EGE11B1

DIRECT FIRED PROCESS HEATERS DESIGN AND FABRICATION
DECEMBER 1989
PAGE 1 OF 31
EGE 11-B-1 1989
TABLE OF CONTENTS 1. 2. 3. 4. Scope References Proposals Design 4.1 General 4.2 Radiant Section 4.3 Convection Section 4.4 Tubes 4.5 Headers and Terminal Fittings 4.6 Piping 4.7 Tube Supports 4.8 Setting 4.9 Structure and Appurtenances 4.10 Burners 4.11 4.12 4.13 4.14 4.15 4.16 5. Dampers Sootblowers and Related Requirements Setting Doors and Ports Breechings and Ducts Stacks Instrument and Utility Connections Air Preheater System 5.1 Air Preheater 5.2 Fans and Motors 5.3 Ducting Fabrication, Erection, Inspection, and Testing Painting Drawings and Data Guarantee
6. 7. 8. 9.
1. SCOPE This Guide covers the basic requirements for the proposal, design, and fabrication of direct fired process heaters used in hydrocarbon and steam services. Applicable sections of this Guide shall also apply to proprietary hydrogen steam reformer and pyrolysis heaters. 2. REFERENCES The following publications form a part of this Guide. Unless otherwise specified herein, use the latest edition.
Mobil Engineering Guides EGE 00-B-3 EGE 00-B-5 EGE 00-B-20 EGE 00-B-21 EGE 00-C-4 EGE 11-D-1 EGE 11-B-20 EGE 11-B-50 EGE 15-B-13 EGE 15-B-21 EGE 16-B-1 EGE 16-B-22 EGE 16-B-30 Structures and Equipment External Loading Design Basis Equipment Sound Levels Pressure Casting Inspection Pressure-Containing Equipment Welding and Weld Inspection Equipment Purchases General Engineering Requirements Direct Fired Process Heater Data Sheet (a and b) Steam Boilers Critical Service Design and Fabrication Stacks Design and Construction Special-Purpose Couplings for General Refinery Services Special-Purpose Centrifugal Fans for Refinery Services Piping General Design Piping Process Equipment Piping Selection and Application of Piping Components and Materials (With Classification Sheets and Appendix)
MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

EGE 16-B-40 EGE 31-B-1 EGE 32-B-15 EGE 33-B-19 EGE 34-B-15 EGE 35-B-10 EGS 629
PAGE 2 OF 31 DECEMBER 1989
Piping Fabrication, Erection, Inspection, and Testing Steel Structures Design and Fabrication Instrumentation Heater Controls Electrical Induction Motors Fireproofing General Requirements Painting Manufacturing Facilities Fire Protection and Loss Prevention Refineries and Petrochemical Plants
AISC (American Institute of Steel Construction) Specification S326 Specification for the Design, Fabrication and Erection of Structural Steel for Buildings
API (American Petroleum Institute) Publications RP 530 RP 532 RP 533 Std 560 Recommended Practice for Calculation of Heater Tube Thickness in Petroleum Refineries Measurement of the Thermal Efficiency of Fired Process Heaters Air Preheat Systems for Fired Process Heaters Fired Heaters for General Refinery Services
ASME (American Society of Mechanical Engineers) Standards Boiler and Pressure Vessel Code, Section 1, Power Boilers B16.5 Pipe Flanges and Flanged Fittings AWS (American Welding Society) Code D1.1 Structural Welding Code, Steel
3. PROPOSALS 3.1 3.2 The vendor shall comply with the general purchase requirements of EGE 00-C-4. The following information shall be submitted with the vendors proposal: (a) (b) (c) Detailed description of any exceptions to the project specifications or to this Guide. Completed data sheet, EGE 11-D-1 (a or b), for each heater. Preliminary drawings showing: (1) Dimensions of each radiant section of the firebox.
(2) Location and arrangement of tubes, intermediate tube supports, sootblowers, burners, inspection fittings, crossovers, and inspection ports. (3) Location and size of all platforms supplied by the vendor for operation and maintenance, including ladders and stair access. (4) Overall layout for air preheaters.
(d) For vaporizing services, tube station profile curves covering temperature, pressure, vaporization, and velocity for each coil.
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DECEMBER 1989 PAGE 3 OF 31
EGE 11-B-1 1989
(e) Description of the extent of shop and field fabrication including weight and dimensions of modules proposed. (f) For hydrogen steam reformer and pyrolysis heaters, process, flue gas, and tube metal temperature profiles along the full length of the radiant tubes. Stress rupture data, Larson-Miller parameter equation, and tube thickness calculation shall also be provided. (g) Maximum allowable loads and movements that can be imposed on the heater terminals by external piping. (h) Description of the burner, fan, and motor noise attenuation devices and a completed sound level data sheet incorporating the information required by EGE 00-B-5 and outlined in Appendix B of that Guide. (I) Description of the procedure for tube replacement of any unique tube arrangement.
(j) Complete information on all special equipment, such as burners, fans, blowers, drivers, air preheaters, and sootblowers. (k) The expected and guaranteed NOx, CO, unburned hydrocarbons, and particulates concentration in the flue gas. NOx shall be expressed in ppm by volume and kg/MW (lb/MM Btu/h) and total NO x emissions in kg/h (lb/h). (l) Expected flame pattern for the burners.
3.3 When the heater has been designed by Mobil, the vendor shall check the design and guarantee the thermal and hydraulic performance of the heater. 4. DESIGN 4.1 General
4.1.1 Heaters shall conform to the requirements of API Std. 560 and this Guide, except as modified and supplemented by the project specifications and EGE 11-D-1. In case of conflict between this Guide and API Std. 560, this Guide shall take precedence. The project specifications shall include all local and federal/national mandatory statutory rules and regulations that apply, such as safety, emissions, sound levels, etc. Any such requirements that are in addition to, or more stringent than, Mobil requirements shall take precedence. 4.1.2 It is preferred that a heater contain a single process service. A combination heater handling multiple services is acceptable with Mobil approval, provided the overall heater design permits individual control of each service without affecting the other process services. When one process coil is split between radiant and convection sections, a minimum of 50 percent of that coil duty shall be in the radiant section. 4.1.3 The number of tube passes shall be minimized. The heater design shall permit safe operation at the design rate and at reduced flowrates down to 60 percent of design rate. The cost of instrumentation, piping, and coil pressure drop shall be considered in the overall economics of multipass designs. 4.1.4 Multipass heaters shall be designed for hydraulic and thermal symmetry of all passes. Mixed phase flow shall not be split within the heater. To achieve uniform heat distribution to each pass, jump fittings shall be provided for coking service with a fouling factor $0.00053 m@C/W (0.003 h@ft @F/Btu).

4.1.5 For natural draft combustion, efficiencies shall be based on 20 percent excess air when gas is the primary fuel and 25 percent excess air when oil is the primary fuel. For forced draft combustion, efficiencies shall be based on 15 percent excess air for fuel gas and 20 percent excess air for fuel oil. 4.1.6 Calculated and guaranteed efficiencies shall be based on the lower heating value of the given primary fuel, and shall include a minimum radiation loss of 1.5 percent of the total heat liberation. When heaters are designed with an air preheat system, a minimum radiation loss of 2.5 percent of the total heat liberation shall be included. Excess air shall be determined at the exit from the heater. 4.1.7 All heaters, except those in reformer charge and reheat services, shall be designed for thermal expansion at 760C (1400F) tube metal temperature. 4.1.8 Permanent steam/air decoking facilities shall be installed for coking service with a fouling factor $0.00053 m @C/W (0.003 h@ft @F/Btu). 4.1.9 Heaters, including accessories such as air preheaters, fans, and motors, shall be designed to meet the sound level requirements of EGE 00-B-5. 4.1.10 The selection of material, if not otherwise indicated herein or specified in the project specifications, shall satisfy the temperature limitations listed in Table 1. 4.1.11 4.2 All heaters shall be designed for maximum shop assembly in order to minimize field work.
Radiant Section
4.2.1 The H/D ratio of vertical cylindrical heaters or H/W ratio of cabin or box heaters shall not exceed 2.75, where H is the height of the radiant wall tube bank or the straight tube length of vertical tubes, D is the tube circle diameter, and W is the greatest horizontal distance between the centerlines of single-fired tubes or the distance between the burner centerlines of either side of double-fired tubes, all measured in the same units. For coking services with a fouling factor $0.00053 m @C/W (0.003 h@ft @F/Btu), a maximum H/D or H/W ratio of 2.0 shall be used. 4.2.2 The maximum allowable average radiant heat flux density and the minimum fouling factor shall be as listed in Table 2. 4.2.3 For vertical cylindrical heaters, the average radiant heat flux density shall be limited to 3200 W/m (1000 But/h@ft) less than specified for horizontal tubes in the same service.
TABLE 1 MATERIAL TEMPERATURE LIMITATIONS Maximum Metal Temperature Material* Carbon steel 11/4 Cr-1/2 Mo 21/4 Cr-1 Mo 5 Cr-1/2 Mo 7 Cr-1/2 Mo 9 Cr-1 Mo 18 Cr-8 Ni 25 Cr-20 Ni C 425 595 635 650 675 705 815 1040 F 800 1100 1175 1200 1250 1300 1500 1900
*Materials for temperatures above 1040C (1900F) shall be submitted for Mobil for approval.

EGE 11-B-1 1989
TABLE 2 ALLOWABLE AVERAGE RADIANT HEAT FLUX DENSITY AND FOULING FACTOR Heat Flux Density* Service Atmospheric tower charge Vacuum tower charge (fuel) Vacuum tower charge (lube) Coker unit charge Visbreaker unit charge PtR charges and reheat Pretreater charge Hydrocracker charge Hydrotreater charge CHD charge Reboilers Hot oil belt for Mobiltherm Furfural raffinate mix Furfural extract mix Asphalt mix W/m
2
Fouling Factor
2
Btu/hCft 12,000 10,000 9,000 9,000 7,000 12,000 10,000 12,000 10,000 12,000 12,000 12,000 7,000 7,000 6,000
m CC/W 0.00053 0.00070 0.00070 0.00088 0.00088 0.00026 0.00035 0.00035 0.00044 0.00035 0.00026 0.00035 0.00044 0.00044 0.00044
hCft CF/Btu 0.003 0.004 0.004 0.005 0.005 0.0015 0.002 0.002 0.0025 0.002 0.0015 0.002 0.0025 0.0025 0.0025
37,860 31,550 28,395 28,395 22,085 37,860 31,550 37,860 31,550 37,860 37,860 37,860 22,085 22,085 18,930
*The radiant heat flux density pertains to a single-row horizontal cabin or vertical tube box type with a nominal two-tube diameter spacing, fired from one side only. When larger tube spacing is used, the allowable average flux density may be increased and the vendor shall submit the proposed average flux density in his proposal for Mobil approval. Convection section shield tubes shall not be considered as radiant surface in determining the average radiant heat flux density.
To minimize heater cost and process coil pressure drop, a double-fired design may be used.
The allowable average radiant heat flux density for the double-fired design may be 50 percent higher than for a single-fired design for the same tube spacing.
4.2.4 Volumetric heat release shall not exceed 155,000 W/m (15,000 Btu/h@ft ) for oil fired heaters and 186,000 W/m (18,000 But/h@ft ) for gas fired heaters. The calculated volume shall be based on the distance between tube centerlines in the radiant section and the heat input based on the normal heat release. 4.2.5 All floor fired heaters shall be provided with 305 mm (12 in.) high, first quality firebrick walls running the entire length of the heater floor between the burners and the radiant tubes to prevent flame bending due to uneven flue gas recirculation. The clearance between these walls and the outside surface of the burner floor tiles shall be 150 mm (6 in.). 4.3 Convection Section
4.3.1 Convection sections shall be a cross-flow type with at least two rows of bare tubes acting as a shield. Radiant section suspended roof tubes shall not be counted as shield rows. 4.3.2 When the shield and radiant tubes are in the same service, the shield tubes shall be of the same material and thickness as the radiant tubes.

