TALISMAN

NAO ENGINEERING SPECIFICATIONS - HEAT TRANSFER

DIRECT AND INDIRECT FIRED HEATER NAO-SPC-D-HT-001

DIRECT AND INDIRECT FIRED HEATER

Issue: 2011/01/01

Next Review Date:

June 2011

HSE/OI Staff Responsible:

Mechanical Technical Authority

Published by: Talisman Energy Inc. Operational Integrity Department

APPROVALS:

Calgary

Tech Auth:
Eng. Auth:
VP-HSEOI:
Copyright is owned by Talisman Energy Inc. All rights are hereby reserved. This document (in whole or in part) may not be reproduced, stored in a retrieval system, or transmitted, in any form or means, without the prior written permission of Talisman, or as expressly permitted by law.

Note: This is an existing specification currently being used by Talisman and has not been technically reviewed or signed off by the Technical Authority at this time. Over time, these specifications will be rebuilt and validated through a specification review process. Please ensure that you use the most current copy of the specs listed on the NAO Portal under Engineering Specifications. The Technical Authority identified on the cover sheet is the point of contact for this specification.

Attention: Paper copies are uncontrolled. This copy is valid only at time of printing, 12/15/2010. The controlled document is available on the Talisman NAO Portal.

TALISMAN ENERGY INC.

GENERAL SPECIFICATION
Rev 2A

DIRECT AND INDIRECT FIRED HEATER ES1.F101

Oct 2002

Page 1 of 9

TABLE OF CONTENTS
I. SCOPE.................................................................................................................................................................2

2. APPLICABLE REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS................................2

3. APPLICABLE REGULATIONS, CODES AND STANDARDS ...................................................................2
4. DOCUMENTATION .........................................................................................................................................3

5. SOUR SERVICE ...............................................................................................................................................3

6. GENERAL DESIGN ..........................................................................................................................................3
7. BURNERS ...........................................................................................................................................................4

8. STACK ................................................................................................................................................................4
9. CONTROLS........................................................................................................................................................4

10. DIRECT FIRED HEATERS........................................................................................................................5

i I. INDIRECT FIRED HEATERS.....................................................................................................................8

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GENERAL SPECIFICATION
Rev 2A

DIRECT AND INDIRECT FIRED HEATER ES1.F101

Oct 2002

Page 2 of 9

1. SCOPE
1.1.1. This specification covers the general requirements for the design,
manufacture and testing of direct and indirect fired heaters.

2. APPLICABLE REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS

2.1. TLM Specifications

2.1.1. All direct and indirect fired heaters shall be designed, manufactured and
tested in accordance with this specification. The following TLM

specifications form part of this specification:

ES1.J101 -Instrumentation
ES1.L 102 - Piping Fabrication, Erection and Testing

. ES1.L 104 - Welding . ES1.N101 - Electrical

. ES1.Q1 05 - Structural Steel

ES1.v101 - Unfired Pressure Vessels

ES 1.z403 - Painting and Coatings . ES1.z404 - Insulation
2.1.2. Colt Specification:

GS903.03 - General Specification Piping Materials - Line Classes,

TLM Specific

GS902.03 - General Specification Mechanical - Pressure Vessels

3. APPLICABLE REGULATIONS, CODES AND STANDARDS
3.1. All direct and indirect fired heaters shall comply with the latest editions of the

following:

ASME Boiler and Pressure Vessel Code; ANSI B31.3 Chemical Plant and Petroleum Refinery Piping;

API Std. 661 MR Cooled Heat Exchangers for General Refinery

Service;
. API Std. 665 API Fired Heater Data Sheet;

API RP631 M Measurement of Noise from Air-Cooled Heat

Exchangers;

API RP530 Calculation of Heater Tube Thickness in Petroleum

Refineries;

API RP532 Measurement of the Thermal Effciency of Fired Process

Heaters

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GENERAL SPECIFICATION
Rev 2A

DIRECT AND INDIRECT FIRED HEATER ES1.F101

Oct 2002

Page 3 of 9

3.2. Conflict Between Specifications, Codes and Standards

3.2.1. Where a conflict occurs between this specification and any specification, regulation, code or standard which has been specified for a particular service or item of equipment, then TLM shall be consulted and a ruling in writing shall be obtained before any work is started.

