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NASHPA Gas Processing and LPG Recovery Plant

PROC-FC-CB/NASHPA/PROJ-1247 /2015

PROJECT NO.: NASHPA 1247

DOCUMENT NO.:
SPECIFICATION PAGE 1 OF 22
NGP-001-PCS-15.03-2001-15

Specification for Fired Heater

REVISION DETAILS

00 26/07/2016 Approved for Design Wu Changjian Kong Weiguang Zhang Zhiyong Du Maomin

C 20/05/2016 Issued for Approval Wu Changjian Kong Weiguang Zhang Zhiyong Du Maomin

B 25/01/2016 Issued for Review Wu Changjian Kong Weiguang Zhang Zhiyong Du Maomin

A 14/01/2016 Internal Discipline Check Wu Changjian Kong Weiguang Zhang Zhiyong Du Maomin

REV DATE DESCRIPTION PRPD CHKD REVD APPD

Doc Size: A4
NASHPA Gas Processing and LPG Recovery Plant
PROC-FC-CB/NASHPA/PROJ-1247 /2015
DOC. NO. NGP-001-PCS-15.03-2001-15
DESCRIPTION Specification for Fired Heater
REVISION 00
PAGE 2 OF 22

REVISION HISTORY

REV. DATE REVISION DESCRIPTION

A 14/01/2016 Internal Discipline Check

B 25/01/2016 Issued for Review

C 20/05/2016 Issued for Approval

00 26/07/2016 Approved for Design


NASHPA Gas Processing and LPG Recovery Plant
PROC-FC-CB/NASHPA/PROJ-1247 /2015
DOC. NO. NGP-001-PCS-15.03-2001-15
DESCRIPTION Specification for Fired Heater
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TABLE OF CONTENTS
1.0 GENERAL ................................................................................................................................................................ 5
1.1 Introduction .................................................................................................................................................. 5
1.2 Scope ............................................................................................................................................................ 5
1.3 Definitions .................................................................................................................................................... 5
1.4 Errors or Omissions ..................................................................................................................................... 5
1.5 Deviations ..................................................................................................................................................... 5
1.6 Conflicting Requirement .............................................................................................................................. 6
1.7 Reporting Procedure .................................................................................................................................... 6
1.8 Unit Responsibility ....................................................................................................................................... 6
1.9 Documentation ............................................................................................................................................. 6
2.0 CODES AND STANDARDS ................................................................................................................................... 7
2.1 Codes, Standards and Regulations ............................................................................................................. 7
2.2 Other requirement ........................................................................................................................................ 8
2.3 Project Specification .................................................................................................................................... 8
3.0 ENVIRONMENTAL DESIGN CRITERIA ............................................................................................................... 8
3.1 General ......................................................................................................................................................... 8
3.2 Area Classification ....................................................................................................................................... 8
3.3 Environmental Data ...................................................................................................................................... 8

4.0 SCOPE OF SUPPLY ............................................................................................................................................... 8


4.1 General ......................................................................................................................................................... 8
4.2 Scope of Supply ........................................................................................................................................... 9

5.0 PROCESS REQUIREMENTS ................................................................................................................................. 9


6.0 DESIGN REQUIREMENTS ................................................................................................................................... 10
6.1 General ....................................................................................................................................................... 10
6.2 Pressure Retaining Components............................................................................................................... 10
6.3 Tube Supports ............................................................................................................................................ 11
6.4 Heater Body ................................................................................................................................................ 12
6.5 Connections ............................................................................................................................................... 12
6.6 Burners ....................................................................................................................................................... 12
6.7 Structure ..................................................................................................................................................... 13
6.8 Access Doors and Peepholes.................................................................................................................... 13
6.9 Ladders and Platforms ............................................................................................................................... 14
6.10 Burner Management System.................................................................................................................... 14
7.0 MATERIALS ........................................................................................................................................................... 15
7.1 Tubes and Fittings ..................................................................................................................................... 15
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7.2 Bolting ........................................................................................................................................................ 15
7.3 Gaskets ....................................................................................................................................................... 15
7.4 Tube Supports ............................................................................................................................................ 15
7.5 Refractories and Insulation........................................................................................................................ 16
8.0 FABRICATION ....................................................................................................................................................... 16
9.0 DRAWINGS, CALCULATIONS AND DOCUMENTATION ................................................................................ 17
10.0 INSPECTION, TESTING AND CERTIFICATION ................................................................................................ 18
10.1 General ..................................................................................................................................................... 18
10.2 Inspection ................................................................................................................................................. 18
10.3 Tests ......................................................................................................................................................... 18
10.4 Hydrostatic Tests ..................................................................................................................................... 19
10.5 Performance Tests ................................................................................................................................... 19
10.6 Material Testing and Certification Requirements.................................................................................... 19
10.7 Final Reports and Data Sheets ................................................................................................................ 20
10.8 Identification and Stamping ..................................................................................................................... 20
11.0 PAINTING AND PREPARATION FOR SHIPMENT ........................................................................................... 21
11.1 Painting and Protective Coating .............................................................................................................. 21
11.2 Preparation for Shipment......................................................................................................................... 21

12.0 SITE ACCEPTANCE TEST (SAT) AND COMMISSIONING ASSISTANCE .................................................... 21


13.0 PERFORMANCE GUARANTEE .......................................................................................................................... 21
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1.0 GENERAL
1.1 Introduction

OIL & GAS Development Company Ltd. (OGDCL) is operating NASHPA Oil & Gas fields in Khyber
Pakhtunkhwa of Islamic Republic of Pakistan. OGDCL intends to install LPG Recovery Plant, Compressors &
Allied Facilities at this field.

