DESIGN MANUAL

SEM - 3115E

Piping Design Manual

Piping Design Standard around Fired Heater

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DATE :

1

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Piping Design Standard around Fired Heater

SEM - 3115E

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2003. 8.29 PAGE OF

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ii

Table of Contents

Page

1. General

1.1 Purpose --------------------------------------------------------------------- 1

1.2 Scope ----------------------------------------------------------------------- 1

1.3 Reference ------------------------------------------------------------------- 1

1.4 Terms and Definition --------------------------------------------------------- 1

2. Heater General

2.1 Heater Type ---------------------------------------------------------------- 2

2.2 Heater Major Components ---------------------------------------------------- 3

3. Heater Layout

3.1 General -------------------------------------------------------------------- 6

3.2 Arrangement Height --------------------------------------------------------- 8

3.3 Maintenance Area ------------------------------------------------------------ 8

3.4 Operation Space ------------------------------------------------------------- 8

3.5 Structure & Platform ------------------------------------------------------- 9

3.6 Steam Drum ------------------------------------------------------------------ 9

3.7 Crossover & Jump-over ------------------------------------------------------- 9

4. Piping Layout

4.1 Process Piping -------------------------------------------------------------- 9

4.2 Burner Piping --------------------------------------------------------------- 10

4.3 Snuffing Piping ------------------------------------------------------------- 11

4.4 Soot Blower Piping ---------------------------------------------------------- 12

5. Notice in Drafting

5.1 Stress Analysis -------------------- ------------------------------------ 13

5.2 Information to be Handled ----------- --------------------------------------- 13

6. Revision History ----------------------------------------------------------------- 14

APPENDIX

Ⅰ. Process Pipings

Ⅱ. Burner Pipings

Ⅲ. Stiffener Ring Size

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1. General

1.1 Purpose

This Manual aims to enhance the efficiency and standardize the Piping Design around Heater (or

Direct Fired Heater, Furnace, Reformer, etc, Heater) of Chemistry, Oil, and Oil Refinery to

design by SECL.

1.2 Scope

This Manual is applied to Piping Design around Heater of all Plants done by SECL. But, in case

Job Features (Client's Requests or Contract) is in discord with this Manual, Job Features must

be given precedence over SECL's Manual.

1.3 Reference

1.3.1 SEM-2002E "Plant Layout Standard"

1.3.2 SEM-3002E "Piping Design Instruction"

1.3.3 SEM-3039E "Piping Design Standard"

1.3.4 SEM-3040E "Pipe Support"

1.4 Terms and Definition

1.4.1 Electric Radiator Section (Radiant Section)

Electric Radiator Section is the part of heating Tube or Coil directly by the use of

burner flame. In case of Heater in part, it also includes the part where radiant heat of

Refractory heated by flame convects to Tube.

1.4.2 Convection Current Section (Convection Section)

It is called Upper Part of Heater Body, where tube heats up by using Hot Flu Gas emitted

to Stack discharged from Electric Radiator Section. Electric Radiator Section(Convection

Section) can be a part to utilize heat emitting to air.

1.4.3 Transfer Line Exchanger (TLE or TLX)

It is Transfer Line Exchanger (TLE) which cools in a short time by minimizing the

Pressure Drop against High Cracked Gas discharged from Tube in Electric Radiator

Section. Boiler Feed Water(BFW) is used as cooling water.

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1.4.4 Riser & Downcomer

It is called a Riser & Downcomer, Pipe made by High-frequency Bending connecting to TLE

and Steam Drum. Downcomer plays a role of supplying BFW or Condensate in Steam Drum to

TLE for Cooling, while Riser is to transfer Steam which is generated by heat exchange of

High temperature TLE and BFW to Steam Drum.

1.4.5 Soot Blower

In case of using Fuel Oil for Heater fuel, due to Imperfect Combustion, Soot sticks to

the surface of Heat Absorbing(Tube or Coil) and this causes Heat Transfer to get

interrupted. Soot Blower which sprays compressed air or steam is used to dispose of black

powdry deposite from smoke.

1.4.6 Crossover

It is a Pipe which connects Tube in Convection Current Section to Tube in Electric

Radiator Section and installed inside or outside of Heater Shell. Heater Vendor designs

and supplies Piping and related Support even when Crossover Pipe is installed outside of

Heater Shell.

