Chevron Fired Heaters

SAFETY INSTRUCTIONS

Abstract

This document gives safety instructions for all equipment in general and for all heat transfer equipment
specifically. Section IV is a guideline for completing the Fired Heater Safety Instructions Sheet.

CONTENTS

SECTION I SAFETY INSTRUCTIONS FOR ALL EQUIPMENT .................................................2

SECTION II SAFETY INSTRUCTIONS FOR FIRED HEATERS...................................................5

SECTION III HOW TO PREPARE SAFETY INSTRUCTION SHEETS .........................................7

SECTION IV INSTRUCTIONS FOR PREPARING THE FIRED HEATER SIS ............................9

SAFETY INSTRUCTION SHEET: HTR-EF-789

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SECTION I
SAFETY INSTRUCTIONS FOR ALL EQUIPMENT

Hazards

The following potential hazards are encountered in the operation and maintenance of all equipment.

1. Rupture or unsafe condition of equipment due to excessive operating pressure, temperatures,

dynamic load, material thickness, or other conditions beyond the established safe limits.

2. Unsafe condition resulting from corrosion that reduces material thickness to below the minimum
allowable limit. Such corrosion may be general or localized, internal or external. It may result
from normal process conditions, areas of turbulence or high velocities, failures at linings, leaks,
inadequate neutralization, chemical cleaning, operating temperatures higher than design, etc.

3. Embrittlement, cracking, and other deterioration resulting from

• hydrogen attack or graphitization if metal temperatures exceed safe limits for the alloy,

• temper embrittlement for some alloys or

• stress corrosion cracking or caustic embrittlement, particularly if not post-weld heat treated.

These causes are discussed in more detail in the Corrosion Prevention Manual.

4. Fatigue failures, particularly at supports, attachments, and connections, caused by excessive

vibration or other cyclic loadings including those resulting from thermal or pressure stress.

5. Reduction of strength, ductility, toughness, and/or setting up of high residual stress as a result of
improper welding or heating operations. This hazard is particularly applicable to alloy or higher
strength materials.

6. Unsafe condition or failure due to process thermal excursions, failure of internal insulation, or
exceeding the established limiting rate of temperature change (°F/hr), or temperature gradients
(°F/inch) during heating, cooling, or operating cycles.

7. Excessive strain or failure (particularly at equipment connections) due to heating of lines or

equipment above design temperature for which expansion provisions are made.

8. Unsafe condition or failure or reciprocating of rotating machines, or motors due to operation at

speeds or loads in excess of design limits or operation at critical intermediate speeds.

9. Failure, plugging, too-high settings, inadequacy or blocking-off of pressure relieving equipment.

Failure of control equipment resulting in excessive pressure, temperature or volume.

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10. Excessive pressure caused by thermal expansion of liquid ("sun pressure") in filled equipment or
freezing of contained water, especially at drains.

11. Damage to equipment caused by testing at pressures in excess of established limits, by testing at
too low a temperature, or by excess loading due to weight of testing medium.

12. Release of hot flammable, poisonous, or corrosive gases or liquids due to failure of equipment
from causes such as rupture, cracking, draining, venting or opening of equipment, or leakage as
covered in item 14 below.

13. Leakage at threaded, riveted, or gasketed joints, or at packing glands of pumps, compressors,
valves, level controls and instruments.

14. Possible hazards associated with opening of relief valves, particularly where discharge is not to a
closed system.

15. Explosive mixtures in equipment caused by improper purging or the failure of control valves,
motor operated valves, or cycle timers.

16. Collapse of towers, columns, stacks, tanks, supports, etc., under wind or earthquake loading due
to corrosion below minimum safe thickness, corrosive leakage, excessive temperatures,
inadequate provision for thermal expansion, binding of thermal expansion features, excessive
external pressure, fire exposure, or deterioration of foundations, supports, or guys.

17. Collapse or buckling of equipment due to external pressure (vacuum) loading in excess of design
limits. Rapid cooling after steam-out has caused collapse or buckling in the past.

18. Shock loading of equipment from sudden stoppage of flow (water hammer), internal explosions,
or external loads. This hazard applies to cast iron equipment, equipment in low-temperature
service or equipment with marginal toughness.

19. Violent pressure surges resulting from admitting, trapping or pocketing of water or light products
in hot equipment or equipment to be heated.

20. Chemical reactions, either inherent in the process or accidental, causing excessive pressure,
temperature or corrosion.

