KINGDOM OF THAllAND
P T O E M A T O I Y O THAILAND
E R L U U H RT F

BONGKOT - ERAWAN - KHANOM
GAS TRANSMISSION PIPELINE P...
5.0

VOLUME 5 TABLE OF CONTENTS
5.0

VOLUME 5 TABLE OF CONTENTS

5.1

2001-F-03 A&B (HS-101 A&B) Heating Medium Heaters
5.1.1 Purchase Order
5.1.2 Specifi...
5.1

2001-F-03 A&B (HS-101 A&B) Heating Medium Heaters
Badger Oesian 6 Constructors. I ~ c .
8313 ~ o u t h G s Freeway
t
Suite 300
Houston. TX 77074

(713) 272-2400

FAX (713) ...
Badger Design 6 C~nSt~ctoIa.
InC.
8313 Southwest Freeway
Suite 300
Houston. TX 77074

TO: AMERICAN HYDROTHERM
470 PARK AVE...
Badgec Oesign d l Constructors. tnc.
8313 Southwest Fraeway
Suite 300
Houston. T X 77074

(713) 272-2400
FAX (713) 272-242...
Badger O 4 i n 6 Constructon. Inc.

(713) 272-2400

8313 SarMwed Freeway
Suite 300
Houston. T X 77074

FAX (713) 272-2424
...
Badger Design JConstructom. lnc.
l
8313 Southwe& Freeway

Suite 300
Houston. TX 77074

(713) 272-2-

FAX (713) 272-2424

B...
Badger Design 6 Con?rtructofa. Inc.

(713) 272-2400

0313 !Southwest Frwway
Suite 300
Houston. TX 77074

FAX (713) 272-242...
(713) 272-2400

Badger W i n & C o n s t ~ d o r sInc.
.
8313 Southwest Freeway
Suite 300
Houston, TX 77074

FAX (713) 272...
Badger W i n & Comt~ctora.
Inc.
8313 Southwest Freeway
Suite 300
Houston. TX 77074

(713) 2702FAX (713) 272-2424

AGENT FO...
Badger Design 6. Conot~ctm,
Inc.
8313 Southwest fre%way
Suite 300
Houston, T X 77074

-

(713) 272-2400

FAX (713) 272-242...
Badger Design i ConstructOfS. Inc.
%
8313 Southwest Freeway
Suite 300
Houston. TX 77074

(713) 272-24M)
FAX (713) 272-2424...
Badger Design 6 Constructors. Inc.
8313 southwest Freaway
Suite 300
Houston. T X 77074

(713) 272-2400

FAX (713) 212-2424...
Badger Design & Const~ctors.
Inc.

(713) 272-2430

8313 Southwest Freeway

FAX (713) 272-2424

Suite 300
Houston. TX 77Q74...
Badger Design 6 Constructo(s. I ~ c .
8313 Sarthwest Fresway
Suite 300

(713) 272-2400

FAX (713) 272-2424

Houston. TX 77...
Badger W i n & Const~ctors.
Inc.
8313 Sournwest Freeway
Suite 300

(713) 272-2400
FAX (713) 272-2424

Houston. TX no74

--...
BADGER DESIGN & CONSTRUCTORS, INC.
AB.l(*raC.m~..1

Houston, Texas
SPECIFICATION
FOR
HEATING MEDIUM HEATERS

BADGER ITEM N...
TABLE OF CONTENTS

1.0

SCOPE

2.0

CONFLICTING REQUIREMENTS

3.0

REFERENCE SPECIFICATIONS

4.0

SITE CONDITIONS

5.0

IT...
SPECIFICATION

FOR
HEATING MEDIUM HEATERS
ITEM NO. HS-1-01A/B
1.0

SCOPE
This specification covers the requirements for fu...
5.0

ITEMS TO BE SUPPLIED BY VENDOR
The following shall be included with each basic
structure:
5.1
5.2
5.3
5.4
5.5

6.0

B...
8.4

Burner design shall permit a turndown ratio of 4: 1 of
design heat load with either fuel

8.5

Burners and heaters sh...
8.11 Heater vendor shall provide one (1) tube skin
thermocouple on the outlet tube of each radiant pass
located such as to...
8.19 Stack Requirements
8.19.1

8.19.2

The stack shall include 3 inch IPS flanged
onnections for EPA type stack sampling,...
(setting the fuel burning priorities)
9.1.4

Both the liquid fuel (Stream 8 ) and the
natural gas (Stream 5) must be capab...
10.2.7

All washers shall be covered with LDS-moldable
(or equivalent) or a ceramic fiber patch,
after the fasteners are l...
14.5 In addition to the normal requirements for erection
drawings, the furnace vendor shall submit a written
erection proc...
15.7 ~ l l
radiant tube hanger castings shall be given 100%
liquid penetrant examination. Any defective areas found
near s...
SAIPEM S.P.A.
KHANOM OFFSHORE FACILITIES
(IIEATING-MEDIUM IIEATER SPECIFICATION)

L,

-

MASS BALANCE Ill

BADGER DESIGN 8...
FIRED HEATER DATA SHEET
I
cient

S,t?d.

SX/PE&

I

F I R E D H E A T E R L?b.T,4 S i . ! C : C : T
-----

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I t e m no.

I

I

COMBU...
Client

S A ? / P W C.P.4.

Item no.

ns- a /A/&
1

MECHANICAL DESIGN CONDITIONS

1

Plot L l m t t a t l o n s .

2

Tube...
F I R E D HEATER
client

SAIPP'M

sk&!

DATA SHEET

KS-/e/

I tern no.

MECHANICAL DESIGN D E T A I L S ( C 0 N T ' D . l
...
FIRED HEATER DATA SHEET
Itemno.

&-/a/

M E C H A N I C A L D E S I G N D E T A I L S ICONT'O I
1

2

CASING. R E F R A C ...
F I R E D H E A T E R
Client

S A / P k > ? Z,E4,

D A T A SHEET

Item no.

&'S-

/o/
A/&

D E T A I L S OF H E A T E R AP...
W

cr

m-

I

BADGER DESIGN &

I
Phone (211) 889-7100

AMERICAN HYDROTHERM CORPORATION
470

Park Avenue

South

New Yo&, New Y d 10016

HANDBOOK OF INSTRUC...
American Hydrotherm Corporation
470 Park Avenue South
New York, NY 10016
Job No. AM-2579

HYDROTHERM HEATING MEDIUM HEATER...
AMERICAN HYDROTHERM CORPORATION

Job No.

AM-2579

EOUIPMENT DESCRIPTION
2.

Heating Medium Heaters:
Stack for Heaters
:

...
AMERICAN HYDROTHERM CORPORATION
Job NO. AM-2579
111. SYSTEM

1.

-

SUGGESTIONS

Heatins Medium Svstem
Basic heating mediu...
AMERICAN HYDROTHERM CORPORATION
Job No. AM-2579

3.

Heatins Medium Svstem Testins, Ventinu, Steaminu Out
(continued)
Firs...
AMERICAN HYDROTHERM CORPORATION

1.

Turn circuit breaker CB-1A I8ONNlocated inside the electrical
control panel and close...
AMERICAN EYDROTHERM CORPORATION
Job No. AM-2579

5.

If all limits in operational limit circuit are satisfied and
when SS-...
AMERICAN HYDROTHERM CORPORATION
Job NO. AM-2579

12.

Upon detection of pilot flame by scanner, Fireye programmer
proceeds...
AMERICAN HYDROTHERM CORPORATION

Job NO. AM-2579

SET POINT SCHEDULE
NOTE :

Initial settings listed herein are preliminar...
AMERICAN HYDROTHERM CORPORATION

TAG

FUNCTION

RANGE

Fuel Oil Pressure
Reducing Valve
Differential Pressure Gage

INITIA...
INPORTANT NOTICE T O OUR CLIENTS

Due t o t h e growth i n claimed product l i a b i l i t y and p r o f e s s i o n a l
l...
Equipment S t a r t - S t o p Buttons
I t i s p r e f e r r e d t o have s t a r t - s t o p b u t t o n s w i t h i n s i...
Combustion Eauipment
Diaphragm v e n t s on g a s r e g u l a t o r s and gas a i r r e g u l a t o r s
and t h e g a s v ...
I

N

D

E

X

DESCRIPTION

INDEX NO.

B-A, B-B
AB-A, AB-B
BAS-A, BAS-B
FCV-001-A, FCV-001-B
ESV-001-A, ESV-002-A
ESV-001-...
I
TAG
-

N

D

E

X

DESCRIPTION

INDEX NO.

MAIN GAS PRESS. REGULATOR

16

MAIN GAS SOLENOID

17

TEMPERATURE CONTROLLER
...
INDEX NO.

DUAL FUEL BURNER
B-A,

B-B

A I R BLOWER
AB-A,

AB-B

BURNER A I R SHUTTER
BAS-A,

BAS-B

BUTTERFLY GAS VALVE

...
FY-6033

American H y d r o t h e r m

North American

SERVICE MANUAL

Cleveland, OH 44105 USA

American H y d r o t h e r...
'

Nortb American



Mfg. Co.
Cleveland. OH 44105 USA

'

4131, 5131, 6131
PACKAGED AUTOMATIC

L


BURNERS

Engineering
SP...
NORTH AMERICAN Mfg. Co.
Cleveland, OH 44105 USA

The Packaged Automatic Burners are ideal for steel firebox,
scotch marine...
i

I!

Instruction Manual
Mfg. Co.
Cleveland. OH 44105 USA

Norm

Gas, Light Oil & Dual-Fuel Burners

Full Modulating Oper...
NORTH AMERICAN Mfg. Co.
Cleveland, OH 44 105 USA

Engineering Supplement 6 13 1-1. 7-89
Page 2

T a b l e 3. N a t u r a l...
North American


Mfg. Co.
Cleveland. OH 44105 USA

'

l

4/5/6131 BURNER

Capacities, Flame Characteristics, Pressures

En...
3

North American
4/5/6131

Mfg. Co.
Cleveland, OH 44105 USA

L

Engineering



DIMENSIONS 6131

BURNERS

12-90



J

4/51...
NORTH AMERICAN Mfg. Co
Cleveland, O H 44105 USA

Engineering Dimensions 613 1, 12-90
Page 2

41516131-D, E, and FA FRAME S...
i
Initial Starting Procedure

M f g . Co.

121 Service Manual
Section II

Natural Gas Burner
Full Modulating Control

Dece...
NORTH AMERICAN Mig. Co.
Cleveland, OH 44105 USA

16.

Service Manual 121. Section I1
Page 2 o 4
f

Turn t h e manual p o t...
Mfg. Co.
Cleveland. OH 44105 USA

Initial Starting Procedure
Light Oil Burner

121 Service Manual
Section I1
December, 197...
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B 320009 vendor data catalog vol.5

