Fired Heaters for General Refinery Service

API STANDARD 560

FIFTH EDITION, FEBRUARY 2016

Special Notes

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Copyright © 2016 American Petroleum Institute

Foreword

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.

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Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standards@api.org.

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Contents

Page

1. Scope 1

2. Normative References 1

3. Terms, Definitions, Symbols, and Abbreviations 4

   1. Terms and Definitions 4

   2. Symbols and Abbreviations 15

4. General 16

   1. Pressure Design Code 16

   2. Regulations 16

   3. Heater Nomenclature 17

5. Proposals 17

   1. Purchaser’s Responsibilities 17

   2. Vendor’s Responsibilities 17

   3. Documentation 21

   4. Final Reports 22

6. Design Considerations 23

   1. Process Design 23

   2. Combustion Design 23

   3. Mechanical Design 23

7. Tubes 24

   1. General 24

   2. Extended Surface 25

   3. Materials 26

8. Headers 27

   1. General 27

   2. Plug Headers 27

   3. Return Bends 27

   4. Materials 28

9. Piping, Terminals, and Manifolds 28

   1. General 28

   2. Allowable Movement and Loads 30

   3. Materials 30

10. Tube Supports 30

    1. General 30

    2. Loads and Allowable Stress 33

    3. Materials 34

11. Refractory Linings 35

    1. Refractory System Considerations by Heater Section 35

    2. Refractory Lining System Selection Specifications 35

    3. Firebrick Layer Lining and Gravity Wall Construction 38

    4. Alkaline Earth Silicate/Refractory Ceramic (AES/RCF) Fiber Construction 38

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       Contents

       Page

    5. Castable Layer Design and Construction 42

    6. Anchors and Anchor Hardware Components 46

    7. Responsibilities 48

12. Structures and Appurtenances 50

    1. General 50

    2. Structures 51

    3. Header Boxes, Doors, and Ports 52

    4. Ladders, Platforms, and Stairways 52

    5. Materials 53

13. Stacks, Ducts, and Breeching 54

    1. General 54

    2. Design Considerations 54

    3. Design Methods 56

    4. Static Design 56

    5. Wind-induced Vibration Design 57

    6. Materials 58

14. Burners and Auxiliary Equipment 58

    1. Burners 58

    2. Sootblowers 63

    3. Fans and Drivers 63

    4. Dampers and Damper Controls for Stacks and Ducts 63

15. Instrument and Auxiliary Connections 64

    1. Flue Gas and Air 64

    2. Process Fluid Temperature 65

    3. Auxiliary Connections 66

    4. Tube-skin Thermocouples 66

    5. Access to Connections 66

16. Shop Fabrication and Field Erection 67

    1. General 67

    2. Structural-steel Fabrication 67

    3. Coil Fabrication 69

    4. Painting and Galvanizing 69

    5. Preparation for Shipment 70

    6. Field Erection 71

17. Inspection, Examination, and Testing 71

    1. General 71

    2. Weld Examination 71

    3. Castings Examination 72

    4. Examination of Other Metallic Components 73

    5. Refractory QA/QC, Examination, and Testing 73

    6. Testing 79

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Contents

Page

Annex A (informative) Equipment Datasheets 80

Annex B (informative) Purchaser’s Checklist 109

Annex C (informative) Proposed Shop-assembly Conditions 113

Annex D (normative) Stress Curves for Use in the Design of Tube-support Elements 115

