23376545 procedure for natural draft fired heater

7/28/2019 23376545 Procedure for Natural Draft Fired Heater

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PROCEDURE FOR FIRE HEATER PROCEDURE NO.-

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1.0 SCOPE

1.1 This specification along with datasheets, standard specifications and attachments, outlines the minimum

requirements for design\ engineering. material procurement, manufacture/ fabrication, testing, assembaly,site erection, inspection, pre-commissioning of Fired Heaters as per process package and datasheets of

heaters in MSQ Upgradation Product of IOCL Panipat refinery.1.2 EPCC contractor is not allowed to change design parameters already defined in the Process data

sheets / Mechanical data sheets.

Please refer UOP specification 939463-201 and process data sheers for heater 301-H-101.

1.3 The EPCC contractor’s scope shall include but not be limited to the following.a) Thermal and mechanical design of heater system. Contractor to submit all filled in data sheets

along with bid.

b) Mechanical and structure design of heater system including detailed engineering.c) Heater coil flexibility analysis taking care of loads from extemal piping.

d) Procurement of all materials and bought-out components e.g. pressure parts, burners, dampers,spring supports, expansion joints etc.

e) Fabrication, erection and assembly of complete heater.f) Detailed engineering and application of refractory and insulation lining.

g) Primer coats and final painting of heater.h) Fire proofing of structures as required.

i) Inspection requirements including stage wise third party inspection.

j) Hydro testing of heater coil testing/verification by air leak test of complete heater for fabrication

and gasketting.k) Performance testing of all bought-out equipment likes burners, dampers, at the supplier’s work.

l) Flushing/chemical cleaning( pickling/passivation/neutralisation )

m) Pre-commissioning and refractory dry-outsn) Start-up and commissioning.

o) Obtaining approval from any authority required as per statutory rules and regulation of Central/state Government including the necessary co-ordination and liaison work.

p) Supply of mandatory spares.q) Stack with associated ducting and application of silicon based high temperature Aluminium paint

after necessary surface preparation .

1.4 For requirement and scope of supply civil/foundation, piping and external insulation, painting,fireproofing, electrical, equipment and instrumentation, hazardous area classification refer respective

sections.1.5 Vendor shall supply in sequence and at the appropriate time, all the materials including bought-out items, spates,

consumables etc. required for completion of the job in all respects. It shall consist of all the items and

materials as indicated in job specifications, data sheers, atamdard specifications and codes . As a minimum

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and any other items required to make the heater systemFunctionally complete in all respects and safe during operation. Any work not specifically mentioned, but

otherwise necessary for satisfactory completion and safe operation of heaters shall be done by EPCCcontractor.

2.0 GENRAL

EPCC contractor, after studying the contents of this package may decide to obtain clarifications beforemaking the offer so that, it shall be in strict compliance to the requirements and technical specifications of

this package.

2.2 Various technical specification and data sheets as referred to in this specification form part of this package.Any deviation to this specification shall have prior approval of Owner/PMC. All such deviations shall be

raised at bidding stage in the “Deviation schedule format”. Any deviation/exception listed at any other

place in the bid will be disregarded and treated as null and void. Any deviation, if listed, may lead to

technical rejection without any further reference to EPCC contractor.

2.3 For successful vendor any deviation at the execution stage, which become unavoidable shall be submittedfor Owner/PMC approval and vendor shall not proceed with such deviation till it’s acceptance by

Owner/PMC. Time taken/delay, if any, in processing of deviation or its rejection shall be solely to EPCCcontractor’s account.

2.4 It is the responsibility of the vendor to design, fabricate and supply the equipment in conformity with

codes/specifications and to meet all requirements if bid package.

2.5 In the event of conflict among following documents, the stringent requirements shall govern in general:i) Equipment datasheets.

ii) Licensor’s specificationsiii) Job specifications

iv) Standard specificationsv) Codes and standards

vi) Statutory requirements

However, all such conflict shall be referred to Owner/ PMC for clarifications and the decision of Owner/

PMC shall be final and binding on vendor, without any cost and delivery implications.

2.6 Heater vendor or his sub-vendor performing design and engineering of heater, fabrication of the same,

supply of any bought out items etc. for heater must submit all information as asked for in ‘Experience recordPerforma: ‘ ( ERP ). Documentary proof/ details as asked for in ERP must be submitted and acceptance from

Owner/PMC shall be taken before proceeding with the job. In case design, fabrication and supply are by

different agencies, separate details for these agencies shall be submitted for Owner/ PMC ‘s approval.However for any item, supplier must have previous track record in line with ERP requirements (wherever “

heater vendor’ terminology is used, it is meant to be a sub-vendor to the vendor as well).

