PETROCHEMICAL INDUSTRIES COMPANY (K.S.

C)
AROMATICS COMPLEX PROJECT

PROJECT SPECIFICATION

FIRED HEATERS

24870-00H-3PS-M000-M0070

Project Management Contractor (PMC)

This document has been generally revised and rewritten. It is based on

Document G5S-1821-01 Dated 01/03/04
REV

DATE

A
0
1
2
3

14-Aug-03
27-Aug-03
26-Apr-04
28-Jul-05
22-Aug-05

REVISION

BY

CHKD

APPR

Issued for IDC

Issued for Review
Issued for FEED
Issued for Re-Bid
Re-issued for Re-Bid

JB
JB
JB
JB
JB

EAP
EAP
PJ
DW
SG

APG
APG/VP
APG/KAS
APG/KAS
AC/KAS

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TABLE OF CONTENTS

1.0

PURPOSE ................................................................................................. 3

2.0

SCOPE ....................................................................................................... 3

3.0

REFERENCES .......................................................................................... 3

4.0

DEFINITIONS ............................................................................................ 5

5.0

SCOPE OF SUPPLY ................................................................................. 6

6.0

DESIGN ...................................................................................................... 9

7.0

FABRICATION........................................................................................... 22

8.0

PAINTING AND COATINGS ....................................................................... 22

9.0

INSPECTION AND TESTING ...................................................................... 23

10.0

VENDOR DOCUMENTS............................................................................. 26

11.0

OPERATING AND MAINTENANCE MANUALS ............................................ 26

12.0

SPARE PARTS .......................................................................................... 26

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1.0

PURPOSE
This specification has been developed to identify the general requirements of the
fired heater packages.
Order of hierarchy of documentation:

Supplement to UOP Project Specifications for each heater package

UOP Project Specifications for each heater package
This specification
UOP specification 2-12-4
Other specification and project documents

Where there are conflicting requirements that are not explicitly clarified,
OWNER/PMC shall be consulted for resolution.

EPC CONTRACTOR shall be responsible for providing all applicable documents

necessary to meet overall project requirements.
2.0

SCOPE
This specification covers scope of work for the heater VENDOR, design,
fabrication, inspection and testing, and minimum documentation requirements.

3.0

REFERENCES
3.1.

3.2.

Referenced Publications
3.1.1

Refer to UOP standard specification 2-12-4, para 2.2, for key

publications applicable to the design and construction of the units.
For associated equipment, e.g. motors and fans, standards shall
be in accordance with the applicable project specifications
referenced in this document. For project general codes and
standards, refer to Project Specification 24870-00H-3PS-M003Z0001 Codes, Standards & National Regulations.

3.1.2

It is the EPC CONTRACTORs responsibility that the equipment

including ancillary equipment shall comply with all applicable local
codes or regulations.

In the case of any discrepancies between any standards and project

specifications, the VENDOR shall request written clarification from the
purchaser. Any work performed before purchaser's written response will
be at the VENDOR's risk.

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3.3.

Reference Project Specifications

2-12-4

Fired Heaters (UOP Standard

Specification)

24870-00H-3PS-EY00-E0003

Electrical Requirements for Packaged

Equipment

24870-00H-3PS-J000-J0002

Instrument Design Criteria

24870-00H-3PS-JQ00-J0001

Package Unit Instrumentation

24870-00H-3PS-M000-M0004

VENDOR Documentation
Requirements for Technical Content

24870-00H-3PS-M000-M0008

VENDOR Documentation
Requirements for long lead items

24870-00H-3PS-M000-M0031

Rotating Equipment Minimum General

Requirements

24870-10H-3PS-M000-M0073

Safety and Control of Fired Equipment

24870-00H-3PS-M002-F0001

Basic Engineering Design Data

24870-00H-3PS-M003-Z0001

Codes Standards and National

Regulations

24870-00H-3PS-NX00-N0001

Shop and Field Painting

KA2S-5120-01

Fabrication and Erection of Structural

Steel

KA2Z-0001-01

Civil Engineering Design Criteria

KA4Z-0010-00

Piping Design Engineering Criteria

KA5S-2310-01

Fans in accordance with API-673,

Second Edition

KA5S-6403-01

Equipment Noise Specification

KA5S-7801-01

Storage and Shipping Preperation

requirements for Rotating Equipment

KA6D-0020-00

Instrumentation and Control

Requirements for Package Mechanical
Equipment

KA7D-0619-00

LV Induction Motors IEC Frame Sizes

up to 400 Standard Type.

KA8S-4001-50

Material Specification for Carbon Steel

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4.0

KA8S-4001-53

Material Specification for Alloys

KA8S-4001-60

Specification for Water Quality used for

Hydrostatic Testing

KA8S-4001-61

Positive Material Identification

KA8S-6500-01

General Welding Specification

KA20S-2181-00

Insulation Instructions

DEFINITIONS
OWNER

Petrochemical Industries Company (K.S.C.) Kuwait

PIC

Petrochemical Industries Company (K.S.C.) Kuwait

PMC

Project Management Contractor

LICENSOR

Provider of Licensed Technology

PROJECT

The Aromatic Complex at the Shuaiba Industrial Area,

Kuwait

EPC CONTRACTOR Engineering Procurement and Construction Contractor

VENDOR

Company / Organisation supplying equipment or

materials

PURCHASER

Company / Organisation that purchases materials or

services.