4.3.3 The maximum bare-tube heat flux density (outside diameter basis) on any extended surface convection tube row in hydrocarbon service shall not exceed 1.8 times the allowable average radiant flux density for single-fired tubes. 4.3.4 Corbels shall be provided in the convection section to prevent flue gas bypassing. Corbels shall not be used at the bottom shield row. 4.3.5 The design, including tube supports, shall incorporate space for future installation of two rows of tubes. When the convection section has one service only, the future tubes shall be equal in size and type to that of the top convection row. When the convection section has a combination of process and nonprocess coils, the future tubes shall be equal in size and type to the top row of process tubes unless otherwise specified by Mobil. End tubesheet sleeves for future tubes shall be provided and shall be blanked off with an easily removable plate. 4.3.6 A minimum clearance of 610 mm (24 in.) shall be provided between the outside diameter of the top future row of tubes and the convection breeching. 4.3.7 Extended surface tubes may be used only in convection sections above the shield tubes. The type of extended surface shall be governed by the following conditions: (a) Gas firing only or turbine exhaust gas. Finned tubes are acceptable. Fin thickness shall be 1.3 mm (0.05 in.), minimum, and fin density shall not exceed 200 fins/m (5 fins/in.). Maximum height of fins shall be 25 mm (1 in.). (b) Combination gas/oil firing, with gas or clean light oil used as the primary fuel (oil used for startup only). Finned tubes are acceptable. Fin thickness shall be 2.5 mm (0.10 in.), minimum, and fin density shall not exceed 120 fins/m (3 fins/in.). Maximum height of fins shall be 19 mm (3/4 in.). (c) Combination gas/oil or oil only firing, with residual oil as the primary fuel. Only cylindrical studs of 12.7 mm ( in.) diameter, minimum, are acceptable. Maximum height of studs shall be 25 mm (1 in.). 4.3.8 The fins of finned tubes shall be attached to the tubes by continuous welding. Stud attachment shall provide full surface contact between the tube and the stud. 4.3.9 Fin material for extended surface convection tubes in reboiler, boiler feedwater (BFW), and steam generation service may be carbon steel for a maximum calculated fin tip temperature of 427C (800F). For all other services fin material shall be 11-13Cr as a minimum. For higher tip metal temperatures, fin material shall be limited to 11-13Cr, Type 304, and Type 310 stainless steel for a maximum calculated tip temperature of 595C (1100F), 705C (1300F), and 815C (1500F), respectively. Stud material may be carbon steel for a maximum calculated tip temperature of 510C (950F). 4.3.10 On adjacent tubes, minimum horizontal and diagonal clearance between fin or stud tips shall be 38 mm (1 1/2 in.). Minimum spacing between tips and convection section sidewall shall be 25 mm (1 in.). Maximum spacing between wall of corbels and the closest tube centerline shall be half of the horizontal tube centerline-to-centerline spacing. 4.4 Tubes
4.4.1 For process service, the tubewall thickness shall be determined in accordance with API RP 530. For rupture design, tube calculations shall be based on a design tube life of 100,000 hours and minimum

EGE 11-B-1 1989
rupture strength. Tubes in steam service shall be designed in accordance with the ASME Boiler and Pressure Vessel Code, Section I. 4.4.2 The maximum tube metal temperature shall be determined in accordance with API RP 530, taking into consideration the tube circumferential and longitudinal variation in heat density, its relative location in the firebox, and the specified fouling resistance. A circumferential maldistribution factor of 1.8, minimum, shall be used for single-row radiant tubes (fired from one side) with a nominal two-tube diameter spacing. An additional multiplying longitudinal maldistribution factor of 1.1 shall be used for each 3 m (10 ft) of radiant section over 6 m (20 ft) high. 4.4.3 The design tube metal temperature shall be equal to the calculated maximum tube metal temperature plus 28C (50F). 4.4.4 The elastic and rupture design pressures shall be as defined in API RP 530, except that these pressures shall be increased by 10 percent or by 175 kPa (25 psi), whichever is greater. 4.4.5 Carbon steel and low-alloy tubes (up to and including 2Cr-1Mo) shall be designed with a minimum internal corrosion allowance of 2.5 mm (0.10 in.). The minimum corrosion allowance for higher-alloy tubes shall be as given in the project specifications. 4.4.6 All tubes and pipes shall be seamless. If tubes cannot be furnished in a single continuous length, one intermediate circumferential weld is permissible. If an intermediate circumferential weld is required, electric resistance flash welding is not permitted. The tubes shall be purchased to minimum or average wall thickness in accordance with ASTM tolerances to provide the required minimum wall thickness. Pipe sizes are preferred. 4.4.7 Maximum radiant effective tube length for horizontal heaters shall not exceed 13.7 m (45 ft) when the heaters are fired from both ends or 24 m (80 ft) when fired from bottom or side. Maximum straight radiant tube length for box heaters with vertical tubes shall not exceed 9 m (30 ft). For vertical cylindrical heaters, straight radiant tube length shall not exceed 15 m (50 ft). 4.4.8 Radiant tubes shall be installed with centerline not less than 1 nominal diameters from heater walls. The clearance between the bottom horizontal wall tube outside surface and floor refractory surface shall be a minimum of 305 mm (12 in.). 4.4.9 When header boxes are used, tubes shall project at least 150 mm (6 in.) outside end tubesheets into header boxes to permit cutting and rewelding for tube replacement. 4.4.10 When fabricated of cast material, pyrolysis heater and hydrogen steam reformer radiant tubes shall have the complete inner surface, including all intermediate girth welds, machined or honed to the maximum surface roughness Ra of 3.2 m (125 in.). 4.4.11 Tube and pipe materials in process service shall conform to the ASTM specifications shown in Table 3. When heater tubes are purchased to ASTM pipe specifications, the hardness shall also conform to the hardness limitation indicated in ASTM tube specification of the same material. 4.5 4.5.1 4.5.2 Headers and Terminal Fittings Center-to-center header dimensions shall be a minimum of two times the nominal pipe size. Headers and terminal fittings shall be attached to tubes by welding.

4.5.3 Terminal connections shall be provided with ASME B16.5 standard pipe flanges. Piping outside the heaters shall be arranged to permit flanged heater terminal connections to be used as the inside diameter (ID) inspection openings. 4.5.4 (a) Headers for all heaters shall be located as follows: Convection section return bends in header boxes at both ends to prevent flue gas bypassing.
(b) Radiant section return bends for coking services, with a fouling factor $0.00053m@C/W (0.003 h@ft@ F/Btu) in header boxes at both ends for easier tube replacement. Radiant section return bends for noncoking services may be located in the firebox. Such return bends may be included as part of the heating surface. 4.5.5 When tube ID inspection openings are specified on heater data sheets, either plug type headers or flanged connections may be used. The deadleg type of inspection opening is not permitted. Plug type headers, if specified, shall be of solid body design and shall be located in header boxes. Corresponding numbers shall be stamped on each plug and header so that the same plug may be replaced in the same header. 4.5.6 Header and fitting ratings shall be based on the elastic design pressure and design fluid temperature specified on EGE 11-D-1 or in the project specifications. All fittings shall be seamless. 4.5.7 Header material shall have a corrosion resistance and corrosion allowance equal to or greater than the tube material. Plugs in alloy headers shall be of the same alloy as the headers. Headers and terminal fitting shall conform to the ASTM specifications shown in Table 4. 4.5.8 Additional requirements for hydrogen steam reformers: (a) Flexible inlet and outlet pigtails shall be used. Pigtails shall be individually insulated with 1425C (2600F), 128 kg/m (8 lb/ft) density, ceramic fiber blanket. The cladding (sheathing) material shall be subject to Mobil approval. Low-melting-point metals, such as aluminum, shall not be used for cladding. (b) Outlet pigtails shall be of Incoloy 800 material. Inlet pigtails shall be of 2Cr-1Mo material. Both inlet and outlet pigtails shall be designed to permit individual radiant tubes to be taken out of service by pinching off pigtails while the heater remains onstream. Therefore, a section of each inlet pigtail shall be made from Incoloy 800 to accommodate pinching. The pinching locations shall be clearly marked on the drawing and in the field for each identification. (c) The inlet pigtail/top flange assembly and spring support design shall permit catalyst loading and unloading without disconnecting any support hangers or removal of any other ancillary equipment. (d) The transfer line between the radiant section outlet manifold and the process gas waste heat boiler shall be internally refractory lined. The vendor shall submit the proposed refractory type and anchor system to Mobil for approval. (e) 4.6 Burner piping, including all valves and fittings, shall be provided by the heater vendor.
Piping

EGE 11-B-1 1989
4.6.1 All external crossovers, manifolds, and piping shall be designed in accordance with EGE 16-B-1. Fabrication and inspection shall be in accordance with EGE 16-B-40. 4.6.2 Crossovers between radiant and convection section tubes shall be flanged except that, for hydrogen service, they shall be welded. All flanges shall be of the welding-neck type. All crossovers shall be external to the firebox.
TABLE 3 ASTM SPECIFICATIONS FOR TUBES AND PIPES (SEAMLESS) Material Carbon steel 11/4 Cr-1/2 Mo 21/4 Cr-1 Mo 3 Cr-1 Mo 5 Cr-1/2 Mo 5 Cr-1/2 Mo-Si 7 Cr-1/2 Mo 9 Cr-1 Mo 18 Cr-8 Ni 16 Cr-12 Ni-2 Mo 18 Cr-10 Ni-Ti 18 Cr-10 Ni-Cb Alloy 800H 25 Cr-20 Ni Pipe Specifications A53, A106, Gr A or B A335, Gr P11 A335, Gr P22 A335, Gr P21 A335, Gr P5 A335, Gr P5b A335, Gr P7 A335, Gr P9 A312, A376, TP304H A312, A376, TP316H A312, A376, TP321H A312, A376, TP347H B407 Tube Specifications A161 A200, A213, Gr T11 A200, A213, Gr T22 A200, Gr T21 A200, A213, Gr T5 A213, Gr T5b A200, A213, Gr T7 A200, A213, Gr T9 A213, A271, TP304H A213, A271, TP316H A213, A271, TP321H A213, A271, TP347H B407 A608, Gr HK40
TABLE 4 ASTM SPECIFICATIONS FOR HEADERS AND TERMINAL FITTINGS Material Carbon steel 11/4 Cr-1/2 Mo 21/4 Cr-1 Mo 5 Cr-1/2 Mo 7 Cr-1/2 Mo 9 Cr-1 Mo 18 Cr-8 Ni (304) 18 Cr-8 Ni (304H) 16 Cr-12 Ni-2 Mo (316) 16 Cr-12 Ni-2 Mo (316H) 18 Cr-10 Ni-Ti (321) Forgings A105, A181 CL 60 or 70 A182, Gr F11 A182, Gr F22 A182, Gr F5 A182, Gr F7 A182, Gr F9 A182, F304 A182, F304H A182, F316 A182, F316H A182, F321 Wrought A234, Gr WPB A234, Gr WP11 A234, Gr WP22 A234, Gr WP5 A234, Gr WP7 A234, Gr WP9 A403, WP304 A403, WP304H A403, WP316 A403, WP316H A403, WP321 A351, Gr CF8C A217, Gr C12 A351, Gr CF8 A351, Gr CF8 A351, Gr CF8M Castings A216, Gr WCB A217, Gr WC6 A217, Gr WC9 A217, Gr C5

