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Measuring Fired
Heater Efficiency
This guide will teach you the
process of measuring and
calculating your heaters
efficiency so you can
optimize your plant and
save money.
Based on method outlined in API 560
Annex G
Procedure intended for fired heaters
burning liquid or gaseous fuels. Not
recommended for solid fuels.
Tulsa Heaters Midstream
FUEL EFFICIENCY
- total heat absorbed divided by heat input derived
from the combustion of the fuel only
Tulsa Heaters Midstream
Equipment Needed
Temperature-measuring devices, such as
thermocouples or thermometers, to
measure the temperature of:
Fuel
Ambient air
Atomizing medium (if applicable)
Flue gas
Thermal fluid
Testing
Test procedure:
The heater shall be operated at a uniform rate throughout the test
Data shall be taken at the start of the test, and every 2 hours thereafter
The duration of the test shall extend until three consecutive sets of
collected data fall within the prescribed limits
Measurements:
Fuel gas quantity and heating value
Flue-gas temperature and composition analysis
Tulsa Heaters Midstream
Example
10
Thermal Efficiency
=
+ + + ( +
+ + +
Where:
11
Step 1:
Combustion Worksheet
Fuel
Component
Column 1
Volume
fraction
%
Nitrogen
1.61
Carbon
dioxide
0.15
Methane
98.17
Ethane
0.08
TOTAL
Total per
pound of
fuel
14
Combustion Worksheet
Fuel
Component
Column 1
Column 2
Volume
fraction
%
Relative
molecular
mass
Column 3
(1x2)
Total
mass
(lb)
Column 4
Net
heating
value
Column 5
(3x4)
Heating
value
(Btu/lb)
(Btu)
Nitrogen
1.61
28.0
0.4508
Carbon
dioxide
0.15
44.0
0.066
Methane
98.17
16.0
15.70
21,500
337,704.80
Ethane
0.08
30.1
0.02
20,420
491.71
TOTAL
16.25
338,196.51
Total per
pound of
fuel
20,814.55
(5)
15
Calculate products of
combustion for fuel
Combustion Worksheet
Fuel
Component
Column 1
Column 2
Volume
fraction
%
Relative
molecular
mass
Column 3
(1x2)
Total
mass
(lb)
Column 4
Net
heating
value
Column 5
(3x4)
Heating
value
(Btu/lb)
(Btu)
Column 6
Air
required
Column 7
(3x6)
(lb air/lb)
Air
required
(lbs)
Column 8
CO2
formed
Column 9
(3x8)
(lbs CO2/lb)
CO2
formed
(lbs)
Column 10
H2O
formed
Column 11
(3x10)
Column 12
N2
formed
Column 13
(3x12)
(lbs H2O/lb)
H2 O
formed
(lbs)
(lbs N2/lb)
N2
formed
(lbs)
Nitrogen
1.61
28.0
0.4508
Carbon
dioxide
0.15
44.0
0.066
Methane
98.17
16.0
15.70
21,500
337,704.80
17.24
270.79
2.74
43.04
2.25
35.34
13.25
208.12
Ethane
0.08
30.1
0.02
20,420
491.71
16.09
0.39
2.93
0.07
1.80
0.04
12.37
0.30
TOTAL
16.25
338,196.51
271.18
43.11
35.38
208.42
Total per
pound of
fuel
20,814.55
16.69
2.65
2.18
12.83
(5)
(7)
(9)
(11)
(13)
16
Column 1
Column 2
Volume
fraction
%
Relative
molecular
mass
Column 3
(1x2)
Total
mass
Column 4
Net
heating
value
Column 5
(3x4)
Heating
value
(Btu/lb)
(Btu)
Column 6
Air
required
Column 7
(3x6)
(lb air/lb)
Air
required
(lbs)
Column 8
CO2
formed
Column 9
(3x8)
(lbs CO2/lb)
CO2
formed
(lbs)
Column 10
H2O
formed
Column 11
(3x10)
Column 12
N2
formed
Column 13
(3x12)
(lbs H2O/lb)
H2 O
formed
(lbs)
(lbs N2/lb)
N2
formed
(lbs)
Nitrogen
1.61
28.0
0.4508
Carbon
dioxide
0.15
44.0
0.066
Methane
98.17
16.0
15.70
21,500
337,704.80
17.24
270.79
2.74
43.04
2.25
35.34
13.25
208.12
Ethane
0.08
30.1
0.02
20,420
491.71
16.09
0.39
2.93
0.07
1.80
0.04
12.37
0.30
TOTAL
16.25
338,196.51
271.18
43.11
35.38
208.42
Total per
pound of
fuel
20,814.55
16.69
2.65
2.18
12.83
(5)
(7)
(9)
(11)
(13)
17
Relative Humidity
Correction for relative humidity:
vapor
18
moisture in air =
air
100 28.85
where:
vapor
air
14.696 psi
18
0.364
50
18
=
Relative Humidity
(a)
vapor
18
moisture in air =
air
100 28.85
where:
vapor
air
14.696 psi
19
0.364
50
18
=
Relative Humidity
Correction for relative humidity:
(a)
16.69
air required (7)
=
=
1 0.0077
1 moisture in air (a)
vapor
18
moisture in air =
air
100 28.85
(b)
where:
vapor
air
14.696 psi
20
0.364
50
18
=
Relative Humidity
Correction for relative humidity:
(a)
16.69
air required (7)
=
=
1 0.0077
1 moisture in air (a)
vapor
18
moisture in air =
air
100 28.85
(b)
(c)
where:
vapor
air
14.696 psi
21
0.364
50
18
=
Relative Humidity
Correction for relative humidity:
(a)
16.69
air required (7)
=
=
1 0.0077
1 moisture in air (a)
vapor
18
moisture in air =
air
100 28.85
(b)
(c)
where:
vapor
air
14.696 psi
(d)
22
Excess Air
Correction for excess air:
N2 formed CO2 formed H2 O formed
(28.85
%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required
NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.
