Beruflich Dokumente
Kultur Dokumente
NIOEC SPECIFICATION
FOR
FIELD ERECTED WATER TUBE BOILERS
FIRST EDITION
JULY, 2005
THIS STANDARD IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY
JULY, 2005 NIOEC-SP-45-02(0)
JULY, 2005 NIOEC-SP-45-02(0)
REVISION INDEX
REV. REV. REV. REV.
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
PAGE PAGE PAGE PAGE
1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100
NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.
1
0 JULY, 2005 K.FARROKHI M.H.ZAKER M.R.FARZAM M.A.A.SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
JULY, 2005 NIOEC-SP-45-02(0)
CONTENTS: PAGE NO.
1. SCOPE 2
2. REFERENCES 2
3. UNITS 3
4. DEFINITIONS & TERMOINOLOGY 3
5. SUPPLY 4
6. DESIGN DATA 6
7. STRUCTURAL DESIGN 8
8. MATERIALS 8
9. DESIGN 8
10. PERFORMANCE CONDITIONS 19
11. GUARANTEE 20
12. PREDICTED PERFORMANCE CONDITIONS 20
13. PREPARATION FOR SHIPMENT 20
14. INFORMATION REQUIRED WITH QUOTATION 21
15. DRAWINGS AND DATA REQUIRED 22
16. FABRICATION 22
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1. SCOPE
1.1 This specification covers the requirements for the supply of field erected water tube
boilers with accessories, design, fabrication, inspection, performance conditions,
preparation for shipment, and information required with quotations.
2. REFERENCES
Throughout this Specification the following dated and undated standards/codes are referred
to. These referenced documents shall, to the extent specified herein, form a part of this
Specification.
For undated references, the latest edition of the referenced document (including any
supplements and amendments) applies. For dated references, the edition cited applies. The
applicability of changes in dated references that occur after the cited date shall mutually be
agreed upon by the Company and the Vendor/Contractor.
The following codes and standards shall be applied as relevant in addition to the
requirements of this Job Specification.
API 613 “Special Purpose Gear Units for Petroleum, Chemical, and Gas Industry
Services” Forth Edition June, 1995
ASME STANDARD
Edition 1989
420.04 “Standard Practice for Helical and Herringbone Gear Speed Reducers and
Increasers”
421.06 “Standard Practice for High Speed Helical and Herringbone Gear Units”
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D1.1 Edition
The official code symbol stamp per the applicable code will not be required, unless other
wise specified.
3. UNITS
International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified in NIOEC-SP-00-50 “Design Criteria”.
4.1 “Employer” means: “National Iranian Oil Engineering & Construction Company”.
(NIOEC)
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4.2 “Purchaser” means: “National Iranian Oil Engineering & Construction Company”.
When quoted in this Specification as per of a direct Purchaser order by NIOEC and
“Contractor” where this Specification is part of contract documents.
4.3 “Vendor” means: The manufacturer from which the equipment is to be purchased.
5. SUPPLY
5.1 Complete self-supporting boiler for outdoor installation including boiler drums, tubes,
drum supports, internals drum and header connections, waterwall tubes, waterwall
headers and drum, waterwall circulator tubes, stack, duct and structural steel.
5.2 Complete superheater assembly including inlet and outlet headers, center outlet,
connecting tubes between boiler drum and saturated steam header and necessary support
for headers and elements.
5.3 Burner assembly consisting of steam atomized burners, pilot assemblies, and air register
for the combustion of fuel oil, gas and gasoline.
5.4 Forced draft fan requirements will be specified on the boiler Data Sheet.
5.5 Soot blowers with electrical accessories, pipes, valves, pipe hangers and guides and
fittings. Soot blowers are not initially required for the boilers fueled with only refinery
fuel gas, but space for future installation of soot blowers, water washing or steam lancing
doors shall be provided.
5.6 All ductwork between forced draft fan and boiler and burner windboxes.
5.7 Boiler valves and accessories including safety valves, blow-off valves, drum vent valve,
chemical feed valve, continuous blowdown valves, steam gauges, water gauge stop
valves, water gauge drain valves, steam gauge line stop valves, water gauges, and
superheater valves.
5.8 A sealing air system shall be provided from the F.D. fan discharge duct for the
observation ports soot blowers etc.
On pressurized boiler, observation doors shall have a view glass and shall be furnished
with:
a) Aspirating air of sufficient pressure to prevent flue gases from blowing out when the
door is open. Each door should be fitted with inter lock.
b) Seal air to minimize flue gas leakage and prevent fogging of the view glass when the
door is closed.
5.9 Outdoor setting, insulation, Refractories and 14 gauge, or 2mm. min. ribbed outer casing
shall be provided with necessary seals, expansion joints, door lining, to complete the
setting.
5.11 Vendor shall furnish ladders, platforms, stairways, stack and ducting from expansion
joint. After flue gas outlet damper to stack.
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5.12 The Vendor shall furnish one (1) complete set of pneumatic tube rollers, two (2)
complete sets of spare rolls for each size tube, and three (3) sets of spare gaskets.
5.14 Instrumentation, including feedwater regulator, flame failure devices, three element
control system, alarms, recorders, instrument panels, etc. Boiler instrumentation shall be
included in the specified Data Sheets.
5.15 Concrete foundation design information and all relevant drawings only.
5.22 Where data presented on Data Sheets conflict with the requirement of this specification,
the individual Data Sheet shall govern.
5.23 Field erection, Vendor must however supply erection schedule and details.
5.26 The Vendor shall furnish the following valves and accessories, all per ASME Codes,
details of which will be specified on the Data Sheets.
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Double valves in series should be used for blow down facilities, upper drum venting,
sample connection (boiler water, saturated and superheatered steam)
Two 1″ I.D-lbs. ASI R.F Flanged openings for the installation of the thermowells.
