Specification For Fired Heaters

Specification for Fired Heaters
Doc No. SP-00-M-0008 Rev 2
Contents
Introduction
1.1
1.2
General
Vendor Responsibility
4
4
Definitions
Reference Documents
3.1
3.2
Codes and Standards

Company Specifications
4
5
Scope of Supply
4.1
4.2
Work Included
Vendors Responsibility
5
5
Environmental Design Criteria
5.1
5.2
Location and Environmental Conditions

Hazardous Area Classification
6
6
Design Requirements
6.1
6.2
6.2.1
6.2.2
6.3
6.4
6.5
6.5.1
6.5.2
6.5.3
6.6
6.7
6.7.1
6.7.2
6.7.3
6.8
6.8.1
6.8.2
6.8.3
6.8.4
6.9
6.10
6.11
6.12
General
Tubes
General
Extended Surfaces
Piping and Manifolds
Tube Supports
Structures
General
Wind Loads
Earthquake Load
Stacks and Ducts
Burners and Auxiliary Equipment
Burners
Damper Controls
Plenums
Instrumentation and Control
General
Burner Management System (BMS HIMA)
Air Fuel Ratio Control
Auxiliary Connections
Electrical
Insulation
Noise
Nameplates
6
6
6
7
7
8
9
9
9
10
10
11
11
12
12
13
13
13
14
14
15
15
15
15
Inspection, Testing And Certification
16
7.1
7.2
7.3
7.4
7.5
General
Inspection and Testing
Hydrostatic Tests
Equipment Performance Tests
Functional Tests
16
16
17
17
17
SP-00-M-0008 Fired Heaters
Sheet 2 of 18
7.6
Material Testing and Certification Requirements
17
Performance Guarantees
18
Painting and Preparation for Shipment
18
9.1
9.2
Painting and Protective Coating

Preparation for Shipment
18
18
10
Document and Data Submittal Requirements
18
11
Quality Assurance
18
Sheet 3 of 18
Introduction
1.1
General
This Specification covers the Purchasers minimum requirements for the design,
manufacture, supply, inspection and testing of Fired Heaters to API 560.
1.2
Vendor Responsibility
The Vendor shall be responsible for the design, production of materials, manufacture,
assembly, preparation for shipment, supply of drawings and data, all sub-vendor coordination, testing and guarantees, plus the provision of skilled personnel for the works
assembly and testing of the complete unit in accordance with this Specification.
Definitions
2
Company
OMV (Pakistan) Exploration GmbH
Purchaser
Clough Engineering Limited
Vendor
Entity engaged by the

equipment and services
Manufacturer
Entity who manufactures the equipment of concern.
Reference Documents
3.1
Codes and Standards
Purchaser
to
provide
Equipment packages shall be supplied in accordance with the latest editions of the
following Codes and Standards (where applicable).
AISC
Manual of Steel Construction
API 530
Calculation of Heater Tube Thickness in Petroleum

Refineries
API 531
Measurement of Noise from Fired Process Heaters
API 560
Fired Heaters for General Refinery Services
ASME V
Non-Destructive Examination
ASME VIII
Boiler and Pressure Vessel Code
ASME B16.5
Pipe Flanges and Flanged Fittings
ASME B31.3
Chemical Plant and Petroleum Refinery Piping
DIN 19250
Control Technology; Fundamental Safety Aspects to be

Considered for Measurement and Control Equipment
EN 10204
Metallic Products - Type of Inspection Documents
IEC 61508
Functional Safety of Electrical / Electronic / Programmable

Electronic Safety-related Systems
IEC 61511
Functional Safety: Safety Instrumented Systems for the

Process Industry Sector
Sheet 4 of 18
3.2
NACE MR-0175
Sulfide Stress Cracking Resistant Metallic Materials for