4.1.

SUB-VENDORs
Heater VENDOR shall meet the requirements of the project approved
VENDORs list, and shall provide a list of all remaining sub-VENDORs
considered in their proposal, which shall be subject to approval by EPC
CONTRACTOR and OWNER/PMC

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5.0

SCOPE OF SUPPLY
The heater VENDOR shall provide the requirements for Design, fabrication,
inspection, testing and delivering fired heaters with: combustion air pre-heater,
forced and induced draft fans, heating coils, combustion air ducts, radiant and
convection section, stack, and all accessories stated in this specification, and
described in the UOP Project Specifications for each fired heater.
The EPC CONTRACTOR shall take overall responsibility for the design and
performance of all equipment and accessories provided both individually and as
a system.
Heater VENDOR scope shall include but not be limited to the following
components:

Structural Steel, casing, ducting, breeching and stack.

Coils, supports, crossovers and terminals per Project Specifications.
Tube Supports
Insulation/ refractory and supports
Burners, pilots, ignitors, windboxes and plenums
Steam injection system (for oil firing)
Ladders, Stairways and Platforms
Access doors and observation windows.
Air Preheat system, including fans and drivers
Soot blowers and control system logic.
Process and Instrument Connections
Painting:
Prime coating of outer casing, and stack.
Full painting system for burners, sootblowers, fans, motors, air
preheat system etc, and selected instrumentation.
Ducts shall include but not be limited to:
Inlet screen, filter and stack,
Cold air from F.D. fans to Preheaters.
Hot Air from Preheaters to Furnace Burners

EPC CONTRACTOR may consider additional scope for heater VENDOR e.g.

Instrumentation identified on the P&IDs.

Self checking Flame Scanners, and purge fans
Fire box Pressure Transmitters
Tube skin thermocouples.
Fuel control skids and burner piping
Burner management logic programming and local panels
Coil Manifolds.

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The EPC CONTRACTOR shall provide the following items:

Foundation and Anchor Bolts

Field Erection (Under VENDORs Supervision)
External Insulation of Piping
Fireproofing (As Required)
Motor Starters and Overload protection
Instrumentation not in the agreed Heater VENDORs scope.
Final coat of paint for casing, and touch up at site.

5.1.

Battery Limits
5.1.1

Process Coil
Heater VENDORs scope shall be taken from the termination
points identified in the UOP project specifications and supplement
for each heater. This is typically the flange located close to entry
and exit of the heater.

5.1.2

Pipe work general

Provision shall be made for supporting and anchoring all pipe
work run from grade, or piperack.

5.1.3

Heater Instrumentation
Instrumentation shall generally not be in Heater VENDORs
scope. The only exception shall be for the damper controls.
Heater VENDORs scope shall be to provide all connection points
as required of the P&IDs and heater specifications.
Provision (i.e. fixings) for cabling and cable trays shall be provided
for routing around the heater structure.
Where heater VENDOR/ sub VENDOR considers specialist
components are required, these shall be offered as an option with
full specification provided for technical review.

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5.1.4

Controls
The heater VENDOR shall be fully responsible for the engineering
design and validation of the instrumentation, control, interlock,
Burner Management and firing control schemes for the heater.
Instrumentation will be supplied by the EPC CONTRACTOR,
heater controls, interlocks, Burner Management and firing
schemes will be implemented by the EPC CONTRACTOR in the
Plant wide Control Systems, validated and approved by the
VENDOR. Refer to Project Specification 24870-00H-3PS-M000M0073, Safety and Control of Fired Equipment

5.1.5

Electrical Supply.

Heater VENDOR shall provide electric motors, ignition

systems complete with local terminal boxes.
Option for aircraft warning lights shall be in heater VENDORs
scope from terminal box at grade.
Heater VENDOR shall make provision for cable, cable trays and
supports routed around the heater structure to all connection
point.
EPC Contractor shall provide interconnecting cabling, MCC, and
lighting at all access areas of the heater.
5.1.6

Civil / Structural
Heater VENDOR shall provide all structural steel, ladders and
platforms for the heater. EPC Contractor shall provide foundation
to top of concrete, however all necessary loading details shall be
provided by Heater VENDOR.

5.1.7

Burners.
Heater VENDOR shall supply burners, pilots, and ignition systems
including transformer. Supply of all burner piping shall be by
others, however, provision for routing pipework and cable around
heater casing shall be made.
The Burner Management System shall be within the DCS and
ESD system for the Aromatics plant. EPC CONTRACTOR shall
determine scope of work for heater VENDOR regarding the
development of the logic, and programming.

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5.2.

Guarantees.
The Heater VENDOR shall provide a warranty and guarantee all items
within Heater VENDORS scope in accordance with EPC
CONTRACTOR'S purchase order or contract.
Performance:

Thermal Efficiency of Heater at design conditions. (*)

Max Allowable Pressure drop through coils for the specified
cases. (*)
Design heat absorption duty of the heater not exceeding the
stated Design Tube Metal Temperatures. (*)
There is no flame impingement on coils, linings or tube supports.
Auxiliary equipment performs as specified in the Data Sheets.
(*) Licensor shall provide guarantee on UOP heaters. Heater
VENDOR shall provide guarantee for Non UOP heaters.

