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NIOEC-SP-45-02(0)

DOCUMENT CODE NO. OF PAGES: 33


PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG ME SP 4502 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY


NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

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

APPENDICES DATA SHEETS 26

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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 (AMERICAN PETROLEUM INSTITUTE)

API 613 “Special Purpose Gear Units for Petroleum, Chemical, and Gas Industry
Services” Forth Edition June, 1995

ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

Boiler and pressure vessel code edition 2002.


ASME Code Sec. I
ASME Code Sec. II
ASME Code Sec. VIII
ASME Code Sec. IX

ASME STANDARD

B 16.5 “Steel Pipe Flanges and Flanged Fitting” Edition 1996


B 31.3 “Petroleum Process Piping” Edition 2002

AISC (AMERICANS INSTITUTE OF STEEL CONSTRUCTION)

Edition 1989

AGMA (AMERICAN GEAR MANUFACTURERS ASSOCIATION)

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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NEMA (NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION)

SM-23 “Mechanical Drive Steam Turbines” Edition 1985

AWS (AMERICAN WELDING SOCIETY)

D1.1 Edition

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-00-01 “NIOEC Specification for Civil Design Criteria”


NIOEC-SP-00-11 “NIOEC Specification for Site Conditions”
NIOEC-SP-00-10 “NIOEC Specification for Units”
NIOEC-SP-20-01 “NIOEC Specification for Structural Steel Fabrication”
NIOEC-SP-41-03 “NIOEC Specification for Pressure Vessels”
NIOEC-SP-43-14 “NIOEC Specification for Centrifugal Fan”
NIOEC-SP-45-07 “NIOEC Specification for Refractory Linings”
NIOEC-SP-46-02 “NIOEC Specification for General Purpose steam Turbins”
NIOEC-SP-47-10 “NIOEC Specification for Permissible Noise Level”
NIOEC-SP-50-04,07,08 “NIOEC Specification for Piping”
NIOEC-SP-60-02 “NIOEC Specification for Squirrel Cage Indution Motors”
NIOEC-SP-60-07 “NIOEC Specification for Aircraft Warning Lights”
NIOEC-SP-80-01 “NIOEC Specification for Insulation”
NIOEC-SP-80-02 “NIOEC Specification for Painting”
Data Sheet for “Water Tube Boiler”
Data Sheet for “General Purpose Steam Turbine”

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. DEFINITIONS & TERMINOLOGY

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.

5.10 Miscellaneous roof steel, buckstays and lower header supports.

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.

5.13 Fluegas outlet damper at boiler outlet.

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.

5.16 All anchor bolts for major foundations.

5.17 Feedwater pipings to steam drums as per flow diagram.

5.18 Steam pipings per flow diagram.

5.19 Piping to all burners.

5.20 Chemical injection, continuous and intermittent blowdown pipings.

5.21 Desuperheater complete with injection facility, at superheater outlet.

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.

5.24 Economizer and static air preheater are required.

5.25 Maximum degree of shop fabrication commensurate with shipping limitations is


preferred.

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.

Boiler Valves & Accessories


Safety Valve
Blow-Off Valve (Tandem)
Drum Vent Valve
Chemical Feed Stop Valve
Chemical Feed Check Valve
Cont. Blowdown Micrometer Valve
Cont. Blowdown Line Stop Valve
Steam Gauge
Water Gauge Stop Valve
Water Gauge Drain
Steam Gauge Line Stop Valve
Water Gauge
Feed Water Stop and Check Valve

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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)

Water Wall Valves


Drain - As required

Drain connections (lower drum, water walls, superheater)

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 Boilers shall be designed for the following operating conditions:

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%).

6.5.3 Guaranteed turn down ratio Vendor to specify.

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.

6.5.7 Feedwater inlet temperature 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.

6.5.13 Steam for Fan Drivers Specified on Data sheet.

6.5.14 Exhaust Steam from Fan Drivers Specified on Data Sheet.


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6.5.15 Stack temperature. Vendor to Specify.

6.5.16 Boiler feedwater and chemical injection Specified on Data Sheet.

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 Wind load shall be in accordance with chapter 16 of U.B.C as following:

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

9.1 Mechanical 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 Boiler Tubes and Superheater

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.

