GP 07-05-01 Coils for Fired Heaters and Boilers March 2002

Coils for Fired Heaters and Boilers

GP 07-05-01

Scope
[I] This Global Practice (GP) covers the design, fabrication, inspection, and shipping of bare and extended
surface tubes/pipes and fittings for new or replacement coils for fired heaters, boilers, and heat recovery
steam generators (HRSG). It does not apply to cast tubes.
[I] An asterisk (*) indicates that a decision by the Owner's Engineer is required or that additional
information is to be supplied by Purchaser.

Downstream, Chemical, Downstream

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Imperial Oil

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Table of Contents
1. Required References ............................................................................................ 3
1.1. Global Practices–ExxonMobil Engineering Practices ................................... 3
1.2. API–American Petroleum Institute................................................................ 3
1.3. ASME–American Society of Mechanical Engineers ..................................... 3
1.4. ASTM–American Society for Testing & Materials......................................... 3
2. Additional Requirements...................................................................................... 4
2.1. Global Practices-ExxonMobil Engineering Practices.................................... 4
2.2. ASME–American Society of Mechanical Engineers ..................................... 4
3. Design of Tubes and Headers.............................................................................. 4
3.1. Fired Heater Tubes ...................................................................................... 4
3.2. Return Bends, Headers, and Manifolds........................................................ 5
3.3. Extended Surface......................................................................................... 5
3.4. Boiler and HRSG Tubes ............................................................................... 6
4. Fabrication of Tubes and Tube Assemblies ....................................................... 7
4.1. Fired Heater Tubes and Headers ................................................................. 7
4.2. Extended Surface–Fins ................................................................................ 7
4.3. Extended Surface–Studs.............................................................................. 7
5. Inspection .............................................................................................................. 8
5.1. Tube Inspection............................................................................................ 8
5.2. Extended Surface Inspection–Finning .......................................................... 8
5.3. Extended Surface Inspection–Studding ....................................................... 9
5.4. Inspection of Fittings .................................................................................... 9
5.5. Final Inspection ............................................................................................ 9
6. Testing ................................................................................................................... 9

7. Preparation for Shipment ................................................................................... 10

7.1. Protection ................................................................................................... 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 03-16-01 Flanged Joints, Gaskets, and Bolting
GP 03-18-01 Piping Fabrication Shop or Field
GP 18-03-02 Statically Cast Steel and Alloy Pressure Containing Parts and Tube
Supports for Fired Heaters
GP 18-07-01 Welding Procedures
GP 18-10-01 Additional Requirements for Materials
GP 18-12-01 Positive Material Identification
GP 20-01-01 Inspection of Equipment and Materials

1.2. API–American Petroleum Institute

API STD 530 Calculation of Heater-Tube Thickness in Petroleum Refineries
API STD 560 Fired Heaters for General Refinery Services

1.3. ASME–American Society of Mechanical Engineers

ASME B1.20.1 Pipe Threads, General Purpose (Inch)
ASME SEC I BPVC Section I - Rules for Construction of Power Boilers

1.4. ASTM–American Society for Testing & Materials

ASTM E 570 Standard Practice for Flux Leakage Examination of Ferromagnetic Steel
Tubular Products

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

2.1. Global Practices-ExxonMobil Engineering Practices

GP 03-06-01 Piping for Instruments
GP 20-01-02 Administrative Procedures for Obtaining Inspection
GP 18-10-01 Additional Requirements for Materials

2.2. ASME–American Society of Mechanical Engineers

ASME B31.1 Power Piping
ASME SEC II A BPVC Section II A - Materials Part A - Ferrous Material Specifications
ASME SEC II B BPVC Section II B - Materials Part B - Nonferrous Material
Specifications
ASME SEC II C BPVC Section II C - Materials Part C - Specifications for Welding Rods,
Electrodes, and Filler Metals
ASME SEC II D BPVC SECTION II Materials Part D - Properties Non-Interfiled
ASME SEC V BPVC Section V - Nondestructive Examination

