Document No.

GIS 22-101
Applicability Group
Date 30 December 2005

Guidance on Industry Standard for

ISO 13705 Fired Heaters (API 560)

GIS 22-101

BP GROUP
ENGINEERING TECHNICAL PRACTICES
30 December 2005 GIS 22-101
Guidance on Industry Standard for ISO 13705 Fired Heaters (API 560)

Foreword

This is the first issue of Engineering Technical Practice (ETP) BP GIS 22-101. It is based on ISO
13705 and documents of three merged companies, BP, Amoco, and Arco listed below.

In addition, reference is made to other standards and reports that provide guidance in use of heritage
documents or similar documents.

Normative references are mandatory to extent that they are referenced and not superseded by this
guide.

British Petroleum
GS 122-1 Fired Heaters to API 560.
GS 122-2 Natural Drought Burners for Fired Process Heaters.
GS 122-3 Forced Draught Burners for Fired Process Heaters.

Amoco
A FE-FH 560-G Fabricated Equipment Fired Heaters Guide.
A FE-FH 560-E Fabricated Equipment Fired Heaters API 560 Engineering Specification.

ARCO
ES 30 Fired Process Heaters.
ES 110 Refractory Linings.

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Guidance on Industry Standard for ISO 13705 Fired Heaters (API 560)

Table of Contents
Page
Foreword............................................................................................................................................2
Introduction ........................................................................................................................................6
1 Scope (1.1) ...............................................................................................................................6
1.1 Data sheets ...................................................................................................................7
1.2 Scope exclusions...........................................................................................................7
2 Normative references (1.6/1.7/1.3) ...........................................................................................7
2.1 Local codes ...................................................................................................................8
2.2 Compliance....................................................................................................................8
2.3 Precedence ...................................................................................................................8
3 Terms and definitions (1.4) .......................................................................................................9
4 General .....................................................................................................................................9
4.5 Alternative designs ........................................................................................................9
4.6 Material safety data sheets (MSDS) ..............................................................................9
5 Proposals (1.8) .......................................................................................................................10
5.1 Purchaser’s responsibilities .........................................................................................10
5.2 Vendor’s responsibilities (1.2 Alternative designs) ......................................................10
5.3 Documentation (1.9) ....................................................................................................12
5.3.1 Drawings for purchaser’s review .................................................................................12
6 Design considerations (2) .......................................................................................................12
6.1 Process design (2.1)....................................................................................................13
6.2 Combustion design (2.2) .............................................................................................15
6.3 Mechanical design (2.3 Mechanical) ...........................................................................15
7 Tubes (3) ................................................................................................................................16
7.1 General (3.1) ...............................................................................................................16
7.3 Materials (3.3)..............................................................................................................16
8 Headers (4).............................................................................................................................17
8.1 General (4.1) ...............................................................................................................17
8.2 Plug headers (4.2) .......................................................................................................17
8.3 Return bends (4.3).......................................................................................................17
8.4 Materials (4.4)..............................................................................................................17
9 Piping, terminals and manifolds (5) ........................................................................................18
9.1 General (5.1) ...............................................................................................................18
9.2.1 Allowable movement and loads...................................................................................18
9.3 Materials (5.3)..............................................................................................................18
10 Tube supports (6) ...................................................................................................................18
10.1 General (6.1) ...............................................................................................................18
10.3 Materials (6.3)..............................................................................................................19

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11 Refractories and insulation (7)................................................................................................19

11.1 General (7.1) ...............................................................................................................19
11.2 Brick and tile construction (7.2) ...................................................................................20
11.3 Castable construction (7.3)..........................................................................................20
11.4 Ceramic fibre construction (7.4) ..................................................................................21
11.5 Multicomponent lining construction (7.5) .....................................................................23
11.6 Materials (7.6)..............................................................................................................23
12 Structures and appurtenances (8) ..........................................................................................23
12.1 General (8.1) ...............................................................................................................23
13 Stacks, ducts and breeching (9) .............................................................................................24
13.1 General (9.1) ...............................................................................................................24
13.2 Design considerations (9.2).........................................................................................24
14 Burners and auxiliary equipment (10).....................................................................................25
14.1 Burners (10.1)..............................................................................................................25
14.2 Sootblowers (10.2) ......................................................................................................28
14.4 Dampers and damper controls (10.3) ..........................................................................29
15 Instrument and auxiliary connections (12) ..............................................................................30
15.3 Auxiliary connections (12.3) ........................................................................................30
15.4 Tube skin thermocouples (12.4) ..................................................................................30
16 Shop fabrication and field erection (13) ..................................................................................31
16.1 General (13.1) .............................................................................................................31
16.2 Structural steel fabrication (13.2).................................................................................32
16.3 Coil fabrication (13.3) ..................................................................................................32
16.5 Refractories and insulation (13.5)................................................................................32
16.6 Field erection (13.7).....................................................................................................32
17 Inspection, examination and testing (14) ................................................................................32
17.1 General (14.1) .............................................................................................................32
17.2 Weld examination (14.2)..............................................................................................33
17.3 Castings examination (14.3)........................................................................................33
17.4 Examination of other components (14.4).....................................................................34
17.5 Testing (14.5) ..............................................................................................................34
Annex A (Appendix A) (Informative) Equipment data sheets...........................................................36
Annex B (Appendix B) (Informative) Purchaser’s checklist..............................................................37
Annex C (Appendix C) (Informative) Proposed shop assembly conditions .....................................38
Annex E (Normative) Centrifugal fans for fired heater systems .......................................................39
E.2. Design.....................................................................................................................................39
E.2.1. General........................................................................................................................39
E.2.5. Rotating elements........................................................................................................39
E.3.2. Drivers .........................................................................................................................39
Annex G (Appendix F, F.A., F.B., F.C., F.D., F.E., F.F.) (Informative) Measurement of thermal
efficiency of fired process heaters ..........................................................................................41
Bibliography .....................................................................................................................................42

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Guidance on Industry Standard for ISO 13705 Fired Heaters (API 560)

List of Tables

Table 1 - RCF temperature limits.....................................................................................................21

Table 2 - Soluble Ceramic Fibre temperature limits.........................................................................22
Table 3 - Casing coating requirements based on sulfur content of fuel ...........................................23

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Guidance on Industry Standard for ISO 13705 Fired Heaters (API 560)

Introduction

a. Guidance for design, fabrication, erection, and testing of fired process heaters is based on
ISO 13705:2001.
b. Guidance statements of this GIS are modifications to ISO 13705.
c. Modifications to ISO 13705 are identified as Add, Modify to Read, or Delete.
d. Paragraph numbers in this specification correspond to ISO 13705.
e. Paragraphs of ISO 13705 that are not revised remain applicable.
f. Commentary additions to Paragraphs in this GIS are provided to further identify BP
practices with fired process heaters.
g. Due to a similarity between ISO 13705:2001 and API Std 560, API Std 560 may be used
as a base for process design and purchase of process fired heater. However, all Add,
Modify to Read, Delete, or Commentary from this GIS still apply.
h. Paragraph numbers in parenthesis provides reference to API Std 560 sections.
By necessity, ISO 13705:2001 and API Std 560 provide more flexibility than
required by BP. These two documents do not include specific BP experience. This
GIS adds requirements that BP has found necessary for safe and cost effective
operation.
From experience of the industry as a whole, the ISO and API standards are a
distillation of general experience. Individual companies have different cultures and
operating procedures (again learned from experience). BP requirements in this GIS
fit with the BP operating and design philosophy.
This GIS may refer to certain local, national, or international regulations, but the
responsibility to ensure compliance with legislation and any other statutory
requirements lies with the user. The user should adapt or supplement this GIS to
ensure compliance for the specific application.

1 Scope (1.1)

Add
This GIS provides guidance on industry standard for the design, materials, fabrication,
inspection, testing, documentation, and preparation for shipment of fired process heaters based
on ISO 13705:2001.
Engineers should be acquainted with BP and Industry requirements for fired heater
services and ensure appropriate requirements are applied to the specific fired
heater application. BP Process Hazard Analyses and siting studies are important
sources for both input and review of the engineering of fired heaters. BP experts in
applicable areas of heater design should be consulted on new heater designs that
have not been previously reviewed.

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Add

1.1 Data sheets

Completion of fired heater data sheets should follow ISO and API documents and exceptions
noted in this GIS.
ISO and API documents provide equipment data sheets in Annex A (Appendix A).
Equipment data sheets are not included in this GIS. Equipment data sheets and
instructions for use are included in DS 22-100.

1.2 Scope exclusions

This standard does not cover steam boilers, except as steam generating and superheating
becomes incidental to the process and practical from the standpoint of economic fuel use.
Indirect type oilfield heaters or emulsion treaters are not covered by this GIS and
should be designed to API Spec 12K and API Spec 12L.

