Purchase_Description_-_Hot_Oil_Heater_System.docx

Purchase Description - Hot Oil Heater System 1 each – (Brand Name / No Substitute) Sigma Thermal Hot Oil Heating System. This system involves the design, fabrication, and start-up of a thermal fluid heating system. The thermal fluid system will provide heating for an undisclosed number of secondary users. A single fuel fired thermal fluid heater will be supplied. This heater will heat a circulated thermal fluid. The fluid will be pumped at a constant flow rate through the heater, and distributed directly to the secondary users. The users will utilize flow control valves to modulate the flow rate and control the process outlet temperature. Scope of Supply shall include but is not limited to: thermal fluid system equipment engineering - design, - project management, thermal fluid heater, burner and fuel train, heater control panel and burner management system, exhaust stack, 1 x 100% primary loop pump skid with motors, pumps, and valves, expansion tank with inert gas blanket, 1 x 100% standby loop pump skid with motors, pumps and valves, drain tank, fill / drain pump, P&ID drawings, PLC logic, wiring diagrams, panel layouts, operation and maintenance manuals, trouble shooting guide, spare parts list, and equipment manufacture data sheets and specifications.

See below for a detailed scope of supply:

Preliminary Engineering Design – Preliminary engineering design includes the initial engineering design work for the system. The intent of preliminary engineering design is to present a package of drawings to the customer for formal review and approval. Document deliverables will be as noted in ST-SEDP-0002 Standard Document Deliverables.

Detailed Engineering Design – Detailed engineering design includes the development of all final engineering details. The intent of detailed engineering is to develop and incorporate the review comments, and complete a documentation package fit for fabrication and/or construction. Document deliverables will be as noted in ST-SEDP-0002 Standard Document Deliverables.

Project Management – Project management will be provided throughout the course of the project to insure that all contract details are executed as agreed, and to generally communicate with and support all customer project personnel. Project management duties includes schedule development, schedule maintenance, equipment list development, vendor expediting, logistics coordination, coordination of documentation, invoicing and milestone tracking, and to serve as the primary contact for all formal project communication. Project Management deliverables include:

· Periodically updated project schedules

· Formal transmittals for all documentation submittals

Thermal fluid Heater – A high efficiency heater utilizing a double helical coil design. The heater performance will be as stated in the Design Data section of this quotation.

Coil: The heater coil will be designed and stamped per ASME as noted in the design datasheet. The design utilizes two concentric helical coils, each on 1-d centers. The coils are positioned such that the flue gasses make three complete passes, utilizing both the inside and the outside of the coil face. Coil velocities and available surface area are carefully calculated and chosen to minimize fluid film temperatures. Inner coil bending diameter and length are carefully chosen to prevent flame impingement and to optimize space heat release.

Shell: The shell is manufactured from A-36 carbon steel plate. The high efficiency double coil design eliminates the need for internal shell insulation, creating a significant advantage over single helical coil designs. The heater shell is externally insulated with ceramic fiber insulation and covered with aluminum cladding.

Heater Assembly & Factory Testing: The saddle mounted heater, burner, fuel train, heater mounted instruments, and control panel will be completely pre-piped, pre-wired, and factory tested (simulated operation) prior to shipment.

Burner – A gas fired burner will be provided. The burner package will contain a combustion air fan and fuel/air control system that allows for good control throughout the burner turndown. The burner will be mounted to the heater and pre-wired to the control panel (if locally mounted). A summary of the burner equipment provided is as follows

· Qty. 1 burner with integral combustion air damper

· Qty. 1 combustion air fan and TEFC motor

· Qty. 1 fuel control valve

· Qty. 1 air control damper

· Qty. 1 low combustion air pressure switch

· Qty. 1 flame scanner

· Qty. 1 spark igniter

· Qty. 1 ignition transformer

Control Panel & Burner Management System – A control system will be designed to meet current NFPA requirements for safety instrumented systems as it relates to burner management and combustion control systems. The control panel will monitor and/or control all aspects of the Sigma Thermal process heater. The main control panel will be designed for installation in environment as specified in the system design datasheet. The control system will have a locally mounted emergency stop and provisions for a remote emergency stop from the customer. The engineering and design package will be detailed in the drawings and documentation list on Sigma Thermal’s Standard Document List. These documents will be submitted to the customer for approval prior to the release for construction. Upon completion of the project, the engineering documentation will be revised to “as built” and submitted to the customer for their final records.

