direct and indirect fired heater nao-spc-d-ht-001

TALISMANE N E R G y

NAO ENGINEERING SPECIFICATIONS - HEAT TRANSFER

DIRECT AND INDIRECT FIRED HEATERNAO-SPC-D-HT-001

DIRECT AND INDIRECTFIRED HEATER

Issue: 2011/01/01

Next Review Date:June 2011 Published by:

HSE/OI Staff Responsible: Talisman Energy Inc.Mechanical Technical Authority Operational Integrity Department

APPROVALS:Calgary

Tech Auth:Copyright is owned by Talisman Energy Inc. All

Eng. Auth: rights are hereby reserved. This document (inwhole or in part) may not be reproduced, stored in

VP-HSEOI: a retrieval system, or transmitted, in any form ormeans, without the prior written permission ofTalisman, or as expressly permitted by law.

Note: This is an existing specification currently being used by Talisman and has not beentechnically reviewed or signed off by the Technical Authority at this time. Over time, thesespecifications will be rebuilt and validated through a specification review process. Pleaseensure that you use the most current copy of the specs listed on the NAO Portal underEngineering Specifications. The Technical Authority identified on the cover sheet is the point ofcontact for this specification.

Attention: Paper copies are uncontrolled. This copy is valid only at time of printing, 12/15/2010.The controlled document is available on the Talisman NAO Portal.

TALISMAN ENERGY INC. GENERAL SPECIFICATION

DIRECT AND INDIRECT FIRED HEATER Rev 2A Oct 2002 Page 1 of 9ES1.F101

TABLE OF CONTENTS

I. SCOPE.................................................................................................................................................................2

2. APPLICABLE REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS................................2

3. APPLICABLE REGULATIONS, CODES AND STANDARDS ...................................................................2

4. DOCUMENTATION .........................................................................................................................................3

5. SOUR SERVICE ...............................................................................................................................................3

6. GENERAL DESIGN ..........................................................................................................................................3

7. BURNERS ...........................................................................................................................................................4

8. STACK ................................................................................................................................................................4

9. CONTROLS........................................................................................................................................................4

10. DIRECT FIRED HEATERS........................................................................................................................5

i I. INDIRECT FIRED HEATERS.....................................................................................................................8

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1. SCOPE

1.1.1. This specification covers the general requirements for the design,manufacture and testing of direct and indirect fired heaters.

2. APPLICABLE REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS

2.1. TLM Specifications

2.1.1. All direct and indirect fired heaters shall be designed, manufactured andtested in accordance with this specification. The following TLMspecifications form part of this specification:

· ES1.J101 -Instrumentation

· ES1.L 102 - Piping Fabrication, Erection and Testing

. ES1.L 104 - Welding

. ES1.N101 - Electrical

. ES1.Q1 05 - Structural Steel

· ES1.v101 - Unfired Pressure Vessels· ES 1.z403 - Painting and Coatings

. ES1.z404 - Insulation

2.1.2. Colt Specification:

· GS903.03 - General Specification Piping Materials - Line Classes,TLM Specific

· GS902.03 - General Specification Mechanical - Pressure Vessels

3. APPLICABLE REGULATIONS, CODES AND STANDARDS

3.1. All direct and indirect fired heaters shall comply with the latest editions of the

following:

· ASME Boiler and Pressure Vessel Code;· ANSI B31.3 Chemical Plant and Petroleum Refinery Piping;· API Std. 661 MR Cooled Heat Exchangers for General Refinery

Service;. API Std. 665 API Fired Heater Data Sheet;

· API RP631 M Measurement of Noise from Air-Cooled HeatExchangers;

· API RP530 Calculation of Heater Tube Thickness in PetroleumRefineries;

· API RP532 Measurement of the Thermal Effciency of Fired ProcessHeaters

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3.2. Conflict Between Specifications, Codes and Standards

3.2.1. Where a conflict occurs between this specification and any specification,regulation, code or standard which has been specified for a particularservice or item of equipment, then TLM shall be consulted and a rulingin writing shall be obtained before any work is started.

3.2.2. Where regulatory codes or regulations conflict with this specification, themore rigid specification shall govern.

4. DOCUMENTATION

4.1.1. The data required for a fired heater shall include, but not be limited to,the following:

. A fully completed API 665 fired heater data sheet.

. Drawing showing the general arrangement, the tube layout, the

position and locations of accelerating equipment.. Details of burners.

. Flue gas temperature profile through the heater at the design

conditions.. Process fluid pressure, temperature and velocity profies at the design

conditions.. Tube stressing calculations when requested.

. Details of any instrumentation or control system supplied or proposed

by the Contractor.

. The manufacturer shall supply drawings in legible reproducible form,showing "as built" measurements of the finished vessel aftercompletion of all fabrication and heat treatment.

4.1.2. Drawings shall be supplied in electronic format, compatible to AutoCadlatest version release.

5. SOUR SERVICE

5.1.1. Materials, fabrication and installation shall comply with ES1.v101Vessels Supplement for Sour Service and ES1.A408 Piping Material -Sour Service Supplement.