  1. 1. KINGDOM OF THAllAND P T O E M A T O I Y O THAILAND E R L U U H RT F BONGKOT - ERAWAN - KHANOM GAS TRANSMISSION PIPELINE PROJECT KHANOM ONSHORE FAClLl.TIES VENDOR DATA CATALOG Volume 5 Heating Medium Heaters Saipem S.p.A. Badger Design & Constructors Badger Job No. BH283 1 November 1993
  2. 2. 5.0 VOLUME 5 TABLE OF CONTENTS
  3. 3. 5.0 VOLUME 5 TABLE OF CONTENTS 5.1 2001-F-03 A&B (HS-101 A&B) Heating Medium Heaters 5.1.1 Purchase Order 5.1.2 Specification 5.1.3 Handbook of Operating Instructions
  4. 4. 5.1 2001-F-03 A&B (HS-101 A&B) Heating Medium Heaters
  5. 5. Badger Oesian 6 Constructors. I ~ c . 8313 ~ o u t h G s Freeway t Suite 300 Houston. TX 77074 (713) 272-2400 FAX (713) 272-2424 Purchase Order No. : BH-2831-~01-10 Revision: 1 To: AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 File No.: Attn: AL BRUHN H01 Date: 06/07/93 - 7- Issue: 3. Page 1of ~~~~~ 2 - 1 (The Vendor by accepting this order agrees to the several Instructions and Conditions contained herein, including those on the re.[ Ireverse side hereof. Vendor shall sign and return at once to the Purchaser the attached -Vendor's Acceptance of Purchase O d r ' I I J Item Quantity Description Previous P.O. Total: Changes This Revision: NEW PURCHASE ORDER TOTAL: Pricing Details: This revision is issued to delete one (1) Combustibility @, For RICHARD KINATEDER Manager of Procurement BDC-PP-1-1 ( R e v 5191 1
  6. 6. Badger Design 6 C~nSt~ctoIa. InC. 8313 Southwest Freeway Suite 300 Houston. TX 77074 TO: AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, N Y 10016 (713) 272-2400 FAX (713) 272-2424 Purchase Order No.: BH-2831-~01-10 Revision: 1 File No.: H01 Issue: 3. Date: 06/07/93 Page - r 2 of 2 - - 1 llhe Vendor by accepting this order agrees to the several Instructions and Conditions contained herein, including those on the Ireverse side hereof. Vendor shall sign and return at once to the Purchaser the attached *Vendor's Acceptance of Purchase Odr( re: I 1 1 Item Quantity Description NOTES 1 BDC-PP-1-1 (Rev 5/91 1 All other terms, conditions, and instructions of our original purchase order and subsequent revisions thereto remain unchanged and in effect.
  7. 7. Badgec Oesign d l Constructors. tnc. 8313 Southwest Fraeway Suite 300 Houston. T X 77074 (713) 272-2400 FAX (713) 272-2424 AGENT F To: AMERICAN H D O H R Y R T EM 470 P R AVE. SOUTH AK NEW YORK, NY 10016 W P A P u r c h a s e O r d e r No.: F i l e No.: Date: H01 12/21/92 BH-2831-H01-10 Issue: Page 2. 1 of 11 A t t n : AL B R ~ H N I The Vendor by accepting this order agrees to the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once t o the Purchaser the attached uVendorls Acceptance of Purchase Order." I Description Confirming o u r v e r b a l a u t h o r i z a t i o n d a t e d 12/21/92, p l e a s e e n t e r o u r P u r c h a s e O r d e r f o r t h e f o l l o w i n g equipment p r i c e d i n a c c o r d a n c e w i t h y o u r p r o p o s a l P-6915 d a t e d 10-27-92 , r e v i s i o n s d a t e d 11-2-92, 11-4-92, 11-9-92 and f a x ( s ) d a t e d 11-20-92,12-3-92,12-10-92 & 12-21-92 e x c l u d i n g a n y c o n d i t i o n s o f sale t h e r e i n which c o n f l i c t w i t h o r a d d t o t h e "Terms and C o n d i t i o n s n a s l i s t e d o n t h e r e v e r s e s i d e . o f t h i s page, " I n s t r u c t i o n s t o B i d d e r s " i n c l u d e d i n o u r o r i g i n a l i n q u i r y , t h e " I n s t r u c t i o n s t o Vendors" as o u t l i n e d o n t h e f o l l o w i n g pages and any a d d i t i o n a l terms a s set f o r t h below. T o t a l I t e m s Cost: Misc. C o s t s : Pricing Details: MISC. COSTS: -----------$5,000.00 For l ( o n e ) C o m b u s t i b i l i t y test. $5,324.00 For s p a r e p a r t s a s o u t l i n e d on a t t a c h e d e x h i b i t "A". P u r c h a s e O r d e r T o t a l US$: ) Buyer: C. H. STRAUSS For RICHARD KINATEDER 1
  8. 8. Badger O 4 i n 6 Constructon. Inc. (713) 272-2400 8313 SarMwed Freeway Suite 300 Houston. T X 77074 FAX (713) 272-2424 f+PA AGENT To: AMERICAN HYDROTHEFW 470 PARK AVE. SOUTH NEW YORK, NY 10016 Purchase Order No.: File N . o: H01 Date: 12/21/92 BH-2831-H01-10 Issue: 2. Page 2 of 11 The Vendor by accepting t h i s order agrees t o the several Instructions and Conditions contained herein, including those.on the reverse side hereof. Vendor shall sign and r e t u m a t once t o the Purchaser the attached "Vendor's Acceptance of Purchase Order." Item Quantity 1 Description HEATING HEDIUM HEATER in strict accordance with the attached Badger specification SPBH-2831-H-101 Issue # 2 Cost Code: HSOOlOl ------------Drawing Schedule Dates Fab Re1 -------------- Material Shipment from Vendor 04/26/93 01/18/93 HEATING MEDIUM HEATER in strict accordance with the attached Badger specification SPBH-2831-H-101 Issue # 2 Cost Code: HSOOlOl Schedule Dates Drawing Fab Re1 -------------- Material Shipment from Vendor 01/18/93 REFERENCE SPECIFICATIONS SPBH-2831-R-1 Issue 1 SPBH-2831-GN-1 Issue 1 SPBH-2831-N-2 Issue 1 SPBH-2831-K-102 Issue 1 SPBH-2831-D-1 Issue 2 SPBH-2831-D-2 Issue 1 SPBH-2831-C-1 Issue 3 SPBH-2831-E-13 Issue 2 04/26/93
  9. 9. Badger Design JConstructom. lnc. l 8313 Southwe& Freeway Suite 300 Houston. TX 77074 (713) 272-2- FAX (713) 272-2424 Badger ~~il~m~at~ompaw AGENT FOR SAIPEM SPA To: AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 Purchase Order No.: File No.: BH-2831-H01-10 H01 Date: 12/21/92 Issue: 2. Page 3 of 11 The Vendor by accepting t h i s order agrees t o the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once t o the Purchaser the attached uVendor8s Acceptance of Purchase 0rder.u Item Quantity Description SPECIAL NOTES 1 NOTE: Progressive payment terms shall be as follows: 10% Upon submittal and acceptance of drawings for approval. 35% Upon verification of receipt of major materials. 45% Upon shipment. 10% Upon -commissioning and or plant start-up, not to exeeed 90(ninety) days after delivery. 2 LADDERS and PLATFORMS as outlined in this order are included in the base price of each item. DRAWINGS: Drawing for approval are promised 4 weeks after receipt of verbal award, or no later than 01/18/93, or as individually referred to by item. The drawings, manuals, and data required per the attached "VENDOR DATA COMMITMENT SHEETn are integral to this order. Vendor accepts responsibility for costs of change or cancellation of equipment or materials ordered prior to drawings being reviewed by Badger and returned marked "Proceed with Fabricationn. *** IMPORTANT NOTES *** 1. All data to be submitted by Vendor must bear on the document itself; P.O. number, item number, client name, and jobsite location. 2. All documents submitted must be clear and legible. All documents submitted must be in the correct number of reproducibles and copies as stated on the "VENDOR DATA COMMITMENT SHEET". 3. 4. Failure to comply with any of the above will delay payment of Invoices and/or result in backcharges to Vendor. SHIPMENT PROMISED Shipment sh.all be completed within 18 weeks after verbal award , or no later than 04/26/93, or as individually referred to by item. Partial shipments must have written prior approval from the Project Expeditor
  10. 10. Badger Design 6 Con?rtructofa. Inc. (713) 272-2400 0313 !Southwest Frwway Suite 300 Houston. TX 77074 FAX (713) 272-2424 AGENT FOR SAIPEM SPA To: AMERICAN HYDROTHERM 470 PARK AVE. SOUTH N W YORK, NY 10016 E P u r c h a s e O r d e r No.: F i l e No.: Date: BH-2831-H01-10 H01 12/21/92 Issue: Page 2. 3 of 1 1 The Vendor by accepting t h i s order agrees t i t h e several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once to the Purchaser the attached Wz-ndoras Acceptance of Purchase Order." 1 Item Quantity Description INSPECTION REQUIREMENTS Authorized, Progressive, Final F.O.B.: 4 Port of exit. SHIP TO: 1 Badger Design & C o n s t r u c t o r s , I n c c / o F r e i g h t Forwarder (To f o l l o w ) FREIGHT : 1 F r e i g h t costs are n o t i n c l u d e d i n t h e p u r c h a s e o r d e r t o t a l . F r e i g h t s h a l l b e p r e p a i d and added t o t h e i n v o i c e w i t h s u p p o r t i n g documentation. RELEASE T SHIP: O 1 Vendor w i l l b e r e l e a s e d t o s h i p a f t e r c o m p l e t i o n a n d a c c e p t a n c e o f equipment, e n g i n e e r i n g drawings, and any o t h e r requirements of t h e order. Vendor must n o t s h i p u n t i l r e l e a s e d by Badger E x p e d i t i n g , o t h e r w i s e t h e material w i l l b e C o n t a c t M s . Brenda Leared r e t u r n e d a t t h e Vendor's expense. (713)272-2450, f o r s h i p p i n g a n d i n s p e c t i o n i n s t r u c t i o n s . TERMS OF PAYMENT: 1 N e t 6 0 d a y s upon c o m p l e t e d s h i p m e n t o f a l l i t e m s . RETENTION POLICY 1 Ten p e r c e n t o f t h e p u r c h a s e o r d e r v a l u e w i l l b e w i t h h e l d from f i n a l payment u n t i l s a t i s f a c t o r y p l a n t s t a r t - u p is performed. I n v o i c e must b e f o r t h e f u l l amount less t e n p e r c e n t r e t e n t i o n n o t t o e x c e e d 90 d a y s a f t e r s h i p m e n t .
  11. 11. (713) 272-2400 Badger W i n & C o n s t ~ d o r sInc. . 8313 Southwest Freeway Suite 300 Houston, TX 77074 FAX (713) 272-2424 AGENT FOR SAIPEM SPA Purchase Order No.: To: AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 File No.: H01 Date: 12/21/92 BH-2831-H01-10 Issue: 2. Page 4 of 11 The Vendor by accepting t h i s order agrees t o the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor s h a l l sign and return a t once to the Purchaser the attached *aVendor's Acceptance of Purchase Order." Item Quantity Description PRICE BASIS 1 Price is firm and not subject to esclation. VENDOR ACCEPTANCE 1 No payments shall be made on the Purchase Order until the signed "Vendor's Acceptance Copy" is signed, dated, and returned to Badger Design and Constructors, Inc. BADGER CONTACT INFORMATION 1 . . Strauss (713) 272-2469 Fax: (713) 272-2484 BUYER: C H " EXPEDITOR: Brenda Leared (713) 272-2450 Fax: " " INVOICES 1 Invoices shall be submitted, in accordance with invoicing instructions in the "Instruction to Vendors", to: SAIPEM SPA C/O BADGER DESIGN AND CONSTRUCTORS, INC. 8313 SOUTHWEST FREEWAY HOUSTON, TX 77074 ATTN: C. ETHERIDGE WARRANTY 1 Warranty shall be in effect for Twelve(l2) months from plant start-up or Twenty Four(24) months from date of shipment, which ever occurs first. INSPECTION REQUIREMENTS 1 This order requires authorized, progressive and final inspections by Badger and/or Saipem SPA. VENDOR DOCUMENTATION 1 Badger approval required prior to manfacturer. CONTACTS
  12. 12. Badger W i n & Comt~ctora. Inc. 8313 Southwest Freeway Suite 300 Houston. TX 77074 (713) 2702FAX (713) 272-2424 AGENT FOR SA-PA Purchase Order No.: T o : AMERICAN HYDROTHEW 470 PARK AVE. SOUTH NEW YORK, NY 10016 BH-2831-H01-10 Issue: 2 . F i l e N o . : H01 Date: 12/21/92 Page 5 of 11 The Vendor by accepting t h i s order agrees t o the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once t o the Purchaser the attached "Vendor's Acceptance of Purchase Order." Item Quantity Description 1 AMERICAN HYDROTHEW: ------------------- Sales: M r . A. L e d i c (212) 889-7100 F a x : ATTACHMENTS 1 S p e c i f i c a t i o n s as l i s t e d herein. 2 "Vendor D a t a Commitment S h e e t " (212) 576-1426
  13. 13. Badger Design 6. Conot~ctm, Inc. 8313 Southwest fre%way Suite 300 Houston, T X 77074 - (713) 272-2400 FAX (713) 272-2424 - Badger A-Canpany INSTRUCTIONS TO VENDORS AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 1 . Page 6 of 11 CORRESPONDENCE -------------- All correspondence shall be sent t o the following address: Badger Deslgn & Constructors, Inc. 8313 Southwest Freeway Suite 300 Houston, TX 77074 .......................... Commercial Issues: to the attention of Buyer (by name) All Other Correspondence: t o the attention of Expeditor as listed in the Purchase Order. 2. VENDOR DOCUMENTATION APPROVAL .............................. The documents listed on the Vendor Data Commitment (VDC) for are subject t o approval as noted in the body of the Purchase Order. 3. VENDOR DATA REPORTS AND FINAL DOCUMENTATION ........................................... Final documentation (as required by the VDC form or specification) containinq material certification, results of nondestructive examination, inspection results,reports,etc., shall be submitted in book form. 4. PRODUCTION SCHEDULES .................... The vendor will be required to submit production schedules stating applicable milestones as follows: Issue of drawings, specific-atiand procedures for approval and certified for manufacture, placement of suborders, receipt of materials, start of manufacture, completion of major manufacturing steps, final assembly, preparation for shipment and delivery date. When suborders entail manufacture and assembly, similar information shall be included for the subassembly parts. ORIGIN OF MANUFACTURE It is understood and agreed that all products used in manufacture of this order will be products of United States manufacture. In the event that the vendor or a subvendor wishes to use products not of United States manufacture, they must obtain specific written authority from Badger prior to the start of manufacture.
