Industrial Boilers IP 7-2-1

Page 1 of 13
(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

Changes shown by 

SCOPE
I 1.1 This practice covers the design, fabrication, and inspection of gas and oil fired water tube (membrane or
tangent tube) industrial boilers (other than gas turbine exhaust boilers) having steam outlet conditions not
exceeding 1700 psig (11730 kPa) and 950F (510C).
I 1.2 An asterisk (  ) indicates that a decision by the Purchaser is required or that additional information is
specified by the Purchaser.

SUMMARY OF ADDITIONAL REQUIREMENTS

I 2.1 Table 1 lists the practices, codes, standards, and specification which shall be used with this practice.
I  2.2 Table 2 lists the practices, code, and standards which shall be used with this practice as specified by the
Purchaser.
 TABLE 1

PRACTICES

IP 1-1-1 Drawings, Diagrams, and Line Lists IP 15-4-1 Flow Instruments

IP 2-1-1 Plant Noise Design Criteria IP 15-5-1 Level Instruments
IP 3-4-1 Piping for Fired Equipment IP 15-6-2 Environmental Protection for Instrumentation
IP 3-6-1 Piping for Instruments IP 15-7-2 Protective Systems
IP 3-12-1 Valve Selection IP 15-9-1 Control Valves
IP 3-16-1 Flanged Joints, Gaskets, and Bolting IP 15-11-1 Instrument Control Panels
IP 3-18-1 Piping Fabrication Shop or Field IP 18-7-1 Welding Procedures
IP 4-1-2 Structural Steel Design IP 18-8-1 Precommission Cleaning of Steam Generating
IP 4-1-3 Design Loads for Structures Equipment and Piping Systems for Rotating
IP 4-2-1 Auxiliary Structures for Operation and Maintenance Equipment
IP 7-5-1 Coils for Fired Heaters and Boilers IP 18-10-1 Additional Requirements For Materials
IP 10-13-1 Special Purpose Centrifugal Fans IP 18-12-1 Positive Material Identification
IP 14-1-1 External Insulation IP 19-1-1 Paint and Protective Coatings
IP 15-2-1 Temperature Instruments IP 19-3-3 Linings for Fired Heaters
IP 15-3-1 Pressure Instruments IP 20-1-1 Inspection of Equipment and Materials

CODES, STANDARDS AND SPECIFICATION

ASME Codes ASTM Standard

Section I Power Boilers C 680 Standard Practice for Determination of Heat Gain
Section II Materials or Loss and the Surface Temperatures of
Section V Nondestructive Examinations Insulated Pipe and Equipment Surfaces
B31.3 Power Piping NFPA Standards
PTC 4.1 Steam Generating Units 8501 Single Burner Boiler Operation
PTC 19.11 Water and Steam in the Power Cycle 8502 Prevention of Furnace Explosion / Implosions in
AMCA Standard Multiple Burner Boiler
210 Laboratory Methods of Testing Fans for Rating SSPC Specification
Purposes SP7 Brush Off Blast Cleaning
ASME Standard
B1.20.1 Pipe Threads, General Purpose (Inch)

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 IP 7-2-1 Industrial Boilers
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Rev. 1 March 1998 (This practice is appropriate for attachment to Inquiry or Purchase Document)

 TABLE 2

PRACTICES
IP 4-5-1 Steel Stacks
IP 4-5-2 Reinforced Concrete Chimneys
IP 5-1-2 Additional Requirements for Heavy Wall Pressure Vessels, Thickness Over 2 In.
IP 7-3-1 Sootblowers for Fired Equipment
IP 10-7-2 Special Purpose Steam Turbines
IP 15-8-1 Process Stream Analyzers
IP 16-9-1 Low Voltage A-C Motors Up to 200 HP (150 kW)
IP 18-3-2 Statically Cast Steel and Alloy Pressure Containing Parts and Tube Supports for Fired Heaters
CODE AND STANDARDS

ASME Code
Section VIII Pressure Vessels, Division 1
ISO Standard
R-831 Rules for Construction of Stationary Boilers
ASTM Standards
A276 Stainless and Heat-Resisting Steel Bars and Shapes
A578/A578M Straight-Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special Applications

I  2.3 Proposals to use codes other than listed in Table 1 shall be submitted to the Purchaser for approval by
Purchaser. To be considered for acceptance, all of the following criteria must be met:
a. The code must be acceptable to the inspecting authority of the country in which the boiler will be
installed.
b. All provisions of ISO R-831 are met.
R 2.4 A corrosion allowance of 1/16 in. shall be used for drums, headers and all tube and crossover piping.

