Certificate of Conformity No. ROSS RU. AB28. H05762. Rostekhnadzor permission РRS 414-0196
Line heater PP-1,6(AM) (automated block gas furnace with water heat carrier) is designed for heating dehydrated oil emulsions, viscous oils during transportation through pipelines, as well as water for various technological purposes.
Main technical data
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Useful fuel capacity, MW (Gcal/h), no more |
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Productivity for the heated product, kg/s (t/day): |
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Product coil pressure, MPa (kg/cm2): Working, no more Estimated Trial hydraulic |
6,3 (63) 6,3(63) 8,2 (82) |
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Pressure drop in the coil, MPa (kgf/smg), no more |
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Temperature, K (°С): At the product inlet to the heater, within. Product heating, no pain. Intermediate heat carrier heating, no more. Average of the coldest five-day period, no less. Absolute minimum ambient air, no less |
278…232 (5…50) 343 (70) |
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Intermediate coolant |
Fresh water |
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Heated medium - oil, oil emulsion, reservoir water, content, % mol, not more than: .Hydrogen sulfide (H2S) Carbon dioxide (CO2) |
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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 |
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Efficiency, %, not less than |
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Overall dimensions (length, width, height), no more |
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Heater weight without intermediate coolant, kg, max |
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Reliability indicators: . Average term service, lay down |
Note:
* Given that calorific value fuel gas 40.3 MJ/m (9625 kcal/m).
* * At low ambient temperatures, it is possible to heat the combustion air with 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 for operation on fuel gas with HjS content up to 5% can be manufactured.
The heater consists of the following main parts: a vessel, two coils, a sleigh, two furnaces, two burners, a platform and a ladder, two brownie chimneys.
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 storing the root cause in case of unacceptable deviations of technological parameters from the specified norms, power failure and communication lines break with sensors that control the limit parameters, issuing a notification 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.
The PP-1.6 line heater is supplied with the SAU.PP-1.6 automation system, which is manufactured on the basis of various controllers (Direct Logic, Siemens, Alen Bradley, Schneider and others) and can be placed both in the BAO hardware unit and supplied in outdoor climate-protected design.
These automation systems are designed for remote control of ignition, automatic protection with cut-off of fuel supply and receipt of an audio and visual signal to the operator's control panel. The system deciphers and remembers the root causes in case of unacceptable deviations of technological parameters from the specified norms, power failure and breakage of communication lines with sensors that control limit parameters, issuance of a warning signal about the stop or operation of the furnace to the control room (to the upper level), as well as communication with the machine of the upper level via the RS-485 interface, using standard industrial protocols, which makes it easy to integrate the heater into the process control system of the site, as well as organize remote monitoring and control of its parameters.
Fuel
Depending on the configuration of the PP-1.6 heater, it can operate on gaseous fuel - natural and associated petroleum gas, or combined form fuel - PP-1.6AZH (gas/oil or diesel fuel).
When using oil as a fuel, it is necessary to use the BPZhT liquid fuel preparation unit (see the BPZHT liquid fuel preparation unit).
Technical characteristics of the installation
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Main technical data |
Parameter value |
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Pressure in the product coil, MPa (kgf/cm2) |
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estimated |
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Temperature, |
at the product inlet to the heater, not less than |
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product heating, no more |
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heating of the intermediate heat carrier |
386 (95) |
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absolute minimum ambient air, not below |
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Name |
oil, oil emulsion, formation water containing acid gases: |
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characteristic |
Explosive |
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Explosive zone class according to GOST R 51330.9-99 |
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Corrosion compensation allowance, mm |
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Productivity for oil emulsion when heated to 25 0С, water cut 30%, t/day |
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Useful thermal power, MW (Gcal/h), no more |
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Heater efficiency, not less |
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Estimated service life, years |
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Fuel - natural or associated petroleum gas with parameters: |
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calorific value, MJ/nm3, within |
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Pressure in front of the burner, kPa, within |
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Fuel gas consumption, m3/h, not more than: |
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for one burner |
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Industrial heat carrier |
fresh water*** |
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Pressure drop in two coils, MPa (Kgf / cm 2), no more |
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Number of heater blocks, pcs, total including: |
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gas manifold |
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fan unit |
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Control system SAU.PP-1.6 |
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Power consumption SAU.PP-1.6 in the system with connected solenoid valves, not more than |
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Overall dimensions (length x width x height), mm, no more |
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14200x3136x3450 |
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heater in operation |
18500x4780x7440 |
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Heater weight, kg, no more |
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filled with water |
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Note:
* The given parameters are provided for heated media with a viscosity at a temperature of 200C, not more than 100x10 * -6 m * 2 / s (100 cSt).