21. Sudden release of LPG causing auto-refrigeration and a resultant loss of metal toughness at low
temperature.

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Pressure Tests

Pressure tests may be divided into two categories: 1) strength tests and 2) field tests for tightness.

1. For strength tests, the test pressure shall be determined in accordance with the applicable
Company requirements for new equipment tests with consideration given to thinning due to
corrosion. Code test all equipment after any major repair affecting the strength of the equipment;
except where approval is obtained to waive such a test based upon factors such as additional
nondestructive examination and/or superior design details.

2. The test pressure for field tightness tests of equipment shall be as given in the SI Sheets. Field
tightness tests should only be used when repairs not affecting the strength of the equipment are
made. An example of this would be plugging exchanger tubes to extend the bundle life until the
next shutdown.

3. Hydrostatic testing procedure should conform to PIM-MS-3541, Field Hydrostatic Testing of

Piping Systems, or as given on special Hydrostatic Test Schedules prepared for particular
installations.

4. Certain equipment, such as boilers, must be tested at specified intervals as called for in the
Equipment Inspection Schedules.

5. Follow all local engineering procedures and obtain appropriate Engineering Division approval
before applying any pneumatic test.

6. Do not apply pressure tests without adequate protection against low temperature brittle
fracture. See the equipment SI Sheets for specified limits. Secure engineering guidance when
in doubt. See the Pressure Vessel Manual for information on brittle fracture.

7. Actual code tests applied during shop fabrication or field construction are given on the SI Sheets
or on Hydrostatic Test Schedules prepared to cover initial testing.

8. Remove, test, and reset safety or relief valves protecting the equipment at frequencies given in
the Equipment Inspection Schedule for the plant, or in lieu of such a schedule as recommended
on the SI Sheets.

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SECTION II
SAFETY INSTRUCTIONS FOR FIRED HEATERS

Hazards

The hazards to fired heater installations in operation include:

I. Those general hazards listed in the General Safety Instructions Applying to All Equipment which
apply to fired heater installations.

2. Excessive tube temperatures resulting in damage to, or failure of, tubes. Excessive temperatures
may be caused by coke or other deposits, by excessive firing rates or by uneven heat distribution.

3. Excessive pressures caused by stoppage or restricted flow due to obstructions or coke formation
in the heating element or transfer lines. Cores, collapsed liners, pass or outlet control valves,
may cause restricted flow.

4. Excessive pressures due to failure, plugging or coking of relief valves.

5. Failure or loosening of rolled joints or of tube seal welds due to repeated cycles of temperature
change or to sudden changes in temperature, or to improper use of dissimilar metals in rolled
joints or in adjacent tube positions.

6. Leakage or opening of header plugs due to damaged seats, or to breakage, loss of strength or
excessive wear of screws and holding members, or to insecurely seated plugs.

7. Damage or actual rupture of parts involved in flashes from leakage of rolls or plugs.

8. Explosions in firebox from ignition of explosive fuel-air mixtures or interruption of fuel flow.

9. Structural failure from overheating or deterioration of tube supports, supporting steel structures,
breechings, stacks, internal insulation, etc.

10. Damage to tubes, particularly alloy tubes, by abuse in cleaning, by continued service at excessive
temperatures, or by too rapid cooling.

11. Corrosion or oxidation of exterior tube surfaces by furnace gases in operation; and corrosion -
inside or outside - by residual salts and moisture during idle periods, including intergranular
corrosion of 19-8 CrNi material.

12. Release of H2S from chemical cleaning of tubes.

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Recommendations For Avoiding Hazards

1. Proper firing control is one of the most important factors in avoiding conditions leading to tube
failure. Avoid flame impingement on tubes, excessive flame length, distorted flames from dirty
or faulty burners, or uneven heat distribution with multiple burners. Maintain proper combustion
control. Visually check fires and heated surfaces at regular and frequent intervals.

2. Take all precautions to prevent sudden change or stoppage of flow through tubes. Maintain
cores, check valves, outlet and pass control valves in dependable condition. Pass control valves
must be set to ensure positive and balanced flow at all times.

Inspections and Tests

I. Make periodic inspections for corrosion or deterioration. Make special inspections for possible
damage after fires, flashes, or local overheating - particularly where alloy materials are involved.

2. Apply hydrostatic leakage tests as required. Apply hydrostatic strength tests at specified regular
intervals and after any tube rolling or strength welding.

