04939E03

eni spa 04939.EQP.MEC.
SPC
Rev.03 – November 2015
Page 3 of 38
Consulted Distribution List
Nome Cognome/Unità / Name Società /

Data/Date
Surname/Business Unit Company
S. Gree Babu / MECC eni/ITEM
R. D’Ambra / TEPI eni/ITEM
A. Roman Herrera / TEPI eni/ITEM
P. Bussini / TEOF eni/ITEM
P. Cavassi / TEMC eni/ITEM
F. Locati / TEMC eni/ITEM
M. Negretti / TEIMA eni/ITEM
W. Manghisi / TESA eni/ITEM
C. Patanè Tecnomare
E. Palumbo Tecnomare
P. Carnovali Tecnomare
F. Artuso / COETA eni/ITEM
M. Lombardi / PRECO eni/CONSTR
C. Callari / TEEL eni/ITEM
R. Scanferlini / TEEL eni/ITEM
L. Malaguti Tecnomare
Informed Distribution List
Nome Cognome/Unità / Name Società /

Data/Date
Surname/Business Unit Company
G. Petio / TEPI eni/ITEM
A. Fisogni / TEOF eni/ITEM
T. Cheldi / TEMC eni/ITEM
S. Mollica / TEIMA eni/ITEM
A. Zanoni / TESA eni/ITEM
F. Vailati Tecnomare
I. Hashi Omar / COETA eni/ITEM
M. Gorlini / TEEL eni/ITEM
S. Fasoli Tecnomare
F. Mastai Tecnomare
F. Girardo Tecnomare
REVISION TRACKING
Rev 03: Actual revision is of 38 pages.

This revision is in compliance with API560, 4th Edition, August 2007 / ISO 13705: 2006.
Interdisciplinary comments implemented.
Date March 2015

This revision is in compliance with API560, 4th Edition, August 2007 / ISO 13705: 2006.
Date March 2015
ENGINEERING COMPANY STANDARD

Documento riservato di proprietà di eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of eni spa. It shall neither be shown to third parties not used for purposes other than those for which it has been sent.
eni spa 04939.EQP.MEC.SPC
Page 4 of 38

Date January 1992
INFORMATION REQUEST
Il personale eni può accedere ai company standard tramite il seguente link:

http://wwweandp.eni.it/TSServices/ITEM/Standards-/Normalizat/Documents-/index.asp
Gli utenti esterni devono fare riferimento al Project Engineering Manager.
Per informazioni relative ai contenuti tecnici del documento si può fare riferimento alle
persone indicate come responsible e accountable nella precedente tabella RACIE oppure al
Technical Authority coordinator (COETA).
eni personnel can access company standard repository at:

http://wwweandp.eni.it/TSServices/ITEM/Standards-/Normalizat/Documents-/index.asp
External user shall refer to the Project Engineer Manager.
For information about the content of this standard, please refer to responsible and
accountable person as per above RACIE table or to Technical Authority coordinator (COETA).
GERARCHIA DI VALIDITÀ / HIERARCHY OF REGULATIONS
1. Disposizioni di legge della nazione ove le attrezzature e i materiali sono installati

2. Secifche di Progetto e Fogli Dati
3. Specifiche di società
4. Norme e Codici Internazionali
1. Local Regulations of the Country where the equipment is installed;

2. Project Specifications and Data Sheets;
3. Company General Specifications;
4. International Codes & Standards


Page 5 of 38
CONTENTS
CONTENTS ................................................................................................................ 5
1. INTRODUCTION ............................................................................................. 7
1.1 PURPOSE ....................................................................................................... 7

1.2 DEFINITIONS AND TERMS ................................................................................ 7
1.3 ABBREVIATIONS ............................................................................................. 8
1.4 UNITS OF MEASUREMENT ................................................................................. 8
2. GENERAL ....................................................................................................... 9
2.1 COMPANY SPECIFICATIONS & STANDARDS ......................................................... 9

2.2 INTERNATIONAL CODES & STANDARDS ........................................................... 10
3. DESIGN ....................................................................................................... 11
3.1 PROCESS DESIGN ......................................................................................... 11

3.2 COMBUSTION DESIGN ................................................................................... 12
3.3 MECHANICAL DESIGN .................................................................................... 13
4. TUBES ......................................................................................................... 14
4.1 GENERAL ..................................................................................................... 14

4.2 EXTENDED SURFACE ..................................................................................... 14
5. PIPING, TERMINALS AND MANIFOLDS ........................................................ 14
5.1 GENERAL ..................................................................................................... 14

5.2 ALLOWABLE MOVEMENT AND LOADS ............................................................... 15
5.3 MATERIALS .................................................................................................. 16
6. TUBE SUPPORTS .......................................................................................... 16
6.1 GENERAL ..................................................................................................... 16

6.2 LOADS AND ALLOWABLE STRESS .................................................................... 17
7. REFRACTORIES AND INSULATION ............................................................... 17
7.1 GENERAL ..................................................................................................... 17

7.2 CASTABLE CONSTRUCTION ............................................................................ 17
7.3 CERAMIC FIBRE CONSTRUCTION ..................................................................... 17
7.4 MATERIALS .................................................................................................. 18
8. STRUCTURES AND APPURTENANCES ........................................................... 18
8.1 STRUCTURES ................................................................................................ 18

8.2 HEADER BOXES, DOORS AND PORTS ............................................................... 19
8.3 MATERIALS .................................................................................................. 19
9. STACK, DUCTS AND BREECHING .................................................................. 19
9.1 GENERAL ..................................................................................................... 19

9.2 DESIGN CONSIDERATIONS............................................................................. 19
9.3 MATERIALS .................................................................................................. 20
10. BURNERS AND AUXILIARY EQUIPMENT ...................................................... 20
10.1 BURNERS ..................................................................................................... 20

10.2 SOOTBLOWERS............................................................................................. 20
10.3 NOISE LEVEL ................................................................................................ 21
11. SHOP FABRICATION AND FIELD ERECTION ................................................. 21
11.1 STRUCTURAL STEEL FABRICATION .................................................................. 21

Page 6 of 38
11.2 COIL FABRICATION ....................................................................................... 21

11.3 TUBE SUPPORTS AND GUIDES ........................................................................ 23
11.4 REFRACTORIES AND INSULATION ................................................................... 24
12. INSPECTION, EXAMINATION, AND TESTING ............................................... 24
12.1 WELD EXAMINATION ..................................................................................... 24

12.2 EXAMINATION OF OTHER COMPONENTS ........................................................... 30
12.3 TESTING ...................................................................................................... 32
12.4 INSTRUMENTATION AND CONTROLS ................................................................ 33
13. CENTRIFUGAL FANS FOR FIRED-HEATER SYSTEMS ..................................... 34
13.1 DESIGN ....................................................................................................... 34

13.2 ELECTRIC MOTOR DRIVES .............................................................................. 34
14. CONTROLS AND INSTRUMENTATION ........................................................... 34
14.1 GENERAL ..................................................................................................... 34

14.2 HEATER INSTRUMENTATION ........................................................................... 34
14.3 FUEL CONTROL SKID ..................................................................................... 35
14.4 FUEL PIPING AND MANIFOLDS ........................................................................ 36
14.5 BURNER MANAGEMENT SYSTEM PANEL ............................................................ 37
15. PRESERVATION, STORAGE, HANDLING & SHIPPING ................................... 38
15.1 GENERAL ..................................................................................................... 38

15.2 INSTRUMENTATION AND CONTROLS ................................................................ 38
15.3 PIPEWORK AND VALVES ................................................................................. 38
15.4 SURFACE FINISHING ..................................................................................... 38

Page 7 of 38
1. INTRODUCTION
1.1 PURPOSE
This company specification defines the minimum requirements for the design, fabrication,
installation, commissioning, inspection and testing and shipping of Direct Fired Heaters for
both onshore and offshore installations.
Direct Fired Heaters shall conform to the requirements of API Std. 560 / ISO 13705, as
modified by this specification, by the mechanical data sheets or by the documentation issued
for the specific project.
This specification and the associated particular specifications shall not release the Supplier
from his responsibility, fulfilment of his duties, guarantee and/or liabilities. Any acceptance or
approval does imply any assumption of responsibility by the COMPANY for the conformance of
the equipment to the requirements of the Code and/or of the Governing Authority.
1.2 DEFINITIONS AND TERMS
The following Parties are involved in the Project activities:
Company Eni SpA, affiliated Companies or a third party,

appointed by Eni SpA to operate on its behalf.
Contractor The party, which carries out all or part of the

design, engineering, procurement, construction,
commissioning or management of a project or
operation or maintenance of a facility. The
Company may undertake all or part of the duties
of the Contractor.
Sub-Contractor Any organization who supplies services to the

Contractor.
Supplier (Vendor/Manufacturer) The party, which manufactures or supplies

equipment and services to perform the duties
specified by the Supplier (Vendor/Manufacturer).
Sub-Supplier The party, which manufactures or supplies

equipment and services to perform the duties
(Sub-Vendor/Sub-Manufacturer)
specified by the Supplier (Vendor/Manufacturer).
The word shall indicates a requirement.

The word should indicates a recommendation.