18 Cr-10 Ni-Ti (321H) 18 Cr-10 Ni-Cb (347) 18 Cr-10 Ni-Cb (347H) 25 Cr-20 Ni
A182, F321H A182, F347 A182, F347H A182, F310
A403, WP321H A403, WP347 A403, WP347H A403, WP310 A351, CK20 A608, Gr HK40 A351, Gr CF8C
4.6.3 Crossovers shall be of the same material as the tubes with which they connect. When they connect two coils of different materials, either material may be used. All connections, such as steaming out, blowdown, and pressure gage, shall be of the same material or of a more corrosion resistant material than that to which they are attached. 4.6.4 The vendor shall provide distribution and collection manifolds where specified in the project specifications. When manifolds are provided, they shall be designed to give uniform flow distribution to all passes. Manifold supports shall also be provided by the vendor. Manifolds in hydrogen service shall be of the extruded opening type. 4.6.5 All manifolds shall have provision for venting and drainage.
4.6.6 All crossovers, manifolds, and external piping shall be arranged so that they do not interfere with removal of tubes. 4.6.7 Heater terminals shall be designed to accept the moments and forces imposed by the thermal expansion of the transfer line. As a minimum, heater terminals shall be designed to accept twice the moments and forces listed in Table 7 of API Std 560, unless otherwise specified. 4.6.8 Flexible metal hoses shall be used for oil burners to permit each removal of burner guns for cleaning. Flexible metal hoses can also be used for gas burners for easy maintenance subject to Mobil approval. 4.6.9 Burner piping, including all valves and fittings, shall be steel and shall be provided by other than the heater vendor. For details see EGE 16-B-22. 4.7 Tube Supports
4.7.1 Minimum corrosion allowance for all exposed surfaces of each tube support and guide contacting flue gases shall be 2.5 mm (0.10 in.) For austenitic materials and 5.0 mm (0.20 in.) For ferritic alloy materials. 4.7.2 The maximum unsupported horizontal tube span shall not exceed 35 times tube outside diameter (OD) or 6 m (20 ft), whichever is less. Vertical tubes shall be properly supported and guided to provide for expansion. When vertical tube straight length is 9 m (30 ft) or longer, an intermediate guide shall be provided approximately at the midpoint of the tubes. Vertical tubes shall be supported at the top and guided at the bottom. As a minimum, the bottom guide shall be NPS 2 (NPS = nominal pipe size, inches) pipe, Schedule 80, and Type 310 stainless steel material. 4.7.3 The minimum design temperature for the radiant section supports shall be the radiant section exit flue gas temperature plus 110C (200F) or 980C (1800F), whichever is greater. The design temperature for convection supports shall be equal to the maximum flue gas temperature in contact with the support at design operation plus 55C (100F).

EGE 11-B-1 1989
4.7.4 Tube supports shall be designed to permit tube thermal expansion, avoid mechanical damage to the extended surface, and permit easy removal and insertion of the tubes. Where extended surface tubes are used, a bearing surface with a minimum width of 50 mm (2 in.) shall be provided. This bearing surface shall extend at least 30 degrees on each side of the vertical centerline. Holes in tube supports shall be approximately 13 mm ( in.) greater than the extended surface tube OD. 4.7.5 End tubesheets for radiant and convection tubes with external headers shall be designed as follows: (a) Tubesheets shall be carbon steel of 13 mm ( in.) minimum thickness and shall be designed for the entire tube and header load in case of failure of all intermediate supports. (b) Tubesheets shall be insulated on the flue gas side with a premixed castable refractory [a minimum of 100 mm (4 in.) For convection sections and 125 mm (5 in.) For radiant sections], held in place by Type 304 stainless steel anchors fastened to the tubesheet. The refractory shall have a minimum 1100C (2000F) rating. (c) Type 304 stainless steel sleeves with ID approximately 13 mm ( in.) greater than the tube OD (including extended surface, if any) shall be welded to the tubesheet at each tube hole to prevent the refractory from being damaged by the tubes. 4.7.6 Intermediate radiant tube supports and guides shall be designed to permit replacement of the supports and guides without tube removal and with minimum refractory replacement. Intermediate tube supports for horizontal radiant tubes shall be the hook type. A maximum of two tubes shall be carried on one support. 4.7.7 Intermediate convection tube supports shall be sectioned, and a maximum of five horizontal rows of tubes shall be supported on each section. 4.7.8 Intermediate tube supports shall be designed for dead load, plus reactions from uneven expansion of the tubes. Frictional loads caused by tubes sliding on supports shall be based on a friction coefficient of 0.30 minimum. Each support shall be designed to carry the load corresponding to 1.5 times the unsupported tube spans. 4.7.9 The design stress for all intermediate tube supports shall be 50 percent of the stress for a rate of one percent creep in 10,000 hours at the design temperature. The shear and bearing stress shall be 80 percent and 160 percent, respectively, of this allowable stress. 4.7.10 All parts of radiant and convection intermediate tube supports for design temperatures from 425C to 1040C (800F to 1900 F) shall be cast 25Cr-20Ni alloy steel, ASTM A297, Grade HK. For design temperatures below 425C (800F), carbon steel is acceptable. 4.7.11 When the fuel contains more than 100 ppm total vanadium and sodium and the tube support design temperature exceeds 650C (1200F), it is preferred that all tubes be supported externally. When tubes are supported internally, the supports shall be covered with 50 mm (2 in.) of dense castable refractory, with a minimum density of 2080 kg/m (130 lb/ft ). The castable refractory shall be supported by Type 310 stainless steel anchors. 4.8 Setting
4.8.1 The design temperature of the outside casing surface, including breechings and hot flue gas and air ducts, shall not exceed 77C (170 F) at an ambient still air temperature of 27C (80F).

4.8.2 The refractory used shall be suitable for a service temperature at least 280C (500F) above its hot-surface design temperature. 4.8.3 The refractory of walls, arches, and floors shall be designed to allow for proper expansion of all parts under design conditions. All types of construction shall be designed to hold setting layers tightly together with no voids. Expansion joints in insulation and refractory shall be staggered to ensure tightness. 4.8.4 Burner tiles shall be in accordance with the burner manufacturer's recommendations. Burner tiles shall be prefired at a minimum of 260C (500F) and contain a minimum of 60 percent alumina (A1203). Burner tiles shall be reinforced with Type 310SS fibers (4 percent by weight, minimum). Burner primary air tiles of double-block design for oil and combination burners shall have a minimum of 85 percent alumina content. The minimum service temperature rating of all burner tiles shall be 1540C (2800F). 4.8.5 The floor shall be of dual-layer castable construction. The hot face shall be 75 mm (3 in.) of dense castable with a minimum service temperature of 1540C (2800F) and a minimum density of 2010 kg/m (125 lb/ft). The bottom layer shall consist of 250 mm (10 in.). Lumnite-Haydite-Vermiculite castable refractory (1:2:4 mix of dry, loose volume) or other approved insulation. 4.8.6 Radiant section, self-supporting divider walls shall have a height equal to or greater than 80 percent of the radiant section height but shall not exceed 7 m (24 ft). The walls shall be at least first quality firebrick. The base width shall be a minimum of 8 percent of wall height. The height-to-width ratio of each section of step wall shall not exceed 5 to 1. 4.8.7 Castable construction shall be as follows: (a) Where possible, castable material shall be applied by gunning. Low lime content (maximum 15 percent by weight), bagged premixed castable shall be used. The minimum service temperature shall be 1093C (2000 F). (b) For dual-layer castable construction, the hot face layer shall be a minimum of 75 mm (3 in.) thick. The anchoring system shall provide support for each layer. (c) Insulation anchor height shall not be less than 70 percent of the castable thickness. The anchor penetration shall not exceed 13 mm ( in.) from the hot face. (d) The anchor spacing shall be a maximum of twice the lining thickness but shall not exceed 305 mm (12 in.) on a square pattern for walls and 230 mm (9 in.) on a square pattern for arches. The anchor orientation shall be varied to avoid shear planes. (e) Anchor material shall be Type 304 stainless steel for walls and Type 309 stainless steels for arches. (f) All inside surfaces of steel casing, including anchor-to-casing welds, shall be protected with a minimum of 300 m (12 mil) dry film thickness (DTF) of coal tar epoxy. 4.8.8 (a) Ceramic fiber modules construction shall be as follows: Ceramic fiber modules or blankets shall not be used in convection sections.
(b) The radiant section walls and arch shall be insulated with ceramic fiber modules as shown in Table 5.

EGE 11-B-1 1989
(c) The modules shall be installed in soldier courses with compressed batten strips between courses. (d) Each 305 mm x 305 mm (12 in. x 12 in.) module shall consist of fourteen 25 mm (1 in.) thick layers of folded ceramic fiber blankets. Each 305 mm x 610 mm (12 in. x 24 in.) module shall consist of twenty-eight 25 mm (1 in.) thick layers of folded ceramic fiber blankets. Ceramic fiber blankets shall be of needled type and of 128 kg/m (8 lb/ft) density. When installed, these modules shall be under compression. (e) The batten strips shall be made from a minimum of two 25 mm (1 in.) thick layers of 128 kg/m (8 lb/ft ) density blanket, and shall have shiplap joints between adjacent lengths. When installed between modules, the batten strips shall be compressed to half their nominal thickness.
TABLE 5 CERAMIC FIBER MODULES FOR RADIANT SECTION INSULATION Blanket Rating Min. Temperature Rating C 1430 F 2600
Module Dimensions Type of Service Hydrogen steam reformer and pyrolysis (ethylene) heater Other heaters Walls unprotected by tubes Walls protected by tubes 200 mm x 305 mm x 610 mm (8 in. X 12 in. x 24 in.) 150 mm x 305 mm x 610 mm (6 in. x 12 in. x 24 in.) Min. Thick. Max. Width Max. Length
305 mm x 305 mm x 305 mm (12 in. x 12 in. x 12 in.)
1260 1260
2300 2300
(f) A positive anchor system shall be used to hold the modules to the steel casing. Anchors shall be prepositioned on the casing before the modules are installed. The anchor system, including the method of attachment to the heater casing, shall be subject to Mobil approval. (g) Anchors shall be type 304 stainless steel or higher alloy.
(h) The method used to attach the anchors to the casing must be tested prior to the start of fabrication, and periodically during the course of fabrication to assure that a sound attachment is being obtained. The testing procedure shall be submitted to Mobil for approval. (I) After installation of the module has been completed, the entire surface shall be tamped with a wood block to assure the lining is free of any voids. (j) All inside surfaces of the steel casing, including anchor-to-casing welds, shall be protected with a minimum of 3 mm (1/8 in.) wet film of Bitumastic barrier coating. (k) When the fuel contains more than one percent by weight sulfur in fuel oil or 50 ppm by volume hydrogen sulfide in fuel gas, ceramic fiber modules shall be backed by one layer of 25 mm (1 in.) thick, 128 kg/m (8 lb/ft) ceramic fiber blanket covered by a stainless steel vapor barrier. The thickness of module may then be reduced by 25 mm (1 in.). The temperature between

module and blanket layer shall be at least 28C (50F) above the acid dew point at design conditions. If 25 mm (1 in.) thick blanket is not sufficient, then vendor shall increase this thickness and submit an alternate detailed design to Mobil for approval. The foil shall be impaled over the studs, and edges shall be overlapped approximately 200 mm to 300 mm (8 in. to 12 in.). The stud punctures in the foil shall be sealed with ceramic fiber cement. 4.8.9 Ceramic fiber blanket construction shall be as follows:
The vendor may offer ceramic fiber blanket insulation as an alternate (if economical) instead of modules, and shall describe in detail the proposed construction in his proposal for Mobil approval. The wall construction shall be in accordance with the following: (a) Ceramic blankets shall be of the needled fiber type.
(b) For all radiant walls unprotected by tubes and for all arches, use the following as a minimum: 20 mm (8 in.) of 128 kg/m (8 lb/ft) density with 1260 C (2300F) rating. Hot face shall consist of two layers, each 25 mm (1 in.) thick. (c) For all radiant walls protected by tubes, use the following as a minimum: 150 mm (6 in.) of 128 kg/m (8 lb/ft) density with 1200 C (2300F) rating. Hot face shall consist of two layers, each 25 mm (1 in.) thick. (d) A layer of stainless steel foil shall be installed as a vapor barrier between ceramic fiber layers where temperature is at least 28C (50 F) above the acid dew point at design conditions and below the allowable metal temperature of the foil. The foil shall be impaled over the studs, and edges shall be overlapped approximately 200 mm to 300 mm (8 in. to 12 in.). The stud punctures in the foil shall be sealed with ceramic fiber cement. (e) Anchor spacing shall be as follows:
Vertical Walls Maximum Spacing Transverse to blanket length Along blanket length mm 230 305 in. 9 12 Arch mm 150 230 in. 6 9
In addition, for the hot face layer of both vertical walls and arch, no more than 75 mm (3 in.) of blanket shall be outside a line of anchors when the blanket is installed and no more than 70 mm (2 3/4 in.) after blanket butt joints have been compressed. (f) Anchors shall have either metal washers covered by a ceramic fiber blanket [25 mm (1 in.) thick, of 128 kg/m (8 lb/ft) density with 1260C (2300F) rating] or ceramic cuplocks filled with mastic. (g) Anchor material shall be Type 310 stainless steel (25Cr-20Ni).
(h) Ceramic fiber blankets are to be installed with butt joints for the backing layers and compressed joints for the hot face layer. All joints in successive layers shall be staggered to avoid a direct heat path to the casing.

