Materials System Specification

32-SAMSS-029 Manufacture of Fired Heaters Heat Transfer Equipment Standards Committee Members
Anizi, Salamah Salem, Chairman Bagawi, Jamil Jarallah, Vice Chairman Anezi, Mohammed Ali Dossary, Musfir Abdullah Fernandez, Gabriel Thomas Gahtani, Moraya Saif Guthami, Mohammed Mohsen Hamam, Ibrahim Hassan Harbi, Abdullah Mohammed Saeed Mansour, Khalid Mohammad Naffaa, Mahmoud Youniss Rumaih, Abdullah Mohammad

16 December 2009

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Scope............................................................. 2 Normative References.................................... 2 Terms and Definition...................................... 4 Proposals....................................................... 4 Design Considerations................................... 5 Tubes............................................................. 6 Headers.......................................................... 7 Piping, Terminals and Manifolds.................... 7 Tube Supports................................................ 8 Refractory and Insulation............................... 8 Structures and Appurtenances....................... 9 Stacks, Ducts, and Breechings.................... 11 Burners and Auxiliary Equipment................. 13 Instrument and Auxiliary Connections.......... 16 Shop Fabrication and Field Erection............ 17 Inspection, Examination and Testing........... 19 Life Cycle Cost Evaluation........................... 22

Previous Issue: 28 January 2004 Next Planned Update: 16 December 2014 Page 1 of 25 Primary contact: Anizi, Salamah Salem on 966-3-8760203
CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Heat Transfer Equipment Issue Date: 16 December 2009 Next Planned Update: 16 December 2014

32-SAMSS-029 Manufacture of Fired Heaters

Table of Contents Appendix E Centrifugal Fans for Fired Heater Systems..................... 24 Appendix F Air Preheat Systems for Fired Process Heaters.................... 25 The following paragraph numbers refer to API STD 560, Fourth Edition, August 2007, which is part of this specification. The text in each paragraph below is an addition, deletion or exception to API STD 560 as noted. Paragraph numbers not appearing in API STD 560 are newly added paragraphs inserted in numerical order. 1 Scope (Exception) The scope of this specification covers the minimum requirements for the process design, mechanical design, materials, shop and field fabrication, shop and field testing, preparation for shipment, and field erection of direct-fired and pyrolysis excluding radiant section fired heaters. 1.1 Any conflicts between this specification and other applicable Saudi Aramco Materials System Specifications, (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by Saudi Aramco or its Representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this specification in writing to Saudi Aramco or its Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran

1.2

Normative References Materials or equipment supplied to this specification shall comply with the latest edition of the references listed below, unless otherwise noted. 2.1 Saudi Aramco References Saudi Aramco Engineering Procedures SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement Qualification of Non-Saudi Aramco Personnel
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SAEP-1142

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Saudi Aramco Engineering Standards SAES-A-112 SAES-A-206 SAES-B-054 SAES-H-100 SAES-N-100 SAES-N-110 SAES-N-130 SAES-N-140 SAES-W-011 Meteorological and Seismic Design Data Positive Material Identification Access, Egress and Materials Handling for Plant Facilities Painting Requirements for Industrial Facilities Refractory Systems Installation Requirements - Castable Refractory Installation Requirements - Fireclay Bricks Installation Requirements - Refractory Ceramic Fiber Welding Requirements for On-plot Piping,

Saudi Aramco Forms and Data Sheets 175-323700 7305-ENG NMR-7900 Manufacture of Fired Heaters Equipment Noise Data Sheet Non-Material Requirements for Fired Heaters

American Society of Mechanical Engineers/Boiler and Pressure Vessel Codes ASME B16.20 ASME B16.21 ASME B16.5 ASME B31.1 Metallic Gaskets Ring Joint and Spiral Wound Non-Metallic Gaskets for Pipe Flanges Pipe Flanges and Flanged Fittings Power Piping

American Society for Testing and Materials ASTM A297 Standard Specification for Steel Castings, IronChromium, and Iron-Chromium-Nickel, Heat Resistant for General Application

American Institute of Steel Construction AISC 325 AISC 326 Manual of Steel Construction Detailing for Steel Construction

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Terms and Definition 3.85 3.86 Design Engineer: The Engineering Company responsible for specifying on the data sheet the thermal and mechanical design requirements for heaters. Direct-Fired Heaters: Heaters used to provide heat primarily by conductive heat by flame impingement used for heating asphalt or bunker oil for loading or mixing. Engineering Company: The company responsible for specifying the design requirements for Heaters on the data sheet. Heater fabricator: The Company responsible for manufacturing heaters in accordance with the design requirements specified by the heater designer. Heater supplier: the Company responsible for the design, materials, fabrication, testing, preparation for shipment, of fired heaters in accordance with this specification. Hydrocarbon Service: Process streams of liquid or gaseous hydrocarbon materials. Pyrolysis Heaters: Heaters that provide heat for chemical reactions inside heater tubes for cracking and have service descriptions of ethylene crackers Reformer Heaters: to provide heat for catalytic chemical reaction and have process description such as: steam (hydrogen) reformer. Saudi Aramco Engineer: The chairman of standard committee, Consulting Services Department, Dhahran. Saudi Aramco Inspector: The person or company authorized by the Saudi Aramco Inspection Department to inspect heaters to the requirements of this specification.