Location:
a: Burner air inlet
b: Bailer outlet
Superheater Valves
Safety
Drain-Inlet Header
Drain-Outlet Header
Steam sampling connection from
Inlet header
Vent
Non-return and stop valves on superheater outlet. Non-return valve means combined
stop/check valve.
Superheater outlet safety valves to be furnished and set at 47.2 barg (685 psig)
according to ASME Sec.I PG-71.
5.27 Sample collector for checking of boiler TDS shall be provided with sample cooler and
pressure reducing device.
6. DESIGN DATA
6.1 The maximum heat flux density at any localized "hot spots’ shall not exceed 300 kW/m2
(95,000 Btu/ft2h). The boiler designer shall present with his proposal the predicted
furnace heat flux distribution along the length and height of the furnace at MCR and state
the maximum and average heat flux and the furnace flue-gas exit temperature.
Note:
The heat flux density is the quantity of heat passing through unit surface area in unit
time and is expressed as kW/m2 (Btu / ft2h). The surface area shall be that of the flat
projected area of exposed tubes and exposed extended surface, integral with the tube.
Refractory covered surfaces shall not be included.
6.2 The furnace width shall enable sufficient spacing of burners to ensure burner flame
discrimination by individual viewing heads and also to make certain that there is no flame
impingement on the side walls. The furnace depth shall be sufficient to ensure that burner
flames do not impinge on the rear wall or penetrate the screen tube arrangement.
The depth of furnace shall not be so disproportionate to the width that a significant volume
of furnace is not occupied by the flame, thereby making the total projected surface area not
truly reckonable for the radiant heat rate calculations.
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6.3 Vendor’s guarantee of boiler performance shall be based on specified ambient conditions
at plant site as per NIOEC-SP-00-09 “Site Conditions”.
Ease of operation, inspection, maintenance, repair and cleaning are of major concern in
design and arrangement of boiler.
6.4 Boiler and ancillaries shall be capable of continuous 24 hours a day operation between a
26 month statutory shut down period.
6.5.1 Guaranteed net steam capacity, each boiler at superheater outlet excluding all
blowdown per paragraph 5.3.12 heat losses and all steam used for boiler auxiliaries
such as fans, soot blowers, burners, etc. as specified on data sheet.
6.5.2 Overdesign capacity for four hours continuous operation with an interval of not less
than 20 hours between periods Vendor to specify (Minimum acceptable 15%).
6.5.4 Minimum thermal efficiency when firing gas Job Specification to specify.
6.5.5 The steam temperature at desuperheater outlet shell be controlled between 371ºC
and 397ºC through the operating range 40% to 100% load. And the steam
temperature at esuperheater outlet shall be guaranteed 397 ± 3ºC at 100% (MCR).
6.5.6 Guaranteed operation superheater outlet pressure, and Specified on Data Sheet.
6.5.8 Steam drums shall be equipped internally with steam separators and scrubbers to
ensure that the carry-over of total solids from the boiler water shall not exceed the
following:
1 ppm up to 65 bar
5 ppm from 65 bar up to 135 bar
The boiler manufacturer shall state the maximum total dissolved solids (TDS) in
the boiler water at which the required steam quality can be obtained.
6.5.9 Heat release per cubic foot of furnace volume when firing Specified fuels. Vendor
to specify.
6.5.10 Superheater, drums and boiler tube system maximum design pressure Vendor to
specify, but a minimum of 3 bar (50 psi) above operating pressure is required.
6.5.11 Steam drum and boiler tube system maximum design temperature. Superheater
design temperature per code. Design temperature specified on Data Sheet.
6.5.12 Total continuous and intermitted blowdowns will be no more than 5% of steam
generated. Vendor to specify capacity at 100% rating.
6.5.17 Boiler dynamically shall be able to maintain a constant steam pressure for any
load change occurring within a 3 minute interval between 30% and 100% of
maximum continuous rating (MCR) or vice versa.
7. STRUCTURAL DESIGN
7.1 Earthquake load shall be in accordance with civil design criteria NIOEC-SP-00-01
(Clause 2.10).
7.2.1 Basic wind speed and exposure cofficent as site NIOEC-SP-00-11 (Cylindrical
surfaces shall be taken as 60% of the loads of the flat surfaces).
7.2.2 Design wind pressure shall be in accordance with the chapter 16 of U.B.C. Volume
2 Division III.
7.3 Boiler setting design shall consider the possibility of oscillation at critical wind and flue
gas velocities.
8. MATERIALS
Materials and construction for all pressure parts shall be as specified in the relevant ASME
Boiler and Pressure Vessel Codes.
Refractories shall be in accordance with the ASTM relevant codes. Other materials of
construction shall be as a minimum equal to the following:
ASTM
Columns, beams and other structural shapes Carbon Steel ASTM A 36
Steel Plate Enclosure Carbon Steel ASTM A-283 Gr.C.
Bolts and Nuts Carbon Steel ASTM A-307
Vendor may quote on other equivalent materials, but all substitutions shall be subject to written
approval by the Purchaser.
Vendor must state details of materials he proposes to use for tubes, headers, steam drum.
9. DESIGN
A detailed welding procedure shall be submitted to the purchaser for approval before
commencing fabrication. Facilities shall be provided for acid cleaning of the boiler with
particular reference to the supply of adequate connections.
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9.1.1.1 Tube materials and tube wall thickness shall be in accordance with ASME
Section I.
Membrane type tube walls are required (tubes with strips or tubes with
extruded fins. Either type to be welded over the whole length.)
No header shall be in furnace or convection passes. Adequate provision
should be provided for inspection and cleaning of water wall headers
(Minimum two, one at each end of header).
