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FOR
DESCRIPTION
SPECIFICATION
FIRED HEATERS
HSB
CONFIDENTIAL
DATE
NO.REV.
8/29/07
BY
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND MAY NOT BE
DISCLOSED TO ANY PERSONS OR COPIED OR REPRODUCED EXCEPT AS PERMITTED IN WRITING
BY VENTECH ENGINEERS, INC. ALL CONTENTS OF THIS DOCUMENT AND ALL COPIES OF IT ARE
THE PROPERTY OF VENTECH ENGINEERS, INC. AND ARE LENT OUT ON THE EXPRESS CONDITION
THAT THEY ARE SUBJECT TO RETURN UPON DEMAND.
PREPARED BY
H.S. BUCU
DATE
8/29/2007
APPROVED BY
C.W. FRANKENFIELD
DATE
REV.
8/29/2007
TABLE OF CONTENTS
1.0
SCOPE
2.0
PROPOSAL
3.0
4.0
5.0
MATERIALS
6.0
SPECIAL APPROVAL
7.0
IDENTIFICATION
8.0
9.0
16
10.0
17
1.0
SCOPE
1.1
1.2
1.3
Application
1.1.1
This specification, along with process data sheets, covers the minimum
requirements for the design, material, fabrication, testing, inspection, and
performance of fired process heaters purchased by VEIC.
1.1.2
This specification does not cover steam boilers except as steam generating
and superheating becomes incidental to the process and practical from the
standpoint of economic fuel usage.
1.1.3
The heater shall comply with any drawings, data sheets, and VEIC standards
or specifications referred to and attached as part of this specification.
Responsibility for becoming familiar with such standards, specifications,
codes or regulations and compliance with it rests with the Vendor.
1.1.4
VEIC's data sheets and attachments shall govern should there be a conflict
with this specification.
All heaters shall meet legal requirements as set forth in any national, state and
local code or regulation. All codes, regulations, specifications, etc. shall be
interpreted as meaning the latest revisions of said code, regulation,
specification, etc. If later revisions go into force following the issuance of
the purchase order, the revision in force as of the date of the purchase order
shall govern.
1.2.2
1.3.1.2
1.3.1.3
1.3.1.4
1.3.1.5
1.3.1.6
NFPA 85B Prevention of Furnace Explosions in Natural GasFired Multiple Burner Boiler Furnaces
1.3.2
1.4
1.5
1.3.1.7
1.3.1.8
1.3.1.9
1.3.1.10
1.4.2
1.4.3
1.4.4
Workmanship
All work shall be executed by skilled mechanics under competent supervision. All
work shall be subject to VEIC inspection and approval.
2.0
PROPOSAL
Technical information required with the quotation is as follows:
2.1
2.2
2.3
Drawings showing general arrangements, overall dimensions and tube layout. These
drawings shall clearly show the terminal connections to which VEIC will connect the
piping. Drawings shall show arrangements of platforms, walkways, stairways, and
ladders to indicate provisions that will be made for convenient operation, maintenance
and access to heater instruments.
2.4
Schedule and complete specification for all machinery and equipment, including
instrumentation, furnished and required.
2.5
2.6
3.0
4.0
The degree of heater prefabrication clearly defined, including man-hours required for
field erection.
3.2
At his option, the seller may supplement his basic quotation with an alternate
quotation provided the following two conditions are met:
3.2.1
3.2.2
Upon receipt of procurement document, the vendor shall submit preliminary drawings
in one (1) electronic format and one (1) hard copy for approval. Final approval is
required before fabrication is started.
4.2
Final and as-built drawings shall be submitted showing English and metric units. This
requirement applies to all drawings and data and does include ladders, platforms,
burners, etc., drawings and data.
4.3
Vendor shall provide VEIC with a final vendor data package consisting of the
following items. All data shall be clearly legible. All documents shall reference the
heater item number, part of the heater and date. The folded dimensions of each
document and drawing in the package shall be no greater than 8 wide x 11 long x
necessary thickness. In addition all vendor data shall be supplied to VEIC in an
electronic format (i.e., AutoCAD, Word, Excel, etc.)
