GP 07-04-01 Burners for Fired Heaters July 2001

Burners for Fired Heaters

GP 07-04-01

Scope
[I] This Global Practice (GP) covers the design, fabrication, and inspection of burners and related
components for fired heaters in general refinery service. Burners covered under this Practice include:
premix and raw gas, natural and forced draft, combination gas/oil, conventional, and low NOx.
[I] An asterisk (*) indicates that a decision by the Purchaser is required, or that additional information is
furnished by the Owner.

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Table of Contents

1. Required References ............................................................................................ 3

1.1. Global Practices-ExxonMobil Engineering Practices.................................... 3
1.2. ASME–American Society of Mechanical Engineers ..................................... 3
1.3. API–American Petroleum Institute................................................................ 3
2. Additional Requirements...................................................................................... 3
2.1. Global Practices-ExxonMobil Engineering Practices.................................... 3
3. Definitions.............................................................................................................. 4

4. Documentation ...................................................................................................... 4

5. General Design...................................................................................................... 6

6. Burner Fuel Gas Injector Tip and Venturi Design .............................................. 7

7. Pilot Design ........................................................................................................... 7

8. Tile Design ............................................................................................................. 8

9. Air Register Design ............................................................................................... 8

10. Plenum Design ...................................................................................................... 9

11. Fuel Oil Injector Design ........................................................................................ 9

12. Shop Inspection and Tests................................................................................. 10

13. Guarantee ............................................................................................................ 10

Record of Change ....................................................................................................... 11

Attachment: Purpose Codes Definitions.................................................................. 12

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1. Required References
[I] This Section lists Practices and Standards that are generically referenced and assumed to be a part of
this document. Unless otherwise specified herein, use the latest edition.

1.1. Global Practices-ExxonMobil Engineering Practices

GP 02-01-01 Plant Noise Design Criteria
GP 03-16-01 Flanged Joints, Gaskets, and Bolting
GP 15-01-01 Instrumentation for Fired Heaters
GP 18-04-01 Postweld Heat Treatment of Equipment Handling Alkaline Solutions
GP 18-12-01 Positive Material Identification
GP 19-01-01 Paint and Protective Coatings
GP 20-01-01 Inspection of Equipment and Materials

1.2. ASME–American Society of Mechanical Engineers

ASME B1.20.1 Pipe Threads, General Purpose (Inch)

1.3. API–American Petroleum Institute

API STD 560 Fired Heaters for General Refinery Services

2. Additional Requirements
* [I] The following Practices and Standards shall be used with this Practice as specified by the Purchaser.

2.1. Global Practices-ExxonMobil Engineering Practices

GP 03-18-01 Piping Fabrication Shop or Field
GP 20-01-02 Administrative Procedures for Obtaining Inspection

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3. Definitions
Term [I] Description

Air Doors Air inlets that are an integral part of a single burner providing air
regulation. Air doors are typically located symmetrically around the air
plenum with each having a vertical axis. Air doors can provide a tight
shut off.
Air Louvres Multiple blades mounted with either horizontal or vertical axis; all
blades operate in a parallel or opposed blade mode. Air louvres offer
good air control and tight shut off.
Air Register An air inlet that is an integral part of a single burner and provides for
regulation of air. Air registers are typically composed of concentric
sliding parts that do not offer a tight shut off.
Burner tip The burner component(s) by which the fuel is injected into the
combustion zone(s).
Fuel Injector Any device used to inject or direct fuel into the burner combustion zone.
Gas Spud or Orifice Associated with premix burners. The orifice in conjunction with the
Venturi uses the kinetic energy (force) of the fuel to inspirate (primary)
air.
Plenum An enclosure which normally houses one or multiple burners and
provides for the distribution of air. A plenum is often used in the supply
of pre- heated air. A plenum is sometimes called a windbox.
Ports Openings in tips.

4. Documentation
[I] All information listed in Table 1 shall be submitted by Vendor as indicated. All quantities related to
firing rates shall be expressed in both LHV and HHV. Units to be consistent with API STD 560 burner
data sheet.

