At Tulsa Heaters Midstream (THM), one of the most frequent questions we answer is, “How big can you make your heater?” It’s a great question, especially in the midstream industry where operations often demand high-performance, large-capacity systems. The answer isn’t just about size; it’s about what’s practical, efficient, and cost-effective.
Heater Sizing 101
When it comes to heaters, size is determined by the amount of heat that needs to be absorbed, which is measured in BTUs per hour. To handle more heat, heaters need larger and more robust components. But heater sizing also involves considerations like design configurations, transport logistics, assembly requirements, and operational reliability.
At THM, we categorize heaters into four main size ranges based on heat output and design complexity.
Small to Medium Heaters (2 to 35 Million BTUs/Hour)
These heaters represent the starting range in terms of size and capacity. They are designed with a single-piece radiant box, a helical coil, and one burner. This simple configuration makes them highly efficient for shipping and assembly.
Small and medium heaters ship in three main components:
- The radiant box (including burner management systems like control panels and fuel trains)
- The convection box
- The stack and transition
With just a couple of field joints to connect, these heaters are quick to assemble and deploy. They’re ideal for projects that don’t require extremely high heat absorption but still need a reliable, midstream-grade heater.
Large Heaters (35 to 80 Million BTUs/Hour)
When you venture into the large heater range, the design begins to evolve to accommodate higher heat absorption. These heaters still feature a helical coil and a single burner, but the radiant box ships in two separate pieces (a top half and a bottom half) instead of one.
Field assembly includes:
- Setting the bottom half of the radiant box.
- Installing the loose helical coil.
- Securing the top half of the radiant box.
This configuration requires one additional field joint compared to small and medium heaters, but it remains relatively straightforward to transport and assemble. These large heaters are perfect for operations needing increased heat output without jumping into more complex designs.
Jumbo Heaters (80+ Million BTUs/Hour)
For jumbo heaters, the game changes. The higher heat outputs require not only larger equipment but also a transition from a simple helical coil design to a serpentine coil configuration. Why this shift?
- Helical Coil Limitations
Helical coils are circular in shape, which makes them efficient up to about 80 million BTUs/hour. However, increasing their diameter beyond 13.5 feet (the practical shipping limit) leads to prohibitive transport costs. Making a helical coil any larger also becomes impractical for field handling and installation. - Introducing the Serpentine Coil
Serpentine coils are laid out horizontally in panels, with tubes parallel to the roof and floor of the radiant box. These panels offer incredible flexibility. They can be pre-assembled into sections, allowing for more cost-effective shipping and easier assembly in the field.
Field assembly of a jumbo heater might include setting up a multi-piece radiant box and attaching several sections of serpentine coil. For even greater capacities, jumbo heaters can include multiple burners to distribute the workload effectively. For example:
- 90-100 million BTUs/hour heaters typically have two burners.
- Larger heaters with upwards of 120 million BTUs/hour may feature two or more burners.
If the project needs go beyond what can be managed horizontally, a vertical heater configuration with multiple burners (like six burners) becomes a viable option.
Beyond Size: Other Considerations
While it’s clear that size matters, there are other critical factors when sizing and designing heaters for your operation.
- Flame Management
The flame itself becomes a big consideration as heaters scale up. Larger flames require more space in the radiant box to avoid issues like flame impingement, which can lead to coil failures. Simply stretching a helical coil to handle more heat isn’t a practical solution.
- Shipping Logistics
Transporting oversized components can quickly escalate project costs. That’s why THM designs larger systems with modular components that are easy to ship and reassemble in the field. Compact shipping options, like flat-packed serpentine panels, keep costs reasonable without compromising performance.
- Assembly and Field Configuration
A modular design not only keeps shipping affordable but also streamlines field assembly. With careful planning, jumbos can be broken into manageable pieces, reducing the need for heavy equipment and extensive field labor.
Is There a Limit?
The short answer is no, there’s no hard cap on how big a fired heater can get. However, as sizes increase, so do the challenges. At THM, we approach each project with scalability in mind, balancing performance, cost, and practicality. Whether your project needs 2 million BTUs/hour or a massive 120 million BTUs/hour system, we have the expertise to design a solution tailored to your needs.
The Bottom Line
Heater sizing isn’t just about making something as big as possible. It’s about carefully balancing heat transfer, design practicality, shipping logistics, and field assembly complexity. At Tulsa Heaters Midstream, we leverage decades of expertise to deliver heaters that meet your specific needs, regardless of size. If you’re looking for a straightforward, small-to-medium heater or a custom-designed jumbo system, we’re here to help you go as big as you need.
If you’d like to discuss your needs or explore the best configuration for your operation, reach out to our team. We’ll make sure you’re not trying to pack five pounds into a three-pound bag when it comes to heater performance.
Contact Tulsa Heaters Midstream today.