DEFINITIONS
I 3.1 Radiant heating surface in the furnace is defined as the flat projected area of all surfaces enclosing the
furnace volume exclusive of superheater cavity opening. Calculation of furnace heat release is to be based
on this definition.
I 3.2 Effective projected radiant surface in the furnace shall be calculated as the flat projected area of exposed
tubes and exposed extended surface integral with tubes. Refractory covered surfaces shall not be included.
Calculation of furnace heat absorption is to be based on this definition.

DOCUMENTATION
I 4.1 Proposal information. A technical description, including the following information for the boiler and
auxiliaries, shall be supplied:
 a. An itemized descriptive list of valves, instruments, controls, piping, and other boiler accessories
included in the scope of supply.
b. The system resistance curve, overplotted on the fan characteristic curve for all FD and ID fans, for
each operating combination.
c. Guaranteed ramp rates (load change) through entire range for:
1. Cold start-up
2. Upward load charge
3. Downward load charge
d. A functional logic diagram showing the light-off and shutdown sequence for the burners.
e. Heat transfer surface in the furnace and boiler bank reported in accordance with the definitions given in
this practice.

f. The applicable performance data shown in Table 3 for the maximum continuous rating and other
specified operating points.

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 Industrial Boilers IP 7-2-1
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(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

DOCUMENTATION (Cont)
 g. A dimensional drawing or drawings showing drum internals, drum and header material, outside
diameter, plate thickness; water and steam circuit arrangement, furnace configuration, burner locations,
flue and duct arrangements, and dimensions and material of expansion joints, size location of
observation, access and inspection doors and sizes and locations of vents and drains.
h. Materials of construction.
i. Extent of platforming, ladders, and stairways to be supplied.
j. A list of exceptions to this practice or, if there are no exceptions, a statement to this effect in the
proposal.
k. Maximum boiler turndown with all burners in operation and minimum recommended excess air for the
specified design fuel and fuel pressure. The maximum capacity of liquid fuel guns shall be stated in
lb/hr (kg/h).
l. A curve showing the variation of superheater outlet temperature with boiler load over the range of
operation of the boiler.
m. Method of tube replacement/plugging for each coil.
n. Complete description of all field work required. Drawings shall show all break points and weights of
individual shop assembled items.
o. A curve showing circulation rate versus steam production over the range of boiler operation.
p. One copy of the Vendor's quality control manual.
q. Proposed chemical cleaning arrangement/procedure. Procedures shall show nozzle/line sizes and
locations, blinds, circulation paths and flow rates through each section of the boiler.
I 4.2 Post award review. As a minimum, the Vendor shall provide for review by the Owner's Engineer the
following design details:
a. All changes to proposal information.
b. Burners including general arrangement, air/fuel capacity curves, pilot details including ignitor and
burner front piping.
c. Air and flue gas ducting including dampers, expansion joints, turning vanes, blinds, pressure drop and
heat loss calculations.
d. Tubesheets and tube supports including stress calculations.
e. Castable manufacturer's recommended procedure for refractory dryout.
f. Complete tube to drum/header installation procedures.
g. Foundation loading diagram and steel structure and casing.
h. Calculation steam/water side pressure drop and of superheater metal temperature and flow balance.
i. Lining details including material selection, anchor details, heat loss calculations, installation procedures
and expansion provision.
j. Observation and access doors.
k. Thermocouple details and installation procedure for non-drainable superheater.
l. All attemperator design criteria and heat transfer calculations.
m. Pressure relief valve calculations.
n. Tube vibrational analysis.
o. Combustion control, air flow measurement device and feed water control.
p. Code calculations for all pressure parts.
q. Auxiliary equipment such as air preheaters, induced and forced draft fans, sootblowers, and fuel filters.
r. Burner management system.
s. Emissions.
I 4.3 The final records to be submitted to the Purchaser are:
a. Operating manuals shall be written specifically for the unit being supplied. The manuals shall include
all details necessary for commissioning, startup, and operation without the need for vendor's
assistance.