1.4.7 Jump-over

It is a high temperature Pipe connecting Tube in Convection Current Section and Tube to

outside of Heater Shell or connecting Process Line in addition by connecting Tube and

Tube to outside of Heater Shell

1.4.8 De-coking

Coke left inside Tube when Fluid contains high carbonhydrate which passes through high

temperature Tube. A series of process to get rid of this coke is called De-coking. De-

coking is done by injecting Steam and Air heated by High temperature in general to Tube

through related Pipe outside of Heater Shell.

2. Heater General

Heater Type is generally composed of Horizontal(or Box) Type, Vertical Type, Helical Coil Type

according to Shape.

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2.1 Heater Type

2.1.1 Horizontal(or Box) Type

In the horizontal Type, Tube is installed horizontally in general, Tube installation or

its area can be arranged differently according to heat temperature of each part inside

Box Heat Flux Density Heater. Tube in Electric Radiator Section is called "Radiant

Coil", Tube in Convection Current Section is called "Convection Coil".

Tube Size and arrangement in Horizontal Type is in accordance with Operating Process like

Crude Oil distillation or Cracking, and Flow Rate through necessary Heating Area or Tube.

In some cases, Auxiliary Tube is installed in Convection Current Section for the purpose

of heating Air or Process Fluid supplying to Burner in advance or making more Steam.

2.1.2 Vertical Type

Vertical Type is a cylinder or right angled and the entire part or the most part of Tube

is installed vertically. Radiant Coil is all installed vertically and, In case of Upper

end part of Tube, because Flow Area of Gas gets smaller, it can be installed in

Convection Zone where Velocity increases.

In some cases, Oil Economizer or Air Heating Section is installed right on the Main

Vertical Heating Section for the purpose of operation efficiency. In case of the most

part of Vertical Type, Burner is installed and burnt below Heater and Stack is installed

at the Top of Heater.

2.1.3 Helical Coil Type

Helical Coil Type is cylinder shaped. Tube in Electric Radiator Section is installed in

alignment with inside Heater in the form of Helical Coil. Convection Current Section can

be made by installing Flat Spiral or Horizontal Tube Bank if necessary. Stack is

installed right on the body of Heater.

2.2 Heater Major Components

2.2.1 Burner

It is a heating device which burns liquid or gas fuel. Oil burner is sprayed and burned

by mixing heavy oil, light oil with air or steam. Burner is classified as Floor Fired

Burner, Wall Fired Burner and Roof Fired Burner according the installation position.

[Figure 2-1] shows Burner Assembly (Floor Fired)

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[Figure 2-1] Floor Burner

2.2.2 Radiant Section

(1) The Tubes in Radiant Section of Vertical Heater are arranged vertically, in even or

odd numbers, Tube Quantity can be increased to lower Heater Height.

(2) Even Numbers of tubes will place the Inlet & Outlet Nozzles at the same end of the

heater. See [Figure 2-2].

1Pass 2Tubes 2Pass 4Tubes 1Pass 4Tubes

[Figure 2-2] Even Number Tube Arrangement

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(3) In case Heater has Odd number Tubes, inlet and outlet Nozzle is to be arranged in

the opposite direction as the below figure.

1Pass 1Tube 1Pass 3Tubes 1Pass 3Tubes

[Figure 2-3] Odd Number Tube Arrangement

(4) In some cases, there would be cases to increase or decrease Heater Height. In this

case, Request of Nozzle Position Change can be made to Vendor for Piping Design

Advantage. But, Vendor will decide exclusively Support or Nozzle Position of

Crossover Pipe connecting from Convection Current Section to Electrical Radiant

Section, which cannot be changed by SECL's request.

(5) It is very important to understand Tube Support and Position because Nozzle

Position of Heater and Pipe which is to be designed by SECL is affected directly by

Tube Support Type and its Location.

[Figure 2-4] Tube Arrangement and Crossover Piping

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2.2.3 Convection Section

The Length of Tubes in the Convection Section of the Vertical Heater is usually very

short because of the limited area available on top of the radiant section( 1.8m ~ 3.5m ).

Tube in Convection Section is Vertical Type but is to be usually arranged horizontally to

enhance Thermal Efficiency.