2 Normative references (1.6/1.7/1.3)

Add

BP
DS 22-100 Data Sheet for Fired Heaters.
GIS 12-201 Guidance on Industry Standard for Low Voltage Induction Motors (IEC).
GIS 12-202 Guidance on Industry Standard for Low Voltage Motors (IEEE 841).
GIS 12-203 Guidance on Industry Standard for High Voltage Induction Motors (IEC).
GIS 12-204 Guidance on Industry Standard for Medium Voltage Motors (API 541).
GIS 72-001 Guidance on Industry Standard for Procurement of Refractory (Including
Material Performance Requirements).
GIS 72-002 Guidance on Industry Standard for Refractory Installation.
GIS 72-003 Guidance on Industry Standard for Refractory Dry-out.
GIS 72-004 Guidance on Industry Standard for Refractory Inspection.
GIS-72-102 Guidance on industry Standard for Vee Anchoring Systems.
GIS 72-103 Guidance on Industry Standard for Hex-mesh Anchoring Details.
GIS 72-104 Guidance on Industry Standard for Independent Anchor Systems –
Corner Tabs, U-Tabs and Ring Tabs.
GIS 72-105 Guidance on Industry Standard for Refractory Construction Details.
GIS 72-106 Guidance on Industry Standard for Independent Anchor Systems – Hex
Cells, S-Bars and Curl Anchors.
GIS 72-108 Guidance on Industry Standard for Miscellaneous Refractory
Construction Details.

American Institute of Steel Construction (AISC)

AISC Specification for Design, Fabrication, and Erection of Structural Steel for Buildings.

American Petroleum Institute (API)

API Std 530 Calculations of Heater Tube Thickness in Petroleum Refineries.
API Std 535 Burners for Fired Heaters in General Refinery Services.
API Std 534 Heat Recovery Steam Generators.

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API Std 556 Heaters Instrumentation and Controls.

API Std 560 Fired Heaters for General Refinery Services.
API RP 531 Measurement of Noise from Fired Process Heaters.
API RP 537 Inspection of Fired Boilers and Heaters.
ASME Sec IX Boiler and Pressure Vessel Code, Section IX, Welding and Brazing
Qualifications.
ASME B16.9 Factory-Made Wrought Buttwelding Fittings.
ASME B16.11 Forged Fittings, Socket-Welding and Threaded.
ASTM A 407 Standard Specification for Steel Wire, Cold-Drawn, for Coiled-Type
Springs.
ASTM E 165 Standard Test Method for Liquid Penetrant Examination.
ASTM E 186 Standard Reference Radiographs for Heavy-Walled (2 to 4 ½ in) [51 to
114 mm]) Steel Castings.
ASTM E 446 Standard Reference Radiographs for Steel Castings up to 2 in. (51 mm) in
Thickness.

American Society of Civil Engineers

ASCE 7 Minimum Design Loads for Buildings and Other Structures

British Standards Institute (BS)

BS 6651 Code of practise for protection of structures against lightning.

International Conference of Building Officials (ICBO)

ICBO Uniform Building Code.

National Fire Prevention Association (NFPA)

NFPA 8501 Single Burner System.
NFPA 8502 Multiple Burner Systems.

2.1 Local codes

a. National, state, or local applicable code or regulation shall be considered part of this
standard.
b. Responsibility for becoming familiar with such standard, specification, code, or regulation
and compliance with such standard rests with BP and Vendor.

2.2 Compliance
BP and Vendor shall mutually determine measures that must be taken to comply with federal,
state, or local codes, regulations, ordinances, or rules that may be applicable to equipment.
As an example, Material Safety Data Sheet is required for all chemicals received at
BP Company facilities within the United States (refer to Section 4.6 for more
details)

2.3 Precedence
a. Order of application of the specification shall be:
1. Statutory or local regulations.
2. Equipment requisition and data sheets.
3. BP specifications.

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4. ISO 13705.
b. In absence of specified order of precedence, Vendor shall obtain written approval from BP
before proceeding with work.

3 Terms and definitions (1.4)

Add

3.82

coil pressure drop

Difference between coil inlet pressure and coil outlet pressure between terminals, excluding effect of
static head.

3.83

guillotine or isolation blind

Single blade device used to isolate equipment or heaters.

3.84

header or return bend

Common term for 180 degree cast or wrought fitting that connects two or more tubes.

3.85

volumetric heat release

Heat released divided by net volume of radiant section, excluding coils and refractory dividing walls,
expressed in kW/m3 (BTU/h/ft3).

4 General

Add

4.5 Alternative designs

a. Alternative designs may be offered in addition to base design if permitted by inquiry.
b. Variances with this standard or BP specification shall be clearly indicated in proposal.

4.6 Material safety data sheets (MSDS)

a. Equipment or materials that contain or are coated with any regulated substances, such as
the following, shall be prominently tagged at openings to indicate nature of contents and
precautions for shipping, storage, and handling:
1. Insulating oils.
2. Corrosion inhibitors.
3. Antifreeze solutions.
4. Desiccants.
5. Chemical substances.
6. Hydrocarbon substances.
b. Regulated substances shall have MSDSs.

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c. MSDSs shall fully comply with regulations for MSDS preparation specified by entity that
has jurisdiction and shall include a statement that the substance is considered hazardous by
regulation.
d. If any substance is exempt from regulation, a statement to that effect shall be included.
e. Before shipment, MSDSs shall be forwarded to receiving facility.
f. At shipment, MSDSs in protective envelopes shall be affixed to the outside of the
shipment.

5 Proposals (1.8)

5.1 Purchaser’s responsibilities

5.1.1
DS 22-100 heater data sheets shall be used to provide BP requirements for heater
design, shop fabricated, and field erected fired heaters, sootblowers, air preheaters,
fans, and burners.
5.1.2
Verification of Vendor quality system is normally part of the prequalification
procedure and is therefore not specified in core text of this specification. If this is
not the case, clauses should be inserted to require Vendor to operate and be
prepared to demonstrate the quality system to BP. Quality system should ensure that
technical and QA requirements specified in the enquiry and purchase documents are
applied to all materials, equipment, and services provided by subcontractors and
any free issue materials.

5.2 Vendor’s responsibilities (1.2 Alternative designs)

Add

5.2.1 Heater design

a. Vendor shall coordinate design and ensure satisfactory functioning of complete unit (i.e.,
heater, air preheater, forced/induced draft fans, drivers, transmissions, and other
ancillaries).
b. Detailed design of fired heater system shall be total responsibility of Vendor.
c. The inquiry document may offer the Vendor an option to offer BP alternative designs in
addition to the base design, but any variance with this standard or the BP specification
shall be discussed and clearly indicated in the proposal.
d. Drawings and related documents supplied in BP Specifications shall be used by Vendor as
a guideline for requirements and for location of fired heater system components.
e. Vendor shall perform detail analysis and calculations to establish optimum configurations
for system.
f. If fired heater Vendor supplies equipment that Vendor has not manufactured, Vendor shall
ensure that designs of such items are compatible with each other and with Vendor’s own
equipment in all respects, and these items shall be included in Vendor guarantee. In
particular, these items shall be compatible dimensionally, in performance, in control, and
in vibration such that fully integrated unit is achieved.
g. Design information enclosed in attached specification defines minimum requirements for
design, materials, fabrication, assembly, testing, and preparation for shipment of proposed
process fired heater system.

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Guidance on Industry Standard for ISO 13705 Fired Heaters (API 560)

5.2.2 Equipment guarantee

a. Vendor shall guarantee that equipment meets all requirements as set forth in this standard,
that heater will continuously render satisfactory performance, including noise
requirements, at design conditions as outlined in data sheets, and that all parts which prove
defective within 1 yr from start of operation because of design, workmanship, or materials
will be replaced without charge.
b. Review of Vendor submitted bid documents, by BP or its representative, will not relieve
Vendor from complete compliance with drawings and specifications.
c. Nothing contained in any specifications or data sheets shall be deemed to relieve Vendor
of any warranty expressed or implied.

5.2.3 Furnace stack loss guarantee

a. Vendor shall state and guarantee furnace stack loss, based on 20% excess air and methane
as fuel, unless different fuel is specified for rating purposes on data sheet.
b. Overall furnace efficiency shall be calculated and guaranteed using guaranteed stack loss
in a., plus assumed radiation losses of 1-1/2% in radiant section, 1/2% in convection
section, and 1/2% for air preheat system for a total of 2% without air preheat and 2-1/2%
with air preheat.
c. Efficiency calculations shall be based on higher heating value or lower heating value as
specified on data sheet.