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Table 1: Required Documentation

Required Documentation Proposal Approval Final

Information Information “As Built”
Required Submit for Records
with Owner’s Required as
Vendor Engineer Applicable
proposal Approval

1. Burner General Arrangement Drawing

Containing the following information: X X X
a. Design firing rates X X X
b. Operating fuel temperature and pressure X X X
c. Combustion air conditions X X X
d. Fuel heating value. SG and MW X X X
e. Type of oil gun (if applicable) X X X
f. Fuel oil and fuel gas orifice drilling size X X X
g. Heater floor and plenum cutout or air X X X
inlet dimensions
h. Atomizing steam rate and conditions X X X
i. Construction of air register X X X
j. Bill of Material with component part — X X
number and material designation
k. Orientation and dimensional location of
burner fuel injectors, pilot igniter, pilot — X X
flame detector, tiles, and diffuser
2. Detail Drawings — X X
Showing the following as applicable:
a. Burner tile geometry — X X
b. Air diffuser or vane geometry — X X
c. Geometry of fuel injectors — X X
d. Cutaway of oil gun with each part — X X
identified
e. Burner mounting details showing all — X X
adjustment mechanisms

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Required Documentation Proposal Approval Final

Information Information “As Built”
Required Submit for Records
with Owner’s Required as
Vendor Engineer Applicable
proposal Approval

3. Complete Documentation Of — X —
Burner Test Matrix
4. Complete Burner Data Sheet X X X
5. Recommended Spare Parts List X X X
6. Burner Operating Curve For Each Fuel — X X
Pressure vs. Heat release LHV, including draft
(and showing orifice size, steam rate and
condition)
7. Certified Test Data
Oil gun flow test, nox emissions, etc., As — X Test Results
required by the job specification
8. Operating & Maintenance Manual — — X
9. Guarantees
a. Burner turndown and XS air X X X
b. Noise Level X X X
c. NOx emissions for each fuel X X X
d. CO emission for each fuel X X X
e. Particulate emissions for each fuel X X X
f. Total hydrocarbons X X X
g. Flame length X X X

5. General Design
1) [O] Burners firing fuel gas only shall be designed and sized to meet performance guarantees at a
maximum of 15 percent excess air.
2) [O] Burners firing fuel oil only or a combination of liquid fuels and fuel gas shall be designed and
sized to meet performance guarantees at a maximum of 25 percent excess air.
3) * [M] All burners, pilots, fuel injectors and burner bottom plates shall be removable without
removing any common plenum, air register, or ducting and while the heater is in operation. Further,
fuel injectors shall be constructed and arranged to allow for removal for maintenance and

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reinstallation to the original position such that all injector parts are accurately aligned relative to the
tile and other burner parts. If burner components are not interchangeable they shall be either match-
marked for accurate assembly or other Owner’s Engineer approved procedure must be used. All
burner risers and tips shall be engraved with a number to identify its use with the respective burner.
All risers and tips for identical burners shall have the same identification number.
4) [O] There shall be adequate access for lighting the pilot with a portable igniter and good visibility of
the burner fuel injector(s) and pilot from the burner front plate.
5) [O] A common air plenum and/or air distribution system shall be designed for not more than a 2
percent RMS (Root Mean Square) airflow to each burner and not more than 10 percent RMS within
or around each burner.
6) [R] Main fuel gas piping and fittings smaller than NPS 3/4 (19 mm) are not permitted. Also, main fuel
oil and pilot fuel piping and fittings smaller than NPS 1/2 (12.5 mm) are not permitted.

6. Burner Fuel Gas Injector Tip and Venturi Design

1) * [R] Main firing ports shall have a minimum 1/8 in. (3 mm) diameter unless otherwise approved by
the Owner's Engineer.
2) [R] Surface defects in cast premix burner tips wider than 1/8 in. (3 mm) or deeper than 1/16 in. (1.5
mm) are unacceptable.
3) [R] Fuel gas orifice, ports, and tip drillings shall be manufactured such that the hole drillings shall
each have a tolerance of ±2.5 percent of the specified area. For hole sizes less than 1/8 in. (3 mm), the
drilling tolerance shall be increased to ±3.5 percent of the specified area. Firing port angle of drilling
shall be within 2 degrees of specification.
4) [M] When burner tips are attached by threading a minimum of 5 turns is required in the assembly, and
a high-temperature thread compound shall be used. No visibly apparent defect on any threaded part is
acceptable.
5) [R] Fuel injector tip material shall be minimum 25/20 chrome-nickel. Burner tips for steam-cracking
furnaces shall be 25/35 chrome-nickel or wrought Incoloy 800.
6) [R] Cast Venturis shall be in one piece. The inside of the Venturi shall be free of any protrusions.