9.1.1.2 All tubes shall be fabricated from maximum lengths to produce a continuous
tube section with a minimum number of circumferential joints. Boiler tubes
shall be seamless. Superheater tubes shall be seamless. Tubes shall be bent
in shop to drawing templates and the end ground and checked for roundness.
Tube end shall be adequately protected from damage prior to shipment. All
fabricated tubes shall be paint-marked with sequential numbers for ease of
identification during assembly.
Vendor shall include not less than 5% extra of straight tubing for each size
of tube used in the boilers. Tubes over 20 meters or 63 feet in length shall be
shipped in two sections.
9.1.1.5 Bent tubes shall have a radius to allow free turbining of each tube.
9.1.1.6 Necessary connections shall be provided for chemical cleaning and nitrogen
sealing of Boilers.
Each unit shall have an upper drum and lower drum of electrically welded
constructions. A 515 material is the minimum requirement for pressure parts of
drums. All welding on drums shall be 100% radiographed and drums shall be fully
stress relieved regardless of code requirement. Should the manufacturer choose to
make the lower half or upper half of either drum from a different thickness than the
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other half, abutting different thickness plates shall have a tapered transition
conforming with the code requirement.
Each drum shall be equipped with two (2) 16″ diameter manholes with steel cover.
The interior surfaces of the steam drum shall be shop sandblasted, leaving smooth
clean surfaces, properly protected during the shipment and erection period.
Drum connections as required shall be provided for steam outlet, safety valves,
continuous blowdown, chemical feed, water column level controls, level alarms,
feed water vent and bottom blowdown.
For winterization of boiler, Vendor shall provide steam coils in each lower drum.
9.1.3 Furnace
Access doors 600mm Diameter minimum size shall be provided into all places
requiring maintenance within the setting. Peepholes shall be provided on the target
wall and the firebox sidewall in a manner and size to allow observation of all radiant
tubes and all burner flames. Facilities shall be provided as necessary to eliminate
any possibility of fire or hot flue gases from blowing back when peepholes are in
use. Minimum peephole size shall be 50mm (2″) diameter.
The sidewall tubes and headers to be shop welded into panels each with their own
supply and riser connections. Water wall headers shall be of steel to ASME
Specifications No. SA-106-B. Handholes in headers shall be provided as required.
Connections to and from the boiler drum shall bearranged to form a complete
integral circulating system.
Water cooled bottom tubes shall be party or wholly covered by refractory, and shall
be elevated a minimum of 900mm to permit access beneath the furnace floor.
9.1.4 Burners
9.1.4.1 Combination forced draft steam atomized burners for firing all specified gas,
all gasoline, all oil or any combination thereof shall be provided. The fuel on
which boiler performance shall be guaranteed shall be specified. Provision
shall be made for changing fuel of any one burner without affecting
operation in any way.
One liquid fuel burner gun and one gas fuel burner shall be provided per
each burner, separate tips for fuel oil and gasoline fuel shall be provided.
Vendor to specify possibility of using single tip for both liquid fuels.
Provision shall be made for preventing flue has leakage when oil burner gun
is removed for tip change or cleaning by use of air purge etc..
9.1.4.4 Gas burner tube and barrels shall be of stainless steel. The burner tip should
be stainless steel alloy.
9.1.4.5 Burners shall be sized to enable operation @ 110% rated boiler capacity,
when one burner is not in operation.
9.1.4.6 The Vendor shall offer specified burners, able to operate on all fuels and
combination of fuels specified.
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9.1.4.7 Each furnace shall be supplied with burners with insulatable forced draft
registers with steam atomizing oil units, center fire type gas units, flexible
metallic oil and steam hose, flexible S.S. gas hose, oil and steam shut-off
valves and oil burner fittings. The oil units shall be equipped with swing
check valves and air seals for use in a pressurized type steam generating
unit. The registers will be equipped with necessary seals. Where gasoline
fuel is specified each burner shall be equipped with an interlocking device
on the gasoline and atomizing steam supply complete with valves, interlock
discs, piping and flexible joints on gasoline supply lines.
Each burner shall be provided withan electric gas ignitor with complete
flame protection system with flame scanners flame protection relays,
interlocks, purge cycle timer, operating switch indicating lights, transformer,
safety shut off valves, S.S. gas hose, air hose, S.S. gas strainer and air seal.
One burner holder and wrench assembly shall be provided for each boiler.
Steam atomizing oil units for gasoline and one spare gun complete with tip
end assembly shall be provided for each boiler.
Fuel oil return lines should be equipped with non-return valves. The liquid
fuel oil lines should be large enough with low friction factor.
9.1.4.8 The boiler manufacturer shall furnish a burner windbox cut and drilled to
accommodate the burners described herein. Windbox shall be complete with
necessary supports, division plates and access door, if required.
9.1.5 Economizer
9.1.5.1 Economizer shall generally be integral part of the boiler; Construction shall
be steel tubes, either plain or finned. Fins may be of steel or cast von
according to the existing flue gas conditions (refer to next item of this
Specification).
9.1.5.2 With flues containing no sulphur, either steel or cast iron fins may be used.
With flues containing sulphur, the metal operating temperature in contact
with the flue gases shall preferably not fall below 150ºC (302ºF), and fins
may be of steel or cast iron. Company may specify or agree flue gas
temperatures down to 105ºC (220ºF), when cast iron fins shall be used.
Designs involving any metal temperatures below 105ºC (220ºF) shall not be
used.
9.1.5.3 Tube bends shall be all-welded except where feed water conditions make it
necessary for frequent cleaning or inspection, in which case, for boiler
pressures up to 38 barg (ASME class 300), steel bends shall be flanged.
9.1.5.4 In line tube arrangement is preferred. Water velocity shall be of the order of
1 m/s for water up flow circuits and 2 m/s for down/flow. Header should
preferably be external to the casing and tubes efficiently sealed where they
pass through to the bends and headers.
