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Engineering Specification

Mechanical basis of design for a cracking furnace

Pages modified under this revision:

Page 9: Maximum fin tip temperature for Carbon Steel changed

1 31-10- Revised J.W.A Brinkman/ J. H.A. de Vrij P. ten Veldhuis

2001 den Uijl

0 28-06- Released for Engineering J.W.A Brinkman/ J. H.A. de Vrij P. ten Veldhuis
2001 den Uijl
Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MM/YY (name & visa) (name & visa) (name & visa)

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the right margin

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1. GENERAL 3
1.1 INTRODUCTION 3
1.2 PURPOSE 3
1.3 CODES AND STANDARDS 3
1.4 REFERENCES 3

2. MECHANICAL DESIGN OF A CRACKING FURNACE 3

2.1 GENERAL 3
2.2 CRACKING FURNACE STRUCTURE 4

3. STRUCTURAL STEEL 5
3.1 GENERAL 5
3.2 MATERIALS 5
3.3 PLATFORMS, LADDERS AND STAIRS 5
3.4 ACCESS FOR OPERATION, MAINTENANCE AND INSPECTION 6
3.5 PRESERVATION 6

4. FURNACE INTERNALS 6
4.1 RADIANT COILS 7
4.2 CONVECTION COILS 8
4.3 L.T.- AND H.T.-CROSSOVERS 10
4.4 TUBE SUPPORTS OF THE CONVECTION COILS 11
4.5 SUPPORTING RADIANT COILS AND H.T.-CROSSOVERS 11

5. REFRACTORY LINING 12
5.1 DESIGN BASIS 12
5.2 CALCULATION METHOD FOR THE REFRACTORY LINING 12
5.3 REFRACTORY MATERIAL SELECTION 13
5.4 ANCHORING MATERIAL SELECTION 13

6. EXCEPTIONS AND DEVIATIONS TO API 560 14

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1. GENERAL
1. 1 INTRODUCTION
The purpose of this Engineering Specification is to define the minimum requirements for the detailed
engineering and design of a cracking furnace for the following disciplines: structural steel, furnace
internals and refractory.

1. 2 PURPOSE
The purpose of this document is to:
• achieve a clear understanding between TECHNIP and the Client on the design basis for the
mechanical design of a cracking furnace.
• obtain Client approval and
• allow smooth and efficient execution of the engineering detailed design activities.

1. 3 CODES AND STANDARDS

The Codes and Standards mentioned in this document under the respective sections, including their
amendments and/or supplements shall be followed.

Note:
• The API 560 (ISO 13705), being a standard for fired heaters for general refinery purposes, is
referenced in many ITB’s / Contracts, but considered not completely suitable for higher temperature
range cracking furnaces. Therefor TP has indicated in par. 6 of this specification a list of main
deviations to this standard.

1. 4 REFERENCES
References to other TECHNIP specification and Standards are sometimes indicated in this document to
refer to further details. These documents are considered not to be of major importance for determining
the basis of design and will be issued separately during the execution of the project.

2. MECHANICAL DESIGN OF A CRACKING FURNACE

2. 1 GENERAL
Furnace design will be based on TECHNIP standards and API 560 will be used as a guideline. Deviations
will be further covered under par. 6.

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2. 2 CRACKING FURNACE STRUCTURE

A cracking furnace structure consists of several parts, which are:
Radiant box with platforms attached, the radiant box contains the radiant coils.
Above the radiant box in an offset position a convection section is located. On top of the radiant box,
connected to the radiant coil outlet, quench coolers are located. Furthermore a steam drum and a fluegas
fan are located on the top of the furnace structure.

Note: Fire protection of the furnace structure is not foreseen.

2. 2.1 RADIANT SECTION STRUCTURE

The radiant section consists of a steel box construction reinforced by columns and horizontal sections.
The columns are provided with base plates at the bottom, which are fixed with anchor bolts to concrete
foundation columns. The radiant section floor, side walls and top are all constructed as prefabricated
panels, which shall be bolted together at site. The complete steel box is on the inside covered with
refractory lining as described further on. The thickness of the wall and arch steel panels is in general 5
mm. The floor panels are 6 mm thick. The inside of the wall panels are provided with strips, shelf plates,
and/or anchors for fixing the refractory lining.

The radiant box is provided with various platforms, which allow access to peepdoors, access doors,
burners, etc., as indicated on the drawings. The platforms can be reached by means of a
stairhouse/stairs, which is extended to the top of the convection bank (steam drum & flue gas fan)
platform. The radiant box can be accessed through access doors located at the lowest platform level.
The radiant section side walls + end walls are provided with observation peepdoors for checking the
burners and radiant coils during operation. All peepdoors can be accessed from a platform.

2. 2.2 BURNERS
The radiant section is provided with a number of burners, for which the location, type, and number is
specified on the process datasheets. All burners are connected to a burner piping system.
The piping system includes for each individual burner a block valve.

2. 2.3 CONVECTION SECTION

The convection section is a steel box construction build-up from prefabricated panels, which have to be
assembled at site. The inside of the convection section steel box is fully protected with a refractory lining.
The convection section contains various convection tube bundles. The convection tube bundles are
supported by tube sheets, which rest on tube sheet brackets mounted to the side walls columns

2. 2.4 REFRACTORY LINING

The inside of the furnace radiant box, convection section and ducting, which are exposed to high flue gas
temperatures are lined with one or a multiple layer of refractory material, suitable for a specific service, as
specified in the lining description.

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The refractory lining will be installed at site after erection of the pertaining steel parts. Castable
refractories such as for ducting and stack are usually applied at ground level prior to erection of the part.
See for more details paragraph 5.

3. STRUCTURAL STEEL
3. 1 GENERAL
TP standard structural design is based on TP standards and the codes listed below.
In countries other than European local codes will be used, however for items which are not covered in the
local codes, TP standards and codes will be followed.
In case of construction and/or fabrication of the steel structure in Europe hot rolled products as per EN
10025 will be used.

Issue / Edition Description

ISO 13920 ’96 Welding, General tolerances for welded constructions..

ISO 898 ’88 Mechanical properties of fasteners

ISO 8501-1 ’88 + Amd. Preparation of steel surfaces before painting

’94

UBC ‘97 Uniform building code

AISC 9th edition ’89 Manual of steel construction ASD

AISC 9th edition ’92 Manual of steel construction ASD, Volume II - Connections

ANSI/AWS D1.1 ‘96 Structural welding code

3. 2 MATERIALS
Standard material and grade for structural steel: Carbon Steel grade A36.
Standard material and grade for bolts and nuts: Galvanized Carbon Steel grade 8.8 (used without pre
tensioning).
Instrumentation and process nozzles on casing and ducting: Material and grade for pipe depending on
temperature at connecting element. Flanges and bolts:150# carbon steel.

