Fired Heater Repair

• Issue: The radiation zone tubes (walls and roof) exhibit excessive permanent deformation and internal coking.
• Damage Mechanism: Short-term Overheating.
• Capacity: Total coil heating surface: 192m²
• Original Construction Code: API-560/ASME BPVC Sec. VIII Div. 1.
• Repair Code: NBIC Part 3.
• Original Materials: Tubes 5.5625”OD and 4.5”OD, SA-335 P9, Headers: 5.5625”OD and 4.5”OD SA-234 WP9. Wall and Hook Tube Brackets: ASTM A560 Gr. 50Cr-50Ni.
• Solution: Fabrication and replacement of new coils for the heater's radiation zone, fabrication and replacement of 50Cr-50Ni wall and hook brackets, and replacement of the radiation zone's thermal insulation.
• Scope: Repair procedure, drawings, ITP, procurement of materials, qualification of WPS’s and welders, fabrication and replacement of coils, wall and hook tube brackets, replacement of thermal insulation, quality assurance and quality control activities, PWHT, NDE.
• Results: Safe return of fired heater to operation within the deadline.