3. Consult a specialist for proper test pressure and procedure in the event of any question on
pressure testing.

4. Use only fresh water (or oil; never salt water) in hydrostatically testing a chrome-nickel furnace
coil.

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SECTION III
HOW TO PREPARE SAFETY INSTRUCTION SHEETS

Definition of Safety Instruction Sheets (SIS)

The engineer prepares SIS's by filling in the blanks on Company (EF) forms. Different forms are used
for various equipment. The forms for preparing SIS are listed below and are located in the Standard
Drawings and Forms Section of Company manuals. The three-letter code in the form number (PVM,
EXH, etc.) identifies the manual in which a form is located.

Form Use

PVM-EF-786 Columns and Vessels

EXH-EF-787 Shell and Tube and Double Pipe Heat Exchanger
EXH-EF-788 Air Cooled Heat Exchanger
HTR-EF-789 Fired Heater
PMP-EF-790 Centrifugal Pump
PMP-EF-791 Reciprocating Pump (Motor, Engine or Turbine)
PMP-EF-792 Reciprocating Pump (Direct Acting Steam Driven)
CMP-EF-793 Centrifugal Compressor
CMP-EF-794 Reciprocating Compressor

Information on SI Sheets. SI Sheets summarize pertinent equipment data; designate safe operating
limits of the equipment; describe precautions necessary for continued safe operation; establish such
limiting conditions as pressure, temperature, thickness, corrosion, and speed; specify routine tests as; and
reference sources of additional information necessary to operate, repair, and maintain the equipment.

Purpose of the Information. The information provided in the SI Sheet helps to direct engineers to the
sources of information used to document the sheets and to information required for reevaluation of
equipment design in the event of changes in the operating requirements. The SI Sheets also provide
operators with concise operating limits and inspectors with factual data on minimum thickness, corrosion
allowance, test pressures, and relief valve settings.

Preparation, Completion and Distribution of SI Sheets

Who Prepares SIS's. The Project Engineer is responsible for preparation of SI Sheets. His signature
and that of the Operating Representative are required before the sheets are issued. At some locations
hazard assessment committees, such as LPG/H2S committees, require their approval for specific services
before the SI Sheets can be issued.

Where the Information Comes From. Data presented on the SI Sheets are taken from initial design
sheet forms, drawings, design notes, inspectors' and manufacturers' data reports, vendor prints, and
similar sources. It is essential that all information given be accurate and representative of the
equipment as actually built.

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Suggestions for Preparation. For those making up SIS's for the first time, the following suggestions
may be helpful. Experience has shown that the least backtracking and recalculation will be needed if the
vessel sheets are made up first, then the pump, heat exchanger, furnace, and piping sheets in that order.
In the average plant, the data accumulated for vessels will be advantageously referred to in making up the
pump sheets. Then both the vessel and pump sheets will be used in the preparation of the remaining data.
Safety Instruction Sheets should be started early in a project by the design engineers responsible
for the equipment. This will minimize the amount of backtracking required to complete the sheets as
the project nears completion.

When purchasing new equipment, it is often expedient to require the vendor to make a first pass at the SI
Sheet. If this is desired, it must be a condition of the purchase order.

Timely Preparation of SI Sheets. Plant operators need the SI Sheets before the equipment is released
for service. Whenever possible, approved sheets in final form should be issued by that time. In the event
that the sheets are incomplete, a preliminary issue of the available data may be necessary. If a
preliminary issue is necessary, it should be approved by the Project Engineer and Operating
Representative and clearly marked as preliminary.

Distribution of SI Sheets. SI Sheets may be issued as part of both the Inspection Record Books and
the Equipment Manuals. Distribution is outlined in the Project Instructions for each project or in the
design contract specifications. The engineer should ensure that the proper operating group gets a copy.

Sets of SI Sheets for a Project. When grouped as a set for a project, SI Sheets are arranged by
equipment groups in the order shown below. The entire set of Safety Instruction Sheets for each plant or
unit should be given one drawing number. This number should be taken from the project drawing
number series.

a. Columns
b. Vessels
c. Heat Exchangers
d. Fired Heaters
e. Pumps
f. Compressors
g. Piping

Additional Safety Instructions

In order to properly complete the SI Sheet, an engineer must understand the potential hazards involved in
operating that piece of equipment. The general hazards to be considered in the operation of all process
plant equipment are given in Section I. Section II discusses hazard specific to heat transfer equipment.
Any special hazards, inspections, or tests not covered by Sections I and II should be noted on the
individual SI Sheet.