Mechanical:
The heater VENDOR shall provide a mechanical guarantee for the
operation of the heater for a period of (12) months after start up of plant,
or (18) months after site erection which ever is sooner.
Emissions:
The heater VENDOR shall provide a guarantee for the emissions for each
heater to meet the emission requirements as identified in the
Environmental Design Philosophy 24870-00H-3PY-H001-H0002.
Guarantees shall cover:

6.0

NOx
CO
Particulates
Unburnt Hydrocarbons.

DESIGN
6.1.

General
6.1.1

6.2.

The design and construction of the unit and accessory equipment

shall conform to the latest edition of API 560 and UOP standard 212-4, with additional requirements as detailed below.

Site Conditions
6.2.1

All equipment and accessories supplied shall be suitable for

outdoor installation and operation in a chemical plant located in
KUWAIT. Refer to Project Specification 24870-00H-3PS-M002F0001 Basic Engineering Design Data for site conditions.

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6.3.

6.4.

Maintenance
6.3.1

Equipment layout and orientation shall provide for ease of

maintenance . Refer to KA4Z-0010-00, Piping Design
Engineering Criteria for general plant requirement.

6.3.2

The furnace coils will not require provision for cleaning, unless
identified as a requirement in the data sheets.

Environmental and Safety Requirements

6.4.1

Furnace effluent emissions shall be verified by Heater VENDOR,

and stated in the data sheet.

6.4.2

The VENDOR shall provide a detailed list of any potential safety

hazards of the equipment provided. The EPC CONTRACTOR will
work with the VENDOR to eliminate these hazards as practical,
with consultancy from OWNER/PMC.

6.4.3

The equipment shall be designed to meet a sound pressure noise

level of 85 dB(A) at 1m or as specified on the project specification
data sheets. The quoted sound level shall be determined per the
requirements of noise specification KA5S-6403-01.
6.4.3.1.

6.5.

Utilities
6.5.1

6.6.

If the anticipated noise levels exceed the

levels specified, VENDOR shall provide details of the
required acoustical treatment (blankets, silencers, etc.)
required to meet the maximum noise level specified.

Utilities shall be generally available at the site as described in the

Project Specification 24870-00H-3PS-M002-F0001 Basic
Engineering Design Data document for the start-up, operation and
maintenance of the equipment provided. EPC CONTRACTOR to
advise any restrictions. Vendor shall state utility requirements in
proposal.

Instrumentation, Instrument Connections, and Controls

6.6.1

Instrumentation shall be in accordance with Project Specification

24870-00H-3PS-JQ00-J0001, Package Unit Instrumentation,
24870-00H-3PS-J000-J0002, Instrument Design Criteria, and
KA6D-0020-00 Instrument and Control Requirements for Package
Mechanical Equipment.

6.6.2

The control system shall be in accordance with Project

Specification 24870-10H-3PS-M000-M0073, Safety and Controls
for Fired Equipment.

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6.7.

Electrical
6.7.1

Refer to Project Specification 24870-00H-3PS-EY00-E0003 ,

Electrical requirements for Packaged Equipment

6.7.2

Routing of cable tray shall be evaluated to eliminate exposure to

high temperatures.

6.7.3

Motors shall be squirrel cage induction motors purchased in

accordance with Project Specification KA7D-0619-00 and data
sheets.

6.7.4

All conductive parts of non-electrical equipment shall be provided

with earthing lugs to receive the plant's earthing cable(s).
6.7.4.1.

6.8.

The earthing clip(s) shall be located at the outer

periphery of the equipment or baseplate(s). The
diameter of the connector hole shall be 12 mm (1/2
inch). Refer to Project Specification 24870-00H-3PSEY00-E0003 , Electrical requirements for Packaged
Equipment for full detailed requirements.

Material Considerations
6.8.1

The use of the following materials are restricted for any and all
components, accessories, or consumables supplied without
specific approval provided by the OWNER/PMC, in writing.
-

ASTM A515
Asbestos or Asbestos Containing Materials
Copper or Copper Containing Alloys
Glass in pressure retaining service
(The use of Pyrex glass installed on observation doors for
viewing of burner flames is permitted)
Brittle Materials i.e. gray cast iron

6.8.2

The following Project Specifications and referenced specifications

shall be utilized: KA8S-4001-50 and KA8S-4001-53.

6.8.3

Where Tube material has not been stated for project

specifications, they shall be as a minimum seamless carbon steel,
ASTM A106 grade B, and shall be subject to review by
OWNER/PMC.

6.8.4

Structural Bolting shall be ASTM A325 Type I high strength bolts.

6.8.5

Coil support brackets shall be selected based on maximum design

temperature (API 560, Table 8) and as a minimum shall be type
309 or 310 stainless steel.

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6.9.

6.10.

6.8.6

The material for firebox internals that are not cooled will be a
function of firebox temperature and the fuel used. VENDOR shall
provide a proposal supported with stress and creep calculations.
Contrary to UOP 2-12-4 para 4.5 c. Materials must be approved
by OWNER/PMC. (Type 304 SS is not recommended due to
potential chloride stress cracking. Acceptable use of 304SS shall
be agreed between EPC CONTRACTOR and VENDOR.)