3.2.2. Where regulatory codes or regulations conflict with this specification, the

more rigid specification shall govern.

4. DOCUMENTATION
4.1.1. The data required for a fired heater shall include, but not be limited to,
the following:
. A fully completed API 665 fired heater data sheet.

. Drawing showing the general arrangement, the tube layout, the

position and locations of accelerating equipment.

. Details of burners.

. Flue gas temperature profile through the heater at the design

conditions.
. Process fluid pressure, temperature and velocity profies at the design

conditions.
. Tube stressing calculations when requested.
. Details of any instrumentation or control system supplied or proposed
by the Contractor.

. The manufacturer shall supply drawings in legible reproducible form,

showing "as built" measurements of the finished vessel after

completion of all fabrication and heat treatment. 4.1.2. Drawings shall be supplied in electronic format, compatible to AutoCad

latest version release.

5. SOUR SERVICE

5.1.1. Materials, fabrication and installation shall comply with ES1.v101

Vessels Supplement for Sour Service and ES1.A408 Piping Material -

Sour Service Supplement.

6. GENERAL DESIGN
6.1.1. Design effciency shall not be less than 70% based on the heating value
of the fueL.

6.1.2. Unless otherwise specified by TLM the heater shall be designed to

operate on natural draft with a slight vacuum existing in the firebox at all points within the normal operating range.

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GENERAL SPECIFICATION
Rev 2A

DIRECT AND INDIRECT FIRED HEATER ES1.F101

Oct 2002

Page 4 of 9

7. BURNERS
7.1.1. Burners shall be designed to give an effcient heater operation from 30%

to 125% of the design-heating load. Suffcient burners shall be supplied

to give an even temperature throughout the firebox. Each burner is to
be provided with a pilot light.

8. STACK
8.1.1. The stack shall be of steel and shall be self-supporting, designed to

provide adequate height and diameter for maximum draft requirements.

8.1.2. Dampers shall be of the butterfy type, with one-inch clearance around the entire periphery to avoid complete shut-off, and equipped for manual operation from grade.
8.1.3. Pipe sleeves in the stack shall support dampers. They shall be properly designed to prevent warping or buckling during operation. A pointer

shall be provided on the main damper shaft, outside of the stack to indicate damper position. A counterweight shall be provided to adjust
the damper to wide-open position in case of failure of the adjusting mechanism.
8.1.4. Dampers shall be of 18% chrome, 8% nickel stainless steel.

9. CONTROLS
9.1.1. The fuel gas line to the heater shall be split into two legs. One leg shall supply fuel to the main burner(s) and the other shall supply fuel to the pilot(s).

9.1.2. The ESD valves shall only be latched if the safety conditions are
completed as shown on the trip legend.

9.1.3. The ESD systems on each heater shall be supplied from a common air or electrical supply system.

9.1.4. No bypass on any ESD valve shall be permitted (spare ESD valves
should be supplied on hand for servicing).

9.1.5. Manual ESD stations, block valves and snuffing lines shall be easily
accessed and be controllable at a safe distance from the heater.

9.1.6. Fuel gas scrubbers shall have a high liquid level device that will activate alarms/shutdowns as indicated in the legend.

9.1.7. Hand operated isolating valves shall be provided on individual lines to

each pilot and main burner.
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GENERAL SPECIFICATION
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DIRECT AND INDIRECT FIRED HEATER ES1.F101

Oct 2002

Page 5 of 9

9.1.8. A temperature control loop and control valve shall be provided

downstream of the latching ESDV in the main burner fuel supply line. A
suitable bypass valve arrangement shall be provided to allow servicing of the temperature control loop.

9.1.9. Ultraviolet or thermocouple type flame failure devices shall monitor

flame at the pilots and initiate alarms/shutdown.