3.87 3.88 3.89

3.90 3.91 3.92 3.93 3.94

Proposals 5.1 5.1.4 Purchasers Responsibilities (Exception) The number of copies of drawings, data sheets, specifications, data reports, operating manuals and installation instructions shall be in accordance with Form NMR-7900, Nonmaterial Requirements. Vendors Responsibilities The Heater supplier is to supply the following additional information with
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5.2

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the proposal. This information is necessary and will be used to complete the technical evaluation of the quotation. The quotation will be technically unacceptable if any of the information required is not included. (e) (k) 5.3 5.3.1 to 5.4 5.5 (Exception) A completed noise data sheet (Form 7305-ENG) with a detailed description of acoustical design. Energy conservation recommendations including: use of air-preheats, high-efficiency burners, etc.

Documentation (Exception) Documentation shall be in accordance with Form NMR-7900. Performance Guarantees The following shall be guaranteed when heaters are operated at 100% of design heat release and design excess air, with the feeds and fuels specified on the data sheet and at the process and ambient conditions specified. These requirements are in addition to any other guarantees detailed in the purchase order or contractual documents. (a) (b) (c) (d) Flue gas emission levels at normal and design conditions Sound levels at all specified operating conditions shall not exceed 85 dBA one meter from the source. Efficiency as specified in the data sheet based on the procedures of API STD 560. Maximum pressure drop as specified in the data sheet.

Design Considerations 6.1 6.1.6 6.3 6.3.13 Process design The values of average heat flux densities shall be in accordance with process licensor specified by the Engineering Company. Mechanical design A minimum 30 inch diameter manway shall be provided to heater/furnace areas such as radiant section, convection tube banks and passes, areas of flue gas breaching and stack, and air ducts or breaching. Environmental All fired heaters and their associated equipment shall be suitably designed
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6.4 6.4.1

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for outdoor operations in a desert climate where the atmosphere is salt laden and highly corrosive and in accordance with the climatic data specified in SAES-A-112. 6.4.2 6.5 6.5.1 6.6 6.6.1 6.6.2 Accessories provided for the heater which are exposed to direct sunlight shall be designed for a temperature of 70C. Noise The Engineering Company shall specify limits for the sound pressure levels (SPL) at the designated locations, on Form 7305-ENG. Emissions Heaters shall be designed to operate in compliance with local environmental regulations as detailed by the Engineering Company. The Heater supplier shall calculate and guarantee emission rates of Nitrogen oxides. The emission rates shall be expressed in PPMv at 3% O2 dry basis when the heater is operated at its design rate firing the fuels specified. Flue gas emissions (NOx, CO, particulates, hydrocarbons, etc.) will not exceed the specified levels. Decoking A recommended procedure including steam and air rates shall be provided by the Heater Supplier as part of the operating procedures.

6.7 6.7.2

Tubes 7.1 7.1.1 General (Exception) Tube wall thickness for coils shall be determined in accordance with the procedures set forth in API STD 530. Minimum design tube life shall be 100,000 hours. Heater coils and piping that contain steam and water shall be designed in accordance with the Boiler and Pressure Vessel Code, ASME SEC VIII. Where allowable stresses are not covered by the ASME Code or API RP 530, data from a reliable published source may be used subject to approval of the Saudi Aramco Engineer. Minimum rupture coil design pressure shall be the maximum operating inlet pressure plus 10% or plus 345 kPa (50 psig), whichever is greater.

7.1.8 7.1.9

7.1.10

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7.1.11 7.1.12 7.1.13

The radiant tubes shall be located with two nominal diameters minimum spacing between centerlines of adjacent tubes. spacing between the convection section walls or corbelling ends and the closest tube centerline shall be one half of the horizontal tube spacing. Provision shall be made to facilitate the removal and reinstallation of radiant and convection tubes. A description of the removal and replacement procedures shall be provided. All crossovers, manifolds, and external piping shall be arranged so that they do not interfere with tube removal. Extended Surfaces The method of protecting carbon steel and fins from corrosion, prior to startup shall be specified by the Heater Supplier.

7.1.14 7.2 7.2.4

Headers 8.3 8.3.5 Return Bends Inside diameter of fittings shall match that of the heater tube.