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 IP 7-2-1 Industrial Boilers
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Rev. 1 March 1998 (This practice is appropriate for attachment to Inquiry or Purchase Document)

DOCUMENTATION (Cont)
b. All as-built assembly and shop detail drawings and instructions necessary for fabrication, erection, and
continued maintenance of the boiler, including adequate details and specifications for fabricating and
installing any and all replacement parts.
c. All proposal information, corrected to the as-built conditions.
d. Approved procedure for refractory dryout.
e. Vendor's recommendations and detailed procedure for both boil-out and chemical cleaning.
f. Vendor's detailed procedure to plug tubes and tube holes. Provide mechanical features of plugs and
details of tube expanding equipment required.
g. An outline drawing shall be furnished for each significant pressure part. This drawing will be used as
an overall summary drawing for in-plant inspection and maintenance tasks. This drawing shall show
the size and orientation of all nozzles and connections, layout of all appendages to the pressure part,
and sufficient data to adequately describe the part. The location of vessel marking or nameplate shall
be indicated on this drawing.
h. Fabrication drawings shall show weld details and materials, and shall reference applicable welding
procedures. When impact testing is required, the drawings shall include:
1. Component
2. Material Specification
3. Critical Exposure Temperature (CET)
4. Appropriate Charpy Impact Requirements (Average/Minimum Values)
i. Additional information shall be supplied as follows:
1. Certified Material Mill Test Reports from the mill of manufacture for all pressure parts.
2. Nameplate Rubbings.
3. Code Calculations.

MATERIALS
S  5.1 Drums, headers and tubes. Material with a maximum tensile strength in excess of 112,500 psi (775 MPa)
is not acceptable. Proposals to use proprietary alloy material shall be submitted for approval by the Owner's
Engineer.

DESIGN
LAYOUT AND ARRANGEMENT
R  
6.1 The boiler design and fuel combination shall be commercially demonstrated in a similar service to the
satisfaction of the Owner’s Engineer.
 6.2 Based on design fuel higher heating value, the maximum heat release at Maximum Continuous
Rating (MCR) in the furnace shall not exceed the following limits:

HEAT RELEASE BASED ON:

FUEL FIRED Furnace Volume Furnace Radiant Heating Surface

Btu/hr-ft3 kW/m3 Btu/hr-ft3 kW/m3

Gaseous fuels and liquid fuels lighter 80 000 828 150 000 473
than 15 API (0.966 relative density)
Liquid fuels 15 API and heavier 60 000 620 150 000 473

O 6.3 The boiler and auxiliary equipment, with the exception of the forced draft fans and drivers, shall be
designed for a minimum of 10% excess air for firing gas fuel and 15% excess air for firing oil fuel or
combination gas and oil fuel.
O 6.4 All circuits and coils shall be drainable. For superheater exception see Par. 6.15.

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 Industrial Boilers IP 7-2-1
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(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

DRUMS AND HEADERS

O  6.5 The maximum boiler operating pressure must be a minimum of 5% below the setpoint of any safety valve.
R 6.6 Steam/Mud drum internal piping shall be designed for even distribution with no functional interference along
the length of the drum.
I 
6.7 The size of blowdown nozzles shall be determined based on the blowdown rate and back pressure
specified.
O,R 6.8 For boilers operating over 500 psig (3450 kPa), steam drum internals shall include centrifugal type
primary separators and secondary separators. Separators shall be sealed below water level.

