FIRED HEATER INSTALLATION PROCEDURE | METHOD STATEMENT

1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITY
5. WORK METHODOLOGY
6. SAFETY
7. ATTACHMENTS

1.0 PURPOSE

This Procedure / Method Statement shall provide minimum guidelines for installation of fired heater at buildings, plants and refineries.

2.0 SCOPE

This specification covers the minimum requirements for Erection of Fired Heater to be applied at buildings, plants and refineries.

3.0 REFERENCES

3.1 ARAMCO Project Specifications and Standard

3.1.1 SAEP-302 – Instruction for obtaining a waiver of a mandatory Saudi ARAMCO Engineering requirement.
3.1.2 SAES-H-101 Paint and Coating
3.1.3 Related Vendors Installation and maintenance manuals and /or specifications.
3.1.4 SATIP-F-001 Fired Heaters – Field Installation

3.2 Industry Codes and Standards:

3.2.1 AWS D1.1 Structural Welding Codes
3. 2.2 API 560 Fired Heaters for General Refinery Services

3.3 Latest Revision of the following Documents shall be used.

3.3.1 Vendor Drawings
3.3.2 Structural Drawings
3.3.3 Equipment Details

3.4 Saudi ARAMCO Safety, Health and Environmental Standard:

3.4.1 Construction safety manual – compliance with schedule D.
3.4.2 General Instructions (G. l’s) at the work site.

4.0 RESPONSIBILITY

4.1 Site Manager shall study, analyze and schedule all construction activities with his department to include, overall implementation of HSE procedure, manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. Study all aspects of work procedure as per technical Scope of Work.
4.2 Construction Manager shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with Safety Standard Procedure He shall discuss to the workers the characteristics of related materials and Status of work area giving reminders as an additional point to work safely.
4.3 Mechanical Superintendent/Supervisor shall study and review all necessary documents for the Erection works in his area to include, technical scope of work, specification, bill of quantities, planned milestone dates and construction procedure in support to his Mechanical Foreman. He shall monitor the availability of materials in accordance with the schedules and construction analysis. He shall be directly reporting to the Construction Manager. He shall coordinate with other discipline to visualize possible conflicts in the drawings as well as in the schedules to provide other options in preventing unnecessary delays and obstructions.
4.4 The Welding Supervisor and/or Foreman are solely responsible to ensure that all welding works are in conformance with applicable codes, standards, specifications and approved procedures.

4.5 Mechanical Foreman shall be responsible for the direct work supervision at site and the work is performed in accordance with JGC/DAEWOO Technical Scope of Work ensured that and latest approved for construction drawings. He shall monitor the availability of materials in line with his required schedule.
4.6 QC Inspector shall be responsible in monitoring and inspection of the work and ensured that the work is performed and properly documented in accordance with JGC/DAEWOO Technical Scope of Work and Standards.

4.7 HSE Manager shall monitor and ensure the effectiveness of the full implementation of HSE requirements of this activity.

5.0 FIRED HEATER INSTALLATION PROCEDURE | METHOD STATEMENT

5.1 Material Unloading and Storage

Materials arriving at site shall be carefully checked by the receiver in order to ascertain that they have not been damaged during land and sea transportation and that quantity and type correspond to what is indicated in the relevant Packing List.

Refractory materials are packed in bags and boxes both stowed on pallets and covered by plastic film. After unloading it shall be stored indoor in a dry storehouse, unless they have been shipped in containers; in this latter case, refractory materials can be kept therein up to the installation. Burners are packed in wooden cases. Packing should be suitable for storing in open area; it is suggested anyhow to put the equipment in a closed and protected storehouse for better conservation.

Radiant panels of the radiant box will be delivered in shop fabricated sections, complete with shop installed refractory anchors ready to be lined on site. Packing shall be suitable for storing in open area on transport frames, keeping the panels in the same position as per the transport; the frames and bracings used for the transport will be removed only when the panels will be handled for final installation.

The convection section shall be delivered in modules. Each module is provided with lifting lugs on top and bottom framing. The open top will be protected by corrugated plate. The modules are suitable for storage in open area. The framing on the bottom, provided for transport, will be unbolted and removed only before the site erection of the modules. The Stack is supplied in sections. Transition Duct and Convection section bottom shall be supplied in lined sections.

Radiant coils shall be fabricated in bundles. Crossovers and headers shall be delivered in spools to be welded on site. All Coil terminals shall be kept closed during the transportation and storage time. Radiant bundle fasteners used for transport shall be removed only when the radiant coils will be fully inserted inside the radiant box and suspended to the arch. Bolting materials, gaskets and other small items will be delivered in wooden boxes and shall be stored in a closed storehouse.