Piping, Terminals and Manifolds 9.1 9.1.9 9.1.10 9.1.11 9.1.12 9.1.13 9.1.14 General Unless otherwise specified in the data sheet, Process coil inlets and outlets shall be flanged. Minimum flange rating shall be ASME Class 300. Terminal connections on steam and water coils shall be beveled for welding, unless stated on the data sheet. Swages shall be schedule 160 minimum taper bored. Manifolds and associated piping shall be furnished as required to provide a single outlet connection for each heating service. Manifold thickness shall not be less than standard thickness. Manifolds shall be sized so that the dynamic head in the manifold at the point of maximum velocity is not more than 10% of the individual pass pressure drop.

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10

Tube Supports 10.1 10.1.7 10.1.8 10.1.9 10.3 10.3.3 10.3.4 General Keepers shall be provided on horizontal tube supports as required to prevent tubes from becoming dislodged from the support. Supports for horizontal tubes maximum straight tube overhang shall not be more than six outside diameters. Start-up, shutdown, and part-load operation shall be considered when setting the design temperature. Materials Bolting used to tie tube support brackets or hangers to the structure shall be stainless steel type 304H, as a minimum. Carbon steel end tube supports shall be protected on the flue gas side by castable insulation. Minimum thickness shall be 100 mm for convection end-tube supports and 150 mm for radiant supports.

11

Refractory and Insulation 11.1 General (Exception) The design temperature of the outside casing surfaces of radiant and convection sections shall be determined in accordance with SAES-N-100. 11.1.5 11.1.13 11.1.14 11.1.15 11.2 11.2.10 11.2.11 (Exception) The design of refractory for heater floors shall be in accordance with SAES-N-100. The design and material selection of refractory systems shall be in accordance with SAES-N-100. Burner blocks shall be high-duty refractory laid in high temperature bonding cement. Expansion joints shall be provided around each burner. Brick and Tile Construction The design of brick and tile construction shall be in accordance with SAES-N-100. Burner tile for floor-mounted burners shall extend at least 2 inches above floor refractory.
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11.3

Castable Construction

11.3.1 to 11.3.11 (Exception) The construction of castable refractory shall be in accordance with SAES-N-100. 11.4 Ceramic Fiber Construction

11.4.1 to 11.4.21 (Exception) The design of refractory ceramic fiber insulation shall be in accordance with SAES-N-100. 11.5 Multi-component Lining Construction

11.5.1 to 11.5.9 (Exception) Multi-component Lining shall be in accordance withSAES-N-100. 11.6 Materials

11.6.1 & (Exception) Material selection for refractory and refractory anchors 11.6.2 shall be in accordance with SAES-N-100. 12 Structures and Appurtenances 12.1 12.1.1 12.1.2 General (Exception) Structural steel shall be designed and detailed in accordance with AISC M016 and AISC 326. (Exception) Heaters shall be designed for wind and earthquake loads in accordance with ASCE 7. With reference to ASCE 7, the wind Category Classification to be used in the calculations of wind loads shall be Category III, and the Seismic Hazard Exposure Group to be used in calculations of earthquake loads shall be Group III. Wind pressures shall be assumed to act on the projected surface area of the heater and shall include due allowances for platforms, ladders, piping, insulation, and equipment supported from the heaters. 12.1.5 (Exception) The design metal temperatures of structures shall be the calculated metal temperature plus 56C, based on the maximum flue gas temperature expected for all operating modes with an average ambient temperature specified in accordance with SAES-A-112. Additional structure shall be provided at the convection section ends above the base platform level to support temporary scaffolding for maintenance.
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12.1.8

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12.1.9 12.1.10 12.2 12.2.7 12.2.11

All removable panels and access doors shall be provided with an eye or lifting lug suitable for use with a crane or cable lifting hook. Designs shall provide for adequate ventilation of enclosed or partially enclosed areas of the heater structure. Structures (Exception) The extent and thickness of fireproofing shall be specified by the engineering contractor. Heater structures which contain more than one heater shall be designed to accommodate differential thermal expansion when one heater is operating and the adjacent heater(s) is out of service. All bolted connections for ducts, plenums, and header boxes shall be provided with suitable gaskets to prevent air or flue gas leakage. Header Boxes, Doors, and Ports Header Boxes (Exception) Housings shall have bolted removable sections or header box doors. All removable panels are to be provided with an eye or lifting lug suitable for use with a crane or cable lifting hook. Header box doors shall be equipped with hinges, latches, and handles. Handles shall be designed so that their external temperature does not exceed 50C

12.2.12 12.3 12.3.1

12.3.1.6 12.3.1.7

Header boxes containing plug fittings shall be provided with threaded couplings for drains and smothering steam connections. Removable header box panels at ends of convection section shall be lined with ceramic fiber blanket held in place by appropriate anchoring system as internal insulation. If return bends are located outside fireboxes, they shall be enclosed in steelplate housings. Return header housings shall be internally insulated as required to meet the casing temperature limitation. Doors and Ports Access doors shall be an airtight design. Two explosion doors shall be furnished to relieve each combustion chamber of a multi-cell heater with a common convection section having tubes
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12.3.1.8 12.3.1.9 12.3.2 12.3.2.7 12.3.2.8

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oriented parallel to the radiant tubes. 12.3.2.9 For radiant sections over 6 m high, a second elevation set of peep doors shall be installed.