5.2.4 Exceptions
a. BP approval of Vendor of design and drawings for construction or release of equipment by
authorized inspector shall not relieve Vendor of responsibility for heater and does not alter
conditions of guarantee.
b. At bid submittal stage, all exceptions taken to these specifications, all variances from these
specifications, and all substitutions of operating capabilities or equipment called for in
these specifications shall be listed in writing and forwarded to BP or its designated
representative. Any such exceptions, variances, or substitutions that are not listed at time
of bid and which subsequently are identified by BP or its representative in the submittal
shall be grounds for immediate disapproval without comment.
c. Fabrication shall not begin until drawings have been stamped approved for construction by
BP or their designated representative.

5.2.5 Emission levels guarantee

Emission levels of heater for sulphur oxides, nitrogen oxides, carbon monoxide, and particulate
shall be guaranteed.

5.2.6 Local approvals

Special approvals, if required by national, state, or local code or regulations, shall be obtained
without expense to BP.

5.2.7 Safety measures

Adequate safety measures shall be provided and maintained at all times during development and
execution of project.

5.2.8 Delivery date

Throughout duration of work, BP or its representative shall be kept informed of changes that
may affect equipment delivery.

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5.3 Documentation (1.9)

5.3.1 Drawings for purchaser’s review

Add
k. Proposal drawings showing heater general arrangement, tube layout, positions and
locations of ladders, platforms, peepholes, sootblowers, dampers, isolating plates,
expansion joints, ductwork, fans, burners, and air preheaters.
l. Details of ancillary equipment (e.g., air preheaters, fans, dampers, sootblowers, and
burners).
m. Details of instrumentation or control system supplied or proposed by heater Vendor.

Add

5.3.1.1 Exceptions, variances, and substitutions

a. At bid submittal stage, all exceptions taken to these specifications, all variances from these
specifications, and all substitutions of operating capabilities or equipment called for in
these specifications shall be listed in writing and forwarded to BP or its designated
representative.
b. Any such exceptions, variances, or substitutions that are not listed at the time of bid and
which subsequently are identified by BP or its representative in submittal shall be grounds
for immediate disapproval without comment.
c. Fabrication shall not begin until drawings have been stamped approved for construction by
BP or its designated representative.

5.3.3 Documents for purchaser’s review

5.3.3.1 Add
Drawings shall include the following additional details:
a. Heat treatment requirements.
b. Nondestructive testing, including hydrostatic test requirements.
c. Hardness requirements.
d. Gasket details.
e. Other details needed for maintenance and repairs.
f. Painting requirements.
g. Details of auxiliary equipment and controls.
h. Weld joint details in cross section, locations, and applicable welding procedures.
i. Alloy electrode designation, if applicable.
j. Bolting requirements.

6 Design considerations (2)

Add
Fired heaters and their auxiliary equipment covered by this GIS shall be suitable for all
specified operating conditions and shall be designed and constructed to operate for at least 4
years of uninterrupted continuous service periods between shutdowns, unless otherwise
approved by BP.

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If the heater is expected to run longer between shutdowns, that timeframe should be
specified to replace the “4 years”.
The 4 years operational requirement shall consider the following:
a. Design should take into consideration component design and selection of materials of
construction to ensure thermal and hydraulic performance is maintained during this period.
b. If 4 years of continuous operation requirement cannot be met, Vendor should specify:
1. Why this requirement cannot be met (this could be for process and/or economic
reasons).
2. Which operating periods can be guaranteed.

6.1 Process design (2.1)

Add
General process design requirements include:
a. If dew point corrosion may be present, Vendor shall submit following data for BP review:
1. Flue gas acid dew point data for various fuels and/or combination of fuels to be fired.
2. Minimum metal temperature calculations for metal parts in contact with flue gases
operating less than 28°C (50°F) above flue gas acid dew point.
3. Minimum calculated temperatures for nonmetallic parts in contact with flue gases
operating less than 11°C (20°F) above flue gas acid dew point (e.g., air preheater cold
end elements, seal packings, duct/stack linings).
4. If applicable, account shall be taken of metallic and nonmetallic parts in header
boxes.
b. Design exit stack temperature shall be a minimum of 14°C (25°F) over sulphur dew point
if furnace is to be fired with fuel oil or sulphur contaminated gas.
c. Maximum average heat flux and maximum required process film temperature for fired
heater shall be obtained from BP. If film temperature is not critical, design tube metal
temperature may be provided.
d. Fired heater design flow rates and heat loads shall be obtained from BP.
e. Maximum allowable process fluid bulk temperatures, maximum allowable average heat
flux on radiant section tubes, and minimum mass velocity of fluid in tubes, if not specified
by BP, shall be subject to BP approval.
f. If both oil and gas are specified, heater shall be capable of firing either fuel separately or in
any combination to attain design heat absorption.
6.1.2 Add
a. In designing fired reboilers, phase condition at heater outlet shall not exceed 80% vapour
by weight.
b. In designing heaters with multiple services in either the radiant or convective sections,
Vendor shall provide estimates of extremes in temperatures to be expected for each service
and resulting heater limitation for range of potential operating conditions furnished by BP.
1. Pass splitting within a fired heater shall be avoided where possible.
Pass splitting within a fired heater can result in flow maldistribution and tubes
overheating/failing
2. If pass splitting is used, it should be addressed by proper heater coil arrangement.
Vendor shall identify precautions taken to ensure uniform flow splitting.

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Avoiding pass splitting may not be possible in all applications, such as vacuum
heaters and ethylene crackers.
c. If convection sections of process heater are either wholly or partially used to generate
steam, following requirements shall be met:
1. If steam superheater coils are used, these shall not form part of first three rows of
convection shield sections. This requirement shall also apply to stripping steam coils
located in convection section of process heater.
Preferably, this coil should be “sandwiched-in” within steam generation tubes. This
assures that superheater tubes can be operated, particularly during the heater/unit
start-up, in “dry” or without flow through conditions without risk of heat damage to
the tubes.
2. Design of steam generator shall be subject to BP approval.
The allowable water-steam circulation rates, the minimum allowable tube side
velocities and the maximum allowable heat fluxes for steam generations are a
function of steam pressure and water quality.
3. Proposed steam generation operation should not prejudice process operation and this
shall be taken into account if steam generation coil is proposed.
Possible problems shall be addressed, including:
• Statutory authorities’ requirements for boiler inspections that are more frequent
than heater inspections.
• Loss of boiler feed water requiring heater shutdown.
• High superheated steam temperatures requiring either heater to be shut down or
heater operation limited by steam temperatures.
• Loss of any section of steam generation (boiler feed water coil, steam generation
coil or steam superheat coil) may result in heater shutdown.
d. Helical or circular coil configurations shall not be used for two phase flow applications
unless approved by BP.
6.1.3

Add

6.1.3.1 Process convection section

a. Maximum local heat flux density in process convection section, excluding those exposed
to direct radiation from radiant section, shall not exceed maximum local heat flux density
elsewhere in process coil of heater. Both rates refer to bare external surface of tubes.
b. Process convection section tubes exposed to direct radiation from radiant section (shield
tubes) shall be spaced at tube centres not less than those process tubes located in radiant
section.

6.1.3.2 Local heat flux density

a. Vendor shall advise maximum local heat flux density for each section of all coils (process
and utility), local heat flux (circumferential, longitudinal), and metal temperature variation
factors as generally described in ISO 13705.
b. Maximum local heat flux density in process convection section of ethylene, methanol, and
steam reformer furnaces shall be subject to BP approval.

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6.2 Combustion design (2.2)

Combustion air may be supplied by the use of natural draught or fans. In either
case, the draught or pressure shall be sufficient to supply to all the burners a
combustion air flow 25% greater than that required for operation at the heater
design load, with the specified excess air at the maximum ambient air temperature
with and without air preheat (where relevant)
6.2.6 Add
a. Flue gas system
1. Flue gas system shall be designed such that:
a) Pressure shall be at least 0,25 mbar below atmospheric pressure (–0,1 in water
gage) anywhere in combustion chamber (radiant section).
b) Pressure shall be at least 0,12 mbar below atmospheric pressure (–0,05 in water
gage) anywhere in ducting and in stack.
2. If flue gas quantity is at least 130% of heater design load, flue gas quantity with
design excess air and flue gas temperature at fans (if supplied) being at least 15°C
(30°F) above calculated temperature with furnace on design load.
b. ID fans
On most fired heaters it is easy and relatively inexpensive to install an induced
draught (ID) fan bypass for ID fan failure. Where this is not the case, then
consideration should be given to installing two fans (one operating and one stand-
by) or two 50% - 60% operating fans.
1. Unless otherwise approved by BP, if ID fans are fitted, provision shall be made to
bypass induced draught fans automatically on failure.
2. If ID fans are bypassed, heater shall still be capable of operating at normal load.
3. Loads lower than normal may be BP approved. Minimum 70% of normal load shall
be provided.