6.8.7

In order to avoid the use of any counterfeit fasteners, VENDOR

shall provide proof of compliance with ASTM specifications by
submitting ,for review to EPC CONTRACTOR inspector, material
certificates or lab test reports.

6.8.8

OWNER/PMC or EPC CONTRACTOR may test random samples

of fasteners for compliance with ASTM specifications, at their
expense. If any tested sample fails to meet the specified
properties, composition, hardness, etc., then all fasteners shall be
replaced at VENDOR's expense, with materials that comply with
specifications.

6.8.9

Thermowells in the radiant and convection sections should be

made from the same material as nearby coil supports.

Fired Heater
6.9.1

All passes shall be designed for hydraulic and thermal symmetry

6.9.2

Explosion vent doors shall not be used on Fired Heaters

Tubes
6.10.1 Tubes shall be arranged to permit replacement without loss of
other tubes or dismantling of baffles, casing, or insulation. Tube
supports shall not interfere with the removal of tubes and/or
fittings.
6.10.2 Coils shall be designed such that field welds are minimized.
6.10.3 Crossovers shall be designed to permit thermal expansion of the
tubes without overstressing any part or causing any interference
with expansion of the tubes from uneven heating between
sections.

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6.10.4 In addition to UOP Specification 2-12-4 para 3.2(5) the extended

surface in convection sections shall be of the solid fin type, where
helical wound fins are continuously welded to the tube. Material
shall be supplied in a product form and with a suitable finish for
manufacture into heat transfer fins. Welding of fins shall be by the
Electric Resistance Welding (ERW) method only. If joining of tube
sections is required to make the specified length for finned tubes,
all welds between tube sections shall be examined by liquid
penetrant and radiographic examinations, in accordance with the
requirements for other butt welds, prior to finning. Butt welds
under fins are not permitted.
6.10.5 Tube bundles where possible, should be designed so that they
can be removed as a complete assembly without any cutting.
6.11.

Tube Supports
6.11.1 Corbels shall be used in the convection section of the furnace in
order to minimize flue gas bypass.
6.11.2 All corbels shall have rounded corners to eliminate high thermal
stress cracking or spalling.
6.11.3 Tube supports shall be designed to support the fired heater coils
full of cold water or process fluid at ambient temperatures.
6.11.4 Sufficient intermediate supports for horizontal tubes shall be
provided so that the maximum sag of the unsupported tube length
does not exceed 2.5 mm (0.1 inch).
6.11.5 Supports, guides, and brackets shall be designed to permit
thermal expansion under all conditions without over stressing any
part or causing any interference that would obstruct expansion of
the tubes.

6.12.

Refractory and Insulation

6.12.1 The heater VENDOR shall supply all refractory and internal
insulation. Refractory shall be installed and supported in a manner
consistent with the refractory manufacturers recommended
method. Refractory must not contain asbestos.
6.12.2 VENDOR shall identify the style, type and grade of all
refractory/insulation anchors, supports, etc. used throughout the
heater and their method of attachment for EPC CONTRACTOR
approval.
6.12.2.1.

The VENDOR shall provide start-up instructions for

drying/curing the refractory/insulation.

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6.12.3 The maximum outside skin temperature of the fired heater shall
not exceed 60C when calculated using a wind velocity of 8 km/h,
an ambient temperature of 30C and a relative humidity of 85%.
6.12.4 A containment ledge shall be supplied around the radiant doors to
insure radiant wall insulation remains intact when door is in use.
6.12.5 Doors shall utilize the same refractory or insulation as specified for
that section of the fired heater where they are to be installed.
Vacuum formed refractory shall be used for the doors.
6.12.6 Prior to installing refractory, a high temperature protective coating
shall be applied to inner surface of the heater shell after all
anchors have been welded. This coating must have a temperature
resistance of at least 180C (350F). This coating shall cover the
anchors so the uncoated parts are above water vapor and any
acid dew point temperatures.
6.12.7 EPC CONTRACTOR shall be responsible for ensuring that
refractory installed at site is stored, preserved, prepared, installed,
tested and cured in accordance with refractory VENDOR
instructions. Castable samples of each mixed batch shall be
tested per ASTM C401.
6.12.8 Radiant Section Floor Lining:

6.12.9

6.12.8.1.

Lining shall be insulating castable (next to shell)

topped with a protective layer of firebrick or high
strength castable.

6.12.8.2.

Firebrick shall be a minimum 65 mm (2 1/2 inch) thick

and at least a high-duty grade. Floor brick shall not be
mortared. A 12mm gap for expansion shall be
provided at approximately 2 metre intervals. This gap
should be packed with 1260C (2300F) ceramic fiber
material in strip, not loose bulk form.

6.12.8.3.

High strength castable shall have a minimum

modulus of rupture strength of 41 bar and meet or
exceed the requirements of ASTM C401 Class C.
Insulating castable shall meet ASTM C104 Class Q
requirements. All castable/gunite refractory shall be
suitable for a service temperature at least 165C above
its calculated hot face temperature.

Radiant Section Shell/Roof & Convection Section Tubesheets:

6.12.9.1.

Lining can be either insulating castable/gunite or

ceramic fiber (layered or modules) or a combination
there of.

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6.12.9.2.