Page 8 of 38
1.3 ABBREVIATIONS
AARH Arithmetic Average Roughness Height

AFNOR Association Française de Normalisation
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ATEX ATmospheres EXplosibles
BMS Burner Management System
BS British Standard
DIN Deutsche Industrie Norm
EN European Norm
ESD Emergency Shutdown System
ICSS Integrated Control and Safety System
ISO International Organization for Standardization
JIS Japanese Industrial Standard
MSS Manufacturers Standardization Society
NPS Nominal Pipe Size
PED Pressure Equipment Directive
P&ID Piping and Instrumentation Diagram
RF Raised Face
PCS Process Control System
PLC Programmable Logic Controller
RJ Ring Joint
SIS Safety Instrumented System
UV Ultra Violet
1.4 UNITS OF MEASUREMENT
The SI system shall be used according to the requirements of specification

20183.COO.GEN.FUN “Units of measurement”, unless otherwise specified in the documents
issued for the specific project.

Page 9 of 38
2. GENERAL
The latest edition of the Company specifications and standards and the international codes
and standards listed below shall be considered an integral part of this specification.
Any conflicts between this Specification and any other International Codes and Standards,
Company General Specification and Standards and Project Documentation shall be brought to
the Company/Contractor attention for clarification in writing prior to any further action or
start of work.
In the case of conflict amongst documents of the same priority level, the more stringent
conditions shall prevail. In addition, Supplier shall bring to the attention of
Company/Contractor immediately any apparent error or omission in this specification and
shall ask for written clarification.
Pressure equipment intended for the European market shall be in compliance with the safety
requirements of the European directive 97/23/CE PED and any additional requirements
according to the data sheets and the documents issued for the specific project.
Pressure equipment intended for the non-European market shall be in compliance with the
safety requirements of the laws and norms in force in the intended Countries and with
possible additional requirements according to data sheets and the documents issued for the
specific project.
Equipment operating in explosive atmospheres and intended for the European market shall
be in compliance with the safety requirements of the European directive 94/9/CE ATEX and
possible additional requirements according to data sheets and the documents issued for the
specific project.
Equipment operating in explosive atmospheres and intended for the non-European market
shall be in compliance with the safety requirements of the laws and norms in force in the
intended Countries and with possible additional requirements according to data sheets and
the documents issued for the specific project.
Equipment operating in explosive atmospheres shall be supplied together with all anti-spark
tools necessary for installation, operation, and maintenance.
2.1 COMPANY SPECIFICATIONS & STANDARDS
03653.VAR.GEN.SPC Thermal Insulation for Hot Temperature Service
05490.MAT.MEC.SDS Design, Fabrication and Testing of Pressure Vessels under ASME BPV
Code
05494.MAT.MEC.SDS Allowable Loads on Equipment Process Nozzles
05882.COO.MEC.PRG 2 Years Operation Spare Parts for Mechanical Equipment and

Machines
05883.VAR.GEN.SDS Packing for the Dispatching of Materials and Equipment
05892.PIP.MEC.SDS Pipes and Piping Components for Plants
05894.PIP.MEC.SDS Pipes and Piping Components for Plants, Assembling and Inspection of
Piping
07108.EQP.MEC.STD Standard for Nameplate Holder
07212.EQP.MEC.STD Symbols-references and miscellaneous
07219.EQP.MEC.STD Vertical ladders

Page 10 of 38
07221.EQP.MEC.STD Handrail – Toe Board
07223.EQP.MEC.STD Circular Platforms for Columns and Vessels
08035.MAC.MEC.FUN Fans
20000.VAR.PAI.FUN Protective Coating, Galvanising and Metalizing for Internal and

External Surfaces of Offshore and Onshore Structures and Related
Components
20047.VAR.STA.SDS Requirements for the Installation of Instrumentation
20048.VAR.STA.SDS Instrumentation Philosophy
20167.EQP.ELE.FUN Asynchronous Motors
20183.COO.GEN.FUN Units of measurement
20215.PKG.ETI.SDS Electric and Instrumentation Plants Included in Package Supplies
20368.PIP.MEC.FUN Carbon Steel Piping Welding
20370.PIP.MEC.FUN Austenitic Stainless Steel Piping Welding
20371.PIP.MEC.FUN Cr-Mo Steel Piping Welding
20372.PIP.MEC.FUN 0.5 Molybdenum steel piping welding
20374.PIP.MEC.FUN Dissimilar Metals Piping Welding
20375.PIP.MEC.FUN Nickel Alloy Piping Welding
20377.PIP.MEC.FUN Piping Weld Examination General Requirements
28037.CMP.STA.SDS Instrumentation & Automation included in Package Plants
opi.sg.hse.012.ep Noise and Vibration Management
2.2 INTERNATIONAL CODES & STANDARDS
API STD 560 Fired Heaters for General Refinery Service
API RP 556 Instrumentation and Control System for Fired Heaters and Steam
Generators
API 531M Measurement of Noise for Process Fired heaters
API 535 Burners for Fired Heaters in General Refinery Service
API 556 Instrumentation, Control, and Protective Systems for Gas Fired
Heaters
ANSI/API STD 530 Calculation of Heater-tube Thickness in Petroleum Refineries
ASME B31.1 Power Piping
ASME B31.3 Process Piping
ASME B16.5 Pipe Flanges and Flanged Fittings

Page 11 of 38
ASME B16.9 Factory-made Wrought Buttwelding Fittings
ASME BPVC Sec. I Rules for Construction of Power Boilers
ASME BPVC Sec. II Materials
ASME BPVC Sec. V Nondestructive Examination
ASME BPVC Sec. Rules for Construction of Pressure Vessels Division 1

VIII
ASME BPVC Sec. IX Welding, Brazing, and Fusing Qualifications
3. DESIGN
3.1 PROCESS DESIGN
The average radiant section heat flux density is the heat absorbed by the circumferential tube
surface in the radiant section and the first row of the shield section when in radiant service,
inclusive of return bends where applicable.
Unless otherwise specified in the process data sheet, the average radiant heat flux density
shall not exceed the values indicated in Table 3.1.
The coke thicknesses and fouling factors shown in the table are indicative figures only.
Table 3.1 Allowable Average Radiant Section Heat Flux Density
Average Heat Coke Fouling Factor

Flux Density Thickness (m2°C/W)
(W/m2) (mm)
Atmospheric Tower Charge 37860 1.5 0.00053
Vacuum Tower Charge (fuel) 31550 3.0 0.00070
Vacuum Tower Charge (lube) 25240 3.0 0.00070
Visbreaker Heater (heating sect.) 31550 3.0 0.00070
Visbreaker Heater (soaking sect.) 25240 3.0 0.00088
Coking 25240 3.0 0.00088
Pretreated Feed Heater 31550 0.2 0.00035
Cat. Ref. Feed Heater and Reheat 37860 0.2 0.00026
Hot Oil 37860 0.5 0.00035
Hydrotreating/Hydrocracking 37860 0.2 0.00035
Reboilers 37860 0.2 0.00026
Diathermic Fluid 37860 0.5 0.00035
Asphalt Mix. 25240 1.5 0.00070
Furfural Raffinate Mix. 22000 1.5 0.00053
Furfural Extract Mix. 22000 1.5 0.00070

Page 12 of 38
Notes:
1) Coke thickness shall be considered only if temperature exceeds 315°C.
2) Fouling factor shall be considered during thermal calculation (heat transfer)
3) Coke thickness shall be considered during pressure drop calculation.
A) The average heat flux densities shown in Table 3.1 apply to tubes fired on one side,
backed by refractory placed at 1.5 x (NPS) from the centre of the tubes and having a
centre to centre spacing of twice the nominal diameter.
B) The pressure drop on the process side shall be calculated on the basis of the internal
diameter of the tube corresponding to the mean thickness, reduced by the coke
thickness, as shown in Table 3.1, unless otherwise specified
C) The average heat flux densities shown in Table 3.1 may be modified to suit other tube
configurations, such as two-sided firing, provided that the maximum heat flux density
remains unchanged. For the calculation of maximum heat flux density, refer to API
530/ISO 13704.
When calculating the maximum tube wall temperature, consideration shall be given to the
operating and design flow rates, coke layer and specified fouling factor.
The tube skin temperature shall be calculated as per API 530/ISO 13704. The temperature
allowance as defined in API RP 530/ISO 13704 shall be:
- 45°C min. for a double fired, single row of tubes.

- 30°C min. for a double fired, double row of tubes.
- 15°C for any other case
Deviations to the above may be considered only in particularly onerous process conditions.
When considering oil firing with horizontal tubes in the radiant section, a thermal calculation
shall be performed applying an external fouling factor to the radiant tubes such that the
bridgewall temperature is increased by 30°C, relative to the case with no external fouling.
The burner heat release shall be sufficient to achieve the required duty in the external fouling
case. The design temperatures of materials (tubes, refractory etc.) shall be determined
without external fouling but a check shall be carried out to ensure the design temperature is
not exceeded in the external fouling case.
3.2 COMBUSTION DESIGN
The minimum velocity of the flue gases through the stack shall be 7.5 m/s at design load and
design excess air.
The minimum outlet stack velocity shall not be less than 4 m/s at minimum load; this velocity
can be obtained also by means of a removable cone. Excess air at minimum load shall be
appropriately increased compared to the design case, in order to take into account realistic
operating conditions at minimum load.
The minimum pressure loss across the stack damper shall be 0.025 kPa.
The furnace shall be so designed that a vacuum of at least 0.050 kPa at the level of the
burners is assured.