6. GENERAL DESIGN

6.1.1. Design effciency shall not be less than 70% based on the heating valueof the fueL.

6.1.2. Unless otherwise specified by TLM the heater shall be designed tooperate on natural draft with a slight vacuum existing in the firebox at allpoints within the normal operating range.

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7. BURNERS

7.1.1. Burners shall be designed to give an effcient heater operation from 30%to 125% of the design-heating load. Suffcient burners shall be suppliedto give an even temperature throughout the firebox. Each burner is tobe provided with a pilot light.

8. STACK

8.1.1. The stack shall be of steel and shall be self-supporting, designed to

provide adequate height and diameter for maximum draft requirements.

8.1.2. Dampers shall be of the butterfy type, with one-inch clearance aroundthe entire periphery to avoid complete shut-off, and equipped for manualoperation from grade.

8.1.3. Pipe sleeves in the stack shall support dampers. They shall be properlydesigned to prevent warping or buckling during operation. A pointershall be provided on the main damper shaft, outside of the stack toindicate damper position. A counterweight shall be provided to adjustthe damper to wide-open position in case of failure of the adjustingmechanism.

8.1.4. Dampers shall be of 18% chrome, 8% nickel stainless steel.

9. CONTROLS

9.1.1. The fuel gas line to the heater shall be split into two legs. One leg shallsupply fuel to the main burner(s) and the other shall supply fuel to thepilot(s).

9.1.2. The ESD valves shall only be latched if the safety conditions arecompleted as shown on the trip legend.

9.1.3. The ESD systems on each heater shall be supplied from a common airor electrical supply system.

9.1.4. No bypass on any ESD valve shall be permitted (spare ESD valvesshould be supplied on hand for servicing).

9.1.5. Manual ESD stations, block valves and snuffing lines shall be easilyaccessed and be controllable at a safe distance from the heater.

9.1.6. Fuel gas scrubbers shall have a high liquid level device that will activatealarms/shutdowns as indicated in the legend.

9.1.7. Hand operated isolating valves shall be provided on individual lines toeach pilot and main burner.

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9.1.8. A temperature control loop and control valve shall be provided

downstream of the latching ESDV in the main burner fuel supply line. Asuitable bypass valve arrangement shall be provided to allow servicingof the temperature control loop.

9.1.9. Ultraviolet or thermocouple type flame failure devices shall monitorflame at the pilots and initiate alarms/shutdown.

9.1.10. Thermal relief valves shall be installed in product lines to prevent overpressure.

9.1.11. All automatic valves, ESD valves, relays, solenoids etcetera shall be offail-safe design.

9.1.12. All devices used for critical shutdowns shall be primary monitoringdevices, e.g. devices monitored by computer, which in turn initiates ashutdown, are not acceptable.

9.1.13. Heater charge pumps are required to have the capability toautomatically restart following a power outage.

10. DIRECT FIRED HEATERS

10.1. General

10.1.1. Heaters shall be of radiant or a combination of radiant and convectiondesign, and horizontal tube design. Convection and radiant sections areto be flanged and bolted for easy dismantling.

10.1.2. All parts of the heater, including walls, floors, arches and roofs, shall bedesigned to permit necessary thermal expansion at maximum operatingtemperature. All refractories shall be designed to permit their removaland replacement while the main steel structure; heater tubes and tubeheaders or return fittings remain in place.

10.1.3. The volume of the firebox shall be sufficient size to prevent flameimpingement against the tubes.

10.1.4. Convection section piping shall be flanged connected or fitted withflanged crossovers, and designed for easy dismantling and removaL.

10.1.5. In design of fired heaters, the average heat flux shall not exceed 31.5kW/m2 of outside tube surface, and the maximum heat flux on anyonetube shall not exceed 47 kW/m2 of outside tube surface.

10.1.6. In the design of U-tube direct-fired glycol reconcentrators the averageheat flux shall not exceed 19 kW/m2 of outside tube area with amaximum heat flux not exceeding 31.5 kW/m2 at the U-type entrancenear the burner.

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10.2. Tube Supports

10.2.1. Tube supports shall be designed to resist the vertical reactions of thesupported tubes, plus operating contents at maximum operating flowconditions, plus frictional forces developed and transmitted to thesupports during short time conditions. The frictional load shall beconsidered to be equal to one-sixth of the vertical reaction at the pointunder consideration.

10.2.2. Horizontal tube support spacing shall not be greater than 35 nor lessthan 25 times the OD of the tubes.

10.2.3. End radiant and convection section tube sheets shall be provided withsuitable insulating concrete on the fire side.

10.2.4. Radiant and convection end tube supports may be of carbon steel plateif adequately protected by 75mm of insulating concrete applied overstainless steel wire mesh and secured to cast in place tube sheet studs.

