STEAM BOILERS FIRETUBE DESIGN AND FABRICATION

APRIL 1992

PAGE 1 OF 17

EGE 11-B-21 1992

TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. Scope References Codes and Safety Measures Standard Products Location of Boiler Design 6.1 General 6.2 Mechanical 6.3 Tubes 6.4 Furnace (Combustion Chamber) 6.5 Shell 6.6 Superheater 7. Economizer 7.1 General 7.2 Economizer Tubes 7.3 Enclosure 8. Fuel Burning Equipment 8.1 General 8.2 Fuel Oil Burner 8.3 Fuel Gas Burner 8.4 Combination Firing (Gas and Oil) 8.5 Fuel Oil Pumps 9. Forced Draft Fan 9.1 Fan Design 9.2 Fan Material 10. 11. 12. 13. Breeching Stack 11.1 General 11.2 Design Sound Control Boiler Trim and Instrument Connections 13.1 General 13.2 Special Connections 13.3 Boiler Trim 13.4 Instrumentation Combustion Control System 14.1 General 14.2 Combustion Safety Controls Boiler Panels and Instruments 15.1 General 15.2 Instrumentation 15.3 Alarms Painting Special Protection Requirements Inspection and Testing 18.1 General 18.2 Tests Required Performance Guarantees Preparation for Shipment Proposal Documentation

14. 15.

16. 17. 18. 19. 20. 21.

1. SCOPE This Guide covers basic requirements for the design, fabrication, installation, and performance of a multipass horizontal firetube boiler fired by fuel oil, fuel gas, or both. The firetube boiler is designed to produce steam at a pressure of 100 to 1725 kPag (15 to 250 psig) and capacities of 680 to 30,000 kg/h (1,496 to 66,000 lb/h). Typical applications in lube and blending plants, terminals, and HVAC have been used at other Mobil installations. When capacities above 30,000 kg/h (66,000 lb/h) or steam pressures above 1725 kPag (250 psig) are required, watertube boilers are used and designed in accordance with EGE 11-B-20. Process waste heat recovery firetube design boilers are not applicable to this Guide. 2. REFERENCES The following publications form a part of this Guide. Unless otherwise specified herein, refer to the latest edition.

MOBIL ENGINEERING GUIDE EGE 11-B-21 1992

Mobil Engineering Guides: EGE 00-B-5 EGE 11-D-21 EGE 15-B-2 EGE 15-D-2 EGE 33-B-9 EGE 33-D-9 Equipment Sound Levels Steam Boiler (Firetube) Data Sheet Positive Displacement Pumps Rotary Rotary Pump Data Sheet Electrical Induction Motors Induction Motor Data Sheet
PAGE 2 OF 17 APRIL 1992

ASME (American Society of Mechanical Engineers) Code Boiler and Pressure Vessel Code: Section I, Power Boilers ASTM (American Society for Testing and Materials) Standard A36/A36M Structural Steel A242/A242M High-Strength Low-Alloy Structural Steel D1066 Standard Practice for Sampling Steam Code of Federal Regulations Chapter XVII, Part 1910: Occupational Safety and Health Standards NFPA (National Fire Protection Association) Code 78 Lightning Protection 85A Prevention of Furnace Explosions in Single Burner Boiler Furnaces UL (Underwriters Laboratories) Gas and Oil Equipment Directory

3. CODES AND SAFETY MEASURES The boiler and associated equipment shall conform to the following: ASME Boiler and Pressure Vessel Code, Section I. Industrial Risk Insurers (IRI) and Factory Mutual (FM) requirements. Mobil Engineering Guides listed herein. Applicable local, state, or other regulatory requirements, such as Code of Federal Regulations OSHA), at the site specified.

The boiler shall be stamped with the ASME standard symbol and UL approved, or shall have the stamp of the local equivalent authority at the site. 4. STANDARD PRODUCTS Equipment and components of standard manufacture shall be provided to ensure the availability of spare parts. Boiler components and accessories can be produced by different manufacturers. The boiler manufacturer, however, shall assume full responsibility regardless of source of supplies. 5. LOCATION OF BOILER The boiler design and materials of construction shall be suitable for continuous indoor/outdoor operation as specified on EGE 11-D-21. Where winter temperatures may drop to 0C (32F) the entire installation must be suitable for service in a freezing climate.

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EGE 11-B-21 1992

Regardless of the climatic conditions, all external surfaces shall be self-draining and protected against corrosion. 6. DESIGN 6.1 General

The boiler shall be a multipass horizontal firetube updraft type. It shall have a minimum of 0.46 m (5 ft) of heating surface per boiler horsepower (bhp), measured on the fireside. It shall have a maximum heat input of 1550 kW/m (150,000 Btu/ft) of furnace volume, operating at rated capacity. The boiler shall be designed to operate continuously in the automatic mode, with manual override, under all conditions specified in EGE 11-D-21.
NOTE: A boiler horsepower is equivalent to 34.5 lb/h of water evaporated at 100C (212F). It is equivalent to 33,475 Btu per hour. Furnace volume is defined as the cubical volume contained within the surrounding firetubes and the tubesheets.