4.3.1
A table of contents
4.3.2
4.3.3
Weld Maps, showing applicable welders stamp and weld procedures used
4.3.4
Nameplate Rubbings
4.3.5 Material Test Records (MTR) and Certifications (cert). Each MTR and cert.
shall clearly reflect the applicable heat number used to manufacture the
referenced part. The tag number of the referenced heater and a description of
the part made from the heat number shall be marked on the MTR or cert.
4.3.6 Post Weld heat Treatment (PWHT) Chart and Records. These shall clearly
show the part(s) being heat treated, heater tag number, start time & date, finish
time & date, furnace start temperature, rate of temperature increase, hold time
& temperature, and rate of temperature decrease.
4.3.8.2
4.3.8.3
4.3.8.4
4.3.9 Provide foundation load diagram showing locations and sizes of all anchor
bolts and base plates. Provide empty weight, operating weight, test weight
wind shear and wind overturning moment.
4.3.10 VEICs review of vendors drawings is of a general nature. Approval of any
drawings by VEIC does not serve as approval of any errors or as approval of
any deviation from the applicable instructions and procedures listed in this
specification or other special instructions relating to the work. Vendor shall call
attention to any such deviations by separate written notice when submitting the
drawings for purchases approval.
5.0
MATERIALS
Material specifications for tubes, castings, welding and refractory shall meet ASTM
specification.
6.0
SPECIAL APPROVAL
Special approvals, when required by the national, state, and local code or regulations shall be
obtained without expense to VEIC.
7.0
IDENTIFICATION
Correspondence, drawings and other documents in connection with this work shall be labeled
with the VEIC procurement document number, item number, unit number, and purchase order
number and / or contract number if supplied by the general contractor.
8.0
8.1.1
8.2
8.1.1.2
The design exit stack temperature shall be not lower than 350F if
the furnace is to be fired with fuel oil or sulfur contaminated gas.
8.1.1.3
8.1.1.4
For furnaces fired with residual fuel oil, the stack shall be
designed such that the passage of flue gas from firing the burners
at their rated capacity shall be possible even though 50% of the
extended surface may become completely fouled with soot.
8.1.1.5
8.1.1.6
General
8.2.1.1
8.2.1.2
8.2.1.3
8.2.1.4
8.2.1.5
8.2.1.6
8.2.2
8.2.3
8.3
8.4
All header box covers shall be gasketed and bolted tightly all
around.
8.2.2.2
8.2.2.3
8.2.3.2
If extended surface tubes are used for the convection section, the
bottom three-tube rows (shield section) shall be bare tubes.
8.2.3.3
Coils
8.3.1
8.3.2
8.3.3
8.3.4
Tubes shall be seamless and standard pipe size. Other sizes are permissible if
required by design and approved by VEIC.
8.3.5
Fitting material shall be equal to the adjacent alloy. Wall thickness shall be
equal to or greater than of the adjacent tubes.
8.3.6
8.3.7
8.4.1
8.5
8.6
Design Temperature
Fins
Carbon Steel
500C (932F)
1 Cr Alloy Steel
600C (1,112F)
5 Cr Alloy Steel
650C (1,202F)
13 Cr Alloy Steel
700C (1,292F)
18 Cr - 8 Ni Stainless Steel
815C (1,500F)
The heater manufacturer shall design and furnish all inlet and outlet headers,
crossovers, terminals, and pigtails unless otherwise specified by VEIC.
8.5.2
Inlet and outlet headers and terminals shall be flanged unless otherwise
requested. The flanges shall match the adjacent piping. Terminals shall be
supported in the heater structure.
8.5.3
8.5.4
Inlet and outlet headers and crossovers shall be sized to give even
distribution to all tube passes.
8.5.5
The wall thickness of inlet and outlet headers, crossovers, and terminals shall
be designed per ASME B31.3.
8.5.6
All crossovers shall be external and flanged unless internal crossovers are
approved by VEIC.
Coils Fabrication
8.6.1
8.6.2
Carbon steel girth and fillet welds shall be fully radiographed to the extent of
100 percent of all welds.