** As an industrial heat carrier, it is possible to use aqueous solutions of ethylene glycol, DEG.
*** It is possible to execute the product heating coil DN100 and DN150.
When collecting highly paraffinic, viscous oils, as well as oils that have 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 CPS and treatment of oil and gas.
Wellhead heaters UN-0.2 and PTT-2 are used to heat well production in flow lines, and PP-0.4 track heaters are used to heat well production in oil-gathering collectors; PP-0.63; PP-1.6 and pipeline heaters of the PT type.
The device and principle of operation of oil heaters
Consider the device diagram and functional features oil heating devices on 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 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 through a valve enters the product coil of the heater (heating unit), heats up from the intermediate coolant (water), and then is removed from the heater. The fuel is burned in the heater furnace, giving off heat to the intermediate heat carrier, the cooled combustion products are discharged from the heater furnace into the atmosphere by means of a chimney.
The track heater PP-1.6 is produced 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 subjected to preliminary purification and reduction using the BPZhT liquid fuel preparation unit. To ensure safe working conditions, the PP-1.6 heater is equipped with the SA-PNG-I (AB-2G-3) control and automation system, which allows remote ignition of nozzles, regulates the parameters of the oil heating process, performs the functions of working and emergency alarms and automatic protection in case of deviation of technological parameters.
Specifications
| № | Indicators | PP-0.63 | PP-1.6 |
| 1 | Productivity on liquid at heated 25ºС and water cut 30%, t/day | 1150 | 2350 |
| 2 | Heat output of the combustion device, MW (Gcal/hour) | 0,73 (0,69) | 1,86 (1,6) |
| 3 | Pressure in the coil, MPa (kgf / cm 2) | 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 inlet pipes 7, a furnace 1 with a gas injection two-nozzle burner 2 and a chimney 3 with a casing 4 for protection service 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, being purified in the separator, enters through the control unit to the burner. Due to the combustion of gas in the furnace, the furnace 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. Some ethanol has been added to the pipes to prevent freezing during a possible shutdown of the oven. The pipes in the heater are located with an inclination towards the furnace, equal to 100 mm per 1 m of the 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 is 1 m long in the furnace.
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, manometers OBM1-100, temperature controller RT-P25-2 and pressure controller RD-32M. The complex 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 over temperature and pressure.
Technical characteristics of the PTT-0.2 heater
Heaters of pipeline type PT-R/D designed for heating water, oil, gas and their mixtures.
Technical characteristics of heaters PT-R/D
Principle of operation: the gas-air mixture prepared in the injection burners enters the flame distributor. The heat flow obtained during the combustion of gas, passing through the convection chamber, washes the finned surface of the heater pipes, heating the product passing through the pipes. At the top of the convection chamber, the flue gases heat up the separator and the fuel gas coil.
The source of fuel gas can be the heated medium itself, and if it is not combustible or has a low free gas factor (less than 40 m 3 /t), then it is necessary to connect to external source nutrition.
Oil heaters HH- for heating oil emulsions in front of deep dehydration and desalting units of oil treatment plants. It is recommended to use for the preparation of medium, heavy oils.
Block oil heater BN-2M designed for heating watered oils in front of deep dehydration and desalination apparatuses. Allowed at oil treatment plants with a 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.
Tube furnace PTB-10-64 designed for heating watered oils in front of deep dehydration and desalting units with OTU with a capacity of 3.6 and 9 million tons per year.
LINE HEATERS WITH INTERMEDIATE COOLANT.