The boiler and auxiliaries, including control instrumentation, shall be designed for continuous operation during electrical power outages through an uninterrupted power supply (UPS) system. The UPS shall be provided by others. The power requirements shall be stated on EGE 11-D-21. The boiler shall be designed to operate continuously over the control range within the emission standards as required by the local authority. The boiler insulation shall consist of a minimum of 51 mm (2 in.) thick fiberglass blanket installed under a sectional preformed 16 gage sheet metal lagging. The insulation must be readily removable and reinstalled, if required. Rear refractory and insulation shall be contained in the formed rear door, which must swing open for inspection, cleaning, or repairs/removal of tubes and tubesheet. 6.2 Mechanical

The design and construction of the boiler(s), including all auxiliary facilities, shall be of proven and commercially demonstrated design. The boiler, burners, all necessary appurtences, and auxiliary equipment shall be mounted on an integral steel base to provide a complete, self-contained steam generating unit. The unit shall be ready for immediate mounting on the floor or foundation. The unit shall be ready for attachment of steam, water, fuel, electrical, blowdown, and vent connection. The boiler shall be designed and manufactured in accordance with ASME Code, Section I, which includes stress relieving and 100 percent X-ray of all welded seams. The boiler must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. The boiler shall have hand holes, manholes, and gas-tight inspection doors for thorough inspection and cleaning. All manholes and hand holes shall be provided with stiffeners or reinforcing rings. Front and rear doors on the boiler shall be davited. The door design shall show the direction of door swing (from left to right or from right to left). Boiler design shall allow for servicing, removal, and replacement of tubes from either front or rear end doors. 6.3 Tubes

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Tubes shall be electric resistance welded (ERW) steel. Tube material shall be selected based on fuels fired, anticipated metal temperatures, and flue gas composition. The plain tube end shall be firmly expanded, rolled, and beaded into the tubesheets. The stay tube ends shall be firmly expanded, rolled, and welded to the tubesheets. 6.4 Furnace (Combustion Chamber)

The furnace shall be attached with a full penetration weld, with the furnace extending through the full thickness of the tube sheet. 6.5 Shell

The steam space shall be adequately sized to contain separation equipment necessary to obtain the guaranteed steam purity throughout the control range of the boiler as specified on EGE 11-D-21. 6.6 Superheater

When a superheater is required, the design and configuration shall be reviewed and approved by Mobil. 7. ECONOMIZER 7.1 General

An economizer shall be provided when specified on EGE 11-D-21. The economizer metallurgy shall be designed for a minimum of 371C (700F). A connection for water washing shall be provided. The economizer shall be completely drainable by gravity. When specified or required by the manufacturer, sootblower equipment shall be included by the vendor. Sootblowers shall be installed transversely to provide maximum cleaning capabilities. 7.2 Economizer Tubes

Selection of economizer tube material shall be based on the flue gas composition and metal temperatures developed during minimum load operation. Tube arrangement shall be square pitch. Finned tubes shall have a maximum of 5 fins per 25 mm (1 in.). The fins shall be helically wound and attached by high frequency continuous resistance welding. Fin thickness shall be a minimum of 1.5 mm (0.06 in.). 7.3 Enclosure

The economizer shall be prefabricated for field installation with minimum assembly and field welding. Inner casing shall be a minimum of 10 gage carbon steel. Outer casing shall be weatherproof with a minimum of 22 gage, corrugated galvanized carbon steel casing.

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EGE 11-B-21 1992

8. FUEL BURNING EQUIPMENT 8.1 General Oil burning equipment shall meet the requirements of the UL Gas and Oil Equipment Directory, or equivalent. The type of burner furnished shall be designed for the fuels or combination of fuels specified on EGE 11-D-21. The burner and controls shall be designed for rapid changeover from one fuel to the other. Fuel changeover shall be accomplished by a mechanically operated electrical selector switch and an automatic fuel valve. All burner hardware including piping, tubing, hoses, and shutoff valves shall be of steel or steel alloys. Cast-iron, copper alloys, aluminum alloys, etc. shall not be used. 8.2 Oil Burner

The oil burner shall be an integral part of the boiler front. The burner shall be provided with either a low-pressure air atomizer or mechanical pressure type atomizer designed for fully automatic operation. Air required for the air atomizing burner shall be supplied from a separate self-lubricating air compressor and lube system module completely pre-piped and mounted on the boiler base. The burner shall be capable of completely atomizing the oil through a 5:1 turndown, without changing nozzles or spray plates. The oil burner shall be designed for quiet operation, without "blowtorch" effects, or tendency to localize heat or to deposit unburned oil in any part of the combustion chamber (furnace). 8.2.1 Oil Heater

When an oil heater is required, it shall be provided by the manufacturer and approved by Mobil. 8.2.2 Oil Burner Piping

As a minimum, the fuel oil burner piping shall conform to Factory Mutual (FM) requirements. The fuel oil burner shall be equipped, as a minimum, with the following: On/off oil switch, operating light, and an adjustable fuel oil pressure regulator with relief device. Cam-operated fuel oil flow control valve with characterizing adjustments to match air flow. Dual automatic safety shutoff valves. Low-pressure oil switch. Fuel oil meters (located on the supply line). Fuel oil pressure and temperature gage (located on the supply line). Oil flow limit switches.

MOBIL ENGINEERING GUIDE EGE 11-B-21 1992 Oil strainers (duplex type). Oil lockout switch (if required for cold start). Atomizing Air Train
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8.2.3

The atomizing air train shall include, as a minimum, the following items: 8.3 Pressure regulator. Inlet air filter. Level indicator. Cooler. Strainer. Fuel Gas Burner

A gas burner shall be capable of burning fuel gas as specified on EGE 11-D-21. The burner shall operate throughout the full burner turndown range (5:1) without evidence of instability, pulsation, "blowtorch" effects, or other indications of poor combustion. 8.3.1 Pilot and Main Gas Train

The pilot and main gas train shall comply with utility requirements as specified on EGE 11-D-21, and shall include the following items: Pilot Gas Train Shutoff cock. Gas pressure regulator. Pressure gage. Solenoid valve. Interconnecting piping. Main Boiler Gas Train Cam-operated flow control valve with characterizing adjustments to match air flow. Motorized shutoff valves. Intermediate solenoid vent valves. Dual lubricated plug cock. Plugged leakage test cocks.

