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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

Kesler Engineering, Inc.

Fired Heater Sentinel

introduction to kei
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
fired heater sentinel problem statement
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
fired heater sentinel coking and scaling
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.
fired heater sentinel economics
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
fired heater sentinel economics8
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
fired heater sentinel heater health
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
fired heater sentinel heater health10
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
fired heater sentinel safety
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
fired heater sentinel implementation
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
models com objects
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
fired heater sentinel value
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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