32-SAMSS-029

Previous Issue: 28 January 2004 Next Planned Update: 16 December 2014 Page 1 of 25 Primary contact: Anizi, Salamah Salem on 966-3-8760203

Copyright©Saudi Aramco 2009. All rights reserved.

Materials System Specification

32-SAMSS-029 16 December 2009

Manufacture of Fired Heaters

Heat Transfer Equipment Standards Committee Members Anizi, Salamah Salem, Chairman Bagawi, Jamil Jarallah, Vice Chairman Anezi, Mohammed Ali Dossary, Musfir Abdullah Fernandez, Gabriel Thomas Gahtani, Moraya Saif Guthami, Mohammed Mohsen Hamam, Ibrahim Hassan Harbi, Abdullah Mohammed Saeed Mansour, Khalid Mohammad Naffaa, Mahmoud Youniss Rumaih, Abdullah Mohammad

Saudi Aramco DeskTop Standards Table of Contents 1 Scope............................................................. 2 2 Normative References.................................... 2 3 Terms and Definition...................................... 4 5 Proposals....................................................... 4 6 Design Considerations................................... 5 7 Tubes............................................................. 6 8 Headers.......................................................... 7 9 Piping, Terminals and Manifolds.................... 7 10 Tube Supports................................................ 8 11 Refractory and Insulation............................... 8 12 Structures and Appurtenances....................... 9 13 Stacks, Ducts, and Breechings.................... 11 14 Burners and Auxiliary Equipment................. 13 15 Instrument and Auxiliary Connections.......... 16 16 Shop Fabrication and Field Erection............ 17 17 Inspection, Examination and Testing........... 19 18 Life Cycle Cost Evaluation........................... 22

Document Responsibility: Heat Transfer Equipment 32-SAMSS-029

Issue Date: 16 December 2009

Next Planned Update: 16 December 2014 Manufacture of Fired Heaters

Page 2 of 25

Table of Contents

Appendix E – Centrifugal Fans for Fired Heater Systems..................... 24 Appendix F – Air Preheat Systems for Fired Process Heaters.................... 25

The following paragraph numbers refer to API STD 560, Fourth Edition, August 2007,

which is part of this specification. The text in each paragraph below is an addition,

deletion or exception to API STD 560 as noted. Paragraph numbers not appearing in

API STD 560 are newly added paragraphs inserted in numerical order.

1 Scope

(Exception) The scope of this specification covers the minimum requirements for the

process design, mechanical design, materials, shop and field fabrication, shop and field

testing, preparation for shipment, and field erection of direct-fired and pyrolysis

excluding radiant section fired heaters.

1.1 Any conflicts between this specification and other applicable Saudi Aramco

Materials System Specifications, (SAMSSs), Standard Drawings (SASDs),

or industry standards, codes, and forms shall be resolved in writing by Saudi

Aramco or it’s Representative through the Manager, Consulting Services

Department of Saudi Aramco, Dhahran.

1.2 Direct all requests to deviate from this specification in writing to Saudi

Aramco or its Representative, who shall follow internal company procedure

SAEP-302 and forward such requests to the Manager, Consulting Services

Department of Saudi Aramco, Dhahran

2 Normative References

Materials or equipment supplied to this specification shall comply with the latest edition

of the references listed below, unless otherwise noted.

2.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-302 Instructions for Obtaining a Waiver of a

Mandatory Saudi Aramco Engineering

Requirement

SAEP-1142 Qualification of Non-Saudi Aramco Personnel




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Saudi Aramco Engineering Standards

SAES-A-112 Meteorological and Seismic Design Data

SAES-A-206 Positive Material Identification

SAES-B-054 Access, Egress and Materials Handling for Plant

Facilities

SAES-H-100 Painting Requirements for Industrial Facilities

SAES-N-100 Refractory Systems

SAES-N-110 Installation Requirements - Castable Refractory

SAES-N-130 Installation Requirements - Fireclay Bricks

SAES-N-140 Installation Requirements - Refractory Ceramic

Fiber

SAES-W-011 Welding Requirements for On-plot Piping,

Saudi Aramco Forms and Data Sheets

175-323700 Manufacture of Fired Heaters

7305-ENG Equipment Noise Data Sheet

NMR-7900 Non-Material Requirements for Fired Heaters

American Society of Mechanical Engineers/Boiler and Pressure Vessel

Codes

ASME B16.20 Metallic Gaskets Ring Joint and Spiral Wound

ASME B16.21 Non-Metallic Gaskets for Pipe Flanges

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B31.1 Power Piping

American Society for Testing and Materials

ASTM A297 Standard Specification for Steel Castings, Iron-

Chromium, and Iron-Chromium-Nickel, Heat

Resistant for General Application

American Institute of Steel Construction

AISC 325 Manual of Steel Construction

AISC 326 Detailing for Steel Construction




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3 Terms and Definition

3.85 Design Engineer: The Engineering Company responsible for specifying on

the data sheet the thermal and mechanical design requirements for heaters.