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EGE 11-B-21 1992

High- and low-pressure switches. Gas ring. Unit main train pressure regulator. Damper motor limit switches. Fuel gas valve position indicator.

The gas train vent shall be piped to atmosphere and shall comply with local environmental code. 8.3.2 Fuel Gas Burner Pilot (Ignitor)

A Class 3 gas ignitor shall be provided as defined by NFPA 85A. The ignitor shall be installed for use with optical flame detectors. The ignitor shall be "blowoutproof" and capable of maintaining ignition while maximum combustion air is flowing through the main burner throat when the main fuel is shut off. Ignitors that are not retractable shall be air cooled to withstand furnace radiation. The gas supply line to the ignitor shall be provided with block and bleed valves. The bleed shall be vented to atmosphere at a safe distance from the boiler. The ignitor shall be of the automatic air- and gas-type, complete with a high voltage electric spark device. The ignitor may be designed to use either instrument air, or air that is supplied from an ignitor air fan, or main burner combustion air. The air supply to the ignitor shall be interlocked with the supply of combustion air to the main burner. This will allow simultaneous shutoff of combustion air to both the ignitor and main burner. 8.4 Combination Firing (Gas and Oil)

Burners shall be of the multiport, removable type. Burners shall be designed to minimize exposure to furnace radiation. Burner parts that are exposed to furnace radiation shall be of heat-resistant alloys. Center-fired gas guns, when offered, shall be retractable. 8.5 Fuel Oil Pumps

Two fuel oil pumps shall be supplied. Each pump shall be positive displacement, rotary type and shall conform to EGE 15-B-2 and EGE 15-D-2. Each pump shall deliver a minimum of 125 percent of the fuel oil required at maximum burner capacity. Each pump shall be designed for continuous operation with manual startup from a local panel. Each pump shall be directly connected to an electric motor. The motor shall conform to EGE 33-B-9 and EGE 33-D-9. The motor shall meet all requirements specified on EGE 11-D-21. Each pump shall be rated at a discharge pressure required by the burner manufacturer, taking into

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consideration the pressure drops for piping and the control valve range. 9. 9.1 FORCED DRAFT FAN Fan Design

The fan shall be a centrifugal blower. It shall be connected to the burner combustion air damper inlet via ducting and flexible connection. A flexible connector shall be provided on the fan inlet. 9.2 Fan Material

The fan shaft material shall be 304 stainless steel. Casing and fan blades shall be fabricated from epoxy-coated steel to minimize the effects of possible corrosive atmosphere. 10. BREECHING

Breeching shall be a minimum of 10 gage (0.1345 in.) thick black steel sheets. Breeching shall be reinforced and braced with structural steel angles a minimum of 51 mm x 51 mm x 6 mm (2 x 2 in. x 1/4 in.). All joints and seams in the sheets and angles shall be welded. Expansion joints shall be the flexible type that require no packing. The breeching shall have an angle flange for connection to the boiler. The breeching shall extend into the stack. It shall be corked tight around with insulation rope and sealed with castable refractory cement to form an air-tight joint. Cleanout openings of suitable size shall be provided at approved locations for access to all sections of the breeching. 11. STACK

11.1 General Unless otherwise specified on EGE 11-D-21, stacks shall be furnished by the boiler vendor. The stack shall be self-supporting. Minimum stack height shall be indicated on EGE 11-D-21. Where applicable, the stack height and location shall be approved by the authorities having jurisdiction. Connections shall be provided for emission measurement required by local code. 11.2 Design The stack design shall be in accordance with local meteorological data, as specified on EGE 11-D-21, and applicable governmental and local codes. Where design flue gas temperature is below 426C (800F), unlined stacks may be used for natural gas and clean fuel application. For other fuels and design flue gas temperature below 315C (600F), external insulation shall be used to ensure that inside stack metal temperature is above the SO3 dew point temperature. Stacks shall also be internally protected against acid dew point corrosion attack that can occur during shutdown periods where fuel may contain S2 or H2S. The steel casing (including anchor-to-surface welds) shall be protected with a minimum of 300 m (12 mils) dry film thickness of coal tar epoxy, such as Valspar 84-J-5 or equivalent. Exterior steel stack surfaces that do not exceed 176C (350F) shall be given a 50 m (2 mils) dry film thickness shop primer coat. Surfaces shall be cleaned by commercial blast or shop pickle prior to painting.

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EGE 11-B-21 1992

Stack surfaces exceeding 176C (350F) shall be given a 50 m (2 mils) dry film thickness shop prime coat of Valspar 13-F-12 or equivalent. Surfaces shall be cleaned by near-white blast or shop pickle prior to painting. Steel stack shell plate thickness shall be 6 mm ( in.) minimum, including a corrosion allowance of 3 mm (1/8 in.). The stack shall be constructed of materials conforming to ASTM A36 or A242. Stacks with floors shall be provided with a 50 mm (2 in.) drain as a minimum. Sound levels for exhaust stacks shall meet requirements of EGE 00-B-5. All stacks shall have an adequate, electrically uninterruptible metal path to the grounding grid system or separate grounding rods for lightning conduction. When lightning protection is required, it shall be provided in accordance with NFPA 78 or equivalent national code. At least one access door, a minimum of 610 mm x 610 mm (24 in. x 24 in.), shall be provided for access to the bottom of the stack for inspection, cleaning, and maintenance. 12. SOUND CONTROL The entire boiler installation, as well as all individual components and accessory items associated with the boiler, shall be designed to meet sound level limitations at all operating conditions in accordance with EGE 00-B-5. 13. BOILER TRIM AND INSTRUMENT CONNECTIONS 13.1 General The boiler vendor shall supply all the connections and equipment described in this Section. All instrument connections, except for temperature sensing devices in thermowells, shall be provided with separate block valves to permit removal of the device without affecting other active devices. All valves shall be of steel body construction. The use of cast iron for boiler trim is not permitted. 13.2 Special Connections

The boiler shall be provided with connections for the following: (a) (b) Chemical cleaning. Draining of all water from the boiler after shutdown. Drain valves shall be sized for a NPS (NPS 1 1/2 minimum.