9.1.1.3 Superheater should be so designed as to allow easy maintenance and repair


work as well as easy access for inspection. The equipment for the
superheater shall include the following:
Inlet and outlet headers; sufficient welded joint elements to meet
specification; tubing materials to meet ASME Code requirements;
connecting tubes between boiler and saturated steam header and necessary
supports for headers and elements. Equipment supplied by the Vendor ends
at the superheater outlet.
All superheater tubes shall be seamless low alloy (2¼ chrome) steel as a
minimum. Higher chrome low alloy steel shall be used if necessary.
Thermocouples for monitoring superheater tube metal temperature shall be
installed on a minimum of one of each four passes on the end.
Back washing facility is not required to provide on steam superheater of
each boiler.

9.1.1.4 Superheater tubes shall be drainable or non-drainable, as specified in the


Specification Sheet.

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.

9.1.2 Boiler Drums and Drum Header Connections

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..

9.1.4.2 Requirements for pilots will be specified on boiler Data Sheets.

9.1.4.3 Pilot ignitor requirements will be also specified.

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.

9.1.4.9 Specification of fuels to be burnt will be indicated on Specification sheets


for each installation.

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.

9.1.5.8 Means for off-load water washing of economizers shall be provided on


boilers firing residual fuel oils or unsweetened gas.

9.1.6 Air Heater

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 Structural Steel and refractory Design

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.

9.2.4.2 Stacks shall be of welded construction and have a minimum thickness of


16mm. a minimum allowance for corrosion from the inside of the stack of
3mm (1/8″) shall be specified.

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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9.2.5 Platforms and Ladders


Platforms shall be a minimum of 1066mm (3′-6″) wide and shall provide ample
work room at the drum elevation. Platforms adjacent to boilers should be self-
supporting from the boiler steel. Platforms, stairways, and ladders shall be provided
to allow access to all water columns. Relief valves, stop-check valves, sample
valves, steam pressure gauges, manholes, and peepholes. Miscellaneous blowdown,
vent, or drain valves not accessible shall be provided by the Vendor with chains or
other extensions allowing operation from an accessible location. The main firing
isle shall be provided by Vendor with adequate platform. An elevated platform
between boilers shall be provided by the Vendor to connect the platforms
accommodating individual main steam drums. Two stairways should be provided by
the Vendor, one at each extreme end of the connected elevated platform. Platforms
shall be designed for a live load of 50 psf.
The boilers shall be scattered in the plot space, while considering a minimum
spacing of 25 meters between adjacent boiler-casings.
All platform area shall be covered with open grating. Stair treads shall be of the
open grating type with checker-plate nosing. All stairways and platform areas shall
have safety toe guards and handrails shall be of the double-rail type made up of 1¼″
pipe. All necessary ladders shall be equipped with safety cages. A common platform
for watching all steam drum level gages is required.

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.

9.2.7 Refractory Setting, Insulation and Outer Casing


A complete refractory setting, including wall insulation, shall be furnished. The
refractory and insulated walls shall be provided with adequate for absorbing
expansion to eliminate danger of cracking, spreading, or displacing the refractory or
insulating brick. Seals in the setting shall keep leakage and infiltration to a
minimum, including locations where anchors, instrument inserts, and other
appurtenances are built into the walls.
Maximum exterior casing shell temperature shall not exceed 82ºC (180ºF) with no
out side insulation in still air with an ambient temperature. Minimum thickness of
external casing will be as specified in 1.3.9.
The Vendor shall supply, according to the following requirements. Any exceptions
shall be noted by the Vendor.

Front roof, side Blanket insulation and 2mm.(14ga.)


and rear walls minimum ribbed steel outercasing.

Rear roof Castable refractory

Floor Flat tile

Boiler sidewalls Flat tile blanket and 2mm (14 ga.) min.
ribbed steel casing.

Baffles Monolithic construction

Burner wall Field installed refractory


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JULY, 2005 NIOEC-SP-45-02(0)

Drum shells Blanket refractory and 2mm (14 ga.) min.


ribbed steel casing.

