TE-STA-GLN-00-0038

GUIDELINE REV. 1

EXTERNAL INSPECTION OF FIRED 13-MAY-2009

HEATERS GUIDELINE Page 1 of 7

TABLE OF CONTENTS

1. INTRODUCTION................................................................................................2

2. SCOPE / PURPOSE.............................................................................................2

3. DEFINITIONS.....................................................................................................2

4. EXTERNAL INSPECTION GUIDELINE........................................................3

5. RESPONSIBILITIES..........................................................................................7

6. REFERENCES.....................................................................................................7

APPENDICES..............................................................................................................7

Prepared Chk’d Appr’d

Rev. Issue Date Amendment Description
By: By: By:
0 23-Jun-2003 First Release JIK MJK MJK
1 13-MAY-2009 Reviewed BF JIK WH

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1. INTRODUCTION

An in-service external inspection of all fired heaters is required at Q-Chem Plant

and will comply with the provisions of API RP 573, Inspection of Fired Boilers and
Heaters.

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2. SCOPE / PURPOSE

External inspections and evaluations of Q-Chem Company's Fired Heater will

meet or exceed the requirements of API RP 573, Inspection of Fired Boilers and
Heaters, in a continuing effort to maintain suitability for service and safety of
personnel, equipment and environment.

This procedure includes a thorough visual inspection of all parts of the fired
heater and appurtenances that are readily accessible without taking the heater
out of service, and without use of scaffolding.

This procedure outlines the requirements for conducting on stream external

visual inspection of fired heaters, incinerators and stacks.

Inspection of Steam Boilers is beyond the scope of this procedure.

This procedure is intended to ensure a uniform approach in inspecting different

heaters, incinerators and stacks within Q-Chem.’s plants without overlooking
salient points.

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3. DEFINITIONS

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4. EXTERNAL INSPECTION GUIDELINE

4.1. Frequency and Extent of Inspection

4.1.1. "In-Service" Inspections are normally performed at one (1) year intervals. This
can be less than 1 year, if an internal inspection indicates a problem or if
Operation's daily survey indicates a problem that requires further
investigation. This inspection includes the external visual inspection, spring
hangers, and counterweights of the fired heaters being inspected.

4.1.2. Inspection intervals should be based on all of the following criteria, System
service classification (critical, essential, non-critical).
 Applicable jurisdictional requirements.
 Judgment of the inspector/engineer or inspection supervisor.
 Operating conditions.
 Previous inspection history.
 Industry published inspection data.
 Hazard risk

4.1.3. Inspection intervals must be reviewed from time to time and/or adjusted after
each inspection or change in operating conditions.

4.2. Visual Aides

4.2.1. Inaccessible and hard to see surfaces may be inspected with the aide of a
mirror or boroscope where possible. Use binocular and thermographic
imaging where necessary.

4.3. Pre-Inspection

4.3.1. Prior to performing a fired heater inspection the inspector should read and
fully understand this guideline and supporting documents. In preparation for
the inspection the following tasks should be completed

4.3.2. Review individual fired heater history records to become familiar with the type
of fired heater being inspected, it's corrosion control measures, and repair
history.

4.3.3. Review previous scheduled and unscheduled inspection reports to get an

overview of potential problems.

4.3.4. Review the operating conditions/parameters for the fired heater being
inspected and the trends of such parameters during the period since last
internal/external inspection, as applicable.

4.3.5. Discuss with the Operations Specialist any operational problems and
determine if there are any additional inspection requirements.

4.3.6. Observe the entire fired heater and surrounding area as you approach the
heater for any obvious change in condition.

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4.3.7. Determine that there are no unsafe conditions that would prohibit the visual
inspection of the fired heater.

4.4. Visual Inspection, Detailed

The inspection process will be divided into five (5) categories, surrounding
area and foundation, access structure, supporting columns/casing, stack, and
appurtenances.

4.4.1. Surrounding Area and Foundation

Inspection of the surrounding area and foundation should include areas in the
general vicinity of the equipment being inspected.

 Surrounding Area: Visually inspect the area around the fired heater to
ensure that there is no excess vegetation or trash build up. Make sure that
no flammable materials are being stored near the fired heater.
 Drainage: Visually inspect area around the fired heater to ensure
adequate drainage. Verify that drainage is away from the fired heater
support pads.
 Foundation: Inspection of the foundation includes visual checks to
Concrete Support Pads. Observe fired heater casing, piping, and concrete
supports for indications of settlement or cracking. Check steel supports
and columns for corrosion, distortion, cracking and bending. Inspect earth
ground for loose connections and frayed or broken cable.

4.4.2. Access Structure

 The access structure includes all ladders and platforms that are used to
inspect external surfaces that cannot be inspected from ground level.
 A careful visual inspection, supplemented by hammering and scraping to
remove scale, as necessary, should be made for:
i. Corroded or broken parts,
ii. Cracks,
iii. Tightness of bolts and rivets,
iv. Condition of paint,
v. Wear of ladder rungs and stair treads,
vi. Security of handrails, and
vii. Condition of flooring on platforms and walkways.
 Pay particular attention for crevice corrosion in tight locations that are not
easily accessible for painting or surfaces that tend to hold water.