3. 3 PLATFORMS, LADDERS AND STAIRS

TP standard platform, ladder and stair design is as per Furnace steel standards and Structural steel
standards with the following dimensions:

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Minimum width of platforms:

Side wall burner platforms 1500 mm. behind burner wind box
Operating and maintenance 900 mm.
Walkways 750 mm.
Stairs 750 mm.

Note: The available width in not frequently used maintenance areas can be less than the above
mentioned dimensions! Furthermore free passage is considered not required in not frequently used
maintenance areas.

Minimum head clearance:

Burner platforms 2100 mm.
Operating platforms and walkways 2100 mm.
Maintenance areas 2100 mm.

3. 4 ACCESS FOR OPERATION, MAINTENANCE AND INSPECTION

The radiant box has for each burner lane an access door as per Furnace steel standards
In between each convection coil, inspection hatches as per Furnace steel standards are located.

The minimum space between two convection coils is 500 mm measured from outside tubes.

At the ends (header boxes) of the convection coils no operation, maintenance or inspection platforms are
installed. Inspection and maintenance at the headers, end tube sheets etc. is not required on a regular
basis (inspection intervals 3-5 years). For inspection/maintenance scaffolding should be installed.

3. 5 PRESERVATION
Grating and stair treads: galvanized.
All other carbon steel parts as per specification Shop fabrication of structural steel furnaces

4. FURNACE INTERNALS
Radiant coils, convection coils and cross-over piping are designed in accordance with the following
Codes and Standards:

Furnace Internal part Applicable Codes and Standards

Radiant coil API 530 (Only for wall thickness calculation)
Convection coils:
- Process; ASME BPVC - Section VIII, Div. 1
- Steam ASME BPVC - Section I
Cross-over piping ASME Code for pressure piping - B31.3
Materials ASME BPVC - Section II, Part D

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4. 1 RADIANT COILS
4. 1.1 GENERAL
The radiant coils are formed by vertical tubes, connected by return bends, in the radiant box.
The unique configuration of the radiant coils is in accordance with the applicable TP process data sheets.
The inlets of the radiant coils protrude through the arch of the radiant box and are welded to the HT-
cross-over piping.
The openings between the protruding tubes (inlet tubes, outlet tubes and support guide tubes) and the
furnace roof are air sealed by either multi-tube bellows or by single flexible sealing, allowing the required
movement of the tubes..
The outlets of the radiant coils are welded to the special transition pieces which are connected to the
transferline exchangers, located directly above the radiant coils.
The radiant coil design is based on the ‘top outlet’ system, which means that the radiant coils are
supported for 100% from the top of the coil.
The complete coil is free to expand in downwards direction to allow for its thermal expansion and
permanent creep.
The bottom part of the radiant coils is guided with guide tubes, welded to bottom part of the radiant coils
in metal sleeves in the floor of the furnace.
In order to avoid leakage of excess air, each guide tube is provided with a flexible sealing.

The radiant coils are delivered in prefabricated modules, which welds are 100% rediographed.

All separate assemblies are hydrostatic tested in the workshop with test pressure calculated in
accordance with design standard and based on the weakest part, but not higher than 10 Mpa.
The size of the modules is such that erection from the top of the furnace is possible.
When all parts of the radiant coil sections are placed into the furnace radiant box, the parts are temporary
supported, lined-out and welded together.

After welding of the radiant coil modules and connection to the inlet- and outlet piping, the connecting
welds are all radiographed 100% and the complete system is leak tested at
0.1 Mpa by use of Nitrogen or dry air. This leak testing is done instead of hydrostatic pressure testing to
avoid the problems of removal of remaining water in the vertical coils.

4. 1.2 MATERIALS AND DESIGN

Materials for radiant coils are as listed in the Table below: *)

Radiant coil parts Material Specification

(Reducing) inlet elbows

(outside radiant box) 20Cr10NiCb A351 CF8C
Radiant tubes / fittings Centrifugally/statically cast
25Cr35NiNb MA A608-Base / A351-Base
35Cr45NiNb MA A608-Base / A351-Base

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Radiant coil parts Material Specification

Radiant outlet tubes / Centrifugally/statically cast

fittings 20Cr33NiNb A608-Base / A351-Base
(outside radiant box)
Bottom guide tubes Centrifugally cast
25Cr35NiNb A608-Base
Support/guide tubes Centrifugally cast
28Cr48Ni5W A608-Base

Design of the radiant coils shall be in accordance with TP standards and practice.

The wall thickness of the radiant coil tubes and fittings is calculated in accordance with TECHNIP's
standard engineering practice based on API RP 530. As allowable stress 80% of the average stress to
produce rupture in 100,000 hours at design temperature is used.
The values for the average stress to produce rupture are taken from the TP specification; ‘Centrifugally
cast tube sections and statically cast fittings for radiant coils’ or from the selected vendor’s data sheets.
For corrosion allowance for radiant coils see paragraph 6.

4. 1.3 FABRICATION
All radiant coil tubes are machined inside to a maximum roughness of 3.18 micrometer.

The tube assembly consists of centrifugal cast segments. Each tube assembly comprises a number of
tube segments of which none is shorter than 1000 mm with a maximum of 5 (five) sections per tube
assembly.

Welding is done in accordance with ASME BPVC Section IX.

Welding method is in accordance with approved vendor’s standard.

4. 2 CONVECTION COILS
4. 2.1 GENERAL.
Convection section coil design parameters, pipe configurations, lengths, pitches and types of finning are
in accordance with the TP process data sheets. Return bends and manifolds are separated from the flue
gas and located in header box casings. Design conditions for all coil parts are specified by process
department and material selection is done on basis of these parameters.
The materials are selected accordingly and might result in coils containing several materials.
E.g.; Within one coil the tubes, fittings, inlet and outlet manifold can be constructed of different materials.

Pipes are attached to the manifolds either directly by branch connection or by means of reinforcing
nozzles.

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Bare pipes, when projected in the header box housings, extend 150 mm (in cold condition) beyond the
center line of the tube supports. Finned pipes extend 150 mm of which 100 mm is bare.