Oilfield Equipment
NFPA 85
Boiler and Combustion Systems Hazards Code
UBC
Uniform Building Code
Company Specifications
The following Specifications shall be included as part of this Specification:
SP-00-E-0003
Low Voltage Induction Motors
SP-00-E-0010
Electrical Requirements for Packaged Equipment
SP-00-P-0001
Site Conditions and Utilities
SP-00-J-0002
Instrumentation Requirements for Packaged Equipment
SP-00-L-0001
Piping Design and Materials
SP-00-M-0015
General Packaged Equipment
SP-00-M-0017
General Painting and Coating
SP-00-M-0018
Insulation
Scope of Supply
4.1
Work Included
4.2
The detailed scope of supply for each compressor package shall be as specified in
Exhibit A of the RFQ / Purchase Order.
Vendors Responsibility
The Vendor shall be responsible for the complete design, engineering, co-ordination,
inspection, testing and proper functioning of the equipment, notwithstanding any
omissions from this Specification.
To enable the Vendor to offer performance and mechanical guarantees in accordance
with the requirements of this Specification and referenced documents, the Vendor, as a
minimum, shall be responsible for:
Sizing of all equipment
Selection of materials for construction
Layout of items of equipment within the specified skid dimensions
Procurement and testing of individual items of equipment
Assembly and testing of the packaged equipment
Full compliance with the requirements of any certifying authority nominated

by the Purchaser and the supply of all documentation as required to obtain
final acceptance certification
Confirmation of the final weight, centre of gravity position and dimensions of

equipment package and its suitability for transportation.
Sheet 5 of 18
The Vendor shall provide the Purchaser with a complete list of sub-suppliers with the
tender.
Environmental Design Criteria
5.1
Location and Environmental Conditions

Unless otherwise stated on the Data Sheets, the equipment will be located in an open
exposed area, subject to the conditions as detailed in SP-00-P-0001.
5.2
Hazardous Area Classification

The equipment shall be suitable for operation within the hazardous area classification
specified in the Data Sheets.
Design Requirements
6.1
General
The design of Fired Heaters shall be in accordance with the requirements of API 560,
with heater tube thickness to API 530, and any additions or exceptions as detailed
below.
6.2
Tubes
6.2.1
General
Tube wall thickness for coils shall be determined in accordance with the procedures set
forth in API 530. Minimum design tube life shall be 100,000 hours at minimum rupture
strength.
Heater coils and piping that contain steam and water shall be designed in accordance
with the Boiler and Pressure Vessel Code.
Where allowable stresses are not covered by the ASME Code or API 530, data from a
reliable published source may be used subject to approval of the Purchaser.
Minimum coil design pressure shall be the in-tube fluid pressure plus 10% or 345kPa (50
psig), whichever is greater.
The ratio of the height of horizontal radiant tube banks to the width between the banks of
wall tubes in a cabin type design shall not exceed 2:1.
The radiant and shield tubes shall be located with two nominal diameters minimum
spacing between centerlines of adjacent tubes.
A minimum clearance of 750mm shall be provided between the nearest face of the flue
gas lining and the outside fin diameter of the last convection tube row or future row.
Provision shall be made to facilitate the removal and reinstallation of radiant and
convection tubes. A description of the removal and replacement procedures shall be
provided.
Sheet 6 of 18
All necessary access doors or removable panels for tube removal shall be provided by
the fired heater Manufacturer.
All crossovers, manifolds, and external piping shall be arranged so that they do not
interfere with tube removal.
6.2.2
Extended Surfaces
Fin type extended surfaces shall be used for gas firing.
A minimum safety factor of 55C shall be added to the calculated fin metal temperature
for material selection of extended surfaces.
The method of protecting carbon steel and low-alloy fins from corrosion prior to startup
shall be specified by the fired heater Manufacturer.
6.3
Piping and Manifolds

All pipework shall be in accordance with ASME B31.3 and SP-00-L-0001, Piping Design
and Materials.
Inspection openings are required for fouling services.
All piping termination points/interfaces shall be flanged to ASME B16.5 with rating and
facing to match the appropriate piping material class.
Vendor to provide details of interface connections (tie-in schedule) including maximum
allowable nozzle loadings.
Vents and drains shall be provided on radiant tubes and convection coil external piping
when specified on the data sheet. The minimum sizes of vents and drains shall be 1
inch NPS. Tubes and coils shall be arranged such that they are self draining.
Lateral and/or axial clearance requirements between heater nozzles and heater housing
at penetration holes shall be provided. Such clearances may be required if the piping
system is supported and/or restrained by the adjacent heater structure.
Process coil inlets and outlets shall be flanged and radiant-convection crossover piping
shall be butt welded. For hydrocarbon services flanges are to be oriented to allow direct
viewing of the full length of the connected tube.
Manifolds and associated piping shall be furnished as required to provide a single outlet
connection for each heating service, including crossover piping between heating coils.
Manifolds and piping located inside heater walls and exposed to hot flue gas or outside
heater walls shall be designed in accordance with the most severe design criteria of the
tubes to which they attach.
Manifolds and piping located either external to the heater or located in a header box
protected by an insulated tubesheet shall be designed in accordance with ASME B31.3
or ASME VIII, whichever is applicable.
Sheet 7 of 18
Manifold thicknesses shall not be less than standard weight.