Annex E (normative) Centrifugal Fans for Fired-heater Systems 131

Annex F (normative) Air-preheat Systems for Fired-process Heaters 149

Annex G (informative) Measurement of Efficiency of Fired-process Heaters 205

Annex H (informative) Stack Design 271

Annex I (informative) Measurement of Noise from Fired-process Heaters 281

Annex J (normative) Refractory Compliance Data Sheet 319

Bibliography 324

Figures

1. Typical Heater Types 18

2. Typical Burner Arrangements (Elevation View) 19

3. Heater Components 20

4. Diagram of Forces for Tubes 31

5. Diagram of Forces for Manifolds 32

6. Illustration of Gravity Wall Dimensional Requirements 39

7. Typical Stud Layout for Overlap Blanket System 40

8. Typical Layered Fiber Lining Anchoring Systems 41

9. Examples of Modular Fiber Systems 42

10. Hardware Span Required for Overhead Section Modules 43

11. Typical Module Orientations 43

12. Typical Blanket Lining Repair of Hot-face Layer 44

13. Typical Blanket Lining Repair of Multiple Layers 44

14. Typical Repair of Modular Fiber Linings 45

1. Carbon Steel Castings: ASTM A216, Grade WCB 118

2. Carbon Steel Plate: ASTM A283, Grade C 119

3. 21/4Cr-1Mo Castings: ASTM A217, Grade WC9 120

4. 21/4Cr-1Mo Plate: ASTM A387, Grade 22, Class 1 121

5. 5Cr-1/2Mo Castings: ASTM A217, Grade C5 122

6. 5Cr-1/2Mo Plate: ASTM A387, Grade 5, Class 1 123

7. 19Cr-9Ni Castings: ASTM A297, Grade HF 124

8. Type 304H Plate: ASTM A240, Type 304H 125

9. 25Cr-12Ni Castings: ASTM A447, Grade HH, Type II 126

10. Type 309H Plate: ASTM A240, Type 309H 127

11. 25Cr-20Ni Castings: ASTM A351, Grade HK40 128

12. Type 310H Plate: ASTM A240, Type 310H 129

13. 50Cr-50Ni-Nb Castings: ASTM A560, Grade 50Cr-50Ni-Nb 130

E.1 Fan Performance Nomenclature 134

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Contents

Page

1. Balanced-draft APH System with Direct Exchanger 152

2. Balanced-draft APH System with Indirect Exchangers 152

3. Forced-draft APH System with External-heat-source Exchanger 153

4. General Relationship Between the Sulfuric Acid FGADP Temperature and the Concentration of

   Sulfur in a Fuel Gas 160

5. General Relationship of Sulfuric Acid FGADP Temperature and the Concentration of Sulfur in a

   Fuel Oil 160

6. System Worksheet for Design and/or Analysis 176

7. Moody’s Friction Factor vs Reynolds Number 179

8. Duct Pressure Drop vs Mass Flow 181

9. Equipment Lengths for (L/D) for Multiple Piece Miter Elbows of Round Cross-section 187

10. Location of Pressure-measuring Points 1, 2, and 3 188

11. Branch Loss Coefficients 189

12. Duct Zones 191

1. Instrument and Measurement Locations 207

2. Typical Aspirating (High-velocity) Thermocouple 208

3. Typical Heater Arrangement with Nonpreheated Air 211

4. Typical Heater Arrangement with Preheated Air from an Internal Heat Source 212

5. Typical Heater Arrangement with Preheated Air from an External Heat Source 213

6. Enthalpy of H2O, CO, CO2, and SO2 235

7. Enthalpy of Air, O2 and N2 236

1. Measuring Positions and Surfaces for Burner Areas and Walls Without Burners on Cabin-type

   Heaters 288

2. Measuring Positions and Surfaces for Burner Areas and Walls on Vertical Cylindrical Heaters 289

3. Typical Measuring Positions—Walls with Burners 291

4. Measuring Positions and Surfaces for Annular Area Between Fired-heater Sections 294

5. Measuring Positions for Suction Openings of Forced-draft Fans 296

6. Typical Measuring Positions for Exhaust Ducting 297

7. Example Sketch of a Generalized Crude Heater Showing Microphone Measuring Positions

and Dimensions 308

Tables

1. Extended Surface Materials 25

2. Extended Surface Dimensions 26

3. Heater-tube Materials Specifications 26

4. Tube Center-to-center Dimensions 28

5. Plug Header and Return Bend Materials 29

6. Allowable Forces and Moments for Tubes 31

7. Allowable Movements for Tubes 31

8. Allowable Forces and Moments for Manifolds 32

9. Allowable Movements for Manifolds 32

10. Maximum Design Temperatures for Tube-support Materials 34

11. Lining System Decision Matrix Guidelines 37

12. Maximum Temperatures for Anchor Tips 47

13. Minimum Hammer/Bend Test Frequency 48

    Contents

    Page

14. Minimum Yield Strength, Fy, and Modulus of Elasticity, E, for Structural Steel 55

15. Minimum Clearances for Natural-draft Operation 59

16. Minimum Clearances for Forced-draft Operation 60

17. Materials of Construction 62

18. Documentation Required for Refractory Type Selected 74

19. Acceptance/Rejection Criteria for Defective Firebricks in Lot 75

20. Tolerance Requirements for Brick 76

D.1 Sources of Data Presented in Figure D.1 Through Figure D.13 117

1. Driver Trip Speeds 134

2. Maximum Shaft Runout Indicator Readings 138

3. Service Factors 142

1. Comparison of APH Systems 168

2. Loss Coefficients for Common Fittings 182

3. Recommended Damper Types 197

1. Allowed Variability of Data Measurements 209

2. Sample Calculation 268

1. Minimum Shape Factors and Effective Diameters for Wind Loads 275

2. Fundamental Structural Damping Values 277

3. Structural Shape Factors 279

4. Chemical Loading Criteria 279

5. External Corrosion Allowances 280

6. Internal Corrosion Allowances for Unprotected Carbon Steel Stacks 280

1. Corrections for Measured Noise Level 286

2. Near-field Correction 287

1. Requirements for Compliance Data Sheet Property Listings for Monolithic Refractories as per

   Annex B of API 936 320

2. Test Methods to Determine RCF/AES Properties 321

3. Manufacturer’s Product Compliance Data Sheet—Brick Materials 322

4. Manufacturer’s Product Compliance Data Sheet—Mortar Materials 323

Fired Heaters for General Refinery Service

1. Scope

   This standard specifies requirements and gives recommendations for the design, materials, fabrication, inspection, testing, preparation for shipment, and erection of fired heaters, air preheaters (APHs), fans, and burners for general refinery service.

   
   

   This standard does not apply to the design of steam reformers or pyrolysis furnaces.

   
   

2. Normative References

The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

API Standard 530, Calculation of Heater Tube Thickness in Petroleum Refineries

API Standard 936, Refractory Installation Quality Control—Inspection and Testing Monolithic Refractory Linings and Materials

ABMA Standard 9 1, Load Ratings and Fatigue Life for Ball Bearings

AMCA 210 2, Laboratory Methods of Testing Fans for Aerodynamic Performance Rating AMCA 801:2001, Industrial Process/Power Generation Fans—Specifications and Guidelines ASME B17.1 3, Keys and Keyseats

ASME Boiler and Pressure Vessel Code, Section VIII: Pressure Vessels

ASTM A36 4, Standard Specification for Carbon Structural Steel

ASTM A53, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A105, Standard Specification for Carbon Steel Forgings for Piping Applications

ASTM A106, Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A123, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A143, Standard Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement

ASTM A153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A181, Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

1. American Boiler Manufacturers Association, 8221 Old Courthouse Road, Suite 207, Vienna, VA 22182, www.abma.com

2. Air Movement and Control Association International, Inc., 30 W. University Dr., Arlington Heights, IL 60004, www.amca.org.

3. ASME International, 2 Park Avenue, New York, New York 10016-5990, www.asme.org.

4. ASTM International, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428, www.astm.org.

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