  14. 14. Badger Design i ConstructOfS. Inc. % 8313 Southwest Freeway Suite 300 Houston. TX 77074 (713) 272-24M) FAX (713) 272-2424 INSTRUCTIONS TO VENDORS AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 6 . Page 7of 11 SUBORDERS --------Copies of all orders issued by the vendor in connection with this Bad er order shall be sent to Badger Design t Constructors, Inc., inc?uding copies of any orders placed by a subvendor. Copies of any referenced attachments not in Badger's possession should also accompany the suborders. ........................ All vendor and subvendor orders shall contain the following in£ormation: a. Complete description including any relevant drawings or specifications. b Promised delivery date. . c Requirements for origin of manufacture approval (see Paragraph 5). . d. For mill ordered material the mill order number and date of acknowledgement. e. Requirements for final documentation. f A statement extending the required Badger inspection levels, . rights and notification of inspection for the subordered material. ------------------ The copies of the vendor and subvendor orders sent to Badger shall be identified with the Badger purchase order and item number(s). INSPECTION AND TEST REQUIREMENTS ................................ NOTIFICATION of readiness for inspection shall be made by telex, telegraph, telephone or letter at least fifteen (15) working days in advance. Readiness for inspection means either the equipment is complete or that a point in fabrication has been reached which requires witnessed inspection per specification, code requiremen+or written agreement between Badger and/or vendor and Authorized Inspection Agency. REVISIONS TO PURCHASE ORDER ........................... Requests for clarification or change to the purchase order requirements shall be made in writing through the Badger or expeditor. Badger will not be liable to the vendor for any claims for reimbursement for additional costs for extra work or changes to the scope of work which have not been approved in advance and in writing by the Buyer.
  15. 15. Badger Design 6 Constructors. Inc. 8313 southwest Freaway Suite 300 Houston. T X 77074 (713) 272-2400 FAX (713) 212-2424 - INSTRUCTIONS TO VENDORS AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 Page 8 of 11 INVOICING INSTRUCTIONS ...................... Payment of vendor invoices will not be made until all documentation required in accordance with with this order is received. ------- The following information must be included in each invoice for each shipment or partial shipment. Equip./MatVl/Services description and pricing used in vendor's invoice are to be identical to those used in this purchase order. .................... a. ~ u a n t i t ~description, purchase order number and item number. , b Net unit prices, extensions and total amount. . c. Routing, shipping point, FOB point and car number if shipped as a car load. d. Cash discount allowance, if any. e Invoice shall be marked "Partial" or "Final." . ---------------- Mail total, original and copies of invoice with attached supporting documentation as required to the address stated in the body of this order. PUBLICITY --------In the event the vendor wishes to obtain any publicity or to indulge in advertising of the products which they are furnishing against the subject purchase order, it is first necessary that they apply in writing, outlining the details of the publicity or advertisement they wish to accomplish, and obtain written permission from Badger. Under no circumstances shall the vendor approach the client to obtain publicity privileges. OCCUPATIONAL SAFETY AND HEALTH ACT .................................. The vendor further warrants that it, its employees, agents, and suppliers shall comply with the Occupational Safety and Health Act of 1970, any subsequent amendments thereto, or further legislation relating to the subject matter thereof, as well as all applicable standards and regulations promulgated by the United States Department of Labor thereunder. The vendor further agrees that all mechanical design and equipment performance shall comply with all the foregoing requirements and to indemnify and shall hold Contractor and Owner harmless from any and all liablity thereunder for or by reason of any violations, citations thereof or penalties, civil or criminal, arising by reason of any failure so to do on the part of the vendor and/or its employees, agents or suppliers. -
  16. 16. Badger Design & Const~ctors. Inc. (713) 272-2430 8313 Southwest Freeway FAX (713) 272-2424 Suite 300 Houston. TX 77Q74 INSTRUCTIONS TO VENDORS AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 Page 9of 11 EQUAL OPPORTUNITY EMPLOYER .......................... For purchase order made in connection with.a government contract, the vendor, during performance of work under the purchase order, shall agree to comply with executive Order 11246, Section 504 of the Rehabilitation Act of 1973, and Section 402 of the Vietnam Era Veterans Readjustment Assistance Act of 1974, as amended. VENDOR DATA COMMITMENT FORM INSTRUCTIONS ........................................ Required Documents will be indicated by an "Xu in the approiate column by Badger. ----------------- Document Description describes, in general, the type of document required. More specific and detailed requirements are indicated on the Vendor Data Commitment Form (VDC). ...................................... Number of Copies (Print or reproducible) required for review and final issue will be indicated by Badger. ........................................ ARO/ARRD indicated at the time of quotation, the number of weeks after receipt of Purchase Order (ARO) or after receipt of reviewed drawings (ARRD) that the vendor has commited to issue each document.
  17. 17. Badger Design 6 Constructo(s. I ~ c . 8313 Sarthwest Fresway Suite 300 (713) 272-2400 FAX (713) 272-2424 Houston. TX 77074 INSTRUCTIONS T V N O S O E D R A E I A H DOHR M RC N Y R T E M O T 470 PARK AVE. S U H O K NW Y R , NY 10016 E 14. Page 10 of 1 1 D C M N A I N REQUIREMENTS O U E T TO ................................ a. I n a d d i t i o n t o t h e v e n d o r ' s name and drawing number; t h e drawing t i t l e b l o c k s h a l l i n c l u d e a symbol o r letter i n d i c a t i n g t h e l a t e s t i s s u e o r r e v i s i o n , t h e Badger Purchase Order Number and Equipment A 3-inch h i q h by 6-inch wide s p a c e above t i t l e b l o c k is t o b e l e f t b l a n k f o r a p p l r c a t l o n of t h e Badger "Action S t a t u s " d e c a l . ( I f drawing s i z e a l l o w s ) . I t e m Number. ..................................................................... b. R e v i s i o n s made t o drawkngs between i s s u e s s h a l l b e c l e a r l y identified. I n a d d i t i o n , a b r i e f t a b u l a t e d d e s c r i p t i o n s h a l l be g i v e n f o r e a c h drawing i s s u e . The term " L a t e s t Revision" s h a l l n o t b e used. ..................................................................... c. I f t h e vendor is s u b m i t t i n g f i n a l documents a s d i r e c t e d by Bad er, o n l y t h o s e document changes r e s u l t i n from Badger comments ehayl be incorporated. N o t h e r changes s h a y l b e made. o ..................................................................... d. Documents s h a l l b e s u i t a b l e f o r microfilming, and m e e t t h e f o l l o w i n g minimum requirements: - Drawinus s h a l l b e c l e a r and l e q i b l e . Shadinu on d r a w i n s s i s n o t - permissifhe. - L e t t e r i n a s h a l l be a minimum of 1 / 8 i n c h hiah. A r e d u c e z p r i n t s c a l e s h a l l b e prbvided f o r - e a c h drawing where s c a l e is e s s e n t i a l . e. Drawing r e p r o d u c i b l e ~s u b m i t t e d s h a l l n o t be f o l d e d . Prints s h a l l b e f o l d e d t o 8 1 / 2 by 1 i n c h s i z e , and shipped w i t h t h e 1 reproducibles. .................................................................... f. I f "As-built" drawings a r e r e q u i r e d it w i l l be s p e c i f i e d i n t h e purchase order. The q u a n t i t y of "As-builts" drawings r e q u i r e d s h a l l b e t h e same a s f o r f i n a l c e r t i f i e d drawings.
  18. 18. Badger W i n & Const~ctors. Inc. 8313 Sournwest Freeway Suite 300 (713) 272-2400 FAX (713) 272-2424 Houston. TX no74 -- Badger A-Company INSTRUCTIONS TO VENDORS AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016 Page 11 of 11 VENDOR DATA COMMITMENT GENERAL REQUIREMENTS ........................................... a . The Badger Vendor Data Commitment Form ( M C ) indicates the scope, timing, and quantity of documents required. The documents are divzded into two categories: submitted for review, and submitted for information. Documents submitted for review shall be resubmitted as final after Badger's review. b . All vendor documents, including transmittals, shall be clearly marked with the Badger Purchase Order Number, Equipment Number and Title. Failure to comply with these requirements may prolong Badger's review. ..................................................................... c. All document requirements for prime vendor shall be equally binding, as applicable, to any subvendor. The prime vendor shall be responsible to ensure that appropriate documentation requirements are contained in the suborders. ..................................................................... d . Vendor should allow three weeks for review'from receipt by Badger to transmittal by Badger, unless otherwise negotiated or stipulated in the terms of the purchase order.
  19. 19. BADGER DESIGN & CONSTRUCTORS, INC. AB.l(*raC.m~..1 Houston, Texas SPECIFICATION FOR HEATING MEDIUM HEATERS BADGER ITEM NO. HS-101 A/B TAG NO. 2001-F-03 KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND SAIPEM SPA BADGER PROJECT BH-2831 PETROLEUM AUTHORITY OF THAILAND SPECIFICATION NO. SP.G-9210.04-2001-02
  20. 20. TABLE OF CONTENTS 1.0 SCOPE 2.0 CONFLICTING REQUIREMENTS 3.0 REFERENCE SPECIFICATIONS 4.0 SITE CONDITIONS 5.0 ITEMS TO BE SUPPLIED BY VENDOR 6.0 ITEMS TO BE SUPPLIED BY OTHERS 7.0 UTILITIES AVAILABLE 8.0 DESIGN REQUIREMENTS 9.0 CONTROL SYSTEM 10.0 REFRACTORY AND INSULATION 11.0 STRUCTURES, STAIRS AND LADDERS 12.0 DAMPERS 13.0 PIPING 14.0 OTHER VENDOR REQUIREMENTS 15.0 INSPECTION 16.0 PREPARATION FOR SHIPMENT 17.0 GUARANTEE
  21. 21. SPECIFICATION FOR HEATING MEDIUM HEATERS ITEM NO. HS-1-01A/B 1.0 SCOPE This specification covers the requirements for furnishing two (2) horizontal heaters as described in this specification. The heaters shall operate 24 hrs/day continuously. The location of the equipment will be outdoors, unprotected, in an industrial seashore environment. The heater shall be designed, fabricated, inspected and constructed in accordance with API Std. 560. If any portion of API Std. 560 is in conflict with this specification, this specification shall govern. 1.2 1.3 2.0 Compliance by the vendor with the provisions of this specification does not relieve him of the responsibility of furnishing the unit and accessories of proper design, mechanically suited to meet the operating guarantees at the specified service ,conditions. The heaters shall be prefabricated and preassembled in vendor's shop to the maximum extent possible. CONFLICTING REOUIREMENTS 2.1 3.0 All conflicts between the requirements of this specification, purchase order, specification sheets, and standards shall be referred to the purchaser for clarification before proceeding with the manufacture of the affected parts. REFERENCE SPECIFICATIONS Issue SPBH-2831-GN-1 SPBH-2831-R-1 SPBH-2831-D-1 SPBH-2831-D-2 SPBH-2831-C-1 A 4.0 Equipment Noise Level Limits Shop Painting Design of Structures Fabrication of Structural Steel Pip.inq Material Class 1 1 2 1 2 SPBH-2831-~-2 SPBH-2831-K-102 SPBH-2831-E-13 piping Insulation Instrumentation for Packaged Systems Low Voltage NEMA Frame Motors Q 1 1 2 SITE CONDITIONS Ambient Temperature: Environment : Electrical Area Classification: BADGER DESIGN & CONSTRUCTORS. INC. ISSUE 76OF to 91°F Seashore, Industrial Class I, Group D, Div. 2 DAIT: 4 - 1 -& s ~ a 3 of 2 0 SPBH-2831-H-101
  22. 22. 5.0 ITEMS TO BE SUPPLIED BY VENDOR The following shall be included with each basic structure: 5.1 5.2 5.3 5.4 5.5 6.0 Burners with electric ignition pilots Platforms and ladders Outlet manifold Flame safeguard and control system with purged, weatherproof panel. Panel to display motor on/off (system logic) Fuel piping trains, including flexible connections at the burner(s). . ITEMS TO BE SUPPLIED BY OTHERS 6 : l 6.2 6.3 6.4 6.5 7.0 heater ~oundation,support piers and-anchorbolts Heater erection piping between fuel piping/safeguard manifold and heater. Motor starters ~eletedn UTILI-TIESAVAILABLE Power Supply: Controls: Instrument Air: 415V/3 Phase/50 Hertz 220V/1 Phase/50 Hertz 80 psig, -40°F Dew Point Design Temperature - 100°F FUELS: Gas to Fired Heater (Stream 5) Design Pressure - 450 psig Design Temperature - 200°F Cold Stable Condensate (Stream 8) Design Pressure - 125 psig ~esign Temperature - 350°F Stabilizer Overheads (Stream 12) ~esign Pressure - 125 psig ~esign Temperature - 350°F 8.0 DESIGN REQUIREMENTS 8.1 Each heater shall be designed, fabricated, inspected, and constructed in accordance with the criteria of ASME A oiler and Pressure Vessel Code, Section I. 8.2 Each heater shall be designed to fire the three fuels described in the data sheets. 8.3 Each furnace shall be furnished with one dual f u e l A burner. The burner pilot shall burn fuel gas and shall be suitable for electric igniti0n.n I 1 BADGER DESIGN b CONSTROC TORS. INC . ISSUE DATE 1.4 1 3 - ~ 1 - 4 3 1 = ~ OF20 SPBH-2831-H-101