Manifolds shall be sized and arranged to ensure uniformity of flow through each parallel
stream in the heating coils.
Manifolds shall be sized so that the dynamic head in the manifold at the point of
maximum velocity is not more than 10% of the individual pass pressure drop.
Manifolds shall be located so as not to block access for the removal of single tubes or
hairpins. Crossovers and manifolds shall be located so as not to interfere with platform
access.
Suitable supports and/or restraints to the piping system from an adjacent heater
structure shall be provided in order to reduce piping loads on heater nozzles without
imposing excessive loads on the heater structure.
6.4
Tube Supports
Tube support holes shall be designed to prevent damage to finned heating surfaces.
Holes shall be large enough to permit easy removal and insertion of tubes without
binding. Tube holes shall be at least 12mm larger in diameter than the tube or extended
surface outside diameter including the bearing plate. Tube bearing surfaces shall not
have sharp points or ridges that could damage heater tubes.
Tube bearing surfaces shall be a minimum of 40mm wide for bare tubes.
Keepers shall be provided on tube supports as required to prevent tubes from becoming
dislodged from the support while the unit is operating.
Bearing surfaces for extended surface tube supports or hangers shall be a minimum of
50mm wide and shall extend around the tube a minimum of 30 degrees on each side of
the vertical centerline.
Fins or studs shall extend at least 75mm past the end tube sheets in the cold position to
prevent coil binding due to uneven thermal movement.
Supports for horizontal tubes may be spaced to correspond to vertical members of the
external framework for the heater, but the maximum spacing shall not exceed 30 times
the outside diameter of the tube and a maximum overhang of six outside diameters.
Stainless steel sleeves, of a material suitable for the flue gas conditions, with an inside
diameter of at least 12mm larger than the tube or extended surface outside diameter,
shall be welded to the tube sheet to prevent the insulation from being damaged by the
tubes. Packing or other means of minimizing hot flue gas leakage into return header
compartments through annular spaces between tubes and sleeves to be provided.
Thermal expansion of tubes shall not be restricted.
Radiant and convection section end-tube sheets shall be designed to support the entire
tube and header load in the event that all intermediate tube supports should fail.
Start-up, shutdown, and part-load operation shall be considered when setting the design
temperature.
Sheet 8 of 18
The minimum corrosion allowance for all exposed surfaces of each tube support and
guide contacting flue gases shall be 1.5mm for austenitic materials and 3mm for ferritic
materials.
6.5
Structures
6.5.1
General
Structural steel shall be designed and detailed in accordance to AISC.
Additional structure shall be provided at the convection section ends above the base
platform level to support temporary scaffold for maintenance.
All removable panels and access doors shall be provided with an eye or lifting lug
suitable for use with a crane or cable lifting hook.
Designs shall provide for adequate ventilation of enclosed or partially enclosed areas of
the heater structure.
All surfaces of the heater structure shall allow for free draining of rainwater.
The inner surfaces of casings shall be protected from corrosive flue gases.
All bolted connections for ducts, plenums, and header boxes shall be provided with
suitable gaskets to prevent air or flue gas leakage.
Housings shall have bolted removable sections or header box doors. All removal panels
are to be provided with an eye or lifting lug suitable for use with a crane or cable lifting
hook. Header box doors shall be equipped with hinges, latches, and handles. Handles
shall be designed so that their external temperature does not exceed 50C.
Removable header box panels at ends of convection section shall be lined with ceramic
fibre blanket held in place by stainless steel studs, washers, and nuts as internal
insulation.
Doors shall be located so that tubes and burners are clearly observable.
6.5.2
Wind Loads
All structures and equipment shall be designed to withstand wind load. Wind load shall
be calculated as per code provisions in Uniform Building Code. The following formula
will be applicable for calculation of the design wind pressure.
P = CeCqqsIw
Ce = Combined height, exposure and gust factor co-efficient.
Cq = Pressure co-efficient for the structure or portion of structure under
consideration
Iw =
Importance factor.
qs =
Wind pressure at the standard height of 10m.
The design wind speed adopted shall be 45m/s at a height of 10m (50 year return
period). The corresponding qs value for this wind speed is 1.23kPa.
Sheet 9 of 18
The importance factor shall be Essential Facility with Iw = 1.15.