3. Design of Tubes and Headers

3.1. Fired Heater Tubes
1) [R] Minimum tube wall thickness calculations shall be based upon all of the following:
a) Minimum thickness calculated per current edition of API STD 530.
b) 100,000 hour design life (minimum rupture strength).
c) * Design temperature, if not specified by Owner, shall include 25°F (14°C) temperature
allowance (TA).
d) * Operating conditions (normal and emergency) specified by the Owner.
e) * Corrosion allowance, if not specified by the Owner’s Engineer, shall be per the current edition
of API STD 560.
2) [R] Minimum new wall thickness for any tube shall be:
a) Radiant, Shield and Convection Tubes: 0.125 in. (3.18 mm) + CA but not less than Schedule 40.
b) Studded Tubes: 0.220 in. (5.59 mm).

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3) [R] The bottom two bare rows of convection tubes, when exposed to the radiant section, shall meet
the following:
a) Material shall be the same as the first radiant tube, if in the same service.
b) Tube thickness shall be at least equal to that of the first radiant tube, if in the same service and
equal tube outside diameter.
4) [R] Tubes shall be of continuous length with no intermediate welds except where the furnace length
exceeds the available tube length; then one intermediate weld is permitted.
5) [R] Tubes in economizer, steam generating, and superheating services shall be in accordance with
ASME SEC I, Boiler and Pressure Vessel Codes.

3.2. Return Bends, Headers, and Manifolds

1) * [R] Forged return bends are preferred. Cast return bends are acceptable if they meet the
requirements of GP 18-03-02. Fabricated return bends may only be used if specifically approved by
the Owner’s Engineer.
2) * [M] Plug headers and rolled fittings are not acceptable unless expressly approved by the Owner’s
Engineer.
3) [R] Piping external to the heater such as crossovers, jumpovers, and including manifolds shall be as
follows:
a) Crossover and jumpover piping shall be welded and insulated.
b) * Design criteria for Incoloy 800 piping shall be specified by Purchaser.
4) [O] Distribution and collection manifolds on multipass heaters shall be designed so that the dynamic
head in the manifold at the point of maximum velocity is not more than 10 percent of the individual
pass pressure drop unless otherwise specified.

3.3. Extended Surface

1) * [O] Convection section surface selection shall be governed by the requirements as shown in Table
1.

Table 1: Convection Surface Selection

Fuel Fired Tube Surface

a. Gas Bare; or "Thin" Fins 1 in. (25 mm) high max and
60 fins per ft max (197 fins per m)
b. Liquid fuel lighter than 25° API (0.904 relative Bare; Studs; or Fins 3/4 in. (19 mm) high max and
density) and containing less than 0.01% (mass) 42 fins per ft (138 fins per m)
ash
c. Liquid fuels heavier than 25° API or containing
more than 0.01% (mass) ash Bare; Studs; or "Thick" Fins 3/4 in. (19 mm) high
max and 36 fins per ft max (118 fins per m)
d. Dirty gaseous fuels producing more than 5 ppm
(mass) or 5 mg/kg particulates in flue gas

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2) [O] Fin-type extended surface shall be as follows:

a) * Fins shall be solid (serrated fins may be bid as an alternate).
b) Flanged or "L"-shaped fins are not acceptable.
c) * Alternative proposals of other fin-type extended surface shall be submitted for approval.
d) "Thin" fins shall have a nominal thickness of 0.05 in. (1.27 mm).
e) "Thick" fins shall have a nominal thickness of 0.105 in. (2.67 mm).
3) [O], [R] Fin material selection shall be based on calculated fin tip temperature. Representative fin
materials and their maximum allowable temperatures are shown in Table 2.