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9.1.5.5 Feed water operating pressure and temperature in the economizers shall at
no time permit the possibility of steam being generated. Recirculating type
economizers shall not be included unless agreed by company.
9.1.5.6 When economizers can be isolated on the water side, a safty relief valve
shall be fitted.
9.1.5.7 Flue gas by pass and/or recirculating facilities shall only be provided with
the agreement of company.
9.1.6.1 The flue gas exit temperature from the air heater shall not be less than
120ºC (250ºF), but may need to be considerably higher to meet the
environmental requirements.
In any case the gas exit temperature shall not be less than the recommended
by the air heater manufacturer who must consider the air/flue-gas
temperature differential in relation to the possibility of corrosion.
9.1.6.2 Air heaters using surplus low-pressure steam shall be considered. The
condensate discharge shall be returned to the deaerator. On-line cleaning
facilities for the firmed tubes shall be provided.
9.2.1 General
The unit shall be of the bottom supported type. The Vendor shall furnish a system of
buckstays for the unit to prevent warping and buckling of the walls, and shall supply
the miscellaneous roof steel and lower header supports. Boiler stack, ductwork and
miscellaneous steelwork shall be fabricated in Iran.
9.2.2 Lifting
Lifting lugs should be provided on drume water walls and similar heavy boiler parts
to facilitate construction work.
9.2.3 Ducts
9.2.3.1 Boiler manufacturer shall be responsible for providing adequate design for
thermal expansion in the hot ducts.
9.2.3.2 All duct work and breeching shall have insulation to provide not more than
121ºC (250ºF) at the outer paint surface. In areas where they are within
reach of operating personnel temperature should be limited to 82ºC (180ºF)
in still air at an ambient of 15ºC (60ºF).
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9.2.3.3 The Vendor shall provide the design and materials of air ducts. Air ducts
between forced draft fan and burner windbox for each unit shall be 4.5mm
steel plate properly stiffened and reinforced to prevent warping and buckling
and shall be provided with required doors, expansion joints, supports and
hangers.
9.2.3.4 The Vendor shall provide the design and materials of gas ducts and stack for
the unit. It shall have a minimum thickness of 6mm a gunite insulation of
38mm (1½″) minimum thickness. The insulation shall be reinforced with
carbon steel ties or expanded metal grating welded on 225mm (9″) centers.
Bellows type expansion joints are required. Connection with valves should
be provided for drainage of ducts.
9.2.3.5 Gas outlet damper for control of furnace pressure should be supplied by
Vendor fitted with extended shaft. Material of damper shall conform to
ASTM A-447.
9.2.3.6 All duct work shall be designed for fabrication in flanged sections. Particular
attention should be paid to the design of the ducting from the boiler fans to
the stack to ensure proper performance of one or both fans at all loads.
9.2.4 Stacks
9.2.4.1 The stack shall be designed as an individual self-supporting steel stack with
minimum height specified for each boiler, but in any case not less than 76
meters. Stack shall be designed for complete lining at jobsite with a gunited
insulating concrete lining of 38mm minimum thickness. Lining shall be
reinforced with carbon steel “hexteel” of platform grating welded to the
stack on minimum of 225mm centers.
9.2.4.3 Each boiler shall have separate stack, unless otherwise specified.
9.2.4.4 An access opening for internal inspection and cleanout shall be provided at
the base of each stack. Access opening and gas duct to stack opening shall
be adequately reinforced all around to resist static and dynamic loads sharp
corners shall be avoided.
9.2.4.5 Stacks shall be equipped with aircrait warning lights per NIOEC-SP-60-07.
9.2.4.6 Maintenance access for boiler stacks shall be provided. This should enable
two men, with paint spray or gunite machine to work inside or outside each
stack. Inside access will be via 3 point stack tip mounted stainless trolley
bars and stainless pilot cables, and outside access via a trolley rail around
stack tip with pilot cable. In both cases loading should be designed for a
trolley capacity of a minimum of one ton. Stack shall be equipped with an
external ladder, landing platforms and a platform with handrail close to top.
A trolley is supplied by others.
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9.2.6 Preassembly
All structural parts for each boiler shall be of bolted construction and shall be shop
assembled and matched marked before shipment.
Boiler sidewalls Flat tile blanket and 2mm (14 ga.) min.
ribbed steel casing.
Necessary seals, expansion joints, door lining, etc. to complete setting shall be
furnished.
9.3.1 Fans, drivers and gearboxes shall be at an easily accessible location at the rear of the
boiler. Each boiler should have two 75% capacity fans.
The forced draft fans on all boilers should be identical. Fan speed shall not be more
than 1000 rpm and gears speed changer to be in accordance with API 613 with a
minimum service factor of 2 or AGMA 421-06.
9.3.2 Turbines shall be in accordance with Data Sheet for General Purpose Steam
Turbine, and NIOEC-SP-46-02. Woodward hydraulic governors conforming to
NEMA SM-2 Class D shall be fitted to the turbine drive for speed control and
moreover provide a complete pressurized lubrication system as per NIOEC-SP-46-
02 Section IV paragraphs 28 and 29. The speed of turbines should be adjusted from
utilities control room by hand.
9.3.3 Fan performance shall be guaranteed to meet all operating conditions specified on
the Data Sheets. A characteristic fan performance curve shall be submitted in
Vendor’s proposal for NIOEC approval.
9.3.4 Fans and associated drivers shall be designed, sized, (and capable of handling all air
requirements for all fuels) as follows:
a. Fan rating shall be established on the maximum ambient temperature for the
location. Each fan shall be sized to provide 75% capacity at rated load and at a
pressure 35% above requirements at rated load.