6.3 Mechanical design (2.3 Mechanical)

a. Air-in leaks through the fired heater casing shall be minimized by utilizing the following:
1. Heater shell shall be all welded or bolted and seal welded.
2. Skip welding shall not be used.
3. Flanged and bolted transition pieces shall be packed from within with sealing
material. Details of these joints shall show clearly on appropriate drawings.
4. Piping passing into heater (terminals or crossovers) shall have packing glands,
stainless steel bellows, spring loaded sliding seal plates, or other BP approved
arrangements.
5. Access and inspection openings shall be capable of tight closure.
6. End tube sheets
a) Unused holes in end tube sheets for horizontal convection sections shall be
sealed with refractory.
b) If extended surface is used, fins or studs shall extend through tube sheet and
shall be packed with refractory to minimize flue gas bypassing and air
infiltration.
c) Openings between tube sheet and refractory shall be packed with ceramic fibre.

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Guidance on Industry Standard for ISO 13705 Fired Heaters (API 560)

7. Header box covers shall be gasketed and bolted tightly all around.
Keeping the air-in leaks to the minimum is very important for heater performance.
b. If steam air decoking is specified, coil material together with provisions for thermal
expansion shall be suitable for short term tube metal temperature of at least 675°C
(1250°F).

7 Tubes (3)

7.1 General (3.1)

7.1.1 Add
a. Tube design pressure shall be at least equal to maximum inlet pressure to heater or that
required by code.
b. Maximum inlet pressure shall take into account possible increases of pressure above
normal inlet pressure caused by internal coke formation, restriction of flow area
downstream of heater, variations in operating conditions, or “blocked in” system
conditions, etc.
c. Design shall take into consideration stresses by differential thermal expansion along length
of tubes (between adjacent interconnected tubes) and to stresses resulting from weight of
tubes and their contents.
d. Tubes in hydrocarbon service shall have tube wall thickness not less than 6,35mm (0,25 in)
minimum wall, including corrosion allowance.
7.1.4 Add
a. Each tube shall be marked for identification.
b. Colour code painting of austenitic type steels shall be avoided.
This avoids embrittlement at high temperatures by zinc, aluminium, or low melting
point alloys in paint.
7.1.5 Add
If rolled plug headers are used, tube length shall include bare tube projection equal to two times
tubeseat dimension, plus 50 mm (2 in).

7.3 Materials (3.3)

Add

7.3.1 Austenitic steels

a. Austenitic steels shall be supplied in solution heat treated (fully softened) condition.
This is to avoid stress corrosion cracking.
b. Austenitic type steel tube materials shall not come in contact with zinc, aluminium, or low
melting point alloys. These contaminants are usually present in paints.
This is to avoid material embrittelment at high temperatures.

7.3.2 Thermal stabilising

If austenitic steels in Grades Type 321 or 347 are exposed to H2/H2S/hydrocarbon conditions
above metal temperature of 400°C (750°F), solution heat treated pipe shall be given final
thermal stabilising treatment at 900°C to 950°C (1650°F to 1740°F) for 4 hr.
This is to minimise intergranular attack from polythionic acids.

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8 Headers (4)

8.1 General (4.1)

8.1.3 Add
a. 90 degree or 180 degree bends in furnace coils, whether cast, formed, or forged, shall be
one piece seamless.
b. Other cast or forged fittings shall be one piece seamless or fabricated from standard forged
seamless fittings, as BP approved.
c. Formed and forged bends shall comply with ASME B16.9 or ASME B16.11.

8.2 Plug headers (4.2)

8.2.3 Add
a. Heater tubes for crude duty, vacuum duty, and thermal cracking duty may have, if
applicable, plug type headers installed at ends of selected tubes, even if steam air decoking
facilities are used.
b. Pigging
1. Pigging is the preferred technique for internal tube surfaces cleaning.
2. Pigging requires nozzles for pig access to tubes.
3. Position, type, and number of plug type headers and/or nozzles for pig access are
subject to BP approval.
Sometimes internal tube surface inspection may be required in heaters with coking
duties. It is suggested that 2 or 3 plugs be installed in each process pass if coke
laydown or tube corrosion/erosion is expected (shield tubes and tubes where
vapourisation begins). Positions should be discussed and agreed upon with BP and
Vendor.
c. If pigging is mechanical cleaning method, contoured plugs are required. Contoured plug
top must be clearly marked to ensure proper orientation.
8.2.8 Add
a. Dimensions of tube seat shall conform to details shown in API Std 560 Table 1 for tube
wall thickness within limits shown.
b. Dimensions for tube walls thinner or thicker than shown in Table 1 are not within scope of
API Std 560.

8.3 Return bends (4.3)

8.3.1 Add
d. If pigging is mechanical cleaning method.

8.4 Materials (4.4)

8.4.1 Add
Carbon - 1/2% Mo materials shall not be used.

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9 Piping, terminals and manifolds (5)

9.1 General (5.1)

Add
9.1.9 a. Unless approved by BP in writing, manifolds shall have extruded instead of welded in
stubs.
b. If extruded manifolds are carbon steel, stress relieving shall be used.
c. If manifolds are stainless steel, solution annealing shall be used.

9.2.1 Allowable movement and loads

The allowable loads for fired heater terminals specified in Table 6 are extremely
limiting. These values are intended to optimise around the heater design. Heater
vendor and piping designer maybe able to specify higher allowable moments and
forces on the fired heater terminal that may result in lower overall cost of
installation.

9.3 Materials (5.3)

Add
a. Bolting shall be compatible with flange material with respect to thermal expansion
characteristic.
b. For duties above 650°C (1 200°F), bolting shall be subject to BP approval.
c. Attachments, clips, lugs, and guides welded to radiant or convection tubes shall be same
material as tube.

10 Tube supports (6)

10.1 General (6.1)

10.1.1 Add
e. Radiant tube supports shall be replaceable without removing the tubes, with the exception
of helical coil supports, where their method of replacement shall be subject to BP approval.
10.1.2 Add
Method of replacement of helical coil supports shall be subject to BP approval.

Add

10.1.7 Tube supports and guides

a. Vertical tubes shall be supported from top and shall have guide supports at bottom end.
b. Intermediate tube guide supports for vertical tubes shall have spacing of 50 outside tube
diameters, except that maximum spacing between guides or guides and end supports shall
not exceed 7,6 m (25 ft).
c. Convection section end tube supports and intermediate tube supports (where applicable)
shall have provision to accommodate two additional rows of tubes
d. Vendor shall include cost adder for including intermediate tube supports for two additional
rows of convection tubes required in this paragraph.

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10.1.8 Sleeves
a. Stainless steel sleeves shall be attached and filled with refractory for the provision of the
two additional tube rows stated in section 10.1.7.
b. Structural end wall plate shall be partially cut to indicate position of sleeves.

10.1.9 Insulated tube supports

Insulated tube supports shall not be used unless approved by BP.
Insulation can fall off the tube supports. Insulation could be used on existing heaters
where the alternative is expensive.

10.3 Materials (6.3)

Add
Alloy cast iron materials shall not be used.

11 Refractories and insulation (7)

11.1 General (7.1)

Add
Design and selection of heater lining systems shall comply with GP 72-00
a. Refractory material type shall be selected using GIS 72-001 or per data sheet when it is
specified by BP.
b. Refractory materials procurement shall be per GIS 72-001
c. Details of refractory installation, including engineering drawings, shall be per GIS 72-002
and is subject to BP approval.
The following additional requirements for anchoring systems shall apply:
a. Ceramic fibre module hardware shall be ASTM Type 304 stainless steel or higher alloy
material that will provide better performance for intended service, unless approval of other
materials is obtained from BP.
b. Fully solution annealed anchors shall be used for:
1. Cast vibrated refractory applications.
2. Equipment known to damage refractory lining systems with vibration.
c. For process temperatures up to 815°C (1 500°F) in an oxidizing environment, anchors may
be ASTM Type 304 stainless steel.
d. For process temperatures up to 982°C (1 800°F) in an oxidizing environment, anchors may
be ASTM Type 310 stainless steel.
e. For process temperatures up to 1 150°C (2 100°F) in an oxidizing environment, anchors
may be Inconel 601.
f. For process temperatures above 1 150°C (2 100°F), anchors shall be ceramic type.
11.1.1 Add
Consider selecting a design temperature of the outside casing surface of the radiant
and convection sections of 65°C (149°F) at an ambient temperature of 15°C (60°F)
in still air.
The 65°C (149°F) casing temperature has been established for personnel protection
reasons. If personnel protection is provided or the casing is not accessible during

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normal operation, then this casing temperature can be increased provided there is
economic justification for the increased heat losses, e.g. the ducting downstream of
the heater or air preheater to the stack.
For most of the heater casings the 65°C (149°F) temperature limitation is not a
problem but there could be difficulties on the roof and floor. Obviously the casing
temperature can be increased downstream of the heat exchanger where the furnace
efficiency is not affected, provided the casing cannot be touched during normal
operation.
The Vendor/Contractor should ensure that the paintwork on the casing is suitable
for the maximum temperature that the casing can attain (with still air and the
maximum ambient air temperature).