Table 2: Maximum Fin Tip Temperatures

Fin Material Maximum Fin Tip Temperature

CS 850°F 455°C
1
2 /4–5 Cr 1000°F 540°C
11–13 Cr 1250°F 675°C
18/8 Cr/Ni 1450°F 795°C
25/20 Cr/Ni 1800°F 980°C

4) [C] Calculated stud tip temperature for CS studs shall not exceed 1050°F (565°C).
5) * [R], [M] If there is a gap along the tube length in the studs or fins, a minimum of three equal spaced
skid shoes or other means to bridge the gap shall be provided on the tube to prevent extended surface
damage during installation. Use of cylindrical sleeves welded at the ends to studs or fins is not an
acceptable method for bridging a gap. Design of skid shoes is to be approved by the Owner’s
Engineer.

3.4. Boiler and HRSG Tubes

1) * [R] Tubes shall be as follows:
a) Steam generator and economizer tubes to be seamless carbon steel or electric resistance welded
unless specified otherwise with supplier approved by the Owner’s Engineer.
b) Superheater tubes shall be seamless: carbon steel or alloy steel, with grade approved by the
Owner’s Engineer.
2) [R] Tube and bend thickness shall be:
a) Calculated per ASME SEC I, Boiler and Pressure Vessel Codes
b) * Corrosion allowance shall be approved by the Owner's Engineer
c) Minimum wall thickness of 0.22 in. (5.59 mm) for studded tubes (not applicable for widely
spaced studs used to support refractory)

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4. Fabrication of Tubes and Tube Assemblies

4.1. Fired Heater Tubes and Headers
* [R] Butt welds shall conform as follows:
1) Not permitted under extended surface for tubes with less than 0.250 in. (6.35 mm) minimum wall.
2) Be full penetration welds.
3) Use an inert gas welding process for the root pass.
4) Flash welding is NOT permitted.
5) Intermediate tube welds, when approved, shall be flush with tube wall plus 1/32 in. (0.8 mm), minus 0
in.

4.2. Extended Surface–Fins

1) [O], [R] Fin OD Tolerance shall be ±0.07 in. (1.8 mm).
2) [O] Specified pitch shall not vary more than +3, −1 percent measured over at least 100 fins.
3) [O] Attachment Weld—Fins shall be continuously attached to the tube by high-frequency resistance
welding. The minimum acceptable attachment weld shall be 90 percent of the cross-sectional area of
the fin for 90 percent of the fin length and 50 percent of the remaining 10 percent.
4) [O] Any corrugation at the root of the fins shall not exceed the fin strip thickness each side. The
corrugation shall not be perceptible further than 1/3 the fin strip width from the root.
5) [O] Weld Interruptions (skipping) along the fin length shall not exceed 1/2 in. (12.5 mm). In addition,
consecutive weld interruptions shall not be closer together than 6 in. (150 mm).
6) [O] Fin Geometry—After welding, fins shall be perpendicular to the tube wall within 8 degrees. All
acceptable offsets in perpendicularity shall be in the same direction.
7) [R] All welds covered by extended surface shall be 100 percent radiographed prior to applying the
extended surface.

4.3. Extended Surface–Studs

1) [R] Studs shall be attached to the tube by a resistance welding method that provides full fusion as
demonstrated by the welding procedure, over a minimum of 85 percent of the cross-section area of
the welding face.
2) [R] Stud Attachment—Studding machines that use a copper shoe in contact with the tube or a copper
stud holder that is not protected against short-circuiting through the tube, or other machines that in
any way can cause copper contamination of the tube surface, are not acceptable.