They provide "soft" heating due to the presence of an intermediate heat carrier and can be used to heat oil emulsion, oil, gas, gas condensate, water, heat carriers at oil production, transportation and primary treatment facilities.
Fresh water (mineralization not more than 1 g/l), as well as any non-flammable non-viscous heat carriers (water solutions of ethylene glycol, propylene glycol, antifreeze, antifreeze, etc.) can be used as an intermediate heat carrier.
When using ethylene glycol solutions as a heat carrier, it is necessary to indicate this in the questionnaire, because they require the use of one-piece gaskets on the flanged connections of the tank-coil, tank-firebox, without adhesive seams.
It is possible to manufacture without a coil, for heating water for technological or heating purposes.
Line heater coils are manufactured for a design pressure of 6.3 MPa; if a lower pressure is indicated in the questionnaire, the measurement limits of the supplied instrumentation and control systems change, the coil design does not change.
When using gas that does not meet the requirements of GOST 5542-2014 as a fuel, it is necessary to indicate the composition, paying attention to the content of hydrogen sulfide and other sulfur-containing components, ballast gases (CO2 and N2), and the presence of a droplet fraction.
The line heaters are designed for a stable, without sharp fluctuations, gas pressure at the inlet from 0.2 to 0.4 MPa, in case of a different pressure or the likelihood of sharp fluctuations, it must be specified when ordering. If there are requirements for manufacturers or brands of instrumentation used - specify when ordering. Line heaters are technological devices that use in technological process open fire and therefore do not require the use of explosion-proof equipment.
If there are requirements for the completion of explosion-proof instrumentation and automation - indicate in the questionnaire, preferably with a breakdown of the reasons for installing explosion-proof instrumentation and automation (company standard, the need to meet the requirements for climatic performance, etc.), while taking into account that burners, igniters, spark ignition units does not exist in an explosion-proof version.
Standard supply of a line heater: line heater, complete instrumentation, automation system, terminal boxes. If it is necessary to supply without automation and instrumentation - specify specifically when ordering. If it is necessary to supply a line heater with factory thermal insulation, please specify it when ordering. If it is necessary to supply cable products - specify specifically when ordering, indicating the distances.
The track heaters are supplied without site lighting, ATS, gas control system, fire alarm system, fire extinguishing system, steam curtain, heated product and fuel metering units, top level(SCADA systems). If you need to supply the above components - you must specify this separately when ordering.
Automation systems BUK-5PUR, BUK-4.X3.APN are supplied without BKA (blocks of switching devices) and insulated cabinets. In the presence of blast burners, instead of the BKA, a control unit for the ventilation unit is supplied.
The need to supply these automation systems with BKA or in insulated cabinets with electric heating is specified when ordering. ALL of the following heaters can be manufactured to operate on gas, liquid or combined (gas-liquid) fuels, to operate on associated petroleum gas with a high content of hydrogen sulfide, to operate with high-viscosity oils.
The selection of the track heater should be carried out according to the thermal power. Performance is given approximately, for the initial selection of the heater.
Track heating PPT-0.2.
The marking may contain the letters G, K, Zh, GZh. The letters mean:
G - the heater is equipped with a gas burner;
G - the heater is equipped with a liquid burner;
ГЖ - the heater is equipped with a combined burner;
K - the heater is designed to work with high-viscosity oils.
PPT-0.2 line heaters are equipped with automation systems SA-PNG.M (by default), BUK-5PUR, BUK-4.X3.APN (at the request of the customer or selection according to the questionnaire).
As a fuel, operation is implemented on gas (natural, associated petroleum, process gas), liquids (oil, diesel fuel, heating oil, stable gas condensate) or a combined gas-liquid version.
Available with burners:
- IGK 1-15 (injection Kazantsev, the main version);
- NUS-01 (injection specially designed, version for operation on associated petroleum gas with the presence of a drop fraction, do not go out when the drop fraction is thrown into the burner nozzle);
- IGK 4-50 (for track heaters of increased power - up to 0.3 Gcal / h, reduce the efficiency of the track heater);
- GGV-25 (blowing, a fan unit is required);
- GGV-50 (for line heaters of increased power - up to 0.3 Gcal / h, they reduce the efficiency of the line heater, blast heaters, a fan unit is required);
- non-precision supercafitting mechanical nozzle (blowing, requires the presence of a BPZhT or a pump unit to create pressure in front of the nozzle, they work on any type of fuel, including oil);
- block burners Ekoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences, a BPZhT or a pumping unit is not required, unsuitable for oil operation).
