Track heater 1 6. Oil heaters and furnaces. Operating principle of track heaters
Description
PP track heaters are used for heating various oil emulsions and oil products, including viscous ones, intended for transport. Basically, oil heaters are used as part of an oil treatment complex at oil producing and oil refining enterprises.
Design and operating principle of PP track heaters
Structurally, PP oil heaters are a horizontal or vertical cylindrical vessel. Inside the container there is a heating unit, consisting of two coils (a tubular product coil and a fuel heating coil) and two combustion chambers. In the lower part of the body, a frame support for the sled structure is welded to the vessel.
The principle of operation of the heater is the heat exchange process between the oil emulsion and the intermediate coolant, which is heated to operating temperature from the heat of fuel combustion products. The fuel can be natural gas, associated petroleum gas, diesel fuel or treated, purified and reduced oil.
The fuel first enters a gas or liquid fuel burner, and then into a U-shaped firebox with a diameter of 630 mm, where it heats the intermediate coolant.
The heated oil emulsion enters the product coil, which is heated by the coolant, which occupies the entire volume of the vessel, and is then discharged from the container into the main pipeline.
Exhaust and cooled gases are removed from the heater through chimneys.
For ease of maintenance, PP track heaters are equipped with a ladder and a service platform.
The automation and alarm system ensures the safe operation of explosive equipment. The PP heater kit includes indicators and sensors for coolant and oil emulsion levels, pressure gauges, thermometers, shut-off and safety devices and breathing valves. The heater automation is configured to automatically regulate the temperature of oil heating.
If diesel or oil is used as fuel, the PP heater includes a liquid fuel preparation unit, in which it is purified and reduced.
Model range of supplied track oil heaters
Specialists of TD SARRZ supply the following types of track oil heaters to the operation site:
- heaters PP-0.63A and PP-1.6A using natural or associated petroleum gas
- heaters PP-0.63AZh and PP-1.6AZh using liquid fuel (field refined oil)
- heaters PP-0.63AZh-K with a single-flow coil design with combined fuel supply
- heaters PP-0.63A-D with double-flow coil designs (two parallel flows with two input and output flows)
- heaters PP-0.63AMZhG and PP-1.6AMZhG on gas and liquid fuel
- heaters PP-0.063AS
Diagram of the PP oil track heater
1-furnace body, 2-sleigh, 3-fixed support, 4-movable support, 5-platform, 6-fence, 7-firebox, 8-smoke pipe, 9-furnace front, 10-fuel system installation, 11-manifold oil inlet, 12-oil outlet manifold
Purpose of fittings: A1-oil supply, B1-oil drainage, B1-water filling, G1-water overflow, D1-fuel oil supply, E1-drainage, Z1-installation hatch
Technical characteristics of PP type track heaters
| Options | PP- 0.63A |
PP- 0.63АJ |
PP-0.63 AMZHG |
PP- 0.063AC |
PP- 1.6A |
PP- 1.6AZH |
PP-1.6 AMZHG |
|---|---|---|---|---|---|---|---|
| Thermal power, MW (Gcal/h) | 0,73 (0,63) | 1,86 (1,6) | |||||
| Capacity for heating product, t/day: oil emulsion, water content 30% mass at t=25ºC | 1150 | 23500 | |||||
| Product temperature, ºC: | |||||||
| at the entrance to the heater | +5 | ||||||
| at the exit | +70 | ||||||
| heating the intermediate coolant | +95 | ||||||
| Efficiency, %, no more | 80 | 80 | 70 | 80 | |||
| Type of intermediate coolant | fresh water, ethylene glycol solution and other non-flammable | ||||||
| Pressure in the product coil, MPa: | |||||||
| working | 6,3 | ||||||
| calculated | 6,3 | ||||||
| hydraulic | 8,2 | ||||||
| Working environment | oil, oil emulsion | ||||||
| Working environment characteristics: | |||||||
| density at 20ºC, kg/m 3 | 900 | ||||||
| viscosity at 20ºC, cSt | 100 | ||||||
| hydrogen sulfide content (H2S), %mol. | 0,01 | ||||||
| content of carbon dioxide CO2, % mol. | 1,0 | ||||||
| Fuel characteristics - natural or associated petroleum gas: | |||||||
| hydrogen sulfide (H2S) content, wt. share, % | 0,002 | - | 0,002 | 5 | 0,002 | - | 0,002 |
| calorific value, MJ/m 3 | 35-60 | - | 35-60 | 35-60 | 35-60 | - | 35-60 |
| pressure at the inlet to the fuel preparation unit, MPa | 0,2-0,4 | - | 0,2-0,4 | 0,2-0,4 | 0,2-0,4 | - | 0,2-0,4 |
| pressure in front of the burner, MPa | 0,07-0,15 | - | 0,03 | 0,07-0,15 | 0,07-0,15 | - | 0,03 |
| fuel gas consumption, m 3 /h | 100 | - | 100 | 100 | 180 | - | 180 |
| Fuel characteristics - oil and diesel fuel: | |||||||
| lower calorific value, kcal/kg | - | 6800 | - | - | 6800 | ||
| hydrogen sulfide content H2S, wt. share, % | - | 0,002 | - | - | 0,002 | ||
| pressure in front of the nozzle, MPa | - | 4,0 | - | - | 4,0 | ||
| fuel oil consumption, kg/h | - | 50-100 | - | - | 100-200 | ||
| Weight, kg | 13000 | 13000 | 13880 | 13000 | 32300 | 34100 | |
| Service life, years | at least 10 | ||||||
Description of design and operating principle:
A track heater with an intermediate coolant is designed for heating oil products during transportation, as well as oil emulsions and gas condensate in oil treatment plants. It can be equipped with burner devices operating on both gaseous (PP-1.6G) and liquid fuel (PP-1.6Zh).