Allowable movements and loads on thermal points are in accordance with TP Standard.
4. 2.2 MATERIALS AND DESIGN.
Standard materials for convection section coils are, depending upon design temperature, as listed in the
Table below:

Material Seamless Seamless Forgings Maximum

type pipes piping fittings design
temperature
C-Si (S) A 106 Gr. B (S) A 234 Gr. WPB (S) A 105 425°C
C-1/2Mo (S) A 335 Gr. P1 (S) A 234 Gr. WP1 (S) A 182 Gr. F1 500°C
11/4Cr-1/2Mo-Si (S) A 335 Gr. P11 (S) A 234 Gr. WP11 (S) A 182 Gr. F11 550°C
21/4Cr-1Mo (S) A 335 Gr. P22 (S) A 234 Gr. WP22 (S) A 182 Gr. F22 600°C
18Cr-8Ni (S) A 312 Gr. TP304H (S)A 403 Gr. WP304H (S) A 182 Gr. F304H 816°C
18Cr-10Ni-Ti (S) A 312 Gr. TP321H (S)A 403 Gr. WP321H (S) A 182 Gr. F321H 816°C
18Cr-10Ni-Cb(Nb) (S) A 312 Gr. TP347H (S)A 403 Gr. WP347H (S) A 182 Gr. F347H 816°C
25Cr20Ni (S) A 312 Gr. TP310H ---- (S) A182 Gr. F310H 816°C
33Ni-42Fe-21Cr (S)B 407 UNS N08810 --- (S)B 564 UNS N08810 According Code
33Ni-42Fe-21Cr (S)B 407 UNS N08811 --- (S)B 564 UNS N08811 According Code

Design of convection coils is done in accordance with the following codes:

- Process coils (incl. dilution steam coil) ASME BPVC - Section VIII, Div. 1
- Steam coils ASME BPVC - Section I

For corrosion allowance see paragraph 6.

Dimensions of finning is in accordance with TP standards and practice and is specified in the
TP process data sheets, see also paragraph 6.

Finning materials are as listed in the Table below:

Material Maximum fin tip temperature

Carbon Steel up till 454°C [1]
11%÷13% Cr up till 593°C
18%Cr8%Ni up till 815°C

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4. 2.3 FABRICATION.
Steam coils are manufactured with “S” stamp.

Welding is done in accordance with ASME BPVC Section IX.

Welding method is in accordance with approved vendor’s standard.
Post weld heat treatment is in accordance with applicable standards.

All prefabricated convection coils are hydrostatic pressure tested in the shop with test pressures
calculated in accordance with design standard and based on the weakest parts.

4. 3 L.T.- AND H.T.-CROSSOVERS

4. 3.1 GENERAL
LT- and HT-crossovers design parameters are in accordance with TP process data sheets.

The LT-crossover piping forms the connection between the applicable process coils of the convection
section.

The HT-crossover piping distributes the preheated process gas mix from the process convection coils,
by means of manifolds, to the individual inlets of the radiant coils.

To minimize the bending of the radiant coil tubes the forces and moments from outside parts are reduced
by guiding the coil movements and designing the H.T.-crossovers with high emphasis on flexibility.
Flexibility is required since displacements have to be absorbed, due to; thermal expansion of the
Transferline exchanger, the outlet part of the radiant coil, the difference in temperature between inlet- and
outlet tubes of the radiant coils plus the expected permanent creep in the radiant coils due to weight load
mainly.

4. 3.2 MATERIALS AND DESIGN.

Materials for LT- and HT-crossover piping is selected, depending upon design temperature, as listed for
convection section coils under 4.2.2.

Design of L.T.- and H.T.-crossover piping is done in accordance with: ASME Code for Pressure Piping
B31.3.

Corrosion allowance is as listed for convection section coils under 4.2.2.

4. 3.3 FABRICATION.
LT- and HT-crossover piping parts are prefabricated to a maximum extend.

Welding is done in accordance with ASME BPVC Section IX.

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Post weld heat treatment is done in accordance with the applicable standards.

4. 4 TUBE SUPPORTS OF THE CONVECTION COILS

4. 4.1 GENERAL.
The convection section coils are mainly supported in statically cast tube supports and rest on statically
cast brackets which are fixed to the steel structure.
Design parameters for the tube supports and brackets are specified in the TP process data sheet.

4. 4.2 MATERIALS AND DESIGN.

Support and bracket material for convection section coils are, depending upon design temperature, as
listed in the Table below:

Material Specification Maximum design

(static casting) temperature
Carbon steel A216 Gr.WCB up till 425°C
C - ½ Mo A217 Gr.WC1 up till 500°C
2¼Cr1Mo A217 Gr.WC9 up till 600°C
19Cr9Ni A297 Gr.HF up till 800°C
25Cr12Ni A447 TP. II up till 1000°C
25Cr20Ni A297 Gr.HK40 up till 1050°C
25Cr35NiNb A297 base up till 1125°C
28Cr48Ni5W A297 base up till 1200°C

Design and calculations are in accordance with TP standards and practice.

Refractory lined end tube supports are not used.
End tube supports and intermediate tube supports are identical.

For corrosion allowance see paragraph 6.

4. 5 SUPPORTING RADIANT COILS AND H.T.-CROSSOVERS

4. 5.1 GENERAL.
The H.T.-crossovers, the inlet manifolds, the inlet tubes as well as the intermediate passes of the radiant
coils are supported by constant load spring supports.
The travel range of the constant load spring supports is calculated to compensate for the thermal
expansion of the Transferline exchanger, the outlet part of the coil, the difference in temperature between
inlet- and outlet tubes of the radiant coils plus the expected permanent creep of the outlet tubes in the first
years.

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The outlets of the radiant coil tubes are connected to the Transferline exchanger and depending upon
TLE design, supported by variable spring supports.

During commissioning of the furnace the constant load spring supports of radiant coils and H.T.-
crossovers are adjusted by furnace specialists to balance the complete system.

4. 5.2 MATERIALS AND DESIGN.

Design and material selection of supporting systems are in accordance with TP standards and practice.

5. REFRACTORY LINING
5. 1 DESIGN BASIS
The lining will be calculated for the following requirements:
• The average outer skin temperature of the furnace will not exceed 70 °C at design ambient conditions
of 20 °C and a wind velocity of 2 m/s.
• The average floor temperature of the furnace will not exceed 90°C at design ambient
conditions of 20°C and a wind velocity of 2 m/s.
• Lining must be stable at maximum ambient temperature, 0 m/s wind and solar radiation. The used
safety margins on lining materials are as per par. 5.3.
• Heat loss through wall, at operating conditions, will not exceed 800 W/m² at 20 °C and a wind velocity
of 2 m/s.
• Lining must be suitable for the minimum ambient temperature and a wind velocity of 2 m/s.

The temperatures used in the calculation are the by the process department calculated hot face
temperature for the radiant box and flue gas temperature for the rest of the furnace. All temperatures
used are for maximum operating and end of run condition.