- GGV-25, GV-50 with a non-precision super-cafitting mechanical nozzle (blast burners, a fan unit is required).
The marking may contain the letters A, AJ, AM, AC, D
The letters mean:
A - the heater is supplied complete with an automation system (of any type);
AM - the heater is supplied complete with a microprocessor-based automation system (PLC-based);
АЖ - the heater is supplied complete with an automation system (of any type) and a liquid or combined burner;
AC - the heater is supplied complete with an automation system (of any type) for operation on gas with a high content of hydrogen sulfide (up to 5% and more);
D - the heater is supplied complete with an automation system (of any type) and a two-flow coil.
Track heaters PP-0.63A and PP-1.6A are equipped with automation systems SA-PNG.M (by default), BUK-5PUR, BUK-4.X3.APN (at the request of the customer or selection according to the questionnaire).
Available with burners:
- PP-0.63.04.00.000 (special design for associated petroleum gas injection) - the main option;
- IGK 4-50 (Kazantsev's injection burner, for line heaters of reduced power);
- IGK 4-100 (Kazantsev's injection burner);
- GGV-100, GV-100 (blast burners, a fan unit is required);
- block burners Ecoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences).
- non-precision supercafitting mechanical injector (requires the presence of a BPZhT or a pump unit to create pressure in front of the injector, they work on any type of fuel, including oil);
- block burners Ekoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences, a BPZhT or a pumping unit is not required, unsuitable for oil operation);
- GGV-100, GV-100 with a non-precision super-cafitting mechanical nozzle (blast burners, a fan unit is required)
The marking may contain the letters M, MK, M-KS. The letters mean:
M - the heater is supplied complete with an automation system (of any type);
MK - the heater is supplied complete with an automation system (of any type) and a liquid or combined burner;
M-KS - the heater is supplied complete with an automation system (of any type) for operation on gas with a high content of hydrogen sulfide (up to 5% and more);
Path heaters PBT-1.6 are equipped with automation systems SA-PNG.M (by default), BUK-5PUR, BUK-4.X3.APN (at the request of the customer or selection according to the questionnaire).
Gas (natural, associated petroleum, process gas), liquid fuel (oil, diesel fuel, heating oil, stable gas condensate) or gas and liquid fuel (combined gas-liquid) are produced for use as fuel.
Available with burners:
- GGV-200 (basic version);
- foreign-made block burners Ecoflam, Unigas, Lamborghini (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences);
- with a non-precision supercafitting mechanical nozzle (blowing, requires the presence of a BPZhT or a pump unit to create pressure in front of the nozzle, they work on any type of fuel, including oil);
- block burners Ecoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences, the presence of a BPZhT or a pumping unit is not required, unsuitable for oil operation).
- GGV-200, GV-200 with a non-precision supercaficating mechanical nozzle (blast burners, a fan unit is required).
Travel heater is an automated block gas furnace with water intermediate heat carrier. With its help, oil, oil emulsions, gas are heated in order to prepare them for transportation through pipelines. They also heat water for various technological purposes.
Line heater PP-0.63
Device and principle of operation
It is a vessel in the form of a cylinder with flat bottoms. Inside it is a product coil and a combustion chamber equipped with a burner with a chimney and an igniter. The cylindrical vessel is mounted on a welded sledge, with the help of which the heater is able to move within the fishing area. On the outer side of the vessel there are special control devices for automation, a pipeline for fuel piping, oil supply, removal, a service platform, a ladder, a water level indicator, and an expansion tank. In the combustion chamber, oil or gas is burned through the water intermediate heat carrier, as a result of which the product is heated.