Description of design and operating principle:
The heater is a cylindrical horizontal container with flat bottoms, in the inner cavity of which two U-shaped fireboxes and two 4-inlet tubular coils are installed in the lower part; the PP-4D model has four 4-entry coils, providing reduced hydraulic resistance. The container is filled with coolant liquid through the expansion tank.
Units for preparing and supplying fuel to burner devices, a ladder, and a service platform are mounted outside the vessel.
The heater is located on the frame of a welded structure.
The product is fed into coils, in which it is heated from the coolant to 70˚C. The coolant temperature is maintained automatically at +95˚С by adjusting the power of the burners.
Technical characteristics of the PP-1.6 track heater
|
Parameter |
Z meaning |
|
|
0,3…1,2 (3,0…12,0) 0,07…0,15 (0,7…1,5) |
||
|
Density, kg/m³, no more Viscosity, m²/s (cSt) |
4,0…6,2 (40…62) |
|
|
11700x4800x7400 |
||
|
Reliability indicators: Average life before major overhaul, years Average service life, years |
||
|
Parameter |
Meaning |
|
|
natural or petroleum associated gas, liquid fuel (oil, fuel oil, diesel fuel) |
||
|
Characteristics of gas fuel: Natural, associated petroleum gas, with parameters: Heat of combustion, MJ/nm, within Pressure at the inlet to the fuel preparation unit, MPa (kgf/cm2), within Pressure in front of the burner, MPa (kgf/cm2), within Fuel gas consumption, m 3 /h, no more |
0,3…1,2 (3,0…12,0) 0,07…0,15 (0,7…1,5) |
Characteristics of gas fuel: Natural, associated petroleum gas, with parameters: Heat of combustion, MJ/nm, within Pressure at the inlet to the fuel preparation unit, MPa (kgf/cm2), within Pressure in front of the burner, MPa (kgf/cm2), within Fuel gas consumption, m 3 /h, no more |
|
Characteristics of fuel oil: Heat of combustion, MJ/m³, within Density, kg/m³, no more Viscosity, m²/s (cSt) Hydrogen sulfide H 2 S, % mol., no more Carbon dioxide CO 2,% mol., no more Operating temperature, K (ºC), no more Pressure at the inlet to the heater, MPa (kgf/cm²), within Pressure in front of the burner, MPa (kgf/cm²), no more Fuel oil consumption, kg/h, within |
4,0…6,2 (40…62) |
|
|
Efficiency, %, not less |
||
|
Overall dimensions (length x width x height), no more |
11700x4800x7400 |
Overall dimensions (length x width x height), no more |
|
Heater weight without intermediate coolant, kg, no more |
||
Certificate of Conformity No. ROSS RU. AB28. H05762. Permit of Rostekhnadzor RRS 414)0196
The PP-1.6(AM) track heater (automated block gas furnace with water coolant) is designed for heating dehydrated oil emulsions, viscous oils when transported through pipelines, as well as water for various technological purposes.