1.2 Scope

This specification covers the minimum technical requirement for design, manufacture, supply, inspection,
testing and commissioning of fired heaters required to heat a liquid phase heat transfer medium (Hot Oil) to be
used in Gas Processing, LPG Recovery Plant and Allied Facilities at Nashpa Oil Field.

1.3 Definitions

Within this document the following definitions apply:

Project NASHPA Gas Processing and LPG Recovery Plant


PROC-FC-CB/NASHPA/PROJ-1247 /2015

Company/Owner Oil & Gas Development Company Ltd.(OGDCL)

Consultant Zishan Engineers (Pvt.) Ltd.

Contractor Hong Kong Huihua Global Technology Limited Wholly owned


subsidiary of China OIL HBP Science and Technology
Corporation Ltd.

Manufacturer/Supplier/Vendor Party(ies), which manufactures and/or supplies material,


equipment and service to perform the duties as specified by
CONTRACTOR in the scope of supply

Shall Indicates a mandatory requirement

Should Indicates a strong recommendation to comply with the


requirement of this document

1.4 Errors or Omissions

1.4.1 The review and comment by COMPANY/CONSULTANT/CONTRACTOR of any VENDORs drawings,


procedures or documents shall only indicate acceptance of general requirements and shall not relieve
VENDOR of its obligations to comply with the requirements of this specification and other related parts
of the Contract Documents.

1.4.2 Any errors or omissions noted by VENDOR in this Specification shall be immediately brought to the
attention of COMPANY/CONSULTANT/CONTRACTOR.

1.5 Deviations
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All deviations to this Specification, other related specifications or attachments shall be brought to the
knowledge of COMPANY/CONTRACTOR as a section in the bid. All deviations made during the procurement,
design, manufacturing, testing and inspection shall be with written approval of COMPANY/CONTRACTOR
prior to execution of Work. Such deviations shall be shown in the documentation prepared by VENDOR

1.6 Conflicting Requirement

In the event of any conflict, inconsistency or ambiguity between VENDORs scope of work, this Specification,
National Codes and Standards, and referenced in the Project Specification or any other documents, VENDOR
shall refer to COMPANY/CONTRACTOR whose decision shall prevail.

1.7 Reporting Procedure

1.7.1 A reporting and documentation system shall be agreed between VENDOR and
COMPANY/CONSULTANT/CONTRACTOR for the status of procurement, design, manufacturing,
inspection, testing and shipment of the equipment/material to be supplied under this specification.
VENDOR shall provide reports and summaries for production performance and testing operations in
conformance with a manufacturing schedule approved by COMPANY.

1.7.2 Daily, weekly, monthly and run summaries of all major aspects of the production process shall be
provided as reports to COMPANY/CONSULTANT/CONTRACTOR.

1.7.3 Third Party Inspection

In addition to the inspection and witnessing of tests by the inspectors to be appointed by the
COMPANY during the manufacturing and shipment of the equipment/material, COMPANY may appoint
a third party or its own inspector for witnessing of the inspection and tests to be carried out at
VENDORs facility under this specification.

1.8 Unit Responsibility

VENDOR shall be responsible for the complete design, manufacture, supply, fabrication, construction,
installation/erection, inspection and testing of the fired heater, including full compliance with all applicable
design codes and standards, including those listed in Section 2.0 of this document and the requirements of the
certifying authority, if applicable. VENDOR shall handle and expedite drawings and data, and supervise and
coordinate all inspection and testing.

VENDOR shall guarantee that all material and parts included in construction of the specified Centrifugal pump
shall be new, unused and of the required/ specified grade.

1.9 Documentation

1.9.1 Documents, calculation sheets, drawings, etc., to be submitted to the COMPANY/CONTRACTOR shall
be in English Language.

1.9.2 Unless otherwise specified, the imperial units shall be used in documents and drawings.

1.9.3 The form of drawings and documents may be as per the CONTRACTOR/VENDORs Standards.
However, the format of the data sheet will be submitted to COMPANY for approval.
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1.9.4 Variations from or additions to this specification shall be called to the attention of the COMPANY and
approved in writing by the COMPANY prior to starting fabrication.

