Calculation Software Development And Structural Optimization Design Of Indirect Fired Tube Heater

As a thermal system equipment in process of oil-gas exploration, exploitation, gathering and transportation, indirect fired tube heater is an important component, especially for heavy oil exploitation, indirect fired tube heater become more widely available, which can affect the trouble-free operation of the entire oil-gas gathering and transportation processes. Meanwhile, indirect fired tube heater is a lager energy consumer in the process, where requirements of energy saving and emission reduction increase, so it is necessary to optimize indirect fired tube heater to improve thermal efficiency, which will reduce fuel consumption and heat loss of exhaust gas. In this work, the calculation software and structural optimization of indirect fired tube heater has been researched and developed, which can help engineers increases efficiency and free their mind from the tedious calculations to focus the quality of design. Furthermore, optimized program of the calculation software can provide some reference for the design and transformation of indirect fired tube heater, and it is helpful to simulation and analysis sensitive parameters by use the characteristic of quickly calculate on the calculation software, which can enhance operation and improve economic efficiency. The main work and results are as follows:(1) According to process requirements and structural characteristics of indirect fired tube heater, analysis on key parameters were studied and applicable theoretical model were established, which can help to develop the software framework. Combined with the needs of users and modular design concept, the calculation software of indirect fired tube heater has been developed by using Visual Basic6.0with Microsoft Office hybrid programming approach, which can design calculations and check the calculation.(2) Using the software of indirect fired tube heater to calculate an800kW water jacket heater, which service in a northwest oilfield. Through the analysis and comparison of the original design and software calculated results, it was found that the calculation error is less than5%, which can satisfy requirements of engineering design and provide some practical value.(3) Basised on the principle of lowest cost and minimum weight, a structural optimization model of indirect fired tube heater has been established, which selected the heat transfer area as the optimization target. The mathematical models of fire tube, smoke pipe and coiled pipe were constrained optimization problems, and can be sloved by penalty function method (based on pattern search) and univariate search technique, where placing optimized program as one of software modules. Using the software of indirect fired tube heater to optimizate structure of the800kW water jacket heater, the software calculated results show fire tube and smoke pipe decreased by12.95%and coiled pipe decreased by16.92%the original design value, respectively, which has great significance for the design and reconstruction indirect fired tube heater.(4) Simulation and analysis the system characterization of indirect fired tube heater, which focused on the influence of structure type, sensitivity of thermal parameters and variable load conditions of the entire heater system. The general rules were drew, in order to guide the selection of smoke tube type, pass number and variable design parameters, which can provide effective reference for the design and production operations.