3.86 Direct-Fired Heaters: Heaters used to provide heat primarily by

conductive heat by flame impingement used for heating asphalt or bunker oil

for loading or mixing.

3.87 Engineering Company: The company responsible for specifying the

design requirements for Heaters on the data sheet.

3.88 Heater fabricator: The Company responsible for manufacturing heaters in

accordance with the design requirements specified by the heater designer.

3.89 Heater supplier: the Company responsible for the design, materials,

fabrication, testing, preparation for shipment, of fired heaters in accordance

with this specification.

3.90 Hydrocarbon Service: Process streams of liquid or gaseous hydrocarbon

materials.

3.91 Pyrolysis Heaters: Heaters that provide heat for chemical reactions inside

heater tubes for cracking and have service descriptions of ethylene crackers

3.92 Reformer Heaters: to provide heat for catalytic chemical reaction and have

process description such as: steam (hydrogen) reformer.

3.93 Saudi Aramco Engineer: The chairman of standard committee, Consulting

Services Department, Dhahran.

3.94 Saudi Aramco Inspector: The person or company authorized by the Saudi

Aramco Inspection Department to inspect heaters to the requirements of this

specification.

5 Proposals

5.1 Purchaser’s Responsibilities

5.1.4 (Exception) The number of copies of drawings, data sheets, specifications,

data reports, operating manuals and installation instructions shall be in

accordance with Form NMR-7900, Nonmaterial Requirements.

5.2 Vendor’s Responsibilities

The Heater supplier is to supply the following additional information with




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the proposal. This information is necessary and will be used to complete the

technical evaluation of the quotation. The quotation will be technically

unacceptable if any of the information required is not included.

(e) (Exception) A completed noise data sheet (Form 7305-ENG) with a

detailed description of acoustical design.

(k) Energy conservation recommendations including: use of air-preheats,

high-efficiency burners, etc.

5.3 Documentation

5.3.1 to 5.4 (Exception) Documentation shall be in accordance with Form NMR-7900.

5.5 Performance Guarantees

The following shall be guaranteed when heaters are operated at 100% of

design heat release and design excess air, with the feeds and fuels specified

on the data sheet and at the process and ambient conditions specified. These

requirements are in addition to any other guarantees detailed in the purchase

order or contractual documents.

(a) Flue gas emission levels at normal and design conditions

(b) Sound levels at all specified operating conditions shall not exceed

85 dBA one meter from the source.

(c) Efficiency as specified in the data sheet based on the procedures of

API STD 560.

(d) Maximum pressure drop as specified in the data sheet.

6 Design Considerations

6.1 Process design

6.1.6 The values of average heat flux densities shall be in accordance with process

licensor specified by the Engineering Company.

6.3 Mechanical design

6.3.13 A minimum 30 inch diameter manway shall be provided to heater/furnace

areas such as radiant section, convection tube banks and passes, areas of flue

gas breaching and stack, and air ducts or breaching.

6.4 Environmental

6.4.1 All fired heaters and their associated equipment shall be suitably designed




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for outdoor operations in a desert climate where the atmosphere is salt laden

and highly corrosive and in accordance with the climatic data specified in

SAES-A-112.

6.4.2 Accessories provided for the heater which are exposed to direct sunlight

shall be designed for a temperature of 70°C.

6.5 Noise

6.5.1 The Engineering Company shall specify limits for the sound pressure levels

(SPL) at the designated locations, on Form 7305-ENG.

6.6 Emissions

6.6.1 Heaters shall be designed to operate in compliance with local environmental

regulations as detailed by the Engineering Company.

6.6.2 The Heater supplier shall calculate and guarantee emission rates of Nitrogen

oxides. The emission rates shall be expressed in PPMv at 3% O2 dry basis

when the heater is operated at its design rate firing the fuels specified. Flue

gas emissions (NOx, CO, particulates, hydrocarbons, etc.) will not exceed

the specified levels.

6.7 Decoking

6.7.2 A recommended procedure including steam and air rates shall be provided

by the Heater Supplier as part of the operating procedures.

7 Tubes

7.1 General

7.1.1 (Exception) Tube wall thickness for coils shall be determined in accordance

with the procedures set forth in API STD 530. Minimum design tube life

shall be 100,000 hours.

7.1.8 Heater coils and piping that contain steam and water shall be designed in

accordance with the Boiler and Pressure Vessel Code, ASME SEC VIII.

7.1.9 Where allowable stresses are not covered by the ASME Code or API RP 530,

data from a reliable published source may be used subject to approval of the

Saudi Aramco Engineer.

7.1.10 Minimum rupture coil design pressure shall be the maximum operating inlet

pressure plus 10% or plus 345 kPa (50 psig), whichever is greater.