Page 13 of 38
A stack or equivalent flue gas outlet duct section shall be provided for each 12 m of exposed
length of convection section tubes.
Air ducts shall have the following characteristics:
a. They shall be designed to provide uniform distribution of air to all burners.

b. At peak velocity, the dynamic head shall not exceed 5% of the total pressure loss
across the burner at design conditions.
c. They shall be suitable for the fan delivery pressure at peak fan speed and at the
minimum design pressure specified.
Unless otherwise indicated on the data sheet, the emissions from the heater shall not exceed
the values indicated in Table 3.2 measured at the stack base of each heater running at 100%
of design load.
Table 3.2 Pollutant Emissions
NOx CO Particulate
Nitrogen Carbon
oxides monoxide
Fuel Oil Firing 500 250 80
Fuel Gas Firing 200 50 60
The above limits are based upon 3% volume oxygen content in the flue gas on a dry basis.
The values shown are in mg/Nm3 of flue gases referred to 0°C and 101.325 kPa.
The content of nitrogen in bound form in the fuel oil shall be assumed to be zero.
3.3 MECHANICAL DESIGN
The convection section tube layout shall include space for sootblowers as indicated in Table
3.3.
For each row of sootblowers (installed or provision for future installation), one
inspection/cleaning door shall be provided in each space between two adjacent sootblowers.
Table 3.3 Provision for Sootblowers
Type of fuel Requirement
Gas firing only No provision
Gas firing with provision for Space for future installation of

future sootblowers
conversion to dual fuel
Liquid fuel firing Sootblowers shall be provided

Page 14 of 38
Corbelling shall be provided in the convection section except where it corresponds with the
lowest shield row.
The corbelling shall not be less than one half the centreline spacing between tubes of the
corresponding horizontal tube row.
For any type of heater (including double fired heaters with horizontal tubes), the radiant
chamber must be designed with clearance sufficient to allow free internal movement of
personnel during maintenance or inspection, without need to exit the heater to reach any
location in the radiant chamber.
For double fired horizontal tube heaters, the minimum clearance from floor refractory to the
tube outside diameter shall not be less than 700 mm.
4. TUBES
4.1 GENERAL
Under no circumstances shall the minimum thickness of process tubes be less than that
corresponding to schedule 40 pipe. Plug headers shall not be used.
4.2 EXTENDED SURFACE
Maximum number of studs per circumferential plane shall be as follows:
Table 4.1 Studs
Tube O.D. inches No. of studs per

plane
2.375 8
2.875 10
3.5 12
4 14
4.5 16
5 18
5.563 20
6 22
6.625 24
8.625 30
5. PIPING, TERMINALS AND MANIFOLDS
5.1 GENERAL
Flanges
Flanges shall be manufactured in accordance with ASME B.16.5.

Unless otherwise requested by the Company, the facing of RF flanges shall be smooth finish
125 AARH in accordance with ASME B.46.1.

Page 15 of 38
Gaskets
Unless otherwise specified, RJ and spiral wound gaskets shall be manufactured in accordance
with ASME B.16.20 and flat gaskets in accordance with ASME B 16.21.
Fittings
Fittings shall be manufactured in accordance with ASME B 16.9 / ASME B 46.1
Bolts and nuts

Bolts and nuts shall be manufactured in accordance with:
Bolts: dimensions ASME B 16.5

tolerances ASME B 16.5 and ASME B 1.1
Nuts: dimensions ASME B 18.2.2

tolerances ASME B 18.2.2 & ASME B 1.1
Manifolds
Manifolds shall be of a single piece in accordance with ANSI B.36.10 and B.36.19.
5.2 ALLOWABLE MOVEMENT AND LOADS
Manifold
Where the terminal is a manifold anchored at the heater, the allowable loads shall be in
accordance with Company specification 05494.MAT.MEC.SDS.
Single flange or pipe
Unless indicated otherwise each single inlet and outlet terminal shall be designed to accept
the following loads and moments from external pipework. The total load on the terminals
shall not exceed 1600 kg.
The following allowable moments and loads are applicable to piping class ≤ 300#.
For piping class > 300# the values indicated below shall be doubled.
a) Horizontal tube
a) Tubes with nominal diameter equal to or larger than 5"

Fx max = Fy max = Fz max = ± 8 kN
Mx max = My max = Mz max = ± 5 kNm
b) Tubes with nominal diameter smaller than 5"

Mx max = My max = Mz max = ± 2 kNm
b) Vertical tube
a) Tubes with nominal diameter equal to or larger than 5"

Mx max = My max = Mz max = ± 2.5 kNm
b) Tubes with nominal diameter smaller than 5"

Mx max = My max = Mz max = ± 1.00 kNm

Page 16 of 38
Displacements
Unless otherwise indicated each inlet and outlet terminal shall be designed for the following
displacements.
a) Horizontal tube
Movement of inlet and outlet nozzles, outwards in the direction of the tube axis is
permitted, equal to half the total expansion of the coil. A displacement equal to ± 12.5
mm in the horizontal plane in a direction normal to the tube axis is permissible for
inlet and outlet nozzles.
c) Vertical tube
Movement of inlet and outlet nozzles, outwards in the direction of the tube axis is
permitted, equal outwards in the tube axis direction and shall be equal to the
expansion of the coil from its rest point. Inlet and outlet nozzle displacement is
allowed for ± 12.5 mm in the direction of the horizontal plane.
5.3 MATERIALS
Bolting material shall be ASTM A 193 B7 and 193 2H. For stainless steel flanges, the use of
ASTM A193 B7 or ASTM A 193 B8C shall be evaluated as a function of the material
temperature.
6. TUBE SUPPORTS
6.1 GENERAL
Tube guides, radiant section intermediate tube supports, and top supports for vertical and
horizontal radiant tubes shall be designed to permit their replacement without tube removal
and with minimum refractory repair.
The supports for horizontal tubes in radiant sections where there is vaporisation of the charge
shall be equipped with restraints or an equivalent device.
For both horizontal and vertical tube heaters, the tube supports and guides shall not bear on
refractory but shall be attached to the metal structure.
Tube supports shall be designed to permit free expansion of the tubes. Elements (supports
and brackets) directly fastened to the metal structure, shall be of the same material grade as
the supports, guides or tube sheets to which they are connected.
Vertical coils tubes may be supported at the top and guided at the bottom or bottom
supported and guided at the top. When top supported, intermediate guides are not required
for tube lengths shorter than 18 m. When bottom supported, intermediate guides are
required for each 6 m of length.
Tube supports for two phase flow must avoid a reduced area of contact between tube and
support, which may produce a localized reduction of the tube thickness due to wear caused
by the friction induced by vibrations resulting from vaporisation inside the tubes. The use of
sleeves, plane supports, or widely rounded surfaces of contacts, is required.

Page 17 of 38
6.2 LOADS AND ALLOWABLE STRESS
For horizontal double-fired tubes, the following additional requirements are applicable:
 Each main member of the supporting structure must be sized at its design
temperature and checked at the bridge wall temperature for a vertical load increased
by 20%.
 Each single support detail in direct contact with tubes must be sized to support the full
tube load without considering the other similar members along the tube length.
 The connecting points between the main members of the supporting structure and the
external heater structure must be particularly strengthened and rigid in order to avoid
sagging that might cause non uniform loading of the coil support system.
7. REFRACTORIES AND INSULATION
7.1 GENERAL
Lining shall not be used either as a whole or in part, as a bearing structure. Manufacturer's
detail drawings for the design of furnace wall and flat arch linings shall be approved by the
Company. All expansion joints shall be thoroughly packed/stemmed and staggered to avoid
any leakage paths.
Where included in the supply, external heat insulation external manifolds and crossovers shall
be provided in accordance with Company specification 03653.VAR.GEN.SPC.
Surface temperatures at the heater casing shall be calculated in accordance with API 560
section 11.1.2. Personnel protection in the form of galvanised expanded metal mesh shall be
applied areas where the heater casing is accessible to operating personnel and the surface
temperature exceeds 60 °C.
7.2 CASTABLE CONSTRUCTION
All details concerning the application of castables shall be submitted to the Company for
approval.
Low iron content materials (max 1.5% mass fraction) shall be used on the exposed layer
(min. 50 mm) of exposed walls when the total heavy metals content within fuels exceeds 150
ppm on a weight basis.
7.3 CERAMIC FIBRE CONSTRUCTION
The use of ceramic fibre is allowed only if clearly authorized by the end user. In all cases it is
allowed only subject to the precautions stated in local codes/laws/regulations. Linings may be
made of ceramic fibre in the case of fuel gas firing only and in the absence of provision for
sootblowers (installed or future).
Detailed drawings of the ceramic fibre lining design shall be submitted by the supplier and
will be reviewed and commented by the Company.
All inside casing faces of any heater lined with ceramic fibre shall be protected against acid
corrosion. If not otherwise specified, the protection shall consist of a coal tar epoxy base
product applied in two layers of a minimum of 200 microns each. The surface preparation
and roughness shall be as required by the product specification of the paint supplier. The coal
tar epoxy based product shall resist a continuous operating temperature of 90°C with
excursions to 120°C.

