Revamping

Revamping Fired Heaters

★Longer Run Lengths
★Capacity Increase
★Efficiency Improvement
★Lower NOx Emissions

Revamping fired heaters is a practical and effective way to improve heater performance. This focuses on working with existing components and as a result, investment and downtime is minimized. Revamping provides : 

  • Longer Run Lengths
  • Capacity Increase
  • Efficiency Improvement
  • Lower NOx Emissions

A 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 and Project Services.

Furnace Improvements’ scope of services includes but is not limited to:

  • Engineering
  • Project Management
  • Procurement
  • Fabrication
  • Site Services

FIS office in Delhi carries out Mechanical and Structural Design work, Detailed Engineering and provides support for other disciplines. Due to the time difference between US and Indian offices, work gets done round the clock.

FIS Technologies

Heaters have many common problems such as low capacity, high tube skin temperature, coking issues and bad burner flame. To combat these issues FIS developed and patented different technologies.

Reference List:

Alon Refining: Revamp of Atmospheric Heaters 1H-1A/B/C and Vacuum Heater (2H-1)
Scope of Work: Engineering & Project Services for Installation of Low NOx Burners in Atmospheric Heaters 1H-1A/B/C and Vacuum Heater (2H-1)

CITGO Corpus Christi, TX: No.4 Platformer Heater Efficiency Improvement and NOx Reduction (Split Flow)
Scope of Work: Design, Detail Engineering, Structural Design Checks and Shop Drawings, Erection and Start-up Assistance

CITGO Corpus Christi, TX Reboiler Trim Heaters Efficiency Improvement
Scope of Work: Design, Detail Engineering, Fabrication Drawings, Engineering Specifications, Material Requisitions and Supervision of Field Activities

Husky Oil, Lima, OH Crude Furnace NOx Reduction and Efficiency Improvement
Design, Detail Engineering, Fabrication Drawings, Detailed Specifications for Tubes, finning, Tube Supports, Burners, Burner Supports, fabrication and Erection

Phillips66, Ponca City, OK NOx Reduction Project for Reformer Furnace H-48
Scope of Work: Engineering and Project Services for Reformer Furnace H-48 NOx Reduction Project

Alon USA, Big Spring, TX FCCU Feed Preheater
Scope of Work: Low NOx Burner Replacement

Valero, Texas City, TX: NHT and Platforming Heaters Capacity Increase with Patented Split Flow Technology
Scope of Work: Replacement of Coils, Radiant Floor, Burners, New Convection Section and Stack Damper

Valero, Wilmington, CA : Platformer Heater Capacity Increase with patented Split Flow Technology
Scope of Work: Process Design, Detailed Engineering, Structural Design Check, Shop Drawing, Fabrication of Convection Section. FIS provided Erection and Commissioning Assistance

Phillips66, Belle Chasse, LA NOx Reduction in Crude Heater
Scope of Work: Design, Engineering and Supply for revamp of Crude Heater involving new Waste Heat Recovery unit, modification of existing convection section and upgradation of FD and ID Fans. FIS also carried out CFD Modeling Study of its SCR unit and developed Process Design Package.

Valero, Port Arthur, TX Capacity Increase Revamp Project for Charge Heater
Scope of Work: Engineering and Installation of Stack Damper and Air Preheater

Alon Refining, Big Spring, TX: Capacity Improvement of Reactor Charge Heater (080-H-001)
Scope of Work: Design, Engineering, Supply and Commissioning

Phillips66,Borger, TX: U40 Boiler NOx Reduction Project
Scope of Work: Design, Engineering, Fabrication, Supply and Site services for revamp of CO Boiler (U-40) involving new Superheater, Economizer, Burners, FGR system, Dampers, Expansion joints etc.

Phillips66, Roxana, IL: Alky Heater (HM2) NOx Reduction Project
Scope of Work: Design, Engineering, Fabrication & Supply for revamp of Alky Heater (HM2) involving New Convection Section, Stack, Floor and Ultra Low NOx Burners

Alon USA, Big Spring, TX: Replacement of FCCU Feed Preheater
Scope of Work: Process Design and Engineering, Fabrication Drawings and Material Requisition. FIS also provided Erection and Commissioning Assistance

Valero, Texas City, TX : CDHDS Reboiler Heater (H-60) Efficiency Improvement
Scope of Work: Revamp of Convection Section and Stack. Efficiency of Heater was improved to 90%

CountryMark CO-OP, Mt. Vernon, IN: Vacuum Heater 200-H4 Capacity Increase
Scope of Work: Process Design, Detail Engineering, Structural Design, Mechanical Design, GA Drawings, Shop Fabrication Drawings, Erection and Commissioning Supervision

Lion Oil Eldorado Refinery, Eldorado, AR NOx Reduction Project
Scope of Work: Process Design, Detail Engineering, Procurement, Fabrication and Erection Services

Alon USA, Big Spring, TX: ULSG Hydrogen Heater Efficiency and Capacity Increase (77H-001)
Scope of Work: Detail Engineering, Procurement and Fabrication of New Convection Section and Stack. FIS used Split Flow Technology.