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7.1.11 The radiant tubes shall be located with two nominal diameters minimum

spacing between centerlines of adjacent tubes.

7.1.12 spacing between the convection section walls or corbelling ends and the

closest tube centerline shall be one half of the horizontal tube spacing.

7.1.13 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.

7.1.14 All crossovers, manifolds, and external piping shall be arranged so that they

do not interfere with tube removal.

7.2 Extended Surfaces

7.2.4 The method of protecting carbon steel and fins from corrosion, prior to

startup shall be specified by the Heater Supplier.

8 Headers

8.3 Return Bends

8.3.5 Inside diameter of fittings shall match that of the heater tube.

9 Piping, Terminals and Manifolds

9.1 General

9.1.9 Unless otherwise specified in the data sheet, Process coil inlets and outlets

shall be flanged. Minimum flange rating shall be ASME Class 300.

9.1.10 Terminal connections on steam and water coils shall be beveled for welding,

unless stated on the data sheet.

9.1.11 Swages shall be schedule 160 minimum taper bored.

9.1.12 Manifolds and associated piping shall be furnished as required to provide a

single outlet connection for each heating service.

9.1.13 Manifold thickness shall not be less than standard thickness.

9.1.14 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.




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10 Tube Supports

10.1 General

10.1.7 Keepers shall be provided on horizontal tube supports as required to prevent

tubes from becoming dislodged from the support.

10.1.8 Supports for horizontal tubes maximum straight tube overhang shall not be

more than six outside diameters.

10.1.9 Start-up, shutdown, and part-load operation shall be considered when setting

the design temperature.

10.3 Materials

10.3.3 Bolting used to tie tube support brackets or hangers to the structure shall be

stainless steel type 304H, as a minimum.

10.3.4 Carbon steel end tube supports shall be protected on the flue gas side by

castable insulation. Minimum thickness shall be 100 mm for convection

end-tube supports and 150 mm for radiant supports.

11 Refractory and Insulation

11.1 General

(Exception) The design temperature of the outside casing surfaces of radiant

and convection sections shall be determined in accordance with SAES-N-100.

11.1.5 (Exception) The design of refractory for heater floors shall be in accordance

with SAES-N-100.

11.1.13 The design and material selection of refractory systems shall be in

accordance with SAES-N-100.

11.1.14 Burner blocks shall be high-duty refractory laid in high temperature bonding

cement.

11.1.15 Expansion joints shall be provided around each burner.

11.2 Brick and Tile Construction

11.2.10 The design of brick and tile construction shall be in accordance with

SAES-N-100.

11.2.11 Burner tile for floor-mounted burners shall extend at least 2 inches above

floor refractory.




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11.3 Castable Construction

11.3.1 to 11.3.11 (Exception) The construction of castable refractory shall be in


11.4 Ceramic Fiber Construction

11.4.1 to 11.4.21 (Exception) The design of refractory ceramic fiber insulation shall be

in accordance with SAES-N-100.

11.5 Multi-component Lining Construction

11.5.1 to 11.5.9 (Exception) Multi-component Lining shall be in accordance

withSAES-N-100.

11.6 Materials

11.6.1 & (Exception) Material selection for refractory and refractory anchors

11.6.2 shall be in accordance with SAES-N-100.

12 Structures and Appurtenances

12.1 General

12.1.1 (Exception) Structural steel shall be designed and detailed in accordance

with AISC M016 and AISC 326.

12.1.2 (Exception) Heaters shall be designed for wind and earthquake loads in

accordance with ASCE 7.

With reference to ASCE 7, the wind Category Classification to be used in

the calculations of wind loads shall be Category III, and the Seismic Hazard

Exposure Group to be used in calculations of earthquake loads shall be

Group III.

Wind pressures shall be assumed to act on the projected surface area of the

heater and shall include due allowances for platforms, ladders, piping,

insulation, and equipment supported from the heaters.

12.1.5 (Exception) The design metal temperatures of structures shall be the

calculated metal temperature plus 56°C, based on the maximum flue gas

temperature expected for all operating modes with an average ambient

temperature specified in accordance with SAES-A-112.

12.1.8 Additional structure shall be provided at the convection section ends above

the base platform level to support temporary scaffolding for maintenance.




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12.1.9 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.

12.1.10 Designs shall provide for adequate ventilation of enclosed or partially

enclosed areas of the heater structure.

12.2 Structures

12.2.7 (Exception) The extent and thickness of fireproofing shall be specified by

the engineering contractor.

12.2.11 Heater structures which contain more than one heater shall be designed to

accommodate differential thermal expansion when one heater is operating

and the adjacent heater(s) is out of service.

12.2.12 All bolted connections for ducts, plenums, and header boxes shall be

provided with suitable gaskets to prevent air or flue gas leakage.

