ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994

REVIEWED BY: BB
APPROVED BY: GH
9.0

FUEL FIRED HEATERS

9.1.0

Scope: This is All Tech Inspection's guideline for the inspection of fuel fired heaters.

9.2.0

Personnel:
a.
b.

9.3.0

Inspectors - Shall meet the minimum requirements to API-510 pressure vessel code.
Technicians - Shall be certified to SNT-TC-1A level II in Ultrasonics in accordance with
ATI's written UT-WP.

Types of equipment.
a.
b.

9.4.0

900- 1

Vertical heaters.
Horizontal heaters.

External Inspection: Properly inspect and document the data and conditions in accordance with
All Tech Inspection's TA-001 the following areas.
9.4.1

9.4.2

Structures/concrete/fireproofing.
a.

Visually inspect supports and structure for cracks, spalling and deterioration.

b.

Hammer test to check for soft spots or disbonded areas.

Closely examine the exterior of the casing for:

a.

Hotspots - discolored oxidized areas. These areas are caused by a breakdown of

the insulating refractory.

b.

Check the convection section, duct work, breeching transitions, air preheater and
stacks for externa l corrosion and hotspots.

c.

Check around all mechanically flanged (bolted) connections and other areas for
loose and missing bolts, damaged gaskets and hotspots.
1.
2.
3.

Access doors.
Explosion doors.
Inspection ports.

ATI UNPUBLISHED WORKS COPYRIGHT 1994, ALL RIGHTS RESERVED

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH

900- 2

4.
Mechanical connections.
example: Bolted areas such as the convection section to the radiant section convection to
the stack, etc.
9.4.3

9.4.4

9.4.5

Snuffing Steam and Fuel Gas Line.

a.

Perform a visual inspection and an ultrasonic thickness examination or hammer

test to detect corrosion/erosion.

b.

Check associated piping system for external corrosion, supports and loose or
missing bolts.

c.

This is also a good time to make sure the blinds are installed prior to the confined
space entry permit.

Feed Piping.
a.

Perform a visual inspection and an ultrasonic thickness examination or hammer

test to detect corrosion/erosion.

b.

Check associated piping system for external corrosion, supports and loose or
missing bolts.

c.

This is also a good time to make sure the blinds are installed prior to the confined
space entry permit.

Access - Ladders, Platforms, Stairways.

a.

Carefully examine all components of ladders, platforms and stairways for damage
(loose, broken missing or corroded parts).

b.

Check all platforms for:

c.

1.

Tripping hazards.

2.

Obstructions that may cause bodily injury

ie., valve stems or other items protruding in access ways.

Check all ladder cages for:

1.

Obstructions protruding in the ladder cages, valve stems, level gages,

piping, etc.

2.

Personnel access devices, gates bars, chains, etc. at platforms access.

ATI UNPUBLISHED WORKS COPYRIGHT 1994, ALL RIGHTS RESERVED

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
3.
d.
9.5.0

900- 3

Loose or missing bolts.

Make notes on all conditions.

Internal Inspection: Conduct visual and nondestructive test as described.

9.5.1

Radiant Section.
a.

Perform ultrasonic thickness measurements on all accessible tubes and return.

1.

Layout the heater coils if this has not been previously done.

2.

Identify each pass first by location.

example:

1.

For vertical heaters, Southwest radiant tubes Coil "A".

2.

For horizontal heaters, Bottom north radiant tubes Coil "B".

3.

Always call the inlet tube, tube 1, and number the pass tubes consecutively
to the outlet pass.

4.

Returns are identified by its tube passes.

example: The return between tube 4 and 5 is called 4-5.

b.

Take at least one reading on the fire side on each side of each weld.

c.

Creep damage - To detect creep damage either use a go- no-go gauge made for the
tube outside diameter plus five percent (5%) allowable growth, or strap the tubes
with a tape and measure at various intervals.

d.

There are several styles of return bends:

1.
2.