1.9.5 Information for installation, operating, maintenance or inspection purposes shall be submitted to
COMPANY.

2.0 CODES AND STANDARDS


2.1 Codes, Standards and Regulations

Heating medium heaters shall be designed, manufactured and tested in accordance with the requirements of
this specification, other referenced Project Specifications and the Latest Editions of following Codes, Standards
and Statutory Regulations (where applicable):

ASME IV Heating Boilers

ASME VIII Div 1 Pressure Vessels

ASME V Non Destructive Examination

ASME IX Welding and Brazing Qualifications

ASCE 7-98 Building Code Requirements for Minimum Design Loads in


Buildings and other Structures

API 630 Tube and Header Dimensions for Fired Heaters for Refinery
Services

API RP 530 Calculation of Heater Tube Thickness in Petroleum Refineries

ANSI B16.5 Steel Pipe, Flanges and Flanged Fittings

ANSI B31.3 Petroleum Refinery Piping

API 560 Fired Heaters for General Refinery Services

ANSI/ISA 84.00.01 Functional Safety: Safety Instrumented Systems for the Process
Industry Sector

ISA-TR84.00.05 Guidance on the Identification of Safety Instrumented


Functions

IEC 61508 Function Safety of Electrical/Electronic/Programmable Electronic


Safety-Related Systems

IEC 61131-3 Programmable controllers Part3: Programming


Language

NFPA 85 Boiler and Combustion Systems Hazards Code

NFPA 86 Standard for Ovens and Furnaces


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NFPA 87 Fluid Heaters

NFPA 70 National Electrical Code (NECr)

ANSI / API RP 556 Instrumentation and Control Systems for Fired


Heaters and Steam Generators

2.2 Other requirement

In addition to the requirements of this General Specification, all requirements of the governing Statutory
Authority, i.e., in the country and/or its subdivision where fired heats are to be installed, shall be met.

2.3 Project Specification

Piping Material Specification NGP-000-PIP-15.03-0001-00

Specification for Fabrication Installation of Equipment & Piping NGP-000-PIP-15.03-0005-00

Specification for Coating and Painting NGP-000-PAI-15.03-0001-00

Specification for Skid Mounted Packages NGP-000-PAI-15.03-0013-00

Specification for Insulation NGP-000-PAI-15.03-0005-00

Specification for Structural Steel Works NGP-000-SCW-15.03-0004-00

Specification for Electrical Requirements of Packaged Equipment NGP-000-ELE-15.03-0006-00

Specification for Instrumentation for Packaged Unit NGP-000-INS-15.03-0004-00

Hazardous area schedules NGP-000-ELE-15.08-0007-00

Hazardous Area Classification Layout NGP-000-ELE-15.01-0001-00

3.0 ENVIRONMENTAL DESIGN CRITERIA


3.1 General

The design life of the equipment shall be 25 years minimum. Unless otherwise stated on the data sheets the
heating medium heaters will be located in an open exposed area.

3.2 Area Classification

The package shall be suitable for installation in non hazardous area, which is shown in Hazardous Area
Classification Layout.

3.3 Environmental Data

Environmental conditions for the equipment covered by this specification shall be in accordance with
Specification Environmental Conditions.

4.0 SCOPE OF SUPPLY


4.1 General
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The CONTRACTOR / SUPPLIER shall be responsible for the design, production of materials, manufacture,
fabrication, construction, and installation/erection assembly, supply of drawings and data, all
sub-CONTRACTOR coordination, testing and guarantees, plus the provision of skilled personnel for the testing
and commissioning of the complete unit.

4.2 Scope of Supply

4.2.1 The scope of supply of each unit shall include, but not necessarily be limited to, the following:

Direct Fired Heater, placed in a refractory lined duct complete with all necessary controls and
instrumentation for gas firing operation.

Forced draft combustion air system complete with fan, ducting and burner management system. The
CONTRACTOR / SUPPLIER is referred to the attached system P&ID for minimum requirement.

All necessary platforms, ladders and other access facilities required for the proper operation and
maintenance of the package.

All necessary lifting devices, including lifting lugs, spreader beams, slings and shackles.

All necessary interconnecting pipe work, valves, supports and termination points as defined in the
attached project documentation.

All necessary instrumentation and controls, inclusive of signal devices and accessories, for the control and
monitoring of the heater, as defined on the data sheets. In addition to the instruments shown on P&ID this
shall include alarm and shutdown devices for flame failure, low combustion air pressure and other
hazardous situations. Interlocks for safe start up & shutdown shall be provided.

Protective coating of all equipments and exposed areas.

All necessary refractory and insulation provisions for safe, economical and reliable service including
suitable facilities for personnel protection.

Vendor to confirm that 3D model(.step file) for fired heater will be provided.

3D model(.step file) is mandatory and Vendor shall confirm it can be provided.

4.2.2 The CONTRACTOR / SUPPLIER shall be responsible for the complete design, engineering,
coordination, inspection, testing, delivery and proper functioning of the equipment, not withstanding any
omissions from this specification.

5.0 PROCESS REQUIREMENTS


Heaters shall be of an approved type compatible with the service conditions and any space limitations imposed.
Vertical cylindrical type with or without cross convection section are preferred, maximum tube metal
temperature, fuel gas criteria and burner criteria, not stipulated herein or on the data sheets, shall be restricted
to accepted good practice.

The heater design shall permit operation at 50 percent of the lowest normal operating process fluid flow rate.
2
Rate of heat absorption shall be based on an average of 9,000 Btu/ft .h of outside tube surface. The heat flux
(peak) shall not exceed 15,000 Btu/ft2.h.
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The furnace volume, enclosed by radiant tubes only, shall be such that the maximum rate of heat release does
3
not exceed 186,000 W/m . The volume shall be determined by the distances between the tube centerlines.