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b. Fan or fans shall be turbine or electric driver or both as specified on the Data
Sheets.
c. Fans shall be supplied with inlet screen and cleanout door. A silencer should be
provided for air intake. Main connection for silencer shall be flanged and a
minimum 3.2mm corrosion allowance shall be considered and pressure drop
through each silencer shall not exceed 12.7mm (0.5in) H2O.
d. Draft fan capacity shall be varied by turbine drive speed, and any variable
louvers furnished by boiler supplier.
e. Vendor shall furnish for each draft fan inlet a suitable air intake device to reduce
sand and dust intake.
g. The boiler Vendor shall provide, in the air duct between the fan and the burners,
a primary air measuring element for the purpose of measuring total air flow.
This device shall be designed for operation with a transmitter having a
0-254 mm. H2O differential.
h. Fan blade design shall be backward curve, non-over loading type. Fan housing
shall be of 4.5 mm plate and braced for rigidity, housing shall be split design for
rotor removal.
Fan bearing shall be easily removable for repair and maintenance and shall not
form an integral part of fan casing. Fan shall be suitable for out-door installation
and continuous service with a minimum uninterrupted run of 20,000 hours.
The critical speed shall be about 25% above max. running speed and rotor shall
be statically and dynamically balanced.
9.4 Instrumentation
Vendor shall submit the proposed instrument and control schematic drawings including
combustion and feed water controls, adequate to fulfill the requirements of his process
and mechanical guarantees, for Purchasers approval. The Vendor shall furnish the
necessary instrument connections for gas flow, furnace and duct pressures and
temperatures as may be required.
9.4.1 Retractable thermocouples for superheater flue gas inlet temperatures and
superheater skin temperatures thermocouples, should be included for use during
start ups.
9.4.2 There shall be local indication of instruments for each boiler and all controls and
indicators shall be brought to a central control room.
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9.4.3 The high and low level alarms for which provision is made shall have different
sounds and be sufficiently loud to be heard in the boiler area.
9.4.4 Identical gage glasses shall be provided on each side of each boiler. Each gage glass
shall be fed by independent feed lines.
9.4.5 Provision of mirror level indicating system for one of the level gages on the boiler
drum shall be made and be of sturdy construction to overcome vibration.
9.4.6 Design of low level steam drum switches shall be such as to avoid tripping due to
vibration.
9.4.7 The following water columns with level gages shall be furnished by the boiler
Vendor:
a. An external float type water column with switches for high and low level alarms
with different sounds and low water cut off. Low water cut off shall be separate
from the low level alarm.
b. An illuminated bi-color level gage and mica shields at both ends of drum shall
be provided if boiler circulation is such that level may differ between ends of
drum. One gage shall be equipped for viewing from grade.
d. Water columns shall be fitted with flanged shutoff valves installed between the
column and the drum.
9.4.8 A pressure tap connection and thermowell connection at superheater outlet header
shall be provided.
9.4.9 Draft gage pressure tap connections shall be 2 inch. NPS size and located one in the
burner windbox, one in the furnace zone, one upstream of air preheater and one at
the boiler outlet.
9.4.10 Connection of gas sampling shall be provided at the boiler outlet and shall be
1 inch. NPS minimum size. Its location shall be such that a representative sample
is obtained.
9.4.11 An external junction box shall be provided for connection to superheater tube
metal thermocouples.
9.4.13 A completed flame monitoring and safety control system to perform the functions
shall be furnished by the Vendor. The system shall be clearly described in the
proposal and shall be guaranteed for safe and efficient operation of the boiler.
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JULY, 2005 NIOEC-SP-45-02(0)
Logic circuitry being proposed shall be included in proposal.
1. Draft gauges
2. Flame safety equipment
3. Soot blower control equipment
4. The following indicators shall be easily and significantly visible from the local
panel or located on local panel.
An adequate number of soot blowers shall be provided to keep each boiler clean in
service. Soot blowers may be of the retractable or rotary type per operational requirement
and shall come complete with electric motor drive.
Retractable sootblowers shall be operated automatically. Controls for automatic
sequential operation of sootblowers to be mounted on local panel provided by Vendor.
Each sootblower shall also be capable of independent manual operation. The system shall
be designed for automatical removal of condensate and avoiding water shock to tubes and
keep steam temperature above saturation upstream of lance tubes.
Motors and limit switched to be shop wired in terminal strip junction box. The junction
box and the limit switched shall be weather resistant with IP55 enclosure. The motors
shall be according to NIOEC-SP-60-02.
All headers, branches, fittings, valves, drain valves, control valves, pipe hangers and
guides as required for soot blowing system, to be supplied.
9.6 Tools
One complete set of pneumatic tube rollers with two complete ser of spare tools for each
size of tube to be expanded should be furnished. Any other special tools required for
maintenance of operation shall be provided. These furnished tools are to be used only for
owners maintenance.
Any other special tools required for carrying out normal maintenance should be specified
and provided.
9.7 Inspection
9.7.1 All materials and work including the work of sub-suppliers shall be subject to
inspection as indicated in the conditions of contract.
9.7.2 All inspection certificates, (i.e. mill certificates, shop and field inspection
certificates etc.) should be furnished to NIOEC.
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JULY, 2005 NIOEC-SP-45-02(0)
10. PERFORMANCE CONDITIONS
Performance data for the equipment supplied will be submitted herewith and made part of this
Specification in the form recommended by the American Boiler Manufacturers Association and
affiliated industries as follows:
10.1 General
10.1.1 It is recognized that the performance of the equipment supplied cannot be exactly
predicted for every possible operating condition. In consequence, any predicted
performance data submitted are intended to show probable operating conditions
which may be closely approximated to, but which cannot be guaranteed except as
expressly stated in the guarantee clauses.