2.7 Heater vendors registered with Owner/ PMC for supply and erection of heater work are acceptable andEPCC contractor shall ascertain the same before finalisation of heater contract. However any delay in

getting a new heater vendor approved by Owner/ PMC, shall be on contractor’s account and due to this, no

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time and cost implication shall be acceptable.

2.8 It is mandatory that following activities shall be performed in-house departmentally by heater vendor.Project management for heater system

ProcurementPressure part fabrication

Quality assuranceInspection at shop/site

InstallationSite supervision

Pre-commissioning in co ordination with entire plantDesign, engineering and detailing shall preferable be done in house by the heater vendor.

2.9 Sub-contracting, if envisaged, for application of refractory etc. and any other portion of the work can only be

done with prior approval of Owner/ PMC. Name of proposed sub-vendor along with the bio-data of key personnel having work experience on similar job must be4 submitted as per requirements of ERP. It will be

mandatory on the part of heater vendor and his sub-vendor to depute key personnel as listed in their detailssubmitted for approval and which Owner/ PMC accepts.

2.10 Technical questionnaire sheet shall be filled-up by vendor in totality and must be duly signed and submitted

along with the bid.

2.11 Mandatory spares, as per the list given shall be included I lump sum price. However, any additionalrecommended spares for two years of normal operation over and above the mandatory spare, not to beincluded in the lump-sum price and the same shall be quoted item wise separately.

2.12 For all the materials in the vendor’s scope of supply, the fabrication, erection, commissioning spares shall be

worked out and shall be included within the quoted lump-sum price. Owner/ PMC will not allow taking outany left over items.

2.13 After award of contract, EPCC contractor/vendor shall arrange a kick off meeting with the following

agenda.

Review and selection of heater vendor and other sub-vendors along with details as per ERP.Review and finalisation of master drawings/documents schedule.

Any clarification on the data sheets and specifications enclosed in the bid package.

Identification of critical documents, which need to be reviewed on priority.Identification of multi-disciplinary review of document.

2.14 Complete list of drawings/ documents with anticipated submission date must be submitted within 15

days after award of contract. Vendor must adhere to the following order of submission of documents.Detailed quality plan.

Master document index with schedule of submissions.Purchase specifications.

Thermal, mechanical / structural design calculations with soft copy.Derailed drawings/ documents.

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Documents submitted by vendor for approval / review records shall be strictly as per package requirements.

2.15 All documents shall be thoroughly checked and duly signed by vendor. Documents, which are unchecked /unsigned and without revisions clearly marked, shall be returned without review. Any delay on account of

this shall be to contractor’s account. Also, successive reviews by Owner/ PMC to the same documents shallapply only with respect to the same document’s comments on the previous revision.

2.16 All sub-vendor’s and vendor’s drawings/documents must also be reviewed/ approved by heater vendor

before submission to Owner/ PMC.

2.17 All drawings/ documents submitted to Owner/PMC shall be legible and of good quality. Poor qualitydocuments/ drawings shall be to vendor’s accounts. All documents shall be submitted along with updated

master document index showing revision number and status of submission/approval.

2.18 It shall be the sole responsibility of the contractor to co-ordinate with agencies doing piping,instrumentation, electrical and structures for compatibility of the equipment with respect to interface, piping

support, head room clearance and structural work etc.

2.19 For making purchase specifications, vendor has to supplement Owner/ PMC‘s job specification withrequirements of API datasheet, other applicable standard specifications and codes.

2.20 Quality and inspection plan of vendor shall comply with requirements as specified in inspection section in

the bid package. In addition to that, “Minimum Inspection Requirements” as per clause 4.0 of this

specification must also be complied.

2.21 All third party inspection and testing shall be in vendor’s scope. The name of inspection agency shall be

mentioned in respective purchase specifications and also during bid stage.

3.0 DESINE/ ENGINEERING AND FABRICATION REQUIRMENTSThe heater shall comply with the codes and standards as specified in UOP specifications, process datasheets, Mech. Datasheets and standard specifications.

In addition to above codes when fluid such as steam is there under IBR preview, the piping shall meet the

requirements of Indian Boiler Regulation (IBR) latest edition

ASME Sec. VIII Div 1 shall be used for full vacuum check of heater coil work.