Add

11.1.11 Dry-out
Heater lining dry-out procedure shall be per GIS 72-003.
Vendor may propose an alternate dry-out procedure if the requirements of GIS 72-003 cannot be
met. Alternate refractory dry-out procedure shall be subject to BP approval.

11.2 Brick and tile construction (7.2)

Brick linings should be only specified if unusual service conditions, such as in areas
where ceramic bonded products are necessary to withstand environmental and
mechanical condition of the equipment, which preclude use of ceramic fibre linings
and castables.
Add
a. If dewpoint corrosion may be present, casings and steelwork behind refractory bricks shall
be protected by anticorrosion coating compound.
b. Corrosion coating shall be subject to BP approval.

Add

11.2.10 Brick lining material

Brick lining material selection shall comply with GIS 72-001, Table 4, for Firebrick Linings and
Table 5, for Insulating Firebrick (IFB) Linings.

11.3 Castable construction (7.3)

Add
Castables shall be used primarily in stacks, convective sections, and similar areas where
strength and durability are essential.
Refer to GP 72-00 for material selection, requirements, and details for use of
castable refractory linings and anchoring systems.
11.3.1 Modify to read
a. Proprietary castable refractories instead of field mix Luminite-haydite-vermiculite (LHV)
mixes, shall be required for applications above 540°C (1 000°F).
b. Field mixes are acceptable from 540°C (1 000°F) and below with BP approval.
c. Castable refractories should be selected from Table 1 of GIS 72-001 unless BP approval of
other materials is obtained.

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d. For furnaces, fired heaters, stacks, and ducting, categories selected shall be AC-10, AC-11,
AC-14, or AC-15.
e. For Reforming furnaces categories selected shall be AC-18 or AC-19.
11.3.9 Add
Stainless steel fibres shall be type 304 unless BP approval for substitute materials is obtained.
The stainless steel fibres provide an element of structural integrity to thin layer
linings where independent anchoring is utilized. The fibres act as reinforcing that
improves mechanical integrity when cracking is evident. The fibres do not improve
other physical properties of the refractory lining. In most instances the compressive
strength is slightly reduced when stainless steel fibres are used.
Use of premix castables with metallic fibres should be avoided. Metallic fibres tend
to segregate within the mix before use. Adding fibre to premix castable prior
application is preferred option.

Add
11.3.11
a. Impervious organic coating shall be applied immediately after castable placement and
reapplication of same coating shortly after 24 hr cure to reduce tendency of hydraulic
setting castables to develop alkaline hydrolysis.
b. If alkaline hydrolysis has occurred, loss in refractory thickness is usually less than 10 mm
(3/8 in). If this occurs, loose material shall be brushed off and impervious organic coating
applied.
Hydraulic setting castables, in particular lightweight and medium weight insulating
castables, are susceptible to development of alkaline hydrolysis (carbonization) if
placed under high ambient temperatures and/or high humidity conditions shortly
after placement.
Use of forced drying by air movement or low temperature to remove a percent of
mechanical water prior to application of impervious coating can further reduce
possibility of development of alkaline hydrolysis. Alkaline hydrolysis is a naturally
occurring phenomenon such that use of either or both of above procedures may not
entirely prevent formation.

11.4 Ceramic fibre construction (7.4)

11.4.1 Modify to Read
Ceramic fibre, which includes refractory ceramic fibres (RCF) and soluble ceramic fibre linings,
in layered or modular construction may be used in all heater areas except stacks, ducts and
floors.
a. RCF materials shall be selected from Table 3A of GIS 72-001 unless BP approval of other
materials is obtained.
b. RCF linings shall be limited to the temperatures shown in Table 1.

Table 1 - RCF temperature limits

Hot Face
Product Form Manufacturer’s Fiber Temperature Rating
2 300°F 2 600°F
Blanket 1 400°F N/A
3
Module, not folded, 10 lb/ft min. 1 800°F 2 000°F
3
Module, folded, 9,3 lb/ft min. 1 900°F 2 200°F

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c. Soluble ceramic fibre, also known as Alkaline Earth Silicate Wool, linings shall be
selected from Table 3B of GIS 72-001.
Manufacturers of RCF have developed an alternative to refractory ceramic fibres
called soluble ceramic fibre linings. This fibrous product, which is made with
alkaline earth silicates, does not contain aluminium oxide and has proved to
dissolve in body fluids of the lung. This fibre material is considered safer for use
than RCF materials and each facility is encouraged to research this material with
the manufacturers, for possible applications, to ensure that the work force is
adequately protected.
d. Soluble ceramic fibre linings shall be limited to the temperatures shown in Table 2.

Table 2 - Soluble Ceramic Fibre temperature limits

Hot Face
Product Form Manufacturer’s Fiber Temperature
Rating
980°C (1 800°F)
Blanket 760°C (1 400°F)
Module, not folded N/A
Module, folded or stacked 815°C (1 500°F)

e. Soluble ceramic fibre products should not be exposed to long term flame impingement.
Very short flame impingement will not cause significant damage, but long term
flame impingement will cause sufficient damage that could lead to hot spots and
maintenance requirements.
11.4.3 Add
Ceramic fibre exposed to direct heat shall be rated for 1 200°C (2 200°F) service, minimum.
11.4.17 Modify to read
When the fuel contains ≥ 0,5% (mass) sulfur, the following applies:
a. A protective coating to prevent acid corrosion shall to be applied to the casing.
When sulfur containing fuel is used to fire the heater the casing surface beneath the
fire protection material may be less than the condensation temperature of sulfuric
acid, a byproduct of the combustion process. Acid corrosion of the steel heater
casing will be the result. An appropriate coating can eliminate this threat.
b. Castable materials shall have a total concentration of free alkali, MgO, and iron in the
aggregate of less than 15%.
c. The “facing” of a castable or brick lining shall be “medium weight” or heavier.
d. Block insulation shall not be used when fuel sulphur content exceeds 1%.
e. When a ceramic fiber blanket is used with fuel with sulphur contents exceeding 10 ppm a
casing coating shall be applied to prevent corrosion.
f. When a ceramic fibre lining is used, fuel with ≥ 0,5% sulfur/H2S shall have a stainless
vapour barrier, 50 µm (2 mil), and casing coating. The vapour barrier shall be located
between blanket layers. The foil interface temperature shall be 55°C (100°F) above the gas
condensation temperature.
g. Surfaces to which a shell coating is to be applied for corrosion protection shall be grit
blasted to a near-white finish (SSPC-SP10).

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h. Acceptable shell coatings are coal tar epoxy or silicone acrylic copolymer. Shell coatings
service temperatures shall be a minimum of 28°C (50°F) above the calculated temperature
of the shell.
Table 3 below summarizes casing coating requirements.

Table 3 - Casing coating requirements based on sulfur content of fuel

> 10 ppm ≥ 0,5 wt%

< 10 ppm ≥ 1,0 wt%
< 0,5 wt% < 1,0 wt%
Brick/ No coating No coating Casing coating Do not use Brick/
Block required required required Block
(clause 11.4.17.a) (clause 11.4.17.d)
Ceramic No coating Casing coating Casing coating Casing coating
Fiber required required required plus required plus
(clause 11.4.17.e) vapour barrier vapour barrier
(clause 11.4.17.f) (clause 11.4.17.f)
Castable No coating No coating Casing coating Casing coating
required required required required
(clause 11.4.17.a) (clause 11.4.17.a)

11.4.20 Add
a. If high velocity jets are used, 14 gage 300 series SS blast shields shall be used over fibre
linings exposed to jets.
b. Shield design shall be of specified construction of 460 mm (18 in) by 460 mm (18 in)
panels with 4 anchors each.
c. If sootblowers or other high velocity jets are used in convection section and blast shields
cannot be used over fibre linings, castables shall be specified for entire convection section.

11.5 Multicomponent lining construction (7.5)

11.5.7 Add
Block insulation shall not be used as backup material for ceramic fibre linings.

11.6 Materials (7.6)

Modify to read
a. Refractory shall be obtained in accordance with GIS°72-001.
b. Refractory shall be specified using category designations from Tables 1 through 6 of
GIS°72-001.
c. High early strength Portland cement designated as calcium silicate cement Type I-V shall
not be used.