Insulating castable/gunite shall be meet ASTM C401

Class Q or P requirements. Castable/gunite refractory
shall be suitable for a service temperature at least
165C above its calculated hot face temperature. Low
iron content castable shall be used when total heavy
metals content within fuel exceeds 100 parts per
million.

6.12.9.3.

Ceramic fiber shall be at least 128 kilograms/cubic

metre (8 pound/cubic foot) density needled blanket
when applied as a hot face layer. Needled blanket
used for modules must be rated for a minimum of
1260C (2300F). If a layered ceramic fiber lining is
used, the ceramic fiber suitable for service at least
260C (500F) above its calculated hot face
temperature. However, no ceramic fiber material shall
be rated for temperatures less than 1260C (2300F).
Ceramic fiber board, when applied as a hot face layer,
shall not be less than 250 kilograms/cubic metre (15
pounds/cubic foot) density.

6.12.9.4.

Ceramic fiber blanket shall not be used as a hot face

layer when gas flow over its surface exceeds 12 m/sec
(40 ft/sec). Castable, wet blanket, ceramic fiber board,
or ceramic fiber modules shall be used on hot face
layers where velocities are between 12 to 24 m/sec (40
to 80 ft/sec). When velocities exceed 24 m/sec (80
ft/sec) the hot face refractory shall be castable.

6.12.9.5.

Ceramic fiber systems shall not be used if total heavy

metals content in the fuel exceeds 100 parts per
million.

6.12.10 For external insulation applications, refer to KA20S-2181-00,

Insulation Instructions.

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6.13.

Castable/Gunite Construction Requirements :

6.13.1 All castable/gunite must be pre-formulated/bagged by the
refractory manufacturer; no field mixing of separate components
of calcium aluminate cement and aggregate is allowed.
6.13.2 For dual layer castable construction (ex. floor with insulating &
high strength castable) the minimum thickness of each layer shall
be 75 mm (3 inches).
6.13.3 Installed anchor length shall be approximately 80% of the castable
thickness but no closer than 25 mm (1 inch) to the hot face.
6.13.4 Anchor spacing shall be a maximum of three times the total lining
thickness but shall not exceed 300 mm (12 inches) on a square
pattern for walls and 230 mm (9 inches) on a square pattern
overhead (roof). Anchor orientation shall be varied to avoid
creating continuous shear planes.
6.13.5 Minimum 6 mm (1/4 inch) diameter anchors shall be used when
total refractory thickness <150 mm (6 inches). Minimum 8 mm
(0.32 inch) diameter anchors shall be used if the total refractory
thickness exceeds 150 mm (6 inches).
6.13.6 Anchors shall provide retention and support for each component
layer.
6.13.7 Castable linings in any header boxes, breeching, and lined flue
gas duct and/or stack shall not be less than 50 mm (2 inch) thick.
Anchors in 50 mm (2 inch) thick castable lining shall be held in
place by 10 gauge minimum, bare carbon steel chainlink fencing,
wire mesh, or liner anchors anchored to the shell. If chain link
fence is used as the anchorage system it should be continuous
sheets of fencing. Individual fence wire strands welded to the shell
is not acceptable.
6.13.8 Expansion joints shall be installed around burner blocks and any
other penetrations through the castable lining. Expansion joint
material shall be 25 mm (1 inch) thick ceramic fiber in strip (not
loose bulk form), a minimum density of 100 kilograms/cubic metre
(6 pounds/cubic foot), and rated for at least 1260C (2300F).
Expansion joint width shall not exceed 12 mm (1/2 inch) anywhere
in heater. If wider expansion joint width is needed it shall be
brought to OWNERs attention for approval.

6.14.

Ceramic Fiber Construction

6.14.1 The hot face of layered ceramic fiber blanket installations shall be
a minimum of 25 mm (1 inch) thick.
6.14.2 Ceramic fiber board, when applied as a hotface layer, shall not be
less than 40 mm (1 1/2 inch) thick.

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6.14.3 Ceramic fiber blanket shall be installed with its longest dimension
in the direction of gas flow. The hotface layer of blanket shall be
constructed with all joints overlapping a minimum of 50 mm
(2inch). Overlaps shall be in the direction of gas flow.
6.14.4 Anchors shall be attached to shell before layered fiber or modules
are installed.
6.14.5 The anchor spacing for overhead locations shall not exceed the
following rectangular pattern:
6.14.5.1.
150 mm by 230 mm for 300 mm (6 inch by 9 inch for
12 inch) wide blankets.
6.14.5.2.

230 mm by 230 mm for 600 mm (9 inch by 9 inch for

24 inch) wide blankets.

6.14.5.3.

230 mm by 255 mm for 900 mm (9 inch by 10 inch for

36 inch) wide blankets.

6.14.5.4.

230 mm by 270 mm for 1200 mm (9 inch by 10 1/2 inch

for 48 inch) wide blankets.

6.14.5.5.

The anchor spacing for walls shall not exceed the

following rectangular pattern:

6.14.5.6.

150 mm by 230 mm for 300 mm (6 inch by 9 inch for

12 inch) wide blankets.

6.14.5.7.

230 mm by 300 mm for 600 mm (9 inch by 12 inch for

24 inch) wide blankets.

6.14.5.8.

270 mm by 300 mm for 1200 mm (10 1/2 inch by 12

inch for 48 inch) wide blankets.