10.1.2 The general arrangement of the equipment furnished by the Boiler Manufacturer,
and the general design and arrangement of related equipment furnished by
Purchaser shall be as show on the drawings submitted by the Boiler Manufacturer.
10.1.3 The equipment will be erected in accordance with the Boiler Manufacturer’s plans
and Specifications.
10.2.1 The unit shall have sufficient forced draft fan capacity available to provide the
necessary air for combustion at a pressure at the burner windbox required to
overcome all of the resistance through the unit including the ducting and stack.
Means shall be provided to control the furnace pressure and the supply of air
throughout the operating range.
10.2.2 The CO2 or excess air in gas leaving the furnace shall be determined by sampling
uniformly across the width of the furnace where the gases enter the convection
heating surface. There shall be no delayed combustion at this point nor at any point
beyond.
10.2.3 The fuel burning equipment shall be capable of operation without objectionable
smoke.
10.3 Water
10.3.1 The boiler water concentration in the steam drum shall be specified in to Job
Specification.
Samples of water for testing shall be taken from the continuous blowdown.
Samples shall be taken through a cooling coil to prevent flashing. Sampling and
determination of boiler water. Conditions shall be under the methods contained in
related ASTM.
10.3.2 Test Procedure for Solids in Steam: Samples of condensed steam for determination
of solids shall be obtained in accordance with the method specified in related the
ASTM.
The Electrical Conductivity Method shall be used to determine the dissolved solids
in the steam. The test shall be made in accordance with related ASTM D1125.
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JULY, 2005 NIOEC-SP-45-02(0)
10.3.3 Sample collector for checking of boiler TDS shall be provided with sample cooler
and pressure reducing device.
Prior to acceptance, the boiler manufacturers shall conduct such operating tests as are
necessary or required by the purchaser to demonstrate satisfactory functional and
operating efficiency.
Boiler manufacturer shall be responsible for furnishing all instruments and equipment,
such as portable analyzers, which are required in making the specified performance and
efficiency tests.
Performance tests, and performance calculations shall be made in accordance with the
applicable Short Test Form in the ASME Test Code for Stationary Steam Generating
Units, and the measure of performance shall be the results of such tests. Performance
calculations shall be based on the steam tables of “Thermodynamic Properties of Steam”
by Keenan and Keyes.
11. GUARANTEE
11.1 In addition to the mechanical guarantee required by the conditions of contract, the Vendor
shall guarantee in writing that each boiler will produce from ¼ load to full load of steam
rating as specified on the Data Sheet and section 4.0 of this Specification without
detrimental carryover into the superheater tubes and without flame impingement upon any
boiler tubing when burning any combination of the gas, gasoline and oil fuels specified
herein. The Vendor shall also guarantee that each boiler will be capable of producing the
overload requirements of the 4 hour overdesign capacity specified in paragraph 4.3.2 and
the minimum load for a continuous period of 24 hours.
Vendor shall guarantee that proposed control system shall permit sound and reliable
operation of boiler over the whole range of operation.
Predicted performance data should be filled in by Vendor per Data Sheets as attached. It is
understood that this data is predicted only and shall not be construed as being guaranteed except
where conditions given coincide with those stipulated elsewhere in this Specification.
Boiler manufacturer shall properly prepare the boiler parts for shipment to the jobsite.
13.1 Outside exposed metal surfaces shall be prepared and painted in accordance with NIOEC
Painting Specification SP-80-02.
13.2 Machines surfaces and flange faces shall be coated with heavy rust preventive grease.
13.3 All threads of bolts, including exposed parts, shall be coated with a metallic base
waterproof lubricant to prevent galling in use and corrosion during shipment and storage.
13.4 To prevent damage all flange facings shall be protected with gaskets and ¼″ plates, and all
couplings shall be protected by steel pipe plugs.
13.5 Suitable bracing and supports shall be provided to prevent damage during shipment.
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JULY, 2005 NIOEC-SP-45-02(0)
14.1 Data Sheet should be completely filled out. Additional data normally supplied by
Vendor shall be given separately. Specific performance and design requirements shall
be indicated by the purchaser on process Data Sheet.
The following data must also be included:
14.1.5 Efficiency at full, 75%, 50%, 25% load. Include excess air and ambient
temperature used in calculating these efficiencies.
14.1.7 Turbine water rate and horsepower, indicate fan test block conditions at this
horsepower (KW).
14.2 Capacity capability using natural draft when draft fans fail.
14.3 Proposed field testing procedure including field pressure testing, chemical cleaning, boil
out, dry-out, start-up, sequencing, cold and hot settings of safety valves, time intervals,
etc.
14.4 Overall dimensions for layout purpose, show ladders, stairways and platforms supplied.
14.5 Drawings showing the general layout of the boiler including firebox, tubes, burners, air
ducts, stack ducts and all connections.
14.6 Anchor bolt plan bolt sizes and column loading drawing.
14.7 Vendor shall specify maximum anticipated noise levels at full boiler capacity.
14.8 The proposed design shall be proven in practice, rugged and reliable. Tenderer shall
provide a list of similar installations already in satisfactory operation for a period of at
least 2 years.
14.9 Proposal shall either state compliance with Specifications or list the exceptions taken.
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15.1 All items specified under para. 12 and as additionally specified in purchase order.
16. FABRICATION
Detailed field erection procedure shall be submitted for Purchaser’s approval prior to
commencement of field erection.
Shop fabricated components shall be manufactured in accordance with the codes and
standards as specified in section II.
16.2.1.3 The fabricator shall specify the application of each welding procedure.
For example, for welding the longitudinal seams, or the circumferential
seams, nozzles, etc.
16.2.1.5 In addition to the above requirements the fabrication shall show the
applicable welding procedures on a drawing. The welding procedure
number or identification may be shown either on the drawing notes or on
the applicable weld joint. Also, all non destructive tests shall be shown on
the appropriate drawing.