9.5.5

Standard 180 bends - These are either made by welding two 90 elbows
together or cast in one piece.
Cast returns are often times hard to take ultrasonic thickness
measurements on. Sometimes if this is the case use a low frequency large
diameter transducer on the scope.

Hammer Testing of Tubes:

a.

Tubes maybe hammer tested to detect coke build up. A coked up tube will have a
dead sound.

ATI UNPUBLISHED WORKS COPYRIGHT 1994, ALL RIGHTS RESERVED

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
b.

c.

9.5.6

Do not strike the tube hard enough to leave an impression on the surface; cold
working may damage the tubes. Do not hit tubes below 60F due to damage that
may result from being temper embrittled.
Austenitic stainless steels may have stress corrosion cracking at areas that are cold
worked due to severe hammer blows.

Do not open stainless steel equipment operating with sulfur in the feed and high
temperatures without passivation. See Protection of Austenitic Stainless Steel from
Polythionic Acid Stress Corrosion Cracking During Shutdown of Refinery Equipment
(See NACE RP 0170-85 in the appendix II)

9.6.0

Hangers - Visually inspect and hammer test; note all broken hangers and supports.

9.7.0

Insulation
9.7.1

900- 4

Ceramic fiber - Visually inspect ceramic fiber insulation.

a.

Check for damaged and broken anchors; ceramic fiber generally has the least
amount of repairs unless it is damaged due to an explosion/fire or bumped during
maintenance.

9.7.2

Castables - Inspect for cracks, spalling, buckling and disbonded areas. Do not be
concerned with expansion cracks (small cracks that close up when heated.) A simple way
to check if a crack needs to be repaired is to check the casing outside for a hot spot.

9.7.3

Firebrick - Inspect for loose or missing bricks.

9.8.0

Thermowells and Thermocouples - Check for damage, cracks, broken, oxidized parts.

9.9.0

Burner Assemblies - Check the following for damaged parts.

9.9.1

Burner tips should be proper shape, and the holes should be the proper size.

9.9.2

Pilot tips should be proper size and shape. Look for oxidized tips.

9.9.3

Check flame pattern shields, if applicable, for cracks and distortions.

9.9.4

Check the ignitor for damage or oxidized parts.

9.9.5

Check all burner tiles and aircones for cracked, missing parts, etc.

9.10.0 Convection Section - Check condition of tubes.

9.10.1 Studded and finned tubes are generally fouled with combustion residues on the O.D.
These should be cleaned for more efficient heat transfer.
ATI UNPUBLISHED WORKS COPYRIGHT 1994, ALL RIGHTS RESERVED

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH

900- 5

9.10.2 The bottom two or sometimes three rows are called shock tubes. The shock tubes are
usually bare tubes.
a.
b.

Scaffold the heater radiant section to provide access.

Perform visual, ultrasonic thickness and strapping inspection where access is
available.

9.10.3 The return bends for the convection sections are often times accessible by removing
covers on the outside of the heater where by exposing them for inspection.
9.11.0 Ducts and Breeching - Inspect the insulation for damage. Inspect any dampers for operational
problems or corrosion. Check where dampers may rub on the insulation and their movement may
be restricted.
9.12.0 Stack - Inspect the insulation for damage. Inspect any dampers for operational problems or
corrosion. Check where dampers may rub on the insulation and their movement may be
restricted.
9.13.0 Acceptance Criteria
9.13.1 Minimum Permissible Thickness
9.13.1.1
9.13.1.2
9.12.1.3

Radiant and Shield Tubes - .190" + C.A.

Convection Tubes - .125" + C.A.

For Studded Tubes - .220"

9.12.2 Retirement for deformation:

9.12.2.1
Creep - 5% on the diameter
9.12.2.2
a.
b.

Bulging
Carbon steel tubes: 3% on the diameter
Alloy tubes
1.
Under 750F - 3% on the diameter
2.
Over 750F - Plus .100"

9.12.4 Steam Air Decoking

9.12.4.1
Tube Material

Maximum permissible tube metal temperatures-Temperature

F

ATI UNPUBLISHED WORKS COPYRIGHT 1994, ALL RIGHTS RESERVED

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
Carbon Steel
2- Cr
5 Cr
9 Cr
18 Cr 8 Ni
25 Cr 20 Ni

1275
1325
1350
1375
1700
2000

900- 6

690
718
732
746
926
1093

9.12.4.2.