  23. 23. 8.4 Burner design shall permit a turndown ratio of 4: 1 of design heat load with either fuel 8.5 Burners and heaters shall be sized to permit firing at least 120% of design heat liberation. 8.6 Heater casing temperature shall be calculated based on ambient air to 80°F and a 5 mph wind. Maximum outside casing surface temperature shall be equal to or less than 200°F. 8.7 A complete flame safeguard and temperature control system shall be furnished for each heater by the vendor. The systems shall conform with NFPA standards and shall be FM approvable, Panel mounted items shall be enclosed in a pre-wired and tested fabricated steel panel (NEMA 4X outdoor). All components of the system shall be UL listed and shall i.nclude, but not limited to: .A 8.7.1 8.7.2 with Flame relay w / W scanner on burner(s) with self-checking feature and aux. contacts in local panel annunciator. 8.7.4 Ignition transformer. 8.7.5 Auxiliary relays and selectors. 8.7.6 Time delay relays for purge and trial for ignition. 8.7.7 Space heater and thermostat. 8-7.8 Indicating lights and pushbuttons. 8.7.9 I High temperature switch with DPDT contacts. 8.7.3 8.8 Annunciator (First-out indicating) auxiliary contacts for purchaser's use. I The design and supply of instruments and control systems shall satisfy the requirements of SPBH-2831-K-102 and its annexes. (If required) I II Heaters shall be single pass. A11 manifolds shall b e n sized to minimize maldistribution of hot oil through individual parallel heater passes. Manifolds and crossover piping shall be designed in accordance with ANSI B31.3. 8.10 Lancing doors shall be provided in the convection bank for air cleaning of tubes as required. Access to lancing doors shall be from convection section side wall platform. I BADGER DESIGN b CONSTRUCTORS* INC. 7-4-93 SHEET ~ a SPBH-2831-H-101 a A
  24. 24. 8.11 Heater vendor shall provide one (1) tube skin thermocouple on the outlet tube of each radiant pass located such as to monitor the maximum tube metal temperature for that tube. The thermocouple shall be installed with due consideration for tube movement without causing undue stress on the thermocouple sheathing. 8.13 Structural design conditions shall be per the requirements of Badger Specification SPBH-2831-D-1, Issue 2 and SPBH-2831-0-2, Issue 1 . h 8.14 The furnace shall meet the noise level requirements of Badger Specification SPBH-2831-GN-1, Issue 1 . 8.15 Overall calculated and guaranteed thermal efficiency for the heater shall be based on LHV (lower heating value). Efficiency shall be based on optimum excess air value with operation at design conditions of duty and temperature rise, using the clean equipment. Efficiency -tests shall be based on the stack losses method as outlined by the applicable ASME power test codes. Excess air will be measured at the base of the stack. 8.16 No copper or copper bearing alloys shall be used in contact with the heat transfer oil. 8.17 Clear access ports and/or doors shall be provided to allow for cleaning, inspection and maintenance. The number, size and location of these ports/doors shall be listed in vendor's quotation. Access doors shall be furnished for each chamber of the radiant section and each convection section and breeching. At least one radiant section access shall have an opening approximately 24 x 42 inches. Relief provision shall be furnished for each chamber.n Observation ports shall be provided as required to make all radiant tubes, exposed row of convection section tubes, and the burner flame conditions fully visible. Cast iron observation doors shall be provided with a cast iron closure and cool handle to use. 8.18 When access to the underside of the heaters is required for operation, the minimum clear headroom to and in the access area shall be 6'-6". BADGER DESIGN b CONSTRUCTORS, lNC. ISSUE J. DATE 4 , SSET a 20 SPBH-2831-H-101
  25. 25. 8.19 Stack Requirements 8.19.1 8.19.2 The stack shall include 3 inch IPS flanged onnections for EPA type stack sampling, with adequate platforming and ladder access. The connections shall be located approximately 8 diameters downstream of the stack damper and 90 degrees apart. 8.19.3 9.0 Furnace stack height shall be minimized. Stack to be adequate for draft requirements at 120% of design firing. Draft calcu,lations shall assume convection bank losses based on 120% flue gas quantity and the same temperature profile as the design operating case. The stack shall be self-supporting and shall be designed to be all welded construction. All girth and vertical seam welds shall be the full strength, complete penetration, butt groove weld type. If required for shipping purposes the, the stack may be joined to the heater by a flanged connection. Control Svstem 9.1 Two hot oil heaters will be operating in parallel to supply hot oil at a constant flow and temperature to a number of process exchangers. The hot oil system will be a closed loop system consisting of the hot oil heaters, the process exchangers, an expansion tank and the hot oil pumps. The system must be capable of operating continuously and automatically. The Burners and Burner Management Systems shall satisfy the following conditions: 9.1.1 When liquid fuel (Stream 8) is available, it will be fired preferentially. Dry contact signaling that liquid is available will be provided by Badger. 9.1.2 When liquid fuel (Stream 8) is available, a small amount of combustible vapor (Stream 12) will be present and must be burned. 9.1.3 When liquid fuel is not available the heat to satisfy the hot oil heating requirements will be furnished by firing natural gas (Stream 5) . Natural gas (Stream 5) will only be burned if the combination of the other two fuels (condensate and combustible vapor) is insufficient to provide the required heat. BADGER DESIGN & CONSTRUCTORS* INC* of SPBH-2831-H-101
  26. 26. (setting the fuel burning priorities) 9.1.4 Both the liquid fuel (Stream 8 ) and the natural gas (Stream 5) must be capable of operating over the full range of duties. 9.1.5 Turn-down of each heating system shall be 4 to 1. 9.1.6 Each burner shall have a turn-down that will satisfy the conditions listed in 1 thru 5 above. 9.1.7 The system provided must be able to prevent an abrupt opening of the natural gas supply valve if the liquid fuel is shut off. 9.1.8 The stabilized overheads combustible vapor (Stream 12) should be separately piped or vented into the heater burner box. This line should have a check valve and/or other devices installed to prevent back pressure into the system. 9.1.9 The heater control panel shall operate from 420ma supplied signals and shall send out 420ma signals as the output to valves and other devices. 9.1.10 The heater panel shall receive a remote shutdown signal from the SCADA system and contacts shall be provided to the SCADA system to status heater shutdown. 9.1.11 Deleted 10.0 REFRACTORY AND INSULATION 10.1 Type of refractory used shall be suitable for shipment to Thailand. 10.2 Heaters shall be internally insulated. 10.2.1 The hot face layer shall be HYDRECON FrancoLite #21. 10.2.2 The hot face blocks shall be TR-19. 10.2.3 HYDRECON 186 E.S. shall be used for heater front plate around the burner title. 10.2.4 HYDRECON 2400 shall be used for the outer face of the heater back plate. 10.2.5 FRANSET HI-TEMP mortar (thin layer only) shall be applied between adjacent faces of block insulation. BADGER DESIGN b CONSTRUCTORS* INC- ISSUE DATE (. "-14-7-3 I "ET OF SPBH-2831-H-101
  27. 27. 10.2.7 All washers shall be covered with LDS-moldable (or equivalent) or a ceramic fiber patch, after the fasteners are locked in place. 10.3 Deleted A 10.4 ~ e l e t e d n 10.5 External insulation is not required.A 11.0 STRUCTURES, STAIRS AND LADDERS A Permanent steel platforms shal-l be provided for access to points requiring inspection or maintenance. Burners shall be accessible for maintenance and operation. Thermowells and draft control connections shall be accessible. Accessibility by a ladder is satisfactory. Ladders, stairs, etc., shall conform to SPBH-2831-D-1 and SPBH-2831-D-2. All handrails, stairs, ladders, etc., shall satisfy OSHA requirements. ( . 12 0 DAMPERS (DELETED1 a 13.1 Piping materials and design shall satisfy the following requirements: & liquid hydrocarbons (Streams 5, 8 See Piping Materials - Class: C10 13.1.1 Gas 13.1.2 Instrument Air See Piping Materials Class: 12) E30 13.2 All piping terminations shall be flanged. I I C10 Heating Medium (Hot Oil) See Piping Materials - Class: 13.1.3 I - & 14.0 OTHER VENDOR REQUIREMENTS 14.1 The heater design shall maximize the extent of shop fabrication and assembly. I I 14.2 Heater vendor shall state maximum allowable forces, moments, and movements on heater terminal connections on the initial submittal of general arrangement drawings. 14.3 Vendor shall state erection weight of unit and maximum weight of components to assess crane requirements on the initial submittal of General Arrangement Drawings. ". I 7: ~2 14.4 The vendor shall submit pressure-temperature curves showing the profile of operating pressure, fluid and calculated tube wall temperatures, and fluid velocity along the length of each radiant pass. L z l - . 3 : , I Q) we BADGER DESIGN & I IJ 1 d - , 1 ~ t - 4Ism 3 ISSUE DATE w 2 d ISPBH-2831-H-101 II
  28. 28. 14.5 In addition to the normal requirements for erection drawings, the furnace vendor shall submit a written erection procedure prior to any shipment of heater sections. 14.6 The vendor is required at the time of the proposal, to submit an estimate of the actual productive man-hours and time in weeks to field erect the unit. Vendor to state the weight of each heater section to allow assessment of crane requirements. 14.7 All openings and flanges shall be covered with plywood to protect from damage during shipping and storage. Vendor will submit for purchaser's review sketches detailing extent of framing and bracing to secure the heater and shop installed refractory for shipping. 15.0 INSPECTION 15.1 Inspection shall be made at the place of manufacture by the purchaser during manufacture and prior to shipment. 15.2 Purchaser's inspector shall have free entry to the manufacturer's plant, including the sub-vendor's plant, at all times, where work on or testing of the equipment is being performed. The vendor shall instruct his subsuppliers of the inspection requirements of the purchaser. 15.3 In order to reduce purchaser's inspection work to a minimum, the vendor shall supply the inspector without charge: all tools, instruments, and documentation to satisfy him that the equipment furnished is in accordance with this specification with this specification and other supporting documents. 15.4 No surfaces or parts thereof shall be painted until the inspection is completed. The vendor shall notify the purchaser not less than (5) days when the equipment is ready for inspection. 15.5 Acceptance of the equipment does not constitute a waiver of requirements to meet field tests under specified operating conditions, nor does inspection relieve the manufacturer of his responsibilities in any way whatsoever. 15.6 Shop fabricated components shall be tested and code stamped in the shop. BADGER DESIGN d CONSTRUCTORS. INC. ISE SU DAE hydrostatically SPBH-2831-H-101
  29. 29. 15.7 ~ l l radiant tube hanger castings shall be given 100% liquid penetrant examination. Any defective areas found near support points shall be given radiographic examination to meet the quality of ASTM E-466, severity ~epair/replacement due to level 3 for all defects. defects found in the castings will require final approval of the client. Any repair procedure will require a final liquid penetrant examination. 16.0 PREPARATION FOR SHIPMENT 16.1 The equipment shall be cleaned to remove all mill scale and other foreign material and painted in the manufacturer's shop in accordance with Badger Specification SPBH-2831-R-1. 16.1.1 Structural steel - shall be accordance with SPBH-2831-R-1D2 16.1.2 Piping shall be painted in accordance with SPBH-2831-R-1C2. S6.1.3 All exposed. heater surfaces shall be painted in accordance with SPBH-2831-R-1M2, taking into proper account the temperature of the exposed surface. 16.1.4 Other equipment (machinery, instrument hardware. etc. , shall be painted in accordance with SPBH-2831-R-1P. painted in 16.2 Exposed machined parts shall be coated with rust preventive. If vendor considers additional protection is necessary, he shall furnish his recommendations. 16.3 Each separate container shall be marked with the address, purchaser's job number, purchaser order number, item number, and each mating part shall be match-marked for ease of assembly. 16.4 Vendor shall furnish his recommendations for protective measures to be applied by purchaser to the unit after its delivery to the construction site. 16.5 All purchaser connections shall be adequately tagged or marked with a corrosion resistant tag for easy field hook-up. 17.0 GUARANTEE 17.1 All equipment and component parts shall be guaranteed by the Vendor against fault in design, defective materials, and/or workmanship as stipulated in the instructions and conditions section of the Purchase Order. BADGER DESIGN & CONSTRUCTORS. INC* ISE SU h/ DATE s+ET (7. ,)-!-97 -a 11 Of 38 SPBH-2831-H-101
  30. 30. SAIPEM S.P.A. KHANOM OFFSHORE FACILITIES (IIEATING-MEDIUM IIEATER SPECIFICATION) L, - MASS BALANCE Ill BADGER DESIGN 8, CONSTRUCTORS* INC. h a
  31. 31. FIRED HEATER DATA SHEET