5. 2 CALCULATION METHOD FOR THE REFRACTORY LINING

The heat transfer calculations are done with a program that calculates heat transfer by comparing the
heat flux due to conduction with the heat transfer from a hot wall. By iteration, a wall temperature and heat
flux is calculated. The calculation method is according ASTM C 680 or for ambient temperatures of less
than -17.8° C according VDI 2055.

The casing temperatures will deviate from the calculated casing temperatures in the following areas:
- At peephole/inspection doors
- Around burners
- At location of tube sheet ears
- At locations of welded stiffeners and/or supports on the inside wall
- Around tube entries and instrument connections
- Floors and arch in the vicinity of hot equipment

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This is considered to be acceptable.

5. 3 REFRACTORY MATERIAL SELECTION

Materials are selected considering, maximum application temperature, expected shrinkage at operation
temperature and mechanical stability as described by process.
Further material selection is based on operation conditions being normal for the type of furnace specified,
such as thermal shocks during emergency shut downs, combustion atmosphere, fuel impurities,
chemical attack, etc.

The following safety margins are put on the maximum service temperatures as claimed by the
manufacturers:

− Dense bricks, shapes and mortar: 50 K

− Monolithic: 50 K
− Insulating firebricks and mortar: 130 K
− Insulating block/ -Mixes: 100 K
− Ceramic fiber products
- for packing purposes: 100 K
- for thermal linings: 200 K

5. 3.1 BURNER BLOCKS

Requirements for burner blocks can be found in technical specification: Burner block.

5. 4 ANCHORING MATERIAL SELECTION

Allowable anchor tip temperatures in continuous and intermittent service are according following table:

Material: Up to and including

Alloy 601 1100 °C
Alloy 330 1035 °C
SS 310 1000 °C
SS 304 or SS 316 800 °C
Carbon Steel 425 °C

For anchors applied in overhead location, above maximum temperatures should be reduced with 50 K.

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6. EXCEPTIONS AND DEVIATIONS TO API 560

The in paragraph 6 listed deviations/clarifications from API 560 are the same as indicated on
previous document “DA-20513-00-04-002, rev. 4”, attached to the minutes of the kick-off
meeting.
In addition Technip has clarified the outstanding issues on API paragraphs 7.4.3, 7.5.6 and
7.6.2b.

1. Introduction
The API standard 560 second edition, September 1995 is developed for fired heaters for
general refinery services, such as cylindrical (charge) heaters, box type (crude, visbreaker)
heaters, etc.

This means that for cracking furnaces (with a much higher fire box temperature) the API 560 is
not completely suitable.

TECHNIP standards/practice uses the API 560 as a guideline, however, deviates on several
point. A list of deviations is given in chapter 2.

Because of the close relation between the API 560 and the refractory lining TECHNIP design
basis the latter is incorporated in chapter 34 of this document.

2. The contents of his document were reviewed by PPC and discussed on 14-1-2001 in
PPC offices at Tehran.

3. Agreements achieved are incorporated/reflected in this document, including further

actions to be undertaken by parties

4. List of Deviations
Note that the following textual indications are used:
Normal text - quote from the API
Italic - TECHNIP Standard deviation
Bold - Project specific information
underlined -agreement reached/further actions

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 9TH OLEFIN COMPLEX

ETHANE CRACKING PLANT PARS PETROCHEMICAL COMPANY

CONTRACTOR DOCUMENT N° OWNER DOCUMENT N°

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31961 30 JSD 0126 001 0 15/36 3930 30 JSD 0126 001 1 15/36

Section 1 - General:

1.6.1:

The editions of the following standards, codes, or specifications that are in effect at the time of
publication of this standard shall, to the extent specified herein, form part of this standard. ….

TECHNIP uses always the latest edition of standard, codes, and specifications at the time of
signature of the contract.

Accepted
1.7.2 a:

The vendor’s proposal shall include complete API fired heater and associated equipment data
sheets for each heater.

TECHNIP’s practice is to use their own standard process data sheets.

Technip will fill in the applicable process data for design in the API datasheet. This includes the inlet
conditions and outlet conditions of each coil (not each tube). However, vaporizing does not occur in
this ethane cracking furnace.

Accepted

1.7.2 f:

The vendor’s proposal shall include: curves shall be provided for heaters in vaporizing service
showing pressure, temperature, vaporization, and bulk velocity as a function of the tube number.

Normally TECHNIP does not provide this information on the process data sheets.

Accepted, as cracking furnace is not in vaporizing service

Section 2 - Design considerations

2.2.1:

Calculated and actual efficiencies shall be based on the lower heating value of the primary fuel and
shall include a minimum radiation loss of 1.5 percent of the calculated normal heat release.

The exact calculation method is given in appendix G of the API 560. TECHNIP calculates normally
the efficiency on basis of fired heat with 25°C as reference basis and not on basis of the lower

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heating value with 15°C as reference basis.. Differences in efficiency can be 0.4% (absolute) if the
air temperature is 25°C.

Note that the heat losses in the radiation and convection section (= radiant loss) are often different
from 1.5 percent of the calculated normal heat release.

Technip will calculate the efficiency according the in italic described method and the figures which
are part of the contract. Note that the efficiency figure is not a contractual matter so the efficiency
calculation method can not influence the design.

The fuel gas consumption is a contractual matter, so the design will be determined by the operating
battery limit temperatures and ambient conditions. It is important that the ambient design conditions
(27°C and 50% RELATIVE HUMIDITY) and battery limit conditions (feed, DS, BFW and fuel gas)
will be the same as in the contract .

Action: Technip will calculate the efficiency using the temperature specified by API (i.e. 15°C as
reference basis) using the actual calculated heat losses.

Ambient design conditions: refer to the design basis / basic design data as sent for approval and
commented by PPC. It is important that the acceptable number of design condition to be specified.

2.2.4:

Volumetric heat release shall not exceed 12,000 British thermal units per hour per cubic foot (124
kilowatts per cubic meter) for oil-fired heaters and 16,000 British thermal units per hour per cubic
foot (165 kilowatts per cubic meter) for gas-fired heaters based upon the design heat absorption.

TECHNIP does not base the furnace design on volumetric heat release.

However, the current design is in accordance with 2.2.4.

The normal operating heat release is approximately 68.1 MW for H2 rich gas and 72.00 MW for
natural gas. The firebox volume is approximately 771 m 3.

The normal operating heat release per cubic meter is approximately 88 kW/m 3 for H2 rich gas and
93 kW/m 3 for natural gas.

The design heat release per cubic meter is approximately 106 kW/m 3 for H2 rich gas and 112
kW/m 3 for natural gas.

Noted, design will be in line with API criteria.