Maximum steam outlet temperature used 1200F.

9.12.4.3.

Maximum steam flow design at 1200F steam outlet temperature should be 18

lb/sec/sq ft. of flow area.

9.12.4.4.

Permissible pressure drop in decoking system for furnaces with "short" coils - 15
to 20 psi.

9.12.5 Stacks
9.12.5.1.

9.12.6 Headers
9.12.6.1

Maximum temperature of unlined carbon steel is 90F. Below 350F. line stack
with acid resistant material.

Welded fittings or rolled plug headers equal to Ohio Steel Foundry's Type 1500.
Roll tube 3/8" beyond back side of header.

9.12.6.2

Final roll D3 = D1 + (DH - D2) + JE

where D1 is the original tube inside diameter.
DH is the header opening diameter.
D2 is the original tube outside diameter.

9.12.6.3

The minimum tube wall thickness in the roll shall be the greater of the calculated
tube wall thickness, or 0.12".

a.

b.

WALL THICKNESS

FACTOR "E"

0.250"
0.375"
0.500"
0.625"
0.750"
0.875"

.090" to .106"
.106" to .121"
.137" to .153"
.168" to .184"
.199" to .215"
.215" to .231"

OUTSIDE DIAMETER OF TUBE

MINIMUM PROJECTION IN HEADER

AFTER ROLLING

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900- 7

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
3.500"
4.000"
4.500"
5.000"
5.500"
6.000" to 6.625"
8.000"
c.

0.250"
0.250"
0.375"
0.375"
0.438"
0.438"
0.500"

OUTSIDE DIAMETER OF TUBE

MINIMUM OD OF FLARE GREATER

THAN TUBE OD

3.500"
4.000"
4.500"
5.000"
5.500"
6.000" to 6.625"
8.000"

0.250"
0.250"
0.313"
0.313"
0.375"
0.375"
0.500"

d.
TUBE EXPANSION REQUIRED IN 64ths
TUBE WALL
.25
.375
.500
THICKNESS
D4 - D2
HEADER
CLEARANCE
.035
.051
.066
.082
.098
.105
MAXIMUM
FOR PLAIN
END TUBES

8 to 9
9 to 10
10 - 11
11 - 12
12 - 13
13 14

9 to 10
10 - 11
11 - 12
12 - 13
13 - 14

11 - 12
12 - 13
13 - 14

.625

.750

.875

13 -14

15 -16
16 -17

16 -17

14 -15
14 - 15
14 - 15

17 -18
18 -19
19 -20
20 -21

15 -16
16 -17
15 - 16
16 - 17
17 -18
18 -19

ATI UNPUBLISHED WORKS COPYRIGHT 1994, ALL RIGHTS RESERVED

17 -18
18 -19
19 -20
20 -21
21 -22

900- 8

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
9.12.7 Limiting Design Metal Temperature for Furnace Tube Alloys
MATERIAL

Carbon Steel

TYPE/
GRADE

LIMITING METAL
DESIGN TEMPERATURE

LOWER CRITICAL
TEMPERATURE

degrees
Fahrenheit
1000

degrees
Celsius
540

degrees
Fahrenheit
1325

degrees
Celsius
720

CS- Mo Steel

T1 or P1

1100

595

1325

720

1Cr- Mo
Steel
2Cr-1Mo
Steel
3Cr-1Mo Steel

T11 or P11

1100

595

1430

775

T22 or P22

1200

650

1480

805

T21 or P21

1200

650

1500

815

5Cr- Mo Steel

T5 or P5

1200

650

1510

820

5Cr- Mo-Si
Steel
7Cr- Mo Steel

T5b or P5b

1300

705

1550

845

T7 or P7

1300

705

1515

825

9Cr-1Mo Steel

T9 or P9

1300

705

1515

825

MATERIAL

18Cr-8Ni
Steel
16Cr-12Ni2Mo Steel
18Cr-10NiTi Steel
18Cr-10NiCb Steel
Ni-Fe-Cr
25Cr-20Ni