Drum heads Block insulation, cement, 6mm (¼″)


weathercoat.

Superheater Blacket insulation and 2mm (14 ga.) min.


enclosure ribbed steel casing.

Exposed part Pipe insulation

S.H. outlet pipe Cement, 6mm (¼″) weathercoat.

Soot blower pipe Molded insulation material 6mm(¼″)


weather coat.

Necessary seals, expansion joints, door lining, etc. to complete setting shall be
furnished.

9.2.8 Doors and Furnace Openings


The Vendor shall furnish all necessary access, observation and lancing doors as
required by design, subject to Employer approval, for pressurized operation all
doors shall be bolted. Vendor to provide sufficient doors in boiler casing at various
elevations, to enable proper ventilation during maintenance periods, as well as
sufficient number of inspection holes for superheaters and boiler tubes.

9.3 Fans and Drivers

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.

f. The control of combustion air will be accomplished by controlling fan inlet


damper. Fan shall be provided with inlet vane-type damper. The damper
operator shall be furnished by the Vendor and shall be equipped with a
pneumatic positioner. The damper operator shall be provided with a
continuously connected handwheel. Damper to be open at 0.2 bar control air
pressure and closed at 1.03 bar control air pressure.

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.

c. Gage glass and water column drain valves shall be furnished.

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.

9.4.12 Combustion control


Components of combustion control shall be:

a. Full metering with oxygen compensation


b. High and low selecting relays
c. Fuel ratio adjuster

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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Logic circuitry being proposed shall be included in proposal.

9.4.14 Local instrument panel:


The following equipment will be mounted on a lighted, free-standing rear-closed
weatherproof local instrument panel.

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.

a. Atomizing steams pressure


b. Combustion air flow
c. Pressure of fuels and pilot gas downstream of control valves
d. Fuel supply pressure
e. Boiler water conductivity
f. Steam purity analyzer

9.5 Soot Blowers

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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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 Air and Gas

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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10.3.3 Sample collector for checking of boiler TDS shall be provided with sample cooler
and pressure reducing device.

10.4 Performance Tests

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.

12. PREDICTED PERFORMANCE CONDITIONS

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.

13. PREPARATION FOR SHIPMENT

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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14. INFORMATION REQUIRED WITH QUOTATIONS

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:

14.1.1 Outside radiant heating surface in square meter.

14.1.2 Outside convection heating surface in square meter.

14.1.3 Outside superheater surface in square meter.

14.1.4 Overcapacity rating. Indicate maximum time allowed to run.

14.1.5 Efficiency at full, 75%, 50%, 25% load. Include excess air and ambient
temperature used in calculating these efficiencies.

14.1.6 Heat release- MJ/m3 (BTU’s/ft. 3) firebox volume.

14.1.7 Turbine water rate and horsepower, indicate fan test block conditions at this
horsepower (KW).

14.1.8 Tube wall diameters and thicknesses.

14.1.9 Steam and mud drum dimensions including wall thicknesses.

14.1.10 Stack height, diameter and wall thickness.

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. DRAWINGS AND DATA REQUIRED

Approval of final drawings and detail design is required as listed below:

15.1 All items specified under para. 12 and as additionally specified in purchase order.

15.2 Flame failure system with list of material.

16. FABRICATION

16.1 Field Fabrication

Detailed field erection procedure shall be submitted for Purchaser’s approval prior to
commencement of field erection.

16.2 Shop Fabrication

Shop fabricated components shall be manufactured in accordance with the codes and
standards as specified in section II.

16.2.1 Welding Procedure and Welder’s Performance Qualifications

16.2.1.1 Welding procedure qualifications and welder’s performance


qualifications shall conform to the requirements of Section I of the
ASME Code, ASME Code and Section IX and to the additional
requirements of this Specification, except for welding on structural parts
where AWS D1.1 applies.

16.2.1.2 Welder’s performance qualification records shall be available for review


by purchaser in the fabricator’s shop.

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.

16.2.1.4 Welding procedures submitted to Purchase shall contain the specific


applicable items.

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 Filler Metal Requirements

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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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 Weld Joint Preparation

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.