The maximum pressure drop of the tube side fluid shall be advised to CONSULTANT / COMPANY to seek
approval.

The heater shall be designed for gas firing with pilot burners. The pilot burners shall have a spark based
ignition system for firing the pilots.

Burners shall have a capacity of 115 percent of the heat release required for the design heat absorption and
shall also be capable of a 3: 1 turndown.

Exhaust systems duct shall be designed to handle 10% excess flow of that normally expected at full duty. For
analysis of exhaust gases sampling connection shall be provided which will be at 50% of stack height (from top)
and end point is easily accessible for operator.

The heaters shall be designed for overall thermal efficiencies of not less than 80 percent. Guaranteed
efficiencies shall be based on the net heating value of the fuel gas, 10 percent excess air, 2 percent radiation
loss and an ambient air temperature of 15C. The CONTRACTOR / SUPPLIER shall guarantee the process
requirements stated on the data sheet.

Depending on heater design, heater CONTRACTOR / SUPPLIER shall provide fluid thermowell connections in
the convection and radiant sections.

The CONTRACTOR / SUPPLIER shall be responsible for the design and supply of all necessary
instrumentation and controls for the safe and efficient operation of the heaters, especially with regard to the fuel
gas supplies, flame failure, high exit fuel gas temperature and low combustion air pressure, low process fluid
flow and high process fluid temperature.

The heaters shall be designed for manual local start with automatic sequencing and unattended operation and
shutdown.

The CONTRACTOR / SUPPLIER shall provide the anticipated and guaranteed NOx, CO, SOx, unburned
hydrocarbon and particulate concentrations in the flue gas. All such emissions shall be expressed in ppm by
volume and lb/MM Btu heat input. The total emissions shall also be provided and expressed in terms of lb/h.

Minimum stack height shall be 3.0m (10ft) above the highest operating platform within a 30m (100ft) radius or
as indicated in the project specifications.

6.0 DESIGN REQUIREMENTS


6.1 General

All equipment and accessories supplied as part of the package(s) shall comply with the requirements of the
Project Specification for Skid Mounted Packages.

6.2 Pressure Retaining Components

Tube layout shall provide for uniform heat distribution with parallel streams exposed equally to the heat source.
Parallel passes and manifolds shall be designed to give symmetrical flow paths and pressure drops.
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Cleaning of tubes will be carried out by a rod if required during shutdown. CONTRACTOR / SUPPLIER shall
provide arrangement of tubes and suitable to permit cleaning of tubes. Maintenance platform required for
cleaning of tubes shall be provided.

Wall thicknesses for tubes and other pressure retaining parts shall be designed to API RP 530, on a stress
rupture basis, and for a design life of 25 years of operation.

Carbon steel and intermediate alloy tubes shall be provided with a minimum corrosion allowance suitable for
the service. In no case shall tubes or piping be thinner than schedule 40 or its equivalent.

The design temperature and pressure rating requirement for the incoming process fluid are as shown in P&ID
(ASME Class 300). Refer to piping specification.

Design tube metal temperatures shall be the calculated maximum tube wall temperature taking account of the
circumferential and longitudinal heat flux variation, fouling resistance, tube wall resistance and fluid bulk
temperature.

The maximum design temperature for the outside casing is 140F based on an ambient temperature of 100F
and for air movement of 1.0/2.0 m/s. Hot spots shall be avoided.

Tubes shall be either seamless tubing or piping and shall have not more than one circumferential butt weld per
tube within the firebox area. Bare tubes shall be spaced at a minimum of two (2) times the tube diameter
(centre to centre).

Temperature profiles within the heater shall be accurately predicted, taking into account fouling and all other
detrimental factors in order to properly design tube supports, refractories, coil expansions and all items within
the package.

Nozzles shall meet the following requirements:

Pressure-temperature ratings for steel pipe flanges and flanged fittings shall be in accordance with ANSI
Specification B 16.5.

All connections shall be forged steel flanges of the weld neck type.

Piping external to the furnace shall be in accordance with the Project Piping Specification.

The minimum size for nozzles and connections shall be 2" unless otherwise stated on the data sheets.

Flanged fluid inlet and outlet nozzles shall have at least a 200mm projection from outside of header boxes to
the flange face, unless otherwise specified on the data sheets.

6.3 Tube Supports

Temperature profiles within the heater shall be accurately predicted in order to adequately design the support
system. This shall define any temperature gradient allowance adopted for the determination of design
temperature at the various parts of the support, e.g. radiant hooks, where the point of maximum bending
moment is within the insulation/refractory.
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Design metal temperatures for tube supports, i.e. radiant hooks, shield supports, etc. shall take into account
direct radiation, fuel gas temperature and flame impingement, where applicable, and shall be based on the
maximum fuel gas temperature plus 100C or 980C, whichever is the greater.

Oxidation and corrosion allowances should be based upon a 25 years support life. Tube sheet casting
thicknesses shall be a minimum of 12mm.

All tube supports shall be carried on the steel work and shall not bear on the refractory.