6.14.6 The hot face layer of ceramic fiber blanket system shall be
anchored a maximum of 75 mm (3 inch) from all edges.
6.14.7 Doors shall be installed with the same refractory/insulation as
specified for that section of the fired heater where they are to be
installed. These shall be ceramic fibre vacuum formed shapes,
not loose fibre

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6.14.7.1.

6.15.

A containment ledge shall be supplied around the

radiant doors to insure the radiant wall insulation
remains intact when the door is in use.

Structure
6.15.1 Structural Design shall be in accordance with Project Specification
KA2Z-0001-01, Civil Engineering Design Criteria and KA2S-512001, Fabrication and Erection of Structural Steel. Windloads and
Earthquake details are provided in Project Specification 2487000H-3PS-M002-F0001 Basic Engineering Design Data.
6.15.2 All handrails, ladders, platforms, stairways, and hardware for the
fired heater and its accessory equipment shall be supplied by the
VENDOR and be of hot dipped galvanized carbon steel material
6.15.3 Structural stiffeners, etc., shall be arranged so there are no blind
spots left uncovered by the standard coating practices. If close
contact is required, the members shall be seal welded.

6.16.

Header Boxes, Doors and Ports

6.16.1 Access openings and observation ports shall be so arranged and
located to avoid obstruction by piping, supports, fired heater parts
or the fired heater setting which would interfere with the inspection
of, repairs to, or replacement of tubes.
6.16.2 Convection section casing access doors shall be pre-insulated,
external, hinged, swing-out type, made as large as possible so as
to facilitate inspection. Grab bars shall be supplied above each
door. Cast iron shall not be used.
6.16.3 Stack access shall be a bolted, removable door, 500 mm (20 inch)
wide by 750 mm (30 inch) high.
6.16.4 Convection header box plates shall be at least 5 mm (1/4 inch)
thick, reinforced against warping where necessary. Housing shall
have bolted removable sections. Horizontal partitions are required
in header boxes to minimise flue gas bypass.
6.16.5 All tube bundles shall be provided with flanged access (end)
covers.
6.16.6 Size, location, and type of all access doors, inspection and
observation ports shall be subject to OWNER's approval and shall
as a minimum meet API 560 requirements.

6.17.

Stack
6.17.1 The stack shall be mounted and supported on the fired heater
structure and be of self-supporting construction without the use of
guy wires.

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6.17.1.1.

Stack design and thickness shall be adequate to

prevent distortion, crimping, or buckling during erection
or operation at design conditions and wind loads.

6.17.2 Wind-Induced Vibration Design

6.18.

6.17.2.1.

Stack shall be designed such that the maximum stack

deflection is less than 100 mm (4 inch) per 30 m (100
ft). Vortex breaker strakes may be added if necessary.
EPC CONTRACTOR shall advise VENDOR of
neighboring tall structures.

6.17.2.2.

VENDOR shall state the deflection to be expected for

various wind conditions. The calculations shall be
submitted for purchaser's approval.

Burners
6.18.1 Burner type shall be selected to meet the emission requirements
as identified in the Environmental Design Philosophy 24870-00H3PY-H001-H0002..
6.18.2 Burners shall be designed for the site conditions stated in the
Project Specification, 24870-00H-3PS-M000-F0001, Basic
Engineering Design Data, in particular the potential for sand and
dust in the combustion air.
6.18.3 Burners shall be designed to prevent direct impingement of the
flame on the refractory, structural members, or pressure parts.
6.18.4 All burners shall have light-off from pilots with ignitors.
6.18.5 VENDOR shall have complete description of pilot / ignitor with
quotation. Pilot/ignitor will be subject to OWNER/PMC approval.
6.18.6 VENDOR to supply minimum, normal and maximum burner
capacity
6.18.7 Unless additional turndown is required per the datasheet, the
minimum heater turndown ratio shall be 4:1.
6.18.8 Nozzles and air mixing devices shall be designed to eliminate
pockets or pools of liquid fuel.
6.18.9 For floor firing furnaces, the burners shall be positioned so the
operator need not get under the furnace to adjust them.

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6.19.

Dampers
6.19.1 Suitable automatic remotely controlled dampers for combustion
control shall be provided. These dampers shall be pneumatically
actuated by a 4-20 mA signal from the DCS, with a manual
override for maintenance.
6.19.2 The dampers shall be provided with mechanical stops so that
closure shall not exceed the maximum furnace turndown.
6.19.3 All bearings and pivots shall have provisions for lubrication while
they are operating.

6.20.

Inlet Air and Silencer

6.20.1 The inlet stack shall be provided with a "bird screen" to prevent
debris from entering the air ducting.
6.20.2 Screen mesh size shall be 6 mm (1/4 inch).
6.20.3 The ambient air intake stack shall be elevated at least 5m above
grade, and located away from possible leakage sources of
combustible products. The site is subject to sand and dust
storms. Inlet Filter shall be designed for dust size and quantity as
specified in the Project Specification 24870-00H-3PS-M002F0001 Basic Engineering Design. Inlet shall be easily accessible
for ease of changing.

6.21.

Combustion Air Preheater (where specified)

6.21.1 Location of the preheater shall be at or near grade and final
location shall require EPC CONTRACTORs approval.

6.22.

