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Kesler Engineering, Inc.

Kesler Engineering, Inc. Fired Heater Sentinel. Introduction to KEI. KEI Established 1979 by Michael Kesler Co-Author of Lee-Kesler Correlation for Thermodynamic Properties of Mixtures Developed First Industry General Process Simulator (MW Kellogg -1958) Main Business Process Engineering

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Kesler Engineering, Inc.

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  1. Kesler Engineering, Inc. Fired Heater Sentinel

  2. Introduction to KEI • KEI Established 1979 by Michael Kesler • Co-Author of Lee-Kesler Correlation for Thermodynamic Properties of Mixtures • Developed First Industry General Process Simulator (MW Kellogg -1958) • Main Business • Process Engineering • Software Products • Sophisticated highly focused models that work on-line with PI and ProcessBook • KEI is Partly Owned by OSI Software

  3. Fired Heater Sentinel - Problem Statement • Correct operation of fired heaters has a large impact on the profitability and safety of plants • Information required for proper operation is obtainable from raw process data only with the aid of detailed models designed for real-time operations

  4. Fired Heater Sentinel - Coking and Scaling • Process Fluids Are Heated to Thermal Stability Limits to Improve Product Quality and Unit Throughput. • Exceeding Thermal Stability Limits Results in Coke Laydown (or Scaling). This is irreversible during operations. • Coking and Scaling Result in High Tube Metal Temperature. Heater Duty Must Be Reduced to Eliminate Risk of Tube Rupture.

  5. Fired Heater Sentinel - Economics • Over-All Process and Fired Side Efficiency Calculations • Process Side Calculations Much More Accurate • Requires Flash and Composition (obtained from reconstituted product specs and flows) • Immediate Notification of Abnormal Situation • Sensor Malfunction • Inefficient Operation • Equipment Failure

  6. Fired Heater Sentinel - Economics • Calculation of Lost $ Due to Excess Air • Calculation of Lost $ Due to Heater Flooding/Bogging • Calculation of Lost $ Due to Capacity Reduction From Coking/Fouling • Advice on Which Heater to Clean and When

  7. Fired Heater Sentinel - Heater Health • Heater Health Baseline Obtained From Historical Data • Pass by Pass Calculation and Monitoring of: • Duty • Heat Flux • Mean Metal Temperature • Convection and Radiant Section Duty • Coking Thickness

  8. Fired Heater Sentinel - Heater Health • Indication of Coking Events • Monitoring of Convection Section After-Burning • Convection Section Fouling • Long Term Ratio of Convection Section Heat Input to Total Heat Input • Draft Limit at Arch, Stack Damper Open, Firing Within Historical Limits

  9. Fired Heater Sentinel - Safety • Key is Calculation of Convection and Radiant Section Duties • Requires Process Flash and Composition (obtained from reconstituted product specs and flows) • Abnormally High Individual Pass Convection Section Duty Suggests Convection Section Seam Split • Increase in COT (Duty Ratios Unchanged), Suggests Radiant Section Leak

  10. Fired Heater Sentinel - Implementation • Easy to Use Setup Wizard • Guides You Through Configuration and Selection of PI Tags • Makes Intelligent Assumptions When Data or Instrumentation Is Not Available • Detailed Knowledge of Heater Geometry and Burner Characteristics is Not Required • Intuitive - Little or No Training Required

  11. Models: COM Objects • Use the same model for off-line what-if analysis • Excel spreadsheets, VB applications • Open equation model format permits flexible case studies • “How much fuel would be required if stack temperature was 550ºF?” • On-line case studies

  12. Fired Heater Sentinel - Value • A 2% Increase In Efficiency For a 200 MM Btu/hr Heater Results in a Savings of US$70,000/yr • If Fired Heater Is the Plant Constraint, 1% Increase in Heat Transfer (by Preventing Coking) Will Increase Throughput by 1% • Up to US$1 Million/yr in Refining Margins for a 100,000 BPD Refinery

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