Loading on tube supports shall include all dead and superimposed loading, including tube contents using a
friction coefficient of one third.

Vertical coils should be top supported and bottom guided.

End tube supports shall be protected on the fire side with refractory securely anchored to the support. End tube
supports shall have provision for tube expansion and should be designed to support the loads applicable at
failure of all intermediate supports.

For horizontal tubes, intermediate supports shall be provided so that the maximum unsupported tube length
shall not exceed 35 tube diameters or 6m, whichever is less.

The minimum distance between centerline of tube and the refractory wall shall be the nominal tube diameter
plus 50mm.

6.4 Heater Body

An access opening (450mm 600mm minimum) shall be provided at an accessible location.

Exposed surfaces shall be lined with 38mm refractory (Lumnite, Haydite, Vermiculite 1-2-4 mix or equal) unless
otherwise specified on the data sheets. The exhaust system prior to applying refractory shall be epoxy coated.

6.5 Connections

All terminal connections shall be flanged and located at an accessible point at the edge of the package.

6.6 Burners

Burners shall be suitable for the fuels specified in datasheet and shall be capable of completely burning the fuel
with 10 percent excess air. The Burners shall be of proven design and shall operate over the specified range
defined in fuel gas composition is given in datasheet.

Burner shall be forced draft-type and shall be equipped with electric motor driven air blower.

Burner adjustment facilities for any secondary air and valving shall be conveniently located so that the burner
can be ignited with a minimum of danger to personnel.

Each burner shall be provided with a continuous, gas fueled, high stability, inspiriting type pilot burner having a
flame retention head.

Gas pilots shall be provided with electric spark ignition.

Burner assemblies shall be equipped with flame failure detectors to monitor the pilot flames and lockout on
flame failure.
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The pilot gas valve shall be a ball valve. It shall have an operating lever arranged 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. The valve shall be positioned so that it will not open when subject to vibration.

Burners, gas rings, air diffusers, burner risers, tips shall be removable for maintenance while the heater is in
operation. Individual tips shall be removable for cleaning without the removal of gas rings or other tips when
multiple tips are used. All gas burner lines shall be hard piped.

The burner CONTRACTOR / SUPPLIER shall state the minimum and maximum fuel pressures for trip on both
the main and pilot burners.

The locations of the ignition port, observation port, pilot and burner piping shall allow unimpaired and complete
view of the pilot while lighting and during operation.

All gas burner tips and air diffusers shall be made of stainless steel. All gas burner risers shall be fabricated
from austenitic stainless steel.

Two flame scanners shall be required for each large, forced draft burner. Heaters with a single burner shall be
equipped with two flame scanners.

Flame arrestor shall be provided for burner.

The number and location of burners shall be such as to completely avoid flame impingement on any tubes,
tube supports or refractory. The minimum clearance between centerline of burner and centerline of tubes will
depend upon the specific burner and the manufacturers data.

6.7 Structure

The heater shall be rigidly supported by a structural steel frames or skid, suitable for shipping and handling
operations such as lifting or skidding, without damage to the unit.

Structures shall be designed to withstand any possible combination of the following structural
loads together with transportation and erection loads:

Dead load

Hydrostatic test load

Operating fluid load


2
Open Area live load - 510 kg/m on platforms and on heater floor

Wind load

External piping loads and moments

6.8 Access Doors and Peepholes

Access and setting doors shall be provided as necessary for maintenance and ease of repair and replacement
of internal parts.
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Sufficient peepholes shall be installed and located so that all burners and all radiant heating surfaces facing the
flame may be observed together with the shield and convection tubes and the full length and root of the burner
flame.

All doors and peephole covers shall be lined with suitable refractory, and sealed.

6.9 Ladders and Platforms

Platforms with access ladders shall be provided for all necessary operating and maintenance functions.

Ladders for peepholes, if required, may be provided with step platforms only. Exits from platforms shall be
located away from any source of hazard and shall be arranged such that any point on the platform is not more
than 10m away from an exit.

Platforms shall be provided for access to all instrument, emission and stack continuous
emission monitoring equipment.

Minimum clear headroom over platforms and walkways shall be 2.13m.

Platform floors shall be open, welded, galvanized bar grating with a minimum of 25 6mm bearing bars.

6.10 Burner Management System

A suitable Burner management system with all necessary instrumentation shall be included to facilitate start-up,
monitor and control the packaged equipment performance and to provide automatic alarm and shutdown
functions on a fault condition.

Minimum requirements for indicators, alarms & control logic etc are shown in the attached P&ID.

Instrumentation shall be supplied in accordance with the attached Specification for Instrumentation for
Packaged Unit.

Burner Management System (BMS) shall be a non-redundant PLC based system local to each heater and shall
be capable to control and monitor the heater operation and allied equipment. BMS shall be provided as a local
panel mounted on skid complete in all respects. BMS shall provide following major features, as a minimum.

System Startup complete with automatic system pre-checks.

Pilot and main burner monitoring including alarms on flame out.

Burner Ignition System.

Pilot and main fuel line pressure monitoring and alarms including shutdown on high and low
pressures.