Proposals to use other types of primary separators shall be submitted to the Owner’s Engineer for approval.
To be considered for approval the vendor must substantiate with test data from a commercial unit that the
solids content of steam entering the superheater will not exceed job specification requirement when
operating with water at high level and with specified boiler water concentration.
R 6.9 Drums with wall thickness greater than 2 in. (50 mm) shall have welded connections as follows:
a. Connections greater than NPS 4 (100 mm) shall be per Figures PW-16.1 (q-1), (q-2), (q-3), or (q-4) of
ASME Code Section I.
b. Connections NPS 4 and less shall be as above or per Figures PW-16.1 (a), (b), (c), (g), (h). Figures
PW-16.1 (y) or (z) may also be used for tube connections NPS 4 and less when the tube wall thickness
is less than 1/2 in. (13 mm).
S,R 6.10 Drums and headers, where both the wrapper plate and tubesheet exceed 2 in. (50 mm) in thickness,
shall be designed per IP 5-1-2.
R 6.11 The interior of the upper and lower drums shall be cleaned to SP7 prior to tube installation.
S,R 6.12 Design of feedwater entry through steam drum shell shall be approved by the Owner's Engineer. Use of a
thermal sleeve is required when differential temperature between fluids exceeds 100F (38C).
S,O 6.13 The steam drum shall:
a. Contain adequate volume to withstand the “shrink" and/or “swell" resulting from maximum guaranteed
ramp rates to and from MCR without reaching the high or low level alarm. For calculation purposes,
assume all steam bubbles collapse during a “shrink" occasion.
 b. Provide minimum holdup of three minutes from low-level alarm to point where damage can occur,
unless specified otherwise.
c. In calculating holdup time, vendor shall consider only that water which can actually enter the tubes
within the stated time. Water cutoff from the tube by internal baffles or partitions must not be
considered.

SUPERHEATER
R 6.14 The superheater shall be arranged such that the inlet tubes are not located in the region of highest flue
gas temperature.
R   6.15 The boiler vendor shall indicate whether the superheater is drainable or non-drainable. The vendor shall
have demonstrated experience with the proposed design.

CONVECTION SURFACE CLEANING

O  6.16 Convection surface cleaning facilities shall be selected per the following criteria. If using a combination
oil-gas burner, the properties of the oil shall govern selection of the cleaning facilities:

FUEL CLASS FUEL FIRED TUBE SURFACE CONVECTION SURFACE CLEANING

I Liquid fuel of less than 25 API (0.904 Bare Retractable sootblowers are required
relative density) gravity and with more
than 0.01 wt % ash
II Liquid fuel of less than 25 API gravity Bare or finned Retractable or rotary sootblowers required.
and with less than 0.01 wt % ash Rotary sootblowers may be used in cooler
flue gas regions below 1200F (650C)
III Liquid fuel of greater than 25 API Bare or finned Sootblower space required
gravity
IV Gas Fuel Bare or finned Sootblower space required

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 IP 7-2-1 Industrial Boilers
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R  6.17 Sootblower shall meet the following:

a. Requirements stated in IP 7-3-1.
b. For Class I fuels only retractable types are acceptable.
c. For Class II, III and IV fuels rotary sootblowers may be used in passes where the entering flue gas
temperature is below 1200F (650C).
O,M 6.18 Maximum radial coverage of a sootblower shall be as follows:

TYPE RADIAL COVERAGE

Retractable 5 ft (1500 mm) for fuels lighter than 15 API (0.966 relative density)
4 ft (1200 mm) for fuels 15 API and heavier
Rotary 3 ft (900 mm)

STRUCTURE AND CASING

E 6.19 Waterwall tubes shall be welded to form a pressure tight envelope to protect insulation and outer casing
from flue gas contact.
O 6.20 Drains shall be furnished at the low point of the boiler furnace and bank areas to permit removal of the flue
gas deposits by water washing. Minimum opening shall be 3 in. (75 mm) diameter. Drain openings shall be
effectively sealed against flue gas bypassing and casing overheating.

OBSERVATION AND ACCESS DOORS

S,R 6.21 Observation doors shall be provided to meet the following requirements:
a. Be located to permit visibility of all burners, flame envelope, furnace surfaces and the superheater
cavity.
b. Have minimum wall opening of 2 x 4 in. (50 x 100 mm) or 3 in. (75 mm) diameter.
c. On pressurized boilers, observation doors shall have a view glass and shall be furnished with:
1. Aspirating air of sufficient pressure to prevent flue gases from blowing out when the door is open.
Each door shall be fitted with an interlock which prevents the door from being opened unless the
aspirating air is turned on.
2. Seal air to minimize flue gas leakage and prevent fogging of the view glass when the door is
closed.
M 6.22 Boilers which have continuous tangent tubes or fin welded furnace floor tubes shall be elevated a
minimum of 3 ft (900 mm) to permit access beneath the furnace floor.