16.2.2.1 For dissimilar joints in base metals consisting of ferritic materials, carbon
steel (P-1) through 12 chrome (P-7), the filler metal shall be of the low
hydrogen type and comparable to the composition of either base metal.
The lower base metal is generally preferred.
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JULY, 2005 NIOEC-SP-45-02(0)
ASME-AWS A5.2-69 filler wire is not permitted for use with the inert
gas tungsten are process.
16.2.2.2 For dissimilar joints consisting of ferritic materials on one side and
austenitic stainless steels, higher chrome-nickel & nickel-chrome,
including monel on the other side, the filler metal shall meet the
requirements of ASME Claseeification NiCrFe-2, or NiCrFe-3, except
types 309 or 309L. Stainless Steel upon specific approval by Purchaser.
16.2.2.3 Ferritic welds made using the submerged are process shall use a neutral
flux, that is a flux which does not increase the alloy content of the weld
compared to the filler metal.
16.2.2.4 Electrodes of the following classifications are not acceptable for pressure
containing welds: E-7020 and E-7024.
16.2.2.5 Electrodes and filler wires should be kept clean, dry and properly stored
according to the manufacturer’s recommendation. No electrodes for filler
wires may be used which are damp, greasy or oxidized.
16.2.3.1 Shell and head joints shall be full penetration, double-welded butt joints.
For joint inaccessible from the inside, the fabricator shall submit for
approval an alternative method where a full penetration and full fusion
weld can be achieved from one side.
16.2.3.3 All weld bevels and weld surfaces shall be free of cracks, excessive
porosity, slag inclusions, and other defects indicative of poor
workmanship.
16.2.3.4 Welds which are deposited by procedures differing from those properly
qualified and approved shall be rejected and completely removed from
the equipment.
16.2.4.2 Post weld heat treatment shall be in accordance with ASME Code Section
I, Paragraph PW-38 and PW-39.
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JULY, 2005 NIOEC-SP-45-02(0)
16.2.5 Inspection
16.2.6.3 Where parts are exempt from 100 percent radiography by PW-11 or PW-
41, circumferential weld shall be examined as follows:
a. At least 10 percent of the number of welds in each material P-group
are to be radiographed around their entire circumference with nozzle
weld excepted. If there are less than 10 welds in each group, one must
be radiographed.
b. At least 10 percent of the number of welds by each welder are to be
radiographed around their entire circumference. If a welder makes
less than 10 welds, one must be radiographed.
16.2.6.5 All steam piping shall be fabricated and meet the acceptance criteria of
ASME B31.1.
16.2.6.6 All remaining items such as water wall tubes. Headers, drums and header
boxes shall be fabricated in accordance with PW-1 and meet the
acceptance criteria of PW-51 of ASME Section I Boiler and Pressure
Vessel Code.
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JULY, 2005 NIOEC-SP-45-02(0)
APPENDICES
PROJ . NO.
UNIT NAME IPS –G –ME- 180(1) P.O NO.
DATE SH.OF
UNIT NO. 1 8
SPECIFICATION SHEET NO .1
TO BE PROVIDED BY PURCHASER
1 SERVICE ITEM
2 MANUFACTURER MANUFAC JOB NO.
3 PURCHASE ORDER NO: NUMBER OF UNITS:
4 OPERATING CONDITIONS: COMTONUOUS STAND BY
5 MAIN STANDBY UNIT NO: SPEC NO.
BOILER TYPE FIELD ERECTED SHOP ASSEMLED
ITEM.
MAIN CHARACTERISTICS GUARANTEED VALUES
6 STEAM CAPACITY FOR EACH BOILER K S / HR MAX CONTINUOUS PEAK.
7 STEEM PRESS AT SUPERHEATER OUTLET VALUE bar(0) NORM=
8 MAX ALLOWABLE WORK PRESSURE bar(q)
9 STEAM TEMPERATURE SUPERHEATER OUTLET VALUE t NORM=
10 FEED WATER TEMP. oC BOILER FEED WATER PRESSURES NORM/DES bar(q)
11 OVERALL EFFICIENCY (REF TO LHV AND AME. TEMP. TEMP . o C)
12 STEAM SOLIDS CONTENT P.P.M WITH P.P.M OF TDS.
13 SUPERHEATED STEAM TEMPERATURE CONTROL F. ANGE FROM TO
14 MINIMUM LOAD UNDER , AUT CONTROL Kg/h MINIMUM ALL OWED LOWED IN MAN . kg/h
15 FULL TYPE GASOIL FUEL GAS
16 NATURAL CIRCULATION CONTROLED CIRCULATION
17 AMPIENT CONDITIONS
WIND VELOCITY K m/h FAEWAILING WIND DIRECTION
EARTHQUAKE FACTOR. RAIN FALL mm
HEIGHT ASL m TEMPERATURE MIN/ MAX C
BAROMETRIC PRESSURE m bar RELATIVE HUMIDITY %
18 INSTALLATION
OUTDOOR UNDER PROOF
INDOOR ROOF ON THE BURNEF.FRONT
ANTIAREEZE PROTECTION NOISE LEVEL MAX d S A. AT m
REMARKS
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APPR.
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JULY, 2005 NIOEC-SP-45-02(0)
PROJ . NO.
UNIT NAME P.O NO.