On-off control and status indications of air blower motor.

Hot oil outlet temperature control through control valves on fuel lines including high /
low temperature alarms.

SDVs on main and pilot fuel lines and its closure on process upsets as shown on the P&ID.
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Respective Heater Shutdown in case of process upsets (SD- 8102, SD-8103, SD-8104) on individual
heater.

Heater shutdown in case of overall Hot oil Unit Shutdown (USD-8101) on receipt of signal from UCP.

All other local indications, alarms andinterlocks as shown on the P&ID and as necessary for the safe
and reliable operation of the equipment.

Modbus Rs-485 Interface with Hot Oil Unit Control Panel (UCP) for communication
of all BMS data to UCP.

Hard-wired signals to and from UCP for communication of shutdown signals.

BMS panel shall be suitable with minimum ingress protection of IP65. The enclosure shall also contain
necessary marshalling terminals and space heaters.

The panel shall also provide mounted indications of major parameters necessary during start-up and
maintenance of the Unit.

Control mechanisms, switches, contacts and relays shall be enclosed such that surrounding atmosphere
conditions shall not corrode or affect control actions. Control mounting on skid shall be such that vibration from
operating unit shall not affect action or life span of control.

Direct-solenoid-operated valves shall be used only in clean, dry instrument air service. Each solenoid coil shall
have Compatible Insulators Class and shall have a continuous service rating.

Cause & Effect Matrix/Shutdown Schedule shall be developed by CONTRACTOR / SUPPLIER, and control
panel schematics and wiring diagrams shall be prepared accordingly.

7.0 MATERIALS
7.1 Tubes and Fittings

Heater tubes shall be seamless in accordance with ASTM A106 Grade B or equal unless otherwise specified
on the data sheets.

Flanges and all forgings shall be in accordance with ASTM AI05 or equal unless otherwise specified on the
data sheets.

Materials for 180 degree U-bends shall be in accordance with ASTM Specification A181, Grade II, A-216,
Grade WCB or equal. The specific material selected shall be approved by the COMPANY.

7.2 Bolting

Bolting shall be furnished by the fabricator for all cover plates, man-ways, and bolted attachments supplied with
the Unit.

7.3 Gaskets

Gaskets shall be supplied in accordance with Piping Material Specification.

7.4 Tube Supports


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Tube support materials shall generally be restricted to the following:

For metal temperatures 650C and above: Cast 25% Cr - 12% Ni.

For metal temperatures under 650C: heat resistant alloy cast iron (ASTM A319 Class III type C) or 2-1/4% Cr -
1% Mo (ASTM A217 Gr WC9)

For prefabricated coils where coils are lifted into place by the tube sheet alloy cast iron shall not be used.

Tube support brackets for the shield section or where fuel gas temperatures are in excess of 650C, shall be
25%Cr - 12%Ni material.

For other areas where the fuel gas is less than 650C, type 321 or 347 stainless steel shall be used (when
brackets are made of plate).

Guide plates in convection sections shall be 18/8 type 321 or 347 stainless steel for tip temperatures greater
than 530C (6mm thick) and C.S. for lower temperatures (6mm thick).

End tube supports in radiant and convection sections shall be 12mm structural steel plate attached to the
structural framing with suitable provisions for expansion. The tube sheet shall be protected with a minimum of
100mm insulation or as stated on the data sheets. 18/8 type 321 or 347 stainless steel sleeves with an inside
diameter approximately 12mm greater than the tubes shall be welded to the plate at each tube hole to protect
the insulation. The clearance between the OD of tube and the ID of sleeve shall be packed with insulation to
protect the end wall.

7.5 Refractories and Insulation

Refractory/insulating materials shall be suitable for a service temperature of at least 615F above the design
surface temperature.

For floor areas subject to maintenance traffic a proprietary castable shall be used. The minimum thickness shall
be 130mm.

Monolithic insulating concrete lining thicknesses of 75mm and above shall be scored with 5mm wide by 25mm
deep grooves in panels 450mm square.

All walls, arches and floors shall be designed to allow for expansion of all parts. The CONTRACTOR /
SUPPLIER shall show on his drawings or associated parts lists, all materials used for refractory walls,
insulation, etc.

8.0 FABRICATION
No fabrication shall commence until CONTRACTOR / SUPPLIER has received written approval of his detailed
shop drawings from the COMPANY.

Acceptance standards for radiography and ultrasonic testing shall be in accordance with Section VIII Div I of
the ASME Boiler and Pressure Vessel Code.

The CONTRACTOR / SUPPLIER shall submit his welding procedures for all weld types to the COMPANY for
approval prior to fabrication. Each weld procedure shall be accompanied by a suitable procedure qualification
record, tested in accordance with the requirements of ASME IX.
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Welding shall be carried out with procedures and operators qualified in accordance with Section IX of the
ASME Boiler and Pressure Vessel Code.

Backing rings shall not be used.

Stitch welding is not permissible on any part of the Heater package.

The heater, skid and all ancillary components, such as ducting, shall be equipped with lifting lugs which shall be
100% checked using MPI.

Stress relieving shall be employed where required by design code or Companies specific requirements, as
indicated on the data sheets.