Piping and Manifolds

6.22.1 Piping shall be designed to provide proper flexibility and normal
accessibility for operation, maintenance, drainage, and thorough
cleaning.
6.22.2 All process connections shall terminate on the same end of the
fired heater and extend a minimum of 300 mm (12 inch) past the
last firebox structural steel member. Other nozzle projections
shall be a minimum of 230 mm (9 inch) from the outside shell.
6.22.3 Back-welded threaded connections and pipe bushings are not
acceptable.
6.22.4 All nozzles and flanges shall be in accordance with ANSI B16.5
and the project specification datasheets.
6.22.5 Flange bolt holes shall straddle the normal centerlines of the pipe
and equipment.

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6.22.6 Consideration for thermal expansion from cold start to maximum

operating conditions shall be examined to insure no excessive
forces are applied to fired heater coils or coil nozzles extending
outside the fire box.
6.23.

Platforms
6.23.1 In addition to UOP standard 2-12-4, platforms shall be provided at

all terminal process nozzles on the furnace.

all end fired burners.
any other area where it is deemed necessary for access to
instruments or for normal maintenance and operation.
for access to the process outlets on the heater radiant roof.

6.23.2 Banded openings shall be provided in the platform grating for

penetration of all piping and cable tray.
6.23.3 All burner access platforms and the hearth platform shall be
accessed by stairs. All other platforms may be accessed by stairs
or ladders.
6.23.4 Design of stairs and ladders shall be in accordance with Project
Specifications KA2D-5510-05, KA2G-5510-00, KA2G-5510-02,
KA2G-5515-01, KA2G-5515-02, KA2G-5515-03, KA2G-5515-04,
KA2G-5515-20, KA2G-5520-00,KA2G-5520-05, KA2G-5520-10,
KA2G-5530-01, KA2G-5530-05, KA2Z-0001-01, and KA2S-512001.
6.24.

Nameplates
6.24.1 The VENDOR shall furnish and affix an engraved Stainless Steel
nameplate (with Stainless Steel Fasteners)to a bracket on the
outside of each tagged item containing at least the following
information:
6.24.1.1.

Fired Heater: Manufacturer, serial number, design

temperature, design pressure, hydrotest pressure, item
number, and purchase order number.

6.24.1.2.

Other Tagged Items: Manufacturer, model, serial

number, item number, and purchase order number.

6.24.2 The VENDOR shall show the location of the nameplate on shop
drawings.
6.25.

Fans and Blowers

For all fan and blower requirements refer to Project Specificaiton

KA5S-2310-01, Fans in accordance with API-673 Second Edition.
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and 24870-00H-3PS-M000-M00031 Minimum Requirements for

Rotating Equipment.
7.0

FABRICATION
7.1.

8.0

General
7.1.1

Welding shall be in accordance with KA8S-6500-01, General

Welding Requirements

7.1.2

The VENDOR shall submit welding procedures (WPS and PQR)

for all piping, tube support welding, casing and structural welding.

7.1.3

Welders shall be qualified to ASME Section IX (or AWS D1.1 for

structural items only)

7.1.4

VENDOR shall maintain records of welder qualifications, welding

procedures, radiographs for a period of at least five (5) years.

7.1.5

Backing rings are not acceptable in any header without OWNER's

approval.

7.1.6

Nozzle reinforcing pads shall be provided with at least one pipetapped vent hole, and shall have brightly colored plastic plugs.

7.1.7

Bolt holes in structural members shall be drilled or punched.

Burning of holes will not be permitted.

7.1.8

Riveted construction is prohibited. All internal and external welds

shall be continuous; skip or tack welding is not permitted.

7.1.9

The gasket surface finish of all nozzles and flanged joints shall be
3 to 6 microinches arithmetic average roughness (Ra) if not
otherwise specified on the specification data sheets.

PAINTING AND COATINGS

8.1.
All exterior carbon steel surfaces and shall be prepared and painted in
accordance with 24870-00H-3PS-NX00-N0001, Shop and Field Painting.
8.2.

Platforms, walkways, stairs, ladders, safety cages, and all structural steel
shall be hot-dip galvanized in accordance with ASTM A123. Associated
nuts and bolts shall be hot-dip galvanized in accordance with ASTM
A153. Refer to 24870-00H-3PS-NX00-N0001, Shop and Field Painting.

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9.0

INSPECTION AND TESTING

9.1.

General
9.1.1

9.2.

Weld Inspection
9.2.1

9.2.2
9.3.

Inspection by the OWNER/PMC or EPC CONTRACTOR

representative shall not relieve the VENDOR from compliance
with this specification, API 560 requirements and documents
referenced in this specification.

Coil Welds
9.2.1.1.

Contrary to UOP 2-12-4, para 3.4, all Radiant and

convection coil welds shall be 100% radiographed
per ASME Section 8 Div 1.

9.2.1.2.

All weld-repaired areas shall be radiographically

reexamined.

9.2.1.3.

All radiographic film shall be available for

examination by OWNER/PMC's representative at
any time.

9.2.1.4.

10% of Burner piping shall be 100% radiographed

per ASME Sec 8 Div 1.

PMI shall be completed in accordance with KA8S-4001-61.

Pressure Testing
9.3.1

Coil assemblies shall be hydrostatically tested in accordance with

API-560. The pressure shall be held long enough for the inspector
to complete the visual inspection.
9.3.1.1.

