Track heater pp 1 6. Oil heaters and furnaces

When fuel gas burns in the furnace, the coolant is heated to a temperature of 90 - 95°C. The coolant transfers heat to the oil passing through the coil. Oil heats up by 25°C.

Fig. 12.1. Oil heater type PP-1.6

Gas is supplied to the pilot burner from a cylinder.
Oil for the heater is taken from the fuel system or from the field network, which, after cleaning, is supplied to the nozzle and burned in the heater furnace, releasing heat to the intermediate coolant.
Cooled combustion products using chimney discharged from the heater furnace into the atmosphere.
Oil from the field network enters the product coil of the heater, is heated by the intermediate coolant, and then removed from the heater.

Track heater PBT – 1.6M/MZh/MK

The PBT-1.6M/MZh/MK track heater is designed for heating oil emulsions, oil, gas, formation water during transportation in oil treatment plants.

Advantages of PBT-1.6M

The PBT-1.6M heater is a development of the design services of the Generation Group; its use provides significant advantages.
The fuel can be natural or associated petroleum gas, dried fuel gas, commercial oil, which allows the use of field resources as fuel.
A heater with an intermediate coolant with a compacted coil and a combustion device with a developed heating surface provides a highly economical “soft” heating mode for oils of various compositions. At the same time, fluctuations in product consumption and the size of the gas phase do not affect the reliability of the product.
The heater PBT-16M / MF / MK with equal thermal power compares favorably with the heater PP-1.6 and heaters of other Russian and foreign manufacturers, being more economical and having reduced overall dimensions and weight. This ensures a reduction in costs for installation and operation of the PBT-1.6M/MZH/MK heater.

12.5. Description of the PBT-1.6M design:

The PBT-1.6M heater consists of the following components: heating unit, fuel preparation unit, ventilation unit unit, automation system.
Technological process heating of the product is carried out as follows: the product from the field network enters the heater coil, is heated by the intermediate coolant, and then removed from the heater. The gas to power the burners is heated in the heating unit and enters the fuel preparation unit.
After cleaning and reduction, the fuel gas is supplied to the ignition and main burners, burned in the heater furnace, giving off heat to the intermediate coolant (fresh water).
The cooled combustion products are discharged from the heater furnace into the atmosphere through a chimney.
The heating unit is designed to transfer heat from the combustion products of fuel gas to the heated product. The heating unit is a container installed on a base frame and filled with an intermediate coolant (fresh water). The container contains a firebox and food coils. It is made as a monoblock, which can be transported by any type of transport.
The fuel preparation unit is designed to accommodate devices for cleaning, reducing and controlling the fuel supply to burner devices. The devices are mounted in an insulated cabinet.
The ventilation unit block is an insulated shelter containing a radial fan with an electric motor of 4 kW.
The heater is equipped with an automation system.

SPECIFICATIONS

Name		PP-1.6	PP-1.6-1
Nominal thermal power of the combustion device, no more	MW (Gcal/h)	1,86 (1,6)	1,86 (1,6)
Productivity of oil emulsion when heated at 25°C, water cut 30%, no more	t/day
Pressure in the food coil, no more	MPa (kgf/cm 2)	6,3 (63)	6,3 (63)
Pressure drop in the coil, no more	MPa (kgf/cm 2)	0,55 (5,5)	0,55 (5,5)
Temperature:
heating the product, no more	°C
heating of the intermediate coolant (fresh water), no more	°C
Heated medium (oil, oil emulsion, formation water) containing acid gases:
hydrogen sulfide (H2S), no more	% mol.	0,01	0,01
carbon dioxide (CO2), no more	% mol.	1,0	1,0
Fuel with parameters:		natural or associated petroleum gas	oil, oil emulsion
calorific value within	MJ/nm 3	35–60	39,8
hydrogen sulfide content, no more	% mol.	0,002	0,01
heater inlet pressure	MPa (kgf/cm 2)	0,3 (3) – 0,6 (6)	3,5–4,4 (35–44)
pressure in front of the burner, within	MPa (kgf/cm 2)	0,07 (0,7) – 0,15 (1,5)	3,5 (35)
Nominal fuel consumption:
per burner, no more	m 3 / h	90*
general, no more	m 3 /h (kg/h)	180*	100–200
Power supply for control, alarm, and protection system devices from AC mains:
voltage	IN
frequency	Hz
Overall dimensions of the stove (length x width x height), no more	m	18.36 x 4.78 x 7.4	16.0 x 4.78 x 7.4
Weight, no more:
dry	T	39,8	39,8
filled with water	T	125,2	125,2
Climatic performance heater	“U”, category 1 according to GOST 1515069