9.0 DRAWINGS, CALCULATIONS AND DOCUMENTATION


Documents, calculation sheets, drawings, etc., to be submitted to the COMPANY shall be in English Language.

Unless otherwise specified, the US Customary System Units shall be used in documents and drawings. Pipe
sizes, flange sizes and bolts/nuts shall be indicated in inches.

The form of fabrication drawings and documents may be as per the CONTRACTOR / SUPPLIERs Standards.
However, the format of the data sheet will be submitted to COMPANY for approval.

Fabrication drawings and documents shall be submitted for the approval of the COMPANY. But, such approval
of the COMPANY shall in no way relieve the CONTRACTOR / SUPPLIER of his obligations with respect to
such drawings and documents.

Variations from or additions to this specification shall be called to the attention of the COMPANY and approved
in writing by the COMPANY prior to starting fabrication.

Welding procedure specification and welding qualification record shall be submitted to the COMPANY prior to
the start of fabrication.

Information for installation, operating, maintenance or inspection purposes shall be submitted to COMPANY.

CONTRACTOR / SUPPLIER shall provide all design drawings, calculations and other design documents for
COMPANYs approval prior to start of fabrication.

In addition, CONTRACTOR / SUPPLIER shall provide a comprehensive Operations & Maintenance Manual to
cover the entire supplied Package.

The CONTRACTOR / SUPPLIERs deliverables shall include but not limited to the following details:

Unit layout

Load data (vertical & horizontal) and Anchor bolt plan

Anchor bolt sizes and location

Fired Heater System, piping and auxiliaries

Skid structural design


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Itemized weights, including maintenance weights

Piping layouts and details of the complete system

Isometrics of the complete system

Step-wise start-up, purging, and shutdown procedures

Test procedures and erection details

Pre-start-up checklists

Maintenance schedules

General arrangement drawings

Cable layout plan on Skid.

JB Termination Drawings.

ISA data sheets for CONTRACTOR / SUPPLIER supplied instruments

List of all components with OEM brochures / catalogs / datasheets for all supplied instrumentation and
cabling system components.

List of recommended start-up, two years operation and overhaul spares for Fired Heater

CONTRACTOR / SUPPLIER connection drawings complete with detailed nozzle schedule.

CONTRACTOR / SUPPLIER shall make detailed calculations and shall prepare detailed shop drawings.
Shop details shall be complete with dimensions.

CONTRACTOR / SUPPLIER shall concurrently submit to the COMPANY, fabrication drawings and detailed
calculations for approval in accordance with the requisition.

Review of drawings, calculation and other documents by the COMPANY does not relieve the CONTRACTOR /
SUPPLIER of his responsibility for the suitability of the design to suit the stated conditions.

10.0 INSPECTION, TESTING AND CERTIFICATION


10.1 General

Inspection, testing and certification shall comply with the requirements as detailed in the requisition
documentation and in the other referenced specifications.

10.2 Inspection

The CONTRACTOR / SUPPLIER shall provide free access to his works and that of all sub-CONTRACTOR for
the authorized representatives of the COMPANY and the certifying authority (where applicable). To verify that
the requirements of the purchase orders are being met all material certification data and shop testing data, etc
shall be available for inspection.

The responsibility for inspection and testing remains with the CONTRACTOR / SUPPLIER.

10.3 Tests
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The CONTRACTOR / SUPPLIER shall give seven (7) days notice, to the COMPANY, of all tests, in order that
an authorized inspector may be present and inspect prior to the tests and witness the tests.

10.4 Hydrostatic Tests

All hydrostatic tests shall be made in the presence of an authorized inspector and with his approval. Heaters
shall not have been previously tested by the CONTRACTOR / SUPPLIER.

All completed heater coils and pipe-work shall be subject to hydrostatic tests as required by the governing code,
but test pressures shall not be less than 1.5 times the maximum allowable working pressure (new and cold).

After the final accepted hydrostatic test, the coil and pipe-work shall be dried and cleaned thoroughly of all
grease, loose scale, rust and weld spatter, both internally and externally.

10.5 Performance Tests

Burner performance or simulation tests will be required for non-proven burners. Also the prescribed tests on
refractory and insulating materials, i.e. test blocks, are required.

The instrumentation and controls shall be subjected to a full witnessed function test at CONTRACTOR /
SUPPLIERs works.

All ancillary equipment, which forms part of the package, such as Fans and Pumps, shall be fully witnessed
tested.

The CONTRACTOR / SUPPLIER may, at the discretion of the COMPANY, be required to conduct a
performance test on the heater when installed at the construction site and to substantiate the guaranteed
efficiency quoted by the CONTRACTOR / SUPPLIER. Performance test shall be as outlined in ASME IV e.g.
heat loss method.

10.6 Material Testing and Certification Requirements

The CONTRACTOR / SUPPLIER shall obtain the necessary approvals from the nominated certifying authority.

All necessary design calculations and drawings for the equipment shall be submitted to
COMPANY for approval.

The CONTRACTOR / SUPPLIER shall maintain a Heater Data Book containing, as a minimum, the following
documents:

Correspondence between COMPANY, CONTRACTOR / SUPPLIER and/or Certifying Authority (if


applicable).