Water quality shall be per project specification KA8S4001-60

9.3.2

Any defects found, as a result of the hydrotest shall be repaired.

After repairs are made the coil assemblies shall be completely
retested.

9.3.3

All reinforcing pads shall be tested with air and soap solution
before the hydrostatic test, at 1 bar (15 psig).

9.3.4

Coils shall be blown free of hydro test water, purged with nitrogen,
and then sealed to prevent rusting.

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9.4.

Burner Testing
9.4.1

9.5.

Air Preheater Testing

9.5.1

9.6.

9.8.

Air Preheater shall be pressure tested for containment of both

flows, and leakage tested to verify cross flow of air to fluegas.
Performance of Air Preheater shall be tested at site as part of the
heater performance test.

Performance Testing
9.6.1

9.7.

Heater VENDOR shall provide a one burner test for each burner
type and size. As a minimum, the test shall demonstrate stable
operation at the specified turndown firing rate and stable operation
at design firing rate and 90% of the theoretical air required. Refer
to API 535 for recommended testing requirements

Each heater with ancillary equipment will be tested In Situ within

90 days of the plant start-up. EPC CONTRACTOR or OWNER will
notify the VENDOR 14 days prior to the start of the test.

Centrifugal Fan Testing

9.7.1

Mechanical Run Test (per API 673 para 4.3.3) for each blower.

9.7.2

Quote (as an option) Performance test in accordance with per API

673 para 4.3.4.1.

Preparation for Shipment

9.8.1

Packing and unpacking instructions shall be provided with each

individual container.

9.8.2

Each container shall be packed with a bill of materials of the items

located within.

9.8.3

All flange faces, nozzles, lugs, supports, etc., shall be protected

from damage during shipment.

9.8.4

All piping connections shall be sealed with light duty, gasketed,

painted, steel flanges.

9.8.5

All screwed openings shall be plugged.

9.8.6

Coils for fabrication at site shall have as a minimum end caps to

minimise ingress during shipment.

9.8.7

All moving parts shall be secured in place for shipment.

9.8.8

The fired heater shall be cleaned of all foreign objects, including

hydrostatic test water, wiped dry, and all openings shall be blinded
before shipment.

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9.8.9

Fired heater sections shall be packaged for shipment such that

rain or other foreign matter cannot collect in the sections during
shipment or storage.

9.8.10 The fired heater shall be marked with the main body of each part
and each removable section thereof identified by painting the
purchase order number, weight, and the fired heater item number
on two opposite sides in clearly visible positions and in letters at
least 50 mm (2inch) high.
9.8.11 All loose items shipped shall be identified with tags giving the
purchase order number, item tag number, and piece marks
corresponding to their respective identification as shown on
VENDOR's drawings.
9.8.12 If special handling in the moving of a unit is required, lift points
and/or any special instructions deemed necessary shall be clearly
marked on the unit with paint in letters at least 75 mm (3 inch)
high.
9.8.13 The VENDOR shall furnish and ship with the fired heater any
special tools required for erection, inspection, and maintenance of
the fired heater and accessories.
9.8.14 Lifting lugs shall be provided at all locations required to facilitate
field handling and erection. VENDOR shall provide detailed lifting
procedure for the fired heaters to the EPC CONTRACTOR.
9.8.15 All bolts and nuts that will be shipped loose shall be sorted and
packaged by size and description and identified in the same
manner.
9.8.16 All rotating equipment shall be prepared for shipping and long
term storage in accordance with Project Specification KA5S-780101.
9.8.17 All modules or units must be fabricated so that they can be
transported over the plant roads and under overhead obstructions.
The method of transport (marine or motor-freight) and axle loading
to the In-plant bridges shall be approved in advance by the EPC
CONTRACTOR. The maximum sizes for transport shall be
confirmed by EPC CONTRACTOR: (NOTE: Site is local to a deep
water port)

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10.0

VENDOR DOCUMENTS
Refer to Material requisition for minimum VENDOR document requirements,and
Project Specification 24870-00H-3PS-M000-M0008, VENDOR documentation
Requirements for Long Lead Items.

11.0

OPERATING AND MAINTENANCE MANUALS

11.1.

Refer to Project Specification 24870-00H-3PS-M000-M0004, Vendor

Document Requirements for Technical Content.

11.2.

Installation and operating manuals for the fan shall contain the pressure,
volume, horsepower and efficiency performance curves operating and
test block conditions. The curves shall indicate the damper position
necessary to obtain each operating point.

11.3. The furnace operating manual shall list basic design assumptions such as
minimum and maximum rates, inlet and outlet process temperatures, maxim fire
box temperatures at various locations, maximum metal temperatures for radiant
and convection tubes. The manual shall explain how to calculate maximum film
temperatures as variables are changed ( e.g. Changes in flow rates, inlet
temperature, firing rate, etc).

11.4.

12.0

If Ceramic Fibre Blanket is used for insulation, then Health and Safety
method statements for initial application, and subsequent heater entry
shall be clearly identified.

SPARE PARTS
Refer to Project Specifications 24870-00H-3PS-M000-M0031 for rotating
equipment spare parts. EPC CONTRACTOR shall confirm overall
requirements for commissioning and start up.

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