12.3.2.10 Peep doors shall be located so that tubes and burners are clearly observable. 12.3.2.11 Clear access shall be provided to the return headers without interfering with working platforms or piping. 12.4 12.4.1 Ladders, Platforms, and Stairways Additional Platforms shall be provided at the following locations: (g) (h) (i) 12.4.12 12.4.13 12.4.14 12.4.15 13 All access doors, observation and instrument connections All stack sampling connections All analyzer and analyzer connections

Walkways shall be provided to inter-connect platforms at each level. Unless otherwise specified by the Engineering Company, stairways shall be provided from grade to burner operating platforms as follows: Heater coil vents, drains, sample, instrument, and chemical cleaning connections shall be accessible from heater platforms or grade. Stairs, ladders and access platforms shall be in accordance with SAES-B-054.

Stacks, Ducts, and Breechings 13.1 13.1.3 13.1.4 13.1.5 13.1.6 13.1.7 13.1.8 General A pneumatically operated flue gas control damper shall be provided at the base of each natural draft stack. Maintenance blinds shall be provided in ducts to isolate air preheaters. In order to avoid inversion and downwash, the flue gas stack exit velocity under heater turndown conditions shall not be less than 4.5 m/sec. Sections of ducts which must be removed for maintenance shall be flanged and bolted. All stacks shall be provided with a painter's rail, trolley, and halyard. Insulation required for noise attenuation and weatherproofing for air ducts
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and windboxes shall be included. 13.1.9 13.1.10 13.1.11 13.1.12 13.1.13 Duct fittings shall be provided with turning vanes as required for proper air distribution and minimum pressure loss. Air ducts shall be of welded steel plate construction. Provision shall be made for expansion between air preheaters and connecting ductwork. Hanger and bracket supports for ducts are to be included. If a forced draft fan is used, combustion air ductwork including forced draft fan inlet and discharge ductwork, air ducts, and any additional features required for operation shall be provided. Design Considerations (Exception) Heater stacks, ducts and breechings shall be designed for wind and earthquake loads in accordance with ASCE 7. With reference to ASCE 7, the wind Category Classification to be used in the calculations of wind loads shall be Category III, and the Seismic Hazard Exposure Group to be used in calculations of earthquake loads shall be Group III. Wind pressures shall be assumed to act on the projected surface area of the heater and shall include due allowances for platforms, ladders, piping, insulation, and equipment supported from the heaters. Minimum design loads shall be in accordance with ASCE 7. All structural steel shall be designed and detailed in accordance with AISC M016 and AISC M013. 13.2.18 (Exception) The design metal temperatures of stacks, ducts and breechings shall be the calculated metal temperature plus 50C, based on the maximum flue gas temperature expected for all operating modes with an average ambient temperature specified in accordance with SAES-A-112. Wind-Induced Vibration Design (Exception) Spiral or staggered vertical plates shall be provided as required by the design. Materials The top edge of the stack lining shall be protected with a Type 316L
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13.2 13.2.14

13.5 13.5.3 13.6 13.6.1

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stainless steel internal angle or other suitable means to prevent water penetration between steel and lining. 13.6.2 13.6.3 The top 600 mm of the stack shall be Type 316L stainless steel. As a minimum, the cable for trolley tracks and halyard shall be 18% Chrome-8% Nickel stainless steel.

14

Burners and Auxiliary Equipment 14.1 14.1.23 Burners Burners in natural draft heaters shall be specified to permit firing at burner design heat release at 10% excess air for fuel gas and 20% excess air for fuel oils and any fuel/oil gas combinations. Forced draft burners shall be specified to permit firing at burner design heat release at 10% excess air for fuel gas and 15% excess air for fuel oil or any combination of fuel oil/fuel gas. 14.1.24 14.1.25 14.1.26 14.1.27 The selection of burners shall be based on verification of satisfactory performance in the same or a similar service. Burners shall be designed to fire all fuels with fuel combinations specified on the data sheet. A pilot for each burner shall be provided. The pilots shall burn continuously while the heater is in operation. Bottom fired heaters shall be arranged to provide sufficient head room, consistent with easy operation of the burners. Sight holes shall be positioned accordingly. Burners shall be supported from the heater structure and burner blocks shall be independent of the heater wall. Burner tips shall be easily removable for maintenance during heater operation. Lighting ports shall be provided so that burners may be manually lighted. Burner fuel and air controls shall be accessible from grade or platforms. Means to view the burner and pilot flame during light-off and operating adjustment shall be provided. The weight of burner assemblies shall be stated on the burner assembly
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14.1.28 14.1.29 14.1.30 14.1.31