TYPE/
GRADE

304 or
304H
316 or
316H
321 or
321H
347 or
347H
Alloy
800H
HK-40

LIMITING DESIGN
METAL TEMPERATURE

LOWER CRITICAL
TEMPERATURE

degrees
Fahrenheit
1500

degrees
Celsius
815

degrees
Fahrenheit
-

degrees
Celsius
-

1500

815

1500

815

1500

815

1800*

985

1850*

1010

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900- 9

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH

* This is the upper limit on the reliability of the rupture strength data (see A.5.5. and A.5.6). These
materials are commonly used, however, for heater tubes at higher temperatures in applications where the
internal pressure is so low that rupture strength does not govern the design.
9.12.8 Tube support and Tube Sheet Material Selection
FUEL GAS TEMPERATURE
MATERIALS (1)
F

800 and below

(427)

Carbon Steel

1150 and below

(621)

5 Chrome- Mo.

1400 and below

(760)

18 Chrome-8 Nickel

1800 and below

(982)

50 Chrome-50 Nickel + Nb (in 657)

1800 and below

(982)

50 Chrome-50 Nickel

1900 and below

(1038)

60 Chrome-40 Nickel

2000 and below

(1038)

25 Chrome-20 Nickel

2000 and below

(1038)

19 Chrome-35 Nickel

2000 and below

(1204)

25 Chrome-35 Nickel

9.12.9 Materials for extended surface on convection tubes shall be selected in accordance with the
following guidelines:
9.12.9.1

Fin tip temperature shall be considered equal to flue gas temperature for 0.05inch-thick fins and 100F (56C) less than flue gas temperature for 0.105- inchthick fins.

9.12.9.2

Stud tip temperature shall be considered equal to flue gas temperature less 300F
(170C).

9.12.9.3

Temperature ranges for the selection of extended surface material shall be as

follows:

MAXIMUM ALLOWABLE TIP

TEMPERATURE
FIN AND STUD TIP
F
C

MATERIAL

850

455

Carbon Steel

950

510

2 Percent-5 Percent Chrome

1050

566

9-11 Percent Chrome

1200

649

12 Percent Chrome-Chromized Carbon Steel

1450

788

18-8 Chrome-Nickel

ATI UNPUBLISHED WORKS COPYRIGHT 1994, ALL RIGHTS RESERVED

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
1800

983

900- 10

25-20 Chrome-Nickel

Note: This table does not apply for heat transfer purposes, but only for material selection of mechanical
and corrosion properties.
9.12.10

It is beyond the scope of inspectors to perform engineering functions unless they are a
licensed professional engineer. Inspectors shall make sound recommendations for
approval by the clients Engineering Department.

9.13.0 The responsibility of the inspector is:

9.13.1 Determine and properly document according to ATI-TA-001 the condition of the equipment.
9.13.2 Advise the client in writing of the condition and offer sound mechanical recommendations.
9.13.3 Insure that the clients repair procedures are properly performed.
9.13.4 Document all work performed on each piece of equipment.
9.14.0 Records and Reports
9.14.1.1

Equipment Forms - The forms are basically self explanatory. There are several
things to remember when properly filling one out.
1.

Be neat

2.

Fill in all appropriate data or put N/A if it is not applicable.

3.

Do not be afraid to write extra notes.

4.

5.

a.

To write a note, first assign it a number; (example: 1,2,3,

etc.)

b.

Put the number in the blank for notes or other.

c.

In the additional lined area or on the back of the page

where ever there is enough room, write the number again
and then on the notes. Be sure to identify the notes with the
corresponding number.