INDIAN REGULATIONS

All requirements of the Indian statutory authorities with regard to Indian Laws, codes, regulations andstandards shall be considered as applicable/

The latest editions of these applicable laws, codes, regulations and standards including documents referred

to therein, shall be adhered.

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As such the documents form part of this package. It shall be vendor’s responsibility to acquire possession of all such documents wherever, referred.

3.1 MODIFICATION W.R.T.API560(THIRD EDICATION, MAY 2001)Heaters shall be designed in accordance with API standard 560 and other applicable codes listed. Only

specific additional requirements are described below.

The titles and number of text follow those of API 560.Additional numbered paragraphs, wherever specified, are to be read as an extension of API 560 section or

sub-section. The API 560 text numbering has been extended accordingly.

Original

Clause of API 560

Supplement Requirements

1.0 GENRAL

1.7 Informative codes and standards

1.7.1 ANSI B 36.19, stainless steel pipe, shall be covered as reference publications.

1.9 Documentation

1.9.1 Final general arrangement drawings shall also include the following:

Additionally, coordination shall be done by EPCC Contractor for coil terminal movements and

associated external piping moments for safe installation.

1.9.3 Type, design, material and location of skin thermocouples.

1.10 Co-ordination of design

Add following as new clause.

The fired heater vendor shall co-ordinate design and ensure satisfactory functioning of the

complete unit, i.e. heater, burners and management system, associated expansion joints, dampersand controls, transmission and other ancillaries. In case where the fired hearer vendor supplies

equipment that he has not manufactured, he shall be responsible for ensuring that the designs of these items are compatible with each other and with own equipment in all respect and they shall be

included in his guarantees.

2.0 DESINE CONSIDERATION

2.1 Process

Add following new clauses.

2.1.5 The design of the fired heater and related equipment shall be such that all metal surfaces in contactwith the flue gases shall, at all operating loads, including minimum turn-down, attain a typical

temperature allowance of at least 8 to 14 deg. C above the calculated dew point of the flue gasesfor specified fuel and excess air.

2.3.9 Add following to existing clause.

It should be ensured that burner body and connected piping/ducting do not cause any obstruction to

headroom or free movement.


A davit shall be provided for manhole cover.

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3.0 TUBES

3.2 Extended surface

3.2.4 Add following as new clause.

After studding of tubes, ferrite alloy steel tubes with chromium content over 3% are required to beheat-treated ensuring hardness specified in ANSI B31.3. Heat treatment shall be carried out at

works with identification marks and related document of hear treatment.

3.2.5 Add following as new clause.

The studding process shall be dully automatic and shall be capable of consistently meeting thequality standards. A destructive sample test on minimum 1.0 m length shall be conducted for

qualifying stud welding procedure for each size and material required. Harness survey shall becarried out for studded tubes at the weld zones and heat-affected zones.

OriginalClause of

API 560


3.2.6 Add following as new clause

Studs shall be completely fused to the tube wall with no injurious defects like cracks, under cuts

etc. in the weld. The welds shall not impair the soundness of the tube. In heaters studded tubes are

not preferred. As far as possible bare tubes shall be used.

5.0 PPING, TERMINALS, AND MANIFOLDS

5.1 General

5.1.6 Add following to the existing clause

All inlet, outlet terminal and manifolds shall have blinded vent or drain. In addition any other

external high points on coil shall be provided with blinded vent and drain respectively.


Crossovers, jump overs, manifold, external piping etc. shall be so arranged, that they do not

interfere with the removal and replacement of tubes, platform walkway and headroom.


Inlet and outlet terminal tubes in a multi pass arrangement shall have c/c distances ensuring no

fouling among them at flange location.


All crossovers and jump-overs shall preferably be provided with 90 deg. Long radius bends.

5.2 Add following to the existing clause

Coil stress/flexibility analysis to be carried out combined with external piping, also all

internal/external crossovers are to be analysed and supported properly. Flange rating given is basedon pressure and temperature conditions only. Their adequacy to be checked for external loads dueto piping. The final design also to account for gasket sealing.

6.0 TUBES SUPPORTS

6.0 General

6.1.1 Add following existing clause

For design of side/end wall tube headers, no temperature drop shall be taken into account up to at

least 50mm from the hot face casing refractory.

6.2 Loads & allowable stress

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6.2.1.4 Add following add new clause

When considering tube support design, account shall be taken of the possible non-uniform

distribution of loads on various tube supports due to thermal expansion of internal crossovers andimposed by external piping.