14.1.32

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drawing. 14.1.33 14.1.34 When a flame detector is specified, the detector mount shall be adjustable for sighting, and be lockable. Burner air registers shall be externally adjustable and removable during heater operation. External position indicators shall be provided for burner registers. Burners gas rings or tips and oil guns shall be removable while the heater is in operation. Sootblowers Soot-blowers shall be fully automatic with selected sequential control and manual override capabilities for individual soot-blowers. Each soot-blower shall be easily maintainable, with readily accessible lubrication fittings at all required lubrication points. The soot-blower manufacturers design shall be substantiated by at least two years of experience in comparable service. Soot-blower pipe work shall be arranged so that condensate buildup drains away from the soot-blower head. Drain valves shall be interlocked with the steam valve to ensure that upstream condensate is drained during warm-up and prior to the operation of soot-blowers. Pipe work and associated fittings shall be in accordance with ASME B31.3. Automatic control shall be obtained via a programmable logic controller (PLC) as designed and specified by the Engineering Company in accordance with 34-SAMSS-830. Automatic mode of operation shall incorporate the following functions: (1) (2) Enable the lockout of any soot-blower from the normal operating sequence. Enable the sequence to be held at any point in the sequence by operator intervention, and allow soot-blowers to operate in the manual or local mode during that hold period. On reselection of the automatic mode, the soot-blower sequence shall continue from where it was interrupted. On the initiation of any emergency stop signal, automatically retract any operating retractable soot-blower and shut down the system to a safe condition.
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14.1.35 14.2 14.2.7 14.2.8 14.2.9 14.2.10

14.2.11 14.2.12

14.2.13

(3)

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14.2.14

The following are the minimum indications of system status that shall be provided: (1) (2) (3) (4) (5) (6) (7) (8) (9) The mode of operation selected When the system is running under automatic sequential control Individual sootblower in operation The direction of travel for individual retractable sootblower during operation Steam system warm-up period is in progress Steam system warm-up period is completed Any sootblower(s) locked out of the normal operating sequence Open/closed positions of main supply valve Open/closed positions of individual heater steam supply shutoff valves

14.2.15

The following are the minimum indications of alarm status: (1) (2) (3) (4) Elapsed time Motor overload Steam pressure Out of sequence

14.2.16

The following shall be provided in the control rooms: (1) (2) (3) Alarm and status indications Automatic and manual mode pushbuttons Soot-blower selector switches

14.4 14.4.1

Damper Controls Include pneumatically operated dampers as required to control combustion air and flue gas flows on heater arrangements with air preheaters and forced or induced draft fans. Pneumatically operated stack damper shall have an alternate means of manual operation from grade level. Stack damper shall be designed with a counterweight to prevent closing if the cable breaks or the operating mechanism otherwise fails. Stack dampers for natural draft shall be designed for clearance of 25 mm in
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14.4.2 14.4.3 14.4.4

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fully closed position. The damper controls shall be designed to prevent automatic closure beyond 85% closed. 14.4.5 14.4.6 For installations where tight shut-off is required as in bypasses to air heaters, etc. dampers shall close against seal. Damper positioners, shall be included for all pneumatically operated dampers. The necessary mechanical linkages shall be included between dampers and positioners and limit switches. All pneumatically operated dampers shall have the facility to vent the motive air from the actuator and bypass the controller so that the damper can be manually positioned.

14.4.7

15

Instrument and Auxiliary Connections 15.1 15.1.1 15.1.2.8 Flue Gas and Air Flue-gas and Combustion-air Temperature A metering venturi, airfoil section or multi-point mass flowmeters located in the forced draft fan inlet or discharge duct, with taps suitable for airflow measurement shall be provided. The device shall be located upstream of any air heater. The system proposed shall be provided with sufficient upstream and downstream straight lengths of duct to ensure accuracy of airflow measurement. Flue-gas Sampling Sample connections shall be provided for oxygen and combustible analyzers at the furnace exit, boiler, economizer, and air preheater outlet. Multiple sampling connections shall be provided in the flue gas duct at the convection outlet and air preheater to obtain flue gas analysis. Each connection shall consist of a stainless steel nipple, valve, and plug with provision for purging. The vendor shall identify the purging media and submit the purging procedure in the proposal. Connections for the measurement of opacity, particulate matter, sulfur dioxide, nitrogen oxides, oxygen, and carbon monoxide shall be provided. Process Fluid Temperature (Exception) Thermowell connections on each pass at the outlets of convection and radiant sections shall be provided.