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SECTION IV
INSTRUCTIONS FOR PREPARING THE FIRED HEATER SIS

This guideline provides an explanation of the information required on the Fired Heater Safety Instruction
Sheet, HTR-EF-789, Design information for the furnace will be found on the Fired Heater Data Sheet
(Form HTR-DS-1350). For additional information on the subjects below, refer to the respective section
in the Fired Heater Manual.
It may be helpful to collect data on the Fired Heater Safety Instruction Worksheet. The worksheet was
developed in 1997 to standardize the process of setting fired heater limits. It incorporates the latest
methods currently being used in Chevron Refining to set radiant tube temperature limits. An Excel
spreadsheet version of this worksheet is planned which will automatically do many of the API 530
calculations it requires. You can call CTN 242-3632 to check on its availability.

Subject Discussion

Total Duty The sum of radiant duty and all convection section duties.

Heater Type The heater should be described in terms of the firing pattern
(single fired or double fired), radiant tube orientation
(horizontal, vertical, arbor, or helical), and firebox shape
(cylinder, box, or cabin (sloping roof box). For example, a
single fired vertical cylinder or double fired horizontal box.

Tube Thickness Cross out one to indicate whether value shown is minimum or
average (nominal) thickness. Tubes can be purchased to either
thickness specification. However, minimum thickness is
preferred since it can be easily related to design calculations.
All operating limits should be based on the minimum thickness.

Governing Design Condition
When tubes are designed in accordance with Model
Specification HTR-MS-1350 or API RP 530, there are three
conditions which may set the design: elastic for lower
temperature tubes; rupture for high temperature tubes; or
arbitrary minimum. This last condition is an arbitrary minimum
of 0.250-inches or 0.100-inches plus corrosion allowance which
is often applied to new tubes. The governing design condition,
Elastic, Rupture, or Arbitrary Minimum, should be noted. (This
does not apply to tubes designed by the ASME Code.)

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Subject Discussion

Maximum and Operating HTR-MS-1350 and API RP 530 make a distinction between
Pressure maximum and operating pressure. The operating pressure is a
long-term loading condition, relatively uniform over years. The
maximum pressure is a short-term loading condition which may
be experienced for periods of minutes or hours. The maximum
pressure is determined by relief valve settings, pump shutoff
pressures, etc. It is the Design Pressure listed on the Fired
Heater Data Sheet HTR-DS-1350.

Temperature Allowance The tube design temperature is set at a value above the
maximum calculated temperature. The temperature allowance
equals the design tube temperature minus the calculated
maximum clean tube wall temperature.

Operating Limits Operating limits are expressed in terms of pressure and

temperature. Since the maximum temperature is usually a
function of pressure, space is provided for two limits. In some
cases, the temperature limit is based on metallurgical
consideration (for example, a limit set to avoid graphitization or
excessive oxidation). In these cases, the temperature limits do
not depend upon pressure.

Temperature Margin The operating tube skin temperature limits is the maximum value
for the indicated skin temperature. This limit is set at some
value below the maximum permissible metal temperature. The
reduction, called the temperature margin, is to account for
temperature measurement uncertainties. In other words, the
operating temperature limit is the maximum permissible metal
temperature minus the temperature margin. With increased
confidence in the indicated temperature, the temperature margin
can be reduced.

(Note: The temperature allowance and the temperature margin

are similar. The temperature allowance is used once in
designing a tube. The temperature margin can change and
should reflect the level of confidence in the indicated
temperature.)

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Subject Discussion

Temperature and Pressure Limits This calculation of maximum pressure and temperature will use
the following notation. Also refer to API 530, included on the
Fired Heater Manual.

Do = outside diameter, inches

tm = minimum new thickness, inches

CA = corrosion allowance, inches
to = tm - (f) (CA), inches
f = corrosion fraction [equals 1 for elastic design,
less than 1 for rupture design; see API RP 530,
paragraph 2.4].
Pe = maximum pressure, psig
Se = elastic allowable stress, psi
Pr = operating pressure, psig
Sr = rupture allowable stress, psi

The elastic and rupture allowable stresses are given as a function

of temperature in API RP 530.

Two situations will be presented here: with the pressure given,

calculate the temperature limit, and with the maximum
temperature given, calculate the pressure limit. The first case is
the most common.