2.2.4 Stack

The Height of Stack is to be over 5m of the other structure within a 30m radius from

center of Stack in consideration of surrounding structure deformation and casualties as a

result of heat or poisonous gas emitting from Stack.

3. Heater Layout

3.1 General

3.1.1 If it is accepted by Process, it is to be arranged in the area of other fire equipment

(Direct Fired Heater, Reformer, Boiler, etc) for safety efficiency.

3.1.2 Heater is to be arranged in the direction of upwind from Process areas as

shown in [Figure 3-1] to minimize damage when flammable gas is leaks.

3.1.3 Road or space is to be provided so that Crane can have an easy access for Tube

Maintenance.

3.1.4 In case of Box Type Heater, Maintenance Space with minimum 1.5m is added to Tube length at

the back side of Heater as [Figure 3-1] should be ensured so that there won't be

problem in case of Tube Pulling.

3.1.5 Box Type Heater is to be arranged as a group as possible for ease of maintenance.

3.1.6 In case Heaters are arranged as a group, distance between Heaters of same purpose is to be

minimized and otherwise safety distance should be minimum 7.5m.

3.1.7 In case layered large Box Type Heater is arranged as a group, Elevator is to be

installed in the center or both ends for the operator's convenience.

3.1.8 Safety Distance between Pipe Rack and front of Heater is usually 3~5m regarding Control

Valve Station, Fuel Manifold & Platform (PF) Size. See [Figure 3-1]

3.1.9 In case of Safety Distance between Heater and device handling Hydrocarbon Fluid, related

law, regulation or job design basis has priority,otherwise the below standard is applied.

(1) Rotating Equipment Handling Flammable Liquid (Pump, Compressor) : Minimum 15m

(2) General Flammable Equipment (Drum, Reactor, etc.) : Minimum 8m

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3.1.10 In case of Fuel Gas Knock-Out Pot Installation, Min.15m is to be maintained from Heater,

provision for operation of Block Valve, Level or Pressure Gauge to be provided.

3.1.11 BFW Supply Pump for Steam generation and Deaerator can be installed near Heater without

considering safety distance.

[Figure 3-1] Box Type Heater Layout

3.1.12 Distance between Heater and Reactor, Reformer and Reactor connecting to Alloy Pipe is to

be installed as close as possible as [Figure 3-2] in the consideration of Pipe Stress

Analysis and Economical Factor. But, related law, regulation, job design basis or minimum

safety distance mentioned in 3.1.9 should be considered.

3.1.13 It should be checked if there is any interference between adjacent Heater Foundation and

PF refer [Figure 3-2]

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[Figure 3-2] Vertical Type Heater Layout

3.2 Arrangement Height

3.2.1 In case burner is not available at the bottom part of Heater, Ground Type is to be

arranged

3.2.2 In case burner is arranged at bottom of heater , maintenance is required so it is to be

arranged at the height of 2m ~ 5m from the ground.

3.3 Maintenance Area

3.3.1 Tube Removal Area is to be ensured for Heater Tube for arrangement and replacement as

[Figure 3-1].

3.3.2 Space for Maintenance is to be ensured in the area of Soot Blower, PF is to be installed

if necessary.

3.3.3 Space for Maintenance of Burner Assembly or Burner Gun is to be considered.

3.3.4 Space for Maintenance for De-coking inside Tube at the bottom of TLE is to be

considered.3.4 Operation Space

3.4.1 Valve around Heater is to be arranged in as a group as far as possible for convenient

approach and operation.

3.4.2 Access Way is to be considered for Heater Operation, Stairway is preferred over would

rather be installed than Ladder. Box Type Heater is to be arranged as a group,

Stairway is to be installed at both ends.

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3.4.3 Easy access is to be ensured for burner ignition, Pipe arrangement should not interfere

with burner access.

3.5 Structure & Platform

3.5.1 At the beginning of Job, Load and Location of Heater Structure for Pipe Support is to be

informed to Vendor through Machinery Engineer, Refer to 5.2 for detail.

3.5.2 If necessary, it has to be taken care of informing to Vendor that Structure is to be

reinforced or Beam for Support is to be added.

3.5.3 Monorail for Maintenance is to be installed at each top and bottom of TLE according to

De-coking method

3.5.4 In case Burner is installed on the side or top of Heater, PLTF for operation is to be

installed in the relevant part.