EGE 11-B-1 1989
(I) All inside surfaces of the steel casing, including anchor-to-casing welds, shall be protected with a minimum of 3 mm (1/8 in.) Wet film of Bitumastic barrier coating. 4.8.10 Handling practices for all refractory materials such as castable, brick, ceramic fiber, and the like shall be in accordance with manufacturers health and safety guidelines. 4.9 Structure and Appurtenances
4.9.1 Structural steel frame, platforms, and ladders shall be designed in accordance with EGE 00-B-3 and EGE 31-B-1. Structural steel shapes shall conform to ASTM A36. Structural steel plates shall conform to ASTM A283 Grade C, A285 Grade C, or A36. 4.9.2 Heater casing shall be reinforced against warpage and deflection. Casing plate thickness shall be 4.5 mm (3/16 in.), minimum. Floorplate thickness shall be 6 mm ( in.), minimum. 4.9.3 The entire heater casing, including joints between shop fabricated sections, shall be continuously seal welded to prevent air and water infiltration. 4.9.4 All arches shall be covered with steel casing and shall be designed to permit runoff of rainwater. All structural steel members shall be designed to be self-draining. Joints between steel beam and heater casing, which may accumulate water, shall be continuously seal welded. 4.9.5 Vertical clearance below heater floor members shall be 460 mm (18 in.) For wall fired heaters. Vertical clearance below burner bottom plate shall be 2 m (7 ft) for floor fired heaters. The height and location of burner piping, as well as burner air plenums, shall be selected to provide the maximum number of unobstructed emergency exit routes from beneath the heater, while at the same time permitting burner maintenance and air register adjustment from grade level without the use of temporary platforming. 4.9.6 If heater foundations are not provided by the heater vendor, the vendor shall furnish design loadings, location of anchor bolts, size of columns, and other data for complete foundation design. 4.9.7 The design of main structural columns shall allow for fireproofing. Fireproofing shall be designed in accordance with EGE 34-B-15. 4.9.8 Temporary end plates attached to shop fabricated modules (such as may be used to retain castable refractories during the shipment of a module) shall be removed before field installation of the modules. Under no circumstances shall uninsulated carbon steel plate be exposed to the flue gas. 4.9.9 (a) Platforms shall be provided by the heater vendor as follows:
For Box and Cabin Heaters:

(1) (2) At hearth level on each end. At second level observation doors on each end.
(3) At hearth level on the side where the burner controls are located for bottom fired heaters, and at connecting platforms between end and burner control platforms. (4) At both ends of the convection section. A connecting walkway along one sidewall also is required. (5) At damper and sootblower locations.

(6) At all access doors, observation ports, doors and instrument connections, and valves. Intermediate stepoff platforms are acceptable. (7) At auxiliary equipment, such as fans, drivers, oilers, and air preheaters for operation and maintenance. (b)
For Vertical Cylindrical Heaters:

(1) At hearth level. A full circular platform is required.
(2) At roof level. A full peripheral platform providing access to both ends of the convection section is required. (3) At damper and sootblower locations.
(4) At all observation doors and ports, instrument connections, and valves. Intermediate stepoff platforms are acceptable. (5) At auxiliary equipment, such as fans, drivers, oilers, and air preheaters for operation and maintenance. 4.9.10 (a) Platforms, stairways, and ladders shall be in accordance with the following: All permanent platforms shall have a minimum width of one meter (3 ft).
(b) Sufficient clearance shall be provided between burner control platform and heater casing for fuel piping installation. (c) Maintenance platforms, including those for sootblowers, wall burners, and decoking connections, and at header box locations, shall have a minimum width of 1.2 m (4 ft). (d) Stairways and connecting walkways shall have a minimum width of 760 mm (2 ft). Stairways shall have a minimum tread width of 240 mm (9 in.), and a maximum riser of 200 mm (8 in.). The slope of the stairway shall not exceed a 9 (vertical) to 12 (horizontal) ratio. The stairway landing (in direction of stairway) shall have a minimum width of one meter (3 ft). (e) Headroom over platforms, walkways, and stairways shall be 2 m (7 ft), minimum.
(f) All burner control platforms shall have two exits, with a stairway at one end and a ladder at the other end. All other heater platforms shall have a minimum of two escape ladders. These ladders shall extend from the top platform to grade, with access to all intermediate platforms, and shall be located at opposite ends of the platforms. (g) Solid flooring (diamond plate or equal) shall only be furnished on hearth level platforms for heaters with hydrocarbon flow in liquid or two phase. All other platforms shall be 25 mm by 4.8 mm (1 in. by 3/16 in.) open grating. Platform structural supporting members shall be located so as not to interfere with pulling tubes. Handrails shall be provided on all platforms, walkways, and stairways. (h) An intermediate landing shall be provided when the vertical rise exceeds 7.5 m (25 ft) for ladders and 4.6 m (15 ft) for stairways.

EGE 11-B-1 1989
(I) Ladders shall be caged from a point 2.3 m (7 ft) above grade. A safety gate shall be provided for all ladders serving platforms or landings. 4.9.11 Header boxes shall be in accordance with the following:
(a) Header box plates shall be 4.5 mm (3/16 in.) thick. When plug type headers are used, header box plates shall be insulated with 50 mm (2 in.) of Lumnite-Haydite-Vermiculite castable refractory or other approved insulation, held in place by nongalvanized carbon steel chain link fencing or wire mesh anchored to the steel. When welded return bends are used, header box plates shall be insulated with 50 mm (2 in.) of 128 kg/m (8 lb/ft ) density ceramic fiber blanket with 1100C (2000F) rating. (b) A minimum clearance of 75 mm (3 in.) shall be allowed between the header box face plate refractory and the header in the hot position. (c) Header boxes or doors shall be bolted and gasketed to prevent air and water infiltration. A separate panel shall be provided for any future rows. 4.10 Burners 4.10.1 Lo-Nox burners shall be provided. Burners shall be designed for natural draft and capable of burning all fuels specified in the project specifications. When air preheaters are provided, forced draft burners shall be used. Burners shall be designed for 70 percent of heat absorbed duty when the air preheaters are out of service unless otherwise specified. Burner designs shall have been commercially proven in comparable service. Special burner designs shall be subject to Mobil approval. 4.10.2 Burners shall be sized for a maximum heat release equal to 125 percent of the required normal liberation at design excess air. Minimum burner turndown ratio shall be 3 to 1. A minimum of three burners shall be supplied for each heater to provide operating flexibility. When only three burners are supplied, each burner shall be capable of 50 percent of the total design heat release. The vendor shall provide fuel pressure vs heat release and draft (air pressure) vs heat release curves. The burner manufacturer shall also provide minimum gas pressure regulation and trip points. 4.10.3 Burner design and installation shall ensure against flame impingement on tubes, tube supports, and refractory when burners are operating at their maximum heat release. 4.10.4 Burners, gas rings, air diffusers, or tips and oil guns shall be removable for maintenance while a heater is in operation. When multiple tips are used, individual tips shall be removable for cleaning without the removal of gas rings or other tips. 4.10.5 When forced draft combustion is used, burners with individual windboxes shall be used. Dampers used in lieu of air register shall be multiple louver, opposed blade type and shall be seal tight. 4.10.6 An individual gas pilot shall be provided for each burner for easy lightoff because burners are provided with a plenum for noise and/or air preheater application. The pilot gas valve shall be a ball valve with an operating lever so arranged as to indicate open or closed position at a glance. This valve shall be located at the burner to allow the operator to view the pilot flame during lightoff. Pilot and fuel gas lightoff safety controls shall conform to EGS 629. 4.10.7 Floor fired heaters shall have manually operated individual burner fuel valves located so that lightoff and fuel adjustments can be made with a full view of the burner from the hearth level platforms without entering the area beneath the heater.

4.10.8 The burner bottom plate shall have one 90 mm (3 in.) diameter ignition port and one 90 mm (3 in.) diameter observation port. For a bottom mounted oil fired burner, the observation port shall have a pipe sleeve extending 50 mm (2 in.) into the burner. 4.10.9 When volatile fuels such as naphtha or gasolines are burned, a safety interlock shall be provided on each burner. The interlock design must, in sequence, shut the fuel off, purge the oil gun, and shut the purge medium off before the gun can be removed. 4.10.10 Special waste gas burners or additional waste gas tips installed in regular burners may be used for disposal of a waste gas stream in a heater. For good heater control, the heat liberation of the waste gas stream shall be limited to 10 percent of the total heat liberation. In a regular burner, the waste gas heat shall not exceed 20 percent of total heat release of that burner. The waste gas burners shall be located so as to maintain uniform heat distribution in the firebox and to avoid flame impingement on tubes and supports. 4.10.11 When block insulation, fiberglass, or mineral wool is used as an internal lining for burner noise plenums, it shall be suitably anchored by studs and have exposed face protected from shredding by galvanized steel wire mesh or expanded metal. 4.10.12 4.10.13 For oil fired heaters, burner plenums shall be designed to permit drainage of any oil accumulation. Minimum clearances required for natural draft burners are as follows:
(a) For vertical gas fired box and cylindrical heaters, the minimum clearances shown in Table 6 shall be provided. (b) For end wall fired box and horizontal cylindrical heaters with gas burner sizes up to 1.17 MW (4 MM Btu/h) maximum liberation, the minimum distance from burner centerline to hot face of radiant tubes shall be 1.2 m (4 ft). Add 150 mm (6 in.) For each additional 0.59 MW (2 MM Btu/h) heat release for larger burners. (c) The spacing of burners shall provide for uniform heat distribution to all radiant tubes. Final burner arrangement shall be submitted to Mobil for approval. (d) For oil firing (unless oil is used only for startup), the clearances given in Items (a) and (b) shall be increased by 305 mm (12 in.). (e) Burner clearances for forced draft and high intensity burners shall be subject to Mobil approval.
4.10.14 As a minimum, all gas burner tips, air diffusers, and oil gun tips shall be made of austenitic stainless steel material. 4.10.15 The joint between the burner baseplate and the casing of plenum to which it is bolted must be gasketed to prevent air leakage. 4.10.16 All burner and pilot tips shall be wrapped to keep them clean during shipment.
4.11 Dampers 4.11.1 Single-blade dampers shall be limited to stacks and ducts having a maximum internal cross-sectional area of 1.2 m (13 ft). Multiblade dampers shall have a minimum of one blade for every 1.2 m (13 ft) of internal cross-sectional area in the stack or duct. Each blade shall have approximately equal surface area.