  32. 32. I cient S,t?d. SX/PE& I F I R E D H E A T E R L?b.T,4 S i . ! C : C : T ----- M S - / o/A/& I t e m no. I I COMBUSTION DESIGN CONOlTlONS I : 5if#dd5-I Type o f F u e l 2 /s Excess A t r . P e r c e n t 3 Erf~ctcncy Guaranreeo. P e r c e n t (L.H.v.) a E f l ~ c ~ e n c y l c u l a l e o . P e r c e n t (L.H.V.) Ca 5 R a o t a t l o n Loss. P e r c e n t o f H e a t Release (L.H.V.) 6 F l u e G a r T e m p e r a t u r e . L e a v l n g R a d t a n t Section. Dag. F. F l u e Gas T e m ~ a r a t u r e .L e a v ~ n g o n v e c t t o n S e c t ~ o n Oeg. F. C . I (See L l n a 1 8 ) 54 7 F l u e Gas Mass V e l o c i t y t h r o u g n Conv. S e c t ~ o n . Lb/Sec./Sq. 1 I F l u e Gas Q u a n t i t y : a'! X-Air D r a u g h t a t B r ~ d g e w a l l / E n t r a n c e o C O W . Section. I n c h e s o f W a t e r t 13 Draught a t O u t l e t t o DuctlStack. Inches o f Water 14 A m b i e n t A i r T e m p e r a t u r e . Deg. F. 15 A l t l t u o e A b o v e Sea Level. 16 C a l c u l a t e d H e a t Release (L.H.V.). 17 V o l u m e t r i c H e a t Release (L.H.V.). 18 ~ o t e : f u e l saving o f A 21 I I 1 76 70 7/ I 5 m. M&?r&S I : 7 ~ :?/ 70 713/ 6;? g i G M M BTU/Hr BTU/Hr/Cu. I Ft. I I M M B T U / H r w i l l o f f s e t a $ 1 0 0 0 increase in t u r n a u c o s t (erected) FUEL C H A R A C T E R I S T I C S 19 20 I fD./ - I I I 1 1 12 t I 1 D r a u g n t a t Burners. I n c h e s o f w a t e r II - I I 9h L i b e r a t i o n (Design) a t 11 I Type of Fuel I I 22 I 1 23 1 / 1 31 1 32 1 H e a t i n g V a l u e (L.H.V.). 1s~me /L S ~ e c i f l c ravity L i q u i d at G I I I / 29 Ash Content. P+rcent b y Weight 30 F u e l Gas C o m p o s i t i o n . M o l e P e r c e n t om post ti on. ole p e r c e n t F U ~ I ~ Somp position. M O I p e r c e n t G ~ I I I I I 1 ! I ! I I / Deg. F. S o e c i f l c G r a v i t y Gas ( A i r = 1.0) ~ u e as l 1 ( B T U I L b ) (BTUISCF) i I I I I I 1 I I 1 I / / / 33 F u e l T e m p e r a t u r e / P r e s s u r e Available. Deg. F./psig 34 A t o m i z i n g S t e a m Pressure R e q u i r e d a t B u r n e r . p r i g I / I 1 I 1 1 I / I I I I I / F u e l Pressure R e q u i r e d a t B u r n e r . p r i g 35 BURNER D A T A m & PI ca vr . pLOo ccrt C ~ + t - ~ r i i f i ~ A 38 Location: 39 P i l o t : M a n u f a c t u r e r a& 20 F l a m e Scanner C o n n e c t i o n s . L o c a t i o n : 11 H e a t Release p e r B u r n e r a t Ossiqn Excess A i r a n d D r a u g h t . N o r m a l : -fffeoiey. Tyw: Nerfh fl-n. FIL). Size: I Manufacturer a n d Type: 37 r; Size: g4-oCI,@, Size: Number: 30 & 03 1I MM B T U / H r . I M i n i m u m Distance B u r n e r Center L i n e t o T u b e c e n t e r Line: Oeslqn F u e l R a t e . C b / H r : Badger Design 8 Constructors. lnc , Hor~zontal: O e r i q n A t o m l r i n g S t e a m Rate. L b f H r : I ISSUE I Q,, ,=, , MM B T U / H r . 4 2 I H e a t Releasa o e r B u r n e r a t Deslqn Excess A i r a n d Orauqht. oeslqn: 43 ' CrCj 36 I I F l u e Gas Q u a n t i t y : 1 0 0 % L i b e r a t i o n ( N o r m a l ) a t :J I 1 Ft. - I I / , L r 9 t /,Y 670 8 1 1 1 1 I 960 7 Sr/r#*.y /2 zrs&*r Verttcal: N/A DATE - 2g -cl sHEET I 7 7 u / 4 OF^ 0 SPGN- 283,- ,4- 1 0 , 1 1 1
  33. 33. Client S A ? / P W C.P.4. Item no. ns- a /A/& 1 MECHANICAL DESIGN CONDITIONS 1 Plot L l m t t a t l o n s . 2 Tube L~mltattons: 3 S t r u c t u r a l Oeslgn Oata: W t n d ~ o a a : 4 ,~)JsI//~s c e 7- StrCK L l m l t a t l o n r Other L ~ m ~ t a t ~ o n r . 88~arthsuake Zone wtna Veloc~ty: ,,,/ 5 7 Ia rI IH A A T / N ~ Haater Sectlon ~awica 8 4 IC O I L A R R A N G E M E N T 19 21 11.m E x t e n d e d Surface Tubes: N u m b e r T u b e Soacing Ctr. t o Ctr.. I In.: R a d i a n t Sact. ( I n L i n a ) (Stag.) I - I I I I TFO NnA- Nnna, ~otal'~xoosed Surface. So. F t . 1 I I # /I T o t a l Exoosed Surface. Sq. F t . 22 v A N D OESIGN: Rare Tubes: N u m b 8 r 20 23 ~i34-- M E C H A N I C A L DESIGN DETAILS 6 I Snow ~ o a a se~sm~c Factor: ,, I 1 1 1 I 1 t C o n v e c t i o n Sect. ( I n L i n e ) (Equ~l.) (Stag.) --. g T u b a Ctr. t o F u r n a c e Wall. In. ( M i n t m u m ) 26 T u b e O r i e n t a t l o n : Verttcal o r H o r t z o n t a l 27 T u b a Material (Soectficatton a n d Grade) 28 T u b a Outside Diameter. In. 29 ~ u b Wall Thtcknass, In. ( M i n t m u m ) (Average) a 30 lo6 ~ c ! R I 240 od~?,ko.a I M a x t m u m T u b a W a l l Temoarature. Deg. F. (Calculated) 0 . 2 ~ - 0.2.r I I I I I Calculated Inside F i l m C o e f f i c i e n t M a x i m u m T u b e W a l l Temoerature. Dea. F. IDesianb -- Oesiqn Basis l o r T u b e Wall Thlcknass DESCRIPTION O F E X T E N O E O SURFACE: Tyoe: (Studs) (Serrated F i n s ) ( S o l i d Fins) Stud o r F i n Material S t u d o r F i n Olmensions S t u d o r F i n Soacina Extension R a t l o ( T o t a l Ar8a/Bare Area) M a x t m u m S t u d o r F i n Tem08rature. Oeq. F. (CdICulatad) 1 41 43 1 PLUG TYPE HEAOERS M a t e r i a l (Soeciflcatlon and Grade) 44 Cocat~on (F.B. = F ~ r e Box: H.B. = Haadar B o x ) 46 , N o m i n a l Ratlng 45 Welded o r R o l l e d 47 I
  34. 34. F I R E D HEATER client SAIPP'M sk&! DATA SHEET KS-/e/ I tern no. MECHANICAL DESIGN D E T A I L S ( C 0 N T ' D . l I I OGNV. I 1 - neater Section 2 Sarvice I b f i l ~ c ~ r 3 R E T U R N BENOS: 4 T Y O ~ 5 Material ( S ~ c i l i c a t ~ oand Grade) ;r 6 Nominal Ratlng o r Scneau~e 7 L o c a t i o n (F.6. = F i r e Eon: H.8. = Header B o x ) I 8 1 TERMINALS AND/OR 1 / b e h l " , ~Srr'fic ~ ~?o I 5,qk /&76 (/ ) I I I I I I I 1 I I I I 1 I I ! I I ! 1 - I I - I IIr/b~o&0 M a x i m u m A l l o w a b l e Moment, Ft.-Lbs. 19 CROSS-OVERS: 20 Welded o r Flanged Size (I.P.S. I MANIFOLDS: 18 21 3 0 -&&/>gg I I o r 0.0.) Flange R a t i n g and Faclng o r Pi04 Schedule 23 1 Material ( S o e c l l l c a t i o n and Grade) 24 1 sk.f?Ah*. F l u i d Ternoerature, Oeg. F. (2 > IE K T - ~ N ~ u c Location I I I I 1 I I I I I TUBE SUPPORTS: I L o c a r l o n (Ends. Top. B o t t o m ) Material ( S o e c t l l c a t ~ o n and Grade) I !&us ! d. 5. =P 25C?,-2 , & Dsrign M e t a l Temoerature. Oeg. F. Thickness. I n . - T y o e and Thickness o f tnsulatlon, In. I Insulation R e i n f o r c e m e n t (Ty00/Mat9ft.l) I N T E R M E O l A T E T U B E SUPPORTS: (As de.@ ) b Cmslgn M e t a l Temoerature. 09 .. 1 %Sf?&. ~ o i ( / , - Material (Soeclflcation and G r a d e l F. Thlckness. I n . Soaclng. F t . T y p e and Thlckness o f lnsulatlon. In. l n r u l a t l o n R e t n f o r c a m e n t (Tyoe/MaterIal) T U B E GUIOES: 41 Location 42 Material 2 3 CA: 7.L)N/ 43 Type 44 Soacing I &rro~ - 1 I C) I Y ~ J-q. ISSUE Badget Des~gn Constructors. Inc & !. , I SHEET /? 0 ~ 2 0 ;? . -. S.- . .-- -, /-If - / 9/
  35. 35. FIRED HEATER DATA SHEET Itemno. &-/a/ M E C H A N I C A L D E S I G N D E T A I L S ICONT'O I 1 2 CASING. R E F R A C T O R Y A N D I N S U L A T l O N D E T A I L S 3 HEAOER BOXES: Location: Ara Header B o x Ooors Boltea or Hlnqea: 4 Sattinq Matortat: Th~ccness.in.: 5 Casing Material: Thtcknels. In.: 6 A n c h o r i n g Material: Ancnoring Typa: 7 EXPOSED V E R T I C A L WALLS: 8 Setting Thickness. In.: 9 Wall C o n r t r u c t t o n : - H o t Faca Tamparature: Oesign: Oaq. F.Calculatea: Oeq. F. Oag. F. 10 Casing Matarial: Thickness. In.: Outside Temperature: 11 Tieback Material: Tyoe: Soacing: In.: 12 Supoort Matarirl: 13 M e t h o d o f Fastaning TieOacks t o Structure: 14 SHIELDED V E R T I C A L WALLS: 15 Setting Thickness: In.: 16 w a l l Construction: 17 Caslnq Material: 18 ~ieback Material: 19 S u p p o r t Material: 20 M e t h o d o f Fastening Tiebacks t o Structura: 21 ARCH: Thickness. In.: ,(?A 33b Arch Conrtructlon: 4 w's~d~ 09 .. F.CaIcutatad Thickness. In.: bd 3 3 0 ? Oeq. F. Spaclng: In.: Oeg. F. CGj~6.c Q&#A*/G Casing Material: Tieback Material: F.Calcutataa: O u t r i a 0 Tarnoeracurs: ~ y w : H o t Face Temoerature: Design: Setting Thicknass: In.: 23 25 09 .. fie&/& @&RH/C 22 24 Dag. F. H o t Face Temoerature: Design: Outsiao Ternoaratore: Type: Spacing; In.: 26 SuPoort Material: 27 28 M e t h o d o f Fastening Tieoacks t o Structure: 29 Setting Thickness; In.: Oag. F. FLOOR: H o t Face T e m ~ e r a t u r a : Oes~gn: . /200°d 30 F l o o r Construction: 31 Casing Material: 32 M i n i m u m F l o o r Elevation: 33 + g/&& &&~g Oeg. F . Outside Temoaratura: &,44y46~4 0cg. ~ . € a l c u t a t a d : Oag. F. Lees C O N V E C T I O N SECTION: 34 - 35 &/@ Thickness. In.: Free Space Balow Planurn: Setting Tilicknass. In.: H o t Face Temoeraturec Oesign: Oeg. F.Calculataa: Oeq. F . /too0 c C R ~ ~ R B ~ ~ wall construction: 36 Casing Material: 37 Tieback M a t e r i a l : 38 Support Material: 39 Outsiae Temperature: M a t h o a o f Fastening Tiebacks t o Structure: ThicKness. In.: 3 0 4 ~ ~ Type: 40 INTERNAL WALL: A1 Tyoe: A2 Oimens~ons:H a i g h t / W i d t h : 43 Dog. F. Soacing. In.: Oatails: Material: 44 45 nvr I'vlSf-d 46 BURNER PLENUM: Casing Material: A7 L i n i n g Material: 48 JIprJ : CG ~f-,," e !j i"/w, if Setting Materials ApoIIad I n Shop or at Sita: O e r Thickness. In.: Thickness. In.: Rsinforcemant Type: n9 50 Notas: 5 1 52 53 ISSUE Badger Design & Constructors, Inc. ~ H E E T / @ o F ~ O sPeiJ-~93/-hj-,-/0/
  36. 36. F I R E D H E A T E R Client S A / P k > ? Z,E4, D A T A SHEET Item no. &'S- /o/ A/& D E T A I L S OF H E A T E R APPURTENANCES 1 2 ~ 3 , S T A C K or S T A C K STUB: Casing Material: 4 1 5 u ~ 0o 4~ 4 ~ : w 1 e m t s r p ) ,o o r f . 5 MR~I~c' se1f-$uooortin9 or Guyed: ~ h,&rrlsw,L tnrlde Metal Olamerer, Ft.: ~ S ~ ~ Helqnt Above Graae. Ft.: /200 O C ~ x t e no f ~ i n i n g : t ~ ~ ~ , #~r i p o ~ Stack Lenoth.. Ft.: - c I a t i o n : r f Thicknass. In.: Lintng Rainforcement Material: 7 y - L l n i n g Material: 8 ~ 0.3 . < Thickness. In.: Tyom: Soaclnq. In.: C?Ad~&t DAMPERS: 1 ~ o c a t l o n :stack. s t a c k - ~ t u e r B o t t o m A i r ~ ~ a n u m : o 9 10 Matarlal: 11 S , m e &4x Oascrlotlon o f Provlrlons f o r Ooeratlon f r o m Grade: M U I ~ I O I ~ o r Single s eat: 12 A r e Oraught G l u w m d Oamper Positlon I n d l u t o r Readable from D a m w r Control Location: 13 14 ~ O DUCT. BREECHING. T 15 Casina Material: 16 17 18 FLUES AND COLLECTORS: ( ~.ttln9 Material: /200Oc C &ST&&&& 1 Ancnorin9 Materia(: g& r - -_< TYlw: - c I Sirm o t A c w u D o o r I n B r o u k l n q . In.: -- I Soaclnq. ln.: isolation B l i n d - C O L D A I R DUCT: 20 Caslng Matmrial: 21 L i n i n g Material: Size. Ft.: Thlckn*u. In.: I 19 7 h/OVl P A Thickness. In.: 1 1 Heater Overall Dimensions: Reinforcement T yoe: II I MISCELLANEOUS: 23 Slre. ~ t . : Thickness. In.: - 22 1 o n PA Thickness. In.: Platforms, Location: 25 -- M 1 . . 1310 d 1 k7 0 r - L -. --- 26 Platforms. Width: 27 Ptatforms. T y p e o f Floorlnq: 28 Stairs. Location: 29 - b d d e r s . Location: 30 Access Doors. L o c a t i o n and Sire: 31 Observation Doors. L o c a t l o n and Sire: 32 Exo~oslon Ooors. L o c a t i o n and Sire: Miscellaneous Connections (Number and Slre): 33 I F & ~ ~ Y + - ~ n.f . ~ a t e r k @ He V Smothering Steam: . 1 34 I 1 35 1 1361 Oraught: Header B o x Dram: Temwrature: C o i l Drain: Tube S k i n Terno.: Stack Drain: - - F l u e Gas Samole: P&& SP&i*'- 2 831 -Re/ 38 Painting Raquirements: 39 A r e Paintar's Trollmy and Rail Included? 40 Soeclal Equlomont: S o o t b l o w ~ n : 41 A l r Prehoater: 42 F.D. Fan(s): 43 N o i w Supprmssorl: 44 A5 Other: Dsaree o f Shoo Fabrlcatlon: N o r Extent o f Tube Handling Fac~litlss: &&@o,&&& Q J / ~ RL + I I I
  37. 37. W cr m- I BADGER DESIGN & I
  38. 38. Phone (211) 889-7100 AMERICAN HYDROTHERM CORPORATION 470 Park Avenue South New Yo&, New Y d 10016 HANDBOOK OF INSTRUCTIONS FOR: --BADGER DESIGN FOR b C O N S T - ~UlC- KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND SAPIEM SPA T h i s book i s t h e properhf of Americon Hydrotherm Corporation a n d i s to be ra turned upon request. It contains confideniial informotion w h i c h must n o t b e d i s It i s loaned w i t h t h e express c l o s e d to anyone without p r i o r written consent. agreement that the book and information therein will not, d i r e c t l y or i n d i r e c t l y be reproduced, copied or o t h e m i r e disposed of, o be used in whole or part t o a s s i s t r i n making or to furnish any information for the making o f drawings, p r i n t s or other reproductions therein, or t o be used for the molting of systems or p a r t s thereof, for any other purpose, without prior written consent. The occcptance o f t h i s book constitutes accept once o f t h e foregoing agreement. SEPI"I' 1993 Date: Account P. 0 A .' # AM-2579 BH 2831-H01-10
  39. 39. American Hydrotherm Corporation 470 Park Avenue South New York, NY 10016 Job No. AM-2579 HYDROTHERM HEATING MEDIUM HEATERS for KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND SAPIEM SPA BADGER PROJECT BH-2831 DESCRIPTION The heating medium heaters furnished to The Petroleum Authority of Thailand, Sapiem SPA, Khanom Onshore Facilities, supply heat up to 490°F temperature to users furnished by others. The heaters are designed to use Exxon Caloria HT43 or equal heating mediums at temperatures up to 550°F at the heater outlet. Please refer to the following American Hydrotherm Corp. drawings when reading this description: Burner Schematic Heater HSlOlA Burner Schematic Heater HSlOlB Burner Equipment List Heater HSlOlA Burner Equipment List Heater HSlOlB Heater Assembly HSlOlA & HSlOlB Electrical Bill of Material Heater HSlOlA Electrical Bill of Material Heater HSlOlB Electrical Schematic - Heaters HSlOlA & HSlOlB Electrical Control Panel Arrangement, HSlOlA & HSlOlB WARNING BURNER SHOULD NOT FIRE UNLESS THE LOW LEVEL IN THE EXPANSION TANK IS SATISFIED AND ADEQUATE THERMAL FLUID FLOW THROUGH THE HEATER COILS ESTABLISHED: MINIMUM FLOW OF 200 GPM THROUGH 5 3-1/28' COIL AND 1 0 GPM THROUGH 3" COIL IS REQUIRED AT ALL TIMES WHILE THE HEATER IS OPERATIONAL. HEATER SUPPLIED INTERLOCKS SHOULD BE SET SO AS TO ACHIEVE THESE OBJECTIVES.