16.2.3.2 Permanent back-up rings are only permitted on the closing


circumferential seams of vessels without an external manway or as
permitted by ASME Section I PW-41, with specific approval by
purchaser. Back-up rings, when permitted, shall match the analysis of the
base material. If back-up rings are removed, the area shall be dressed and
examined for cracks by the magnetic particle method.

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 Heat Treatment

16.2.4.1 Preheating shall be in accordance with ASME Section I, PW-38 and


PW-39.

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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16.2.5 Inspection

16.2.5.1 To be specified if required by Purchaser.

16.2.5.2 Liquid Penetrant Examination


When required or specified, magnetic particle examination shall be in
accordance with the requirements and methods specified in Appendix 8,
Section VIII, ASME Code and ASME Section V, Article 24.

16.2.5.3 Magnetic Particle Examination


a. When required or specified, magnetic particle examination shall be in
accordance with the requirements and methods specified in Appendix
6, Section VIII, ASME Code, and ASME Section V, Article 25.
After removal of fit-up lugs or strongbacks welded to P-4, P-5 or P-6
Group alloys, the weld area shall be dressed and examined by the
magnetic particle method.
b. All nozzle welds shall be magnetic particle inspected after completion
of welding.

16.2.5.4 Ultrasonic Examination


When ultrasonic examination of welds is specified, the method,
procedure, and acceptance criteria shall be in accordance with Appendix
12, Section VIII, of the ASME Code, and method shall be in accordance
with ASME Section V, Article 23.

16.2.6 Radiographic Requirements

16.2.6.1 When required or specified, weld examination procedure are acceptance


criteria shall be in accordance with ASME Section I and V.

16.2.6.2 Additional requirements for radiographic examination shall be as follows:


a. Fine grain film, kodak AA or equivalent shall be used.
b. Only lead screens may be used.
c. Approval is required for used of penetrameters other than those
specified in ASME, Section VIII. Approval will be based on the
thickness sensitivity and hole sensitivity equivalent to that required in
the ASME Code, or sample radiographs of thickness involved
containing both ASME and the proposed penetrameter.

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.

16.2.6.4 Where radiography is to ASME B31.3 rquirements, use 100 percent


radiographic acceptance criteria.
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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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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

WATER TUBE BOILER DATA SHEET

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

19 SUPLY DESIGN AND TESTING GENERAL CODES


GENERAL SPEC.
PRESSURE PARTS DESIGN
MATERIALS
PIPING DESIGN
ELECTRIN MOTOR DESIGN HAZARDOUS AREA CLASSIFICATION
STEAM TURBINE DESIGN OIL COOLERS FOR TURBINE
GEAR DESIGN
INSTRUMENTATION DESIGN TESTING

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 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.

5/2/2007
27
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

WATER AND STEAM CHARACTERISTICS

21 FEED WATER CHARACTERISTICS


RESIDUAL BARONESS mg/kg caco 3
O2 mg/kg
Co 2 mg/kg
CU mg/kg
FE mg/kg
SLO2 mg/kg
OIL mg/kg
PERMANCENATE MAX. KMN4
PH AT 25 o C
CONDUCTIVITY AT 25 o C μ S / cm

22 BOILER WATER CHARACTERISTICS


CONDUCTIVITY AT 25 o C μ S / cm
AM AT 25 o C
PO4 MAX. mg/kg
SIO2 MAX. mg/kg
ALKALIVITY mg/kg CaCO 2

23 STEAM CHARACTERISTICS
SIO2 MAX mg/kg
CONDUCTIVITY AT 25 o C μ S / cm
REMARKS

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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

AVAILABLE LITILINES CHARACTERISTICS

24 MEDIUM PRESSURE STEAM


PRESSURE MIN. / NORM./ MAX / DES bar (q)
TEMPERATURE MIN. / NORM./ MAX / DES. oC
TOTAL CONSUMPTION Kg /m
25 Low pressure steam
PRESSURE. MIN. / NORM./ MAX / DES. Bar(g)
TEMPERATURE MIN. / NORM./ MAX / DES. O
TOTAL CONSUMPTION kg/hr
26 ELECTERIC POWER FOR INSTRUMENTATION
ALTERNATE VOLT HZ NO.OF PHASE
DIRECT VOLT