EGE 11-B-1 1989
4.11.2 Adequate clearance shall be provided between damper blades and inside surfaces of stacks and ducts for damper thermal expansion. However, this clearance shall also be designed to minimize flue gas or air bypassing. When dampers are used to isolate flue gas or air flow in air preheater systems, positive shutoff design shall be used. Damper design shall be approved by Mobil. 4.11.3 Dampers shall be provided at air plenum inlets for overall excess air adjustment. Multiple louver type dampers shall be used in air ducts for air control. The air intake damper, which is used as air register control, shall also be the multiple louver type. All multiple louver type dampers in flue gas or combustion air service shall be of the opposed action type. 4.11.4 All flue gas and combustion air damper shaft bearings shall be the self-aligning, heavy-duty externally mounted pillow-block type with sealed permanent lubrication. 4.11.5 Stack dampers shall be operable from grade, and a position indicator shall be supplied at grade and at the damper location. The damper shaft shall be marked externally to show the position of the damper. Dampers shall be designed so that they will not close in the event of cable or linkage failure. Provision shall also be made to permit the dampers to be locked in any set position.
TABLE 6 MINIMUM CLEARANCES FOR VERTICAL GAS FIRED BOX AND CYLINDRICAL HEATERS Burner Size Maximum Liberation MW 0.59 1.17 1.76 2.34 2.93 3.51 MM Btu/h 2 4 6 8 10 12 From Floor to Hot Face of Roof Tubes or Refractory m 1.83 3.05 4.27 6.10 7.32 8.53 ft 6 10 14 20 24 28 From Burner Centerline to Hot Face of Wall Tubes m 0.91 1.07 1.22 1.37 1.52 1.68 ft 3.0 3.5 4.0 4.5 5.0 5.5
4.11.6 Pneumatically operated stack dampers shall be provided for heaters with 5.9 MW (20 MM Btu/h) or higher heat duty or for heaters with a common stack regardless of heater size. For all other heaters provision shall be made for future installation of the pneumatic operator when not provided initially. 4.11.7 Pneumatic operators shall be located at damper platforms near the dampers. Pneumatic operator control mechanisms shall be located at grade level near the damper indicators for ease of operation. Pneumatic operator emergency actuating mechanisms shall be installed in a fire safe location at the purge steam panel or purge valves, at least 15 m (50 ft) from any heater. 4.11.8 The design for pneumatic operators shall permit manual cable-and-winch operation from grade without the need to disconnect the linkage at the stack. The pneumatic operators shall be designed to hold the damper at the last set position on loss of air. In no case shall pneumatic operators close on loss of air or failure of linkage. 4.11.9 When common stacks are used, guillotine type dampers or other approved means shall be provided to isolate individual heaters. These dampers shall be accessible for maintenance from a permanent platform.

4.11.10 Stack damper shafts shall be Type 304 stainless steel or higher alloy and shall be a minimum of Schedule 80 pipe with both ends open. Damper blades shall be 5Cr-Mo or higher alloy. When flue gas temperature exceeds 650C (1200F), damper blades shall be Type 304 stainless steel or higher alloy. 4.11.11 All damper cables shall be Type 304 stainless steel wire rope of 3 mm (1/8 in.) minimum diameter, with galvanized hardware (such as thimbles, turnbuckles, and clamps). 4.11.12 A positive tight shutoff damper for forced draft hot air combustion shall be provided in each individual burner duct to permit the safe removal of burner tips while the heater is in operation. 4.12 Sootblowers and Related Requirements 4.12.1 Heaters with convection sections shall be furnished with cleaning lanes for convection tube cleaning. 4.12.2 When a heater is designed for residual fuel oil firing, horizontal automatically retractable sootblowers with selected sequential operation shall be provided. For mechanical details of sootblowers and for sootblower controls refer to EGE 11-B-20. The sootblowers shall have electric motor drivers. The control panel shall be located at grade level for easy operation. Individual pushbutton control also shall be furnished at each sootblower. 4.12.3 When sootblowers are not installed, 100 mm (4 in.) diameter couplings with caps shall be provided in the cleaning lanes. 4.12.4 Maximum radial coverage of a sootblower or manual cleaning shall be 1.1 m (3 ft) or four rows, whichever is less, for both bare and extended surface tubes. 4.12.5 Sootblowers shall be positioned midway between adjacent tube supports. No credit shall be taken for cleaning beyond the tube supports. 4.12.6 To prevent tube erosion, the minimum clearance between sootblower pipe OD and OD of bare tube or tip of extended surface shall be 150 mm (6 in.). 4.12.7 Individual sootblowers shall be designed to pass a minimum of 1.26 kg/s (10,000 lb/h) of steam with a minimum steam pressure of 1035 kPa gage (150 psig) at the inlet flange. High-pressure steam above 4100 kPa gage (600 psig) shall not be used. 4.12.8 Sootblowers shall have a maximum of two nozzles each.
4.12.9 When a heater is designed for sootblowing, the entire height of the convection section sidewalls shall be provided with erosion protection. This shall consist of 75 mm (3 in.) dense castable refractory as a hot face layer, with a minimum density of 2010 kg/m (125 lb/ft). 4.12.10 Sootblower lance material shall be 1 chrome-molybdenum material or higher alloy. Sootblower entrance ports through the refractory wall shall be protected with 3 mm (1/8 in.) Type 304 stainless steel sleeves. 4.12.11 Sootblower shall have lubrication points accessible from a platform or, if capable of being greased, have stainless steel tubing installed to a platform. All remote greasing stations will require purge fittings.

EGE 11-B-1 1989
4.13
Setting Doors and Ports
4.13.1 Observation doors shall be constructed of insulated cast iron, with metal frame on casing, and shall be provided with a cool handle. The observation door shall be hinged on the bottom with a locking device at the top. 4.13.2 A minimum of two access doors shall be furnished for each radiant chamber of a box or cabin heater. At least one door shall have an opening approximately 610 mm x 1070 mm (24 in. x 42 in.). All doors shall be accessible from platforms or grade. 4.13.3 Two explosion doors, approximately 380 mm x 460 mm (15 in. x 18 in.), shall be furnished to relieve each combustion chamber of a multicell heater with a common convection section having tubes oriented parallel to the radiant tubes. The explosion doors shall be located so as to direct gases away from operating platforms, occupied areas, and critical equipment. 4.13.4 One access door, 460 mm x 460 mm (18 in. x 18 in.) minimum size, shall be provided in the floor of vertical cylindrical heaters. One tube removal door, 460 mm x 610 mm (18 in. x 24 in.), shall be provided in the arch of vertical tube heaters for radiant tube replacement. 4.13.5 One access door, 460 mm x 300 mm (18 in. x 24 in.), shall be provided in each bay between tube supports of each sootblower lane in the convection section. 4.13.6 Observation doors, approximately 125 mm x 230 mm (5 in. x 9 in.), shall be provided to view all radiant tubes, radiant tube supports, the bottom row of shield tubes, and all burner flames for proper operation and lightoff. The observation doors shall be usable from operating platforms or grade. 4.13.7 When roof or shield tubes, or both, cannot be seen from wall observation doors, a sufficient number of ports shall be provided on the floor to view these tubes. 4.13.8 At least one access door, 610 mm x 610 mm (24 in. x 24 in.), shall be provided in the stack or breeching for access to damper and convection sections. 4.13.9 Sufficient inspections doors, approximately 150 mm x 610 mm (6 in. x 24 in.), shall be provided in the convection sidewall to permit visual inspection of representative samples of all tubes and supports. 4.13.10 All openings in the heater casing, such as access door, explosion doors, and terminal connections, shall be designed to prevent air and water infiltration. 4.13.11 All access and inspection doors shall be gasketed and bolted.
4.14 Breechings and Ducts 4.14.1 Breechings and ducts shall be a minimum of 4.5 mm (3/16 in.) thick carbon steel plate, adequately stiffened, and with provision for thermal expansion. Carbon steel plates for breechings and ducts shall conform to ASTM A36. 4.14.2 Breechings shall be sloped upward a minimum of 15 degrees from the ends toward the stack or flue gas takeoff. 4.14.3 As a minimum, breeching shall be internally insulated with 50 mm (2 in.) of acidproof, premixed castable refractory, held in place by chain link fencing or wire mesh anchored to the steel. For flue gas temperatures up to 425 C (800F), nongalvanized carbon steel reinforcement for the refractory is acceptable; above 425C (800F), Type 304 stainless steel is required. All inside surfaces of steel casing

shall be protected with a minimum of 300 m (12 mil) dry film thickness (DFT) of coal tar epoxy such as Valspar 64-J-5 or equivalent. 4.15 Stacks 4.15.1 Stacks shall be designed in accordance with EGE 11-B-50.
4.15.2 One stack or one flue gas takeoff shall be provided for each 9 m (30 ft) of exposed convection section length. 4.15.3 The design shall provide a negative pressure not less than 2.5 mm (0.10 in.) of water at any point in the heater under all operating conditions, including a 30 percent overload with design excess air at 25C (80 F) atmospheric still air. 4.15.4 Minimum stack height shall be 3 m (10 ft) above the highest operating platform within a 30 m (100 ft) radius of the stack for personnel protection, or as indicated in the project specifications to meet air pollution control requirements. 4.16 Instrument and Utility Connections 4.16.1 Heater controls and instrumentation shall be in accordance with EGE 32-B-15.
4.16.2 All connections through the refractory walls shall be provided with Type 304 stainless steel sleeves flush with the inside surface of the refractory. Connections shall self-drain into the heater. 4.16.3 (a) (b) Draft gage connections shall be furnished and located as follows: At opposite ends of each radiant chamber at burner level. At the arch of each cell of the radiant section in multicell heaters.
(c) At the convection section entrance. One connection shall be provided for each 9 m (30 ft) of convection section length. (d) (e) (f) In the stack above and below the damper. In the inlet and outlet ducts connected with forced and induced draft fans. In the inlet and outlet flue gas and combustion air ducts of the air preheater.
(g) In the burner windbox or plenum combustion air inlet, downstream of any combustion air control damper. Draft gage connections shall be NPS 1, Class 3000, threaded steel couplings. Draft lines shall be Type 304 stainless steel pipe and tubing, minimum NPS . When common draft gage are used, draft lines shall be piped to grade level. There shall be no interconnections between individual draft lines. 4.16.4 Flanged, NPS 1 thermowell connections shall be provided for each service at the coil outlet and crossovers between radiant and convection sections of each parallel pass. If steam injection is used, thermowells shall be located upstream of each steam injection point. Where plug type headers are provided, thermowells shall be located in the plugs of the headers.

EGE 11-B-1 1989
4.16.5 (a)
Flue gas and combustion air thermowell connections shall be furnished and located as follows: At the arch of each cell of the radiant section in multicell heater.
(b) At the convection section entrance 610 mm (24 in.) below the bottom shield tubes. One connection shall be provided for each 9 m (30 ft) of convection section length. (c) (d) (e) Between the convection section coils for each service. In each stack or flue gas takeoff below the damper. In the inlet and outlet air and flue gas ducts of the air preheater.
Thermowell connections shall be NPS 1, Class 3000, threaded steel couplings. 4.16.6 Flanged (ASME B16.5, Class 150) flue gas sampling tube connections shall be furnished and located as follows: (a) One NPS 4 connection at the arch of each cell of the radiant section in multicell heaters.
(b) One NPS 4 connection and one NPS 2 connection shall be provided for each 9 m (30 ft) of convection section length at the convection section entrance. (c) Two NPS 4 connections, 180 degrees apart, in each stack above the damper for smoke density measurement. (d) One NPS 4 connection and one NPS 2 connection in each stack or flue gas takeoff below the damper. A sampling tube shall be extended 460 mm (18 in.) into the firebox or stack. It shall be a removable probe of NPS , 25Cr-20Ni, Type 310 stainless steel pipe or equivalent. 4.16.7 At least two NPS 2, Class 3000, threaded steel coupling purge steam connections shall be provided near the floor at opposite sides of each radiant chamber. The connections shall be sufficient to provide a total of 0.009 kg/s (2 lb/h) of steam per cubic meter (cubic foot) of firebox volume. These connections shall be located and oriented such that the steam will not impinge on any tubes or refractories. 4.16.8 Capped NPS 4 drains shall be provided in the floors of heaters.
4.16.9 One NPS 1, Class 3000, threaded steel coupling purging steam connection and one NPS 2, Class 3000, threaded steel coupling drain shall be provided for each header box. These connections shall be permanently connected to a steam supply when plug heaters are used. 4.16.10 Two NPS 2, Class 3000, threaded steel coupling purge steam connections shall be provided at opposite ends of each common burner plenum in an air preheater system and for all oil fired, natural draft plenum designs. 4.16.11 Two tube skin thermocouples per pass shall be provided for heaters in coking service with a fouling factor $0.0007 m@C/W (0.004 h@ft@F/Btu). Type of thermocouple and proposed locations shall be submitted for Mobil approval.
MOBIL ENGINEERING GUIDE EGE 11-B-1 1989 5. AIR PREHEATER SYSTEM 5.1 Air Preheater
5.1.1 Air preheater selection and design shall conform to the requirements of API RP 533 and this Guide. In case of conflict between this Guide and API RP 533, this Guide shall take precedence. 5.1.2 Combustion air preheaters shall be the recuperative type or other type approved by Mobil such as regenerative type, plate type, heat pipe, indirect closed loop heat transfer medium type, external heat source type, and steam/boiler feedwater type. Selected air preheater type shall be subject to Mobil approval. Figure 1 shows a typical recuperative air preheater system for process heaters. 5.1.3 Maximum flue gas temperature at design heat absorbed duty entering an air preheater shall be 430C (805F). 5.1.4 When air preheaters are provided, the heaters shall be designed to operate at 70 percent of heat absorbed duty when the air preheaters are out of service.
FIGURE 1 TYPICAL AIR PREHEATER SYSTEM FOR PROCESS HEATER
5.1.5 5.1.6
The air preheater shall be prefabricated to minimize field assembly. When a recuperating type air preheater is provided, the design shall meet the following conditions:

EGE 11-B-1 1989
(a)
The recuperative type of an air preheater shall be Deka type or approved equal.
(b) Details of the proposed type of preheater shall be submitted in the vendors quotation. This shall include information such as number of air passes, type of tubes (cast iron tubes with integral fins on both sides, cast iron tubes with fins on outside only, glass tubes), cleaning facilities, testing procedures, etc. (c) The flue gas temperature leaving the air preheater during design case operation shall be as low as possible to achieve maximum efficiency. However, the flue gas dew point (including turndown conditions) must be considered when establishing this temperature. The vendor shall state in his proposal minimum allowable and minimum calculated tube metal temperatures for the specified fuels and average winter ambient air temperature. (d) The air preheater shall have provision for water washing (unless it is mounted directly above the heater convection section). These provisions shall include as a minimum the following: (1) (2) (3) Fixed spray pipes and nozzles for the cold end section. An access door above the top of air preheater. Platforms and ladders to provide access to water wash connections and access doors.
(4) A blinded NPS 4 drain connection in the bottom of the flue gas transition duct below the air preheater. Sufficient clearance shall be provided beneath this connection to permit the attachment of temporary drain piping. (5) The vendor shall quote water quantities and water temperature (if hot water is used for onstream cleaning of the glass tube section). (e) When an air preheater with glass tubes is used, the design and layout shall be subject to Mobil approval. (f) Asbestos is not permitted in gaskets.
(g) All cast tube assemblies shall be pressure tested for leakage prior to assembly of modules. The vendor shall submit the test report for Mobil approval. 5.1.7 All pipe and pipe fittings associated with air preheaters shall be of steel construction in accordance with EGE 16-B-30 and EGE 16-B-40. 5.1.8 The vendor shall furnish the following air preheater performance data for heater design conditions and any other operating condition indicated in EGE 11-D-1:
Air preheater duty Air flowrate in Air flowrate out Flue gas flowrate in Flue gas flowrate out Air temperature in Air temperature out MW (MM Btu/h) kg/s (lb/h) kg/s (lb/h) kg/s (lb/h) kg/s (lb/h) C (F) C (F)

Flue gas temperature in Flue gas temperature out Air side pressure drop Flue gas pressure drop
C (F) C (F) mm H2O (in. H2O) mm H2O (in. H2O)
5.2
Fans and Motors
5.2.1 Fans and drivers for use with fired heaters shall be designed and built in accordance with EGE 15-B-21. 5.2.2 Fans shall have electric variable speed motor drivers unless otherwise specified in the project specifications. 5.2.3 5.2.4 Electrical auxiliary equipment shall be suitable for installation in a Class 1, Division 2 area. Induction electric motors shall comply with EGE 33-B-9.
5.2.5 Variable inlet guide vanes shall be provided for forced draft fans. Inlet box damper or multiple louver (opposed blade) shall be provided for induced draft fans unless otherwise specified in project specifications. 5.2.6 Fan arrangement shall be AMCA Standard 2404 [Standards Handbook, Publication No. 99, Air Movement and Control Association, Arlington Heights, IL (1986)], Arrangement 3, with the fan wheel located between bearings, the bearings mounted on independently supported pedestals, and the bearings protected from the air or gas stream by means of inlet boxes. Other arrangements are acceptable only with specific Mobil approval. 5.2.7 Performance curves shall have a continuously rising pressure characteristic from the rated point, as specified, to 60 percent or less of the rated flow. 5.2.8 Fan wheels shall have nonoverloading characteristics and shall be of the highest possible efficiency. Hollow airfoil construction may be offered only for forced draft applications. Solid blades with airfoil shape shall be used for induced draft fan applications. The fan wheel shall be of welded construction unless other designs are specifically approved by Mobil. 5.2.9 5.2.10 5.2.11 5.2.12 (a) The rated speed of the fan shall not exceed 1800 rpm. A shop test of fan is required as pre EGE 15-B-21. Couplings and guards shall conform to EGE 15-B-13 unless otherwise specified. Test block (rated point) conditions for selection of a forced draft fan shall be as follows:
Air Flowrate: Qa = 1.2 x W a
Where:
Qa = test block air flowrate, kg/s (lb/h) W a = air flowrate at design heat absorbed duty conditions, kg/s (lb/h)

EGE 11-B-1 1989
(b)
Static Pressure: Pa = 1.44 x P1
Where:
Pa = test block static pressure differential across the fan inlet and outlet flanges, mm H 2 O (in. H2O) P1 = total air resistance from fan to heater, including ducts, dampers, air preheater, and burners at design conditions, mm H2O (in. H2O) (c)
Temperature: Ta = maximum ambient air temperature plus 10C (20F)
5.2.13 Motor drivers for forced draft fans shall be sized for undampered fan performance at minimum ambient temperature and test block conditions. 5.2.14 (a) Test block (rated point) conditions for selection of an induced draft fan shall be as follows:
Flute Gas Rate: Qg = 1.2 x W f
Where:
Qg = test block flue gas flowrate, kg/s (lb/h) W f = flue gas flowrate at design heat absorbed duty conditions, dg/s (lb/h) (b)
Static Pressure: Pg = 1.44 x P2
Where:
Pg = test block static pressure differential across the fan inlet and outlet flanges, mm H2 O (in. H2O) P2 = total pressure loss from heater to fan, including heater, ducts, dampers, and air preheater at design conditions, mm H2O (in. H2O) (c) 5.2.15 (a)
Temperature:
Tg = flue gas temperature leaving air preheater at design conditions plus 55C (100F)
Motor drivers for induced draft fans shall be adequate for the following loads: For 125 percent of normal operating loads at normal operating temperatures.
(b) For cold startup (specified minimum ambient temperature) to normal operating temperature undampered. (c) 5.2.16 grade. For 125 percent test block condition at test block temperature. Mechanical devices shall be provided for hand control of forced and induced draft fan dampers at
5.2.17 Induced draft fan shaft shrouds (for extended seal mounts) shall be used to prevent dew point corrosion. Shaft shrouds shall be attached to the fan housing, surround the fan shaft, and be externally insulated.

5.2.18 Forced draft fans shall be isolated from furnace ducting by a fabric expansion joint. Induced draft fans shall be isolated from inlet/discharge ducting by an expansion joint. 5.3 Ducting
5.3.1 Elevation of the duct inlet to the forced draft fan shall be a minimum of 7.5 m (25 ft) above grade level. To prevent potentially damaging foreign materials from entering the fan, the duct inlet shall be covered with a screen of 38 mm (1 in.) mesh and a rain shield. 5.3.2 Based on the design capacity, the maximum velocity in flue gas ducts and air ducts shall not exceed 14 m/s (45 ft/s) and 9 m/s (30 ft/s), respectively. The maximum velocity in individual hot air feed ducts to individual burners shall not exceed 7.5 m/s (25 ft/s). The design of combustion air ducts shall provide uniform flow distribution to all burners. Combustion air duct arrangement shall be submitted for Mobil approval. 5.3.3 Provision shall be made for expansion between the air preheater and connecting ductwork. Location and design of all expansion joints shall be submitted to Mobil for approval. 5.3.4 Adequate drainage facilities shall be provided in horizontal ducts on both sides of the air preheater.
5.3.5 For heaters designed with natural draft operation as backup, several emergency rapid opening doors should be provided in hot air ducts to achieve uniform flow distribution of cold air to all burners in the event of fan failure. The maximum velocity of cold air through emergency doors should not exceed 3 m/s (10 ft/s) at 70 percent of heater design capacity. The doors may be bottom, side, or end mounted. The doors should be of the gravity opening type and should be designed to open on instrument air failure. A fence should be provided around these doors, and the location should be marked as a restricted area. 5.3.6 Ducts may be insulated internally or externally. As a minimum, ducts for hot flue gas and hot air shall be internally insulated with 75 mm (3 in.) of low lime content (maximum 15 percent by weight) premixed castable. A minimum of two inches of acidproof, premixed castable shall be used in cold flue gas ducts. All inside surfaces of steel casing shall be protected with a minimum of 300 m (12 mil) DFT of coal tar epoxy. The vendor shall specify in the proposal the type and thickness of insulation to be used at each duct location. 5.3.7 At least one access door, 610 mm x 610 mm (24 in. x 24 in.), shall be provided on each flue gas duct to and from the air preheater. 5.3.8 Blanking flanges shall be provided in the ducts to permit isolation of the air preheater, fans, and heater for maintenance. 5.3.9 To minimize corrosion in the air preheater by condensation on the flue gas side under cold weather conditions and at low flowrates, an external cold air bypass duct with positive shutoff damper shall be provided. The cross-sectional area of the cold air bypass shall be sized for a maximum velocity of 15 m/s (50 ft/s) with 100 percent of design air flowrate. Hot air recycling, an internal integrated cold air bypass, or a steam coil at the air inlet may be used in lieu of cold air bypass when approved by Mobil. 6. FABRICATION, ERECTION, INSPECTION, AND TESTING 6.1 The heater, all auxiliary equipment, ladders, stairs, and platforms shall be shop assembled to the maximum extent possible consistent with available shipping, receiving, and handling facilities. Individual sections shall be properly marked, braced, and supported to prevent damage during shipment and to permit field assembly without modification.

EGE 11-B-1 1989
6.2 All blocking and bracing used for shipping purposes shall be clearly identified for field removal. No metal bracing members shall remain inside the refractory after erection. 6.3 Prior to the installation of refractory, all steel internal surfaces shall be mechanically cleaned or commercially sandblasted to remove all dirt, grease, weld splatter, paint, loose scale, or other foreign materials. When an inside casing protective coating is required, the cleaning shall be done immediately prior to the coating application. 6.4 All insulation materials shall be prepared and installed in accordance with the refractory manufacturers recommendations. 6.5 Heater steel framework shall be fabricated and erected in accordance with AISC S326 and AWS D1.1.
6.6 For all pressure parts, welding and inspection shall conform to EGE 00-B-21 and EGE 16-B-40 as applicable. The qualifying welding procedure for all shop and field welds on tube coils, pressure fittings, manifolds, crossovers, and all other pressure parts shall be submitted for Mobil approval before the start of fabrication. 6.7 All pressure castings, including heater headers, crossovers, and manifolds, shall be inspected in accordance with the requirements of EGE 00-B-20. The selection of castings and welds to be radiographed shall be approved by Mobil. 6.8 All tube coils, cast pressure fittings, and cast or fabricated manifolds and crossovers shall be subject to shop inspection or witness test by Mobil. 6.9 All chrome-moly or austenitic welds shall be 100 percent radiographed. When postweld heat treatment is required, radiographic examination shall be performed upon completion of heat treatment. 6.10 All welds in chrome-moly coils and manifolds shall be magnetic particle tested. Magnetic particle test shall be performed after postweld heat treatment. All welds in austenitic stainless steel coils and manifolds shall be tested using dye penetrant. 6.11 Ten percent of all carbon steel welds shall be 100 percent radiographed. 6.12 Shop fabricated coils requiring no field welding shall be hydrostatically tested to 1 times the cold maximum allowable working pressure, or as limited by attached fittings. 6.13 The entire coil shall be given a field hydrostatic test after erection at a pressure equal to 1 times the cold maximum allowable working pressure. If the coils is flanged, the test pressure shall be no greater than 1 times the 40C (100F) rating of the flange. 6.14 Test pressure shall be maintained for a minimum of one hour to determine if there are any leaks. 6.15 Water used for hydrostatic testing shall not be polluted or brackish. The chloride content of hydrotest water shall not exceed 50 ppm. 7. PAINTING 7.1 Exterior steel surfaces of heater casing and stack not exceeding 180C (350F) shall be given a shop prime coat of Valspar 13-F-4 or an equivalent approved by Mobil. Dry film thickness shall be no less than 50 m (2 mil). Surfaces shall be cleaned by commercial blast or shop pickle prior to painting.