10.2.5. Insulated (intermediate) tube supports with design metal temperaturesabove 8000C shall be 25% chromium, 12% nickel coatings conformingto ASTM B-190, Type II, modified as follows:

. Nickel 11 - 14%

. Chromium 23 - 27%

. Carbon 0.25 - 0.35%

10.2.6. Un-insulated (intermediate) tube supports with design temperatures of8000C or less, shall be ASTM A-297 Grade HF, 19% chrome and 9%nickeL.

10.3. Structural Steel and Platforms

10.3.1. All tubes, headers and burners shall be supported from the structuralsteel framework independently of the brickwork.

10.3.2. Vertical tube furnaces shall be provided with a structure for pullingtubes.

10.3.3. Access platforms for inspection holes shall be provided.

10.4. Doors and Header Boxes

10.4.1. A sufficient number of observation doors shall be installed in the endwalls to permit unrestricted observation from the operating platform ofthe burner flames and tubes surfaces exposed to the radiant section.One door shall be provided for access and ventilation of eachcombustion chamber.

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10.4.2. Heaters shall be equipped with either 1800 welded return bends or plugtype fittings. Welded 1800 return bends shall be used except whenthere is likelihood of plugging. With either type of return bend, adequateprovision shall be made for thermal decoking. When 1800C weldedreturn bends are used, plug type fittings shall be provided for inspectionpurposes. The number and location of such fittings shall be determinedafter the general design of the heater is submitted. Elbowlets can alsobe used. All welding on heater coils shall comply with ES1.L 104 and

shall be 100% radiographically inspected.

10.4.3. Tube headers and return bends are to be enclosed in header boxesfabricated from steel plate for special services in which corrosion orcracking may occur in the furnace. These boxes are to be equipped

with doors and are to be removable depending upon the size of the box.Woven asbestos packing shall be applied between the boxes and theframework or doors. Drain holes shall be provided in the header boxes.

10.4.4. Convection section must have inspection doors on opposite sides tocheck return bends and inspection plugs.

10.5. Auxiliary Connections

10.5.1. Each furnace shall be equipped with one stack temperaturethermocouple and one stack gas sample port. A Y-" 316 SS stack gassampling line shall be provided at the operating leveL.

10.5.2. Water spray or steam quenching shall be provided as per National FireCode.

10.5.3. 60.3mm diameter snuffing steam connections shall be provided throughthe walls of the firebox and the header boxes. Piping shall be valved forremote operation. When steam is not available, a water spray systemshall be provided.

10.6. Materials

10.6.1. Material for tubes, return bends and fittings shall be as shown on thematerial specifications chart.

10.6.2. Refractory tile and brick shall be suitable for the service and

temperature as specified. High temperature insulating block shall besuitable for temperatures 950C higher than the cold face temperature ofthe refractory lining. Manufacturer's drawings shall include lists ofmaterials used for insulation, refractory, etc.

10.6.3. Refractory anchors shall be fabricated from 304SS materiaL.

10.6.4. Observation and access doors and frames shall be of cast iron,

conforming to ASTM A-48, Class 25.

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10.7. Controls

10.7.1. An automatically operated double block and bleed system shall beprovided in each leg of the fuel gas supply to the heater.

10.7.2. The ESDV on the main fuel line shall be the manual mechanical resettype with electrical latching, Maxon or equal as per CSA B.149.3. TheESDV's on the pilot lines

10.7.3. A timed bypass shall be provided to open the pilot fuel gas block valvesonly to enable the heater to be lit.

10.7.4. Fuel gas to the main burner(s) shall have high-pressure shutdown.

10.7.5. Fuel gas to the pilot(s) shall have a high-pressure device that willactivate alarmslshutdowns should the pressure in the line exceed apredetermined set point condition.

10.7.6. Temperature shall be monitored at each stack and shall initiatealarm(s)/shutdown(s) as indicated in the legend.

10.7.7. Product outlet line from the heater shall have a low-pressure shutdowndevice in the line to shut down the main burners and heater chargepumps.

10.7.8. Product flow devices shall monitor the flow in each inlet pass and initiatealarms and shutdowns for low flows as specified.

10.7.9. High product outlet temperature monitoring devices shall be installed inthe outlet lines of each heater pass and will initiate alarms/shutdowns asspecified.

10.7.10. Thermocouples shall be located on each pass in the heater to allow themonitoring of high skin temperatures on the tubing walls.

11. INDIRECT FIRED HEATERS

11.1.1. Salt bath and glycol heaters shall be fuel gas shutdowns (alarmsoptional) for the following conditions:

. High bath temperature

. Pilot flame failure

. High liquid level in fuel gas scrubber

11.1.2. An automatically reset bypass valve shall be installed to enable theheater to be lit.

11.1.3. A reset valve should be installed between the high temperatureshutdown device and the temperature controller to prevent the TCV




opening as soon as the pilots are lit. The valve should remain closeduntil reset manually.

11.1.4. A flare arrestor shall be provided on the combustion air intake.


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