  40. 40. AMERICAN HYDROTHERM CORPORATION Job No. AM-2579 EOUIPMENT DESCRIPTION 2. Heating Medium Heaters: Stack for Heaters : HSlOlA, HSlOlB HSlOlA, HSlOlB 1. Heatins Medium Heaters: HSlOlA, HSlOlB 1. The Heating Medium Heater is a fully packaged unit manufactured as horizontal version; it is shop assembled, packaged and built on a structural steel base. The shell is internally insulated. It houses two horizontal coils which serve as the combustion chamber. (Each coil is a single tube wound.) The inlet in front of the heater and outlet in rear have 6" manifolds with 6" - 300# flanges. The packaged burner with an integral blower is mounted on the front plate. The Heated Gas (Stream #5) train with all control and safety components is mounted on right side of the heater; the Condensate (Stream #8) and stabilizer Overhead (Stream #12) trains are mounted on heater front base; the Atomizing Air Compressor is mounted on left side of heater base. Burner Manasement System The Hydrotherm heater is provided with a burner management system equipped with fluid temperature control, automatic combustion programming and safety controls which eliminate the need for an operator. These controls ignite the pilot, supervise the pilot flame, start the main flame, control the rate of firing, shut off the burner when the lowest firing rate is more than is required by the heat consumers, restart when heat is again required, and stop the burner or prevent start-up in the event any unsafe condition is sensed by the safety controls. The Heating Medium Heater is provided with a dual fuel burner to burn either one of two fuels at a time: Heated Gas" (Stream #5) or vlCondensaten (Stream # 8 ) . "Stabilizer Overheadg1 combustible vapor (Stream #12)is introduced directly into burner to be burned only when either fuel firing is taking place. In order to prevent flashing of "Conden~ate~~ (Stream #8), a high pressure burner nozzle is provided. Due to low fuel viscosity of Stream #8, fuel pump has to maintain a required pressure at nozzle. The fully modulating burner is controlled by the Temperature Indicating Controller TIC-015A/TIC-015B.
  41. 41. AMERICAN HYDROTHERM CORPORATION Job NO. AM-2579 111. SYSTEM 1. - SUGGESTIONS Heatins Medium Svstem Basic heating medium system consists of Heater Pumps, 9 Expansion Tank, Users, By-Pass and Piping. Expansion Tank absorbs thermal volume between cold and operating conditions. fluctuations Ventinq of the system is very important. It is suggested to provide a device or arrangement that will continually vent the system (say into expansion tank) without inducing fluid flow. 2. BY-Pass Control In case fluid flow to the users is controlled with either manual or an automatic device, the following should be considered: To protect the fluid and installation, automatic or manual by-pass control has to be installed at the end of main headers (supply and return), in order to provide sufficient and constant circulation of thermal fluid through the heater and main headers. Heater is designed for nominal flow of 450 GPM. However, the minimum total flow of 350 GPM through both coils must be maintained at all times. 3. Heatina Medium System Testins. Ventins. Steamins Out The system and the piping should be tested with 100 psi dry air or nitrogen (if at all possible avoid testing with water). If the system is tested with water, water should be removed from heater and piping by draining and blowing hot air through piping. Once the system is tested, cleaned of water and condensate, it can be filled with heating medium. We are recommending that heater be filled with liquid from one end only to avoid air entrapment in the coil. Provide fill connection at the pump suction side (between pump and suction shut off valve). By closing suction side valve and main by-pass valve the system could be filled through the heater and users until liquid appears in the expansion tank (via expansion line) .
  42. 42. AMERICAN HYDROTHERM CORPORATION Job No. AM-2579 3. Heatins Medium Svstem Testins, Ventinu, Steaminu Out (continued) First the system has to be circulated cold for a couple of hours without firing, to remove air from the system. It is very important that heater outlet (each coil) is connected with expansion tank with an auxiliary line for the purpose of venting and steaming out. American Hydrotherm Heaters HSlOlA and HSlOlB have 2 " couplings on heater outlet on each coil which has to be piped to Expansion Tank. These 2 " lines have to be provided with 2 " isolating valves. 2 " valves are kept open only during start-up and heat-up. Once the system is free of air, water and low boilers from thermal liquid and brought at the operating temperature and maintained for a certain period of time, these valves should be closed. NOTE THAT: Heater has cylindrical coils that could not be effectively drained by gravity!!
  43. 43. AMERICAN HYDROTHERM CORPORATION 1. Turn circuit breaker CB-1A I8ONNlocated inside the electrical control panel and close the door. 2. Turn SS-1 selector switch ltONru, control power white light L-7 will come "ONn. 3. Start heater circulating pump; green lights L-2, L-3 or L-4 will come "ONn. Minimum one pump for one heater is required. (Start/Stop pushbutton not in panel - by customer). 4. Turn SS-5 selector switch IfHEATER ENABLED" 8tONw order to in open main header hot oil supply valve. This will allow the thermal liquid to start circulatingthrough the heater. Green light L-5 will come on "VALVE OPENI8. 4A. Fuel Selecting: Fuel selector Position Position Position switch has 1. Fuel : 2. Fuel : 3. Fuel : three positions: Heated Gas (Stream #5) Auto Condensate (Stream #8) Fuel selector switch in Position 1 will burn Heated Gas (Stream #5) only; fuel selector switch in Position 3 will burn Condensate (Stream #8) only. Fuel selector switch in Position 2 will burn Condensate (Stream #8) if it is available and automatically switch to Heated Gas when Condensate is not available (Stream #5), going through the normal procedure shutting down, post purge, prepurge and starting new burning cycle with Heated Gas. When Condensate (Stream #8) is again available the burner management system will automatically shut down the burner and again go through the complete burning cycle switching to Condensate (Stream #8) fuel burning.
  44. 44. AMERICAN EYDROTHERM CORPORATION Job No. AM-2579 5. If all limits in operational limit circuit are satisfied and when SS-2 selector switch is in start position, control relay CR2 is energized and its contact closes Fireye terminals L1 and 3, signaling the burner starting firing cycle. (Temperature is below set point). Blower starts to run, closing non-recycling running interlocks which will energize relay CR3 (its contact closes terminals 3-P on I1BC" 1 6. Modutrol motor starts to drive toward high purge position, opens air damper fully for purging. (10-13 terminal made on IBI 1 ICI 7. When modutrol motor reaches open damper position (fully open) it will close HFS (Hi-Fire Switch) and HFS will close terminals D-8 on "BCI1. 8. After 30 seconds modutrol motor starts to return back towards low fire start position, closing air damper. At low fire start position it closes low fire switch LFS and this closes terminals M-D on l1BCV. 9. After LFS is closed, programmer energizes terminals 6 and X on vlBCw. Terminal X energizes ignition transformer for spark, and 6 energizes pilot gas solenoid valves ESV-005 and ESV-006. 10. Pilot gas is ignited and flame detected by flame scanner. If during 5 seconds pilot proving, pilot flame does not light, the programmer will de-energize terminals and lock out; the burner shuts down; the programmer switches to post purge of 20 seconds in case of flame failure or ignition failure. Red alarm light L-16 I1Flame Failurev1and alarm horn will come I1ONn. The operator must silence alarm horn and reset the programmer by pressing pushbutton PB-1 "Reset Flame FailureI1, located on face of control panel. The programmer starts a new cycle.
  45. 45. AMERICAN HYDROTHERM CORPORATION Job NO. AM-2579 12. Upon detection of pilot flame by scanner, Fireye programmer proceeds to energize terminal 7. SLC input #I11 through SLC logic will energize solenoid valve/valves on fuel oil train which is burning. Depending on which fuel is burning, corresponding pilot light will be lit: L-9 for heated gas, L-10 for condensate. 13. Atomizing air compressor is providing atomizing air for Condensate (Stream #8) burning. When Condensate (Stream #8) fuel is selected for burning at the same time with blower, compressor will start. When selector switch is in Auto position (burning Condensate) compressor will be automatically running when blower is running. 14. Stabilizer Overhead is introduced into burner to be burned two minutes after flame is established, if Stabilizer Overhead low and higher pressure is satisfied. Selector switch SS-3 is provided to turn solenoid valve on or off and pilot light L-11 will indicate if solenoid valve is open or closed.
  46. 46. AMERICAN HYDROTHERM CORPORATION Job NO. AM-2579 SET POINT SCHEDULE NOTE : Initial settings listed herein are preliminary and are intended for use by authorized personnel as a reference for start-up. Only final field settings should be used after commissioning for maintenance and operating purposes. RANGE INITIAL FINAL SETTING SETTING TAG FUNCTION PCV-025-A -025-B Pilot Gas Regulator 411-1211 C. W. 4" W.C. PCV-028-A -028-B Pilot Gas Regulator 1811-42" W.C. 30" W.C. PSL-003-A -003-B Low Combustion Air Cutout PRV-001-A -001-B Pressure Control Valve PSL-007-A -007-B Low Atomizing Air Cutout PSV-018-A -018-B Compressor Safety Relief Valve PCV-033-A -033-B High Gas Pressure Regulator 15 psig PCV-026-A -026-B Low Gas Pressure Regulator 1 psig PSH-003-A -003-B High Gas Pressure Cutoff 2.5 psig PSL-004-A -004-B Low Gas Pressure Cutoff 20" N.C. PCV-027-A -027-B Pressure Reducing Gas Regulator 0- 10 kg/ cm2g PSL-002-A -002-B Low Oil Pressure Cutoff 0-100 psig 1-16 oz 4.5" W.C. 40 psig 0-60 psig 50 psig 100 psig 1 psig 50 psig
  47. 47. AMERICAN HYDROTHERM CORPORATION TAG FUNCTION RANGE Fuel Oil Pressure Reducing Valve Differential Pressure Gage INITIAL SETTING FINAL SETTING 60 psig 0-10 psid Sensitrol Oil Valve Main Gas Pressure Regulator 1 psig High Gas Pressure Cutout 0-15 psig 2 psig Low Gas Pressure Cutoff 0-301'W.C. 1511 W.C. Temperature Controller High Temperature Cutoff High Temperature Cutoff Low Flow Cutoff 2 psig Low Flow Cutoff 2 psig Differential Pressure Gage 0-10 dpsi Differential Pressure Gage 0-50 dpsi Safety Relief Valve PSV-15-A 15-B 150 psig 150 psig Safety Relief Valve 150 psig 150 psig
  48. 48. INPORTANT NOTICE T O OUR CLIENTS Due t o t h e growth i n claimed product l i a b i l i t y and p r o f e s s i o n a l l i a b i l i t y c a s e s , it i s i m p e r a t i v e t h a t t h e f o l l o w i n g requirements a r e s t r i c t l y observed. LEGAL LIMITATIONS American Hydrotherm w i l l n o t a c c e p t l i a b i l i t y f o r any i n s t a l l a t i o n o r equipment 1) which h a s been modified i n any form 2) i s o p e r a t e d under c o n d i t i o n s o t h e r than s p e c i f i e d ( p r e s s u r e , t e m p e r a t u r e , flow r a t e , e t c ) . 3) which was designed o r s u p p l i e d by o t h e r s and i s used i n c o n j u n c t i o n w i t h our system. American Hydrotherm w i l l n o t a c c e p t l i a b i l i t y f o r p i p i n g i n s t a l l a t i o n s o r p a r t s of them, n o t designed i n e v e r y d e t a i l by American i s not a piping Hydrotherm. A flow diagram s u p p l i e d by A.H.C. design or layout. TECHNICAL REQUIREMENTS: ELECTRICAL DESIGN S t a r t b u t t o n s f o r machinery s u p p l i e d by o t h e r s . Press c l o s i n g o r i n j e c t i o n molding s t a r t b u t t o n s should be l o c a t e d w i t h i n s i g h t of t h e p r e s s o r t h e i n j e c t i o n molding machine s o t h a t one o p e r a t o r cannot c l o s e t h e equipment w h i l e a n o t h e r o p e r a t o r h a s h i s hand i n t h e equipment. Panels A l l e l e c t r i c p a n e l s s h a l l have door s w i t c h e s t h a t w i l l s h u t o f f t h e power i f t h e door i s opened. The l e a d s on t h e l i n e s i d e of t h e door s w i t c h s h a l l be s h i e l d e d and i n a c c e s s i b l e s o t h a t t h e y cannot b e touched when t h e door i s opened. A l a r g e warning p l a t e s h a l l be on t h e door n e a r t h e door s w i t c h t h a t s a y s "CAUTION - WHEN PANEL I S OPEN C N R L INTERLOCKS FROM EXTERNAL C I R C U I T S MAY BE ALIVE". O TO
  49. 49. Equipment S t a r t - S t o p Buttons I t i s p r e f e r r e d t o have s t a r t - s t o p b u t t o n s w i t h i n s i g h t I t i s imperative t h a t s t o p buttons of t h e equipment. and lock-out s w i t c h e s a r e n e a r t h e equipment, Grounding A l l e l e c t r i c a l equipment, p a n e l s , motors, e t c . must be grounded. Where w a t e r l i n e s a r e used f o r grounding, check t o s e e t h a t t h e supply system does n o t c o n t a i n p l a s t i c pipe !! MECHANICAL DESIGN Pipinq Specs Piping f o r h i g h p r e s s u r e water ( 5 0 p s i g o r h i g h e r ) , steam, h o t o i l and s a l t s h a l l b e s t e e l and have s t e e l f i t t i n g s , f l e x i t a l l i c g a s k e t s , h i g h temperature b o l t i n g , p r e f e r a b l y 300RF f l a n g e s , and be welded i f p o s s i b l e . Flanqes must never be t i q h t e n e d when a system i s under p r e s s u r e and a t high temperature. T h i s can o n l y be done when pump i s o f f and system i s d e p r e s s u r e d . R o t a t i n q Equipment R o t a t i n g p a r t s , such a s couplings and s h a f t s , should have c o u p l i n g guards t o p r e v e n t touching moving p a r t s . Heat Exchanqers and V e s s e l s S E They s h o u l d a l l b e A M 8 stamped, i n s p e c t e d and hydroDesign t e s t e d a t l e a s t 1+ t i m e s t h e d e s i g n p r e s s u r e . p r e s s u r e should be 20% more t h a n t h e maximum p r e s s u r e t h e equipment w i l l s e e d u r i n g any abnormal c o n d i t i o n , such a s pump s h u t - o f f . R e l i e f v a l v e s must be provided on t h e w a t e r s i d e of h o t o i l c o o l e r s and on a l l equipment t h a t c o u l d be o v e r p r e s s u r e d d u r i n g an u p s e t c o n d i t i o n . System T e s t i n q A i r o r h y d r o t e s t p r e s s u r e f o r t h e system i s s p e c i f i e d on t h e f l o w s h e e t s and/or p i p i n g drawings.