15.1.3 15.1.3.6 15.1.3.7

15.1.3.8 15.2 15.2.1

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15.3 15.3.1 15.3.1.2

Auxiliary Connections Purge-steam Connections (Exception) Snuffing and purge steam connections shall be 2 inch NPS minimum for combustion chambers and 1 inch NPS minimum for header housings. Additional connections for the following shall be provided by the heater manufacturer. (1) (2) Connections for flame monitoring and scanning shall be provided. Connections for draft gages at fan inlet and discharge air outlet of the air preheater, windbox, furnace, outlet, flue gas outlet of the air preheater, and stack entry. Six equally spaced connections installed around the periphery of forced draft fan outlet ducts for pitot tube traverse of airflow. High point's vents, low point drains, and test connections shall be provided, as required, on all manifolds and piping.

15.3.1.6

(3) (4) 15.4 15.4.3

Tube Skin Thermocouples Tube Skin Thermocouples Exception) As a minimum, provide four tube skin thermocouples per pass. For the arbor type heater four tube thermocouples per cell. Thermocouple locations shall be determined by the heater.

15.5

Burner Management Systems All nozzles and instrument connections of the instrumentation system shall be supplied by the Heater supplier if the burner management system is supplied by others.

16

Shop Fabrication and Field Erection 16.1 16.1.5 General The manufacturer shall shop-install sufficient braces, struts, and lifting lugs to permit handling at the construction site with conventional slings or hooks without damage to the equipment. Temporary bracing shall be clearly identified as such. The Heater supplier shall submit plans for handling and shipping heaters for
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16.1.6 16.1.7

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review and approval. 16.1.8 Each part of a heater which is shipped as separate pieces or shop assembly shall be identified. This includes steel and refractory parts which must be set in a specific location in the heater. Drawings which show the location of each piece and the sequence of erection shall be included. Piece marks may be stenciled or painted on according to the manufacturer's standard procedure except as follows: (1) Paints containing lead, zinc, or any other metals which are detrimental to pressure parts operating at elevated temperatures shall not be used for marking. Acceptability of marking paint must be established by prior satisfactory experience of the heater supplier. Die stamping of parts which will contain process fluids under pressure or temperature is prohibited.

16.1.9 16.1.10

(2) (3) 16.1.11 16.1.12

All austenitic stainless steel material shall be protected against salt water spray during ocean shipment. Heater structures shall be designed such that outside columns do not interfere with the lift and setting of convection sections while maintaining structural integrity. Convection sections shall be fully preassembled before delivery to the jobsite including complete box assembly, refractory, tube supports, and tubes. Mating flanges of boxed pieces shall be match punched for proper field fit up. Crossover piping shall be prefabricated to minimize field welding. Platforms shall be shipped in maximum frame sizes allowed by shipping limitations. Stack sections shall be shipped with lifting lugs. Structural-Steel Fabrication General Requirements m) (Exception) Attachment of refractory anchors and tie-backs shall be in accordance with SAES-N-110.
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16.1.13

16.1.14 16.1.15 16.1.16 16.1.17 16.2 16.2.1

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16.3 16.3.8 16.4 16.4.1 16.4.5 16.5 13.5.8 16.6 16.6.17 16.6.18

Coil Fabrication Fabrication of steam or water coils shall be in accordance with Boiler and Pressure Vessel Code, ASME SEC VIII. Painting and Galvanizing (Exception) The type of coating and painting systems to be used shall be in accordance with the data sheet and SAES-H-100. Gasket contact surfaces shall not be painted. Refractories and Insulation (Exception) Refractory materials shall be installed in accordance with SAES-N-110, SAES-N-130 and SAES-N-140 as applicable, Preparation for Shipment Prior to shipping coils are to be completely and thoroughly dried and cleaned. Markings shall be done with water-soluble materials that contain no harmful substances that would attack or harmfully affect coils at both ambient and operating temperature. The marking materials shall be free of Lead, Sulfur, Zinc, Cadmium, Mercury, Chlorine, or any other Halogens. Flanged connections and all other machined surfaces shall be protected by a coating, which is easily removed in the field. Flanges shall be fitted with a steel or wood cover, 3 mm thick and neoprene gaskets. Covers shall be securely attached by a minimum of four bolts equally spaced. For ocean shipment, flanged connections shall also be covered with heavy duty plastic bags securely taped to the nozzles. Field Erection Stainless coil material shall be covered, packaged for off-the-ground storage, and plugged to prevent moisture from entering. Heater radiant and convection sections shall be protected from atmospheric moisture with all coil openings sealed.