Page 18 of 38
7.4 MATERIALS
Only premixed, bagged and commercial refractory products shall be used. Field mixes are not
acceptable. Refractory for floors shall be cast. Refractory for walls and arches can be installed
by gunning.
Exposed furnace walls and flat arches subject to direct flame impingement or to severe
erosion caused by the combustion gases, shall consist of special refractory material
complying with ASTM C 27 for refractory clay material. The bricks shall be staggered to avoid
any leakage paths and cemented in place with ceramic bond mortar.
The basic components of refractory and insulating castables as well as their mixing ratios and
any specific mixing instructions, including water content for wet mixes shall be clearly
indicated and identified in accordance with the applicable ASTM standards.
8. STRUCTURES AND APPURTENANCES
8.1 STRUCTURES
The furnace supporting structures shall have the following characteristics:
a) The structures shall be capable of supporting any ancillary equipment and shall allow for
erection and maintenance requirements. In addition the structures, including the
structures which support the platforms, shall be capable of supporting external piping
for an equivalent weight of at least 5% of the weight of the coils of the furnace, when
considered empty of water.
b) The structures shall consist of shop fabricated sections to the maximum extent possible,
forming portals, trestles and substructures, to facilitate transport and erection.
c) Beams connecting portals, braces, the main and secondary beams of roof
substructures, monorails and handrails shall be fastened by bolts unless otherwise
required.
d) For any parts requiring site welding, the manufacturer shall carry out proper tack-up
and edge preparation at his workshop as well as any other preparations required for
ensuring accurate, quick and economical erection.
The design and the fabrication of members shall allow field assembly using temporary
or fixed bolts. In the case of modular construction, assembly at site shall be by bolted
connections.
e) In no way shall the loads of tubes and fittings be supported by the refractory lining.
Modules or sections with lining shop installed shall have at each end a protective shelf bar (3
mm thickness AISI 304 as a minimum). The shelf bar height shall be 2/3 of the insulation
thickness.
Any platform structure must be removable without affecting the structural stability of the
heater or of any of its appurtenances (ducting, stack, etc.).
Platform width at header boxes shall be 1200 mm minimum. Platforms to service

instrumentation shall have a minimum width equal to the length of the instrument plus 600
mm (e.g. platforms for NOx analysers).

Page 19 of 38
8.2 HEADER BOXES, DOORS AND PORTS
The radiant chamber of horizontal tube heaters (including double fired heaters), must be
equipped with doors or removable panels to allow the installation of radiant tubes ready
assembled in single lengths on their radiant supports.
In the case that explosion doors are provided, the casing around the door must be duly
reinforced with strengthening plates up to the closest structural members, in order to avoid
casing buckling after door opening. No cables, tubing, electrical or instrument device shall be
positioned within 2.5 m around the explosion door. Explosion doors must be as far as
possible from any permanent platform and must not be accessible to personnel from
permanent platforms.
A minimum of two snuffing-steam connections shall be provided in each firebox and one in
each header box. The characteristics of the snuffing-steam connections shall be as per
section 15.3.1 of API 560.
8.3 MATERIALS
Unless otherwise stated, the materials to be used for the construction of furnace supporting
structures are the following:
a) Structural shapes S275JR to EN10025

b) Plates S275JR to EN10025
c) Plates for end tube sheets S275JR to EN10025
d) Tubes P235Tr2 to EN 10216
e) Bolts EN ISO 898-1
Equivalent ASTM, BS, DIN, JIS and AFNOR materials are acceptable.
Under no circumstance shall high strength bolts of class 10.9 and 12.9 of EN ISO 898-1 or
equivalent bolts be used.
In addition to bolts of class 8.8 of EN ISO 898-1 or equivalent which have been suitably
pickled, cadmium plated, galvanized (zinc plated), phosphatized, or equally protected, heat
treatment may be required to remove any absorbed hydrogen. The heat treatment shall be
carried out in accordance with the EN ISO 898-1, Part 6.
9. STACK, DUCTS AND BREECHING
9.1 GENERAL
The top of the stack shall be at least 6 m above the highest access platform, within a radius
of 15 m around the stack.
The stack height shall be specified such that the maximum permissible concentration of
pollutant emissions as required by law or project environmental requirements is not exceeded
at grade, inside or outside the plant boundary.
9.2 DESIGN CONSIDERATIONS
Blades of dampers installed in ducts or stacks having an internal cross sectional area greater
than one square metre (1 m²) and designed for a design temperature higher than 750°C,
shall be suitably reinforced and provided with a stiffener along the blade edge (e.g. rod Ø 5

Page 20 of 38
cm.). Shafts shall be vertical (whenever possible) and prepared with provisions for future
connection with cooling air. A platform for access to the damper shall be provided per API
560 section 12.4.1.
9.3 MATERIALS
The design metal temperature for dampers shall be as follows:
 Flue gas/air contact temperature + 110°C for dampers exposed to direct-flame

radiation (e.g. dampers on stacks of all-radiant heaters)
 Flue gas/air contact temperature + 50°C for all other cases.
10.BURNERS AND AUXILIARY EQUIPMENT
10.1 BURNERS
When combination fuel burners are specified (fuel gas plus fuel oil), burners shall be designed
for firing gas and oil separately or simultaneously, to meet the design release requirements.
The burner emissions measured during a burner performance test shall not exceed 90% of
the values stated in section 3.2 or on the data sheet.
For capacities greater than 4.0 MW the proposed installed distances shall be submitted to the
Company for approval.
Unless otherwise specified, liquid-fuel burners shall be of the steam-atomised type.
The range of turn-down for natural draught burners shall not be less than 1:3 for fuel oil, and
1:5 for fuel gas referred both to the maximum burner capacity.
Oil fired burners designed for a fuel heat release lower than 1.3 MW shall be avoided where
possible, particularly if operated contemporaneously with oil fired burners rated for a higher
fuel heat release.
Muffle blocks for radiant wall burners shall be supplied fully fired at 1000°C.
Each burner shall be equipped with a continuous pilot burner. Each pilot burner shall be
equipped with a flame scanner in the form of a flame ionisation detector.
Where specified in the project specifications and data sheet or as required by any regulations
in the location in which the heater will be installed, burner shall be equipped with UV flame
scanners. For rows of burners the installation of a scanner per each row of burners may be
considered.
When UV flame scanners are provided, air for cleaning and purging is required. Cleaning/
purging air is not acceptable for ionisation rod flame detectors.
Burner steelwork (windbox, silencers, plenum, etc.), shall be manufactured using continuous
welding. Stitch welding is not allowed.
10.2 SOOTBLOWERS
All parts of fixed rotary sootblowers exposed to the flue gases shall be of the following
materials:

Page 21 of 38
Table 5.1 Fixed Sootblower Materials
Flue Gas Temperature (°C) Material
above 700 25 - 20 Cr/Ni

between 700 and 500 18 - 8 Stainless Steel
below 500 5% Chrome
All parts of retractable sootblowers shall be of the following materials:
Table 5.2 Retractable Sootblower Materials
Flue Gas Temperature (°C) Material
above 500 18 - 8 Stainless Steel

below 500 5% Chrome
10.3 NOISE LEVEL
The maximum permissible noise level of the heater including burners and any other ancillary
machinery such as fans and their drivers including electric motors and turbines shall be in
accordance with Company standard opi.sg.hse.012.ep.
11.SHOP FABRICATION AND FIELD ERECTION
11.1 STRUCTURAL STEEL FABRICATION
Materials shall be fully trial assembled under the Supplier’s responsibility at the workshop
prior to preparation for shipment, to ensure that all constituent parts can be assembled
correctly without modifications or adjustment, and in particular that connecting flanges
between the various items are correctly oriented and that bolt holes match.
Where, for reasons of practicality, the complete supply cannot be assembled in one location,
the Supplier may, only by agreement with the Company, substitute another method to
ensure correct alignment, e.g. match drilling of flanges, templates, etc.
In any case, the Supplier shall guarantee the correct assembly of all materials and shall be
entirely responsible for the full cost of any rectification work necessary on site to correct any
misalignment. Structural pieces shall be suitably numbered and identified on steelwork
drawings and the pieces correspondingly marked to facilitate assembly.
11.2 COIL FABRICATION
Coil welds shall comply with the following Company welding specifications for the materials
indicated:
 20368.PIP.MEC.FUN Carbon Steel Piping Welding

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 20371.PIP.MEC.FUN Cr-Mo Steel Piping Welding

 20372.PIP.MEC.FUN 0.5 Molybdenum steel piping welding
 20370.PIP.MEC.FUN Austenitic Stainless Steel Piping Welding
 20374.PIP.MEC.FUN Dissimilar Metals Piping Welding
 20375.PIP.MEC.FUN Nickel Alloy Piping Welding
When applying the above specifications carbon steel coils shall be considered class 2 whilst all
remaining tubes shall be considered class 1.
All welded joints of coils shall have a joint efficiency of 1.
The tubes shall be without longitudinal welds. The use of tubes made of two or more sections
to be welded together shall be approved by the Company.
Welds, if any, must be positioned at a minimum distance of 500 mm from the nearest
support or guide.
Plugs shall be removed from their seats before welding and heat treatment of joints between
tubes and headers. Heat treatment shall be local and not in furnaces.
Heat treatment
a- For all prefabricated coils and materials:

Heat treatment shall be carried out in accordance with the requirements of the
reference ASTM material specifications and Company specifications indicated in
paragraph 11.2 above.
b- For manifolds:
If required by the material specifications, furnace-heat treatment shall be carried out.
c- For extruded manifolds:

If required by the material specifications, furnace-heat treatment shall be carried out;
any straightening shall be executed in the cold condition after normalization and
tempering.
d- For studded tubes:

Heat treatment shall be carried out for all Mo and Cr-Mo alloy steel and for studded
tubes with carbon steel studs where the carbon content is more than 0.2%.
Heat treatment shall be carried out in accordance with the following Cycle:
 heating rate 150 - 180°C/hr from 300°C

 minimum holding time of 2 hours at the heat treatment temperature specified in the
codes for the particular type of material
 cooling rate 100°C/hr to 300°C.
Studding and finning
The surface of tubes shall be smooth and all traces of oxide or scale shall be removed before
applying the studs or fins.
Studding or finning shall commence from the bevelled ends so as to leave the excess length
on the opposite end of the tube.
Tolerances: ± 0.15% of the stud or fin height

± 0.15 mm of the stud or fin diameter

Page 23 of 38
± 0.15% of the stud or fin length, including the distance between

external stud or fin centres with a maximum of + 5 mm.
The above tolerances apply to every stud or fin section of any tube.
The maximum inclination of the stud in relation to the tube shall not exceed 6%.
Studding and finning operations shall be supported by a proper PQR issued by the supplier /
manufacturer.
11.3 TUBE SUPPORTS AND GUIDES
Holes shall be obtained by casting. Machining of holes is permitted where these conform to
manufacturing requirements. This must be supported by documentary evidence. Supports
shall be free from sharp corners and projections so as to avoid damage to the tubes.
Tolerances permitted shall be as follows:
a) Total dimensions ± 0.25% (not more than 10 mm)
b) Hole diameter ± 1.5 mm
c) Lower alignment of holes (tube support) ± 1.5 mm
d) Hole position for tubes ± 1.5 mm between centres (not aggregate)
e) Thickness of brackets and small castings - 0, + 1 mm
f) Tube sheet thickness:  25 mm - 0, + 2 mm

> 25 mm - 0, + 3 mm
g) Surface roughness ± 1 mm
h) Buckling: the maximum flatness (in practice, maximum camber determined by a

straight chord between any two points of the casting) shall not deviate by more than
0.25% of the chord length (not more than a total of 10 mm).
i) Warping: the alignment of opposite edges shall not deviate by more than 0.25% (not
more than a total of 6 mm).
The tolerance relating to the hole position shall in all cases comply with the overall
dimensional tolerances.
Casting thicknesses indicated in the drawings and/or standards shall be the minimum
calculated. Any tolerances below those specified shall not be permitted.
Tube sheet constructions

Tube sheets shall generally be cast in a single piece.
Composite tube sheets of two or more pieces are permitted where dimensional restraints are
exceeded, these shall be fully assembled by welding.
Tube sheets of 50 Cr - 50 Ni consisting of several pieces welded together shall not be permitted.
Welding
Before welding the Manufacturer shall provide the Company with a welding procedure
specification, welding qualification and welders’ qualification in compliance with the latest
edition of ASTM-A-458.
Welds shall be full penetration and, wherever possible, shall include back-welding.
Edges or areas to be welded shall be suitably cleaned and dried before welding.

Page 24 of 38
The welding method adopted shall comply with that used during procedure qualification tests.
Defects and repair of defects

Defects shall be considered on the basis of the quantity of material to be removed from the
casting to obtain sound material on which to re-weld.
The defect shall be considered “major” if:
a) The depth of the cavity is more than 1/5 of the thickness of the material or 25 mm,
whichever is the minimum for the defect location.
b) The length of the cavity is more than 50 mm (25 mm for support zones of tubesheets).
c) The distance between two defects is ten times less than the thickness of the zone
involved.
d) The total surface area to be repaired is more than 10% of the total casting area.
The defect shall be considered “minor” whenever it is less than those conditions stated
above.
The Company’s approval shall be obtained for repairs to “major” defects.
The Supplier shall indicate the position and dimensions of defects on a drawing.
Defects which are considered “minor” may be repaired directly by the Supplier in accordance
with welding procedures that have been approved and without having to obtain Company
approval.
Heat treatment
Heat treatment shall be carried out in accordance with the requirements of the codes or as
specifically requested by the Company for special casting applications. Final heat treatment
shall be carried out on completion of all welding operations and repairs unless otherwise
agreed with the Company.
11.4 REFRACTORIES AND INSULATION
A shop dryout of castable refractories for the purpose of avoiding alkaline hydrolysis shall be
carried out according to API 560 section 16.5.8 e. Final dryout up to operating temperature
on site, after installation as a separate activity or as part of commissioning shall be carried
out according to the instructions of the refractory manufacturer.
12.INSPECTION, EXAMINATION, AND TESTING
12.1 WELD EXAMINATION
Coil Examination
All welded joints shall undergo checks required for compliance with the appropriate
specifications listed in paragraph 2 and in accordance with the procedures laid down in
Company specification 20377.PIP.MEC.FUN, where coils constructed in carbon steel material
shall be considered in class 2, and all remaining coil materials in class 1.
The acceptance criteria for discontinuities in welds shall be those indicated in
20377.PIP.MEC.FUN, where carbon steel coils shall be considered in class 2 and all remaining
coil materials in class 1. Furthermore the following modifications or additions to
20377.PIP.MEC.FUN shall be applied.

Page 25 of 38
a) Table 1 of 20377.PIP.MEC.FUN does not apply with regards to the extent of radiographic
examination to be carried out on the welds of coils in carbon steel material (class 2).
The extent of radiographic examination shall follow the requirements of API 560 or as
specified on the data sheet.
b) Joints having a nominal diameter less than 2” shall be subject to 100% magnetic
particle or liquid penetrant examination.
Welds for which heat treatment is required shall undergo hardness tests to ensure that the
hardness falls within limits laid down for the material. All heat treatment diagrams shall be
subject to review.
Finished coils or sections of coils shall be subject to a hydrostatic test at the pressure
indicated on the coil drawing. Neither seepage nor pressure drop at pressure gauges shall be
permitted during hydrostatic testing. If hydrostatic tests cannot be carried out coils shall be
100% radiographed.
For equipment intended for the European market the minimum requirements shall be in
compliance with the European directive 97/23/CE PED.
Casting examination
For all castings, the tests indicated in Table 12.1 for the material shall be applied as detailed
below:
Table 12.1 Casting Examination
Material Reference Check and tests

specification
A B C D E F G H I L
5 Cr - 0.5 Mo ASTM A-217 Gr C5 X X X X X X X - - X

18 Cr - 8 Ni ASTM A-351 Gr CFB X X X X X X - - - -
25 Cr - 12 Ni ASTM A-447 Type II X X X X X X - X X -
25 Cr - 20 Ni ASTM A-351 Gr HK 40 X X X X X X - - - -
50 Cr - 50 ASTM A-560 and IN-657 X X X X X X - - - -
Ni+Nb
Cast Iron (*) ASTM A-48 CL 25 X X X - - X - - - X
A - Chemical analysis
B - Mechanical tests
C - Visual check
D - Liquid penetrant test
E - Radiographic examination
F - Dimensional check
G - Magnetic particle inspection
H - Tensile test after ageing in accordance with ASTM A 447 II para 8
I - Magnetic permeability test in accordance with ASTM A 447 II para 9
L - Brinnell hardness test (maximum allowable value: 170 HB)
(*) Brinnell hardness test (maximum allowable value: 240 HB)
Chemical analysis (A) and mechanical tests (R)

Page 26 of 38
To be carried out for every heat no. in accordance with the requirements laid down in the
material code and those specifically agreed between the Company and the Supplier.
Visual check (C)
A 100% visual check shall be carried out on all castings. Surfaces must be adequately
cleaned
Liquid penetrant test (D)
The liquid penetrant test shall be carried out in critical zones indicated on the casting
drawings and shall include:
a) All tubesheets
b) All tubesheet brackets
c) Supports shall be 100% checked with liquid penetrant to the following extent:
c1) The first support of the series from every heat no. for supplies of up to 30 pieces
c2) The first support of the series from every heat no. plus another support for
supplies of up to 60 pieces
c3) 3% of supports of the series from every heat no. starting with the first support for
supplies of more than 100 pieces.
Radiographic examination (E)
Unless otherwise specified in the drawings or purchase order, castings shall undergo a
radiographic examination as follows:
a) All tubesheets shall be radiographed in critical zones which shall be indicated in the
drawings. Critical zones are, as a minimum, those close to support areas and those
subject to maximum stress.
b) Brackets of tubesheets shall be 100% radiographed.
c) Supports shall be 100% radiographed in accordance with the following quantities:
c1) The first support of the series from every heat no. for supplies of up to 30 pieces
c2) The first support of the series from every heat no. plus another support for
supplies of up to 60 pieces
c3) 3% of supports of the series from every heat no. starting with the first support for
supplies of up to 100 pieces.
Casting joint welds on plates consisting of two or more parts shall be 100% radiographed.
Dimensional check (F)
A 100% dimensional check shall be carried out on all castings.
Magnetic particle inspection (G)
Magnetic particle inspection shall be carried out on all castings as required to the parts
applicable to liquid penetrant tests (D).
If the results of checks and tests carried out on castings are unacceptable, they shall be
repeated on twice the number of pieces whenever possible. If results are still unacceptable,
all parts shall be checked at no expense to the Company.
Procedure for the execution of checks and tests
Visual check
The visual check aims to detect any surface defects such as cracks, shrinkage, porosity, etc.
and conformity with requirements laid down in ASME, Section V, Article 9.