8.6.3
8.7
8.6.4
Where radiographic examination is not feasible, e.g. branch nozzle dyepenetrant examination shall be performed on all welds.
8.6.5
Qualification tests for welding procedure shall comply with the requirements
of ASME Boiler and Pressure Vessel Code Section IX.
8.6.6
For each radiograph that reveals unacceptable imperfection, at least two (2)
additional welds, designated by VEIC, and shall be radiographed. If any of
the additional welds radiographed reveal unacceptable imperfections, all
welds made to that procedure or by that welder are subject to rejection by
VEIC.
Tube Supports
8.7.1
8.7.2
8.8
8.9
25-20 CrNi
50-50 CrNi
25-20 CrNi
50-50 CrNi
25-20 CrNi
50-50 CRNi
Meehanite HR or HS
25-12 CrNi
50-50 CrNi
8.8.2
The doors and walls shall be insulated with a minimum of 1-1/2" of haydite
lumnite, or equal.
8.8.3
8.8.4
Lifting lugs for cover plate removal shall be provided for the bolted header
box cover plate.
8.8.5
Burners
8.10
8.11
8.12
8.9.1
Dual burners shall be designed for automatic firing of the fuel (Gas & Oil)
as specified on the data sheet. Automatic firing shall be controlled by process
outlet temperature.
8.9.2
Burners shall be of Low NOx type with an individual pilot light operating on
2.8 to 7psig gas fuel.
8.9.3
8.9.4
Burners are to be supplied with burner tile in accordance with the burner
manufacturer's specifications.
8.9.5
8.9.6
Aluminum type mufflers are required on all air inspirating type burners.
Each burner shall have an electrically ignited pilot, flame scanners for main
flame & pilot and sight glass.
Noise
8.10.1
The burner noise level shall not exceed 90 decibels measured on the A scale
of the standard sound level meter at low response as required by the WalshHealy Act nor shall it exceed the requirements of any local code or
regulations, if more stringent.
8.10.2
Noise may be controlled by the proper selection of burner type, fuel pressure,
noise suppressors, or insulated plenums.
Plenum Chamber
8.11.1
If plenums are used, plenum chambers around the burners for noise muffling
devices shall be designed to permit access to burners and pilots.
8.11.2
The plenum chamber shall provide uniform flow distribution to all burners.
8.11.3
The minimum thickness of plenum chamber walls shall be 4.5 mm (3/16 in.).
8.11.4
Refractory
8.12.1
The manufacturer shall present the wall, arch, and floor design for the
approval of VEIC.
8.12.2
The inner surface of the casing behind the insulating block shall be coated
with 1/8" of Eagle Pitcher Stalastic, or equal, if corrosion is anticipated.
8.12.3
8.13
8.13.2
8.13.3
8.13.4
Stack deflection, based on corroded thickness, shall not exceed 6" per 100
feet of height.
8.13.5
Stiffening rings shall be used to prevent ovalling when the natural frequency
of the free ring is less than twice the vortex shedding frequency at the level
under consideration.
8.13.6
Stack height and emissions shall be in conformance with the local codes and
regulations.
8.13.7
Stack exit velocity shall be between 17.5 and 25 feet per second at 130% of
rated load and 30% excess air.
8.13.8
The design of unlined stacks shall consider location and fuel composition.
When unlined stacks are specified the flue gas temperature shall not be less
than 204C (400F) nor greater than 371C (700F).
8.13.9
Stack dampers and shafts shall be constructed of 18Cr - 8Ni stainless steel or
higher alloy material suitable to withstand flue gas temperatures and flue gas
corrosion.
8.13.10 Damper shall have position indicator and a positive acting damper operator
with suitable Type 300 Series stainless steel cables for operation from grade.
Special care shall be taken in locating the cable route so that it will not create
a safety hazard when operating or maintaining. Damper bearing sleeves shall
be 11% Chrome Steel. The damper operator and indicator shall be located
near the firebox peepholes.