16.6.19

16.6.20

16.7 16.7.7 16.7.8

17

Inspection, Examination and Testing 17.1 17.1.5 General The responsibility for inspection rests with the Heater supplier in accordance
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with the applicable Industry Standards and the requirements of this specification. 17.1.6 Heaters manufactured in accordance with this specification are subject to verification by the Saudi Aramco Inspector in accordance with Saudi Aramco Inspection Requirements Form 175-323700. All Nondestructive Testing (NDT) shall be performed in accordance with the Heater Suppliers written procedure prepared in accordance with ASME SEC V with the scope of NDT and acceptance/rejection criteria as defined by the referencing Code section and this specification. Inspection procedures shall be established in accordance with ASME SEC V. A written procedure for each inspection method and technique, including acceptance criteria, to be used shall be submitted to the Saudi Aramco Inspector for approval. Qualification of the procedure by the Heater supplier may be required, as determined by the Saudi Aramco Inspector. Inspection procedures in conformance with other standards are acceptable only with the approval of the Saudi Aramco Inspector. Written reports and evaluations of all inspections performed by the Heater supplier shall be made and submitted to the Saudi Aramco Inspector, at a frequency to be determined by the Saudi Aramco Inspector. The Saudi Aramco Inspector shall have free access to the work at all times. Saudi Aramco shall have the right to inspect the fabrication at any state and to reject material or workmanship which does not conform to the specified requirements. Saudi Aramco reserves the right to inspect, photograph, and/or videotape all material, fabrication, coating, and workmanship and any materials, equipment, or tools used or to be used for any part of the work to be performed. Saudi Aramco may reject the use of any materials, equipment, or tools that do not conform to the requirements of this specification, jeopardize safety of personnel, or impose hazard of damage to Saudi Aramco property. All of the rights of Saudi Aramco and their designated representatives for access, documentation, inspection, and rejection shall include any work done by sub-contractors or sub-vendors. The Heater Fabricator shall furnish, install, and maintain in a safe operating condition all necessary scaffolding, ladders, walkways, and lighting for a safe and thorough inspection.

17.1.7

17.1.8

17.1.9

17.1.10 17.1.11

17.1.12

17.1.13

17.1.14

17.1.15

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17.1.16

Additional inspection of any weld joint at any stage of the fabrication may be requested by the Saudi Aramco Inspector, including re-inspection of previously inspected joints. The Saudi Aramco Inspector also has the right to request or conduct independent NDT of any joint. If such testing should disclose non-conformance to the requirements of the applicable Code or this specification, all repair and NDT costs shall be at the Heater Suppliers expense. All NDT performed in the field shall be by personnel certified in accordance with SAEP-1142. Personnel responsible for interpretation of NDT results shall be certified in accordance with SAEP-1142. All NDT on heater coils which are to be postweld heat treated shall be made after postweld heat treatment. All pressure and non-pressure welds shall be visually inspected where accessible. Prior to final inspection and pressure testing, the inside and outside of the heater shall be thoroughly cleaned of all slag, scale, dirt, grit, weld spatter, paint, oil, etc. All appropriate safety precautions shall be taken for each inspection method. All materials required to be other than, carbon steels, shall be alloy verified in accordance with SAES-A-206. Weld Examination

17.1.17

17.1.18 17.1.19 17.1.20

17.1.21 17.1.22 17.2

17.2.2.1 a) (Exception) Root and cover passes of all welds on austenitic alloy parts shall be liquid penetrant examined. 17.3 Castings Examination

17.3.2 a) & b) (Exception) Radiographic testing of tube support castings shall be given to any cracks or other indications exposed by liquid penetrant inspection that exceed the quality requirements of ASME SEC I, PG-25. 17.3.2 c) (Exception) Areas of stress concentration in corners of castings, especially at support lugs, shall be radiographically inspected. At least two spot radiographs shall be taken of the lower flanges of each cast tube support section. 17.4 17.4.2 Examination of other Components (Exception) Refractory linings shall be inspected in accordance with
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SAES-N-110, SAES-N-130, and SAES-N-140. 17.4.7 One random spot radiograph shall be made for each girth weld and one random radiograph for each two vertical welds of a stack shell. In addition, each vertical and circumferential welds intersection shall be radiographed in the circumferential direction. Testing Pressure Testing Coil assemblies shall be completely drained and dried immediately upon completion of hydrotesting. If coil assemblies are not drainable, demineralized water containing 1% Na2 CO3 (Sodium Carbonate) plus 0.5% Na NO2 shall be used for hydrotesting. For tube coils manufactured from stainless steel, the water shall not contain more than 50-ppm chlorides. Refractory Testing (Exception) Refractory materials shall be tested in accordance with SAES-N-110, SAES-N-130, and SAES-N-140 as applicable. 17.5.4 14.5.4.2 17.6 Positive Material Identification (Exception) All materials, except carbon steel, shall be alloy verified in accordance with SAES-A-206. Burner Testing A production model of each burner type shall be test fired prior to shipment. Test firing may be witnessed by the Saudi Aramco Inspector. A certified test report indicating the test firing shall be provided. 18 Life Cycle Cost Evaluation Unless otherwise approved by the Coordinator, Mechanical Engineering Division, Consulting Services Department, Quotations for heaters shall be evaluated on the basis of Life Cycle Cost (LCC) as explained in SAEP-341. This cost is composed of the initial purchase cost of the heater(s) plus the present worth of the fuel consumption over an assumed operating period of 15 years. The Life Cycle Cost of the Heater(s) shall be determined using the following Life Cycle Cost spreadsheets: LCC-024, Single Fuel Heaters LCC-024A, Dual Fuel Heaters