Fig. 12.2. Track heater diagram PBT-1.6M

SPECIFICATIONS

Name	PBT-1.6M	PBT-1.6МЗ	PBT-1.6MK
Useful thermal power, no more, MW (Gcal)	1,86 (1,6)*	1,86 (1,6)*	1,86 (1,6)*
Productivity for heated product, within, kg/s(t/day)	11,6–18,5 (1000–1600)	11,6–18,5 (1000–1600)	11,6–18,5 (1000–1600)
Product coil pressure:
working, no more	6,3 (63)	6,3 (63)	6,3 (63)
calculated	6,3 (63)	6,3 (63)	6,3 (63)
Temperature:
at the product inlet to the heater, not less	278 (5)	278 (5)	278 (5)
heating the product, no more	343 (70)*	343 (70)*	343 (70)*
heating of the intermediate coolant (fresh water), no more, K (°C)	368 (95)	368 (95)	368 (95)
Heated medium	oil, oil emulsion, formation water containing: hydrogen sulfide, not more than 0.01 mol.%, carbon dioxide, not more than 1.0 mol.%.
Efficiency, not less, %
Consumed electric power, kW, no more	5,0***	12***	12***

Track heater is an automated block gas furnace with a water intermediate coolant. With its help, oil, oil emulsions, and gas are heated in order to prepare them for transportation through pipelines. They also heat water for various technological purposes.

Track heater PP-0.63

Design and principle of operation

It is a vessel in the form of a cylinder with flat bottoms. Inside it there is a food coil and a combustion chamber equipped with a burner with a chimney and an igniter. The cylindrical vessel is mounted on a welded sled, with the help of which the heater is able to move within the fishing area. On the outside of the vessel there are special automatic control devices, a fuel piping, oil inlet and outlet, a service platform, a ladder, a water level indicator, and an expansion tank. In the combustion chamber, oil or gas burns through a water intermediate coolant, causing the product to heat up.

There are 2 versions of the PP-0.63 track heater depending on the type of fuel used:

PP-0.63A Gas (natural or associated petroleum) is used as fuel.

PP-063AZH Oil is used as fuel, which is pre-purified and reduced using a liquid fuel preparation unit BPZHT-0.22-4.0

Track heaters PP-0.63 are equipped with the SA-PNG automation system. This system:

• Automatically regulates the heating capacity of oil heaters that operate on gas;
• Automatic heater protection with fuel cut-off;
• Producing a sound signal;
• Decoding and storing the cause as a result of deviation of technological parameters from the norms, when the supply voltage disappears, or when communication lines with emergency sensors are broken;
• Issuing a notification signal about setting the heater to the highest level.

Characteristics

Weight, t (filled with water)

Characteristic type
Useful thermal power, MW (Gcal/h), no more
Capacity for heated product, kg/s (t/day)	13.3 (1150) no more
Product heating temperature, K (°C), no more
Working pressure in the product coil, MPa (kgf/cm2), no more
	Natural or petroleum associated gas, liquid fuel		oil associated gas
Fuel consumption, m3/h, no more
Overall dimensions (length × width × height), m	10.5 × 2.53 × 3.35	9.34 x 2.42 x 9.19	10.9 × 2.5 × 9.2

Track heater PP-1.6

It heats dehydrated oil, oil emulsions, viscous oil when transported through pipelines, and also heats water for various technological purposes.

Design and principle of operation

Externally, it has the shape of a cylinder, inside of which there are 2 coils and 2 combustion chambers, equipped with burners with chimneys and igniters. On the outside of the vessel there are special automatic control devices, a fuel piping, oil inlet and outlet, a service platform, a ladder, a water level indicator, and an expansion tank. In the combustion chamber, oil or gas burns through a water intermediate coolant, causing the product to heat up.