= nominal pipe size, inches)

(c) Measurement of opacity, particulates, SOx, NOx, O2, and CO, as required by applicable air quality regulations. (d) (e) 13.3 Sampling of boiler feedwater, saturated steam, and blowdown quality. Measuring of draft and exit gas temperatures in the exhaust duct.

Boiler Trim

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The minimum boiler trim requirements shall be provided as follows: (a) Boiler safety valves in accordance with the requirements of ASME Code, Section I, complete with adequately supported discharge piping. All safety valves shall be equipped with lifting levers. (b) A steam outlet stop valve and a nonreturn valve.

(c) A complete set of blowdown valves including two quick opening type valves located at the front end of the boiler. One of the valves in the set must be a slow opening type. (d) (e) (f) A boiler feedwater shutoff valve and a check valve. Chemical feed valves and check valves. All drain piping from source to 1 m (3 ft) above grade.

(g) A feedwater regulator valve with bypass designed to control feedwater flow over the entire range from no load to full load. (h) Observation ports at each end of the boiler.

(i) Sample coolers per ASTM D 1066, complete with rack, valving, and a drainage trough. Each sample cooler shall be separately piped and valved. The drainage trough shall have a drainage connection and piping provided by others. 13.4 Instrumentation The following instruments shall be provided: (a) A 152 mm (6 in.) diameter steam pressure gage with valve and test tee.

(b) A water column complete with gage glass, gage cocks, operating chain, and column blowdown valves. (c) High- and low-level alarms.

(d) A low water cutoff switch, which is an integral part of the boiler feed control, and is wired in the burner control circuit. 14. COMBUSTION CONTROL SYSTEM

14.1 General The combustion control system shall be provided with a PLC (Programmable Logic Controller) mounted in the boiler panel adjacent to the boiler. The boiler manufacturer shall assume full responsibility for the servicing and operation of this system. An automatic combustion control system shall include the necessary digital controllers, transmitters, actuators and manual/automatic selector stations. The boiler shall be designed for automatic/manual operation. 14.2 Combustion Safety Controls

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EGE 11-B-21 1992

The combustion safety control system shall be supplied by the vendor and shall conform to NFPA 85A. The system components shall be UL listed, FM approved, or equivalent. The flame safeguard control unit shall have solid state electronic circuitry, a safety shutdown interlock, and a repetitive self-check feature. It shall have amplifiers, transformers, power supply, indicating lights, and terminal strips, all factory prewired and assembled in a NEMA 4X steel cabinet with door. The door shall be piano hinged, with the latch supporting the chassis. All control components shall be easily accessible. As a minimum, the following combustion control devices shall be installed: (a) Flame scanners: two scanners per burner.

(b) A flame control potentiometer for continuous firing at any desired rate between low fire and maximum fire (20 to 100 percent). (c) Indicating lights and alarms for safety shutdown conditions.

(d) Fan interlocks installed in the flame safeguard relay and control unit to interlock the forced draft fan circuits when there is loss or failure of combustion air flow and flame failure. (e) Low water cutoff interlocks to prevent startup of boiler on low water level.

(f) Low- and high-fuel pressure interlock switches to discontinue burner operation if low- or high-fuel pressure is detected. (g) A purge timer to permit sufficient time until the minimum purge has been completed. Volume to be purged shall be specified as outlined in NFPA 85A, FM, or equivalent, whichever is more stringent. An indicating light shall be provided to indicate purge completion. (h) Flow switches to prove air flow.

(i) Wiring between the sensing element and control cabinet, installed in accordance with manufacturers recommendations. 15. BOILER PANELS AND INSTRUMENTS

15.1 General The boiler instrument panel shall be sized to contain all controls, instruments, gages, alarms, and meters. The panel shall be weather-tight, in conformance with NEMA Class 4. The panel shall be free standing. The faceplate shall be a minimum of 5 mm (3/16 in.) reinforced plate. The instruments shall be mounted flush on the panel, as far as practicable. The back of the panel shall be enclosed with sheet metal. The back shall have adequate access panels for maintenance and removal of any instruments without interfering with other control devices. Proper door latching equipment and hardware shall be provided. Each recorder, indicator, and control unit shall be identified with engraved metal or laminated plastic nameplates secured to the panel. The panel shall have continuous rapid-start fluorescent light fixtures mounted with reflectors. The reflectors shall provide suitable shielding to ensure visibility of all alarms, controls, instruments, gages, and meters.