7. Pilot Design
1) * [S] Each burner shall be equipped with either a continuous gas pilot or main flame detection except
where a large number of small burners [less than 1.5 MBtu/hr (0.44 MW)] make pilots impractical.
2) * [S] Each pilot shall be equipped with a flame sensing device. The pilot flame sensing device shall
be approved by the Owner’s Engineer.
3) [R] Pilots shall be commercially proven to be reliable and flame stable, or demonstrated to be reliable
and flame stable. A stable pilot is one that is continuous, free from pulsation, self sustaining, and free
of smoke.

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The following pilot Qualification Procedure shall be used to demonstrate the pilot flame stability and
reliability.
a) Determine the required fuel gas pressure, for a given fuel gas composition while the main burner
is in and out of service. As a minimum, pilots shall be capable of stable operation at ± 50 percent
of design liberation for each fuel under consideration.
b) Determine flame stability at 130 percent of maximum design combustion airflow (for the main
burner) and at design combustion air temperature range, while the main burner is in and out of
service.
c) Determine pilot capability to light off the main burner at 130 percent of maximum design
combustion airflow. For natural draft burners, light off shall be determined at a minimum burner
air throat velocity of 50 ft/s (15.3 m/s).
d) Pilot shall remain stable with the main burner register(s)/damper fully closed.
e) Pilots used with burners in forced draft service shall remain stable in fireboxes against a
minimum backpressure of 1.5 in. (38 mm) of water at normal pilot gas pressure.
f) Pilots used with burners in natural draft service shall remain stable against a minimum
backpressure of 0.5 in. (12.5 mm) of water at normal pilot gas pressure.
g) Pilot must remain stable while the main burner fuel gas valve is closed/opened once per second,
several consecutive times.
4) [R] Pilot tip material shall be minimum 12 percent chrome stainless steel, and tip shield (if used) shall
be minimum 310 stainless steel.
5) [R] Pilots shall have a 1/16 in. (1.5 mm) minimum size gas orifice.
6) [R] The pilot Venturi mixer shall be outside any plenum to ensure a continuous air supply.
7) * [R] Forced draft pilots, when specified, shall have an independent forced draft air supply.

8. Tile Design
[R] Burner tiles shall be rated for 3000°F (1650°C) service temperature and shall be laid in high-
temperature [3000°F (1650°C)] mortar. Tiles shall be independent of the floor or wall refractory.
Adequate clearance between tile and floor shall be provided and filled with ceramic fiber insulation so
that the burner block will be free to expand and contract as a unit.

9. Air Register Design

1) [O] Individual air register types which are acceptable include:
a) The individual plenum with multiblade damper in the air inlet
b) The air door type register
Concentric air registers are not acceptable.
2) [O] Individual plenum air inlets shall be tight shut-off (98 percent on area) and shall have the
following features:

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a) When a multiple blade damper is used for burner air regulation, it shall be opposed motion.
b) Damper with heavy-duty linkage, carbon graphite bearings, and corrosion resistant parts.
c) Linkage must allow smooth operation and repeatable adjustment (including shut-off) at each
damper.
3) [O] Air door type registers shall be tight shut-off (98 percent on area) and shall have the following
features:
a) Linkage joining each shaft shall be designed to ensure equal opening of air doors and without
backlash in movement.
b) Shaft bearings if registers are used for air regulation.
c) Corrosion resistant parts for linkages, bearing, and shafts.
4) [O] Each damper control mechanism shall be equipped with a locking device, which shall hold the
damper in the position selected. Set screws shall not be used for this purpose. In addition, the control
mechanism shall include a position indicator and a calibrated scale backplate to permit repeatable
positioning.

10. Plenum Design

[O] Design of the plenum shall meet the following criteria:
1) Plate thickness shall be at least 3/16 in. (4.8 mm) thick, stiffened against vibration. Unstiffened areas
must be less than 15 ft2 (1.4 m2), with a 5 ft (1.5 m) maximum span. Stiffeners can be seal welded or
stitch welded on both sides.
2) Designed for the blower maximum pressure conditions.
3) * Owner’s Engineer to specify internal or external insulation.
4) Thermally insulated (if in preheated air service) for a calculated cold face temperature of 150°F
(65°C) in ambient still air conditions of 80°F (27°C). Owner’s Engineer shall review cold face
temperature calculations.
5) Internal insulation shall be retained with perforated galvanized sheet metal with 35 percent open area,
or with 20-gauge Type 304 stainless steel wire mesh with 65 percent open area.
6) Castable refractory shall be used to line windboxes used for oil firing applications.