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5. Inspection
5.1. Tube Inspection
1) * [R] Prior to finning, tubes shall be inspected by Owner's Representative if not waived in writing.
2) [R] Inspection of tubes and tube assemblies shall include but is not limited to:
a) Welder qualification review and acceptance
b) Hydrostatic test of welded tubes
c) Straightness of tubes
d) Overall tube length
e) Tube OD and thickness
f) Tube end preparation
g) Butt welding of tubes
h) Mill test reports for all materials
i) Origin of tubes
j) Weld inspection
k) Hardness of welds per GP 18-10-01
l) Positive Materials Identification (PMI) per GP 18-12-01
3) * [R] Wall thickness measurements for heater coils shall be performed on each tube by either
automatic or manual UT. Where manual UT is employed, this shall be performed at 4 points (12, 3,
6, and 9 o'clock) at each end. The use of the manual UT option must be approved by the Owner's
Engineer.
4) [R] Tube wall integrity shall be reported for heaters with a coil design temperature of 750°F (400°C)
or more and design pressure of 200 psig (1380 kPa) or more.
a) * 100 percent magnetic flux examination of the tube wall shall be performed for all ferritic tubes,
in accordance with ASTM E 570, to ensure freedom from injurious defects. Acceptance levels
shall be approved by the Owner's Engineer.
b) All repairs, including grinding and repair welding, shall be reported to the Inspector. The repair
shall be mapped and subjected to dye penetrant examination.
c) * Inspection requirements for coils fabricated from austenitic materials shall be approved by the
Owner's Engineer.

5.2. Extended Surface Inspection–Finning

[R] Inspection of finning shall include, but is not limited to:
1) Number and evenness of fins
2) OD and thickness
3) Material
4) Dishing or convolution
5) Root corrugation

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6) Weld attachment and undercutting

7) Cross-section area of attachment
8) Bend test of fin attachment weld

5.3. Extended Surface Inspection–Studding

[R] Inspection of studding shall include but is not be limited to:
1) Number and evenness of studs
2) Stud OD and dimension
3) Stud material
4) Stud attachment and undercutting
5) Hammerbend Test (withstand 90 degree bend)

5.4. Inspection of Fittings

1) [R] Fittings shall be checked for color-code markings.
2) [R] Mill certification of all materials is required.
3) [R] Radiographic examination of one fitting of each size from each supplier shall be performed to
verify acceptability of manufacturing process.
4) [R] Ultrasonic wall thickness examination shall be performed on each return bend as follows:
a) 4 points on extrados and both neutral axes
b) 2 points on intrados

5.5. Final Inspection

1) [I] Final inspection shall include but is not limited to:
a) Overall conformance with specification
b) Conformance with data sheets
c) Correct piece markings of components
d) Protection for shipping and storage
e) Review of shipping and loading plan
2) * [I] Material shall require written release from Owner's Representative to ship.

6. Testing
1) * [R] Unless otherwise specified, tube assemblies, including manifolds, shall be pressure tested after
fabrication and prior to field shipment. A final field pressure test of the complete heater coil and
associated manifolds shall also be conducted.

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2) * [R] Pressure tests shall be hydrostatic unless deemed impractical. Subject to Owner’s Engineer
approval, a pneumatic leak test using air or inert gas may be substituted.
3) [R] Pressure testing shall be as follows:
a) Hydrostatic leak test pressure as a minimum shall be 1.5 times the design pressure, or 200 psi
(1380 kPa), whichever is greater.
b) The hydrostatic test pressure shall be further limited to the extent that the weakest component
shall not be stressed beyond 90 percent of the material's yield strength at test temperature.
c) Only potable water shall be used.

7. Preparation for Shipment

7.1. Protection
1) [R] Tubes shall be blown dry internally, and tube ends shall be plugged with plastic caps or other
suitable means to prevent entry of water and damage to tube ends during shipment and storage.
2) * [R] Ferritic tubes and fins shall be coated externally with a rust inhibitor, approved by Owner's
Representative, for protection during shipping and storage.
3) [R] Shipping—Tubes shall be separated by wooden blocks and banded together to prevent damage
during shipping and handling.
4) [R] Marking—Piece markings and other instructions shall be stenciled on each item shipped.

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

Version 1.1.0 Date: 03/02

Section 2.1 Deletion This Section was modified for business sector specific customization.

Version 1.1.1 Date: 03/02

Section 2.1 Modification Version 1 references were marked for Downstream only.

Version 1.2.0 Date: 11/03

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

Version 1.2.0 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 1.2.1.

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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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