5.2 Check of Foundations

Foundation shall be checked on the basis of Approved for Construction (AFC) Drawings. Before the erection of the fired heater commence, the following shall be carefully checked:
o Fired heater orientation
o Elevation of basement foundations

o Anchor bolt location, number, projection and size
o Shear keys pockets depth dimensions

Be sure that anchor bolts have been properly erected and positioned. Do not start erection if anchor bolts are not in accordance with what is provided for in AFC drawing.

Set an elevation reference on each concrete basement in order to verify the right elevation of panel’s base plates to allow correct shimming and reach the required elevation of base plates. Note that non-shrink type of grouting shall be applied after the alignment inspection acceptance of radiant section panels, radiant floor panels, radiant coil, flue gas duct support structures and seal welding of radiant panels and before the installation of convection modules.

• Tolerance on Anchor Bolts Positioning

Base leveling shall be performed by placement of shims. Shims shall be sized and spaced in such a way as to support the structure according to the following requirements:
o A tolerance of ±3mm relative to the design elevation shall be adopted for the elevation. Tolerances on anchor bolts located in the same footing ±3mm within each column Anchor Bolts set.
o Shims shall be arranged close to anchor bolts, about 25mm away from their bodies and shall be totally contained within the support area.
o The maximum height of the padding plate (metal plus mortar) shall be 25mm above the design height.
o The minimum width of the padding plate shall be 50mm.
o The minimum length of the padding plate shall be 1 OOmm.
o After placing the base plate of the structure and padding plates, there shall be enough space for grouting.

5.3 Erection of Sequence

o Erection of radiant walls and floor panels

The Radiant Section is a single shell type. Panels shall be delivered packed in horizontal sandwiches with the internal surfaces positioned face to face to protect the anchors. Start to install the panel’s lower sections on columns selecting one of the four corners, place the panel with a common corner to allow more stability to this assembly when the two panels are bolted to each other.

During the panel’s installation apply only 30 percent of total bolts. Complete one four panel side and again install the panel that close the second corner. Install the two intermediate stanchions that support the floor panel columns and then install the floor central panel. Provide a temporary support at the free end of the panel.

Connect the floor central panel to the already installed panels to increase the stability of these walls and so on. When the radiant box panels are fully installed on three sides, install the remaining floor panel but always provide temporary support on the free side.

Complete the installation of vertical side on the last still open wall and always bolt the panels against the floor. Perform a full check for verticality and planarity and adjust where necessary.
Once the corrections have been performed, start to bolt the panels along the flanges and fully tighten the anchor bolt nuts.

Install a wind girder to ensure a higher stability during the installation of the upper section of each vertical panel. Always put a temporary bracing on every panel installed.
Once the panels are fully installed, perform a full check for verticality and planarity and adjust where necessary. After completion and acceptance of the verticality and planarity inspections, seal welding on the radiant section panels shall commence.

Protective coatings on all welding points shall be done by a qualified coating applicator and as per SAES-H-101. Inspection to be conducted by a qualified Paint Coating Inspector. Once the protective coating was done, place the ceramic fiber lining on vertical panels. Then, install radiant coil and arch panels respectively.

o Radiant Coil and Arch Panel Installation

Before lifting and installation of bundles, every support pin must be covered with ceramic paper kept in place with adhesive tape. The bundles will be inserted into the radiant box through still open arch and positioned it on hard wooden blocks laid down on the floor in correspondence with pipe rows.

The bundles shall be positioned at a very precise elevation corresponding to the final cold elevation of the coils as indicated on the AFC drawings. Provide steel shim on the wooden blocks if necessary to reach required elevation.

Keep in place the stiffeners (temporary support) which will be removed later when the arch panels will be fully installed and fixed on the radiant wall and the pins on the top return bends freely inserted through the sleeves in the slot cover plates. Install scaffolding or temporary structure to keep bundles in vertical position.

Scaffolding will help also to allow people to drive the top welded pin through the slot cover sleeves. After the installation of radiant coils and covers have been completed, a careful inspection shall be carried out in order to ensure that the tubes have been correctly installed and that they are free to expand when heated up without any obstacle.
It is now possible to complete the bolting of the arch panels and to perform general check of radiant box and to correct where necessary. Tighten all bolts after the correction.

Once inspections for bolting joint assembly for arch panel and coil elevation are properly check and done, coil to
coil welding shall commence. Refer again to coil drawing and refractory standard for details relevant to sealing of coil supports. After completion of coil to coil welding, install the fixing pin for coil support then removed the temporary support. o Radiant Arch Platforms and Stairs installation

Assembling of platforms shall be done as much as possible on the ground then lifted and installed at correct position on the fired heater.

Because of the anchoring system, grating panels could safer be installed after the platform frames have been fixed on the fired heater.

o Hot Flue Gas Duct (lower) and Bottom Support Structure for Convection Module Installation.