12 Structures and appurtenances (8)

12.1 General (8.1)

12.1.1 Add
For fired heaters built in accordance with API Std 560, the following design codes shall apply:
a. ICBO Uniform Building Code.
b. AISC Specification for Design, Fabrication, and Erection of Structural Steel for Buildings.
c. ASCE 7, Latest Edition.
d. Local codes as specified by BP.

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13 Stacks, ducts and breeching (9)

13.1 General (9.1)

Add
a. If heater design is based on API Std 560, stacks, ducts, and breaching shall be designed in
accordance with Section 9.
b. Stack draft shall overcome gas friction loss in convection section, burner, and stack.
c. Stacks may be either free standing or mounted on heater.
Stack shall be designed to provide minimum draft of 0,25 mbar (0,1 in water) at all points in
heater under all maximum burner design and firing conditions, with 25% of extended
surface of convection section plugged.
BP requires that if minimum stack efflux velocity is not specified by statutory
authorities, minimum exit area from stack shall be such to give minimum flue gas
exit velocity of 9 m/s (30 ft/s) if all units connected to stack are at 100% design
loads at design excess air.

13.2 Design considerations (9.2)

Add
a. Free standing stacks shall be fitted with drain connection of not less than 50 mm (2 in)
diameter.
b. Inlet air plenum dampers should not be used instead of draught control dampers on units
with tall stacks (greater than 10 m [33 ft] high) or if heaters are used for continuous
operation over long periods (high draught can result in burner instability and air in
leakage).
c. At least two conductors or bonds shall be spaced equally around perimeter and across each
flanged joint to provide adequate continuity for lightning protection.
d. Specific lightning conductor provisions are not required on welded steel stacks.
e. Earthing of structure, and if used, guy lines, shall be as recommended by BS 6651 or
equivalent national standards.
13.2.6 Add
a. Flue gas ducting shall be arranged above grade level and supported and anchored such that
freedom of movement for thermal expansion and contraction is permitted.
b. If main entry to ducting is necessary for cleaning/maintenance activities, ducting shall be
externally ribbed to provide required loading bearing capacity in event of low temperature
corrosion of duct sheeting.
13.2.7 Add
If combustion gases may form acid, top 10 m (33 ft) of stack internal lining or stack steel
section shall be of acid resistant material.
13.2.8 Add
a. Lining
1. Unless otherwise approved by BP, stacks, ducts, and breeching shall be lined
throughout (except in conditions noted below).
2. Lining shall be capable of withstanding, without damage, temperatures of 540°C
(1000°F), or temperature 165°C (300°F) above normal maximum operating flue gas

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temperature, whichever is greater, and of being raised from cold to design operating
temperature at rate of 55°C (100°F) per hr.
3. Specific attention shall also be given to possibility of low temperature conditions, in
particular, below acid dew point level, and possible effects of resultant condensation
within stack.
b. If operating conditions are such that unlined stack appears suitable, proposals may be
submitted and shall be subject to BP approval.
c. Unlined stacks should only be considered/installed if:
1. Process in tubes is noncombustible (e.g., steam superheaters or inert gas heaters).
2. Stacks are very short and easily replaced, e.g., grade mounted stacks about 15 m
(50 ft) high.
3. Reason for internally lining stack is in response to possibility of damage from heater
fire.
13.2.12 Modify to read
Breeching located over horizontal convection zones shall have at least 1 take-off for every 9,1 m
(30 ft) length of convection section.
13.2.15 Add
Steel stacks shall have corrosion allowance appropriate to 20 yr design life.

14 Burners and auxiliary equipment (10)

14.1 Burners (10.1)

Add
a. If specified by BP, burner shall be equipped to burn, in addition to main fuels, waste gas.
b. Quantity, composition, and condition will be specified by BP.
14.1.2 Add
BP will specify limits, statutory or local, on stack emission of particulates, NOx, SOx, CO, and
hydrocarbons.
14.1.9 Modify to read
a. Unless otherwise approved by BP, each burner shall have continuously operating fixed gas
pilot arranged to light all fuels, and if practical, waste gas supplied to main burners.
b. Pilots shall be easily visible in normal operation and be sized to remain lit under all
practical heater draught and pressure conditions.
c. Each gas pilot shall have its own igniter port independent of any viewing ports.
d. Igniter ports shall be freely accessible and suitable for portable electric igniters.
14.1.17 Add
Forced draught burners shall have out of ratio turndown of at least 4:l.
14.1.18 Add
Liquid guns shall discharge within ±2.5% of required flow at design heat liberation operating
pressure and shall be flow tested under conditions discussed and agreed upon with BP.

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14.1.19
BP may specify use of fuel gas or compressed air as substitute for steam as an
atomizing medium.
14.1.20 Add
If liquid fuels are specified to be burned, use of safety interlocking mechanism shall be
considered to ensure that:
a. Liquid fuel gun cannot be withdrawn until supply of liquid fuel and atomizing medium
have been turned off.
b. Liquid fuel and atomizing medium cannot be turned on with liquid gun withdrawn.
c. Liquid fuel cannot be turned on before atomizing medium.
d. Atomizing medium cannot be turned off before liquid fuel.
14.1.22 Add
a. Burner, but excluding any refractory parts located in or attached to heater floor or wall,
shall be suitable for being removed and replaced on process heater while other burners
remain in operation.
b. For dual fuel burners, burner shall be suitable for firing on one fuel with liquid fuel gun or
gas guns for other fuel removed.

Add

14.1.23 Flame Scanners

a. When specified by BP burner shall have nozzle(s) to allow mounting of flame scanner(s).
b. For burners required to fire with both flame failure and permanent pilot, two positions are
required, one for viewing pilot only and other for main flame only.
c. For upfired heaters, it is acceptable to view main flame from side of furnace, as debris in
burner sight tubes may obscure view of flames. As alternative, air purge can be provided
for scanners mounted on burner.

14.1.24 Louvers
a. Combustion air louvers in burner register shall have control handle and be capable of being
locked in position.
b. Louver (damper) spindle bearings shall be capable of being lubricated to ensure continuing
operation.

14.1.25 Burner front plate

a. For burners firing liquid fuel, burner front plate that is located in outside wall of plenum
shall be covered with minimum 25 mm (1 in) of hard refractory (not mineral wool).
b. For upfired burners, burner front plate shall have steel rim that extends 25 mm (1 in) above
refractory to prevent leakage of drips of liquid fuel into mineral wool lining of surrounding
plenum chamber.

14.1.26 Information required

a. Minimum information required from Vendor with offer is as follows:
1. Burner general arrangement drawings.

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2. For forced draught burner application, combustion air ducting arrangement drawings
and calculations to confirm that not more than 10% combustion air misdistribution,
measured within burner throat shall be present.
3. Pilot drawing.
4. Materials of construction.
5. Performance curves showing burner heat liberation for all specified fuels as function
of fuel pressure, atomizing medium pressure, and atomizing medium consumption.
6. Estimate for particulates, NOx, SOx, CO, and hydrocarbons emissions in products of
combustion for specified fuels.
7. Estimate on burner noise levels.
b. Data to be provided as part of burner supply include:
1. Final dimensioned general arrangement drawings with details on vital components,
materials of construction, and burner tip drilling information.
2. Test certificates for materials of construction for burner components.
3. Report on burner acceptance test.
4. Final burner heat release curve for specified fuel(s).
5. Installation, operating, and maintenance instructions.
6. Recommended spare parts with price list.

14.1.27 Burner testing

a. Unless alternative procedure is agreed upon with BP, acceptability of burner performance
shall have been demonstrated by witnessed type testing.
Burner test is normally performed on Vendor test rig, which must be representative
of proposed application in terms of thermal and aerodynamic characteristics.
b. Test program (test protocol) shall be developed and executed to confirm that burner meets
all the requirements.
The test procedure and the test by itself are fairly lengthy and costly.
c. Sometimes an abbreviated test program can be agreed upon.
d. The following are minimum requirements associated with burner performance testing:
1. Test requirements and measurements shall be determined and included in test
program for burning range and any combination of fuels specified by BP for
particular application.
2. If not already included in fuels specified for particular application, BP may specify
any of the following additional test fuels:
a) Light distillate oil (for oil firing).
b) Residual fuel oil of at least 360 centistokes at 50°C (120°F) (for oil firing).
c) Gas of agreed quality (normally mix of natural gas, propane, or butane).
d) Mixes of natural gas, propane, or butane with hydrogen.
3. Methods and equipment used for all measurements, including flue gas analysis during
tests, shall be subject to BP approval.
4. Test requirements shall include (other than out of ratio turndown flame stability test)
all fuels over heat liberation range of 33% to 110% of burner design heat liberation.
Test shall be performed at following excess air conditions:

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a) Range 33% to 60% of design heat liberation at 30% and 50% excess air (all
fuels).
b) Range 60% to 110% of burner design heat liberation at 15% excess air (oil
firing), 10% excess air (gas firing), 15% excess air (all fuels), and 50% excess
air (all fuels).
c) Test to be performed on each fuel burned to determine maximum turndown that
can be achieved with satisfactory and stable combustion.
d) Test to be performed using combustion air at ambient temperature and
additionally, if BP specified, air preheated to nominated temperature.
5. Flame envelope
a) Flame envelope shall be determined during test.
b) Envelope limits could be judged by visual inspection (as minimum) or by
performing CO test by inserting sample probe along flame height and width.
c) CO content of less than 100 ppm is considered as boundary of flame envelope.
6. Stack emissions test of particulates, NOx, SOx, CO, and hydrocarbons shall be within
BP specified limits.
7. Gas pilot test shall be performed during main burner test. Pilot should exhibit stable
flame at gas design operating pressure ±40%, and over entire main burner operating
test range.
8. Pilot shall be able to ignite main burner smoothly and safely for all specified fuels at
all design heat releases and design draught conditions.
9. Burner shall be tested for out of ratio turndown flame stability on all fuels to
determine maximum safe turndown of a fuel with draught at burner remaining
constant. The following test procedure conditions may be considered:
a) Burner air louvers set fully open and drought set to provide 45% excess air at
110% of burner design heat liberation.
b) With same drought maintained at burner, flow of selected fuel to be reduced
until first signs of flame instability occur. This fuel flow and corresponding
excess air shall be recorded.
c) If testing flame stability for combination burners firing fuel gas only, test should
be performed with atomizing medium for liquid fuel gun both “on” and “off”.
d) To ensure flame remains stable at full liberation and at turndown, test to reduce
combustion air until burner is firing close to or substoichiometric should be
conducted or considered.
e. Limitation of burner as determined by test shall be included in burner operating instruction
(operating envelopes) and setting burner operating limits, trips, and alarms.

14.2 Sootblowers (10.2)

Add

14.2.7 Local sootblowing panel

a. Local sootblowing panel shall have:
1. Master switch for sootblowing sequence operation and switches for individual
operation or for bypassing of sootblowers in sequence.
2. Indicating lamps showing operation of each sootblower.

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3. Automatic control of sootblower steam master valve.

4. Interlock to prevent sootblower operation until piping has reached preset temperature,
with lamp to show “drainage complete”.
5. Alarm if sootblower has not retracted within stipulated time.
6. Retraction of sootblower on low steam pressure or overload condition.
b. Buildup of condensate in supply lines shall be avoided by provision of adequate automatic
drains and warming through connections.

14.4 Dampers and damper controls (10.3)

Add
a. Dampers
1. If necessary, dampers shall be provided for control, isolating, and bypass purposes.
2. Isolating plates shall be provided if access is needed for maintenance and inspection
of heaters or heater ancillaries (e.g., air preheater, waste heat boilers) while heater or
heaters that are connected to common flue gas duct or stack continue to operate.
3. Isolating plates, if provided, shall be positioned as close to common flue duct as
practical.
4. If number of flue gas ducts are directly connected to common stack, isolating plates
shall also be provided as close to stack as possible for each duct entry.
b. Flue gas bypass dampers
1. Flue gas bypass dampers, if provided, shall have zero (or an acceptably low)
guaranteed leakage rate under normal operating conditions (i.e., closed).
2. If necessary, bypass dampers shall be quick acting to protect uncooled boiler tubes
and allow for induced draught fan failure.
14.4.2 Add
a. Flue duct and stack dampers used to control furnace draught shall be contra rotating multi
louvre type, set in channel frame, and have position indicators visible from operating
position at grade.
b. Special attention shall be given to blade clearances in frame and adjacent ducting under
operating conditions.
14.4.4 Add
a. Damper shafts shall be supported in self aligning bearings, grease packed or otherwise
lubricated and sealed, suitable for high temperature and located in external pillow blocks.
b. Adequate allowance shall be made for relative expansion of components.
c. For reasons of energy conservation, air cooled shafts where air enters flue gas duct shall be
avoided.
d. Calculations for relative expansion of components shall be submitted for BP review.
14.4.7 Modify to read
a. Operating mechanism
1. Provision shall be made for furnace draught control dampers to be individually
operable by hand from grade level (even if automatic damper operation is fitted).
2. Mechanism shall be arranged to lock in any position.

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3. Operating mechanism shall give positive drive in both opening and closing directions
but shall be counterbalanced to fail in open position.
4. Cable operated mechanisms shall have adequate tensioning devices.
b. Limit stops shall be installed on all control dampers. These stops shall:
1. Prevent complete closure of dampers.
2. Prevent damper blades exceeding their fully open positions.
c. Type (fixed or variable) and position of these stops shall be agreed upon with BP.

15 Instrument and auxiliary connections (12)

Add
a. Instruments may be from Vendor or BP.
b. Data sheet for mechanical design of heater shall provide Vendor with list of instruments
meeting project requirements.
15.1.1.5 Add
Connections shall be provided in common burner ducting of each burner group.

15.3 Auxiliary connections (12.3)

15.3.2 Vent and drain connections

Add
15.3.2.4 If reverse steam air decoking is intended, additional skin thermocouples shall be installed in
each pass on one of the shock tubes.

15.4 Tube skin thermocouples (12.4)

15.4.1 Add
a. Radiant coil tube skin metal thermocouples
1. Radiant coil tube skin metal thermocouples shall be fabricated, attached, and tested.
2. Fired reboilers and all heaters on duties where coking may be expected shall have at
least two skin thermocouples per pass.
3. Other heaters shall have skin thermocouples on selected passes.
4. Thermocouples shall be positioned where maximum metal temperatures are
anticipated and shall be subject to BP approval.
b. Casing connection
1. Casing connection shall be DN 40 (1-1/2 NPS), Class 3000 screwed forged steel
coupling welded to casing plate.
2. Opening in refractory shall be lined with schedule 80 pipe of material suitable for
operating temperature.
3. Each coupling shall have hex head forged steel screwed plug.
c. Tube metal temperatures on cracking and reforming furnaces with cast tubes shall be
measured by portable pyrometers. Skin thermocouples should be avoided.
d. If heater coils are installed in casings prior to shipment to site, all applicable tube skin
thermocouples shall also be fully installed.

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16 Shop fabrication and field erection (13)

16.1 General (13.1)

16.1.1 Add
a. Transportation
1. Vendor shall be responsible for adequacy of provisions employed when handled by
commercial carrier systems.
2. Load out
a) Load out of equipment from manufacturer facility shall be performed under
supervision of BP representative.
b) Responsibility for load out remains with Vendor.
c) Vendor shall load out, tie down, and secure equipment on Vendor furnished
transport.
3. Vendor shall be responsible for transport to BP designated receiving location.
Removal from transport upon arrival at designated receiving location shall be by BP
and designated agent.
b. After hydrostatic test, Vendor shall lubricate plug, plug seating surface, and threaded parts
of plug type return bends with antirust, antiseize lubricant.
c. Threads of bolts shall be heavily coated with metallic base waterproof lubricant.
d. Shop lined castable refractory sections shall be prepared for shipment in such a manner to
allow good air circulation during entire shipping and storage periods to minimize tendency
for alkali hydrolysis. Use of shrink wrap (airtight packaging) coverings shall be avoided.
e. For shop lined fibre refractory sections, shrink wrapping of lined sections is required.
f. Maximum number of shop lined sections that can be stacked and orientation of sections for
shipping and storage on drawings shall be identified by Vendor.
g. Loose items
1. Loose items, such as rods, turnbuckles, clevises, bolts, nuts, and washers, shall be
shipped in bags, kegs, or crates.
2. Bags, kegs, or crates shall be tagged with size, diameter, and length of contents such
that tags for each item are individually identifiable.
3. Tags used for marking shall be metal and markings shall be applied by stamping.
h. Openings shall be suitably protected to prevent damage and possible entry of water and
other foreign material.
i. Connections that are beveled for welding shall be suitably covered to protect bevel from
damage.
j. Exposed ferrous surfaces not otherwise coated shall be given one coat of Vendor standard
shop primer. Additional painting requirements will be specified by BP.
k. Item number, shipping weight, and BP order number shall be painted on heater and loose
components.
l. Boxes, crates, or packages shall be identified with BP order number and equipment item
number.
m. Stencil “DO NOT WELD” (in two places 180 degrees apart, as minimum) on equipment
that has been post weld heat treated.
n. Tubes shall be free of foreign material prior to shipment.

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o. Extent of skidding, boxing, crating, or coating for export shipment will be specified by BP.
p. Long term storage requirements will be specified by BP.
q. Vendor shall be solely responsible for adequacy of equipment preservation provision
employed with respect to materials application.
r. Equipment preservation shall be suitable for at least 18 months of outdoor storage.