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ETHANE CRACKING PLANT PARS PETROCHEMICAL COMPANY

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Project N° Unit Doc. Type Material Code Serial N° Rev. Page Project N° Unit Doc. Type Material Code Serial N° Rev. Page

31961 30 JSD 0126 001 0 17/36 3930 30 JSD 0126 001 1 17/36

2.3.4:

The convection section design shall incorporate space for the future addition of two rows of tubes,
including the end and intermediate tubesheets. …..

TECHNIP does not incorporate space for future addition of two rows of tubes in the end and
intermediate tube sheets. Methods of simulation have improved such, that extra margin in the
design by means of two additional tubes is not required anymore.

Space will be provided for two additional rows in the FPH feed pre-heater convection coil, in order to
enable to enhance the furnace efficiency in future, if desired.
2.3.8:

Convection sections shall be designed with corbels to minimize flue gas bypassing the heating
surface.

TECHNIP’s standard is to install convection coils using so called ‘slotted infills’ prohibits the use of
corbels, since it would be an obstruction element. A corbel design is more vulnerable to damage
than the dummy tube design.

TECHNIP only provides dummy tubes for convection banks with triangular pitches.

Accepted, Technip design philosphy will be applied

Section 3 - Tubes

3.1.1:

Tube wall thickness for coils shall be determined in accordance with the procedures set forth in API
Recommended Practice 530.

TECHNIP uses the API 530 method for radiant coil calculations. API 530 paragraph 1.1 states that
the code is applicable to direct fired heat-absorbing tubes. As a consequence the code is not
applicable to convection coils.

For convection coils, ASME-I is used for steam coils and ASME-VIII for process (inclusive DSSH)
coils.

Accepted, Technip design philosphy will be applied

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ETHANE CRACKING PLANT PARS PETROCHEMICAL COMPANY

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3.1.2:

The following corrosion allowances shall be used as a minimum:

API 560 TECHNIP
Carbon steel through C-½Mo 3 millimeters 1.5 millimeters
Low alloys through 5Cr-½Mo 2.5 millimeters 1.0 millimeters
7Cr-½Mo through austenitic steels 1.3 millimeters 0 millimeters

Not accepted, Technip shall provide corrosion allowances as stipulated in the API 560.
3.1.3:

Maximum tube metal temperature shall be determined by following the procedures set forth in API
Recommended Practice 530.

API 530 appendix C provides a procedure for the calculation of the maximum radiant section tube
skin temperature. However, TECHNIP uses maximum tube metal temperatures calculated by the
SPYRO program instead of this appendix C.

The SPYRO program is the superior tool in order to calculate the tube skin temperatures of the
radiant coil of a cracking furnace. The SPYRO program calculates the tube skin temperature as
function of the on stream time, the processed feedstock with corresponding yields.

The maximum allowable temperature is the same as the design temperature.

Accepted, Technip SPYRO software will be applied for this calculation.

However, design temperature and maximum allowable temperature to be further clarified, Technip
to revert.

3.1.6:

Tube size (outside diameter, in inches) shall be selected from the following sizes: 2.375; 2.875;
3.50; 4.00; 4.50; 5.563; 6.625; 8.625; or 10.75. Other tube sizes should be used only if warranted by
special process considerations.

The above mentioned sizes are used for the convection section by TECHNIP. TECHNIP uses
different tube sizes for the radiant coil because of special process considerations (= optimized
radiant coil design).

Accepted.

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3.2.3:

Extended surface dimensions shall be limited to those listed in Table 3.

Table 3 limits the fin height to a maximum of 1” for gas firing. TECHNIP allows higher fin heights,
except for plants with SCR when fin height shall be limited to ¾”.

The exception for plants with SCR is not applicable to PPC Iran.

Not accepted, Technip will limit the fin height to 1” as per API for this plant as well (already shown in
contract Appendix 19).
Section 4 - Headers

4.1.2:

Headers shall be of the same metallurgy as the tubes.

The header material selection is based on the design temperature and pressure of the header,
because technically there is no objection against it.

Accepted, provided that PPC criteria for design temperature, pressure as per contract are adhered
to.

4.3.4.:

Longitudinally welded fittings are not permitted.

When forced by delivery time considerations, TECHNIP does allow longitudinally welded fittings. In
that case the complete weld is radiographically examined.

Not accepted, Technip shall not use welded fittings.

Section 5 - Piping, terminals, and manifolds

5.1.1:

The minimum corrosion allowance shall be in accordance with 3.1.2.

See remarks at 3.1.2.

Not accepted, Technip will provide corrosion allowances as stipulated in the API. For regular piping
which is part of pipe classes however, TP shall follow the corrosion allowances given in the
contract.

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ETHANE CRACKING PLANT PARS PETROCHEMICAL COMPANY

CONTRACTOR DOCUMENT N° OWNER DOCUMENT N°

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31961 30 JSD 0126 001 0 20/36 3930 30 JSD 0126 001 1 20/36

5.1.5:

Threaded connections are not acceptable.

Union couplings and treaded gas tips are used in burners, see spec. Nozzle mixing type gas
burners.

Technip shall not provide threaded connections, except when maintenance requirements in specific
cases such as burner tips demand otherwise.
5.1.8:

Manifolds inside a header box shall be selected for the same design pressure as the connecting
tubes and for....

TECHNIP standard design allows the use of different materials for coil with maximal design metal
temperature below 537°C (1000°F), because technically there is no objection against it.

Clarification by TP is not very clear as it mentions temperature instead of pressure. However,

design will be in line with API 560 criteria.

5.3:

The cross-over piping shall be the same metallurgy as the preceding heater tube.

The design temperature is calculated based on the actual maximum operating temperature for the
cross-over piping and the tubes in the banks. Hence, the metallurgy of the cross-over piping can
be different from the metallurgy of the preceding heater tube.

Accepted, provide that technical considerations will be considered (eg. Stress calculations, galvanic
corrosion due welding of different materials etc.)

Section 6 - Tube supports

6.1.1.b:

The design temperature for tube support ……: For the convection section, the temperature of the
flue gas in contact with the support plus 100°F (56°C) for gas firing or plus 200°F (111°C) for oil
firing.

TECHNIP uses a computer program to calculate the tube support temperature in the convection
section. This program calculates the tube support temperature on basis of the amount of
convective and radiative heat received by the tube support from the flue gas, and the amount of
radiative heat lost by the tube support to the tubes.

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Accepted, but calculations to be submitted to PPC for approval.

6.1.3:

The unsupported length of horizontal tube shall not exceed 35 times the outside diameter or 20 feet
(6 meters), whichever is less.