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All vendor-supplied equipment shall terminate in a location for easy connection to field piping. Wiring and piping within the panel shall be color-coded for easy identification. When a pneumatic control system is provided, the panel air supply filter and regulator set shall be mounted on the rear of the panel. No high-pressure air lines will be allowed to enter the panel. 15.2 Instrumentation The vendor shall mount all necessary instrument taps on the boiler. The connection between the boiler taps and the boiler panel terminal connections shall be by others. Instrument gages shall be complete with piping between the gages and the points at which measurement is made. A three-way cock shall be provided for shutoff and zero check. The boiler panel shall be provided with the following: (a) Draft gages to measure draft at the furnace (combustion chamber) and breeching at the boiler outlet. (b) A pressure gage to indicate the steam pressure at the outlet connection to the main steam header. (c) A flow meter to measure the steam produced by the boiler at the pressure specified on EGE 11-D-21. (d) A flue-gas temperature indicator/recorder containing a thermocouple type indicator with transmitter to indicate and record flue gas outlet temperatures. (e) (f) (g) Feedwater pressure and temperature recorders. An annunciator to indicate boiler alarms and shutdowns for abnormal conditions. A printer to print a record of alarms and shutdown conditions.

15.3 Alarms Alarms shall be wired to the panel-mounted terminal strips to automatically shut down the boiler through the burner management system (BMS) in accordance with NFPA 85A. 16. PAINTING

The entire boiler system and unit shall have a surface preparation and protective coating, per manufacturers standard, which is suitable for the intended facility exposure. The manufacturers standard finish for elevated temperature service is acceptable only if paints are formulated from recognized heat-resistant ingredients that are adequate for the anticipated temperatures. 17. SPECIAL PROTECTION REQUIREMENTS

The equipment shall be braced, protected, packed, and crated to prevent damage, rust, or any other injurious effect when transported to the site from the vendors shop.

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EGE 11-B-21 1992

Subassemblies shall be piped and wired to terminal blocks. Each boiler may be shipped knocked-down with a maximum of the following complete sub-assemblies: (a) Boiler setting, including burner assembly, furnace tube, insulation, casing, supports, base, and appurtenances. (b) (c) Stack and breeching. Boiler panel, including control cabinet.

Interconnecting instrument tubing and piping, if shipped loose, shall be match-marked. 18. INSPECTION AND TESTING

18.1 General On receipt of the order, the vendor shall supply a production plan listing all timing for critical operation in boiler construction. The vendor shall also supply the names and addresses of selected subsuppliers. 18.1.1 Vendors Site

(a) All materials and work of the vendor and the vendors subsuppliers shall be subject to inspection by the purchaser or an authorized representative. Any rejections made by an inspector shall be final. (b) All pressure part assemblies fabricated in accordance with Section I of the ASME Code shall be inspected, tested, and stamped in accordance with the Code. A copy of the inspection report shall be furnished to the purchaser. 18.1.2 Purchasers Site

(a) Sufficient test connections shall be provided by the boiler vendor to verify combustion air and fuel balances during commissioning and normal operation. (b) A meeting shall be arranged between purchaser and representatives of the vendor. They shall define the acceptance test procedures and agree on the criteria by which the test results will be judged for conformance and acceptance. (c) In the event the boiler does not perform in accordance with the specified requirements, the vendor shall immediately take the necessary steps, at his expense, to correct the deficiencies so that the unit meets the guaranteed performance. The guarantee period shall commence on acceptance of the boiler by Mobil. (d) The vendors representative shall perform the acceptance test on the boiler at the satisfactory conclusion of commissioning. During the acceptance test, the vendors representative shall clearly demonstrate complete and smokeless combustion at all loads within the burner turndown range and with any specified fuel available at the time of the test on the boiler. (e) The purchaser shall provide the operating personnel during commissioning and testing. The vendor shall provide any special apparatus required. (f) Measurements of performance during the acceptance test shall be taken from the existing boiler instrumentation where possible. It is the vendors responsibility to be satisfied with the adequacy of this instrumentation during commissioning of the boiler.

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If additional test instrumentation is required, it shall be provided by the vendor. Such instrumentation shall have documented evidence of recent calibration. (g) If any test is interrupted for any reason, it shall be rejected, unless otherwise agreed upon by Mobil. (h) All fuel, water, and power required for field testing will be furnished by the purchaser. Details of availability and quantity of above supplies should be agreed upon in advance of actual testing dates. 18.2 Tests Required

18.2.1 The following tests represent the minimum tests that are to be performed at the vendors site. They shall be witnessed by Mobil representatives: (a) Burner Management Test A functional test of the complete system that simulates all modes. The vendor shall supply a test procedure for review and acceptance by Mobil at least three months prior to this test. (b) Hydrostatic Test A test of all preassembled pressure-containing sections of the boiler. This test shall be performed per ASME Boiler and Pressure Vessel Code, Section I, before the outer casing is installed. 18.2.2 Tests conducted in the field by the vendor during and after commissioning shall include, but not be limited to the following: (a) Hydrostatic Test A test of all pressure parts per ASME Boiler and Pressure Vessel Code, prior to installation of the casing, if possible. (b)

Burner Management Test A functional checkout of controls and boiler components.

(c)Boiler Control Test A functional checkout of controls and boiler components. 18.2.3 All controllers and indicators shall be tested at the factory complete with relays, transformers, switches, wiring, valves, and piping. 19. PERFORMANCE GUARANTEES

The vendor shall correct all deficiencies in design, workmanship, and materials to satisfy design and performance guarantees at no cost to Mobil. The supplier shall include in the proposal a statement of guaranteed fuel-to-steam efficiency at 25, 50, 75, and 100 percent of maximum continuous rating (MCR) when fired on the fuel(s) specified on EGE 11-D-21. Minimum acceptable fuel-to-steam efficiency at or above 50 percent MCR shall be 80 percent. Combustion controls and accessories shall be designed to maintain steam pressure and capacity as specified on EGE 11-D-21. The combustion control system shall maintain excess air within 10 percent of the set point value. Motors shall be guaranteed by the manufacturer to meet applicable requirements of NEMA, or equivalent, and to operate continuously under all loads. 20. PREPARATION FOR SHIPMENT

