency of the overall system.
Heating Sections:
Radiant Section: This is where most heat is supplied to the tubes as the burners directly heat
the tubes using radiant heat.
Convection Section: This is a section above the radiant section and utilizes hot flue gases to
preheat the fluid through convection.
Burners:
High-efficiency burners burn fuels such as natural gas, diesel, or refinery off-gas. Burners
governed by API 560, dictate burner arrangements, air-to-fuel ratio, and flame monitoring to
ensure stable, clean combustion and safety.
Type of Draft:
Natural Draft: When passive airflow through the heater is achieved through a chimney
effect.
Forced Draft: Uses fans to determine air flow for combustion.
Balanced Draft: Predominantly consists of forced draft with some induced draft to allow for
better control.
Air Preheaters (APH): They are heat exchangers that preheat combustion air with flue gases.
This process increases overall efficiency by using the waste heat that would otherwise be
lost to improve the energy performance of the heater.
Induced Draft (ID) Draft (Forced Draft) fans control the movement of air and gases in the
fired heater. The fans are critical for balancing the delivery of air and fuel, maintaining
efficient combustion, and increasing the overall efficiency of the heating system.
Dampers: They are adjustable plates or valves that regulate airflow in the fired heater.
Dampers allow operators to regulate airflow, which in turn regulates combustion. Using
dampers allows operators to maintain ideal operating conditions to control and optimize
combustion, and fuel efficiency.
Stack: The stack is used to exhaust exhaust gases produced by the heater. It provides
ventilation and maintains the proper airflow. The stack can also play a role in emissions
control; as well as being able to manage the flow of flue gases and to provide safeguarding
against pressure build-up.
Emissions and Safety Controls:
Equipped with flame scanners, pilot igniters, and shutdown systems for emergency and
unintended situations.
2.2 Working of Fired Heaters:
The combustion begins by first establishing a pilot fuel flame—typically a readily consumable
gaseous fuel (e.g., natural gas or propane) to start combustion. The pilot is ignited using a
spark or electric igniter and confirmed by flame detectors. This provides a stable flame
source that can be used for igniting the main fuel, which can either be natural gas or liquid
fuel (such as diesel or refinery gases). Once ignited, both the pilot fuel and main fuel mixes
with combustion air that should be preheated to prevent inefficiencies with ignition and
complete combustion. The air-fuel mixture enters the burners, the main fuel flame is
established, and the heat released is transferred through two zones, comprising the radiant
section where the actual flame exposes the process tubes to radiant heat, and the
convective section, where the hot flue gases flowing over the tubes provide convective heat.
As the process fluid passes through these tubes, it is gradually heated to the appropriate
temperature. The radiant section supplies most of the heat and the convection section
improves thermal efficiency by recovering residual heat from the exhaust gases.
Lastly, the stack is where the exhaust gases are vented from the heater to the atmosphere. It
will often incorporate systems to manage flue gas movement, ensuring proper venting and,
in some cases, assists in limiting emissions using control systems.
API Fired Heater
3.0 Types of Fired Heaters:
1. Based on Configuration and Geometry:
Box-Type (Cabin) Heaters
Rectangular (box-type) enclosure with burners usually placed on one or several walls,
commonly used for crude oil and hydrocarbon heating.
Cylindrical Heaters (Vertical or Horizontal)
Elongated, round (fire-tube-type) heater designs are employed in applications where heat is
evenly distributed and there is a greater ability to handle pressure.
2. Based on Orientation:
Vertical Fired Heaters
The radiant section is vertical. This configuration is typically beneficial when space is limited
and heat transfer must be applied to coils that are vertical or when uniform heat transfer
around the coil is desired.
Horizontal Fired Heaters
Radiant tubes are horizontal. This design is favored if the area has few height restrictions but
has limitations on surface access obstructed. This is also advantageous for maintenance
activities.
3. Based on Heat Transfer Method:
Direct-Fired Heaters
The combustion flame or flue gases directly heat the process fluid. High thermal efficiency
but for processes where the fluid may be contaminated, direct-fired heat may not be
permissible.
Indirect-Fired Heaters
The process fluid contacting flue gases or combustion byproducts is avoided. A heat transfer
medium (for example, thermal oil or steam) can transfer heat to the process fluid or
medium. Useful for temperature-sensitive applications.