Equipped with an AB-2G-3 automation system, which:

• Remotely ignites burner devices;
• Controls technological parameters of the oil heating process;
• Plays the role of a working and emergency alarm;
• It is an automatic protection of the heater in case of deviation of the controlled parameters from the norm;

Certificate of Conformity No. ROSS RU.HO 05.H00009

OKP code 36 6723

Characteristics

Block heater with intermediate coolant PBT-1.6M

Heats oil, gas, formation water and their mixtures.

Has a number of advantages:

• A more economical option compared to PP-1.6;
• Weight and size characteristics are smaller than those of PP-1.6 with equal thermal power;
• It is equipped with burner devices operating on both gas and liquid fuel;
• Equipped with an automation system;

Design and principle of operation

The PBT-1.6M heater consists of the following components:

Fuel preparation unit;

Heating block;

Fan unit;

Automation system;

Product heating sequence:

1) the product from the field enters the heater coil. With the help of an intermediate coolant, it is heated and removed from the heater.

2) Fuel is taken from the product pipeline. Then it is prepared in a special preparation unit and reheated if necessary. And under the required pressure it is supplied to the burner device.

3) Combustion products are cooled. After that, through the chimney they exit the heater furnace into the atmosphere.

Certificate of Conformity No. ROSS RU.HO 05.H00009

OKP code 36 6723

Characteristics

Heater PP-1.6AZh capacitive type

Heats oil products during transportation, and oil emulsions in oil treatment plants.

Comprises:

• Vessel;
• Two coils;
• Sleigh;
• Fireboxes;
• Burners;
• Venues;
• Stairs;
• Chimneys;

The heater has the shape of a cylinder with flat bottoms. The cylindrical vessel is mounted on a welded sled, with the help of which the heater is able to move within the fishing area. Inside the housing there are 2 fireboxes, equipped with burner devices with chimneys and igniters, and 2 coils.

Gas is taken from the production network. It is then purified and reduced. After which it is supplied to the main and ignition burners. Burns in the firebox. At the same time, it transfers heat to the intermediate coolant. The cooled combustion products are discharged from the furnaces through chimneys into the atmosphere.

The heater is equipped with an automation system.

The automation system performs the following functions:

• Controls the level and temperature of the coolant;
• Checks the oil temperature at the outlet of the heater;
• Controls the oil pressure at the inlet to the heater;
• Automatically ignites the heater pilot burner;
• The cause of the emergency is remembered;
• Providing a light and sound signal in case of an accident with gas supply interruption;

Main elements of the automation system:

Spark ignition unit;

Local automation cabinet;

Ultraviolet flame sensor;

Certificate of Conformity No. ROSS RU.HO 05.H00009

OKP code 36 6723

Characteristics

Heated medium	Oil, oil emulsion
Indicators of the heated medium:
Hydrogen sulfide H2S, % mol., no more
Carbon dioxide (CO), % mol., no more
Main fuel type	Preheated fuel oil
Fuel when igniting the stove
Heating capacity, Gcal/h (MW)
Pressure in the product coil, MPa (kgf/cm2),
Working, no more
Estimated
Trial hydraulic
Productivity per heated product,
when heated by 25 °C, kg/s (t/day), no more
Temperature, K (°C)
At the product inlet to the heater, within	278 (5)-323 (50)
Product heating, no more
Heating of intermediate coolant (fresh water), no more
Average of the coldest five-day period, not lower
Absolute minimum ambient air, not lower
Specific fuel consumption, kg/MW, no more
Overall and installation dimensions (length x width x height), mm, no more than:
Heater weight in non-operating state, kg, no more

Certificate of Conformity No. ROSS RU. AB28. H05762. Permit of Rostechnadzor 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
Coefficient useful action, %, 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:

* Given that calorific value fuel gas 40.3 MJ/m (9625 kcal/m).

* * At low temperatures ambient air, 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 (on highest level), as well as communication with the machine top level via RS-232/485 interface, using standard industrial protocols.

When collecting highly paraffinic, viscous oils, as well as oils with high temperature solidification, in order to ensure the fluidity of oil, it is necessary to heat up the production of wells, from the wellhead up to the central processing station and the preparation of oil and gas.