3.5.5 PLTF is to be installed around Valve or Instrument, Observation Door, Soot Blower.

3.5.6 In case Box Type Heater is installed as a group, connecting pathway is to be installed

between Heaters for access and maintenance.It is to be installed in as many stairs as

possible for operator's convenience.

3.5.7 In case Silencer is installed on top of Heater Structure, it is to be taken care of

sending related Structure Information to Heater Vendor and reflecting them.

3.6 Steam Drum

3.6.1 Steam Drum is to be installed on top of Heater Structure

3.6.2 Installation Location is based on Riser & Downcomer type and Cracked Gas (or Heater

Effluent) Line arrangement.

3.6.3 PLTF and Ladder for access to Instrument or Safety Valve (PSV).

3.6.4 Not only PLTF & Ladder but also Information on Pipe Support Clip is to be sent to vendor.

3.7 Crossover & Jump-over

3.7.1 Work scope split of Crossover including related Support, Jump-over Piping DWG., Material

Supply & Installation is to be specified between SECL and Vendor.

3.7.2 It is desirable for Heater Vendor to design and supply most of part in Crossover & Jump-

over because it is not to easy for SECL to adjust Tube Arrangement inside Heater Shell and

Support

3.7.3 In case of Jump-over, let Heater Vendor work on the minimum of Routing and Support Design.

3.7.4 It is to be checked if Pipe, Insulation or Support to design by SECL is not interrupted.

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4. Pipe Layout

4.1 Process Piping

4.1.1 In case Control(Manual/Automatic) Valve is not available in Process Pipe, Inlet/Outlet

Nozzle is composed of more than 2 in even number, check if Inlet/Outlet Pipe is to be

Symmetrical Piping.

4.1.2 In case Valve is available in Heater Inlet, it is to be designed to be able to operate

above ground or Platform.

4.1.3 In case Main Process Pipe of Box Type Heater, requires Slope on Cracked Gas(or Heater

Effluent) Line, Slope is to be kept more than slope indicated in P&ID.

4.1.4 In case Location of Slope Ratio and Slope starting point is not specified in P&ID,

person in charge of Process should check.

4.1.5 If Heater Effluent Pipe is to be designed regarding Vacuum, Stiffener Ring should be

considered according to calculation as per Appendix Ⅲ

4.1.6 In case of De-coking Pipe with Swing Elbow indicated in P&ID, it is to be designed to make

swing possible by attaching Flange to relevant Elbow.

4.1.7 Working space is to be ensured for connecting & dismantling Swing Elbow.

4.1.8 As it is easy for Elbow or Tee to change direction in De-coking Pipe to erode due to Coke,

Elbow or Tee one step thicker than relevant Pipe thickness is to be installed.

4.1.9 In case Drain or Vent is required outside Heater Shell Heater in the scheme of inside

Coil, Drain and Vent is to be installed to Pipe connecting to Inlet or Outlet Nozzle

4.1.10 Pipe connected directly to Heater Nozzle by welding is to be designed for Hydrostatic or

Pneumatic Test and Flushing.

4.1.11 Suitable Support is to be considered to prevent heat expansion of pipe by high temperature

and vibration.

4.2 Burner Piping

4.2.1 Burner Connecting Pipe is composed of Fuel Gas, Fuel Oil, Steam, Pilot Gas, etc. general

burner connecting pipe type is to be as per Appendix II.

4.2.2 Main Block Valve which is installed in Fuel Gas, Fuel Oil, Steam and Pilot Gas connecting

to each Heater by branch from Header of Pipe Rack is to be installed at 15m from Heater or

PLTF so that it can be operated easily in case of emergency.

4.2.3 In case of Branch at Header or Sub-Header, Fuel Oil is to be installed from the bottom of

Header, the rest is to be branched from the top and drain is to be installed at the end of

Header.

4.2.4 Connection pipe is to be installed for Maintenance of Burner Assembly or Burner Gun.

4.2.5 In case Flexible Hose, Union is to be used for Burner Maintenance, it is to be checked if

there is no problem in Spec. in advance.

4.2.6 Burner Piping Sub-Header is Located top of PLTF above Peep or Observation Door as in

[Figure 4-2]. But, It can be installed at the bottom of PLTF as per Alternate "D"

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4.2.7 Pilot Gas Valve is to be installed around burner, it shall be operated through Peep or

Observation Door.