  50. 50. Combustion Eauipment Diaphragm v e n t s on g a s r e g u l a t o r s and gas a i r r e g u l a t o r s and t h e g a s v e n t s o l e n o i d must be piped away t o a s a f e l o c a t i o n ( u p , o u t s i d e , and a t l e a s t 1 0 f e e t away from a working a r e a ) , There should be a t a g on t h e v e n t o u t l e t AC E p i p e a t t h e o u t l e t t h a t s a y s "DANGER, NO SMOKING, M T H S OR OPEN FLAME". (Tag a v a i l a b l e from American Hydrotherm Corporation) , Piping Desiqn High t e m p e r a t u r e p i p i n g runs should be checked f o r s t r e s s , expansion and l o c a t i o n of g u i d e s , anchors, and s u p p o r t s . P i p i n g , v a l v e s and v a l v e h a n d l e s should be l o c a t e d s o t h e r e a r e no "head knockers" o r low l i n e s t h a t can be t r i p p e d over. There should b e 3 f e e t c l e a r around any r o t a t i n g equipment. S t r u c t u r a l i n t e g r i t y of t h e w a l l o r b u i l d i n g s t e e l which w i l l t a k e t h e f o r c e of t h e p i p i n g anchor should be checked. TYPICAL CONSTRUCTION REQUIREMENTS: S a f e t y cage on a l a d d e r t h a t goes above 7 f e e t ; guard r a i l on p l a t f o r m s ; a v o i d p i p i n g o r v a l v e h a n d l e s t h a t can be bumped by o p e r a t o r s ; h e a d e r s h u t - o f f v a l v e s should be a c c e s s i b l e o r be provided w i t h c h a i n wheels t o g r a d e ; room o r a r e a t h a t h a s a f i r e d h e a t e r should have two e x i t d o o r s ; i n s t r u m e n t s o r v a l v e s t h a t have t o be a d j u s t e d d u r i n g normal o p e r a t i o n should be a c c e s s i b l e o r b e provided w i t h p l a t f o r m s ; f u e l o i l t a n k s should n o t be i n d o o r s u n l e s s it meets t h e requirements of NFP, A l l h o t p i p i n g and equipment t h a t w i l l have a s u r f a c e t e m p e r a t u r e of 180°F o r h i g h e r , i n l o c a t i o n s t h a t can be touched, should be provided w i t h p e r s o n n e l p r o t e c t i o n i n s u l a t i o n o r w i r e p r o t e c t i v e mesh, e t c .
  51. 51. I N D E X DESCRIPTION INDEX NO. B-A, B-B AB-A, AB-B BAS-A, BAS-B FCV-001-A, FCV-001-B ESV-001-A, ESV-002-A ESV-001-B, ESV-002-B HIS-A, HIS-B PCV-024-A, PCV-024-B FCV-002B HINGE INTERLOCK SWITCH FUEL OIL PRESS. RED. VALVE SENSITROL OIL VALVE NP-A, NP-B GAS PILOT ASSEMBLY DUAL FUEL BURNER AIR BLOWER BURNER AIR SHUTTER BUTTERFLY GAS VALVE OIL SHUTOFF SOLENOIDS 11 11 11 1 1 1 PILOT GAS SOLENOIDS 11 I1 II PILOT GAS REGULATOR 11 11 II PRESSURE GAGE M-A, M-B LFS-A, LFS-B HFS-A, HFS-B 5 MODUTROL MOTOR LOW FIRE SWITCH AIR PURGE SWITCH LOW COMBUSTION AIR CUTOFF AAC-A, AAC-B PSV-018-A, PSV-018-B CFH-A, CFH-B 7 ATOMIZING AIR COMPRESSOR SET COMPRESSOR SAFETY REL. VALVE COMPRESSOR FLEXIBLE HOSE 8 8 PRESSURE CONTROL VALVE 9 8 HIGH PRESSURE CUTOFF LOW GAS PRESSURE CUTOFF LOW OIL PRESSURE CUTOFF HIGH GAS PRESSURE CUTOFF LOW GAS PRESSURE CUTOFF LOW ATOMIZING AIR CUTOFF 10 10 10 10 10 10 HIGH PRESSURE REGULATOR 11 LOW GAS PRESSURE REGULATOR 12 MAIN GAS SOLENOID PRESS. REDUCING GAS REGULATOR 14 DIFF. PRESSURE GAGE 15
  52. 52. I TAG - N D E X DESCRIPTION INDEX NO. MAIN GAS PRESS. REGULATOR 16 MAIN GAS SOLENOID 17 TEMPERATURE CONTROLLER 18 HIGH TEMPERATURE CUTOFF 11 11 II LOW FLOW CUTOFF 11 11 11 DIFFERENTIAL PRESSURE GAGES I1 It 11 11 I1 11 I1 11 11 21 21 21 21 BC-A, BC-B SC-A, SC-B FLAME PROGRAM CONTROL SCANNERS IT-A, IT-B PILOT IGNITION TRANS. 23 DIG. DISPLAY HEATER STACK TEMP. DIG. DISPLAY FOR HEATER INLET TEMPERATURE 24 24 PRESSURE INDICATOR 25 THERMOMETER 11 FLANGED THERMOWELLS II 11 SAFETY RELIEF VALVE I1 11 It
  53. 53. INDEX NO. DUAL FUEL BURNER B-A, B-B A I R BLOWER AB-A, AB-B BURNER A I R SHUTTER BAS-A, BAS-B BUTTERFLY GAS VALVE O I L SHUTOFF SOLENOIDS ESV-001-A, ESV-001 -B, ESV-002-A ESV-002-B HINGE INTERLOCK SWITCH HIS-A, HIS-B FUEL O I L PRESSURE REDUCING VALVE SENSITROL O I L VALVE FCV - 002B 1
  54. 54. FY-6033 American H y d r o t h e r m North American SERVICE MANUAL Cleveland, OH 44105 USA American H y d r o t h e r m H e a t e r APPLICATION 6131-FA2/P-1 BURNER AVERAGE Pilot - Regulator lnlet Regulator Outlet M a i n Gas - ACTUAL 14 o s i rnax a d i u s t 6131-5 per Sh. Regulator Inlet Regulator Outlet Burner Manifold Pressure - High Fire Light Oil - Pump 1 Regulator Outlet Pressure Sensitrol Valve Setting - Low Sensitrol Valve Setting - High Oil Pressure at Nozzle - Low Oil Pressure at Nozzle - High 34 p s i 40 p s i Atomizing Air Pressure - Low Atomizing Air Pressure High 35 p s i 40 p s i - Heavy Oil - Grade System Oil Pressure Oil Temperature Pump Inlet Regulator Outlet Pressure Oil Heater Outlet Temp. psi F psi F Sensitrol Valve Setting - Low Sensitrol Valve Setting - High - Oil Pressure at Nozzle Low Oil Pressure at Nozzle- High Atomizing Air Pressure - Low Atomizing Air Pressure - High Electrical D r a w i n g Linkage D r a w i n g S y s t e m Oil Piping Gas Piping Drawing NOT APPLY ZC30-50710 6131-8 Note: The above settings are average and are to be used as a guide only. More precise or actual settings will be made t o obtain best results based on CO, check at the time of burner adjustment, and should be entered in spaces provided. PRINTED IN USA DOES bustion equipment. Nonh Amadcan urga compliince
  55. 55. ' Nortb American Mfg. Co. Cleveland. OH 44105 USA ' 4131, 5131, 6131 PACKAGED AUTOMATIC L BURNERS Engineering SPECIFICATIONS 7-89 1 6131 7 J Features of NORTH AMERICAN Packaged Automatic Burners BUILT-IN BLOWER: Delivers 10096 of combustion air required for burner operation. Eliminates need to install an expensive and bulky air delivery system. CONTROL VARIETY: Building from the basic burner package, control systems are available along with many pre-packaged gas and oil trains, motorized controls, flame safeguard accessories, and programming systems. WIDE RANGE OF CAPACITIES: 2 500 000 to 30 000 000 Btufhr, in six frame sizes. Typical air turndown is 4:l on standard models. Greater turndowns are available for special applications. RUGGED, VERSATILE, A N D RELIABLE: An ultra stable burner designed to operate in chambers at temperatures up to 2000 F and under negative or slightly positive pressures. Cold, tight chambers present no problem for this rugged, low-maintenance workhorse. Proven reliability while operating with natural gas, #2 fuel oil, and #6 fuel oil. Crude oil, and pitch have also been successful, however, these are often application dependent. Consult North American Mfg., Cleveland, for applications with these fuels.
  56. 56. NORTH AMERICAN Mfg. Co. Cleveland, OH 44105 USA The Packaged Automatic Burners are ideal for steel firebox, scotch marine, cast iron sectional, and watertube boilers, and industrial process heating equipment, such as air heaters. dryers, oil heaters, ovens, and incinerators. Six frame sizes produce a wide range or capacit~es( 2 500 000 to 30 000 000 Btu/ hr). Design: The 4131 Burner is for any fuel gas; the 5131 for fuel oils, and the 6131 for dual-fuel (combination gas and oil). All are of the nozzle mix design with an integral blower to supply 10096 combustion air. Oil atomizers are of the tip emulsion design, using steam or compressed air as the atomizing medium. The hinged construction provides quick and complete accessibilitv. Fixed fuel lines need not be broken for service because fuel oil enters through the burner hinge and gas enters through a stationary gas section. Construction: This rugged burner consists of a cast iron mounting plate, with slotted mounting holes, fitted with a high strength cast refractory burner tile rated for service up to 2600 F. A stainless steel tile support jacket is available as an option. The grade of stainless steel is application dependent. The circular gas plenum has a bottom gas inlet, a combustion air diffuser, and a spark-ignited premix gas pilot (for natural gas or propane). The hinge-mounted blower section includes the blower motor, impeller, intake guard (or optional intake silencer), a large reinforced glass observation port, provisions for mounting a flame detector, and flange mounted oil atomizer. An accurate linked valve ratio control is provided by a compact arrangement of aircraft-quality linkage rods and swivels that connect the internal main air proportioning shutters with a butterfly gas valve and/or a Sensitrol oil valve and the modulation motor. Engineering Specifications 61 3 1 , 7-89 Page 2 Standard Components: The 4/5/6131 Burner includes the pilot gas regulator, pilot gas solenoid (2nd solenoid optional), 6000 volt ignition transformer, electric modulating control motor (air motor optional), low combustion air interlock, and burner hinge interlock switch. Oil burners also include a solenoid valve (or optional motorized automatic valve), piped between the hinge and atomizer assembly. All electrical components are wired to the burner mounted NENlA 4 junction box. Turndown: Typical air turndown is 4:l on standard models. Greater turndown can be achieved with an optional blower air inlet controller. Consult North American, Cleveland, for details. Excess Air: Standard burner linkage is factory set to deliver 20% excess air. Rates greater than 20% are possible through reduction of fuel input. Flame Characteristics: These burners generate a high degree of turbulance resulting in short, bushy flames. See Supplement 6131-1 for flame sizes at various excess air rates for a particular fuel. Chamber Pressures: Designed for stable operation in ~ chambers with pressures ranging from - 0 . 5 " ~ to 2 . 0 " ~ ~ . The "Nu burner is specified on applications with 0 to - 0 . 5 " ~ ~ chambers (i.e., 2-pass boilers, dryers, heaters, etc.) and the "P" burner is specified on those with 0.1 to 2 . 0 " ~ ~ chambers (i.e., 3-pass boilers, etc.). Consult North American, Cleveland, for burner performance with other pressures. Underwriters Laboratories Listing: The Model 4/5/6131 Burners have been designed in accordance with the requirements of the Underwriters Laboratories. Consult North American Mfg., Cleveland, for labeling service. Hinged construction provides for complete accessibility to burner internals. WARNING: Situations dangerous to personnel and properry can develop from incorrect operation of combustion equipment. Nonh American urges compliance wtth Nat~onal e Standards and Insurance Underwriters recommendations. and care in operation. Saf w PRINTED IN USA
  57. 57. i I! Instruction Manual Mfg. Co. Cleveland. OH 44105 USA Norm Gas, Light Oil & Dual-Fuel Burners Full Modulating Operation 127 Service Manual Contents SECTION TITLE Data Data Sheet I, Pg. 1, 2 General Description IT, Pg. 1, 2 Pg. 3, 4 111, Pg. 1, 2 Pg. 3, 4 Pg. 5, 6 , 6 7 IV, Pg. Pg. Pg. Pg. Pg. V 1, 2 3, 4 6 7, 8 9 Trouble Trouble Trouble Trouble Trouble Shooting Shooting Shooting Shooting Shooting - - - Gas Oil Gas Oil Combination Gas, Light Oil & Dual-Fuel Burner Gas Oil Section V Wiring Diagrams VII, Pg. Pg. Pg. Pg. 1, 2 3, 4 5 6 Pg. 7 Pg. 8 Pg. 9 PRINTED IN USA Operating Instructions Operating Instructions Operating Instructions ....................... No VI VIII Initial Starting Procedure Initial Starting Procedure Spare Parts & Burner Technical Data Gas Pressures for Gas 6 Combination Burners Atomizing Air Compressors for Burners - Oil Atomizing Air 6 Oil Pressures for Oil & Combination Burners Blower Wheels & Motors for Natural Gas 6 Oil Burners Pumps and Pump Motors for Oil Burners Orifice Plate Data ~ a n u f a turer ' s Data c
  58. 58. NORTH AMERICAN Mfg. Co. Cleveland, OH 44 105 USA Engineering Supplement 6 13 1-1. 7-89 Page 2 T a b l e 3. N a t u r a l Gas pressures@ Burner Frame Regulator pressure Manifold pressure "w c T a b l e 4. L i g h t O i l Pressures a n d A t o m i z i n g M e d i u m R e q u i r e m e n t s Burner Frame Atomizing ~ e d i u m s @ C o m p . air f l o w Steam f l o w scfm Ib/hr Pressure psig O i l pressures@ psig 120 90 85 50 55 75 T a b l e 5. H e a v y O i l Pressures a n d A t o m i z i n g M e d i u m R e q u i r e m e n t s Burner Frame A B C D E FA Atomizing ~ e d i u m s @ C o m p . air f l o w Steam f l o w scfm Ib/hr 4 4 8 18 28 28 30 50 70 130 168 200 Pressure ~ s i g O i l pressures@ psig 50 50 25 45 30 30 70 65 70 60 70 90 as burners are intended for use with natural gas or propane. Listed pressures are for natural gas - consult North American for propane pressures. Pressures liaed are maximum values and are for system sizing only. They are not for ratio adjustment. @oil and dual-fuel burners require an accessory package for the atomizing medium. Pressures required at the inlet of that package are 75- 100 psi for air and 50- 125 psi for steam. @oil and dual-fuel burners require oil delivered to burner hinge at a viscosity below 100 SSU and at pressures listed above. If a liquid fuel other than commercial fuel oil is to be used, consult North American for recommendations of pressure and flow requirements. WARNING: Siruatlons dangerous to personnel and propeny can develop from incorrect operation of combustion equipment. with National Safetv Standards and Insurance Underwriters recommendations, and care in operatton. Nonh American urges com~liance PRINTED IN USA