12.3 Header Boxes, Doors, and Ports

12.3.1 Header Boxes

(Exception) Housings shall have bolted removable sections or header box

doors. All removable 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 50°C

12.3.1.6 Header boxes containing plug fittings shall be provided with threaded

couplings for drains and smothering steam connections.

12.3.1.7 Removable header box panels at ends of convection section shall be lined

with ceramic fiber blanket held in place by appropriate anchoring system as

internal insulation.

12.3.1.8 If return bends are located outside fireboxes, they shall be enclosed in steel-

plate housings.

12.3.1.9 Return header housings shall be internally insulated as required to meet the

casing temperature limitation.

12.3.2 Doors and Ports

12.3.2.7 Access doors shall be an airtight design.

12.3.2.8 Two explosion doors shall be furnished to relieve each combustion chamber

of a multi-cell heater with a common convection section having tubes




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oriented parallel to the radiant tubes.

12.3.2.9 For radiant sections over 6 m high, a second elevation set of peep doors shall

be installed.

12.3.2.10 Peep doors shall be located so that tubes and burners are clearly observable.

12.3.2.11 Clear access shall be provided to the return headers without interfering with

working platforms or piping.

12.4 Ladders, Platforms, and Stairways

12.4.1 Additional Platforms shall be provided at the following locations:

(g) All access doors, observation and instrument connections

(h) All stack sampling connections

(i) All analyzer and analyzer connections

12.4.12 Walkways shall be provided to inter-connect platforms at each level.

12.4.13 Unless otherwise specified by the Engineering Company, stairways shall be

provided from grade to burner operating platforms as follows:

12.4.14 Heater coil vents, drains, sample, instrument, and chemical cleaning

connections shall be accessible from heater platforms or grade.

12.4.15 Stairs, ladders and access platforms shall be in accordance with SAES-B-054.

13 Stacks, Ducts, and Breechings

13.1 General

13.1.3 A pneumatically operated flue gas control damper shall be provided at the

base of each natural draft stack.

13.1.4 Maintenance blinds shall be provided in ducts to isolate air preheaters.

13.1.5 In order to avoid inversion and downwash, the flue gas stack exit velocity

under heater turndown conditions shall not be less than 4.5 m/sec.

13.1.6 Sections of ducts which must be removed for maintenance shall be flanged

and bolted.

13.1.7 All stacks shall be provided with a painter's rail, trolley, and halyard.

13.1.8 Insulation required for noise attenuation and weatherproofing for air ducts




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and windboxes shall be included.

13.1.9 Duct fittings shall be provided with turning vanes as required for proper air

distribution and minimum pressure loss.

13.1.10 Air ducts shall be of welded steel plate construction.

13.1.11 Provision shall be made for expansion between air preheaters and connecting

ductwork.

13.1.12 Hanger and bracket supports for ducts are to be included.

13.1.13 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.

13.2 Design Considerations

13.2.14 (Exception) Heater stacks, ducts and breechings shall be designed for wind

and earthquake loads in accordance with ASCE 7.

With reference to ASCE 7, the wind Category Classification to be used in

the calculations of wind loads shall be Category III, and the Seismic Hazard

Exposure Group to be used in calculations of earthquake loads shall be

Group III.

Wind pressures shall be assumed to act on the projected surface area of the

heater and shall include due allowances for platforms, ladders, piping,

insulation, and equipment supported from the heaters.

Minimum design loads shall be in accordance with ASCE 7. All structural

steel shall be designed and detailed in accordance with AISC M016 and

AISC M013.

13.2.18 (Exception) The design metal temperatures of stacks, ducts and breechings

shall be the calculated metal temperature plus 50°C, based on the maximum

flue gas temperature expected for all operating modes with an average

ambient temperature specified in accordance with SAES-A-112.

13.5 Wind-Induced Vibration Design

13.5.3 (Exception) Spiral or staggered vertical plates shall be provided as required

by the design.

13.6 Materials

13.6.1 The top edge of the stack lining shall be protected with a Type 316L




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stainless steel internal angle or other suitable means to prevent water

penetration between steel and lining.

13.6.2 The top 600 mm of the stack shall be Type 316L stainless steel.

13.6.3 As a minimum, the cable for trolley tracks and halyard shall be 18%

Chrome-8% Nickel stainless steel.

14 Burners and Auxiliary Equipment

14.1 Burners

14.1.23 Burners in natural draft heaters shall be specified to permit firing at burner

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 specified to permit firing at burner 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.

14.1.24 The selection of burners shall be based on verification of satisfactory

performance in the same or a similar service.

14.1.25 Burners shall be designed to fire all fuels with fuel combinations specified

on the data sheet.

14.1.26 A pilot for each burner shall be provided. The pilots shall burn continuously

while the heater is in operation.

14.1.27 Bottom fired heaters shall be arranged to provide sufficient head room,

consistent with easy operation of the burners. Sight holes shall be positioned

accordingly.