23
(13)
Excess Air
(9)
(d)
%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required
(e)
NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.
24
(13)
Excess Air
(9)
(d)
%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required
(e)
(e)
2.50
100
16.69
(f)
NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.
25
(13)
Excess Air
(9)
(d)
%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required
(e)
(e)
2.50
100
16.69
(f)
14.98
0.1295 + 2.31
100
= 2.33 total lbs H2O per lb of fuel (corrected for excess air)
=
(g)
26
Stack Loss
Component
Column 1
Component formed
(lb per lb of fuel)
Carbon dioxide
2.65
Water vapor
2.33
Nitrogen
12.83
Air
2.50
Total
20.31
27
Stack Loss
Exit flue-gas temperature, : 500F
Component
Column 1
Column 2
Component formed
(lb per lb of fuel)
Enthalpy at T
(Btu/lb formed)
Carbon dioxide
2.65
100
Water vapor
2.33
192
Nitrogen
12.83
120
Air
2.50
110
Total
20.31
28
Stack Loss
Exit flue-gas temperature, : 500F
Component
Column 1
Column 2
Component formed
(lb per lb of fuel)
Column 3
Enthalpy at T
Heat content
(Btu/lb formed)
(Btu/lb of fuel)
Carbon dioxide
2.65
100
265.31
Water vapor
2.33
192
446.72
Nitrogen
12.83
120
1,539.27
Air
2.50
110
274.98
Total
20.31
2,526.28
29
Step 2:
Thermal Efficiency
=
+ + + ( +
+ + +
Where:
31
Heat Losses
Heat loss due to air:
= a ( ) ( )
= a ( ) ( )
where:
= 46.37 Btu/lb
32
Heat Losses
Heat loss due to fuel gas:
= fuel ( )
= fuel ( )
where:
fuel
= 23.47 Btu/lb
33
Heat Losses
Heat loss due to atomization medium:
= ( )
= 0
where:
enthalpy difference
mass of steam (lb)
34
Radiation Losses
Heat loss due to radiation:
= %radiation loss
= 20,814 0.015
= 312.24 Btu/lb
35
Step 3:
Thermal Efficiency
=
+ + + ( +
+ + +
Where:
20,814 Btu/lb
46.37 Btu/lb
23.47 Btu/lb
0 Btu/lb
312.24 Btu/lb
2,526.28 Btu/lb
Tulsa Heaters Midstream
37
Thermal Efficiency
=
Where:
20,814 Btu/lb
46.37 Btu/lb
23.47 Btu/lb
0 Btu/lb
312.24 Btu/lb
2,526.28 Btu/lb
+ + + ( +
+ + +
=
=
+ + + ( +
+ + +
, + . + . + (. + , . )
, + . + . +
= 86.4%
38
Fuel Efficiency
+ + + ( +
=
Where:
20,814 Btu/lb
46.37 Btu/lb
23.47 Btu/lb
0 Btu/lb
312.24 Btu/lb
2,526.28 Btu/lb
Tulsa Heaters Midstream
39
Fuel Efficiency
+ + + ( +
=
Where:
20,814 Btu/lb
46.37 Btu/lb
23.47 Btu/lb
0 Btu/lb
312.24 Btu/lb
2,526.28 Btu/lb
+ + + ( +
=
, + . + . + (. + , . )
=
,
= 86.7%
40
Conclusion
Knowing how to check your heaters efficiency gives you the
42
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