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EGE 11-B-21 1992

After inspection and tests, equipment shall be completely cleaned, dried, and prepared for shipment. The vendor shall be solely responsible for preparing materials for shipment to their destination. The equipment shall arrive at the site in good working condition. Equipment shall be packed, securely anchored (skid-mounted when required), and protected for the shipment methods to be used. All separate, loose, and/or spare parts shall be boxed, individually protected as required, and packed in a sealed waterproof container for shipment. Each container shall include a complete copy of the Bill of Materials identifying each item in the container. A separate copy of the Bill of Materials in each container shall be submitted to the construction manager. One complete set of installation, operating, and maintenance instructions shall be packaged and shipped with the equipment. This is in addition to the quantity specified for submittal to the purchaser. Equipment/material shall be tagged as follows: (a) Each item shall be identified with its purchase order (P.O.) number and item number. Tags shall be stainless steel and impression stamped with the following: P.O. No. P.O. Item No. Equipment Tag No. (b) Tags shall be attached to the equipment/ material with stainless steel wire. This tagging is in addition to the equipment nameplates. Equipment/material shipped in fully enclosed containers shall also include the above information marked on the outside of the containers. (c) Major equipment assemblies shall have the purchase order number, equipment tag number, and shipping weight stenciled on the assembly. (d) All material to be assembled in the field shall have the erection or assembly mark identification codes (as indicated on the vendors erection and detail drawings) indelibly marked on the piece. (e) Equipment containing lubricating oils, antifreeze solutions, or other fluids shall be suitably tagged at openings to indicate the nature of the contents and shipping and storage precautions. (f) Miscellaneous parts shall be tagged or marked with the tag item number for which they are intended. All such parts shall be suitably boxed, firmly attached to the main item, and shipped with the unit for which they are intended. All prefabricated piping spool pieces shall be match-marked and appropriately tagged to facilitate assembly in the field. After inspection and test, equipment shall be completely free of any liquid used for testing. Bracing, supports, and rigging connections shall be provided to prevent damage during the shipment, lifting, and unloading. All temporary bracing and supports shall be painted a color that contrasts with the color of the equipment assemblies. All temporary bracing and supports shall be appropriately tagged to facilitate proper removal in the field. All instruments and valves, including auxiliary systems, shall be securely mounted, supported, and/or boxed to eliminate damage during shipment.

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PAGE 16 OF 17 APRIL 1992

Exposed finished and machined surfaces, including bolts, shall be given a heavy coating of rust-inhibiting compound. Bearings and seal assemblies shall be fully protected from the entry of moisture and dirt. Flanged openings shall be provided with full flanged diameter protective covers. Cover material shall be a minimum of 5 mm (3/16 in.) thick metal plate. A full diameter gasket shall be supplied between the flange and coverplate. The coverplate shall be held to the flange by a minimum of four full diameter bolts and nuts. All other openings, including tube and pipe ends, shall be adequately sealed for protection. Long shank metal pipe plugs or pipe caps shall be used for all such connections. Tape or plastic plugs/caps are NOT ACCEPTABLE. The material of the plug/cap shall be the same as the sealed opening. Refractory which is shipped loose for field installation shall be prepared for shipment in the following manner: Castable refractory shall be palletized, shrink-wrapped in plastic and encased in waterproof cardboard. Fiberglass insulation shall be palletized and shrink-wrapped in plastic.

The boiler shall be equipped with lifting lugs and structural bracing. These shall be designed and positioned by the vendor to permit handling during shipment and lifting for erection without damage. 21. PROPOSAL DOCUMENTATION

The vendor's proposal shall be submitted in accordance with the requirements of Mobil specifications and Engineering Guides. The proposal shall include all data sheets completed on EGE 11-D-21 and the following preliminary descriptive information with a copy of the quotation submitted: (a) (b) (c) (d) Dimensional outline plan and elevation. Equipment assembly drawings and descriptive literature. Construction materials used. Full specification and operational sequence for loading, unloading, and shutdown system.

(e) Full specifications for capacity regulation, instrumentation, electrical equipment, wiring, and schematics. (f) A list of all equipment with manufacturer's catalog number, size, construction, material, and so forth. (g) (h) (I) (j) Equipment weights. The sound level of equipment when operating at full capacity. Subassembly modular arrangement. Performance guarantees at the conditions specified on EGE 11-D-21.

MOBIL ENGINEERING GUIDE

APRIL 1992 PAGE 17 OF 17

EGE 11-B-21 1992

(k) (l)

Equipment warranties. Recommended spare parts list including price and delivery.

(m) The emission data, stated in mg/Nm (lb/MM Btu) of heat release, for the following: CO2 SOX NOX CO Particulates Hydrocarbons

This emission data shall cover each of the fired fuels at 50 percent MCR (maximum continuous rating) and 100 percent MCR.