14.1.28 Burners shall be supported from the heater structure and burner blocks shall

be independent of the heater wall.

14.1.29 Burner tips shall be easily removable for maintenance during heater

operation.

14.1.30 Lighting ports shall be provided so that burners may be manually lighted.

14.1.31 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.

14.1.32 The weight of burner assemblies shall be stated on the burner assembly




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drawing.

14.1.33 When a flame detector is specified, the detector mount shall be adjustable

for sighting, and be lockable.

14.1.34 Burner air registers shall be externally adjustable and removable during

heater operation. External position indicators shall be provided for burner

registers.

14.1.35 Burners gas rings or tips and oil guns shall be removable while the heater is

in operation.

14.2 Sootblowers

14.2.7 Soot-blowers shall be fully automatic with selected sequential control and

manual override capabilities for individual soot-blowers.

14.2.8 Each soot-blower shall be easily maintainable, with readily accessible

lubrication fittings at all required lubrication points.

14.2.9 The soot-blower manufacturers design shall be substantiated by at least two

years of experience in comparable service.

14.2.10 Soot-blower pipe work shall be arranged so that condensate buildup drains

away from the soot-blower head. Drain valves shall be interlocked with the

steam valve to ensure that upstream condensate is drained during warm-up

and prior to the operation of soot-blowers.

14.2.11 Pipe work and associated fittings shall be in accordance with ASME B31.3.

14.2.12 Automatic control shall be obtained via a programmable logic controller

(PLC) as designed and specified by the Engineering Company in accordance

with 34-SAMSS-830.

14.2.13 Automatic mode of operation shall incorporate the following functions:

(1) Enable the lockout of any soot-blower from the normal operating

sequence.

(2) Enable the sequence to be held at any point in the sequence by operator

intervention, and allow soot-blowers to operate in the manual or local

mode during that hold period. On reselection of the automatic mode,

the soot-blower sequence shall continue from where it was interrupted.

(3) On the initiation of any emergency stop signal, automatically retract

any operating retractable soot-blower and shut down the system to a

safe condition.




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14.2.14 The following are the minimum indications of system status that shall be

provided:

(1) The mode of operation selected

(2) When the system is running under automatic sequential control

(3) Individual sootblower in operation

(4) The direction of travel for individual retractable sootblower during

operation

(5) Steam system warm-up period is in progress

(6) Steam system warm-up period is completed

(7) Any sootblower(s) locked out of the normal operating sequence

(8) Open/closed positions of main supply valve

(9) Open/closed positions of individual heater steam supply shutoff valves

14.2.15 The following are the minimum indications of alarm status:

(1) Elapsed time

(2) Motor overload

(3) Steam pressure

(4) Out of sequence

14.2.16 The following shall be provided in the control rooms:

(1) Alarm and status indications

(2) Automatic and manual mode pushbuttons

(3) Soot-blower selector switches

14.4 Damper Controls

14.4.1 Include pneumatically operated dampers as required to control combustion

air and flue gas flows on heater arrangements with air preheaters and forced

or induced draft fans.

14.4.2 Pneumatically operated stack damper shall have an alternate means of

manual operation from grade level.

14.4.3 Stack damper shall be designed with a counterweight to prevent closing if

the cable breaks or the operating mechanism otherwise fails.

14.4.4 Stack dampers for natural draft shall be designed for clearance of 25 mm in




Page 16 of 25

fully closed position. The damper controls shall be designed to prevent

automatic closure beyond 85% closed.

14.4.5 For installations where tight shut-off is required as in bypasses to air heaters,

etc. dampers shall close against seal.

14.4.6 Damper positioners, shall be included for all pneumatically operated

dampers. The necessary mechanical linkages shall be included between

dampers and positioners and limit switches.

14.4.7 All pneumatically operated dampers shall have the facility to vent the motive

air from the actuator and bypass the controller so that the damper can be

manually positioned.

15 Instrument and Auxiliary Connections

15.1 Flue Gas and Air

15.1.1 Flue-gas and Combustion-air Temperature

15.1.2.8 A metering venturi, airfoil section or multi-point mass flowmeters located in

the forced draft fan inlet or discharge duct, with taps suitable for airflow

measurement shall be provided. The device shall be located upstream of any

air heater. The system proposed shall be provided with sufficient upstream

and downstream straight lengths of duct to ensure accuracy of airflow

measurement.

15.1.3 Flue-gas Sampling

15.1.3.6 Sample connections shall be provided for oxygen and combustible analyzers

at the furnace exit, boiler, economizer, and air preheater outlet.

15.1.3.7 Multiple sampling connections shall be provided in the flue gas duct at the

convection outlet and air preheater to obtain flue gas analysis. Each

connection shall consist of a stainless steel nipple, valve, and plug with

provision for purging. The vendor shall identify the purging media and

submit the purging procedure in the proposal.