Basic technical data
|
Net fuel power, MW (Gcal/h), no more |
|
|
Productivity of heated product, kg/s (t/day): .Oil emulsion, water cut 30% mass, at t=25°C |
|
|
Pressure in the product coil, MPa (kg/cm2): Working, no more Estimated Trial hydraulic |
6,3 (63) 6,3(63) 8,2 (82) |
|
Pressure drop in the coil, MPa (kgf/cmg), no more |
|
|
Temperature, K (°C): At the product inlet to the heater, within the limits. Heating of the product, without pain. Heating of the intermediate coolant, no more. Average of the coldest five-day period, no less. Absolute minimum ambient air, no less |
278…232 (5…50) 343 (70) |
|
Intermediate coolant |
Fresh water |
|
Heated medium - oil, oil emulsion, formation water, containing, % mol, not more than: Hydrogen sulfide (H2S) Carbon dioxide (CO2) |
|
|
Fuel - natural, associated petroleum gas, with parameters: Heat of combustion, MJ/nm, within Pressure at the inlet to the fuel preparation unit, MPa (kgf/cm2). within Pressure in front of the burner, MPa (kgf/cm*), within Fuel gas consumption, m3/h, no more |
35…60 0,002 0,3…1,2 (3,0…12,0) 0,07…0,15 (0,7…1,5) 180 |
|
Efficiency, %, not less |
|
|
Overall dimensions (length x width x height), no more |
|
|
Heater weight without intermediate coolant, kg, no more |
|
|
Reliability indicators: .Average service life, long |
Note:
* Provided that the calorific value of the fuel gas is 40.3 MJ/m (9625 kcal/m).
* * At low ambient temperatures, it is possible to heat the combustion air using electric heaters with a power of 10 kW. The heater consists of the following main parts: heating unit, fuel preparation unit, ventilation unit unit, automation system.
*** Upon request, a heater can be manufactured to operate on fuel gas with a HjS content of up to 5%.
The heater consists of the following main parts: a vessel, two coils, a sled, two fireboxes, two burners, a platform and a ladder, two house pipes.
It is standardly equipped with the BChK-4X automation system (with on-off control), which is designed for remote control of ignition, automatic protection with fuel cut-off, sound signal, decoding and storage of the root cause in case of unacceptable deviations of process parameters from the specified standards, loss of supply voltage and breakage of communication lines with sensors monitoring limit parameters, issuing a warning signal about the stop or operation of the furnace to the control room (to the highest level), as well as communication with the upper-level machine via the RS-232/485 interface, using standard industrial protocols.
Track heater PP-1.6 (A) AZh designed for heating oil products, oil emulsions, viscous oil during transportation through pipelines, in oil fields and oil treatment plants. The PP-1.6 track heater consists of a cylindrical vessel, inside of which there are two coils and two combustion chambers equipped with burners with igniters and chimneys. The track heater vessel is installed on the basis of a welded structure. On the outside of the vessel there are automatic control devices, a fuel piping pipeline, an oil inlet and outlet pipeline, a ladder, a service platform, an expansion tank, and a water level indicator. The PP-1.6 track heater is available in two versions, differing in the type of fuel used: PP-1.6A (gas) uses natural or associated petroleum gas as fuel; PP-1.6AZH (liquid) uses oil from the fuel system or from the field network, which is pre-cleaned and reduced using a liquid fuel preparation unit BPZHT. To ensure safe working conditions, the PP-1.6 heater is equipped with a control and automation system SA-PNG-I (AB-2G-3), which allows for remote ignition of nozzles, regulates the parameters of the oil heating process, performs the functions of operating and alarm signaling and automatic protection in case of deviation of technological parameters.
The automation system provides for automatic regulation of oil heating temperature
- if the flame of the main and ignition burners fails
- when the fuel pressure in front of the combustion chambers deviates below the operating values
- when the oil heating temperature increases above 70ºС
- when the intermediate coolant level decreases below the operating level
- when the pressure of the heated product increases above 6.3 MPa
The operating and emergency alarm system notifies service personnel about the normal operation of the combustion chamber burners and their flame failure, and about cutting off the fuel supply when the parameters of the oil heating process deviate from the specified values.
Design and principle of operation
:
The track heater consists of the following main parts:
- - heating unit (designed to transfer heat from combustion products to the heated product);
- - fuel preparation unit BPZHT;
- - automation and security system.
Oil from the field network enters the product coil of the heater (heating block) through the valve, is heated by the intermediate coolant (water), and is then removed from the heater. The fuel is burned in the heater furnace, giving off heat to the intermediate coolant; the cooled combustion products are discharged from the heater furnace into the atmosphere using a chimney.
Specifications