Be sure to record sizes and thicknesses in inches for:

a.

Thickness of deposits.

b.

Amount of corrosion/erosion.

c.

Diameter, depth and square footage of pitted areas.

If there are any areas in question, do not hesitate to ask the (ATI) All Tech
Inspection Supervisor. *Remember, too much information is better
than not enough!

* A sample report is included in the attachments.

9.15.1 All notes and information shall be properly documented in the Inspectors pocket note pad as per
ATI field inspection procedure TA-001 REV.0
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ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
9.15.2 Each form shall be properly filled out per ATI procedures.
9.16.0 Forms
a.

Heater Tube Thickness Calculations

b.

Combustion

c.

Air Oxygen Ratio

d.

Steam-air Decoking

e.

All Tech Heater Form (Blank.)

f.

ATI Heater Form (Sample complete report and data page.)

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900- 11

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
HEATER TUBE THICKNESS CALCULATIONS
A.

Elastic Design (Lower Temperature)

ts =

Pe D o
2 S e + Pe

t m = t s + CA
B.

Rupture Design (Higher Temperature)

ts =

Pr D o
2 S r + Pr

t m = t s + CA
t s = Calculated tube wall thickness in inches.
Pe = Maximum allowable pressure.
= Pump shut off pressure.
= Maximum allowable pressure.
Pr = Normal sustained operating pressure.
Se = Elastic allowable pressure.
= .66 Sy for ferritic steels.
= .90 Sy for austenitic steels.
Sr = Rupture allowable stress. (See API Recommended Practice 530, Figures 3-A through 3-Q for
allowable stress values.
Do = Outside d iameter of the furnace tube in inches.
CA = Corrosion allowance in inches.
f = Corrosion fraction - use 1 for most conservative design. (See API Recommended Practice 530,
Figure 1 for values of f.)

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900- 12

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH

900- 13

COMBUSTION
0.1" of water is the desired vacuum for proper draft. 15% (3% oxygen) is teh optimum excess air for
good combustion. A natural draft furnace should not operate with positive pressure in fire box. Burner
gas pressure may run high as 50#. Pilot gas pressure is normally 3# to 5# with a maximum pressure of
20#.
Condition

Adjustment

High draft and low oxygen

Low draft and low oxygen
Low draft and low oxygen
Low draft and high oxygen
High draft and high oxygen

Increase air by opening burner air doors

Open damper
Reduce firing rate (damper 100% open)
Close burner air doors
Closer damper

When the furnace fails to respond to the above adjustments, call in an experienced person.
AIR OXYGEN RATIO
% O2 % Excess Air

% O2 % Excess Air

.50 =
1.00 =
1.50 =
2.00 =
2.50 =
3.00 =
3.50 =
4.00 =
4.50 =
5.00 =
5.50 =
6.00 =

6.50 = 40.00
7.00 = 45.00
7.50 = 50.00
8.00 = 55.00
8.50 = 61.00
9.00 = 67.00
9.50 = 73.00
10.00 = 82.00
10.50 = 89.00
11.00 = 99.00
11.50 = 108.00
12.00 = 119.00

2.5
4.9
7.00
9.00
11.50
15.00 Ideal
17.50
22.00
24.50
28.00
34.00
37.00

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900- 14

ATI-900 FUEL FIRED HEATER Rev 1

APRIL 12, 1994
REVIEWED BY: BB
APPROVED BY: GH
STEAM-AIR DECOKING
Maximum permissible tube metal temperatures:
Temperature
Tube Material

Carbon Steel
2-1/4 Cr
5 Cr
9 Cr
18 Cr 8 Ni
25 Cr 20 Ni

1275
1325
1350
1375
1700
2000

690
718
732
746
926
1023

Maximum steam outlet temperature used - 1200F.

Maximum steam flow design at 1200F steam outlet temperature should be 18 lb/sec/sq ft of flow area.
Permissible pressure drop in decoking system for furnaces with "short" coil - 15 to 20 psi.

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