6.3 Materials

6.3.2 Add following to existing clause

Option (a) shall no be used unless specific approval of Owner/PMC obtained.

6.3.3 Ad following as new clause

All bolts and pins required for fastening tube support casting and are exposed to flue gases shall beof the same material as that of casting, bolts fastening tube support casting to structural steel shall

be fully threaded. ASTM A193Gr. B8 But shall be ASTM A194Gr.8.Original

clause of API 560


7.0 REFRACTORIES AND INISULATION

7.3 Castable construction


The bottom end of anchor welded to the steel plate shall have a contact length of minimum 6mm.

ceramic blandest shall be used where ever necessary.

8.0 STRUCTURES AND APPURTENANCES

8.1 General

8.1.2 Add following to the existing clauseIS 875, code of practice or design loads (other than earthquake) for building and structure shall be

followed for load estimation like wind etc.

Wind pressure applicable for terrain category 2 shall be used.For other site depended data including basic wind speed, refer job specific requirements.

IS: 1893, criteria for earthquake resistant design of structure. Site specific response spectra shall be

followed for seismic analysis.

8.2 Structures.


All furnaces shall have sufficient slope in roofs, facilitating water drainage.

8.3 Header Box, Doors and Ports

8.3.1 Header Boxes

8.3.1.2 Replace existing clause with the following:

Header boxes inclosing plug headers shall have bolted end panels only.8.3.1.5 Add following as new clause

All header boxes shall be bolted and shall be made airtight by the use of suitable gasketed joints.

8.3.1.6 Add following as new clause

Wherever inspection or access doors are used, the same shall be bolted and shall bemade airtight

by the use of suitable gasketed joints.

8.3.2 Doors and Ports

8.3.2.2 Minimum clear opening considered shall be 460x610mm or 610mm dia.

8.3.2.5 Existing clause shall be read as:

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Sufficient number of sight doors shall be provided in the vertical walls of each radiant section to permit.

i) A clear view of each main burner pilots and throat during light up. The burner controls shall be located within arms-length of the sight door giving a view of that burner.

ii) Other sight doors shall be provided as appropriate to permit

a) A check for flame impingement on the furnace tube.

b) A check for tube distortion for entire length of tube.

Sight doors located alongwith the length of the tubes shall meet both the above requirements.

Together, the sight doors shall give a view of all parts of the furnace walls and tubes walls andtubes, including those convection tubes exposed to radiant heat .Where furnace tube wall

temperatures are to be measured by radiant pyrometer, the location and numbers of sight doorsshall provide for this. Sight doors on vertical shall have atleast120mmx220mm clear opening.

Originalclause of

API 560

Supplement Requirements.


The number and location shall be such as to permit visual inspection of convection tube bank andsupports for distortion and fouling detection.


All sight doors on vertical wall shall be airtight self-closing doors fitted with suitable temperaturegrade Pyrex glass and self-retreating internal metal closure.

Provision shall be kept to.

Replace the glass while the heater in operation.

Keep the glass clean.

The metal sight door covers shall be protected with insulation to avoid overheating of sight door assembly and glass.


All sight doors shall have approach without any kind of obstruction.

Add following as new clause

Minimum 1no. self closing type explosion door shall be provided for vertical cylindrical type

heaters and minimum 2no. for cabin or box type heaters, in upper half of the radiant section andshall have air tight seal, when in closed position. Minimum clear opening size shall be 460mm x

460mm.

8.4 Ladders, platforms and stairways.

8.4.1 Add following to the existing clausef) All access and inspection opening, and other operation and maintenance points likeinstrumentation nozzles, tube pulling brackets for radiant section tube removal, coil vent and drain,

terminal flanges etc.At stack pollution control board and at aviation lamps level.


Access to platform serving hearth, burner controls, and arch shall be by stairway.

For dual access, two stairways and one ladder may be provided.

8.4.7 Add to clause

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A safety chain shall be provided for all ladders serving platforms or landings.Ladders shall be at least 300mm away from the heater shell.


Supporting steel members and bracings shall not obstruct headroom/free passage over the platform.

8.5 Materials


f) Structural steel to IS:2062 Gr. B

8.6 Furnace sealing requirements

8.6.1 Where tubes, skin thermocouples and any other pieces of equipment pass through the heater casingor the header box from inside the heater, the hole in the casing/headers boxes shall be fitted with

proper sealing arrangement in order to prevent air leakage or flue gas leaking into or out of theheater.