6.5.3
Earthquake Load
Seismic forces on equipment will be determined in accordance with the Uniform Building
Code. The following shall apply:
6.6
Importance factor:
Essential facility
Zone category:
Zone 2A
Soil classification:
SD (Stiff soil, 50kPa Su 100kPa)
Stacks and Ducts

Maintenance blinds shall be provided in ducts to isolate air preheaters.
Heaters shall be supplied with a steel stack of sufficient height to provide the required
draft and adequate disposal of flue gases.
Stacks and ducts shall be sized to provide adequate draft when a heater is operating at
125% of its design rating with 10% excess air.
The maximum flue gas exit velocity when a heater is operating at 125% of its design
rating with 10% excess air, shall be 7.6m/sec.
In order to avoid inversion and downwash, the flue gas stack exit velocity under heater
turndown conditions shall not be less than 4.5m/sec.
Expansion joints shall be provided where necessary.
Sections of ducts that must be removed for maintenance shall be flanged and bolted.
All stack field welds shall be shop fitted and match marked.
All stacks shall be provided with a painter's rail, trolley, and halyard.
Burners shall be enclosed in a suitably insulated plenum, or windbox, designed to
provide proper distribution of air to the burners.
Insulation required for noise attenuation and weatherproofing for air ducts and
windboxes shall be included.
Duct fittings shall be provided with turning vanes as required for proper air distribution
and minimum pressure loss.
Air ducts shall be of welded steel plate construction.
Expansion joints shall be provided where necessary. Provision shall be made for
expansion between air preheaters and connecting ductwork.
Hanger and bracket supports for ducts are to be included.
Sheet 10 of 18
If a forced draft fan is used, combustion air ductwork including forced draft fan inlet and
discharge ductwork, air ducts, and any additional features required for operation shall be
provided.
In order to eliminate acid corrosion the outside stack temperature shall be designed for a
minimum of 20C above the dew point corrosion temperature.
The top edge of the stack lining shall be protected with a 316L stainless steel internal
angle or other suitable means to prevent water penetration between steel and lining.
The top 600mm of the stack shall be 316L stainless steel.
As a minimum, the trolley racks and halyard cables shall be 18%Cr-8%Ni stainless steel.
The painters rail, supports and trolley shall be 316 stainless steel.
6.7
Burners and Auxiliary Equipment
6.7.1
Burners
Burners in natural draft heaters shall be sized to permit operation from 30% to 120%
design heat release at 10% excess air for fuel gas and 20% excess air for fuel oils and
any fuel oil/gas combinations.
Forced draft burners shall be sized and arranged to permit operation from 30% to 120%
of design heat release at 10% excess air for fuel gas and 15% excess air for fuel oil or
any combination of fuel oil/fuel gas.
The selection of burners shall be based on verification of satisfactory performance in the
same or a similar service.
Burners shall be designed to fire all fuels and flue combinations as specified on the Data
Sheet.
A pilot for each burner shall be provided. The pilots shall burn continuously while the
heater is in operation.
Bottom fired heaters shall be arranged to provide sufficient headroom, consistent with
easy operation of the burners. Sight holes shall be positioned accordingly.
All metal parts of the burners that are exposed to radiant heat shall be made of chromenickel alloy steel. All gas burner tips and air diffusers shall be stainless steel.
Burner tips shall be easily removable for maintenance.
Lighting ports shall be provided so that the burners may be manually lighted.
Burner fuel and air controls shall be accessible from grade or platforms. Means to view
the burner and pilot flame during light off and operating adjustment shall be provided.
The weight of burner assemblies shall be stated on the burner assembly drawing.
