Let us cool your hot tubes !

Furnace Improvements Services (FIS) started in March 1996 in Sugar Land, TX. Our mission is to provide services for improving the performance of existing fired heaters. FIS began providing engineering studies for fired heaters that recommended solutions to customers with operational problems. FIS also saw a need for training engineers and operators on how to operate fired heaters optimally and started offering heater training courses. Progressing from consulting and training services, FIS revamped its first heater in 2000 and subsequently supplied its first new heater in 2002.

For over 20 years now, FIS has been helping end users and owners with design and engineering services to improve the performance and efficiency of their fired heaters and boilers as well as help refinery reduce NOx emissions. FIS has performed over 400 studies for Clients like CITGO, Valero, ConocoPhillips, Alon, Frontier and Total. FIS currently has offices in Sugar Land, TX and in New Delhi, India. We have been growing at the rate of 35% per year with a vision to be the ultimate technology provider for fired heaters and boilers.

New Heater Design

When it comes to buy a new fired heater, it is important to ensure a good design, in paper as well as in reality, keeping key parameters with an economical approach. FIS understand you and for that we offer the most economical, efficient and reliable fired heater designs. We ensure key parameters are not compromised and heaters performance to their full capacity from day one.

We have provided designs of crude, vacuum and hot oil heaters. All of our heaters have been working without any problem. Our crude and Vacuum heaters were designed for 8 years run length. FIS designed the transfer line for these heaters to ensure that there is no mismatch at the heater outlet conditions

Engineering Design

Let us design your new Fired Heater.

With years of experience inspecting and revamping heaters, we know exactly what goes into making an efficient, economical, and long-lasting heater. Our engineering services are:

  • Thermal Design and Modeling
  • 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

Revamping

FIS has the experience and knowledge to revamp any refinery fired heater, industrial boilers or CO Boilers. FIS projects cover the following areas:

  • Capacity Increase
  • Efficiency Improvement
  • NOX Reduction

A fired heater revamping project typically has the following phases:

Phase I → Engineering Study.
Evaluation of the heater is carried out and revamp options are given to the client with a ± 30% Cost Estimation.

Phase II → Project Design Basis Report.
Revamp option is selected, mechanical and structural analysis are done. Supplier quotes are evaluated and a ± 10% Cost is Estimated.

Phase III → Detailed Engineering and Project Services.
Fabrication and erection drawings are drawn, procurement is done and project services are provided for the execution of the project.

Furnace Improvements’ scope of services includes but is not limited to: Engineering, Project Management, Procurement, Fabrication, Site Services.

NOx Reduction

Pollutant-emission laws governing combustion equipment are increasing every year. EPA just release (December 2010) a 2 year plan for setting limits in Green House Gasses (GHG) emissions for oil refineries and power plants.

Finding the means for limiting GHG and also reducing NOx from fired heaters and boilers has become a priority of many sectors in the Chemical Process Industries.

FIS has the knowledge and experience to provide the best economical approach to reduce these emission and at the same time increase capacity, improve efficiency, and/or increase reliability.

FIS results speak for themselves. We have handle and successfully executed more than a dozen of NOx reduction projects. FIS is comfortable using ULNB, Flue Gas recirculation, SCR installation and other technologies for reaching the emission targets.

Troubleshooting

It is common to encounter problems like high tube skin temperatures, high excess air operation, positive pressure, or excess corrosion. We can help.

Computational Fluid Dynamics (CFD) involves the solution of mass, momentum and heat transfer equations in a particular domain, which is comprised of the geometry of interest. CFD was developed during the past two decades. Its accuracy in predicting real world problems has improved with the present age computers and better models.

FIS utilizes CFD to study the design and operating conditions of heaters, analyze problems and provide solutions.

The following are a few areas of concern where FIS has applied this tool:

  • Flow Maldistribution
  • Mixing (Ammonia Injection Grid & Flue Gas Recirculation Mix Box Design)
  • Combustion (Burner & Heater Design)
  • Tube Failures
  • Heat Transfer

FIS offers on-site training programs to train and guide your engineers and operators. Our training programs will provide greater understanding of the principles and practices associated with efficient design and optimum operation of fuel-fired furnaces, with emphasis on enabling participants to improve the performance of their furnaces.

Trainings offered by FIS

  • Refinery Fired Heaters
  • Fired Heaters for Operators
  • Fired Heaters for Engineers
  • NOx Reduction

These trainings are designed to give solid basis and tools to understand how a furnace works. As a result the attendees will make educated decisions to improve the heater performance.

In the training, we present actual case studies discussing various aspects of fired heaters operation and troubleshooting. We encourage engineers and operators to bring their operating and maintenance problems and questions for discussions at the course.

We can customize our trainings for your technical personnel. It can be developed for Engineers, Operators, Senior Engineers, etc. These trainings can also be customized to include the topics that you want us to cover. And we can include your heaters design, which enable the participants to connect more with the subject being explained.