MOBIL ENGINEERING GUIDE STEAM BOILER (FIRETUBE) DATA SHEET

ISSUE 1 2 3 APPROVED 4 5 6 ISSUE APPROVED JOB NO. SERVICE LOCATION EGE 11-D-21 1992 Page 1 of 7

DESIGN DATA Boiler Capacity Steam at Main Header: Pressure Temperature of Feedwater Supply Feedwater Temperature to: (Boiler) (Economizer) Maximum Solids Concentration Minimum Steam Quality Number of Units Type of Installation: (Indoor) (Outdoor) Freezing Climate: (Yes) (No) Continuous Blowdown Boiler Plot Limitations Stack Supplied by: (Vendor) (Others) Minimum Stack Height Aboveground SITE CONDITIONS Ambient Air: Design Temperature Minimum Temperature Design: Wind Load Earthquake Factor UTILITIES Electrical System: Area Classification Frequency Instruments and Controls: Motors: Through Over Steam: Cooling Water: Condensate: Plant Air: Instrument Air: kPag (psig) Temperature kPag (psig) Temperature kPag (psig) Temperature kPag (psig) Oil Free kPag (psig) Dry and Oil Free kW (hp) kW (hp) C (F) C (F) C (F) Hz Volts Volts Volts Phase Phase Phase kg/m (lb/ft )
2 2

kg/h (lb/h)

Design Pressure Temperature C (F) ppm

kPag (psig) C (F)

kPag (psig) C (F)

m (ft)

C (F) C (F)

Relative Humidity (2% of Year) Maximum Temperature kg/m (lb/ft ) m (ft)

2 2

% C (F)

Snow Load Elevation (Above Sea Level)

REMARKS

NOTE: Pages 1, 2, and 3 to be completed by Mobil; remaining pages to be completed by vendor.

MOBIL ENGINEERING GUIDE STEAM BOILER (FIRETUBE) DATA SHEET

BURNER DATA Type Required: (Oil) (Gas) (Combination) (Other) Class of Ignitor Required: Fuel Oil: No. 2 Fuel Gas: Refinery Gas LPG LNG Pilot Gas Source: (Piped) (Bottled) FUEL DATA OIL Flash Point Specific Gravity Viscosity (SSU) (SSF) Total H2 LHV HHV % Wt kJ/kg (Btu/lb) kJ/kg (Btu/lb) C (F) API C (F) GAS Proximate Analysis % Vol H2 CH4 C 2H2 C2H4 C2H6 C3H6 C3H8 Ultimate Analysis % Wt Carbon Hydrogen Oxygen Nitrogen Sulfur Ash Moisture Total Ash Fusion Temp Sodium Vanadium Nickel 100.00 C (F) ppm ppm ppm C4H8 C4H10 C5H12 C6H14 CO CO2 O2 N2 H2S Total (Dry) Mol. Wt (Dry) H2O: Dew Pt @ kPag (psig) H2O: HHV Header Pressure kPag (psig) Max. kPag (psig) Min. LHV % Vol kJ/kg (Btu/lb) kJ/m (std) (Btu/std ft ) kJ/kg (Btu/lb) kJ/m (std) (Btu/std ft ) Heating Value Range kJ/kg (Btu/lb) kJ/Nm (Btu/std ft ) Header Pressure
3 3 3 3 3 3

EGE 11-D-21 1992 Page 2 of 7

No. 5 @

No. 6 kPag (psig)

kPag (psig)

Hydrogen Methane Acetylene Ethylene Ethane Propylene Propane Butylene Butane Pentane Hexane & Heavier

C (F)

Max. Max.

Min. Min.

kPag (psig) Max. kPag (psig) Min.

REMARKS: 1. 2. 3. Pages 1, 2, and 3 to be completed by Mobil; remaining pages to be completed by vendor. Steam pressure and temperature at boiler outlet are downstream of NRV. Efficiency guarantee to be based on fuel (oil) (gas) and calculated according to ASME; using design ambient air temperature from page 1 of this Data Sheet.

MOBIL ENGINEERING GUIDE STEAM BOILER (FIRETUBE) DATA SHEET

TREATED WATER Method Description EGE 11-D-21 1992 Page 3 of 7

Constituent

Average

Range

pH Chloride P Alkalinity M or Total Alkalinity Hardness Silica Conductance ppm ppm ppm ppm ppm mhos

CONDENSATE

Constituent Ammonia CO2 Chloride Silica pH Conductance Iron Sodium mhos ppm ppm ppm ppm ppm ppm

Average

Range

REMARKS
NOTE: Pages 1, 2, and 3 to be completed by Mobil; remaining pages to be completed by vendor.

MOBIL ENGINEERING GUIDE STEAM BOILER (FIRETUBE) DATA SHEET

BOILER Manufacturer Design Code Maximum Continuous Rating Model Type Kg/h (lb/h) EGE 11-D-21 1992 Page 4 of 7

CONSTRUCTION DETAIL Boiler Shells or Drums: No. Shell Plates Longitudinal Joint(s)
(Seamless, Welded)

Diam. Matl Min. Thickness Joint Efficiency

(As compared to seamless)

mm (in.)

Girth Joint(s)
(Seamless, Welded)

No. of Shell Courses Tube Holes

(Matl Spec., Grade, Thickness) (Diam.)

Tubesheet Boiler Tubes: No.

(Matl Spec., & Grade)

Diam. of Shell Heads

Length
(If various, give max. & min.)

Gage
(or thickness)

(Straight or Bent)

(Material Specification No.: Thickness Flat, Dished, Ellipsoidal Radius of Dish)

Furnace No. Type

Size
(OD or W x H)

Length, each section

Total Length

(Plain, Corrugated, etc.)

Seams: Type
(Seamless, Welded) (Mat'l Spec., & Gr.)

Thickness Size
(Diam., Mat'l Spec., Grade, Size, Telltale Area)

Staybolts: No. Pitch

(Horizontal and Vertical)

psi.

Stays or Braces Material Spec. No. & Size Total Net Area Dist. Tubes to Shell Area to be Stayed

Location (a) F.H. above tubes (b) R.H. above tubes (c) F.H. below tubes (d) R.H. below tubes (e) Through stays Other Parts. 1.

Type

Pitch

2.
(Brief Description i.e. Dome, Boiler, Piping, etc.)

3.