The unsupported length of horizontal tubes is defined by calculated deflection limitations (Not by 35
x outside diameter).

Not accepted, PPC insists that the unsupported lenght for this furnace will be maximum 6 meters,
in accordance with API. Technip will limit the length within 6 meters.

6.1.4:

The minimum corrosion allowance for all exposed surfaces of each tube support and guide
contacting flue gases shall be 0.05 inch (1.3 millimeters) for austenitic materials and 0.10 inch (2.5
millimeters) for ferritic materials.

It is TECHNIP’s proven design to apply no corrosion allowance for tube supports since, in an
ethylene plant, the fuel gas and its respective flue gasses are non corrosive and clean (sulfur free).

It was agreed that Technip will provide corrosion allowance on exposed surface of tube supports in
accordance with API 560 (no deviation on this point).

6.1.5.1:

Tube sheets shall be structural plate..........

TECHNIP uses structural plate as well as castings.

API560 is based on the assumption that refractory lined end tube sheets are used. Refer to
paragraph 6.1.5.3. Furthermore high temperature resistant materials are required in cracking
furnaces. Those materials are difficult to weld.

Accepted.

6.1.5.2:

Minimum thickness of tube sheets shall be 13mm.

TECHNIP calculates the required thickness, there is limitation on the thickness of the tube sheet.
API560 is based on the assumption that refractory lined end tube sheets are used. Refer to
paragraph 6.1.5.3.

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Project N° Unit Doc. Type Material Code Serial N° Rev. Page Project N° Unit Doc. Type Material Code Serial N° Rev. Page

31961 30 JSD 0126 001 0 22/36 3930 30 JSD 0126 001 1 22/36

Accepted.
6.1.5.3:

Tube sheets shall be insulated on the flue gas side with a castable having a minimum thickness of
3 inches (76 millimeters) for the convection section and …….

TECHNIP’s standard is not to use refractory lined tube sheets. Application of refractory is difficult
and prone to damage when tube pitches are small (as in many coil designs).
When high design temperatures would lead to expensive high alloy tube sheet materials,

TECHNIP does consider the use of refractory lined tube sheets.

Accepted.

6.1.5.4:

Sleeves with an inside diameter at least ½-inch (13 millimeters) greater than the tube or the
extended surface outside diameter shall be welded to the tube sheet at each tube hole, …

Sleeve ID of 13 mm greater than tube or extended surface will not be used, because of flue gas by-
pass. TECHNIP uses for extended surface 3 - 10 mm and for bare tubes 10 mm.

Accepted.

6.2.2:

The tube support maximum allowable stresses at design temperature shall not exceed the
following:
a. Dead load stress: …..

Tube support allowable design stress used by TECHNIP is 0.8 * the average stress to rupture at
100,000 hours.

Accepted

b. Dead load plus frictional stress: ….

For dead load plus friction (start-up) TECHNIP uses the allowable design stress: 0.8 * the average
stress to rupture in 10,000 hours.

API560 appendix D gives average stress values for rupture and 1 percent creep in 10,000 hours
for a limited amount of materials only. TECHNIP uses many materials that are not covered by this
code

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Accepted.
6.2.3:

For castings, a casting factor multiplier of 0.8 shall be applied to the allowable stress value.

TECHNIP does not use a casting factor to the allowable stress value.
In fact, the factor 0.8 in the TECHNIP standard approach (refer to 6.2.2) replaces the casting
factor.

Accepted.

6.2.4:

Stress data are presented in Appendix D.

TECHNIP is not using design stress data as per appendix D, but stresses to rupture guaranteed by
the vendor.

Accepted, but “average” to be deleted by Technip.

Section 7 - Refractories and insulation

7.1.1:

The temperature of the outside casing of the radiant and convection sections and hot ductwork
shall not exceed 180°F (82°C) at an ambient temperature of 80°F (27°C) in still air```. Radiant floors
shall not exceed 195°F (91°C).

The maximum outside casing temperature of the radiant and convection sections of 82°C at
ambient 27°C and 0 m/sec wind (radiant floor 91°C) cannot be met at all locations, due to high box
temperatures.

This clause is marked •, which means to be discussed with client.

Our proven design basis is incorporated in chapter 3.

Accepted, but Technip to inform actual calculated casing temperatures at ambient site conditions
(temp., wind velocity).

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7.1.3:

Any layer of refractory shall be suitable for a service temperature at least 300°F (167°C) above the
calculated hot face temperature.

TECHNIP proven standard design uses the following margins: (refer to chapter 3)
· Dense brick, shapes and mortar: 50K
· Monolithic: 50K
· Insulating firebricks and mortar: 130K
· Insulating block / -mixes 100K
· Ceramic fiber products for:
· packing purpose: 100K
· thermal lining: 200K

Accepted, in view of temperature levels in cracking furnaces being higher than for heaters.

7.1.4:

The floor hot surface shall be a 6.4 centimeter thick layer of.......

TECHNIP does not apply a standard floor refractory thickness. The floor refractory thickness is a
result of the calculation based on the hot face temperature for the radiant box as calculated by
SPYRO.

Accepted.

7.1.5:

Burner blocks shall have a minimum service temperature of 3000°F (1650°C).

This requirement can give material problems for the blocks and/or anchors. The higher the
minimum service temperature, the higher the thermal conductivity of the burner block. Compliance,
therefore is possible, but it hinders compliance with paragraph 7.1.1. TECHNIP standard of 1599°C
is sufficient from a technical point of view.

Accepted.

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7.1.6:

….. Target walls with flame impingement on one side may be of brick or of plastic refractory of
equivalent maximum service temperature. Either may be backed by a castable or ceramic fiber
board.

TECHNIP allows besides castable and ceramic also calcium silicate fiber board.

Accepted.

7.1.9:

Maximum temperatures for anchor tips are listed in Table 9.

API 560 TECHNIP
Carbon Steel 427°C 425°C
TP 304 stainless steel 760°C 800°C
TP 310 stainless steel 927°C 1000°C
RA 330 stainless steel 1038°C 1100°C
Alloy 601 1093°C 1100°C

TECHNIP’s maximum allowable temperatures are related to the scaling temperature of the material
concerned.

Accepted.

7.2.8:

Brick linings shall be supported by metal support shelves (lintels) attached to the casing on vertical
centers not to exceed 6 feet (1.8 meters). Support shelves shall be slotted to provide for differential
thermal expansions. Shelf material will be defined by the calculated service temperature; carbon
steel is satisfactory up to 700°F (371°C).

Brick shelves are of TECHNIP design, carbon steel integrated in steel wall panel. Not bolted shelf
plates to wall angels. The allowable temperature is 425°C.