Originalclause of API

560


8.6.2 Where the tube guide at the bottom of through the floor of he heater, the hole on the bottom of thefurnace shall be sealed against air leakage.

8.6.3 All box up leakage points should be sealed.

9.0 STACKS, DUCTS AND BREECHING

9.1 General


And shall be provided with painter’s trolley.9.2 Design consideration

9.2.1 & 2 Add following to the existing clause

Stack design shall also comply with all the requirements of IS:6533.

9.2.5 Modifying as following.

Minimum corrosion allowances for stack plate work shall be 3.0mm and 1.5mmfor all other plate

work.


Corrosion allowance of 3.0mm on diameter shall be used for bolts in stack, which resist uplift.


Suitable jerk factor shall be considered for design.

9.2.10 Modify as following:

Minimum breeching plate thickness shall be 6.0mm.

9.2.12 Add following to the existing clause.Where flue gas stack damper are provided, the dampers shall have acceptably low, guaranteed

leakage rate under normal operating condition, and shall be either pneumatic or electrical actuafor.

9.3 Allowable stresses

9.3.1 Add following to the clause

Or the allowable stress as defined in IS:6533.

10.0 BURNERS, SOOT BLOWERS AND DAMPER CONTROLS

10.1 Burners

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Minimum one number for each model, randomly selected from the production lot, shall be tested at

an approved test rig to ensure proper burner performance during actual operation, as per approvedOwner/PMC’s specification. And same should be tested in presence of Owner/PMC’s / third party

representative.

10.1.4 Maximum heat release

Add following

Air flow modelling of the air distribution duct for the burners shall be carried out. Where the heater employs more than three burners or else vendor may offer ducting system which is identical to

already proven duct with air flow modelling.Original

clause of API560


12.0 INSTURMENT AND AUXILIARY CONNECTIONS

12.3 Auxiliary connections

12.3.2 Vent and drain connections

12.3.2.1 Substitute existing clause by the following:

Manifold or piping vents and drains shall be of 50mm minimum (unless specified otherwise)flanged connections covered with blind flanges of same metallurgy and rating as the manifold or

piping.

12.4 Tube skin thermocouples

Add following to the existing clause

Vertical skin thermocouples lead shall be guided along the tube with welded clips or band of SS-

310(min) at an interval of 450mm.

Installation of all the skin thermocouples shall be supervised and certified by skin thermocouples’

supplier for correct installation including that of connecting cables, insulation and support for thesignal cables

13.0 SHOP FEBRICATION AND FIELD ERECTION

This chapter is also applicable for site fabrication and erection.

13.1 General

13.1.3 Local code reference shall be IS800 and other codes referred therein.

13.1.4 Add following to the existing clause.

Steam piping shall be fabricated and erected in accordance with Indian Boiler Regulations.

All branch connections on coil shall use specially designed forged fittings for the purpose likeweldolets, elbolets etc. direct pipe to pipe joints are not to be considered.

13.2 Steel fabrication


Lap joints of casing plates with structural members shall have continuous fillet weld on outside and

minimum 50mm long fillet welds on 230mm centres on inside.


2% radiography of weld joints of stack at ‘T’ joints shall be done as minimum.

For stack shall plate more than 38mm thick, preheat and stress-relieving requirements of ASME

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code shall be applicable.

13.3 Coil fabrication


In order to prevent entrance of extraneous material during fabrication, coil subassemblies shall be

blown out with compressed air and ends capped during storage/interruption during fabrication.

13.4 Painting and galvanising

13.4.2 Replace “Uninsulated flue gas duct and stack….” By “Internal surface of air and Uninsulated fluegas duct and stacks….” This clause does not apply to SS materials. Galvanising is not envisaged

for any structure Aluminium paint requiring minimum maintenance as approved by Owner/PMC

Original

clause of API560


13.7 Field erection


All field joint between modules, duct and stack splice shall be seal welded after erection to

minimise leakage in operation. This however does not apply to joints

14.0 INSPECTION, EXAMINATION AND TESTING

14.2. Add following to the existing clause

Or Indian Boiler Regulations (IBR) as applicable.

14.2.2.3 Delete the existing clause


Only electrical resistance coil should be used for pre-heated / post weld heating of all the alloysteel welding. Pre-heating/post weld heating need to be complied for all the alloy steel irrespective

of fillet/butt weld size.

14.2.2.7 Add following.

All butt welds and nozzles welds in Cr-Mo steel that are post weld heat treated, shall be subjectedto hardness test.