11. Fuel Oil Injector Design

1) [O] Individual oil guns shall be stamped with an easily identifiable number for each heater.
2) * [R], [C] Liquid fuel injector atomizers and tips shall be of the following materials unless otherwise
specified by Owner’s Engineer:
a) Internal atomizers shall be nitrided nitralloy or equivalent and shall have a 0.01 case hardness of
1000 DPN (Diamond Pyramid N Scale).

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b) Tips shall be high-speed tool steel (GP 18-04-01, W-Cr-V, or equivalent), hardened to 55
Rockwell C.
3) [O] Liquid injector spray angles (firing port included angle) shall be within 2 degrees of specification.

12. Shop Inspection and Tests

1) * [O] Test firing of at least one production burner is required unless burner is commercially proven in
comparable service, taking into account fuels fired, orientation, oxygen sources, heat release range of
operating conditions, and fuel injector size, drilling (orifice size) and orientation. Test guidelines will
be provided by Owner’s Engineer.
2) [O] For gas burners, port (orifice) diameters and angles of one injector tip shall be measured by the
Inspector on each burner. If an error is found, then all of the injector tip ports in all burners shall be
measured.
3) [O] For oil burners, 100 percent of production shall be tested by the Inspector as follows:
a) Burner fuel oil injector port diameter and port angle shall be measured.
b) Injector tip shall be disassembled, and the atomizer parts diameters and port angles shall be
measured.
c) All steam and oil orifices shall be flow tested and the results supplied with other burner data. The
burner-to-burner fuel flow deviation shall be within 2.5 percent.

13. Guarantee
1) [R] Burner performance, material, and workmanship shall be guaranteed for 18 months after shipment
or 12 months after startup, whichever occurs first. In the event that servicing of any type is required
during this period due to burner design error or manufacture, such cost shall be borne by the
manufacturer.
2) [O] Burners shall be capable of operating at the guarantee excess air level, draft loss, and heat release
rate without flame instability, flame impingement, or flame interference between adjacent burners.
3) [E] Vendor shall guarantee NOx, CO, total hydrocarbons, and combustion generated particulate
emissions based on the fired heater box temperature, specific fuel and oxidant conditions.
4) * [O] Owner’s Engineer shall specify the required turndown (minimum heat release) at design excess
air (in ratio), as well as the required turndown without regard to excess air (out of ratio).

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Record of Change
Version 1.0.0 Date: 07/01
Location Action Description
Initial Publish.

Version 1.0.0 Date: 07/03

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

Version 1.0.0 Date: 03/05

Initial endorsement by Chemical. Due to Chemical endorsement of the
referenced GP 20-01-02, this version replaces Chemical's previous
customized Version 1.0.1.

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Attachment: Purpose Codes Definitions

Code Description

C Assigned to paragraphs containing specifications whose primary purpose is reduced costs.

Reduced cost in this context refers to initial investment cost and does not include Life-Cycle
cost considerations. Life-Cycle cost considerations are captured under reliability,
maintainability, or operability purpose codes.
E Assigned to paragraphs containing specifications whose primary purpose is driven by
environmental considerations. Environmental considerations typically include specifications
intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the
specifications contained in such paragraphs require formal review and approval according to
local environmental policy.
I Assigned to paragraphs that provide only clarifying information such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs containing specifications whose primary purpose is to provide for
maintainability of equipment or systems. Maintainability provisions are those that facilitate the
performance of maintenance on equipment/systems either during downtimes or during on-
stream operations.
O Assigned to paragraphs containing specifications whose primary purpose is to assure
operability of equipment or systems. Operability is the ability of the equipment/system to
perform satisfactorily even though conditions are off-design, such as during startups, process
swings, subcomponent malfunction, etc.
R Assigned to paragraphs containing specifications whose primary purpose is to improve or
assure the reliability of equipment or systems. Reliability is a measure of the ability of
equipment/systems to operate without malfunction or failure between planned maintenance
interventions.
S Assigned to paragraphs containing specifications whose primary purpose is avoidance of
personnel or operational safety incidents. Any deviation from the specifications contained in
such designated paragraphs requires formal review and approval according to local safety
policy.
Personnel Safety: Refers to the avoidance of recordable personnel injuries; i.e., burns, cuts,
abrasions, inhalation, or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, explosions,
Safety: etc.

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