  59. 59. North American Mfg. Co. Cleveland. OH 44105 USA ' l 4/5/6131 BURNER Capacities, Flame Characteristics, Pressures Engineering SUPPLEMENT 6131-1 7-89 J Table 1 4/5/6131 Burner, Blower, and Motor Capacities Burner Frame Designation Nominal capacity Btulhr Blower volume cf h Developed pressure "w c Motor hp - rpm Sound level, ~ B A @ w / o silencer with silencer O ~ o m i n a capacity for a "C" frame burner when using heavy oil is 8 400 000 Btulhr. l @ w i t h sound level instrument located at the same elevation as the burner center line and 5' away at 45' to the blower inlet-motor center line. Table 2. Flame characteristics@ Burner Frame ( % Excess Air / Flame size, dia. (ft.) x length (ft.) GAS I LIGHT OIL I HEAVY OIL lame characteristics based on firing in a chamber with free air available at atmosphere pressure and without a pilot. With flame supervisory equipment, signal strengths were acceptable over the stability ranges of the burners. l he burner using this fuel at this excess air rate is not recommended.
  60. 60. 3 North American 4/5/6131 Mfg. Co. Cleveland, OH 44105 USA L Engineering DIMENSIONS 6131 BURNERS 12-90 J 4/516131-A, B, and C FRAME SIZE BURNERS junction box DIMENSIONS inches CAPACITIES million Btu/hr Frame / gas and light oil I heavy oil Pilot Regulator --/ Lifting eye - ,~ Pilot Solenoid valve Control motor / 1 3 , / I , 1' ' 6 131 Series B u r n e r F r a m e Size 4131-, 5131-, 6131- Air motora w~th high and low switches I A@ D C B E,@ E,@@ F,@ G F @ , H J K@ L M N P Q FF,@ FF,@ 131 Series B u r n e r Frame Size 4131-, 5131-, 6131 R,@ R , @ S T U W X Y Z AA BB CC DD@ @ANSI 125 Ib flanged connection. Not used on 5121 or 5131 Burners. @ Honeywell M941 or M944 motors shown. For other motor types, check with North American. @ Furnace opening for 131-A, B, and equivalent size 121 burners is 16%" dia. (17 % " dia. with jacketed tile). Furnace opening for 131-C and equivalent size 121 burners is 20"dia. (21" dia. with jacketed tile). @ With stainless steel tile jacket only. @ If one pilot solenoid valve is used, dimension R, applies. Use dimension R for burners with two pilot solenoid valves. , @ Optional, furnished only when ordered. @ If Moore Positioner is used, dimension FF, applies. Use dimension FF, if the Moore Positioner is not supplied. @ If air motor is used, add 50 Ib to these figures. @ I f burner is gas and/or light oil, dimension F, applies. Use dimension F if burner is heavy oil. , EE
  61. 61. NORTH AMERICAN Mfg. Co Cleveland, O H 44105 USA Engineering Dimensions 613 1, 12-90 Page 2 41516131-D, E, and FA FRAME SIZE BURNERS DIMENSIONS inches CAPACITIES million B t u l h r / D E FA gas and light oil heavy oil 12.6 to 18.0 21.0 to 25.2 29.4 to 30.0 Frame 12.6 to 16.8 21.0 to 25.2 29.4 to 30.0 Est. Shipping w e i g h t s @ Pilot Solenotd Valve ! fpt P~lot h gas Control motor 8 slots for U- Blower housrng floor clearance Air motor@ with high and low sw~tches I 131 Series Burner Frame Size 4131-, 5131-. 6131- AO B 131 Series Burner Frame Size 4131-, 5131-, 6131 R,@ R,@ D E FA M N P Q EE FF GG,@ GG,@ 29% 33% 14 155/16 'Ig 263/g 7 % 13% 10 28% 85/a 12% 10% 5'18 7 38% 12'1, 10% 6 % 7 % 35 31% 35% 16'1, 18% 7/, 30 8V8 15% 12 29% 8 13 15 9% 1l3Il6 7 % 35 8V8 15% 12 36 31% 35% 16'/, 18% 7/8 30 33% 30 30 C S D T E,@ U F E,@@ W Y X H G Z AA J BB K@ CC L DD@ O A N S I 125 Ib flanged connection. Not used on 5131 Burners. @ Honeywell M941 or M944 motors shown. For other motor types, check with North American. @ Furnace opening for 131-D, E, and FA Burners is 23 K " dia. (24 ! h dia. with jacketed tile). @ W i t h stainless steel tile jacket only. @ If one pilot solenoid valve is used, dimension R, applies. Use dimension R for burners with t w o pilot solenoid valves. , @ Optional, furnished only when ordered. If Moore Positioner is used, dimension GG, applies. Use dimension GG, if the Moore Positioner is not supplied. @ If air motor is used, add 50 Ib to these figures. " a DIMENSIONS SHOWN ARE SUBJECT TO CHANGE. PLEASE OBTAIN CERTIFIED PRINTS FROM NORTH AMERICAN MFG. C O IF SPACE LIMITATIONS O OTHER CONSIDERATIONS MAKE EXACT DIMENSION(S) CRITICAL. R WARNING: Situat~ons dangerous to personnel and property can develop from incorrect operation of combustion equipment. North Amencan urges compliance with National Safety Standards and Insurance Underwriters recommendations, and care in operation. PRINTED IN USA N A 1 2 9 0 ED6131 4000
  62. 62. i Initial Starting Procedure M f g . Co. 121 Service Manual Section II Natural Gas Burner Full Modulating Control December, 1975 J Page 1 of 4 1. For a s t e a m b o i l e r , check t o make s u r e w a t e r i s a t t h e p r o p e r l e v e l . w a t e r b o i l e r , t h e s y s t e m s h o u l d be f u l l o f w a t e r , 2. S e t t h e o p e r a t i n g l i m i t s t o t h e d e s i r e d s e t t i n g s . blake s u r e t h a t t h e s a f e t y h i g h l i m i t , i f f u r n i s h e d , i s s e t s u f f i c i e n t l y above t h e s e t t i n g o f t h e o p e r a t i n g l i x i t , Be s u r e t h a t t h e m o d u l a t i n g d e v i c e i s p r o p e r l y s e t . 3. Make s u r e t h a t t h e g a s company h a s p u r g e d a l l a i r from t h e main g a s l i n e . WARNING: Gas l i n e s a r e t e s t e d w i t h a i r p r e s s u r e s a s h i g h a s 90 t o 100 p s i , b u t t e s t p r e s s u r e s must n o t be a p p l i e d t o b u r n e r v a l v e s o r r e g u l a t o r s . Keep t h e main and p i l o t manual g a s v a l v e s i n t h e c l o s e d p o s i t i o n . s t o p - s t a r t s w i t c h i n t h e "Stop" p o s i t i o n . For a h o t Place the C l o s e t h e wall-mounted power s r v i t c h . Check t h e blower r o t a t i o n by u s i n g t h e "Manual Purge" s w i t c h . R o t a t i o n may be changed by t r a n s p o s i n g any two motor l e a d s a t t h e l o a d t e r m i n a l s o f t h e blower s t a r t e r . B e f o r e c h a n g i n g motor l e a d s , open t h e power e n t r a n c e s w i t c h , Open t h e manual p i l o t g a s v a l v e o n l y . Move t h e b u r n e r s w i t c h t o s t a r t . Move t h e manual p o t e n t i o m e t e r t o low f i r e . The b l o w e r motor w i l l s t a r t , and a f t e r a p r e p u r g e p e r i o d , t h e g a s p i l o t s y s t e m w i l l be e n e r g i z e d . S e t t h e o u t l e t p r e s s u r e o n t h e p i l o t r e g u l a t o r a t + 1 , 5 t o 2" wc, I f t h e g a s p r e s s u r e ahead o f t h e p i l o t r e g u l a t o r e x c e e d s 14 o s i , a F i s h e r -7347-0 r e g u l a t o r bushed t o s h o u l d be i n s t a l l e d i n t h e p i l o t g a s l i n e . l e t p r e s s u r e on t h i s F i s h e r r e g u l a t o r s h o u l d be s e t between 4 and 6 o s i . 2" 3" Out- Check t o s e e t h a t t h e f l a m e d e t e c t o r g i v e s a d e q u a t e s i g n a l when t h e p i l o t i s on. See s a f e g u a r d b u l l e t i n f o r d e t a i l s . Turn t h e b u r n e r s w i t c h t o s t o p , and remove t h e a d j u s t m e n t c a p from t h e main g a s pressure regulator, Open t h e manual main g a s v a l v e . For a c o m b i n a t i o n b u r n e r , make s u r e t h e f u e l s e l e c t o r s w i t c h i s i n t h e "Gas" position. Turn the b u r n e r s w i t c h t o " S t a r t " . A f t e r t h e main f l a m e i s e s t a b l i s h e d , a d j u s t t h e o u t l e t p r e s s u r e f r o m t h e main g a s r e g u l a t o r t o t h e c o r r e c t p r e s s u r e a s shown i n S e c t i o n V I I , Page 2 , o f t h i s manual, by t u r n i n g t h e r e g u l a t o r a d j u s t m e n t s c r e w down f o r more p r e s s u r e , o r up for l e s s pressure.
  63. 63. NORTH AMERICAN Mig. Co. Cleveland, OH 44105 USA 16. Service Manual 121. Section I1 Page 2 o 4 f Turn t h e manual p o t e n t i o m e t e r o n t h e c a b i n e t t o t h e h i g h - f i r e p o s i t i o n , When 1 f t h e COZ i s low o r h i g h , t h e b u r n e r r e a c h e s h i g h f i r e , t a k e a C02 r e a d i n g . make an a d j u s t m e n t i n t h e main g a s r e g u l a t o r , Run t h e b u r n e r t o low f i r e and t a k e a n o t h e r C02 r e a d i n g . I f the i s low o r h i g h , make an a d j u s t m e n t i n t h e g a s l i n k a g e a t the b u r n e r . (NOTE : 032 s h o u l d be S. 5 - 9 . 5 7 ~on both h i g h and low f i r e ; oxygen s h o u l d r e a d a b o u t -ILT0.) - 17. Check t o s e e t h a t t h e f l a m e d e t e c t o r g i v e s a d e q u a t e s i g n a l a t b o t h h i g h and low f i r e w i t h o n l y t h e main flame. See f l a m e d e t e c t o r b u l l e t i n f o r details. 18. With t h e b u r n e r i n o p e r a t i o n a t t h e l o w - f i r e p o s i t i o n , check t o s e e i f the o p e r a t i n g and s a f e t y h i g h l i m i t c o n t r o l s ( i f f u r n i s h e d ) a r e w i r e d c o r r e c t l y by m a n u a l l y t r i p p i n g e a c h one. The b u r n e r s h o u l d go o f f and s e q u e n c e a new s t a r t when t h e c o n t r o l s a r e r e l e a s e d t o t h e i r normal p o s i t i o n . 19. With t h e b u r n e r a t h i g h - f i r e p o s i t i o n , check t h e m o d u l a t i n g c o n t r o l by manuall y t u r n i n g t h e p o t e n t i o m e t e r t o make s u r e t h e b u r n e r g o e s t o low f i r e , t h e n back t o h i g h f i r e . 20. Blow down t h e low-water c u t o f f w i t h t h e b u r n e r i n o p e r a t i o n ( l o w f i r e ) . I f two low-water c u t o f f s a r e u s e d , check e a c h s e p a r a t e l y , t h e n check t o g e t h e r , The b u r n e r must s t o p and t h e n s e q u e n c e a new s t a r t when t h e w a t e r i n t h e b o i l e r i s r e s t o r e d to the c o r r e c t l e v e l . ( I f t h e second low-water c u t o f f i s a manual r e S e t t y p e , i t w i l l be n e c e s s a r y t o r e s e t i t by hand b e f o r e p r o c e e d i n g . ) 21. S t a r t and s t o p t h e b u r n e r s e v e r a l t i m e s t o make s u r e t h e b u r n e r o p e r a t e s c o r rectly. 22. With t h e b u r n e r i n o p e r a t i o n ( p i l o t o f f ) and o n low f i r e , c l o s e t h e manual main g a s v a l v e . The f l a m e s h o u l d go o u t i n 2 t o 4 s e c o n d s . The blower w i l l c o n t i n u e f o r a p o s t p u r g e . A f t e r t h e flame d i e s , t h e f l a m e s a f e t y w i l l l o c k o u t t h e b u r n e r and l i g h t t h e w a r n i n g l i g h t . R e s e t t h e f l a m e s a f e t y s w i t c h i n t h e combustion s a f e g u a r d and p l a c e t h e u n i t i n o p e r a t i o n w i t h t h e normal o p e r a t i n g procedure.
  64. 64. Mfg. Co. Cleveland. OH 44105 USA Initial Starting Procedure Light Oil Burner 121 Service Manual Section I1 December, 1975 Page 3 o 4 f 1, For a steam b o i l e r , check t o make s u r e w a t e r i s a t the p r o p e r l e v e l . w a t e r b o i l e r , t h e system s h o u l d be f u l l of w a t e r , For a h o t 2. S e t t h e o p e r a t i n g l i m i t s t o t h e d e s i r e d s e t t i n g s . &lake s u r e t h a t t h e s a f e t y h i g h l i m i t , i f f u r n i s h e d , i s s e t s u f f i c i e n t l y above t h e s e t t i n g o f t h e o p e r a t i n g l i m i t . Be s u r e t h a t t h e m o d u l a t i n g d e v i c e i s p r o p e r l y s e t . 3. C l o s e t h e manual p i l o t g a s v a l v e , a l l manual o i l v a l v e s , and p l a c e t h e s t o p s t a r t s w i t c h i n "Stop" p o s i t i o n . 4. C l o s e t h e wall-mounted power s w i t c h . 5. Check t h e blower r o t a t i o n by u s i n g t h e " m n u a l Purge" s w i t c h . R o t a t i o n may be changed by t r a n s p o s i n g any two motor l e a d s a t t h e l o a d t e r m i n a l s o f t h e blower s t a r t e r . B e f o r e changing motor l e a d s , open t h e wall-mounted power s w i t c h . Open t h e manual p i l o t g a s v a l v e . 7. Move t h e b u r n e r s w i t c h Move t h e manual p o t e n t i o m e t e r t o l o w - f i r e p o s i t i o n . to "Start". The blower motor w i l l s t a r t , and a f t e r a p r e p u r g e p e r i o d , t h e gas p i l o t system w i l l be energized. 8, If n a t u r a l g a s i s u s e d , t h e o u t l e t p r e s s u r e on t h e p i l o t r e g u l a t o r s h o u l d be s e t a t +1.5 t o 2" wc. If propane i s u s e d , t h e o u t l e t g a s p r e s s u r e on t h e p i l o t r e g u l a t o r s h o u l d be s e t a t *.Sf' t o 1" wc. (N3TE: If t h e i n l e t g a s p r e s s u r e exc e e d s 14 o s i , a F i s h e r $";-t7347~-0 r e g u l a t o r bushed t o iff h o u l d be i n s t a l l e d i n s t h e p i l o t g a s - l i n e . O u t l e t p r e s s u r e on t h i s F i s h e r r e g u l a t o r s h o u l d be s e t between 4 and 6 o s i . ) - 9. Check t o s e e t h a t t h e f l a m e d e t e c t o r g i v e s a d e q u a t e s i g n a l when t h e p i l o t i s on. 10. Move t h e b u r n e r s w i t c h t o "Stop" and check t o s e e t h a t t h e o i l s u c t i o n and r e t u r n l i n e s a r e c o r r e c t l y p i p e d t o t h e o i l pump and t h a t t h e o i l l i n e s a r e t h e corrzct size. 11. I f t h e b u r n e r i s f a r F?I a p p r o v a l , make s u r e t h a t t h e f u s i b l e - l i n k g a t e v a l v e i s i n s t a l l e d and o p e n , 12. Open a l l of t h e manual o i l s h u t o f f v a l v e s i n t h e s u c t i o n l i n e . 13. The r e t u r n o i l l i n e f r o m t h e pump s h o u l d n o t have a manual s h u t o f f v a l v e . manual v a l v e i s p r e s e n t i n t h i s l i n e , open t h e v a l v e f u l l y and remove i t s handle. 14. D i s c o n n e c t t h e copper o i l t u b e a t t h e i n l e t t o t h e b u r n e r and p u t i t i n t o a l a r g e bucket o r c o n t a i n e r , 15. If t h e burner i s d u a l - f u e l , burner switch t o "Start". If a s e t the f u e l s e l e c t o r switch t o o i l , then t u r n the

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