8.14
Furnace Structure
8.14.1
Furnace casing plate thickness shall not be less than 4.5 mm (3/16 in.).
Where the casing is used as a part of the main structure, the casing plate shall
be a minimum of 6 mm (1/4 in.) in thickness. Corrosion allowance of the
casing plate shall be a minimum of 1/8 in.
8.15
8.16
8.14.2
Furnace casing shall be designed so that air leakage into the furnace is
minimized.
8.14.3
Woven packing shall be attached along the bolted surface of header box
flanges and any other flanged surfaces of structures for air tightness.
8.14.4
Welding of steel structures shall be carried out in accordance with AWS D1.1
Structural Welding Code-Steel.
8.14.5
All plates over 6 mm (1/4 in.) in thickness shall be provided with weld
bevels. Welded joints shall be full penetration-butt types.
Platforms, walkways, stairways, and ladders shall conform to OSHA and API
560 Standards.
8.15.2
Provide at burner and burner controls that are not accessible from grade.
8.15.3
8.15.4
8.15.5
Provide at all observation ports and firebox access doors not accessible from
grade.
8.15.6
8.15.7
Lifting lugs
Lifting lugs shall be designed, fabricated and installed by the heater
manufacturer. VEIC shall approve the design. Lifting of the heater shall not
damage the heater. Special lifting considerations/methods shall be legible and
indelibly marked on the exterior of the heater.
8.17
One access door (18 x 18) shall be provided in the floor for vertical
cylindrical heaters. A bolted and gasketed access door shall also be provided
in any air plenum below the floor access way. Where space is not available,
access via a burner port is acceptable.
8.17.2
One access door (24 x 24) or (24 diameter) shall be provided in the stack
or breeching for access to the damper and convection sections.
8.18
8.17.3
One tube removal door (18 x 24) shall be provided in the arch of each
radiant chamber of vertical tube heaters.
8.17.4
Heater Accessories
8.18.1
8.19
8.18.1.2
8.18.1.3
8.18.1.4
8.18.1.5
8.18.1.6
8.18.1.7
8.18.1.8
8.19.2
8.20
9.0
Inspection
9.1.1
9.1.2
9.2
9.1.3
9.1.4
9.1.5
9.1.6
Testing
9.2.1
9.2.2
9.2.3
10.0
Hydrostatic test pressure for the heater shall not be less that 1.5 times the
normal design pressure adjusted to 100F and not greater than the stipulated
test pressure for the weakest element as determined by design. The
manufacturer shall supply the hydrostatic test pressure information including
rating of weakest element as part of the design. Corrosion allowances shall
not be considered in calculating testing procedures.
Water used for hydrostatic testing of austenitic stainless steel components
shall be of potable quality with less than 10 ppm chlorine. Alternate
hydrostatic test media may be used with approval by VEIC.
All hydrostatic tests are to be performed in the presence of an authorized
VEIC Inspector unless waived.
Individual sections shall be properly braced and supported to prevent damage during
shipment. All and bracing used for shipping purposes shall be clearly identified
blocking for field removal. Coil flange faces and other machined faces shall be coated
with easily removable rust preventive. Openings in pressure parts shall be covered to
prevent entrance of foreign materials.
10.2
For shop lined castable refractory sections, to minimize the tendency for alkali
hydrolysis to occur, the sections shall be prepared for shipment in a way to allow good
air circulation during the entire shipping and storage periods. The use of shrink wrap
(air tight packaging) coverings shall be avoided.
10.3
For shop lined fiber refractory sections, shrink wrapping of lined sections is required.
10.4
All loose items such as rods, turnbuckles, clevises, bolts, nuts, and washers shall be
shipped in bags, kegs, or crates. Bags, kegs, or crates shall be tagged with the size,
diameter, and length of contents so that tags for each item are individually identifiable.
Tags used for marking shall be metal and markings shall be applied by stamping.
10.5
The vendor shall advise the VEIC if any pieces are temporarily fixed for shipping
purposes. Transit and erection clips or fasteners shall be clearly identified on the
equipment and the field assembly drawings to ensure removal before commissioning of
the heater.