3.2 MODIFICATIONTOSTAND STANDARD SPECEFICATION

Following standard specification attached stand modified to the extent as given below.

3.2.1 Specification No. 18-3177-000-M.02-703 (standard specification of coils for fired heaters)

3.2.1.1 Following portion of clause 2.2 shall be read as:

Out of plumb for vertical tubes shall be 1mm/meter length subject to 6mm maximum.

Flattering of any cross-section: lower of the following.

i. 8% of the nominal ODii. 20 D/R where D is the normal diameter of tubes and R the mean Radius of bending.

3.2.1.2 Add following to the existing clause 5.3.2

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Radiography of all shop/site joints upto 8mm shall be carried out using x-rays.

Radiography of in-situ joints can be done using gamma rays but welder qualification must be done using x-rays.

3.2.1.3 Appendix 9.4 to be modified as given below (note 1 and 2 remain unchanged).

Recommended past weld heat treatment and tempering temperatures for coiled and it’s subcomponents suchas fittings, flanges etc. of various metallurgy requirements as given below and these values supersedes the

values noted in the Appendix.

S.No.MaterialComposition

Minimum PWHTTemp.ºC

Minimum Temp.ºC LowerCritical Temp.ºC

1 5 Cr- 0.5 M◦ 705 760 820

2 9 Cr-1 M◦ 705 760 825

3 9Cr-1M◦ (Mod) 760 780 825

(I) Tempering temperature shall not exceed lower critical temperature.(II) PHT temperature shall not exceed tempering temperature.

(III) Welding of dissimilar material of pressure parts.Minimum PWHT temperature shall be as stipulated in he table for the higher metallurgy,

PHT temperature in no case shall exceed the lower critical temperature of lower metallurgy.

While procuring materials the temperature shall be specified in the material specifications

and shall correspond to the higher metallurgy subject to paragraph(s).(IV) Hardness testing of weld metal and heat affected zone on the job shall be carried out as per clause 331.1.7

and Hardness shall not exceed the values specified in table 331.1.1. of ANSI B 31.3. Further the weld

procedure including PWHT shall be qualified for the required hardness values.

3.2.3 Spec No. 18-3177-000-.02-717(Standard specification or insulating castables)

Additional Type: “Acid Resistant castable: to be added to Table -1 at page 5 of 5.

The castable shall have setting characteristics of “hydraulic + chemical” and suitable upto maximum service

temperature of 700.ºC with physical properties as given below:

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Physical Properties

1. Bulk density (kg/m³) min. after drying at110ºC

: 2050

2. Thermal conductivity (kcal/hr-m-ºC) max.At 300ºCAt 500ºC

: 0.6

: 0.6

3. Cold crushing strength (kg/cm² min.

After drying at 110ºCAfter heating at 400ºCAfter heating at 800ºC

: 210

: 250: 320

4. Modules of rupture (kg/cm²) min.

After drying at 110ºCAfter heating at 500ºC

: 60

: 25

5. Linear shrinkage (%) max.

After drying at 110ºCAfter heating at 500ºC

: 0.1

: 0.2

Chemical composition

A12O3 (%)SiO2

: 15-20: 70-76



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3.3 OTHER REQUIREMENTS3.3.1 Piping around heater

3.3.1.1 The vendor shall do piping layout in such a way that minimum loads are transmitted to heater terminals and ensure that these loads are in line with API 560 limitations. All such loads shall beclearly specified and fully analysed to examine its acceptability within permissible code/designlimits ensuring coil safety and leakage at flange joints. For vibration prone services, suitable springsupport, anchors/limit stoops to be provided after flexibility analysis of piping.

3.3.1.2 Heater vendor to ensure that all piping supports shall be designed in such a manner thatheadroom clearance is available and free movement on platform/ground is not obstructed.

3.3.1.3 No piping to be supported on platform, staircase, handrail member unless they are specificallydesigned for that purpose. In any case of vibrating lines/two phase flow line son heater structures/platform is not permitted.

3.3.1.5 Supports of top support vertical radiant coil should preferably be located in such a manner as tohave uniform coil expansion in adjacent tubes to minimise additional stresses.

3.3.1.5 Piping for and around burners should be routed in such a manner that:(i) The valves on the burner utility lines shall be located near to the radiant wall sight doors with in

arms distance from it, so that a single operator is able to operate the controls for fuel as well asview pilot and main flame.

(ii) Piping near a particular sight door shall correspond to the burner flame visible from that sight door.(iii) It doesn’t obstruct the removal and installation of burner sub-assembly, guns and igniter.(iv) It doesn’t obstruct the walkway and headroom for the operator’s movement.