Given the maximum and operating pressures (see definitions in

API 530), calculate the following stresses:

Pe  Do 
Sm = − 1
2  to 

to = tm − ( f ) (CA ) f=1

Pr  Do 
So = − 1
2  to 

to = tm − ( f ) (CA ) f < 1*
(Eq. HTRSIS- 1)
* See API RP 530, Figure 1

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Subject Discussion

Using the curves in API RP 530, find the temperature for which
Sm = Se (called T1) and for which So = Sr (called T2)· The
maximum permissible metal temperature is the smaller of T1 and
T2. From this temperature, subtract the temperature margin to
obtain the tube skin temperature operating limit.

Note that, in the rupture design range, the corrosion fraction f

depends on the temperature T2. This means iteration is required.
Perhaps the most straightforward way to do this is to assume a
range of temperatures (T2); get the corresponding rupture
allowables (Sr = So), rupture exponents (n), stress thicknesses (ts
= to), corrosion fraction parameters B and N, and corrosion
fractions f; leading to a range of minimum (new) thicknesses
(tm).The correct temperature (T2) is the one that gives the
minimum (new) tube thickness (tm) actually furnished.

The tube skin temperature operating limit should never exceed

the maximum temperature for the alloy given in API RP 530.

Given the tube skin temperature operating limit, add the

temperature margin to obtain the maximum permissible metal
temperature. With this temperature and the curves in API RP
530, find the elastic allowable, Se, and the rupture allowable, Sr.
Using the smaller of these stresses, S, calculate the maximum
operating pressure as follows:

2S
P=
 Do 
 t − 1
o
(Eq. HTRSIS-2)
If the arbitrary minimum governed the design of the tube (see
"Governing Design Condition," above), the operating limits will
be above the tube design conditions, since the tube is much
thicker than necessary for the design condition. This excess
thickness can be used to increase the operating limits.

If the tubes were designed in accordance with a Code, the

temperature and pressure limits should be calculated with the
Code equations and allowable stresses.

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Subject Discussion

This procedure can be used for calculating the operating limits

for used tubes by setting tm equal to the minimum measured
thickness and CA equal to the desired corrosion allowance only
if the tubes operate in the elastic range.

Leakage Test Pressure The leakage test pressure is at least two-thirds of the hydrostatic
test pressure and at least 1.5 times the cold equivalent of the
setting for the safety valve protecting the coil.

Hydrostatic Test Pressure This is the pressure required to test the coil after a field repair on
replacement of a tube. Assume all of the corrosion allowance is
used up in calculating this pressure.

Fitting Limits U-bends will usually have the same operating limits as the tubes.
If so, leave blank. One example where the limit could be less is
with carbon and carbon-1/2 Mo steel U-bends. These welds
must be kept below 800°F and 850°F, respectively. If the limits
for headers or flanges may affect furnace operation, list these
limits.

Retirement Thickness The retirement or replacement thickness is given by

Do Pe
tr =
2Se + Pe
(Eq. HTRSIS-3)
where Se is the elastic allowable at the maximum permissible
temperature (i.e., tube skin temperature operating limit plus the
temperature margin). Many refineries arbitrarily set the retire-
ment thickness at 0.100-inch.

Stack Metal Temperature The heater designer should be able to furnish the applied stresses
in and the corresponding temperature limits for the stack. The
limit is at least 650°F since in Section VIII of the ASME Code
the allowable stress for carbon steel is constant from room
temperature up to 650°F.

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Subject Discussion

Minimum Draft at Arch
The pressure inside the firebox should be kept below
atmospheric or else hot flue gases will blow through casing
seams. This leads to early failure. If the pressure at the
convection section inlet (arch) is maintained just below
atmospheric pressure, the pressure everywhere will be below
atmospheric, and air infiltration will be minimized. The draft
(negative gauge pressure) is usually maintained between 0.05
and 0.10 inches water column.

Flue Gas Temperature Limits
If there is a reason to limit the flue gas temperatures at various
points in the system, state the limits and their bases. Arch limits
may be based on convection section tube support temperature
limits or casing and structural steel temperature limits. Similarly
for the stack flue gas limits. The heater designer should be able
to furnish the necessary limits.

Burner Limits Maximum and minimum fuel header limits can be obtained for
each burner model from the burner supplier, or the limits can be
established during a burner test program.

Raw gas burners are usually capable of operating at very low

pressures (below 0.5 psig header pressure). Premix burners
cannot operate at such low pressures; as the pressure is lowered,
the flame drops back into the mixer. Oil atomizing tips work
well within a specific pressure range. Atomization will not be
adequate if the pressure is too low or too high. The basis for
limits should be stated in the notes.

Notes: Use this space to list operating or inspection limits such as

steam-air decoking limits (if any).

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