The duct panels for hot flue gas must be assembled on the ground. Refractory lining (Ceramic fiber bracket) for ducts to be installed on the ground. Once the assembly and installation of ceramic fiber bracket was done, it is now possible to install the Hot Flue Gas Duct. Carefully lift the Hot Flue Gas Duct and precisely place it onto the Radiant Arch.
After the completion of hot flue gas duct installation start to erect the bottom steelwork structure that will provide the support of Convection Section and Crossover coil.

Install the bottom support structure for convection module. It must be checked and inspected properly prior to installation of Convection Module. Check for verticality of columns and planarity of top flange and correct by shimming if necessary. After completion of the required requirement for verticality and planarity, install the convection module. After installation, proceed with the necessary inspection for acceptance and subsequent works.

o Erection of Convection Section

• The Convection Section is supported on a frame system in correspondence with columns (bottom support structure).
• First, install the bottom support structures on desired columns to allow the insertion of the Flue Gas Collector and of the transition ducts. Apply a strip of ceramic fiber on the refractory surfaces in correspondence with the flanges of these duct sections.
• The Convection Section modules must be lifted up using one crane with multiple spreader beam for each module.
• Lift the low module through the lifting lugs installed on top of the module.
• Remove any frame and bracing on the bottom of the module used for the transport; keep in place the top bracing that is required for the stability of the side walls of the module during the lifting operations.
• Check planarity of top flange and the verticality of module columns.
• Insert shim plates if necessary to reach the correct plumbness.
• Provide to coat the surface of top flanges of central walls with a layer ceramic fiber glued onto the surface of the refractory to ensure the air tightness of horizontal flanges.
• When the module is in its final position, install the bolts on the lower flange starting from the center of the longitudinal walls while the module is still kept by the cranes.
• Remove the top structure and the crane when all bolts are installed and tightened.
• Again apply the ceramic fiber on the surface of refractory in correspondence with the top flange.
• Install the top module and complete the erection of the side vertical bracing while the top module is still kept by the crane. This procedure is required to guarantee the stability of the convection section and to distribute the load of modules to the balancing frames.
• When the bracing are installed and firmly bolted, the crane can be removed and all flange bolts will be install and tightened.

o Erection of Stack Support Structure

• All support structures for convection section and stack are to be installed.
• Flue gas duct for Convection section are to be installed after completion of the required inspection and acceptance for support columns and support beams.
• Three (3) flue gas duct block to be assembled on the ground. Pre-assembled flue gas duct to be set on top of the convection module.

o Erection of Stack

• The Stack is supplied in sections. Each section is provided with lifting lug for the main cranes and one lug for the tail crane.
• Two (2) stack blocks and Damper unit are to be pre-assembled and welded on the ground. Pre-assembled lower stack shall be installed at the required support stack support structure.
• Check bolts size, grade, length and quantity before any lifting operation.
• Install on all intermediate flanges a gasket done by a ceramic fiber rope glued on the flanges around the bolt holes.
• The beams provided for the transport at each terminal of the sections shall be removed only when the sections are lifted in the vertical position.
• Erect each section and each time check the verticality. Tighten positively all bolts before to continue the erection of upper stack.
• Install the upper stack.
• Once the whole stack is fully erected check the verticality and correct if necessary.
• The departure of the chimney from the vertical on erection shall not exceed 25 mm or 1/1000 of the height, whichever is the grater at any point.
• Submit for inspection and acceptance.

o Erection of Radiant Outlet Header and Cross-over Piping

• Radiant Outlet Header are to be set on Header Support and Radiant Arch.
• Connection piping between Radiant outlet and Header shall commence after the fit up inspection and acceptance.
• Cross over piping between Convection outlet and Radiant Inlet shall commence after the fit up inspection and acceptance.

o Burner Installation and others

• It is mandatory that the burners and floor refractory shall be installed at the end of fired heater assembly in order not to overload the floor structure during the installation of radiant coil.
• The refractory shall be installed after the coils will be finally suspended from the arch and the wooden blocks have been removed.
• Burners and its support shall installed following the instructions given by the Manufacturer.
• Be sure that the gaps between the muffle blocks have been sealed with the proper refractory cement.
• Ceramic paper shall be installed between the outer surface of the muffle and the floor refractory lining.
• Most of the components of the burners shall be positioned in their right position with a very tight tolerance and shall be securely fixed in place to avoid loss of alignment due to firing vibration.

6. 0 SAFETY

• Fired heater Erection Team shall comply with the necessary safety standards and adhere to safe working practices and guard against hazardous activities as well as unsafe working conditions concerning all works.

7.0 ATTACHMENT

• 7. 1 Job Hazard and Risk Assessment (JHRA)
• 7. 2 Erection Sequence and drawings