15.1.3.8 Connections for the measurement of opacity, particulate matter, sulfur

dioxide, nitrogen oxides, oxygen, and carbon monoxide shall be provided.

15.2 Process Fluid Temperature

15.2.1 (Exception) Thermowell connections on each pass at the outlets of

convection and radiant sections shall be provided.




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15.3 Auxiliary Connections

15.3.1 Purge-steam Connections

15.3.1.2 (Exception) Snuffing and purge steam connections shall be 2 inch NPS

minimum for combustion chambers and 1 inch NPS minimum for header

housings.

15.3.1.6 Additional connections for the following shall be provided by the heater

manufacturer.

(1) Connections for flame monitoring and scanning shall be provided.

(2) Connections for draft gages at fan inlet and discharge air outlet of the

air preheater, windbox, furnace, outlet, flue gas outlet of the air

preheater, and stack entry.

(3) Six equally spaced connections installed around the periphery of forced

draft fan outlet ducts for pitot tube traverse of airflow.

(4) High point's vents, low point drains, and test connections shall be

provided, as required, on all manifolds and piping.

15.4 Tube Skin Thermocouples

15.4.3 Tube Skin Thermocouples

Exception) As a minimum, provide four tube skin thermocouples per pass.

For the arbor type heater four tube thermocouples per cell. Thermocouple

locations shall be determined by the heater.

15.5 Burner Management Systems

All nozzles and instrument connections of the instrumentation system shall

be supplied by the Heater supplier if the burner management system is

supplied by others.

16 Shop Fabrication and Field Erection

16.1 General

16.1.5 The manufacturer shall shop-install sufficient braces, struts, and lifting lugs

to permit handling at the construction site with conventional slings or hooks

without damage to the equipment.

16.1.6 Temporary bracing shall be clearly identified as such.

16.1.7 The Heater supplier shall submit plans for handling and shipping heaters for




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review and approval.

16.1.8 Each part of a heater which is shipped as separate pieces or shop assembly

shall be identified. This includes steel and refractory parts which must be set

in a specific location in the heater.

16.1.9 Drawings which show the location of each piece and the sequence of

erection shall be included.

16.1.10 Piece marks may be stenciled or painted on according to the manufacturer's

standard procedure except as follows:

(1) Paints containing lead, zinc, or any other metals which are detrimental

to pressure parts operating at elevated temperatures shall not be used

for marking.

(2) Acceptability of marking paint must be established by prior

satisfactory experience of the heater supplier.

(3) Die stamping of parts which will contain process fluids under pressure

or temperature is prohibited.

16.1.11 All austenitic stainless steel material shall be protected against salt water

spray during ocean shipment.

16.1.12 Heater structures shall be designed such that outside columns do not

interfere with the lift and setting of convection sections while maintaining

structural integrity.

16.1.13 Convection sections shall be fully preassembled before delivery to the

jobsite including complete box assembly, refractory, tube supports, and

tubes.

16.1.14 Mating flanges of boxed pieces shall be match punched for proper field fit up.

16.1.15 Crossover piping shall be prefabricated to minimize field welding.

16.1.16 Platforms shall be shipped in maximum frame sizes allowed by shipping

limitations.

16.1.17 Stack sections shall be shipped with lifting lugs.

16.2 Structural-Steel Fabrication

16.2.1 General Requirements

m) (Exception) Attachment of refractory anchors and tie-backs shall be in





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16.3 Coil Fabrication

16.3.8 Fabrication of steam or water coils shall be in accordance with Boiler and

Pressure Vessel Code, ASME SEC VIII.

16.4 Painting and Galvanizing

16.4.1 (Exception) The type of coating and painting systems to be used shall be in

accordance with the data sheet and SAES-H-100.

16.4.5 Gasket contact surfaces shall not be painted.

16.5 Refractories and Insulation

13.5.8 (Exception) Refractory materials shall be installed in accordance with

SAES-N-110, SAES-N-130 and SAES-N-140 as applicable,

16.6 Preparation for Shipment

16.6.17 Prior to shipping coils are to be completely and thoroughly dried and cleaned.

16.6.18 Markings shall be done with water-soluble materials that contain no harmful

substances that would attack or harmfully affect coils at both ambient and

operating temperature. The marking materials shall be free of Lead, Sulfur,

Zinc, Cadmium, Mercury, Chlorine, or any other Halogens.

16.6.19 Flanged connections and all other machined surfaces shall be protected by a

coating, which is easily removed in the field. Flanges shall be fitted with a

steel or wood cover, 3 mm thick and neoprene gaskets.

16.6.20 Covers shall be securely attached by a minimum of four bolts equally

spaced. For ocean shipment, flanged connections shall also be covered with

heavy duty plastic bags securely taped to the nozzles.