Add
16.1.6
a. Materials furnished shall comply with materials requirements, including tolerances (if
any), and shown in specification documents.
b. If BP inspector finds materials or finished product in which materials used or work
performed is not in compliance with specifications, work or materials shall be removed or
otherwise corrected by Vendor at Vendor’s expense.

16.2 Structural steel fabrication (13.2)

16.2.1 Add
r. Components to be connected together at site by either welding or bolting (e.g., radiant and
convection sections, stacks, platforms) shall preferably be shop fitted (trial erected) prior to
delivery.
s. If such components cannot be shop fitted, template shop fitting shall be performed.
t. Fitup procedures shall be documented and witnessed by BP inspector.

16.3 Coil fabrication (13.3)

Add
Welded coil sections for field installation shall be shop fabricated in largest possible section to
minimize field welding.

16.5 Refractories and insulation (13.5)

Add
Refractory shop and erection requirements shall comply with GIS 72-003.

16.6 Field erection (13.7)

Add
Refractory field erection requirements shall comply with GIS 72-003.

17 Inspection, examination and testing (14)

17.1 General (14.1)

Add
a. Required inspection and testing shall be provided. BP inspection and testing can be
provided as audit.
b. Approved office space for use by BP inspectors shall be provided. Such office space shall
be located at Vendor facility where fired heater components are fabricated and assembled.
c. Inspection or observation of work performed by BP or its representative does not relieve
Vendor of obligation to meet all specification requirements for scope of work.

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d. Adequate safety measures shall be provided and maintained at all times during
development and execution of project.
e. BP shall be notified 7 working days prior to hydrotesting and functional testing.

17.2 Weld examination (14.2)

17.2.2 Add
a. Inspection of stack welding shall include one radiograph of each junction and one
intermediate shot of all longitudinal welds.
b. Cost of radiographs shall be included in contract price.
c. Radiograph films shall be properly identified and shall be subject to BP approval.
d. Minimum film length shall be 250 mm (10 in.)

Add
17.2.6 a. BP reserves right to require Vendor to remove sections containing completed welds or any
portion of finished weld and prepare specimens and deliver such specimens to BP for
testing.
b. Costs in a. will be borne by BP.
c. Repairs required by test results not meeting specifications shall be charged to Vendor
account.
d. BP reserves right to use destructive testing methods.

17.3 Castings examination (14.3)

17.3.2 Add
d. Testing
1. Testing shall be performed in accordance with ASTM E 165 and ASTM A 407.
2. Acceptance levels shall be specified in accordance with E 433 for type and class.
3. Surface defects and linear discontinuities shall meet requirements specified in ASME
BPVC Sec VIII, Div 1, Appendix 7.
4. Unacceptable defects shall be removed.
5. Removal shall be verified by liquid penetrant examination.
6. Defects
a) Defects shall be considered major if depth of cavity, after preparation for repair,
exceeds 20 % of section thickness or if cavity exceeds 250 mm (10 in) in length.
b) All other defects shall be considered minor.
c) Minor defects may be repaired by welding.
d) Major defects require resolution with BP.
e. The following scope of radiographic examination is required for critical areas of each
convection section support:
1. Include highly tensioned locations, bearing corners, etc.
2. Critical areas shall be defined by heater Vendor and shall be subject to BP approval.
3. ASTM E 446 method of radiographic examination shall be used for castings up to
50 mm (2 in) thick.

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4. ASTM E 186 shall be used for heavy walled castings from 50 mm (2 in) to 115 mm
(4-1/2 in) thick.
f. Severity level for each category shall be as follows:
1. Category A - Gas porosity: level 3.
2. Category B - Sand and slag inclusions: level 3.
3. Category C - Shrinkage, all four types: level 2.
4. Category D - Crack: none.
5. Category E - Hot tear: none.
g. Defects may be repaired by welding. Weld repairs shall be made using welding procedures
approved by BP and operators qualified in accordance with ASME BPVC Sec IX.

17.4 Examination of other components (14.4)

17.4.2 Add
Refractory linings shall be examined in accordance with GIS 72-002 and GIS 72-003.

Add
17.4.7 Lifting lug welds shall be examined 100% by liquid penetration and magnetic particle test.

17.5 Testing (14.5)

17.5.1 Pressure testing

17.5.1.1 Add
c. For coils with headers and removable plugs, pressure test shall be twice maximum process
inlet pressure or 1.5 times decoking steam inlet pressure, whichever is greater.
d. Flange rating requirements shall not be exceeded at test temperature.
e. Yield stress of inlet and outlet header manifolds shall not be exceeded at test temperature.
f. Soap test
1. Cast iron air preheater tubes shall be soap tested to check on soundness of casting and
lack of porosity.
2. Assembly shall be pressurized to 1-1/2 times design pressure and coated with
soap/water solution.
3. More than three separate leaks in one casting prior to attempt to make repairs, shall be
cause to reject casting.
g. Test pressure shall be applied to vent all possible air from tubes.
h. No drop in pressure or leaks shall be permitted except pressure drop due to incidental
temperature change.
i. Hydrotest shall be repeated after completion of any repairs.
17.5.1.3 Add
a. If not possible to test with water containing less than 50 ppm chloride, normal mains water
may be used with the addition of 0.5% solution of sodium nitrate.
b. Pressure parts shall be thoroughly washed with water containing less than 30 ppm chloride
immediately after test and then thoroughly dried.

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17.5.1.4 Add
Heating shall not be used to evaporate water from austenitic stainless steel tubes.

17.5.2 Refractory testing

Add
Refractory linings shall be tested in accordance with GIS 72-002 and GIS 72-003.

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Annex A (Appendix A)
(Informative)
Equipment data sheets

Modify to read
Data sheets and instructions for use of data sheets are in DS 22-100.

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Annex B (Appendix B)
(Informative)
Purchaser’s checklist

Modify to read
Purchaser’s checklist is in DS 22-100.

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Annex C (Appendix C)
(Informative)
Proposed shop assembly conditions

Modify to read
Proposed shop assembly conditions section is in DS 22-100.

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Annex E
(Normative)
Centrifugal fans for fired heater systems

E.2. Design

E.2.1. General
E.2.1.2. Add
c. Fans shall be designed for optimum efficiency at normal heat release and design excess air
(normal operating points).
d. Forced draught (FD) fans shall be sized on combustion air flow requirements as defined in
6 of this GIS.
e. Induced draught (ID) fans shall be sized on flue gas quantities produced from combustion
airflow requirements as defined in 6 of this GIS.
f. Static head required for FD and ID fans shall be consistent with system losses at
combustion and flue gas quantities as defined above.
g. FD fans shall be capable of supplying sufficient air to burners such that heater can operate
at 100% design duty and design excess air with one burner not functioning.
h. Mechanical design temperature for ID fans shall be at least 56°C (100°F) above maximum
expected operating temperature under all conditions of furnace operation.
E.2.1.3. Add
Unless otherwise approved by BP, induced and forced draught fans and their drivers shall be
freely accessible for maintenance and mounted on foundation blocks separate from heater at or
near ground level.
E.2.1.15. Add
If forced draught is used, each heater shall have one forced draught fan with shutoff damper
downstream of fan.

E.2.5. Rotating elements

E.2.5.1. Add
d. Forced and induced draught fans should preferably be centrifugal flow type with backward
curved blades.
e. Radial blades shall be considered for induced draught fans if heaters fire residual fuel oils
or fuels with tendency to form fouling products.
f. For larger fan capacities, blades shall be aerofoil design.

E.3.2. Drivers
E.3.2.7. Add
Electric motor drivers shall comply with relevant requirements of GIS 12-201, GIS 12-202,
GIS 12-203 or GIS 12-204.

E.3.4.2. Control systems

E.3.4.2.2. Add
a. For fans driven by fixed speed drivers, control of total flow should be performed by
adjustable vanes in inlet to fan.

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b. Vanes shall fail open.

c. Discharge damper shall be supplied in addition to inlet vane controller in order to achieve
accurate control throughout entire operating range of heater.
E.3.4.2.8. Add
Fans shall have control room panel alarm to indicate operational failure, sensed on shaft on fan
side of driver coupling.

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Annex G (Appendix F, F.A., F.B., F.C., F.D., F.E., F.F.)

(Informative)
Measurement of thermal efficiency of fired process heaters

The contents of ISO 13705 Annex G and API Std 560 Appendix F.A-F.F cover the
same subjects. However, the subjects are differently organized in these documents.
User has an option to use methodology for measuring of thermal efficiency of fired
process heaters from either of these two documents

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Bibliography

American Petroleum Institute (API)

[1] RP 12K, Indirect-Type Oil Field Heaters.

[2] RP 12L, Indirect-Type Oil Field Heaters.

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