3.3.1.6 For pressure parts flanges, gaskets, studs, nuts, also Refer “Piping Material Specifications”enclosed elsewhere in the bid package.

3.3.2 Refractory

3.3.2.1 All insulating castables, refractory fire bricks, fire clay air setting and ceramic fibre blank shall beas per standard specification enclosed elsewhere in the bid package.

3.3.2.2 For ceramic fibre module lining, the application must be done under the supervision of materialsupplier.

3.3.2.3 Two coats of (90-100 microns per coat) EPIPLUS-56 of M/s Shalimar Paints or equivalent shall be

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applied on shall plate in contact with ceramic fibre unless otherwise specified.3.3.2.4 1 to 2 mm coating of potassium silicate solution shall be applied internally on shell plate in contact

with castable for all cold flue gas ducting unless otherwise specified.

3.3.2.5 Spacing of lugs for castable lining shall be as follow:

Radiant floor 6 Dia v and y lugs 460mm staggered pitch

Bridge floor 6 Dia v and y lugs 460mm staggered pitch

Verticalwalls

Upto

75 thk.

6 Dia v lugs 300mm staggered pitch

75 thk-125 thk


Morethan 125thk

6 Dia corrugated v lugs 400mm staggered pitch

Overheadsurfaces

460mm staggered pitch

Upto 75thk

6 Dia v and y lugs 200mm staggered pitch

75 thk-125 thk


More

than 125thk

6 Dia corrugated v lugs 300mm staggered pitch

End tubesheet

25 x 3 thk.v lugs 400mm staggered pitch

Corbell inconvection

6 Dia corrugated v lugs 300 mm pitch

3.3.2.6 After installation of ceramic fibre blanket module and tarping, the final thickness shall be asspecified in the datasheets. Vendor to design module accordingly, taking into consideration thetarnping loss. Negative tolerance on module dirnension and density is not acceptable.

3.3.2.8 All ceramic fibre modules shall be compressed by 5mm (min) during installation along their length.

3.3.2.9 Any pipe sleeves passing through refractory shall be wrapped with 1.5mm thick ceramic fibreblanket or module, all pipe sleeves to have 40mm diameter SS304/ 316L collar at hot surface

3.3.5 For detail engineering of platform, ladders, staircase, grating, handrail etc. refer civil-structuralspecification enclosed elsewhere in the package.

3.3.6 Spigot guide sleeve top end shall be slightly above the floor refractory top surface.

3.3.7 The net area (inside of lining) in case of single off-take shall not be less than 100% of the stack(inside lining) area and 60% each in case off-takes.

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3.3.8 Only SS shims to be used for equipment alignment.

3.3.9 All brought out components shall be clearly identified by a tag, permanently attached to it;

3.3.10 All the spares supplied by vendor shall be properly wrapped and packed so that spares ill be

preserved in new condition under the normal condition of storage and shall be properly tagged andcoded so as to be identifiable at the later date. Packing list shall be furnished so that the parts canbe identified without un-crating.

3.3.11 Heater outside surface including stack and ducting shall be painted with silicon based hightemperature aluminium paint after adequate surface preparation by shot blasting.

4.0 NATURAL DRAFT BURNERS

The burners shall be low NOx, staged fuel, natural draft type with noise attenuation and individualplenum box design with damper control of air (John Zink PSFG – RM) Flame Each burner shallbe supplied with gas fuelled, inspiriting type pilot burner having a flame retention head (John ZinkST – 1S)

4.1 The specification covers requirement of burners where whole of combustion air is supplied bynatural draft. The burner includes gas distribution piping, gas, nozzles, agitator, pilot and burner management system. This includes mounting the burners to heater and necessary combustion air control.

4.2 The burners design shall be low NOx type with the Nitrous oxides emissions are 100 ppmv or better.

4.3 Burners shall be suitable for outdoor operation in refinery complex under specified ambient inbasic engineering design basis.

Lighting part shall be free accessible and suitable for portable electric or gas ignitors.

4.4 The fuel can be natural gas or process gas as specified in burner data sheet.

4.5 Each burner shall have its own lighting independent of any viewing ports. The 4.6 Burners air supply shall be proctected against variation in wind pressure, which may cause blow backthrough burners.

4.7 All the burner components shall be capable of atleast 25000 hrs. of continuous operation withspecified gas flue. Gas tips/swirter shall have minimum SS 310 material of construction.