There are 2 versions of the line heater PP-0.63 depending on the type of fuel used:
PP-0.63A Gas is used as fuel (natural or associated petroleum)
PP-063AZH Oil is used as fuel, which is preliminarily cleaned and reduced using a liquid fuel preparation unit BPZhT-0.22-4.0
Line heaters PP-0.63 are equipped with the SA-PNG automation system. This system:
- Automatically regulates the heating capacity of oil heaters that run on gas;
- Automatic heater protection with fuel cut-off;
- Issuance of a sound signal;
- Deciphering and storing the cause as a result of deviation of technological parameters from the norms, in the event of a power failure, a break in communication lines with emergency sensors;
- Issuance of a signal-notification about setting the heater to the highest level.
Characteristics
Characteristic type |
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Useful thermal power, MW (Gcal/h), no more |
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Productivity for the heated product, kg/s (t/day) |
13.3 (1150) no more |
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Product heating temperature, K (°C), no more |
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Working pressure in the product coil, MPa (kgf/cm2), |
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natural or petroleum associated gas, |
oil |
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Fuel consumption, m3/h, no more |
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Overall dimensions (length × width × height), m |
10.5×2.53×3.35 |
9.34×2.42×9.19 |
10.9×2.5×9.2 |
Line heater PP-1.6
It heats dehydrated oil, oil emulsions, viscous oil during transportation through pipelines, and also heats water for various technological purposes.
Device and principle of operation
Outwardly, it has the shape of a cylinder, inside which there are 2 coils and 2 combustion chambers equipped with burners with chimneys and igniters. On the outer side of the vessel there are special control devices for automation, a pipeline for fuel piping, oil supply, removal, a service platform, a ladder, a water level indicator, and an expansion tank. In the combustion chamber, oil or gas is burned through the water intermediate heat carrier, as a result of which the product is heated
Equipped with the AB-2G-3 automation system, which:
- Remotely ignites burners;
- Controls the technological parameters of the oil heating process;
- Plays the role of working and alarm;
- It is an automatic protection of the heater in case of deviation from the norm of controlled parameters;
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:
- More economical option compared to PP-1.6;
- Weight and size characteristics are less than those of PP-1.6 with equal thermal power;
- It is completed with the burner devices working both on gas, and on liquid fuel;
- Equipped with an automation system;
Device and principle of operation
The PBT-1.6M heater consists of the following components:
Fuel preparation unit;
Heating block;
Ventilation unit block;
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, in a special preparation unit, it is cooked, if necessary, heated. And under the necessary pressure 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
It heats oil products during transportation, and oil emulsions at 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 sledge, with the help of which the heater is able to move within the fishing area. Inside the body there are 2 furnaces equipped with burners with chimneys and igniters, 2 coils.
Gas is taken from the field network. Then it undergoes purification and reduction. After that, it is fed to the main and pilot burners. Burns in the furnace. At the same time, it gives off heat to the intermediate coolant. The cooled combustion products are removed from the furnaces with the help of 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 oil temperature at heater outlet;
- Controls the oil pressure at the heater inlet;
- Automatically ignites the ignition burner of the heater;
- The cause of the emergency is remembered;
- Giving a light and sound signal in case of an accident with the cessation of gas supply;
The main elements of the automation system:
Spark ignition unit;
Local automation cabinet;
UV 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: |
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Hydrogen sulfide H2S, mol %, no more |
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Carbon dioxide (СО), % mol., no more |
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Main type of fuel |
Heated fuel oil |
Fuel for firing up the stove |
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Heat output, Gcal/h (MW) |
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Pressure in the product coil, MPa (kgf/cm2), |
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Working, no more |
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Estimated |
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Trial hydraulic |
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Productivity on the heated product, |
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when heated to 25 °C, kg/s (t/day), no more |
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Temperature, K (°С) |
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At the product inlet to the heater, within |
278 (5)-323 (50) |
Product heating, no more |
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Heating of the intermediate heat carrier (fresh water), no more |
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Average of the coldest five-day period, not less |
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Absolute minimum ambient air, not below |
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Specific fuel consumption, kg/MW, max |
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Overall and installation dimensions (length x width x height), mm, not more than: |
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Mass of the heater in non-working condition, kg, no more |
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