Accepted.

7.3.5:

Anchors for total castable thickness up to 15.2 centimeter shall be a minimum of 4.8 millimeter
diameter. Greater thickness requires a minimum of 6.3 millimeter diameter anchors.

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TECHNIP uses 6 millimeter diameter bull horn anchors regardless the lining thickness. Exception
are the welded V-anchors which are 4 or 5 millimeter diameter depending on the lining thickness.

Accepted.

7.3.7:

Anchors in 2-inch (5 centimeter) thick castable lining shall be held in place by 10 gauge minimum,
bare carbon steel chain-link fencing, wire mesh, or linear anchors anchored to the steel.

At vendors/TECHNIP the term “linear anchors” is unknown. TECHNIP does not use wire mesh,
because TECHNIP has bad experience with this. TECHNIP practice is to use V-type or bull horns
anchors.

Technip practice accepted.

7.4.3:

Any layer of ceramic fiber shall be suitable for a service temperature at least 500°F (260°C) above
its calculated hot face temperature.

This requirement is often not possible (no materials available which can withstand the temperature).
TECHNIP standard practice is to use a temperature of 200°C.

Technip practice is acceptable to PPC only if no suitable materials in compliance with API can be
found.

A suitable material for a realistic price is not available. Technip would like to point out that
classification temperature of applied fibre is 1430°C . The arch calculated hot face temperature is
1097°C and fluegas temperature in crossover is 1230°C.

7.4.15:

Anchor assembly shall be located in the module at.......

Anchoring depends on execution of module and location. Vendor’s recommendation is important,

and normally followed in this respect.

Accepted.

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7.5.6:

….. Block insulation shall not be used as backup material in floor construction.

TECHNIP uses block insulation (calcium silicate) as backup material in floor constructions as well,
to reach acceptable floor temperatures.

HOLD; Technip to advise if alternatives are available as back-up layer for floor refractory. If no
suitable alternatives are available, then block insulation may be provided instead.

The insulation block is required to reach acceptable floor temperature. Not using insulating block
shall require a total redesign of the refractory floor. Furthermore the steel casing temperature will
increase in case of not using the insulating block. Therefore Technip will proceed with Technip
standard.

7.6.2.b:

The following materials shall have a composition as shown:

Ceramic fiber, at least 45 percent Al 2O3; remainder primarily SiO 3 or ZrO2.

TECHNIP uses (also) ceramic fiber materials with less than 45% Al2O3. Suitability is determined by
the classification temperature and not by the chemical composition.

HOLD; Technip to clarify consequences on material properties in case % Al2O3 is below 45%
(impact on lifetime)

There is no impact on lifetime of the ceramic fibre to be expected.

Section 8 - Structures and appurtenances

8.1.5:

Design metal temperatures of structures and appurtenances shall be calculated metal temperature
plus 56°C, based on..........

TECHNIP uses the calculated metal temperatures without additional safety since maximum load
case is based on operating load plus maximum wind velocity, which gives a casing temperature
equal to ambient.

This clause is marked •, which means to be discussed with client.

Accepted.

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8.2.3:

Heater casing shall ...... Casing when used as part of the main structure, shall be 6 millimeter
minimum thickness. Floor and radiant roof plates.... 6 millimeter minimum thickness....

TECHNIP uses 5 millimeter steel plate for all walls and roofs which are part of main structure,
except for floors, which are 6 millimeter steel plate.
TECHNIP will prove by means of calculation that the combination of plate thickness, stiffeners and
material characteristics is able to withstand the applied loads.

Accepted.

8.3.1.4:

.....horizontal partitions shall be provided in convection section header boxes on a spacing not to
exceed 1.5 meters.

TECHNIP provides one vertical and one horizontal sealplate in between each convection coil in the
header boxes. The distance can be more than 1.5 meters.

Accepted, provided that distance does not exceed 1.7m.

8.4.4:

Platform decking....grating....

TECHNIP uses 30x3 millimeters galvanized grating with a weight of approximately 25 kg/m 2.

Accepted, provided that density is not lower than value resulting from 25x5mm grating as per API
(Technip to check).

8.4.8:

Stairways.........The slope of stairways....

For stairway TECHNIP follows its own standards.

Accepted, PPC prefer to have a uniform design of stairs throughout the plant if feasible.

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Section 9 - Stacks, ducts, and breeching

9.1.9:

Breechings shall have a clear distance beyond the last........convection row of 0.8 meters for
access and flue gas distribution.

TECHNIP uses 0.5 meters, in between the coils.

Note that in TECHNIP’s standard design, the access door is located in the breeching, so above
mentioned clearance can be limited to the value required for flue gas distribution only, being 0.5
meters.

Accepted.

9.2:

Design considerations....

TECHNIP uses European Codes for the standard design, however local codes and client
standards are used if required according to the contract.

API560’s stack calculation method is incomplete. The European codes TECHNIP uses (i.e.
CICIND and BS) provide a complete and consistent calculation method.

Contract appendix 21-D stipulates use of American codes (AISC) and several Iranian codes. DIN
codes may be acceptable to PPC as alternative (not “European codes”), However, Technip to
revert to PPC in case they intend to deviate from the contract.

9.3:

Allowable stresses....

TECHNIP uses European Codes for the standard design, however local codes are used if required.

Refer to 9.2.

See 9.2.

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9.4:

Static design....

TECHNIP uses European Codes for the standard design, however local codes are used if required.

Refer to 9.2.

See 9.2.

9.5:

Wind-induced vibration design....

TECHNIP uses European Codes for the standard design, however local codes are used if required.

Refer to 9.2.

See 9.2. Specific alternate code for stacks (for example DIN) may be used if American codes are
considered inadequate by Technip.

9.6:

Materials....

TECHNIP uses European Codes for the standard design, however local codes are used if required.

See 9.2. Since Technip envisages Iranian supply and fabrication of furnace steel (in order to
achieve the necessary Iranian content) use of DIN shapes/profile sizes in combination with
design/calculations according to AISC is acceptable to PPC, in case required in view of availability
of materials on the Iranian market.

Section 10 - Burners and auxiliary equipment

10.1.6:

Unless otherwise specified, gas pilots shall be provided for all burners.

TECHNIP provides normally only gas pilots if this is a client/authority requirement or in case of fuel
oil firing. Since local operator attendance during lighting of the burners is required in all cases, the

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use of a portable ignition lance requires no additional operational staff, and it ensures the safe start-
up procedure.

Accepted.

10.1.12:

The burner shall be selected to use no less than 90 percent of the maximum draft available for the
maximum specified heat release.