16.7 Field Erection

16.7.7 Stainless coil material shall be covered, packaged for off-the-ground storage,

and plugged to prevent moisture from entering.

16.7.8 Heater radiant and convection sections shall be protected from atmospheric

moisture with all coil openings sealed.

17 Inspection, Examination and Testing

17.1 General

17.1.5 The responsibility for inspection rests with the Heater supplier in accordance




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with the applicable Industry Standards and the requirements of this

specification.

17.1.6 Heaters manufactured in accordance with this specification are subject to

verification by the Saudi Aramco Inspector in accordance with Saudi

Aramco Inspection Requirements Form 175-323700.

17.1.7 All Nondestructive Testing (NDT) shall be performed in accordance with the

Heater Supplier’s written procedure prepared in accordance with

ASME SEC V with the scope of NDT and acceptance/rejection criteria as

defined by the referencing Code section and this specification.

17.1.8 Inspection procedures shall be established in accordance with ASME SEC V.

A written procedure for each inspection method and technique, including

acceptance criteria, to be used shall be submitted to the Saudi Aramco

Inspector for approval. Qualification of the procedure by the Heater supplier

may be required, as determined by the Saudi Aramco Inspector. Inspection

procedures in conformance with other standards are acceptable only with the

approval of the Saudi Aramco Inspector.

17.1.9 Written reports and evaluations of all inspections performed by the Heater

supplier shall be made and submitted to the Saudi Aramco Inspector, at a

frequency to be determined by the Saudi Aramco Inspector.

17.1.10 The Saudi Aramco Inspector shall have free access to the work at all times.

17.1.11 Saudi Aramco shall have the right to inspect the fabrication at any state and

to reject material or workmanship which does not conform to the specified

requirements.

17.1.12 Saudi Aramco 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.

17.1.13 Saudi Aramco 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 Saudi Aramco property.

17.1.14 All of the rights of Saudi Aramco and their designated representatives for

access, documentation, inspection, and rejection shall include any work done

by sub-contractors or sub-vendors.

17.1.15 The Heater Fabricator shall furnish, install, and maintain in a safe operating

condition all necessary scaffolding, ladders, walkways, and lighting for a

safe and thorough inspection.




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17.1.16 Additional inspection of any weld joint at any stage of the fabrication may

be requested by the Saudi Aramco Inspector, including re-inspection of

previously inspected joints. The Saudi Aramco 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 at the Heater Supplier’s

expense.

17.1.17 All NDT performed in the field shall be by personnel certified in accordance

with SAEP-1142. Personnel responsible for interpretation of NDT results

shall be certified in accordance with SAEP-1142.

17.1.18 All NDT on heater coils which are to be postweld heat treated shall be made

after postweld heat treatment.

17.1.19 All pressure and non-pressure welds shall be visually inspected where

accessible.

17.1.20 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.

17.1.21 All appropriate safety precautions shall be taken for each inspection method.

17.1.22 All materials required to be other than, carbon steels, shall be alloy verified

in accordance with SAES-A-206.

17.2 Weld Examination

17.2.2.1 a) (Exception) Root and cover passes of all welds on austenitic alloy parts

shall be liquid penetrant examined.

17.3 Castings Examination

17.3.2 a) & b) (Exception) Radiographic testing of tube support castings shall be given

to any cracks or other indications exposed by liquid penetrant inspection that

exceed the quality requirements of ASME SEC I, PG-25.

17.3.2 c) (Exception) Areas of stress concentration in corners of castings, especially

at support lugs, shall be radiographically inspected. At least two spot

radiographs shall be taken of the lower flanges of each cast tube support

section.

17.4 Examination of other Components

17.4.2 (Exception) Refractory linings shall be inspected in accordance with




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SAES-N-110, SAES-N-130, and SAES-N-140.

17.4.7 One random spot radiograph shall be made for each girth weld and one

random radiograph for each two vertical welds of a stack shell. In addition,

each vertical and circumferential welds intersection shall be radiographed in

the circumferential direction.

17.5 Testing

17.5.1 Pressure Testing

17.5.1.5 Coil assemblies shall be completely drained and dried immediately upon

completion of hydrotesting. If coil assemblies are not drainable,

demineralized water containing 1% Na2 CO3 (Sodium Carbonate) plus 0.5%

Na NO2 shall be used for hydrotesting. For tube coils manufactured from

stainless steel, the water shall not contain more than 50-ppm chlorides.

17.5.2 Refractory Testing

(Exception) Refractory materials shall be tested in accordance with

SAES-N-110, SAES-N-130, and SAES-N-140 as applicable.

17.5.4 Positive Material Identification

14.5.4.2 (Exception) All materials, except carbon steel, shall be alloy verified in

accordance with SAES-A-206.

17.6 Burner Testing

A production model of each burner type shall be test fired prior to shipment.