To heat production from wells in flow lines, wellhead heaters UN-0.2 and PTT-2 are used, and to heat production from wells in oil-gathering reservoirs - travel heaters PP-0.4; PP-0.63; PP-1.6 and PT-type pipeline heaters.

Design and principle of operation of oil heaters

Let us consider the design diagram and functional features of oil heating devices using the example of their most common types.

Automated block gas furnaces with water coolant PP0.63; PP-1,6, PP-4 are designed for heating dehydrated oils, oil emulsions and water, for various technological needs.

The heater consists of the following main parts: - heating block (designed to transfer heat from combustion products to the heated product); - fuel preparation unit (FPU); - 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.

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.

Specifications

№	Indicators	PP-0.63	PP-1.6
1	Liquid productivity at heating 25ºС and water cut 30%, t/day	1150	2350
2	Heating capacity of the combustion device, MW (Gcal/hour)	0,73 (0,69)	1,86 (1,6)
3	Pressure in the coil, MPa (kgf/cm2)	6,4 (64)	6,4 (64)
4	Gas consumption under normal conditions, m 3 /hour	75	180
5	Fuel	associated petroleum gas
6	Weight, kg: dry/filled with water	13019/25920	39801/125201

Oil heater PTT-0.2 consists of an inclined cylindrical vessel 8 with a battery of heat pipes 5, a gas separator 6, oil input pipes 7, a firebox 1 with a gas injection two-nozzle burner 2 and a smoke pipe 3 with a casing 4 to protect operating personnel from burns.

Oil heater type PTT-0.2

The oil and gas mixture entering the heater vessel is heated by heat pipes and leaves the heater. Part of the gas released from the oil, purified in the separator, enters the burner through the control unit. Due to the combustion of gas in the furnace, the combustion ends of the heat pipes are heated. The heat pipe is a thick-walled, seamless steel pipe, filled to 1/3 of its internal volume with distilled water and hermetically sealed at both ends. To avoid freezing of the pipes during a possible shutdown of the furnace, a certain amount of ethyl alcohol was added to them. The pipes in the heater are located with an inclination towards the firebox equal to 100 mm per 1 m of pipe, and are welded to one of the bottoms of the vessel in such a way that one end, 2 m long, is inside the vessel, and the other, 1 m long, is in the firebox.

The oil heater PTT-0.2 is equipped with control and automatic control devices supplied complete with the heater: mercury technical thermometer AN3-1°-110-220, pressure gauges OBM1-100, temperature regulator RT-P25-2 and pressure regulator RD-32M. The set of instruments provides regulation of the temperature of the liquid in the vessel, the pressure of the fuel gas in front of the burner and igniter, as well as technological control for temperature and pressure.

Technical characteristics of the PTT-0.2 heater

Pipeline heaters PT-R/D designed for heating water, oil, gas and their mixtures.

Technical characteristics of heaters PT-R/D

Operating principle: the gas-air mixture prepared in injection burners is supplied to the flame distributor. The heat flow obtained from gas combustion, passing through the convection chamber, washes the finned surface of the heater pipes, heating the product passing through the pipes. In the upper part of the convection chamber, the exhaust gases heat the separator and the fuel gas coil.

The source of fuel gas can be the heated medium itself, and if it is not flammable or has a low free gas factor (less than 40 m 3 /t), then it is necessary to connect to an external power source.

LV Oil Heaters- for heating oil emulsions in front of deep dehydration and desalting units of oil treatment plants. Recommended for use in the preparation of medium and heavy oils.

Block oil heater BN-2M designed for heating watered oils before deep dehydration and desalting units. Allowed at oil treatment plants with a throughput capacity of up to 3 million tons per year. The main technological block of this heater includes four series-connected heaters of the “pipe-in-pipe” type.

Tubular furnace PTB-10-64 designed for heating watered oils before deep dehydration and desalting units with oil treatment plants with a throughput capacity of 3.6 and 9 million tons per year.

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. Can serve as fuel natural gas, associated petroleum gas, diesel fuel or prepared, 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.

Automation and alarm system provides safe operation 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 adjusted to automatic regulation temperature regime heating oil.

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
Characteristics working environment:
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