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4.8 Burners shall be provided with continuous pilot and automatic ignition system. Flame detectorsof ultraviolet self checking type for main flame and flame rod for pilot flame shall be provided.

4.9 Burner noise at any location 1m form heater with one burner firing at design heat release shallnot exceed 85 dBA.

4.10 Burner performance test shall be witnessed by third party inspection agency arranged by EPCCcontractor.

4.11 Test data shall contain, fuel composition, flow rate(max to min), temperature, lower heating value

of fuel, inlet fuel pressure, pilot gas pressure / temperature / flow, flame dimension, CO content instack gas, NOx content in stack gas, draft at burner, calculated excess air, calculated heatrelease, barometric pressure, ambient temperature, noise level and flue gas temperature. Vendor shall submit performanc3e guarantee.

5.0 FUEL GAS PREPARATION SYSTEM

5.1 Fuel gas preparation system shall be provided to remove solid and liquid particles entrained infuel gas to assure reliable and efficient operation of low NOx burners. Also the system shall serveto meet the stringent flue gas emission normal of current and future regulatory requirements.Refer UOP specification No.939463 – 965 for fuel gas preparation system.

5.2 The range of 20% to 150% of the fuel demand of the associated fired heater at design duty shall

be used for fuel gas preparation system design.

5.3 For fuel gas composition and properties refer details elsewhere in the feed documents

5.4 Following shall be included in the fuel gas preparation system as minimum. The MOC, nozzlesand other requirements including piping, instrumentation, isolation valve, steam traps, make of coalescer elements etc. shall be in accordance with UOP specification No. 939463- 965.

1. Fuel gas knockout drum: Vertical vessel shall be provided for separation of liquid particles greater than 250 micron.

2. Coaleser: Multistage high efficiency cartridge type coaescer shall be provi9ded for separation of entrained liquid from fuel gas system.

- The efficiency shall be 99.98% for particles 0.3 micron diameter and larger.- Max. allowable pressure drop clean / dirty shall be 0.035 / 0.35 kg/cm² ( Or 0.5 / 5 psi).

- The vessel shall be supplied with ladder to service coalescer elements.3. Basket Strainers: Basket type strainer shall be peovided on the coalescer bypass.4. Fuel gas heater: Hair pin type heat exchanger (or as per TEAM BEU) shall be provided for

heating the fuel gas to a target temperature indicated in UOP specification No. 939463-965’

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6.0 MINIMUM INSPECTION REQUIREMENTS

S. No. Component/subcomponent

Basisof inspection

Heater SystemSupplier’sInspection

Third partyInspection(Shop)

Owner/ PMC’s Accepatnce

Remarks.

1. Structural steelplates. Profilesetc.

As per code C - D

2. Pipes and

Fittings,fasteners,gaskets etc.

As per

code andpurchaseSpec. (PS)

- A D

3. Studded tubes As per PS - A D

4. Dampers,thermocouples,spring supports,Expansion joints

As per PS - A D

5. Burner As per PS - A D

-Hardware

-Shopperformance test

As per PS - H H

-Air flow modeltesting As per PS - H H

S. No. Component/subcomponent

Basis of inspection

Heater SystemSupplier’sInspection

Third partyInspection(Shop)

Owner /PMC’s Accepatnce

Remarks.

Burner managementsimulation test atshop and ay site

As per PS H H

7. Insulation andrefractorymaterials

As per PS A C D

8. Fabrication andErection work

As per code/PS

A - A In case of fabrication atsite

A A D In case of shopfabrication invendor works.

9. Hydrotest /system leak testat site

As per code /PS

A - H

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NOTES1. All items covered under IBR shall contain relevant IBR/IBR approved certification.2. All items shall be procured from the manufactures directly.3. Inspection categories:

A: Stage wise Inspection.C: Final inspection only.D: Review of documentation onlyH: Hold Point with third party inspection arranged by contractor.

7.0 LIST OF REFERENCE DOCUMENTSRefer all documents attached else where in bid document

i Basis of structural designii Specification for pressure partsiii Specification for design and supply of damper v Technical Questionnaire (TQ)vi Deviation schedule formatvii Document and drawing requirement

viii Mandatory sparesix Design requirements for earthquakex Specification for paintingxi Piping material specification (PMC)xii Electrical and inspection requirementsxiii Design basis for fired heater xiv Fireproofing requirementsxv Process data sheets & P&IDsxvi Standard specificationxvii UOP specification as indicated in this specification .

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