1. Safety Valves: 2. 3.

Setting Pressure

kPag (psig)

Relieving Capacity

kg/h (lb/h)

MOBIL ENGINEERING GUIDE STEAM BOILER (FIRETUBE) DATA SHEET

EGE 11-D-21 1992 Page 5 of 7

BURNER DATA Burner Type/Model No. No. of Oil Burners per Boiler No. of Gas Burners per Boiler Burner Turndown Ratio

Oil Burner Fuel Type Heat Release, MW (10 Btu/h) Excess Oxygen, % Vol (Dry) Fuel Pressure at Burner, kPag (psig) Air Pressure at Burner, C (F) Air Temperature at Burner, C (F) Atomizing Air Flow, kg/h (lb/h) Fuel Temperature, C (F) Fuel Viscosity at Burner (SSU) (SSF) Draft Loss Across Burner, mm H2O (in. H2O) Fuel Fired, kg/h (lb/h) Combustion Air Flow, kg/h (lb/h) Gas Burner Fuel Type Heat Release, MW (10 Btu/h) Excess Oxygen, % Vol (Dry) Fuel Pressure at Burner, kPag (psig) Fuel Temperature, C (F) Loss Across Burner, mm H2O (in. H2O) Fuel Fired, kg/h (lb/h) Combustion Air Flow, kg/h (lb/h) Ignitor No. per Boiler Type/Model No./Manufacturer Fuel Type Capacity, MW (10 Btu/h) Fuel Pressure, kPag (psig) Fuel Flowrate, kg/h (lb/h) Fuel Temperature, C (F) Class
6 6 6

Max.*

Norm.*

Min.

Pilot Pressure Regulator Capacity/Pressure

kg/h (lb/h)/kPag (psig)

*Max. is defined as 110% MCR. Norm. is defined as 100% MCR.

MOBIL ENGINEERING GUIDE STEAM BOILER (FIRETUBE) DATA SHEET

VALVES AND FITTINGS Boiler Valves and Fittings Feedwater Check Valve Feedwater Stop Valve No. Size Matl Conn Mfr Cat. EGE 11-D-21 1992 Page 6 of 7

Steam Nonreturn Valve Steam Stop Valve Steam Drain Valve Steam Drain Check Valve

Water Level Gage (Direct to Boiler) Water Level Gage (to Water Column) Remote Level Indicator Water Gage Isolating Valves Water Gage Drain Valves Water Column Water Column Isolating Valves Water Column Drain Valves

Drum Safety Valves Drum Vent Valve Drum Pressure Gage Drum Pressure Gage Isolating Valve Drum Pressure Gage Test Valve

Continuous Blowdown Control Valve Continuous Blowdown Isolating Valve Steam Sampling Isolating Valve Chemical Feed Isolating Valve Chemical Feed Check Valve Intermittent Blowdown Valves

Pilot Equipment Data Pressure Regulator Solenoid Valve Solenoid Vent Valve Ignition Transformer Ignition Transformer Rating Primary Voltage Secondary Voltage Ignition Electrode Make and Model Volt-Amps

No.

Size

Matl

Conn

Mfr

Mode

MOBIL ENGINEERING GUIDE STEAM BOILER (FIRETUBE) DATA SHEET

FD FANS No. Reqd Type Speed: Air Flow at MCR: Test Block: Fan Sound Level: Motor Driver: Type Motor Sound Level: SUPERHEATER Manufacturer: Arrangement: Effective Surface Area No. Water Passes Max. Allowed Pressure Drop Gas Side Max. Allowed Pressure Drop Water Side Space Restriction (if any) ECONOMIZER Manufacturer: Arrangement: (Staggered) (In-Line) Effective Tube Length No. Tubes Wide No. Rows Deep Tubes: Fins: OD OD Pitch Pitch Thickness Thickness m (ft ) No. Gas Passes Up ; Down mm (in.) WC mm ( in.) WC yrs.
2 2

EGE 11-D-21 1992 Page 7 of 7

Manufacturer Flow Control: (Inlet Vane) (Inlet Damper) (Outlet Damper) rpm Impeller Diameter Oil Gas dm (cfm) @ dm (cfm) @ dm (cfm) @ dBA (Reference 0.0002 microbar) at Manufacturer dBA (Reference 0.0002 microbar) at m (ft) from Motor
3 3 3

mm (in.) C (F) C (F) C (F) kPa (in. H2O): kW (hp) kPa (in. H2O): kW (hp) kPa (in. H2O): kW (hp) m (ft) from Fan kW

Type: (Finned) (Bare Tube) Effective Length m (ft ) No. Gas Passes mm (in.) WC mm (in.) WC
2 2

m (ft)

mm (in.)

Type: (Finned) (Bare Tube) m (ft) m (ft) m (ft) mm (in.) mm (in.) mm (in.) Fins per mm (Fins per in.)
2

mm (in.) Gas Space Width mm (in.) Gas Space Length mm (in.) mm (in.) Total: Material Material m (ft ) Bare Min. Tube Metal Temp ; Horizontal
2

Effective Heating Surface No. Water Passes Flue Gas Flow Thru Economizer Max. Allowed Pressure Drop Gas Side Max . Allowed Pressure Drop Water Side

C (F)

Estimated Payback Period Required By Customer Fuel Oil Gas Hours Operation Space Restriction (if any) /yr Use % Cost /gal /therm

SOOTBLOWERS (if required) No. Location: Control: Steam per Blower: Blowing Time Pressure at Nozzle Block kg/h (lb/h) @ Seconds per Blower kPag (psig) and kPa (psi) C (F) Manufacturer Length No. of Jets

)P Across CV

kPag (psig)