A FM and UL/cUL approved micro-processor based Burner Management System (BMS) will be supplied as part of the heater control system. This BMS system will provide proper burner sequencing, ignition and flame monitoring protection for the automatically ignited gas fired burner. In conjunction with limit and operating controls, it programs the combustion blower, ignition transformer, and fuel valves to provide for proper and safe burner operation. A self-checking flame scanner will be provided as part of the new BMS system. The BMS system will be supplied with expanded text capabilities which will allow for detailed alarm messages to be displayed on a local interface mounted to the panel door.

Temperature control will be accomplished by the use of loop and limit controllers mounted to the control panel door. The loop controller will be configured to handle the PID temperature control of the process heater. The high temperature limit controllers will handle all of the system high temperature monitoring as required to properly protect the process heater. The temperature loop set point can be adjusted locally at the control panel or remotely from the customer’s DCS by a 4-20mA signal. Each high temperature limit will provide a 4-20mA signal for retransmission of their process variable. The high temperature limits will require local reset in the event of a high temperature trip. The following hardwired control signals/connections will be available to the customer.

· Remote Temperature SP (4-20mA)

· High Temperature Controller PV Retransmission (4-20mA)

· Common BMS Alarm (Dry Contact)

· Remote Emergency Stop (Dry Contact)

· Remote Start/Stop (Dry Contact)

· Burner Interlocks as Required ( Dry Contact)

· Burner Running (Dry Contact)

· BMS Operation Data-Modbus (RS485) Hardware and Programming by Customer

· Combustion Blower Start/Stop (Dry Contact)

· Combustion Blower Run Feedback (Dry Contact)

· Fluid Pump Run Feedback as Required (Dry Contacts)

Control Panel Hardware & Fabrication – The system control panel will be assembled and tested at Sigma Thermal’s UL panel shop. The control system will have a factory acceptance test performed and documented prior to shipment. The complete control panel will be inspected and a UL/cUL labeled will be applied. The following is a summary of the components supplied with the control panel:

· Qty. (1) Hoffman Enclosure

· Qty. (1) Hoffman Mounting Kit

· Qty. (1) Hoffman Panel Heater (as required)

· Qty. (1) Schaefer Window Kit

· Qty. (1) Fireye Burner Management System

· Qty. (1) Fireye Display Module

· Qty. (1) Fireye Expansion Module

· Qty. (1) Fireye Self Checking Flame Scanner

· Qty. (1) Yokogawa Temperature Loop Controller

· Qty. (4) Yokogawa High Temperature Limit Controller

· Qty. (1) Allanson Ignition Transformer

· Qty. (Lot) Cutler-Hammer Relays (as required)

· Qty. (Lot) Cutler-Hammer Circuit Breakers (as required)

· Qty. (Lot) Cutler-Hammer Pilot Operators (as required)

· Qty. (1) Hoffman Enclosure Light Kit

· Qty. (1) AB Panel Mount Alarm Horn

· Weidmuller Terminal Blocks (as required)

· Shop Consumables As Necessary

Fuel Train – A pre-piped and pre-wired fuel train manifold will be provided. The fuel train is an integral part of the burner safety system which safely regulates the availability of natural gas to the burner. A summary of the fuel train equipment supplied is as follows:

Gas Train

· Qty. 1 - primary pressure regulator

· Qty. 2 - safety shut-off valves for primary line shut-off

· Qty. 1 - FO vent valve for primary line vent

· Qty. 4 - manual isolation ball valves for primary line isolation

· Qty. 1 - strainer for inlet fuel gas filtration

· Qty. 1 - high & low gas pressure switch

· Qty. 2 – pressure gauges with gauge valves for primary line indication

· Qty. 1 - pilot pressure regulator

· Qty. 2 - FC shut-off valve for pilot line shut-off

· Qty. 1 - FO vent valve for pilot line vent

· Qty. 2 - manual isolation ball valves for pilot line isolation

· Qty. 2 - pressure gauges with gauge valves for pilot line indication

· Pre-Piping & Pre-Wiring – The fuel train will be pre-piped from inlet isolation valve to outlet isolation valve. All of the fuel train components will be pre-wired to the heater mounted control panel or junction box.

Primary Loop Instruments & Controls – Safety and control instruments for the primary loop will be provided. A summary of the primary loop instruments and controls supplied is as follows:

Heater Mounted

· Qty. 4 thermocouples with thermowells for fluid temperature measurement

· Qty. 1 thermocouple with thermowell for flue gas temperature measurement

· Qty. 1 flow orifice for differential pressure measurement

· Qty. 1 DP switch with low and low-low flow switches for low fluid flow interlock

Loose Primary Loop Instruments

· Qty. 1 liquid filled pressure gauge for heat outlet pressure indication

· Qty. 1 PSV for heater coil overpressure protection (per ASME Section VIII liquid relief)

2 x 100% Primary Loop Pump Skid & Valves – A pump skid with a 2 x 100% capacity primary system pump will be provided. The pump skid will be completely assembled on a structural steel skid frame. Isolation valves, strainers, check valves, expansion joints, and pressure gauges will all be provided as part of the assembled skid package. Butt weld connections will be used for all components (when possible) to minimize potential leak points. A summary of the equipment supplied with the primary loop pump skid is as follows:

· Qty. 2 x 100% centrifugal thermal fluid pump & motor

· Qty. 2 air cooled mechanical seal

· Qty. 2 – High temperature gate valve with butt weld connections for pump inlet isolation

· Qty. 2 – High temperature gate valve with butt weld connections for pump outlet isolation and throttling

· Qty. 2 – Y-pattern strainer with butt weld connections and drain valve

· Qty. 2 – Drain valve

Loose Primary System Valves – The following valves will be supplied loose for installation in the primary heating loop piping.

· Qty. 1 – Gate valve with butt weld connections and stainless steel bellows seal for double leg drop isolation

· Qty. 1 – Globe valve with butt weld connection, stainless steel bellows seal, and throttling cone for double leg drop throttling

Expansion Tank– A horizontal cylindrical expansion tank will be provided. The tank will be designed and stamped per ASME Section VIII. Butt weld nozzle connections will be used where possible to minimize potential leak points. A summary of the expansion tank equipment supplied is as follows:

· Qty. 1 horizontal expansion tank with saddles

· Qty. 1 float type low level switches for expansion tank low level detection

Drain Tank – A system drain tank can be provided. This atmospheric tank will be designed and per ASME Section VIII, but not stamped. Butt weld nozzle connections will be used where possible to minimize potential leak points.

Thermal Oil Fill & Drain Pump – A fill and drain pump suitable for filling and draining thermal oil from the system can be provided. The pump will be a baseplate mounted reversible positive-displacement pump with motor and coupling.

· Qty. 2 – 1” loose gate valves will be provided for pump isolation

Approval drawing(s) is/are required and shall be furnished within 4-6 weeks after award.

JMMC-DEE (MCAAP Engineering Support Division) will validate and verify equipment before award is granted.

Qualifying statement was prepared by: Michael Angeli, x6458, on 17NOV2016.

See below for the System Design Criteria / Data Spreadsheet and the Standard Document Deliverables

System Design Criteria

Standard Document Deliverables image1.JPG image2.JPG