Mill Certificates referenced by a parts list giving heat numbers, material, etc.

Welding procedures and qualifications referenced by a weld map giving weld number, welder, etc.

Heat Treatment Reports.

NDE results and certificates referenced by an appropriate list.

Hydrotest results referenced by a line sketch


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10.7 Final Reports and Data Sheets

Upon completion of the heater the CONTRACTOR / SUPPLIER shall furnish to the COMPANY the documents
data and drawings listed in the Purchase Documents.

10.8 Identification and Stamping

Each complete heater shall be provided with a 316 stainless steel nameplate, riveted to a nameplate bracket,
which is continuously welded to the heater structure and so located that it is easily accessible after installation.

Tubes, headers, tube supports, structural steel members, and other parts requiring identification for proper
assembly, shall be marked by paint stenciling, and such marking shall be shown on CONTRACTOR /
SUPPLIER'S drawings.

The nameplate shall contain, as a minimum requirement, the following information, in


English:

Service/Equipment Name.

Operating pressure.

Manufacturer's name.

Manufacturer's serial number.

Maximum allowable working pressure (Psig).

Date tested

Maximum tube test pressure (corroded) in Barg

Material construction of coil/pressure parts and corrosion allowance in mm.

Purchase Order No.

Stamp of Certifying Authority and inspection date (if applicable).

Contractors Equipment No.

Erected weight (lb).

Test weight (lb).

Heat absorption (btu/hr).

Design fluid pressure and temperature (Psig at f).

Design Code.

Year built.

Burner design heat liberation (mmbtu/hr).

Number and Sizes of Tubes - Radiant Section.

Installed Surface Area (m2) - Radiant Section.


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Number and Sizes of Tubes - Convection Section (if applicable).

Installed Surface Area {m2) - Convection Section (if applicable).

11.0 PAINTING AND PREPARATION FOR SHIPMENT


11.1 Painting and Protective Coating

Painting and protective coating and the procedures for preparation for painting shall be in accordance with the
requirements of the Project Specification for coating and painting.

11.2 Preparation for Shipment

All machined surfaces and threaded connections shall be protected by coating with rust preventive.

All flanged openings shall be protected with 6mm thick steel plate covers or one piece plywood covers.
Plywood covers to be 10mm thick for flanged sizes 6 ins and smaller, 13mm for sizes 8 ins. through 12 ins. and
19mm thick for larger sizes.

A minimum of four machine bolts shall be used for flange sizes 12 ins. and smaller and 8 bolts for larger flange
sizes.

Large washers are to be used on the flange side of the bolts. Suitable washers are to be used on the plywood
side of all covers.

Screwed connections are to be protected with threaded forged steel plugs. Cast iron or plastic plugs are not
acceptable.

The preparation for shipment of the package shall meet the requirement as detailed in the Specification for Skid
Mounted Packages.

12.0 SITE ACCEPTANCE TEST (SAT) AND COMMISSIONING ASSISTANCE


The CONTRACTOR / SUPPLIER shall be responsible to undertake a SAT prior to the commissioning and
pre-commissioning activities. It is also envisaged that CONTRACTOR / SUPPLIERs expert(s) will be required
to assist during pre- commissioning and commissioning of the equipment at the time of plant start up.
CONTRACTOR / SUPPLIERs expert(s) will be also required to train (Classroom and field training)
COMPANYs operations and maintenance personnel. All costs associated to the logistics required to perform
these activities shall be included in the bid price.

13.0 PERFORMANCE GUARANTEE


Approval by the COMPANY and the release of a heater for shipment shall in no way relieve the
CONTRACTOR / SUPPLIER of compliance with the provisions of this specification and its attachments and the
responsibility for the equipment to perform as indicated in the CONTRACTOR / SUPPLIER's
quotation/documentation.

The CONTRACTOR / SUPPLIER shall guarantee the following when the equipment is installed in accordance
with the its detail drawings:

1) The equipment meets all requirements of the specifications included in this specification.
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2) The equipment shall render satisfactory performance under continuous operation at the design
conditions. These conditions are outlined on the Data Sheets for this Specification.

COMPANY may subject the heater to a performance test within 12 months after the heater has been placed
into operation. The test procedure for determining the thermal efficiency of the heater shall be based on
Appendix G of API STD 560. The CONTRACTOR / SUPPLIERS representatives may witness these tests. The
CONTRACTOR / SUPPLIER shall take the necessary steps, at his expense, to make the heater meet
guaranteed performance if the heater does not perform in accordance with the specified requirements.

The CONTRACTOR / SUPPLIER shall guarantee that the system provided meets the requirements of the
functional performance of this specification, other project specifications, data sheets and P & IDs.

All equipment shall be guaranteed as follows:

All equipment shall perform satisfactorily under the specific operating conditions as detailed on the data sheet
and shall be fit for the intended purpose.

Tests shall confirm the CONTRACTOR / SUPPLIER's guaranteed performance.

The CONTRACTOR / SUPPLIER shall guarantee the mechanical and structural integrity, workmanship and the
materials of construction used in accordance with the requisition and requirements of this specification.