Test firing may be witnessed by the Saudi Aramco Inspector. A certified

test report indicating the test firing shall be provided.

18 Life Cycle Cost Evaluation

Unless otherwise approved by the Coordinator, Mechanical Engineering Division,

Consulting Services Department, Quotations for heaters shall be evaluated on the basis

of Life Cycle Cost (LCC) as explained in SAEP-341. This cost is composed of the

initial purchase cost of the heater(s) plus the present worth of the fuel consumption over

an assumed operating period of 15 years. The Life Cycle Cost of the Heater(s) shall be

determined using the following Life Cycle Cost spreadsheets:

LCC-024, Single Fuel Heaters

LCC-024A, Dual Fuel Heaters

The efficiency of the heater at 100% of the design heat releases shall be guaranteed. If




Page 23 of 25

the actual efficiency during performance tests is found to be less than the guaranteed

efficiency, then the cost of the heater(s) shall be reduced by an amount equal to the

difference in fuel consumption (MMBTU/hr) for not meeting the guaranteed efficiency,

multiplied by the Evaluation Factor $-hr/MMBTU as given in the provided Life Cycle

Cost spreadsheets included with heater data sheet. The maximum reduction shall not

exceed 15% of the initial cost of the process heater(s).

Mathematically:

Single Fuel:

Efficiency Penalty = [actual efficiency – (guaranteed efficiency-0.01)] * L * EF

Commentary Note:

Efficiency values are in decimal representation. 0.01 in the equation is a 1% test tolerance allowed.

EF = PV * EC * AH

Dual Fuel:

Efficiency Penalty = Sum of Efficiency Penalty of all fuels

For each type of fuel the evaluation factor is defined by

EF = PV * EC * T

Where;

L = Heater Load (Duty) @ normal condition (MMBTU/hr) will be show

on the data sheet.

EF = Evaluation Factor ($-hr/MMBTU) will be shown on the data sheet

that goes with the quotation request

EC = Energy cost in $/MMBTU for each fuel

AH = Annual operating hours

= OF * 8760

OF = Operating Factor, equal 1

PV = Present value factor = 5.85 based on 15% discount rate expressed as a

decimal number and operating period of 15 years.

T = Operating time for each fuel type, in hours

Revision Summary

16 December 2009 Major revision.




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Appendix E – Centrifugal Fans for Fired Heater Systems

E.1 General

E.2 Design

E.2.1 General

E.2.1.2d Should the fouling characteristics of the fuel(s) demand a more stringent

design, the Fan Manufacturer shall submit the fan design criteria with

proposal.

E.2.1.15 Fans shall be designed for not less than the following conditions:

1) Mass flow rate at heater design case plus 10 %.

2) Static pressure through the heater plus 21%.

All the above are based on the average ambient temperature for FD fan

and stack temperature for ID fan.

E.2.1.16 Forced draft fans shall be located at ground level and designed to permit

easy access to the interior of fan casings and to allow easy removal of rotors.

E.2.1.17 Fans shall be supported on a common base plate with the fan driver.

E.2.1.18 Air intakes of fans located outdoors shall be provided with bird screen and

with means to avoid pickup of wind-driven sand. The inlet shall also be

designed to avoid wind effects on combustion airflow measuring devices.

E.2.1.18 Air intake and discharge ducts shall be provided with silencers as required

E.2.2 Fan Housing

E.2.2.4 The housing shall be of all-welded construction and shall be equipped with a

cleanout door and a 2 inch NPS drain. Housings shall be constructed with a

split-flanged bolted joint to allow for rotor removal.

E.2.5 Rotating Elements

E.2.5.9 Fans shall be furnished with inlet guide vanes/dampers and with a vane drive

arm for connection to operator. The drive arm connections shall be of the

ball-and-socket design (or approved equivalent) to minimize lost motion.




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E.3 Accessories

E.3.2 Drivers

E.3.2.11 Turbine drivers shall conform to the requirements of 32-SAMSS-009.

Motor drivers shall conform to the requirements of 17-SAMSS-503.

E.3.2.12 Drivers shall be as specified on the data sheet and shall be in accordance

with the specified electric power supply and steam conditions.

E.3.2.13 Geared drives shall be separately coupled units with a minimum service

factor of 1.5.

E.4 Examination, Testing and Preparation for Shipment

E.4.2 Fan Testing

E.4.2.4 Fans shall be tested by the Fan Manufacturer in accordance with

ANSI/AMCA 210-85 and no load, mechanical run test.

Appendix F – Air Preheat Systems for Fired Process Heaters

F.1 Scope

F.1.1 The Engineering Company together with the Heater supplier must evaluate

the need for air-preheating systems based on energy conservation in

accordance with the requirements of this Appendix. The design and

proposal will be technically unacceptable if an evaluation of a preheat

system based on energy conservation has not been provided.

Documents

32-SAMSS-029