27 ELECTERIC POWER FOR MOTORS


† VOLT HZ NO. OF PHASE
† VOLT HZ NO. OF PHASE
† VOLT HZ NO. OF PHASE
† VOLT HZ NO. OF PHASE
† VOLT HZ NO. OF PHASE
28 INSTRUMENT AIR
NORMAL PRESSURE / DESIGN bar (a) TEMPRETURE oC
† DECLED CONSUMPTION Nm3/h
DEW POIT o C

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

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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 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

34 DESUPERHEATER † NONCONTACT † DIRECT


INSTALATION † INTERSTAGE † FINAL
NOZZEL DIAMETER INCH. MAX WATER FLOW PLATE FOR DESUPERHEATER m3/h
P MAX NOZZLE FLANGE RATING MATERIAL
MAX SPRAY WATER FLOW RATE FOR DESUPERHEATER m3/h I STAGE II STAGE IIISTAGE

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

36 RECOVERY AIR PREHEATER † YES † NO


† REGENERATIVE VERTICAL SHAFT † REGENERATIVE HORIZONTAL SHAFT
† REGUPLATIVE
SEALS LOSSES 1.
MAIN DRIVER TYPE †ELECTRIC MOTOR A.C
TYPE STAND BY DRIVER †ELECTRIC MOTOR A.C
†ELECTRIC MOTOR D.C
† AIR TURBINE
AIR PREHEATER WASHING SYSTEM TYPE † INCLUDED † EXCLUDED

37 STEAM AIR PREHEATER † REQIRED † NOT REQUIRED


AT MAX oC AIR SIDE † SURFACE m 2
† Δ P MAX m .bar AIR SIDE

REMARKS

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IPS –G –ME- 180(1) PROJ . NO.


UNIT NAME P.O NO.
SPECIFICATION SHEET NO .1 DATE SH.OF
UNIT NO. TO BE PROVIDED BY VENDOR 6 8
CONSTRUCTION FEATURES
38 BOILER ORCULATIONS PUMPS † YES † NO
TYPE
NUMBER UNIT MAIN/ SPARE
FLOW DIFFERENTIAL HEAD m ABSORBEC FLOWER kw
MAIN DRIVER /SPARE /
FOR OTHER CHARACTERISTICS SEE DATA SHEET
FOR TURBINE CHARACTERISTICS SEE DATA SHEET
FOR EKECTERIC MOTOR SEE DATA SHEET

39 FUELS/ STCM
TYPE OF FIRINGE † GASOIL †GAS † OIL+ GAS † NATURAL GAS FOR S/U

BURNER CONTROL RANGE OIL GAS


ATOMIZING TYPE † MECHANICAL † SITAM †MIXED
BURNERS NO FOR GASOIL FOR GAS
BOILERS MCR WITH N-1 BURNERS REQUIRED †YES †NO
GAS BURNERS TYPE PILOT BURNER TYPE
BUPNERS DITAILS
BURNER TYPE
BURNER DAMPER DIAMETER mm THROAT OUTLET DIAMETER mm
SUWARLER CLAMETER mm AXIAL DISTANCE PER TWEEN TIF AND THROAT OUTLET mm
DAMPER GERVOMOTOR INCLUDED † YES † NO
PRESSURE /FLOW AT BURNERS 25% MCR 100% MCR 115% MCR DESIGN
SASOL bar/kg/r / / / /
FUEL GAS bar/Nm3/r / / / /

PRESSURE / CONSUMPTION ATOMIZING STEAM bar/kg /hr


LENGTH/DIAMETER OIL FLAME AT MCR mm
LENGTH/DIAMETER GAS FLAME AT MCR mm
AIR EXCESS FOR CU /GAS AT MCR %
NO.1 SFARE BURNER GUN INCLUDED † YES † NO
NO.2 SERIES OF TYPE FOR EACH TYPE INCLUDED † YES † NO
† FLAME PROTECTION SYSTEM
ACCORDING TO NFFA AS TYPE SUPER. VISED MANUAL † YES † NO
EXECUTION TYPE LOCAL CONTROL ROOM
BURNER MANAGEMENT PANEL † LOCAL † CONTROL ROOM
LOGIC TYPE † SOLID STATE
LOGIC † lLOCAL † CONTROL ROOM
NUMBER OF PHOTOCELLIS PER BURNER † YES † NO
VOLTMETER FOR PHOTOCELLS
SELF CHEKING TYPE