7.2 Stack surfaces exceeding 180C (350F) shall be given a shop prime coat of Valspar 13-F-12 or an equivalent approved by Mobil. Dry film thickness shall be no less than 50 m (2 mil). Surfaces shall be cleaned by near-white blast or shop pickle prior to painting. 7.3 All field finish coats shall be furnished in accordance with EGE 35-B-10.
7.4 All platform flooring, supporting steel, handrails, toe plates, stairways, ladders, and cages shall be hot-dip galvanized. Galvanizing shall conform to ASTM A123, A153, and A384, as applicable. 8. DRAWINGS AND DATA Vendor shall furnish drawings and data in accordance with EGE 00-C-4. Specific information shall be furnished as follows: (a) Drawings shall include final certified drawings; foundation layouts or mounting information; a materials list for major components, refractory wall, and arch construction; all coil and manifold weld joint details; shop details; individual subassemblies; fabricated pieces with materials specifications and other applicable data; nozzle locations and allowable loadings; and burner capacity curves. (b) Data shall include final data sheets; manufacturer's data report; partial reports, as defined by the ASME Code, Section 1, for coils in steam service; material test certificates giving chemical and physical properties of all material used in fabrication (each certificate to identify part description or number); stress relieving and pressure test charts; operating and maintenance instructions for heater and auxiliary equipment, including dryout and refractory replacement procedures; and recommended spare parts for the first year of operation, with prices and delivery time indicated for each item. 9. GUARANTEE When the equipment is installed in accordance with the vendor's detail drawings, the vendor shall guarantee that: (a) (b) The heater is free of defective workmanship or materials. The equipment meets all requirements of the specifications included in this Guide.
(c) The equipment will render satisfactory performance under continuous operation at the design conditions outlined on the fired heater data sheets. Satisfactory performance includes operation at the design throughput at the design heat absorption and specified process temperatures at or below the specified pressure drop. (d) (e) The thermal efficiency will not be less than that stated on the data sheet. The sound level will not exceed that stated on the sound level data sheet.
(f) Proposed NOx, CO, unburned hydrocarbons, and particulates concentration in the flue gases will not be exceeded. (g) Heater parts are suitable for operations specified in the "Process Design Conditions" of the fired heater data sheets.

EGE 11-B-1 1989
The guarantee period shall extend one year from the date the heater is placed in service, but shall not exceed 24 months from date of shipment. If the heater does not perform satisfactorily or defects occur during this period, the vendor shall make necessary repairs, alterations, or replacements at no cost to Mobil. If shipment or receipt of the heater or its components or auxiliaries is delayed by the purchaser or by factors outside the control of the vendor or purchaser, extension of the guarantee period shall be subject to negotiation with Mobil. Within 12 months after the heater has been put into operation, Mobil may subject it to a performance test. Test procedure for determining the thermal efficiency of fired process heaters shall be based on API RP 532. Such tests may be witnessed by the vendors representatives. If the heater does not perform in accordance with the specified requirements, the vendor shall take the necessary steps, at his expense, to make the heater meet guaranteed performance.
MOBIL ENGINEERING GUIDE DIRECT FIRED PROCESS HEATER DATA SHEET

SI (METRIC) UNITS
ISSUE 1 2 1. Service 2. Number Required 3. *Total Duty per Heater, MW APPROVED 3 4 Type Absorbed: Process Reference Manufacturer Other ISSUE APPROVED JOB NO. LOCATION ITEM NO. UNIT EGE 11-D-1a 1989 Page 1 of 5
PROCESS DESIGN CONDITIONS

4. *Heater Section 5. *Service 6. *Heat Absorption, MW 7. *Fluid 8. *Flowrate, kg/s 9. 11. 13. 15. 15. 16. 17. 18. Flowrate, m /day Pressure Drop, kPa (Calculated)
2 3
10. *Pressure Drop, kPa (Allowable) 12. *Average Flux Density, W/m (Allowable) Average Flux Density, W/m (Calculated) Maximum Flux Density, W/m Velocity Limitation Maximum Allowable Inside Film Temperature, C Fouling Factor, m CC/W Corrosion or Erosion Characteristics 19. *Temperature, C 20. *Pressure, kPa (Abs) (Gage) 21. *Liquid Flow, kg/s 22. *Vapor Flow, kg/s 23. *Liquid Density, kg/m
3 2 2 2
INLET CONDITIONS:
24. *Vapor Molecular Weight 25. *Liquid Viscosity, mPaCs OUTLET CONDITIONS: 26. *Temperature, C 27. *Pressure, kPa (Abs) (Gage) 28. *Liquid Flow, kg/s 29. *Vapor Flow, kg/s 30. *Liquid Density, kg/m
3
31. *Vapor Molecular Weight 32. *Liquid Viscosity, mPaCs 33. *Distillation Data or Composition Attached REMARKS AND SPECIAL REQUIREMENTS:
COMBUSTION DESIGN CONDITIONS

34. *Type of Fuel 35. *Excess Air, Percent 36. 37. 38. Guaranteed Efficiency, Percent (LHV) Calculated Efficiency, Percent (LHV) Radiation Loss, Percent of Heat Release (LHV)
*Items designated by asterisks are the minimum to be completed and furnished to the manufacturer. All other items shall be completed by the manufacturer.

SI (METRIC) UNITS COMBUSTION DESIGN CONDITIONS Contd
39. 40. 41. 42. 43. Flue Gas Temperature, C, Leaving Radiant Section Flue Gas Temperature, C, Leaving Convection Section Flue Gas Mass Velocity Through Convection Section, kg/m Cs Draft at Bridge Wall, mm H2O Draft at Burner, mm H2O
2
EGE 11-D-1a 1989 Page 2 of 5
44. *Ambient Air Temperature, C 45. *Altitude, m, Above Sea Level 46. 47. Calculated Heat Release, MW (LHV) Volumetric Heat Release, W/m
3
FUEL CHARACTERISTICS
48. *Type of Fuel 49. *Heating Value: HHV 50. 51. *Density, kg/m
3
LHV
52. *H/C Ratio (by Weight) 53. *Temperature at Burner, C 54. *Viscosity: At 55. At C C
56. *Fuel Pressure Available at Burner, kPa (Gage) 57. *Atomizing Steam Pressure, kPa (Gage) 58. *Liquid Fuels: Vanadium/Sodium Content, ppm 59. 60. 62. *Nitrogen Content, Percent by Weight *Sulfur Content, Percent by Weight Composition, Mole Percent
62. *Gas: Molecular Weight
MECHANICAL DESIGN CONDITIONS GENERAL

63. *Plot Limitations 64. *Tube Limitations 65. *Required Drawings 66. *Structural Design Data: Wind Load 67. *List of Applicable Standards or Specifications: Seismic Factor *Stack Limitations Other Limitations
COIL DESIGN
68. *Heater Section 69. *Design Pressure (Elastic/Rupture), kPa (Gage) 70. *Design Fluid Temperature, C 71. *Corrosion Allowance, mm: Tubes 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. Number of Passes Overall Tube Length, m Effective Tube Length, m Bare Tubes: Number Total Exposed Surface, m Extended Surface Tubes: Number Total Exposed Surface, m Tube Center to Furnace Wall, mm Min.
2 2
Fittings Hydrostatic Test Pressure, kPa (Gage)
Tube Spacing, Center to Center, mm (Staggered) (In Line)
83. *Stress Relieve 84. *Weld Inspection Requirements, X-Ray or Other *Items designated by asterisks are the minimum to be completed and furnished to the manufacturer. All other items shall be completed by the manufacturer.

SI (METRIC) UNITS COIL DESIGN Contd
*Heater Section EGE 11-D-1a 1989 Page 3 of 5
TUBES
85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114. 115. 116. 117. 118. 119. Vertical or Horizontal *Tube Material (ASTM Specification and Grade) Outside Diameter, mm Wall Thickness (Minimum) (Average), mm Maximum Tube Wall Temperature, C (Calculated) Inside Film Coefficient, W/m CC (Calculated) Maximum Tube Wall Temperature, C (Design) Design Basis for Tube Wall Thickness Type Fin or Stud Material Fin or Stud Dimensions Fin or Stud Spacing Maximum Fin or Stud Temperature Extension Ratio Manufacturer and Type *Material (ASTM Specification and Grade) Nominal Rating *Location *Welded or Rolled Manufacturer and Type *Material (ASTM Specification and Grade) Nominal Rating or Schedule *Location Manufacturer and Type *Material (ASTM Specification and Grade) Nominal Rating *Location *Welded or Rolled: Flange: Size and Rating Location *Welded or Flanged *Pipe Material (ASTM Specification and Grade) Pipe Size and Wall Thickness Location Flange Rating
2
DESCRIPTION OF EXTENDED SURFACE
PLUG-TYPE HEADERS
RETURN BENDS
TERMINALS
CROSSOVERS
TUBE SUPPORTS ENDS, TOP, BOTTOM:

120. 121. 122. 123. 124. 125. 126. 127. Material Thickness Type and Thickness of Insulation Insulation Reinforcement
INTERMEDIATE:
Material Spacing, m Type and Thickness of Coating
GUIDES: Location
128. Material *Items designated by asterisks are the minimum to be completed and furnished to the manufacturer. All other items shall be completed by the manufacturer.

SI (METRIC) UNITS HEADER BOXES
129. 130. 131. 132. Location Insulation: Material Anchor Material Are Header Box Doors Bolted or Hinged? Material Thickness Thickness EGE 11-D-1a 1989 Page 4 of 5
BURNERS
133. 134. 135. 136. 137. Manufacturer and Type Location Size and Type of Pilots Heat Release per Burner at Design Excess Air and Draft, MW: Normal Maximum Size Number
MINIMUM DISTANCE BURNER CENTERLINE TO TUBE CENTERLINE:

138. Horizontal Vertical
SETTINGS EXPOSED VERTICAL WALLS:

139. 140. 141. 142. 143. 144. Thickness, mm Wall Construction Outside Casing: Thickness, mm Tieback Material Support Material Method of Fastening Tiebacks to Structure Material Outside Temperature, C Hot Face Temperature, C: Design Calculated
SHIELDED VERTICAL WALLS:

145. 146. 147. 148. 149. 150. Thickness, mm Wall Construction Outside Casing: Thickness, mm Tieback Material Support Material Method of Fastening Tiebacks to Structure Material Outside Temperature, C Hot Face Temperature, C: Design Calculated
ARCH:
151. 152. 153. 154. 155. 156. Thickness, mm Arch Construction Outside Casing: Thickness, mm Tieback Material Support Material Method of Fastening Tiebacks to Structure Material Outside Temperature, C Hot Face Temperature, C: Design Calculated
FLOOR:
157. 158. 159. 160. Outside Casing: Thickness, mm Thickness, mm Floor Construction Minimum Floor Elevation Material Outside Temperature, C Hot Face Temperature, C: Design Calculated
CONVECTION SECTION:
161. 162. 163. Thickness, mm Construction Outside Casing: Thickness, mm Material Outside Temperature, C Design Hot Face Temperature, C:

SI (METRIC) UNITS CONVECTION SECTION Contd
164. 165. 166. Tieback Material Support Material Method of Fastening Tiebacks to Structure EGE 11-D-1a 1989 Page 5 of 5
INTERNAL WALL
167. Type Dimensions Material
STACK
168. 169. 170. 171. 172. 173. Number Material Inside Metal Diameter Lining: Material Type of Material or Reinforcement Extent of Lining Self-supporting or Guyed Thickness, mm Height Abovegrade Thickness, mm Location Minimum Thickness, mm Stack Length
DAMPERS
174. 175. 176. Location: Stack or Bottom Air Plenum Material Description of Provision for Operation from Grade Multiple or Single Leaf
HOT DUCTS, BREECHING, FLUES, AND COLLECTORS

177. 178. 179. 180. Material Insulation: Type Type of Anchoring Material Size of Access Door into Breeching ASTM Specification Thickness, mm Size
COLD AIR DUCTS AND PLENUM

181. Material ASTM Specification Size
MISCELLANEOUS
182. 183. 184. 185. 186. 187. 188. 189. Overall Dimensions of Furnace Platforms: Location Width Type of Floor Stairs: Location Ladders: Location Access Doors: Location and Size Observation Doors: Location and Size
MISCELLANEOUS CONNECTIONS (Number and Size)

190. 191. 192. 193. 194. Draft Temperature Header Box Drain Coil Drains Painting and Galvanizing Requirements Flue Gas Sample Smothering Steam Stack Drain Other
195. 196. 197. 198.
Are Painters Trolley and Rail Included? Extent of Tube-Handling Facilities Explosion Doors: Location and Size Special Equipment (Sootblowers, Air Preheaters, Noise Suppressors, Fans, etc.)