4.4.3. Support Columns/Casing

 Examine support columns including fireproofing for signs of paint failure,

corrosion, cracking, distortion or mechanical damage. Follow the
Corrosion Under Insulation Inspection Guideline No. TE-STA-GLN-00-
0007. Check attachment welds for cracks. Note any areas where the paint
has discoloured or blistered due to hotspots.
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 Carefully inspect the exterior surfaces of the casing for bulges or any
indications of corrosion or pitting.
 Inspect the paint or coating for cracks, blistering, thinning or chalking.
Follow the Painting and Coating Inspection Guideline No. TE-STA-GLN-
00-0031.
 Inspect the casing for areas that are suspected to have corrosion or
pitting. Such areas should be examined for metal thickness using such
NDE methods as ultrasonic or radiographic examination.
 Inspect seams and joints for loose or missing caulking.
 Carefully inspect the exterior surfaces of the casing for hot spots, which
could indicate a breakdown of the refractory inside. Carry out
thermographic imaging of the furnace casing, as necessary. Follow the
Guideline for Infrared Thermography of Furnaces No. TE-STA-GLN-00-
0015.
 Examine convection door seals for signs of leaks, corrosion, cracks,
distortion or mechanical damage.

4.4.4. Stack

The following list of inspections should be performed on the stack casing

during the in-service visual inspection. Refer to the Stacks and Flares
Inspection Guideline No. TE-STA-GLN-00-0028

 Carefully inspect the exterior surfaces of the stack for bulges, flat spots,
etc.
 Inspect the paint or coating for cracks, blistering, or thinning.
 Inspect the stack for any indications of corrosion or pitting. Areas that are
suspected to have corrosion of pitting should be examined for metal
thickness using such NDE methods as ultrasonic or radiographic
examination where possible.
 Inspect weather coat and insulation when applicable.
 Carefully inspect the exterior surfaces of the stack and stack transition
section for hot spots, which could indicate a breakdown of the refractory
inside. Carry out thermographic imaging of the stack casing, as
necessary.

4.4.5. Appurtenances

Appurtenances may be attached to the casing or external tubing.

 Inspect all connected piping and transfer line including supports, valves
and insulation for signs of leaks, corrosion, cracks, distortion or proper
operation.
 Inspect the soot blowers for indications of leaking.
 Inspect safety-relieving devices for any leaks, passing or other
abnormalities.
 Inspect expansion joints for free operation, possible mechanical damage
and cleanliness.
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 Inspect forced (induced) draft fan, ductwork and wind box for corrosion,
coating, hot spots, and other physical damage.
 Inspect temperature indicators and fire fighting systems for corrosion or
mechanical damage.
 Inspect convection section and crossover piping for external corrosion,
coating damage, hot spots and other physical damage
 Inspect man-way covers and peep doors for proper fit, warping, clouded
glass (as applicable) and other physical damage.
 Inspect stiffeners for warping, bending, or physical damage.
 Examine burners including fuel gas piping and flexible hoses for signs of
leaks, corrosion, distortion, cracking or mechanical damage.
 Verify that all burners are working properly with satisfactory flame by
viewing them through the peep doors. An erratic, unbalanced flame may
be a sign of damaged swirl vanes, improper air/fuel mixture, coking on the
boiler tip or leaking tubes. An erratic flame may impinge on nearby tubes,
walls casing hot spots and areas of potential ruptures to the tubes or the
casing. Locate and record potential areas of flame impingement on
tubes/casing.
 Examine damper wrench, shaft, bearings, linkage and cable for signs of
corrosion, wear or mechanical damage.

4.5. Documentation

4.5.1. The results of the Fired Heater Inspections should be recorded on form TE-
STA-SFM-00-0002, Fired Heater External Inspection Checklist.

4.5.2. Additional inspection documentation may be required per TE-ERG-GLN-00-

0007, ERG Inspection Report Guideline.

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5. RESPONSIBILITIES

STATIONARY EQUIPMENT INSPECTOR/ENGINEER:

 Comply to, at least, all the requirements and guidelines of this document
insuring that they are all fulfilled while carrying out the external inspections of
fired heaters.
 Prepares necessary reports/checklists for the external inspections of fired
heaters.
 Updates the equipment history in the electronic “Inspection Management
System”.

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6. REFERENCES

API RP 573 Inspection of Fired Boilers and Heaters

TE-STA-SFM-00-0002 Fired Heater External Inspection Checklist.

TE-ERG-GLN-00-0007 ERG Inspection Report Guideline.

TE-STA-GLN-00-0004 Piping Inspection Guideline.

TE-STA-GLN-00-0007 Corrosion Under Insulation Inspection Guideline.
TE-STA-GLN-00-0015 Guideline for Infrared Thermography of Furnaces
TE-STA-GLN-00-0017 Structural Steel/Civil Inspection Guideline
TE-STA-GLN-00-0028 Stacks and Flares Inspection Guideline
TE-STA-GLN-00-0031 Painting and Coating Inspection Guideline

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APPENDICES

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