Page 27 of 38
Acceptance criteria for defects shall comply with MSS SP-55 (Manufacturer's Standardization
Society, Standard Practice).
Dimensional check
The dimensional check aims at guaranteeing full compliance of dimensions with the approved
construction drawings.
The rounding-off of edges of surfaces in contact with tubes shall be checked.
Liquid penetrant test
The liquid penetrant test shall be carried out in accordance with requirements laid down in
ASME, Sect. V, Article 6. Acceptance criteria shall comply with ASME, Sect. VIII, Div. 1,
Appendix 7.
Radiographic examination
The radiographic examination shall be carried out in accordance with ASTM E-94.
Criteria for assessing radiographs shall comply with ASTM E-446 and acceptance levels shall
be as follows:
Table 12.2 Radiograph Acceptance Levels
CATEGORY TYPE OF DEFECT ACCEPTANCE

LEVEL
A Gas inclusion 3
B Slag inclusion 3
C (CA) Gas inclusion shrinkage 3
C (CB) Slag inclusion shrinkage 3
C (CC) Shrinkage 3
C (CD) Shrinkage with cracks 3
D Cracks Not permitted
E Hot tears Not permitted
F Inserts Not permitted
G Mottling Not permitted
If required, X-ray acceleration shall be used depending on the thickness to be radiographed.

Magnetic particle inspection
The magnetic particle inspection shall be carried out in accordance with requirements laid
down in ASME E-109 or E-138. Acceptance criteria shall comply with MSS SP-53.
Cast Headers and Pressure Fittings Examination
Subject to selection of the header material, tests indicated in Table 12.3 shall be carried out
in accordance with the following requirements.
Table 12.3 Cast Headers and Pressure Fittings Examination
Material Reference Specifications Checks and tests

Composition
Header body Seals, plugs, A B C D E F G H
screws, flange
etc.

Page 28 of 38
Carbon Steel ASTM A-216 WCB X X X X - X X X

ASTM-A-185 X X X X - - - -
5 Cr - 0.5 Mo ASTM A-217 Gr C5 X X X X - X X X
ASTM-A-182 F5 X X X X - - - -
9 Cr - 1,0 Mo ASTM-A-217 Gr X X X X - X X X
C12 ASTM-A-182 F9 X X X X - - - -
18 Cr - 8 Ni ASTM-A-351 Gr X X X X X - X X
CF8 Thermowells
ASTM A-312 X X X X - - - -
TP-304
Note: Unless otherwise specified in the data sheet, materials indicated in the table are generally
to be used only for seals, plugs, screws, flanges, thermowells etc.
A - Chemical analysis
B - Mechanical tests
C - Visual check
D - Dimensional check
E - Liquid penetrant test
F - Magnetic particle inspection
G - Radiographic examination
H - Hydrostatic test
Chemical analysis (A)
To be carried out for every heat no. in accordance with requirements laid down in the
material code.
Mechanical tests (B)
To be carried out for every heat no. in accordance with requirements laid down in the
material code.
If a fracture occurs at more than three-quarters from the centre of the working length of a
specimen under tensile conditions during testing, the test shall be repeated on another
specimen from the same heat no.
Visual check (C)
A visual check shall be carried out on all headers to detect any surface defects such as
cracks, shrinkage, porosity, etc. in accordance with requirements laid down in ASME Section
V article 9
Acceptance criteria for defects shall comply with MSS SP-55 (Manufacturer's Standardization
Society, Standard Practice).
The visual check shall also involve quality of manufacture of all headers, which shall be free
from:
- surface cracks
- ridges due to mating of moulds
- oxide scale
- adhesions
- ripples/folds
- slag and sand
- porosity
- blowholes

Page 29 of 38
- projections caused by casting or other circumstances.
Dimensional check (D)

A dimensional check shall be carried out on all headers to guarantee compliance of
dimensions with construction drawings approved by the Company as well as with
requirements laid down in special specifications and anything else possibly agreed between
the Company and the Supplier.
In particular, the purpose of the check shall be to verify: condition and dimensions of screws
and headers, dimensions of holes for tubes, out-of-roundness and condition of expanding
grooves, plug seats, condition and width of contact surfaces and header thickness.
Machine-worked surfaces involving expansion or butt and seal-welding at the plugs shall be
checked to ensure that the finish complies with UNI 3963 code or equivalent, with a
roughness of Ra 0.4" max. (or equivalent).
Liquid penetrant test (E)
Whenever magnetic particle inspection does not apply, a liquid penetrant test shall be carried
out as follows:
a) 100% in zones where there is a change in shape
b) 100% at ends of headers used for tubes to be expanded.
The test shall be carried out in accordance with ASME section V, article 6. Acceptance criteria
shall comply with ASME section VIII, div. I, appendix VII, para. 7.2 (a) (4).
Acceptance criteria for the liquid penetrant test on welds of headers cast in two pieces or
repair welds of defects shall comply with ASME section VIII, div. 1, appendix VIII, para. 8.3
and 8.4.
Magnetic particle inspection (F)
A magnetic particle inspection shall be carried out to the same extent as for the liquid
penetrant test mentioned in para. 4.5.7.1.
The inspection shall be carried out in accordance with requirements laid down in ASTM-E-709.
Acceptance criteria shall comply with ASTM-E-125.
Radiographic examination (G)
The radiographic examination of headers shall be carried out to the following extent:
a) 5% of every model and material, with a minimum of one header, 100% radiography
shall be applied in all critical zones
b) All header ends shall be 100% radiographed.
The radiographic examination shall be carried out with ASTM E-94. Criteria for assessing
radiographs shall comply with ASTM E-446 and/or E-186 and acceptance levels shall be as
follows:
Table 12.4 Radiograph Acceptance Levels
CATEGORY TYPE OF DEFECT ACCEPTANCE

LEVEL

Page 30 of 38
A Gas inclusion 3
B Slag inclusion 3
C (CA) Gas inclusion shrinkage 3
C (CB) Slag inclusion shrinkage 3
C (CC) Shrinkage 3
C (CD) Shrinkage with cracks 3
D Cracks Not permitted
E Hot tears Not permitted
F Inserts Not permitted
G Mottling Not permitted
If required, X-ray acceleration shall be used depending on the thickness to be radiographed.
Hydrostatic test (H)

A hydrostatic test shall be carried out on all headers at the pressure indicated in construction
drawings or in accordance with agreements reached between the Supplier and as per the
following procedure:
a) Headers shall be kept under pressure with a petroleum product first for five minutes at
25% of the test pressure, then for a further five minutes at 50% of the test pressure
and, finally, for ten minutes at the maximum pressure defined.
b) The plug-seat surface seal shall be guaranteed by ensuring that surfaces are completely
free from oil or any other material.
These surfaces shall be cleaned with carbon tetrachloride or another similar solvent.
c) When kept at the maximum pressure headers shall be hammered (approx. 2 lb, 900 g)
to prevent any residual stresses.
d) No seepage nor pressure drop shall be permitted during the test.
e) Hydrostatic tests with lubricated seats shall be authorized in writing by the Employer.
Checking of marking
The marking on all headers shall be checked. Headers shall be marked using an indelible
marker with:
- part number
- material symbols
- overall dimensions
- Manufacturer's trade-mark.
12.2 EXAMINATION OF OTHER COMPONENTS
Steel structures
Compliance of materials with drawings requirements shall be checked by reviewing the

documentation submitted by the Manufacturer.
Compliance of load bearing frame and stack with drawing requirements shall be checked.
Quality of strength welds for stacks to be checked against reference standards.
Check of modules and prefabricated panels

Page 31 of 38
a) The verticality shall be checked. The maximum allowable tolerance shall be 2 mm per
meter with a maximum of 20 mm deflection with regard to the verticality.
b) The plot arrangement and elevation shall be checked.
c) Structural steelwork welds and bolts shall be checked. These shall comply with drawings
and specifications.
A visual check shall be carried out on all modules and loose materials.
Dimensions of all materials and prefabricated parts shall be checked against those shown in
the drawings together with those indicated in project specifications.
Steel preassembly
The prefabricated structure shall be preassembled at shop and checked for compliance with
approved drawings.
Refractory and insulating material
Check that material characteristics comply with the codes and the certificates required by
Company as listed in project specifications.
Test condition carried out according to applicable ASTM specifications.
Studding and Finning
In addition to the requirements of API 560, the following checking of studding or finning shall
be carried out:
a) Dimensional check
b) Checking of heat treatment diagrams.
c) If considered necessary, the Company reserves the right to request the following tests
and checks on a tube section:
c1) Macrographic check to ensure that the connection zone is free from cracks and
that there is no lack of fusion. In the case of studs, the connecting section shall be
at least 80% of the cross-section of the stud diameter and, in the case of fins,
80% of the thickness.
c2) Micrographic check of a section of the weld on the plane passing through the stud
or fin axis to ensure that it is free from fragile structures, microcracks, inclusions
or slag of any significance.
c3) Repeated bend tests.
c4) Tensile test.
Additional check of studding for extended surface tubes, carried out as follows:
a) Check of stud rated dimensions with the following tolerances: 0 ± 0.1 mm
height ± 5%
b) Check of the number of studs per each circumferential row according to shop drawings
or data sheet.
c) Check of pitch between circumferential rows according to shop drawings or data sheet.
d) Check of actual stud number after hammering with a max. tolerance of ± 2% of the
required number.
e) Statistical check of stud welding on the finished tube by hammering (about 2 lbs = 900
g) and shaped punch to be applied at the stud top, according to the following
guidelines:
- Divide the tube lengthwise into quadrants including 100 studs per quadrant