When a flame detector is specified, the detector mount shall be adjustable for sighting,
and be lockable.
Sheet 11 of 18
Burner air registers shall be externally adjustable. External position indicators shall be
provided for burner registers.
Burners and gas rings or tips and oil guns shall be removable while the heater is in
operation.
Materials for burner tips and diffusers shall as a minimum be of a high chrome alloy.
Burner management and ignition system shall be fully automatic.
6.7.2
Damper Controls
Dampers shall be designed with a counterweight to prevent closing if the cable breaks or
the operating mechanism otherwise fails.
All damper shafts shall be mounted in self-aligning, permanently lubricated, carbon
graphite sleeve bearings, pillow block or flanged type, installed external to the stack.
Damper shaft seals shall not interfere with radial movement of shafts nor restrict the
bearings self-alignment function.
For installations where tight shutoff is required, such as in bypasses to air heaters,
dampers shall close against a built in sill.
Damper positioners shall be included for all dampers. The necessary mechanical
linkages shall be included between dampers, positioners and limit switches.
All automated dampers shall have the ability to be manually positioned.
6.7.3
Plenums
Plenums to muffle burner noise shall be provided.
Plenums shall be designed to provide proper distribution of combustion air to the
burners.
Minimum allowable steel plate thickness for plenums shall be 5mm.
Plenums shall be designed for ready access to burners, pilots and any accessory control
or safety equipment mounted on burners.
Plenums shall not obstruct observation locations of burner flames, tubes and tube
supports.
Plenum lining shall be adequately protected with expanded metal to avoid damage
during access though burner opening.
Burner plenum construction shall include spacers to stiffen the burner and to allow
burner assembly movement for alignment with tiles.
Sheet 12 of 18
6.8
Instrumentation and Control
6.8.1
General
The control and safeguarding systems for the fired heaters shall adhere to the relevant
IEC, DIN, NFPA and API standards and codes for fired heaters. Additionally all
instrumentation and controls shall be furnished in accordance with the requirements of
SP-00-J-0002, Instrumentation Requirements for Packaged Equipment.
Fired heater air fuel ratio control and safeguarding shall be performed by separate
systems and field instrumentation, with all required interlocking hardwired. The air fuel
ratio control shall be performed by the Purchasers process control system. Fired heater
startup, shutdown and sequencing logic shall be performed by the Vendor supplied
safety related HIMA Programmable Electronic System (PES) Burner Management
System (BMS). A Graphical User Interface (GUI) to monitor and initiate commands for
the fired heaters BMS shall be provided by others at the plant Process Control System
(PCS) Human Machine Interface (HMI) screens.
Measured process variables for fired heater control and safeguarding (e.g. Pressure,
Temperature, Flow, and Density) shall be transmitted (4-20 mA) analogue signals
wherever possible to their respective systems, rather than digital switches. Separate
instrumentation shall be provided for control & safeguarding functions.
The Vendor shall ensure that sufficient heater status indications and variables are
configured for network access by the plant PCS for display on the CCR HMI graphics.
The fired heaters shall be Factory Acceptance Tested (FAT) utilizing the CCR HMI
graphics.
The Vendor shall provide a local emergency stop pushbutton and local heater reset.
The Purchaser shall provide a CCR emergency trip pushbutton on the critical control
panel.
The Purchaser shall provide and install all field cabling and necessary junction boxes
between the fired heater safeguarding and control instrumentation and the BMS & PCS
respectively.
The hot oil heater HIMA BMS shall be expandable to accommodate a future third heater
without BMS downtime.
6.8.2
Burner Management System (BMS HIMA)