9.1.10. Thermal relief valves shall be installed in product lines to prevent over

pressure.
9.1.11. All automatic valves, ESD valves, relays, solenoids etcetera shall be of

fail-safe design.

9.1.12. All devices used for critical shutdowns shall be primary monitoring devices, e.g. devices monitored by computer, which in turn initiates a shutdown, are not acceptable.

9.1.13. Heater charge pumps are required to have the capability to

automatically restart following a power outage.

10. DIRECT FIRED HEATERS

10.1. General

10.1.1. Heaters shall be of radiant or a combination of radiant and convection

design, and horizontal tube design. Convection and radiant sections are
to be flanged and bolted for easy dismantling.

10.1.2. All parts of the heater, including walls, floors, arches and roofs, shall be designed to permit necessary thermal expansion at maximum operating temperature. All refractories shall be designed to permit their removal and replacement while the main steel structure; heater tubes and tube headers or return fittings remain in place.

10.1.3. The volume of the firebox shall be sufficient size to prevent flame
impingement against the tubes.

10.1.4. Convection section piping shall be flanged connected or fitted with

flanged crossovers, and designed for easy dismantling and removaL.

10.1.5. In design of fired heaters, the average heat flux shall not exceed 31.5 kW/m2 of outside tube surface, and the maximum heat flux on anyone tube shall not exceed 47 kW/m2 of outside tube surface.

10.1.6. In the design of U-tube direct-fired glycol reconcentrators the average heat flux shall not exceed 19 kW/m2 of outside tube area with a maximum heat flux not exceeding 31.5 kW/m2 at the U-type entrance
near the burner.

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GENERAL SPECIFICATION
Rev 2A

DIRECT AND INDIRECT FIRED HEATER ES1.F101

10.2. Tube Supports

Oct 2002

Page 6 of 9

10.2.1. Tube supports shall be designed to resist the vertical reactions of the supported tubes, plus operating contents at maximum operating flow

conditions, plus frictional forces developed and transmitted to the supports during short time conditions. The frictional load shall be
considered to be equal to one-sixth of the vertical reaction at the point
under consideration.

10.2.2. Horizontal tube support spacing shall not be greater than 35 nor less
than 25 times the OD of the tubes.

10.2.3. End radiant and convection section tube sheets shall be provided with suitable insulating concrete on the fire side.
10.2.4. Radiant and convection end tube supports may be of carbon steel plate

if adequately protected by 75mm of insulating concrete applied over stainless steel wire mesh and secured to cast in place tube sheet studs.
10.2.5. Insulated (intermediate) tube supports with design metal temperatures above 8000C shall be 25% chromium, 12% nickel coatings conforming to ASTM B-190, Type II, modified as follows:

. Nickel 11 - 14%
. Chromium 23 - 27% . Carbon 0.25 - 0.35%

10.2.6. Un-insulated (intermediate) tube supports with design temperatures of 8000C or less, shall be ASTM A-297 Grade HF, 19% chrome and 9%
nickeL.
10.3. Structural Steel and Platforms

10.3.1. All tubes, headers and burners shall be supported from the structural steel framework independently of the brickwork.

10.3.2. Vertical tube furnaces shall be provided with a structure for pulling tubes.
10.3.3. Access platforms for inspection holes shall be provided.
10.4. Doors and Header Boxes

10.4.1. A sufficient number of observation doors shall be installed in the end walls to permit unrestricted observation from the operating platform of the burner flames and tubes surfaces exposed to the radiant section.

One door shall be provided for access and ventilation of each

combustion chamber.

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GENERAL SPECIFICATION
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DIRECT AND INDIRECT FIRED HEATER ES1.F101

Oct 2002

Page 7 of 9

10.4.2. Heaters shall be equipped with either 1800 welded return bends or plug

type fittings. Welded 1800 return bends shall be used except when
there is likelihood of plugging. With either type of return bend, adequate

provision shall be made for thermal decoking. When 1800C welded

return bends are used, plug type fittings shall be provided for inspection purposes. The number and location of such fittings shall be determined after the general design of the heater is submitted. Elbowlets can also
be used. All welding on heater coils shall comply with ES1.L 104 and

shall be 100% radiographically inspected.