4.2.8 In case of connecting burner, Fuel Oil, Steam Pipe uses Flexible Hose to remove Burner

Gun, but Fuel Gas, Pilot Gas pipe connecting to burner body is to be connected with pipe

as possible to avoid gas leakage.

4.2.9 Trap is to be installed to remove Condensate at the end of Steam Sub-Header.

4.2.10 Valve to use in Fuel Gas, Pilot Gas Pipe uses Plug Valve is used in Fuel Gas, Pilot Gas

Pipe to prevent gas leakage.

In case of Ball Valve is to be used, Fire-safety Type is to be used.

4.2.11 Drain Valve to installed in Fuel Oil or Fuel Gas Pipe should be able to be operated from

PLTF or above ground.

4.2.12 All Burner Piping is to be designed to be of same type and to prevent inadvertent

mistake in operation.

[Figure 4-2] Burner Piping

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4.3 Snuffing Piping

4.3.1 Snuffing Steam Manifold is to be installed above ground 15m from Heater as

in [Figure 4-3] for easy access and operation in emergency.

4.3.2 In case of Pipe connecting to Heater Nozzle from the behind of Valve in Manifold, Vent,

Drain & Steam Trap is not to be installed and it is not to be kept warm.

4.3.3 Trap is installed at the bottom of Manifold so that Live Steam can be provided in

emergency.

4.3.4 When Live Steam is provided urgently, Guide is to be installed in the proper location so

that Pipe or Support is not to be left.

4.3.5 Low Point Pocket at the end of Block Valve is to be drilled for φ6mm Weep Hole to remove

condensate.

4.3.6 In case of Valve Open, φ6mm Weep Hole is to be made opposite(180 degrees) from Handle at

the end of Valve so that operation can be sensed.

4.3.7 Weep Hole Size and Location is to be indicated in ISO DWG..

4.3.8 In case of Snuffing Pipe, Visual Test can be substituted for site water pressure test.

[Figure 4-3] Snuffing Steam Manifold

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4.4 Soot Blower Piping

4.4.1 Soot blower Steam Pipe is to Slope in the direction of Steam Header which is opposite

from Soot Blower as required by P&ID.

4.4.2 In case Slope is not indicated in P&ID, check with person in charge of Process, generally

is to be designed as 1/10 ~ 1/50 Slope.

4.4.3 In case of Steam Pipe connecting to Soot Blower, Flexibility is to be considered fully.

4.4.4 Pipe is not to obstruct maintenance space of Soot Blower.

4.4.5 In case of Retractable Soot Blower, Flexible Tube is to be installed to cover Travel.

5. Points to be considered in Design

5.1 Stress Analysis

5.1.1 After general Pipe Route is made by using initial Heater Layout, check Load transmitting

to Heater Nozzle.

5.1.2 Allowable Load Data of Force, Moment, Movement, etc about Heater Nozzle connecting to Pipe

is to be requested from Heater Vendor.

5.1.3 In case Allowable Load is not available from Vendor, it is to be reviewed on the basis of

3 times of Allowable Nozzle Force Value indicated in API 560.

5.1.4 In case Nozzle Load by pipe is higher than Allowable Load presented by Vendor, information

shall be sent to Vendor through person in charge of Machinery.

5.1.5 Cold Spring(Cut Short) can be used to reduce Load as indicated in ASME B31.3.

5.2 Information to be handled

5.2.1 In case of Heater Requisition Drafting or Kick-Off Meeting, the following considerations

shall be taken up with Vendor in advance.

(1) Allowable Nozzle Force is applied minimum 3times of API 560 standard.

(2) Steel Structure Extension & Addition for Pipe Support

(3) PLTF Extension & Addition

(4) Ladder Location Change & Addition

(5) Clip for Pipe Support Installation

(6) Heater Structure reinforcement for Pipe Support Point (if necessary)

5.2.2 In case of Pipe Support by using Heater Shell or Structure, it has to be informed to

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Heater Vendor. Pipe Support Location and Load value is to be indicated in Vendor Print,

Support Clip item is to be made by SECL Standard Form.