Page 32 of 38
- Perform hammering on 3% of the studs per each quadrant

- The hammer blow shall be such as to give off a shrill sound
- For each stud identified with defective weld, all studs within a range of 150 mm
shall be hammered
- In case another defective welded stud is found within that range, this operation
shall be repeated until all defects are corrected
- If the number of defective welded studs per each quadrant exceeds 5% of the
quadrant studs, the tube will be set aside and the Manufacturer will be instructed
to proceed with a hammering of all studs and to submit the tube to an additional
test
- If more than 5 tubes of the same material are rejected, the whole lot shall be
rejected and the Manufacturer will be requested to hammer all studs, to restore
any studding removed and to re-submit the lot to a further test.
f) Where agreed between the Company and the Manufacturer, check by means of an
inside calliper gauge that the heat input, during stud welding has not altered the tube
inside diameter.
g) Check of the nominal size of the extended surface included between the centre lines of
the external studs within the tolerance of ± 0.1 with a maximum value of ± 5 mm.
Burner Performance test
A production burner of each burner type shall undergo combustion testing to ascertain its
performance including pollutant emissions for all specified fuels. The test shall be conducted
in accordance with API RP 535 section 12 with any additional requirements as listed in the
project specifications.
All parts used for the burner test must be new. In particular the muffle block must have been
completely dried out before the test. The dry-out procedure shall be prepared and supplied
by the burner manufacturer. No cracks shall be allowed on the muffle block either before or
after the test.
The burner test shall include a thermal shock test on refractory tiles. The test shall be
performed as follows:
- light-up test burner
- increase firing to maximum
- hold for 20 minutes
- sudden firing reduction to minimum
- hold for 20 minutes
- sudden firing increase to maximum
- repeat for minimum three cycles
The air dampers shall be kept locked to the position corresponding to the maximum firing all
through the test. The test must be performed on a production tile
Painting
Painting, coating and galvanising including testing and inspection shall be in accordance with
Company specification 20000.VAR.PAI.FUN and project specifications.
12.3 TESTING
Water for hydraulic tests shall be potable.

Page 33 of 38
Hydrostatic testing of austenitic stainless steel coils shall be carried out in accordance with
the following procedure:
a) For coils that can be completely drained, the chloride content of hydrostatic testing
water shall not exceed 50 ppm by mass (50 mg/kg).
b) For coils that cannot be completely drained, the chloride content of hydrostatic testing
water shall not exceed 2 ppm and the conductivity shall not exceed 20 S/cm.
c) Coils shall be carefully drained and purged after the hydrostatic test. Drying by means
of heating of the coil is not acceptable.
12.4 INSTRUMENTATION AND CONTROLS
12.4.1 FACTORY ACCEPTANCE TEST (FAT)
A Factory Acceptance Test (FAT) shall be performed including the following tests as a
minimum:
 Visual/dimensional Check
 Power up and initialization
 Power failure and recoveries
 Redundancy test for backup controllers, power supply, communication systems,
I/O cards and operator consoles
 Integrated test of all involved system
 Synchronization test of all involved systems via GPS
 The tests required by the IDS
 Total system reboot
 Hardware/software inventory
 Diagnostic test
 RFI protection
 Functional loop checking (100% signals)
 Custom application programs and sequences test
 Logic test
 Graphics & Alarm list Check
 Interface test
 Any other test(s) as per project requirements.
12.4.2 SITE ACCEPTANCE TEST (SAT)
When specified in the project documentation the complete supply shall be subject to a Site
Acceptance Test to verify the System integrity after shipment and installation. The checks
shall include as a minimum:
 Visual and mechanical check
 Power / Earthing connections check:
 Equipment functionality check

Page 34 of 38
13.CENTRIFUGAL FANS FOR FIRED-HEATER SYSTEMS
13.1 DESIGN
Fans for fired heaters shall be supplied in accordance with API 560 Appendix E and Company
specification 08035.MAC.MEC.FUN. The maximum permissible speeds are 1600 rpm and 980
rpm for air fans and flue gas fans respectively.
13.2 ELECTRIC MOTOR DRIVES
Electric motor drives for fans shall be supplied in accordance with Company specification
20167.EQP.ELE.FUN Asynchronous Motors. Electrical installation shall be in accordance with
20215.PKG.ETI.SDS Electric and Instrumentation Plants Included in Package Supplies.
14.CONTROLS AND INSTRUMENTATION
14.1 GENERAL
Heater instrumentation and controls shall be supplied, installed, tested and commissioned
according to the project documentation (including P&IDs) and all applicable international
standards and codes.
The applicable instrumentation Company standards are the following:

• 20048.VAR.STA.SDS Instrumentation Philosophy.
• 20047.VAR.STA.SDS Requirements for the Installation of Instrumentation.
• 28037.CMP.STA.SDS Instrumentation & Automation included in Package Plants
14.2 HEATER INSTRUMENTATION
In the general case that the heater is supplied as panelised components for erection on site
instrumentation to be installed on the heater itself shall be supplied loose. The Package
Supplier’s scope of supply is defined as P1 inside the Company standard 20048.VAR.STA.SDS
(Instrumentation Philosophy).
If the heater is supplied as a fully pre-assembled, skid-mounted or modularised package the

instrumentation shall be installed on the heater and cabled to the relevant skid-mounted
junction boxes. The Package Supplier’s scope of supply is defined as P2 inside the Company
standard 20048.VAR.STA.SDS (Instrumentation Philosophy).
The above mentioned cases shall be considered as sub-assembly units that are part of the
whole package defined as P3 in the Company standard 20048.VAR.STA.SDS (Instrumentation
Philosophy).
In each case, P1, P2 or P3, the battery limits in terms of design, supply, installation and
testing shall be as specified in the project documentation.
Tubeskin thermocouples shall be supplied welded to the heater tube unless otherwise
specified.
The number and location of instrument connections provided shall be as per section 15 of API
560. The supply of heater instrumentation shall be as detailed in the project specifications
and data sheet and shown on the relevant project P&IDs.

Page 35 of 38
14.3 FUEL CONTROL SKID
Where specified in the project specifications and data sheet and shown on the relevant
project P&IDs the Supplier shall provide a fuel control skid containing the valves, piping and
instrumentation required to meter and safely operate the burners on the specified fuel(s).
The Supplier is responsible for the compliance with any applicable regulations regarding
burner management and fuel systems in the place of installation of the heater, including
providing any and all equipment required by any regulation within the Supplier’s battery
limits and providing any certification, including third party, required to install and operate the
system.
The instrumentation shall be installed on the fuel control skid and cabled to a skid-mounted
junction box. The terminal point of the Supplier’s scope of supply is the terminals of the
junction box.
The piping on the fuel gas skid will be supplied according to the piping class per Company
specification 20367.PIP.MEC.SDS as specified on the P&ID. Fabrication of pipework shall be in
accordance with the Company specifications listed in section 11.2 and testing and inspection
in accordance with Company specification 20377.PIP.MEC.FUN. The terminal points for piping
are single flanges inlet and single flanged out connections at the skid edge.
Where specified and shown on the P&ID insulation for heat conservation shall be installed on
the pipework. Where specified and shown on the P&ID heat tracing shall be installed on the
skid and terminated in a junction box at the skid edge.
Instrumentation shall be as stated above in the paragraph 14.1.
A local panel shall be provided with lamps to indicate alarms and the status of interlocks and
pushbuttons for local start-up of the heater.
As a minimum the fuel control skid will include the following items. This list is not exhaustive
and any additional items necessary to comply with any regulation in force or required for the
safe operation of the heater shall be included in the Supplier’s scope.
Fuel Gas
 Manual isolation valve

 Purge / flushing connections with valve and blank flange number as required
 Drain connections with valve and blank flange number as required
 Duplex filters with isolation and drain valves
 Differential pressure transmitter for filters
 Flow transmitter
 Pneumatically actuated pressure control valve with positioner and mechanical
minimum stop
 Pressure control valve bypass globe valves, isolation and drain valves
 Pneumatically actuated block valves with dual solenoid valves and limit switches
 Pneumatically actuated vent valve with dual solenoid valves and limit switches
 Pressure transmitter for indication and control
 Three pressure transmitters for trip on 2oo3 voting
 Pressure gauge
Pilot Gas

 Valved drain connections with valve and blank flange number as required

Page 36 of 38

 Self-acting pressure control valve
 Pneumatically actuated vent valve with dual solenoid valves and limit switches
 Pressure transmitter for pressure indication
 Pressure gauge
Fuel Oil