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

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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

FAN ELECTERIC MOTOR CHARACTERISTICS


POWER KW NO.POLES TRANSMISION
SEE ATTACHE DATA SHEET
FAN STEAM TURBIN CHARACTERISTICS
POWER KW SPEED RAM TRANSMISIONS DIRECT † GEAR †
STEAM SFEQRIC CONSUMPSION kg/ kw /h
SEE ATTACHED DATA SHEET
SELF SYNCRONIZING COUPLING † YES TYPE
FAN INLET SILENCER † Δ P m. bar
COMBUSTION AIR VENTURIMETER † YES Δ P m. bar
FAN INLET CONTROL VANE (WITH SERVOMETER) TYPE
BYPASS AND STOP DAMPERS (WITH SERVOMETER) † INCLUDED † EXCLUDED
41 † AIR DUCTS BETWEEN VARICUS PARTS THICKNESS mm
42 † FLUE GAS BEWEEN VAPORIOUS PARTS THICKNESS mm
† INSULATED † CUNITED
43 SOCT BLOWERS † YES † NO
FOR EVAPORATOR NO. TYPE
FOR ECONOMIZER NO. TYPE
FOR NR PREHEATER NO TYPE
SUPERHEATER NO TYPE
SOOT BLOWERS PANEL † LOCAL † CONTROL ROOM
† MANUAL † AUTOMATIC † BY SEQUNCE
EXECUTION TYPE

44 SAFETY VALVE ON URPER , DRUM


NO. SETTING PRESSURE bar (a) /FLOW OF EACH VALVE kg/ h
MANUFACTURER TYPE

45 SAFETY VALVE ON SUPERHEATER


NO. SETTING PRESSURE bar (a) /FLOW OF EACH VALVE kg/ h
MANUFACTURER TYPE

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

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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

57 VALVES LEVELS AND LOCAL INSTRUMENTATION


VALVES ON PRESSURE PARTS † SINGLE † DOUBLE
FEED WATER VALVES † GATE † CHECK
CONTINUOS BLOW DOWN VALVES † MANUAL † MOTOR
CHECK VALVE ON STEAM OUTLET
START – UP BLOW OFF VALVES † DOUELES † MOTOR
DRAIN AND VENT VALVES † SINGLE † DOUBLES
VALVES FOR INSTR. ON PRESS PARTS † DOUBLES † SINGLE
FUEL VALVES AS PER SPEC
SILENCES ON STEAM LINE TO ATM † YES † NO
FLOW RATE NOISE LEVEL
58 STEAM DRUM LEVEL INDICATORS
NO TYPE ILLUNATED † YES † NO ELEC FEEDING
59 RENOTE LEVEL INDICATOR † YES † NO

60 SAMPLE COOLERS
NO TYPE
BOILER WATER † SATURATED STEAM † SUPERHEATED STEAM

51 BOILER DIMENSIONS AND WEIGHT


TOTAL LENGTH mm
TOTAL MOTH mm
Total height mm
MAX. DIMENSIONS AND WEIGHTS FOR TRANSPORT. Kg x x mm
Dpuns weight kg LOWER UPPER
EVAPORATOR TUBES WEIGHT kg ECONOMIZER kg SUPERHEATER kg
STEEL STRUCTURE WEIGHT kg
STACK WEIGHT kg
DUCT WORK WEIGHT kg FIRING EQUIPMENT kg
AUAL PIPING WEIGHT kg VALVES WEIGHT kg
REFRACT WEIGHT kg INSULATION WEIGHT kg
STEAM AIR HEATER WEIGHT kg AIR HEATER WEIGHT kg
TAN WEIGHT kg TURBINE WEIGHT kg MOTOR WEIGHT kg

TOTAL WEIGHT OF SUPLY kg


REMARKS

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