17.5 17.5.1 17.5.1.5

17.5.2

The efficiency of the heater at 100% of the design heat releases shall be guaranteed. If
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the actual efficiency during performance tests is found to be less than the guaranteed efficiency, then the cost of the heater(s) shall be reduced by an amount equal to the difference in fuel consumption (MMBTU/hr) for not meeting the guaranteed efficiency, multiplied by the Evaluation Factor $-hr/MMBTU as given in the provided Life Cycle Cost spreadsheets included with heater data sheet. The maximum reduction shall not exceed 15% of the initial cost of the process heater(s). Mathematically: Single Fuel: Efficiency Penalty = [actual efficiency (guaranteed efficiency-0.01)] * L * EF
Commentary Note: Efficiency values are in decimal representation. 0.01 in the equation is a 1% test tolerance allowed.

EF = PV * EC * AH Dual Fuel: Efficiency Penalty = Sum of Efficiency Penalty of all fuels For each type of fuel the evaluation factor is defined by EF = PV * EC * T Where; L EF = = Heater Load (Duty) @ normal condition (MMBTU/hr) will be show on the data sheet. Evaluation Factor ($-hr/MMBTU) will be shown on the data sheet that goes with the quotation request Energy cost in $/MMBTU for each fuel Annual operating hours OF * 8760 Operating Factor, equal 1 Present value factor = 5.85 based on 15% discount rate expressed as a decimal number and operating period of 15 years. Operating time for each fuel type, in hours

EC = AH = = OF = PV = T =

16 December 2009

Revision Summary Major revision.

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Appendix E Centrifugal Fans for Fired Heater Systems E.1 E.2 E.2.1 E.2.1.2d General Design General Should the fouling characteristics of the fuel(s) demand a more stringent design, the Fan Manufacturer shall submit the fan design criteria with proposal. Fans shall be designed for not less than the following conditions: 1) 2) Mass flow rate at heater design case plus 10 %. Static pressure through the heater plus 21%. All the above are based on the average ambient temperature for FD fan and stack temperature for ID fan. E.2.1.16 E.2.1.17 E.2.1.18 Forced draft fans shall be located at ground level and designed to permit easy access to the interior of fan casings and to allow easy removal of rotors. Fans shall be supported on a common base plate with the fan driver. Air intakes of fans located outdoors shall be provided with bird screen and with means to avoid pickup of wind-driven sand. The inlet shall also be designed to avoid wind effects on combustion airflow measuring devices. Air intake and discharge ducts shall be provided with silencers as required Fan Housing The housing shall be of all-welded construction and shall be equipped with a cleanout door and a 2 inch NPS drain. Housings shall be constructed with a split-flanged bolted joint to allow for rotor removal. Rotating Elements Fans shall be furnished with inlet guide vanes/dampers and with a vane drive arm for connection to operator. The drive arm connections shall be of the ball-and-socket design (or approved equivalent) to minimize lost motion.

E.2.1.15

E.2.1.18 E.2.2 E.2.2.4

E.2.5 E.2.5.9

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E.3 E.3.2 E.3.2.11 E.3.2.12 E.3.2.13 E.4 E.4.2 E.4.2.4

Accessories Drivers Turbine drivers shall conform to the requirements of 32-SAMSS-009. Motor drivers shall conform to the requirements of 17-SAMSS-503. Drivers shall be as specified on the data sheet and shall be in accordance with the specified electric power supply and steam conditions. Geared drives shall be separately coupled units with a minimum service factor of 1.5. Examination, Testing and Preparation for Shipment Fan Testing Fans shall be tested by the Fan Manufacturer in accordance with ANSI/AMCA 210-85 and no load, mechanical run test.

Appendix F Air Preheat Systems for Fired Process Heaters F.1 F.1.1 Scope The Engineering Company together with the Heater supplier must evaluate the need for air-preheating systems based on energy conservation in accordance with the requirements of this Appendix. The design and proposal will be technically unacceptable if an evaluation of a preheat system based on energy conservation has not been provided.

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