(1) Load value and Location of Heater Structure by Pipe Support

(2) Support Clip detailed dimension, Installation Location and related load value

5.2.3 Nozzle Orientation of Steam Drum to be installed on the top of Heater, PLTF, Ladder &

Support Clip is to be informed to Vendor by the use of SECL's Design Form.

6. Revision History

No Date Page Reason for Revision

0 1998. 9.18 -- Newly established by 98 Piping Team Innovative Promotion

Project

- Department : Piping Team

Prepared by : Chang Hong-jin, Lee Joo-sang

Reviewed by : Kim Ki-pil

Approved by : Lee Myung-hak

1 2003. 8.29the whole

page

- Revision Process

It is revised and supplemented by SEM-0002 "Engineering Manual

Instruction"

And this Manual reorganized fully by focusing on Pipe around

Fired Heater which applies actually to Job and the specific

Heater Parts is left out of the Manual.

- Department : Piping Planning Engineering Team

Prepared by : No Hee-kwon

Reviewed by : Kim Ki-Pil (Engineering Committee)

Approved by : Kim Seok-ki

Appendix Ⅰ:

APPENDIX Ⅰ

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Process Piping (Vertical Heater) SEM - 3115E

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[ Symmetrical Piping for Box Heater ]

[ Symmetrical Piping for Cylindrical Heater ]

Appendix Ⅰ:

APPENDIX Ⅰ

PAGE

Process Piping (Symmetrical Piping) SEM - 3115E

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[ Non-Symmetrical Piping for Box Heater ]

[ Non-Symmetrical Piping for Cylindrical Heater ]

Appendix Ⅰ:

APPENDIX Ⅰ

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Process Piping (Non-Symmetrical Piping) SEM - 3115E

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Appendix Ⅱ:

APPENDIX Ⅱ

PAGE

Burner Piping (for Vertical Heater) SEM - 3115E

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Appendix Ⅱ:

APPENDIX Ⅱ

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Burner Piping (for Box Heater) - Floor SEM - 3115E

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[ In case Sub-Header is on Top of PLTF ]

[ In case Sub-Header is at the Bottom of PLTF ]

Appendix Ⅱ:

APPENDIX Ⅱ

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Burner Piping (for Box Heater) - Wall SEM - 3115E

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* Note : The below Size is just for reference. In case it is to apply to Job, it requires to review

the actual Design Condition and Pipe Thickness is to be reviewed by replacing it with BPV (Boiler &

Pressure Vessel) Code Section Ⅷ, Division 1 UG-28 ~ 30

Size

(B)

OD

(mm)

t

(mm)

L

(mm)

b x w x f

(mm)

Pipe

Weight (kg/m)

Stiffener

Weight (kg/m)

18 457.2 6.0 3000 L65x65x5 66.7 7.2

20 508.0 6.0 3000 L65x65x5 74.3 8.0

24 609.6 6.0 3000 L65x65x5 89.4 9.6

26 660.4 7.1 3000 L65x65x5 114.3 10.4

28 711.2 7.1 3000 L65x65x5 123.3 11.2

32 812.8 7.1 3000 L65x65x5 141.1 12.8

34 863.6 7.9 3000 L65x65x5 166.8 13.6

36 914.4 7.9 3000 L65x65x5 176.5 14.4

38 965.2 8.7 3000 L65x65x5 205.2 15.2

40 1016.0 8.7 3000 L65x65x5 216.1 16.0

42 1066.8 10.3 3000 L65x65x5 268.4 16.8

44 1117.6 10.3 3000 L65x65x5 281.4 17.6

46 1168.4 11.1 3000 L65x65x5 316.7 18.3

48 1219.2 11.1 3000 L65x65x5 330.7 19.1

50 1270.0 11.9 3000 L65x65x5 369.2 19.9

52 1320.8 11.9 3000 L75x75x6 384.2 28.4

54 1371.6 11.9 3000 L75x75x6 399.2 29.5

56 1422.4 12.7 3000 L75x75x6 441.4 30.6

60 1524.0 13.1 3000 L75x75x6 488.1 32.8

66 1676.4 15.0 3000 L75x75x6 614.4 36.1

72 1828.8 16.0 3000 L75x75x6 715.4 39.4

Appendix Ⅲ:

APPENDIX Ⅲ

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Stiffener Ring Size SEM - 3115E

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