The Vendor shall conduct a SIL analysis to ensure all Vendor supplied BMS
safeguarding instrumentation, loop design and logic hardware selection conforms to the
requirements of IEC 61508, DIN 19250 (TUV) and the relevant NFPA & API codes &
standards.
The BMS shall communicate utilizing dual redundant bi-directional communications ports
and transceivers to transmit to, or receive from, the plant PCS, addressable events or
elements as required by the Vendor designed fired heater control scheme. The Vendor
shall guarantee an availability of the BMS system of 99.997% or better based on an
MTTR of 1 hour.
Sheet 13 of 18
6.8.3
The fired heater BMS Logic (by HIMA) shall be written in accordance with the approved
Vendor safeguarding functional logic specification and relevant NFPA, API, IEC and DIN
codes & standards.
Air Fuel Ratio Control
The Purchaser in conjunction with the Vendor shall configure air fuel ratio control for the
fired heaters in the Purchasers process control system. The Vendor shall provide the
Purchaser with all control scheme documentation detailing the Vendors exact
requirements for the air fuel ratio control. The Vendor shall provide a proven air-fuel
ratio control scheme. References for the last six-(6) applications of the control scheme
shall be provided (including the names of purchasing contacts).
The documentation provided by the Vendor shall include, but not be limited to:
Control scheme drawings

Instrument index
Interlock requirements (If required)
Detailed control narrative for control scheme
Calculation formulae to be used in function blocks
Tuning parameters, lead/lag settings and set points
Details of plant tests required to obtain the tuning parameters
Although the Purchaser shall carry out the control configuration, the overall responsibility
lies with the Vendor to ensure complete, accurate and satisfactory interoperability
between the Purchasers PCS and the Vendor supplied BMS. System functionality shall
be rigorously tested by the Vendor at F.A.T (Witnessed by the Purchaser) and as
required during commissioning onsite.
The Vendor is responsible for providing process control expertise to site for starting up
and tuning the control scheme. Said expert shall have demonstrable experience in
heater startup/commissioning. Proposed commissioning support expert resumes shall
be proposed to the Purchaser for approval with the above documents
6.8.4
Auxiliary Connections
The following auxiliary connections shall be provided by the fired heater manufacturer:
Connections for draft gauges at fan inlet and discharge air outlet of the air
preheater, windbox, furnace, outlet, flue gas outlet of the air preheater, and
stack entry.
Six equally spaced connections installed around the periphery of forced draft
fan outlet ducts for pitot tube traverse of airflow.
Thermocouple wells for measuring flue gas temperatures leaving the furnace,
for measuring air temperatures before and after the air preheater and in the
windbox, with provision for purging. The thermocouple hot junction shall be
located to measure the average flue gas temperature, and shall be shielded
to minimize the cooling effects of the surrounding surfaces.
Thermowell connections shall be provided on the heater side of control

dampers.
High points vents, low point drains, and test connections shall be provided,
as required, on all manifolds and piping.
Sheet 14 of 18
The fired heaters shall be supplied with tube wall temperature measurement on the
radiant tubes, and the first row of the convection tubes.
6.9
Electrical
All electrical equipment shall be in accordance with SP-00-E-0010, Electrical
Requirements for Packaged Equipment and applicable specifications listed in the
RFQ/Purchase Order. All electric motors shall be in accordance with SP-00-E-0003,
Low Voltage Induction Motors.
6.10
Insulation
Unless otherwise agreed, the Vendor shall be responsible for the provision of all
necessary insulation and refractories for heat conservation or the safety and protection
of personnel, in accordance with referenced documents and the applicable Statutory
Regulations. This shall include the provision of suitable personnel protection on hot
surfaces within easy reach of personnel. The insulation shall comply with the
requirements of SP-00-M-0018, Insulation, and applicable specifications listed in the
RFQ/Purchase Order.
In no circumstances shall insulation materials contain asbestos.
Sections containing castable refractories shall not be handled or shipped for a minimum
of three days after application of the castable refractory.
6.11
Noise
The noise level from each skid shall comply with the requirements of Statutory
Regulations applicable on the Project site, and shall not exceed 85dBA @ 1m unless
otherwise stated on the relevant Equipment Data Sheets. Measurement of noise shall
be conducted in accordance with API 531.
6.12
Nameplates
All major equipment installed on the package shall be provided with a stainless steel
nameplate suitably located so as to be visible from off the skid. Data to be provided
shall be in accordance with the relevant specification for the particular equipment but
shall include the following as a minimum:
Manufacturers Name
Manufacturers Serial Number
Equipment Tag Number
Equipment Name
Purchase Order Number
Year of Manufacture
Design Code - API 560
Design Heat Load (MW)
Weight - Empty (kg)
Environment - Div ( ) Group ( ) Zone ( )
Sheet 15 of 18
Letters and figures shall be 5mm high and clearly stamped.
Inspection, Testing And Certification
7.1
General
Inspection, testing and certification shall comply with the requirements as detailed in this
Specification, other referenced specifications and Exhibit E of the RFQ/Purchase Order.
7.2
Inspection and Testing

