- Provided revisions to Boiler Design Guide and separate related
boiler engineering standard for a major refining company.
- After review of four (4) critical heater designs and operations,
the scope of work for this West-European client was expanded to cover
design and operations review of seven (7) more heaters. Based on the
evaluation of the current operating conditions, certain areas of
operation were identified as not being consistent with safe or
reliable operation. In addition, the client had requested general
comments related to the coil metallurgy used in each of the seven (7)
heaters included in this phase of study.
- Assisted a European client with troubleshooting furnace operating
- Conducted a “Cold Eyes Review” for a modification to a fired
heater for a client in the Far East.
- Engineering design review and cost estimating consulting support
was provided for a major refinery expansion project with respect to
the fired heaters being supplied for a grassroots delayed coker unit.
Support consisted of reviewing and commenting on the licensor’s
proposed technical specification, and making an independent estimate
of the heater’s cost. The owner then used this information in further
discussions with the licensor.
- Fired equipment and process engineering support provided to
evaluate existing hydrogen plant fired heaters for new conditions. In
separate jobs, continued to provide fired equipment and heat exchanger
support for a major international refining company.
- Fired equipment support being provided for a crude unit furnace
revamp project that is being done for a European client. Thus far, the
results of a thermal study performed by a contractor were reviewed and
recommendations made. Additional work will involve technical support
for furnace test runs, technical bid conditioning of vendor proposals,
and then engineering auditing of the selected vendor’s detailed
- In a multi-year activity, performed engineering design reviews of
fired equipment and heat exchangers being provided for a major
refinery clean fuels project being engineered in the US for a client
in the Middle East. This work involved review of contractor and
equipment supplier design details and calculations with respect to
their conformance to the owner’s specifications. Recommendations were
made to correct deviations that were identified.
- On behalf of the refinery owner, full time engineering design
audits of fired equipment and heat exchangers being provided for a
major clean fuels project being designed in the US for a project
located in the Middle East. This audit involves periodic visits to the
prime contractor’s office to review equipment design drawings and
calculations, discuss the designs with contractor and supplier
engineers, plus visits to equipment supplier locations to discuss
critical equipment matters.
- Over a period of several months, provided fired equipment support
for multiple turnarounds at a US Gulf Coast refinery through a
combination of offsite review of planned furnace modifications and
onsite presence during the actual turnarounds.
- Participated on a team performing an energy efficiency assessment
for a US refinery. CEI provided the fired heater expertise. Total
annual fuel savings identified exceeded $3.5M of which approximately
$350k were in fired equipment.
- Performed engineering design audit of the contractor’s and
vendor’s activities on a grass roots steam reformer and waste heat
recovery unit for a European refiner. Identified cases where the
proposed designs could have led to reliability issues after the unit
was in service (e.g., questionable design details specified for
refractory-lined furnace outlet headers and inlet piping systems).
Recommendations were made to change these designs to others that have
- Provided a fired equipment engineer as part of a team performing
an energy management survey for a US refiner.
- Provided Fired Equipment support in an Energy Management
Assessment for a major oil company. This included participating with a
team of process and equipment specialists in a two-week onsite visit
to one of their facilities that focused on identifying potential
energy savings. When accounting for added equipment and utility costs,
the Fired Equipment component of this team effort identified annual
savings in excess of 3M$. This would represent a return on capital
investment of over 20%.
- Provided fired heater design support for a US client.
- Reviewed the design and operation of several fired heaters located
at a Oil Sands upgrading facility for their suitability for increased
capacity and improved operations. Work also involved simulating the
heater designs and investigating various alternate operating scenarios
- Software simulations were done for several fired heaters that are
located at a refinery in the Far East. This was followed up by an
onsite fired heater operations audit, and a two-day heater operations
and safety training course that was attended by process and operations
personnel. Recommendations were provided that, if implemented, will
improve overall heater operations and safety.
- Software simulations were made of a fired heater installed in an
existing refinery crude oil distillation unit. The objective was to
provide the refinery with a basis for proceeding with a revamp project
to increase the heater’s fuel efficiency. With the results obtained,
the refinery was able to develop the technical specification needed to
solicit bids from fired heater vendors for the detailed engineering
needed to achieve the refinery’s objectives.
- Witnessed burner tests performed at the supplier’s US location for
a furnace to be installed at an Italian refinery. Review of the
planned test procedure before the tests were done revealed several
deficiencies, which were corrected before the testing.
- Carried out a study for replacing or restoring a furnace air
pre-heater for a large refinery in the United States.
- Carried out several furnace/heater reviews and developed design
specifications for furnaces for several clients in Europe and the U.S.
- Provided consulting assistance on a power plant boiler system to
reduce NOx emissions.
- Witnessed the acceptance tests for a fired heater burner to be
installed at a Canadian refinery to assure that the burner complied
with the conditions of the project specification.
- Assisted a major European refiner with a performance test of the
crude heater in the atmospheric distillation unit. The test and
subsequent evaluation saved significant potential investment in heater
upgrade work that was deemed necessary for the expanded operating
- Assisted a major European refiner with a study of seven (7) major
heaters from the point of view of efficiency improvement via better
control of combustion parameters, as well as potential investment in
equipment such as air preheaters, etc. The heaters were also examined
from the points of view of combustion box steel casing corrosion and
cracking that might be responsible for significant air leakage.
- At the conclusion of review of eleven (11) critical heater designs
and operations for a West-European client, general consulting
continued in the area of materials and study of potential hot spots in
radiant section tubes of selected heaters.
- Carried out a technical bid review for the supply of a new boiler
system for a client in the Middle East.
- Carried out CO Boiler reliability and performance assessment
including material evaluation for an East Coast refiner.
- Carried out Coker CO Boiler study for installation of a new
Economizer for a US refiner. The available options were examined and
evaluated in detail to recommend a new design.
- Evaluated (via detailed simulations) the feasibility of expansion
for a delayed coker heater for a domestic refiner in the Gulf Coast.
- After the operational and design review of eleven (11) critical
heaters for a Western European refinery, valuable assistance was
provided relating to materials and study of hot spots in radiant
section tubes of crude vacuum distillation unit heater.
- Assisted a major European refiner with a study of a mild
Hydrocracker preheat furnace for revamped conditions related to a
local expansion project at the refinery. The study involved modeling
the heater based on the existing plant data and testing the
modifications to a validated model to determine the required changes
in the basic design of the heater.
- Continuing to provide a furnace modeling and evaluation service
for a major revamp project for a Canadian refiner – this time
involving a hydrogen plant reformer furnace.
- Evaluated the design and operation of fired heaters on atmospheric
and vacuum units to develop recommendations that will improve
performance and/or run lengths. Recommendations were made that, if
followed, will improve heater performance and reduce coking in the
- Made an initial site visit to review the performance and obtain
operating data of multiple fired heaters installed at a Canadian tar
sands upgrading unit. This one week visit was the starting point for a
more extensive, energy audit of the fired equipment being carried out.
- Reviewed the operations and the performance of the fired heaters
installed at a refinery in Europe during a one-week onsite visit. This
resulted in several recommendations for improving their efficiencies
for enhanced fuel savings, many of which can be accomplished with
little or no capital investment.
- The performance of a revamped refinery fluid coker CO boiler was
examined. Its predicted performance with increased CO fuel gas
availability and a new clean economizer with a fraction of total
available tube passes blocked was assessed and found to be acceptable.
- Provided first line operations and fired equipment health audit
consulting onsite at two different Canadian refineries. Two additional
assessments are also being considered at domestic refinery locations.