 Flow transmitter
minimum stop
 Pressure transmitter for atomising medium control
 Temperature transmitter for indication
 Pressure gauge
Atomising medium

minimum stop
 Temperature transmitter for indication
 Pressure gauge
14.4 FUEL PIPING AND MANIFOLDS
Fuel gas, pilot gas, fuel oil and atomising medium interconnecting pipework between the fuel
gas skid and the heater is excluded from the Supplier’s scope. Fuel gas, pilot gas, fuel oil and
atomising medium manifolds at the heater for distribution to the burners are included in the
Supplier’s scope. The terminal point is a single flanged connection at each manifold.
The manifold piping shall be supplied according to the piping class per Company specification
20367.PIP.MEC.SDS as specified on the P&ID. Fabrication, testing and inspection of pipework
shall be in accordance with the Company specifications listed in section 2.1.
As a minimum the take-off to each burner shall include a manual valve with limit switches. In
the case that operation of burners or groups of burners individually is specified, a

Page 37 of 38
pneumatically actuated block valve with limit switches shall be installed in the take-off to
each burner or group of burners.
The manifold and take-off to each burner shall be so arranged that the manual valve is
operable from the hearth platform level in position adjacent to the burner sight doors and
pilot ignition boxes.
14.5 BURNER MANAGEMENT SYSTEM PANEL
A Burner Management System (BMS) is required to provide the start-up, shut down and
flame safeguarding safety functions. There are two possible routes available to implement the
BMS.
 Use a UCP (Unit Control Panel), split into UCP_C and UCP_S for control and safety
functions, based on a PLC technology suitable for this purpose. This is described here
below as the BMS panel
 Use a SIS (Safety Instrumented System) node that is part of the plant ICSS.
In either case the SUPPLIER shall be responsible for the proper design of the system and for
ensuring its performance and safety. The detailed requirements and scope of supply of
hardware and software will be defined in the project documentation considering the
applicable standards and specifications.
Where specified in the project specifications and data sheet the Supplier shall provide a
Burner Management System (BMS) implemented in a UCP (Unit Control Panel) as defined in
Company standard 28037.CMP.STA.SDS, split into a UCP_C for control and a UCP_S for
safety functions, based on PLC technology suitable for the purpose.
Signals between plant Safety Systems (SIS) and UCP Packages shall be hardwired for
commands and interlocks. Signals between plant control system (PCS) and Package UCP will
be exchanged via redundant serial link or hardwired for critical commands/signals/interlocks.
Whenever control and shutdown functions are present inside the package unit, all the safety
sections of the logic solver shall be independent from those dedicated to control. This safety
section shall be SIL 3 rated.
In the case that the Burner Management System functions are implemented inside the plant
ICSS system, the BMS node(s) will be treated by the ICSS supplier in accordance with the
applicable Company standards and project requirements.
The heater SUPPLIER shall provide all necessary information to implement the BMS in the
ICSS including cause and effect diagram and start-up and shut-down narrative.
The Supplier is any case responsible for the compliance with any applicable regulations
regarding burner management systems in the place of installation of the heater, including
providing any and all equipment required by any regulation within the Supplier’s battery
limits and providing any certification, including third party, required to install and operate the
system.
The BMS, either the BMS panel or the SIS node, shall be implemented in a failsafe SIS
certified as at least SIL 3-capable according to IEC 61508/61511. In addition functional
certification including the following standards related to burner management systems is
required, to provide confirmation that the SIS is suitable for the BMS application:
 NFPA 85 – Boiler and Combustion Systems Hazards Code
 EN 501561 – Electrical equipment for furnaces and ancillary equipment.
Requirements for application design and installation
 EN 298 – Automatic gas burner control systems for gas burners and gas burning
appliances with or without fans.

Page 38 of 38
15.PRESERVATION, STORAGE, HANDLING & SHIPPING
15.1 GENERAL
Material for site erection shall be packed and any box clearly related to the packing list
indicating all mark necessary for the erection activity. Where possible, material will be
packed taking into account the sequence of assembly.
All carbon steel parts shall be externally painted in accordance with the Company
specification 20000.VAR.PAI.FUN.
15.2 INSTRUMENTATION AND CONTROLS
Cable entries, process line connections and pneumatic tubing connections shall be plugged or
capped.
Valves that are shipped separately from the equipment shall be protected with an appropriate
preservative, blinded off with bolted metal covers and gaskets, and sealed with Denso tape.
Items such as panels, cabinets and junction boxes containing electronic or electrical
components shall be sealed with tape or polyethylene sheeting after the installation of silica
gel bags. Panel fronts shall be fitted with protective plywood sheets. Any item containing
desiccant shall be clearly identified.
Individual instruments shall be preserved in polyethylene sheeting/bags with silica gel bags,
or by silica gel bags installed within the instrument housing and resealing the unit with tape.
Locally mounted gauges with glass fronts shall be protected by small plywood boxes, or shall
be removed and separately shipped after suitable packing/protection.
15.3 PIPEWORK AND VALVES
Following hydrotest, piping shall be drained and, where required, coated with an approved
preservative.
All open-end pipe and tubing shall be fitted with plastic end caps, held in place by waterproof
tape.
Flanged pipe ends shall be blinded off using bolted metal covers and gaskets, and sealed with
Denso tape.
All external machined surfaces on valves shall be coated with an approved preservative.
Valves shall be left in the open or closed position in accordance with Manufacturer's
recommendations and valve internals shall be protected with approved suitable
preservatives.
15.4 SURFACE FINISHING
Ladders and walkways shall be hot dip galvanised in accordance with specification
20000.VAR.PAI.FUN.
Carbon steel surfaces shall be sandblasted and painted (primer and finish coats) according to
specification 20000.VAR.PAI.FUN.
Individual components such as burners, sootblowers etc. shall be painted as per the
Supplier’s standard.


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eni spa 04939.EQP.MEC.

Consulted Distribution List

Nome Cognome/Unità / Name Società /

Informed Distribution List

Nome Cognome/Unità / Name Società /

Rev 03: Actual revision is of 38 pages.

Rev 02: Actual revision is of 35 pages.

ENGINEERING COMPANY STANDARD

Rev 01: Actual revision is of 44 pages.

Il personale eni può accedere ai company standard tramite il seguente link:

Gli utenti esterni devono fare riferimento al Project Engineering Manager.

eni personnel can access company standard repository at:

External user shall refer to the Project Engineer Manager.

GERARCHIA DI VALIDITÀ / HIERARCHY OF REGULATIONS

1. Disposizioni di legge della nazione ove le attrezzature e i materiali sono installati

1. Local Regulations of the Country where the equipment is installed;

ENGINEERING COMPANY STANDARD

1.1 PURPOSE ....................................................................................................... 7

2.1 COMPANY SPECIFICATIONS & STANDARDS ......................................................... 9

3.1 PROCESS DESIGN ......................................................................................... 11

4.1 GENERAL ..................................................................................................... 14

5.1 GENERAL ..................................................................................................... 14

6.1 GENERAL ..................................................................................................... 16

7.1 GENERAL ..................................................................................................... 17

8.1 STRUCTURES ................................................................................................ 18

9.1 GENERAL ..................................................................................................... 19

10.1 BURNERS ..................................................................................................... 20

11.1 STRUCTURAL STEEL FABRICATION .................................................................. 21

ENGINEERING COMPANY STANDARD

11.2 COIL FABRICATION ....................................................................................... 21

12.1 WELD EXAMINATION ..................................................................................... 24

13.1 DESIGN ....................................................................................................... 34

14.1 GENERAL ..................................................................................................... 34

15.1 GENERAL ..................................................................................................... 38

ENGINEERING COMPANY STANDARD

1.2 DEFINITIONS AND TERMS

The following Parties are involved in the Project activities:

Company Eni SpA, affiliated Companies or a third party,

Contractor The party, which carries out all or part of the

Sub-Contractor Any organization who supplies services to the

Supplier (Vendor/Manufacturer) The party, which manufactures or supplies

Sub-Supplier The party, which manufactures or supplies

The word shall indicates a requirement.

ENGINEERING COMPANY STANDARD

AARH Arithmetic Average Roughness Height

1.4 UNITS OF MEASUREMENT

The SI system shall be used according to the requirements of specification

ENGINEERING COMPANY STANDARD

2.1 COMPANY SPECIFICATIONS & STANDARDS

03653.VAR.GEN.SPC Thermal Insulation for Hot Temperature Service

05494.MAT.MEC.SDS Allowable Loads on Equipment Process Nozzles

05882.COO.MEC.PRG 2 Years Operation Spare Parts for Mechanical Equipment and

05883.VAR.GEN.SDS Packing for the Dispatching of Materials and Equipment

05892.PIP.MEC.SDS Pipes and Piping Components for Plants

07108.EQP.MEC.STD Standard for Nameplate Holder

07212.EQP.MEC.STD Symbols-references and miscellaneous

07219.EQP.MEC.STD Vertical ladders

ENGINEERING COMPANY STANDARD

07221.EQP.MEC.STD Handrail – Toe Board

07223.EQP.MEC.STD Circular Platforms for Columns and Vessels

20000.VAR.PAI.FUN Protective Coating, Galvanising and Metalizing for Internal and

20047.VAR.STA.SDS Requirements for the Installation of Instrumentation

20048.VAR.STA.SDS Instrumentation Philosophy