Inspection and testing shall be carried out in accordance with this Specification and
Exhibit E of the RFQ/Purchase Order.
The approval of any work by the Purchaser or its authorised representative and the
release of equipment for shipment shall in no way relieve the Vendor of any
responsibility for carrying out the provisions of this Specification.
The Vendor shall inform the Purchaser at the time of Tender of any tests that cannot be
adequately performed.
The Purchaser shall have free access to the work at all times.
The Purchaser shall have the right to inspect the fabrication at any state and to reject
material or workmanship that does not conform to the specified requirements.
The Purchaser reserves the right to inspect, photograph, and/or videotape all material,
fabrication, coating, and workmanship and any materials, equipment, or tools used or to
be used for any part of the work to be performed.
The Purchaser may reject the use of any materials, equipment, or tools that do not
conform to the requirements of this specification, jeopardize safety of personnel, or
impose hazard of damage to the Companys property.
All of the rights of the Purchaser and their designated representatives for access,
documentation, inspection, and rejection shall include any work done by sub-contractors
or sub-vendors.
Additional inspection of any weld joint at any stage of the fabrication may be requested
by the Purchasers Inspector, including re-inspection of previously inspected joints. The
Purchasers Inspector also has the right to request or conduct independent NDT of any
joint. If such testing should disclose non-conformance to the requirements of the
applicable Code or this Specification, all repair and NDT costs shall be done at the
Heater Manufacturer's expense.
All NDT on heater coils that are to be postweld heat-treated shall be made after
postweld heat treatment.
All pressure and nonpressure welds shall be visually inspected where accessible.
Prior to final inspection and pressure testing, the inside and outside of the heater shall
be thoroughly cleaned of all slag, scale, dirt, grit, weld spatter, paint, oil, etc.
Sheet 16 of 18
7.3
Hydrostatic Tests
All pressure vessels and piping shall be hydrostatic tested in accordance with the
relevant referenced documents and Data Sheets.
Only fresh water shall be used for testing. For stainless steel piping or equipment items,
the chloride ion content of the water shall not exceed 30ppm.
Process piping or tubing shall be tested with water after shop fabrication into subassemblies.
The normal test pressure for piping shall be 1.5 times the adjusted cold pressure rating
of the valves, fitting, expansion joints or other limiting elements in the line.
Pressure testing shall be maintained long enough to permit complete inspection but shall
not be less than 60 minutes.
Coil assemblies shall be completely drained immediately upon completion of
hydrotesting. The assembly shall then be dried utilising warm/hot air, with the outlet air
being measured for moisture content, until the limits as agreed upon in the ITP are
reached.
7.4
Equipment Performance Tests

The Vendor shall be required to submit a full testing procedure covering the full extent of
testing on the completed assembly and shall be complete with all equipment test
procedures and check lists. The Vendor shall be responsible for providing all necessary
utility services to conduct the tests.
As a minimum, the following tests shall be conducted:
7.5
Combustion air fan mechanical run test (per API 560 Appendix E).
Minimum fire burner test.
Functional test of Burner Management System (BMS) .
Functional Tests
The Vendor shall be responsible for ensuring all calibration and test equipment has valid
certification.
All instrument functions shall be verified by using water or instrument quality air as a
substitute for the process liquid/gas to prove the integrity of the control equipment and
instrumentation.
7.6
Material Testing and Certification Requirements

Material requirements shall be as detailed in the Purchase Order.
Pressure containing components shall be fully traceable with mill/manufacturers
certificates to EN 10204.3.1b or equivalent.
Inspection procedures and acceptance criteria shall be in accordance with the
requirements of the applicable design Code and the certifying authority (where
applicable).
Sheet 17 of 18

Specification For Fired Heaters

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Specification For Fired Heaters

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Specification for Fired Heaters

Doc No. SP-00-M-0008 Rev 2

Codes and Standards

Environmental Design Criteria

Location and Environmental Conditions

Inspection, Testing And Certification

SP-00-M-0008 Fired Heaters