CUSTOMARY UNITS
ISSUE 1 2 APPROVED 3 4 1. Service 2. Number Required Type 3. *Total Duty per Heater, MM Btu/h Reference Manufacturer Absorbed: Process Other ISSUE APPROVED JOB NO. LOCATION ITEM NO. UNIT EGE 11-D-1b 1989 Page 1 of 5
PROCESS DESIGN CONDITIONS

4. *Heater Section 5. *Service 6. *Heat Absorption, MM Btu/h 7. *Fluid 8. *Flowrate, lb/h 9. 11. 13. 15. 15. 16. 17. 18. Flowrate, bbl/day Pressure Drop, psi (Calculated)
2
10. *Pressure Drop, psi (Allowable) 12. *Average Flux Density, Btu/hCft (Allowable) Average Flux Density, Btu/hCft (Calculated) Maximum Flux Density, Btu/hCft Velocity Limitation Maximum Allowable Inside Film Temperature, F Fouling Factor, hCft CF/Btu Corrosion or Erosion Characteristics 19. *Temperature, F 20. *Pressure, (psia) (psig) 21. *Liquid Flow, lb/h 22. *Vapor Flow, lb/h 23. *Liquid Density, (API) (Sp Gr at 60F) 24. *Vapor Molecular Weight 25. *Liquid Viscosity, cP OUTLET CONDITIONS: 26. *Temperature, F 27. *Pressure, (psia) (psig) 28. *Liquid Flow, lb/h 29. *Vapor Flow, lb/h 30. *Liquid Density, (API) (Sp Gr at 60F) 31. *Vapor Molecular Weight 32. *Liquid Viscosity, cP 33. *Distillation Data or Composition Attached REMARKS AND SPECIAL REQUIREMENTS:
2 2 2
INLET CONDITIONS:
COMBUSTION DESIGN CONDITIONS

34. *Type of Fuel 35. *Excess Air, Percent 36. 37. 38. Guaranteed Efficiency, Percent (LHV) Calculated Efficiency, Percent (LHV) Radiation Loss, Percent of Heat Release (LHV)
*Items designated by asterisks are the minimum to be completed and furnished to the manufacturer. All other items shall be completed by the manufacturer.

CUSTOMARY UNITS COMBUSTION DESIGN CONDITIONS Contd
39. 40. 41. 42. 43. Flue Gas Temperature, F, Leaving Radiant Section Flue Gas Temperature, F, Leaving Convection Section Flue Gas Mass Velocity Through Convection Section, lb/ft Cs Draft at Bridge Wall, in. H2O Draft at Burner, in. H2O
2
EGE 11-D-1b 1989 Page 2 of 5
44. *Ambient Air Temperature, F 45. *Altitude, ft, Above Sea Level 46. 47. Calculated Heat Release, MM Btu/h (LHV) Volumetric Heat Release, Btu/hCft
3
FUEL CHARACTERISTICS
48. *Type of Fuel 49. *Heating Value: HHV 50. 51. *Specific Gravity 52. *H/C Ratio (by Weight) 53. *Temperature at Burner, F 54. *Viscosity: At 55. At F F LHV
56. *Fuel Pressure Available at Burner, psig 57. *Atomizing Steam Pressure, psig 58. *Liquid Fuels: Vanadium/Sodium Content, ppm 59. 60. 62. *Nitrogen Content, Percent by Weight *Sulfur Content, Percent by Weight Composition, Mole Percent
62. *Gas: Molecular Weight
MECHANICAL DESIGN CONDITIONS GENERAL

63. *Plot Limitations 64. *Tube Limitations 65. *Required Drawings 66. *Structural Design Data: Wind Load 67. *List of Applicable Standards or Specifications: Seismic Factor *Stack Limitations Other Limitations
COIL DESIGN
68. *Heater Section 69. *Design Pressure (Elastic/Rupture), psig 70. *Design Fluid Temperature, F 71. *Corrosion Allowance, in.: 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. Number of Passes Overall Tube Length, ft Effective Tube Length, ft Bare Tubes: Number Total Exposed Surface, ft Extended Surface Tubes: Number Total Exposed Surface, ft Tube Center to Furnace Wall, in. Min.
2 2
Tubes Fittings
Hydrostatic Test Pressure, psig
Tube Spacing, Center to Center, in. (Staggered) (In Line)
83. *Stress Relieve 84. *Weld Inspection Requirements, X-Ray or Other *Items designated by asterisks are the minimum to be completed and furnished to the manufacturer. All other items shall be completed by the manufacturer.

CUSTOMARY UNITS COIL DESIGN Contd
*Heater Section EGE 11-D-1b 1989 Page 3 of 5
TUBES
85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114. 115. 116. 117. 118. 119. Vertical or Horizontal *Tube Material (ASTM Specification and Grade) Outside Diameter, in. Wall Thickness (Minimum) (Average), in. Maximum Tube Wall Temperature, F (Calculated) Inside Film Coefficient, Btu/hCft CF (Calculated) Maximum Tube Wall Temperature, F (Design) Design Basis for Tube Wall Thickness Type Fin or Stud Material Fin or Stud Dimensions Fin or Stud Spacing Maximum Fin or Stud Temperature Extension Ratio Manufacturer and Type *Material (ASTM Specification and Grade) Nominal Rating *Location *Welded or Rolled Manufacturer and Type *Material (ASTM Specification and Grade) Nominal Rating or Schedule *Location Manufacturer and Type *Material (ASTM Specification and Grade) Nominal Rating *Location *Welded or Rolled: Flange: Size and Rating Location *Welded or Flanged *Pipe Material (ASTM Specification and Grade) Pipe Size and Wall Thickness Location Flange Rating
2
DESCRIPTION OF EXTENDED SURFACE
PLUG-TYPE HEADERS
RETURN BENDS
TERMINALS
CROSSOVERS
TUBE SUPPORTS ENDS, TOP, BOTTOM:

120. 121. 122. 123. 124. 125. 126. 127. Material Thickness Type and Thickness of Insulation Insulation Reinforcement
INTERMEDIATE:
Material Spacing, ft Type and Thickness of Coating
GUIDES: Location
128. Material *Items designated by asterisks are the minimum to be completed and furnished to the manufacturer. All other items shall be completed by the manufacturer.

CUSTOMARY UNITS HEADER BOXES
129. 130. 131. 132. Location Insulation: Material Anchor Material Are Header Box Doors Bolted or Hinged? Material Thickness Thickness EGE 11-D-1b 1989 Page 4 of 5
BURNERS
133. 134. 135. 136. 137. Manufacturer and Type Location Size and Type of Pilots Heat Release per Burner at Design Excess Air and Draft, MM Btu/h: Normal Maximum Size Number
MINIMUM DISTANCE BURNER CENTERLINE TO TUBE CENTERLINE:

138. Horizontal Vertical
SETTINGS EXPOSED VERTICAL WALLS:

139. 140. 141. 142. 143. 144. Thickness, in. Wall Construction Outside Casing: Thickness, in. Tieback Material Support Material Method of Fastening Tiebacks to Structure Material Outside Temperature, F Hot Face Temperature, F: Design Calculated
SHIELDED VERTICAL WALLS:

145. 146. 147. 148. 149. 150. Thickness, in. Wall Construction Outside Casing: Thickness, in. Tieback Material Support Material Method of Fastening Tiebacks to Structure Material Outside Temperature, F Hot Face Temperature, F: Design Calculated
ARCH:
151. 152. 153. 154. 155. 156. Thickness, in. Arch Construction Outside Casing: Thickness, in. Tieback Material Support Material Method of Fastening Tiebacks to Structure Material Outside Temperature, F Hot Face Temperature, F: Design Calculated
FLOOR:
157. 158. 159. 160. Outside Casing: Thickness, in. Thickness, in. Floor Construction Minimum Floor Elevation Material Outside Temperature, F Hot Face Temperature, F: Design Calculated
CONVECTION SECTION:
161. 162. 163. Thickness, in. Construction Outside Casing: Thickness, in. Material Outside Temperature, F Design Hot Face Temperature, F:

CUSTOMARY UNITS CONVECTION SECTION Contd
164. 165. 166. Tieback Material Support Material Method of Fastening Tiebacks to Structure EGE 11-D-1b 1989 Page 5 of 5
INTERNAL WALL
167. Type Dimensions Material
STACK
168. 169. 170. 171. 172. 173. Number Material Inside Metal Diameter Lining: Material Type of Material or Reinforcement Extent of Lining Self-supporting or Guyed Thickness, in. Height Abovegrade Thickness, in. Location Minimum Thickness, in. Stack Length
DAMPERS
174. 175. 176. Location: Stack or Bottom Air Plenum Material Description of Provision for Operation from Grade Multiple or Single Leaf
HOT DUCTS, BREECHING, FLUES, AND COLLECTORS

177. 178. 179. 180. Material Insulation: Type Type of Anchoring Material Size of Access Door into Breeching ASTM Specification Thickness, in. Size
COLD AIR DUCTS AND PLENUM

181. Material ASTM Specification Size
MISCELLANEOUS
182. 183. 184. 185. 186. 187. 188. 189. Overall Dimensions of Furnace Platforms: Location Width Type of Floor Stairs: Location Ladders: Location Access Doors: Location and Size Observation Doors: Location and Size
MISCELLANEOUS CONNECTIONS (Number and Size)

190. 191. 192. 193. 194. Draft Temperature Header Box Drain Coil Drains Painting and Galvanizing Requirements Flue Gas Sample Smothering Steam Stack Drain Other
195. 196. 197. 198.
Are Painters Trolley and Rail Included? Extent of Tube-Handling Facilities Explosion Doors: Location and Size Special Equipment (Sootblowers, Air Preheaters, Noise Suppressors, Fans, etc.)

EGE11B1

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DIRECT FIRED PROCESS HEATERS DESIGN AND FABRICATION

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

A182, F321H A182, F347 A182, F347H A182, F310

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

305 mm x 305 mm x 305 mm (12 in. x 12 in. x 12 in.)

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

For Box and Cabin Heaters:

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

For Vertical Cylindrical Heaters:

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

Setting Doors and Ports

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

FIGURE 1 TYPICAL AIR PREHEATER SYSTEM FOR PROCESS HEATER

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

C (F) C (F) mm H2O (in. H2O) mm H2O (in. H2O)

Fans and Motors

Air Flowrate: Qa = 1.2 x W a

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

Static Pressure: Pa = 1.44 x P1

Temperature: Ta = maximum ambient air temperature plus 10C (20F)

Flute Gas Rate: Qg = 1.2 x W f

Static Pressure: Pg = 1.44 x P2

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE

EGE 11-B-1 1989

MOBIL ENGINEERING GUIDE DIRECT FIRED PROCESS HEATER DATA SHEET

PROCESS DESIGN CONDITIONS

COMBUSTION DESIGN CONDITIONS

MOBIL ENGINEERING GUIDE DIRECT FIRED PROCESS HEATER DATA SHEET