IPS –G –ME- 180(1) DATE SH.OF
UNIT NO. 2 8
SPECIFICATION SHEET NO .1
TO BE PROVIDED BY PURCHASER
FUEL CHARACTERISTICS
20 FUEL CHARACTERISTICS
TYPE GASOIL FUEL GAS
LOW HEATING VALVE (L. H. V) KJ/KS
DENSITY Kg/m3
PRESS AT BETTERY LOAD MIN / NOR / MAX / D bar(g)
TEMPERATURE MIN / NOR / MAX / D oC
VISCOSITY AT o C CST
VISCOSITY AT BURNERS CST
COMPOSITION VOH . x WT. x
METHANE
ETHYLENE
ETHANE
PROPYLENE
PROPANE
ISO BUTAN
N- BUTANE
PENTANE
HYDRIGEN
NITROGEN
SOLFUR
MOLECULAR WEIGHT
HIGH HEATING VALUE KJ/Kg
REMARKS
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APPR.
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JULY, 2005 NIOEC-SP-45-02(0)
PROJ . NO.
UNIT NAME IPS –G –ME- 180(1) P.O NO.
DATE SH.OF
UNIT NO. SPECIFICATION SHEET NO .1 3 8
TO BE PROVIDED BY PURCHASER
23 STEAM CHARACTERISTICS
SIO2 MAX mg/kg
CONDUCTIVITY AT 25 o C μ S / cm
REMARKS
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APP
R.
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PROJ . NO.
UNIT NAME IPS –G –ME- 180(1) P.O NO.
DATE SH.OF
UNIT NO. SPECIFICATION SHEET NO .1 4 8
TO BE PROVIDED BY PURCHASER
29 UTILITY AIR
NORMAL PRESSURE / DESIGN bar (a) TEMPRETURE oC
DECLED CONSUMPTION Nm3/h
30 NITROGEN
NORMAL PRESSURE / DESIGN bar (a) TEMPRETURE oC
DRY VET
31 COOLNG WATER
COOLING CIRCUIT TYPE OPEN CLOSED
WATER TYPE
PH HARDNESS ALKALINITY
INLET/ OUTLET o C NORM/ DEC PRESSURE bar(a)
Δ F MAX BAR AT MAX o C
FOULING FACTOR. M2 C/W CONSUMPTION m/h
REMARKS
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APPR.
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JULY, 2005 NIOEC-SP-45-02(0)
PROJ . NO.
UNIT NAME IPS –G –ME- 180(1) P.O NO.
DATE SH.OF
UNIT NO. SPECIFICATION SHEET NO .1 5 8
TO BE PROVIDED BY VENDOR
CONSTRUCTION FEATURES
32 BUNCLE TUBE
NUMBER DIAMETER /THICKNESS mm
ARRANGEMENT INLET OTACGERED
PITCH LONGITUDINAL mm. TRANSVERSE mm.
MATERIAL
SMOONS FINNED
PIN PITCH mm HIEGHT / THICKNESS FIX mm
FLUE GAS PASSAGE NO. LONGITUDINAL TRANSVERSE
33 SUPERHEATER YES NO
TYPE RADIANT CONVECTION COMEINATION
PENDANT HORIZONTAL ORAINABLE
SUPERHEATER ELEMENT FIRST STAGE SECOND STAGE THIRD STAGE
DIAMETER /THICKNESS TUBES mm
TUBES MATERIAL
DIAMETER /THICKKNESS MANIFOLDS mm
MANIFOLD MATERIAL
35 ECONONIZER YES NO
TUBE TYPE SMOOTH IN STEEL FINNED CAST IRON FINNED TUBES
DIAMETER /THICKNESS TUBES mm MATERIAL
TRANSVERSE FITCH LONGITUCINAL FITCH
HIEGHT / THICKNESS FIT mm FEW PITCH mm
TUBES ROW PER BANK BANK HIEGHT mm
REMARKS
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APPR.
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JULY, 2005 NIOEC-SP-45-02(0)
39 FUELS/ STCM
TYPE OF FIRINGE GASOIL GAS OIL+ GAS NATURAL GAS FOR S/U
40 FANS
SERVICE AIR SMOKE ITEM
FLOW AT MORE / DESIGN Nm3/h OF SIGN TEMP. o C
TOTAL HEAD m bar ABSORBED POWER kw
SPEED RPN
CHARACTRRISTICS ACCORDING TO DATA SHEET
SEALING AIP. FAN YES NO INSTALLED POWER kw
REMARKS
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APPR.
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PROJ . NO.
UNIT NAME IPS –G –ME- 180(1) P.O NO.
DATE SH.OF
UNIT NO. SPECIFICATION SHEET NO .1 7 8
TO BE PROVIDED BY VENDOR
CONSTRUCTION FEATURES
46 REFRACTORIES
INSTALLATION/ THICKNESS mm
ALUMINA CONTENT % FUSION POINT oC
47 INSULATION
MATERIAL SPECIFIC GRAVITY kg / m2 THICKNESS
48 GASING
THICKNESS INNER / OUTER mm
MATERIAL
REMARKS
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APPR.
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PROJ . NO.
UNIT NAME IPS –G –ME- 180(1) P.O NO.
DATE SH.OF
UNIT NO. SPECIFICATION SHEET NO .1 8 8
TO BE PROVIDED BY VENDOR
CONSTRUCTION FEATURES
56 STACK
MATERIAL SELF SUPPORTING CONCRETE INCLUDED EXCLUDED
INTERNALLY GUNTED EXT.INSULATION FOR PERSONANEL PROTECTION
EXTERNAL ANTIRUST PAINTING EXTERNAL LADDER
WIND LOAD / SPEED bar/kg/h FLATFORMS FOR EXT. LADDER
THICK/DIAMETER BASE mm TOF mm
HEIGHT CORROSION ALLOWANCE mm.
NO. FOR BOILER COMMON TO THE BOILERS
STACK DAMPERS YES NO TYPE
60 SAMPLE COOLERS
NO TYPE
BOILER WATER SATURATED STEAM SUPERHEATED STEAM
2 5
1 4
0 3
REV. DESCRIPTIN DATE BY APPR REV DISCRIPTION DATE BY APPR.
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