The document is a purchase order from Badger Design & Constructors, Inc. to American Hydrotherm for two heating medium heaters. The total purchase order value is [VALUE]. The heaters must be manufactured according to specifications and drawings by [DATE]. Payment terms include progress payments and retention of 10% until satisfactory startup is completed within 90 days of shipment.

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. 5.0
VOLUME 5 TABLE OF CONTENTS

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. 5.1
2001-F-03 A&B (HS-101 A&B) Heating Medium Heaters

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. 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. 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. 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. 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. 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. (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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. (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. 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. 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. 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

31. SAIPEM S.P.A.
KHANOM OFFSHORE FACILITIES
(IIEATING-MEDIUM IIEATER SPECIFICATION)
L,
-
MASS BALANCE Ill
BADGER DESIGN 8,
CONSTRUCTORS* INC.
h
a

32. FIRED HEATER DATA SHEET

33. 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

34. 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

35. 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/

36. 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/

37. 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

38. W
cr
m-
I
BADGER DESIGN &
I

40. 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

41. 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.

42. 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.

43. 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)
.

44. 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!!

45. 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.

46. 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.

47. 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.

48. 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

49. 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

50. 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

51. 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.

52. 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 .

53. 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

54. 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

55. 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

56. 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

57. '
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.

58. 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

59. 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

60. 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

61. 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.

62. 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

63. 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

64. 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.

65. 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.

66. 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