10.4.3. Tube headers and return bends are to be enclosed in header boxes fabricated from steel plate for special services in which corrosion or
cracking may occur in the furnace. These boxes are to be equipped

with doors and are to be removable depending upon the size of the box.

Woven asbestos packing shall be applied between the boxes and the
framework or doors. Drain holes shall be provided in the header boxes.
10.4.4. Convection section must have inspection doors on opposite sides to
check return bends and inspection plugs.
10.5. Auxiliary Connections

10.5.1. Each furnace shall be equipped with one stack temperature

thermocouple and one stack gas sample port. A Y-" 316 SS stack gas
sampling line shall be provided at the operating leveL.

10.5.2. Water spray or steam quenching shall be provided as per National Fire Code.
10.5.3. 60.3mm diameter snuffing steam connections shall be provided through the walls of the firebox and the header boxes. Piping shall be valved for

remote operation. When steam is not available, a water spray system

shall be provided.
10.6. Materials

10.6.1. Material for tubes, return bends and fittings shall be as shown on the material specifications chart.
10.6.2. Refractory tile and brick shall be suitable for the service and

temperature as specified. High temperature insulating block shall be

suitable for temperatures 950C higher than the cold face temperature of

the refractory lining. Manufacturer's drawings shall include lists of

materials used for insulation, refractory, etc.
10.6.3. Refractory anchors shall be fabricated from 304SS materiaL.
10.6.4. Observation and access doors and frames shall be of cast iron,

conforming to ASTM A-48, Class 25.

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GENERAL SPECIFICATION
Rev 2A

DIRECT AND INDIRECT FIRED HEATER ES1.F101

10.7. Controls

Oct 2002

Page 8 of 9

10.7.1. An automatically operated double block and bleed system shall be

provided in each leg of the fuel gas supply to the heater.

10.7.2. The ESDV on the main fuel line shall be the manual mechanical reset type with electrical latching, Maxon or equal as per CSA B.149.3. The ESDV's on the pilot lines
10.7.3. A timed bypass shall be provided to open the pilot fuel gas block valves only to enable the heater to be lit.
10.7.4. Fuel gas to the main burner(s) shall have high-pressure shutdown.

10.7.5. Fuel gas to the pilot(s) shall have a high-pressure device that will activate alarmslshutdowns should the pressure in the line exceed a
predetermined set point condition.

10.7.6. Temperature shall be monitored at each stack and shall initiate

alarm(s)/shutdown(s) as indicated in the legend.

10.7.7. Product outlet line from the heater shall have a low-pressure shutdown

device in the line to shut down the main burners and heater charge
pumps.
10.7.8. Product flow devices shall monitor the flow in each inlet pass and initiate alarms and shutdowns for low flows as specified.

10.7.9. High product outlet temperature monitoring devices shall be installed in the outlet lines of each heater pass and will initiate alarms/shutdowns as

specified.
10.7.10. Thermocouples shall be located on each pass in the heater to allow the monitoring of high skin temperatures on the tubing walls.

11. INDIRECT FIRED HEATERS

11.1.1. Salt bath and glycol heaters shall be fuel gas shutdowns (alarms
optional) for the following conditions:
. High bath temperature
. Pilot flame failure . High liquid level in fuel gas scrubber

11.1.2. An automatically reset bypass valve shall be installed to enable the

heater to be lit.

11.1.3. A reset valve should be installed between the high temperature

shutdown device and the temperature controller to prevent the TCV
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GENERAL SPECIFICATION
Rev 2A

DIRECT AND INDIRECT FIRED HEATER ES1.F101

Oct 2002

Page 9 of 9

opening as soon as the pilots are lit. The valve should remain closed
until reset manually.

11.1.4. A flare arrestor shall be provided on the combustion air intake.

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