This requirement does not specify clearly the burner combustion air system. Combustion air
passes the following items when flowing from outside the furnace into the firebox:
• combustion air duct inlet
• silencer
• combustion air duct
• damper
• burner throat

The “no less than 90 percent” should be considered over the combustion air duct inlet, silencer,
combustion air duct, and burner throat excluding damper.

Correct, accepted (see correction in above sentence)

Section 11 - Instrument and auxiliary connections

11.1.2.4/11.1.2.5/11.1.2.6:

Provide a connection in the convection section outlet immediately after the final process or utility
coil.
Provide connections upstream and downstream of the draft control dampers.
Provide connections in the inlet and outlet ductwork connected with a fan.

TECHNIP provides normally only one connection after the convection section. This connection is
in the convection section outlet after the final process or utility coil, and upstream the draft control
dampers.

Not accepted, Technip shall follow API.

Note: Technip are considering to use speed controlled fans instead of dampers to control the
furnace draft in view of better experiences with this method in the recent years (extra cost will be
absorbed by Technip).

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11.1.3.3:

The connection shall be 4-inch NPS, Schedule 80 pipe with a 150-pound raised flange. The pipe
shall be welded to the outside casing plate and project 8 inches (20 centimeters) to the face of the
flange. ….. The pipe shall extend into the heater to within 1 ½ inches (3.8 centimeters) of the hot
face of the refractory lining.

TECHNIP standard is to use 5.0 centimeters. For both flue gas sample point and process check
nozzle connections TECHNIP uses as standard 2 inch schedule 40 pipe projected 150 mm to the
face of the flange.

For oxygen analyzer connection TECHNIP uses as standard 4 inch instead of 3 inch pipe.

Accepted

11.3.1.2:

A minimum of two purge connections shall be provided for each firebox. ….

TECHNIP provides normally no purge connections in the firebox. The use of purge connections for
snuffing steam in ethylene furnaces is not necessary and advisable, because the firebox can
withstand an internal fire due to the high quality refractory used and the refractory will be damaged
due to large temperature differences if snuffing steam would be used.

Accepted.

Section 12 - Shop fabrication and field erection

12.5.5:

The mortar joints in firebrick construction shall be as thin as possible. ….. Brick should be placed
against the mating surface and tapped gently to ensure uniform joints, no more than 1/16 inch (1.5
millimeters) wide.

Mortar joints in brick lining are between 1 and 2 mm, instead of 1.5 mm maximum as per this
paragraph.

Accepted. Note: erection is done through PPC.

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Appendix E - Centrifugal fans for fired heater systems

E.2.1.10:

Fan arrangement and bearing support shall be …. with fan impeller located between bearings
….when any of the following conditions exist:
Driver rated power of 150BHP (120 kilowatts) or greater.
Speed greater than 1800 revolutions per minute.
Maximum specified operating temperature greater than 450°F (233°C).
Corrosive or erosive service
Services subject to fouling deposits that could cause rotor unbalance

TECHNIP standard is to install overhang fans and not in between bearing fans. The overhang fans
are more compact to install and there is good operating practice with this type of fan.

Accepted. Note: fans are rated <120kW and T<233°C.

E.2.9.1:

…. Unless otherwise specified, fans rated at 150 BHP (120 kilowatts) or greater shall have
horizontally split, self-aligning hydrodynamic bearings.

Horizontally split, self-aligning hydrodynamic bearings means that the bearings are using lube-oil
from a lubrication system. This lubrication system consists of a lube oil tank, lube oil pumps, lube
oil filters, air cooler etc. For all fan powers TECHNIP standard practice is to install fans with only
bearing and lube oil, and not with a separate lubrication system.

Accepted. Note: fans are rated <120kW.

Appendix F - Air preheat systems for fired process heaters

This appendix has not been reviewed.

Not applicable, no air preheater is applied.

5. Refractory lining
5.1 Design Basis
The lining will be calculated for the following requirements:

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1. The average outer skin temperature of the furnace will not exceed 70 °C at design ambient
conditions of 20 °C and a wind velocity of 2 m/s.
2. The average floor temperature of the furnace will not exceed 90 °C at design ambient conditions
of 20 °C and a wind velocity of 2 m/s.
3. Lining must be stable at maximum ambient temperature, 0 m/s wind and solar radiation. The
used safety margins on lining materials are as per par. 2.3.
4. Heat loss through wall, at operating conditions, will not exceed 800 W/m² at 20 °C and a wind
velocity of 2 m/s.
5. Lining must be suitable for the minimum ambient temperature and a wind velocity of 2 m/s.

The temperatures used in the calculation are the by the process department calculated hot face
temperature for the radiant box and flue gas temperature for the rest of the furnace. All
temperatures used are for maximum operating and end of run condition.

Accepted.

5.2 Calculation Method for the Refractory Lining

The heat transfer calculations are done with a program that calculates heat transfer by comparing
the heat flux due to conduction with the heat transfer from a hot wall. By iteration, a wall
temperature and heat flux is calculated. The calculation method is according ASTM C 680 or for
ambient temperatures of less than -17.8° C according VDI 2055.

Accepted.

The casing temperatures will deviate from the calculated casing temperatures in the following
areas:

• At peephole/inspection doors
• Around burners
• At location of tube sheet ears
• At locations of welded stiffeners and/or supports on the inside wall
• Around tube entries and instrument connections
• Floors and walls in vicinity of hot equipment

This is considered to be acceptable.

Accepted.

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5.3 Refractory material selection

Materials are selected considering, maximum application temperature, expected shrinkage at
operation temperature and mechanical stability as described by process.

Further material selection is based on operation conditions being normal for the type of furnace
specified, such as thermal shocks during emergency shut downs, combustion atmosphere, fuel
impurities, chemical attack, etc.

Accepted.
The following safety margins are put on the maximum service temperatures as claimed by the
manufacturers:
· Dense bricks, shapes and mortar: 50 K
· Monolithic: 50 K
· Insulating firebricks and mortar: 130 K
· Insulating block/ -Mixes: 100 K
· Ceramic fibre products
- for packing purposes: 100 K
- for thermal linings: 200 K

Accepted.

5.3.1 Burner blocks

Requirements for burner blocks can be found in technical specification: Burner block.

Accepted, but specification to be submitted for review by PPC during basic design.

5.4 Anchoring Material Selection

Allowable anchor tip temperatures in continuous and intermittent service are according following
table:

Material: Up to and including

Inconel 601 1100 °C
RA 330 1035 °C
SS 310 1000 °C
SS 304 or SS 316 800 °C
Carbon Steel 425 °C

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For anchors applied in overhead location, above maximum temperatures should be reduced with 50
K.

Accepted.

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