PLATFORMS AND STAIRS

I 6.23 Platform, stairs and ladders shall be provided per IP 4-2-1 with the additions and clarifications noted in this
section.
C 6.24 Grating is acceptable for platform flooring. This is an exception to IP 4-2-1.
M 6.25 Minimum clear width of platforms for access to drum manways shall be 4 ft (1200 mm).
O,M 6.26 Stairway access shall be provided to platforms serving burners, burner controls, and sootblowers.
S 6.27 Self closing safety gates shall be provided across ladder openings at each platform landing.

STACK
S   6.28 Top of stack shall be a minimum of 10 ft (3000 mm) above any equipment which is located within 50 ft
(15 m) horizontally of the stack, and shall also be at least 10 ft (3000 mm) higher than any working platform
that is regularly used by operating or maintenance personnel (once per day or more) and is within a
horizontal distance of 100 ft (30 m).

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(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

BURNERS
R 6.29 Burners shall meet one of the following:
a. A burner which has been commercially proven in comparable service (service conditions, fuel,
orientations, turndown excess air and heat release).
b. A demonstration (of the burner being provided) under simulated field conditions to the satisfaction of
the Owner's Engineer.
O 6.30 For liquid fuel only burners, there shall be a minimum of two fuel guns per boiler to facilitate burner
changes without loss of combustion.
O 6.31 Dual fuel burners shall be:
a. Capable of firing the gas and liquid fuels specified, both separately and simultaneously.
b. Dual rated, i.e., must be capable of meeting design requirements on each fuel, fired separately, if
specified.
S 6.32 A device shall be provided to prevent pressurized furnace gases from blowing out through burner gun
openings when guns are removed.
S 6.33 Oil gun heads for liquid fuel having a flash point of 100F (38C) or less shall be so designed that no fuel or
steam will escape if head is removed without first blocking fuel and steam lines.
S,M 6.34 All burners shall have interrupted spark ignited gas ignitors. All ignitors and ignition sources shall be
removable with burner in operation.

DUCTING
O,R  6.35 Ducting for flue gas and air shall be 3/16 in. (5 mm) minimum plate thickness of continuous seal welded
construction to insure air tightness with flanged connections for field assembly.
R  6.36 Flue gas ducting shall be insulated to maintain the bulk flue gas temperature above its acid dewpoint.
Ducting upstream of flue gas heat recovery shall be insulated to produce a calculated cold face temperature
of no more than 180F (82C) based on an ambient still air temperature of 80F (27C).
O,R 6.37 Combustion air ducting shall be:
a. Designed to provide uniform flow distribution to all burners.
 b. Insulated, if an air preheater is provided, to produce a calculated cold face temperature of 150F (65C)
based on an ambient, still, air temperature of 80F (27C).

FORCED DRAFT FANS

R 6.38 Forced and induced draft fans shall meet the following requirements at their rated points:
a. Rated air flow shall be 110% of the air flow required by the unit operating at MCR and firing design
fuel at 20% excess air for oil fuel and 15% excess air for gas fuel.
b. Rated static head shall be 120% of the head required at MCR and firing design fuel at 20% excess air
for oil fuel and 15% excess air for gas fuel.
c. Forced draft fans shall be rated at summer design air temperature, summer design relative humidity
and altitude at site of installation. Induced draft fans shall be capable of maintaining design capacity
and head at inlet design temperature, plus and minus 25F.
O,R 6.39 Fan blading design shall be either of the airfoil or backward curved nonoverloading type.
O,M 6.40 Discharge dampers shall be provided for parallel fans discharging into a common duct. Dampers shall be
actuator or counterweight operated to prevent backflow through any non-operating fan. Discharge isolation
facilities shall be provided on any fan that can be shutdown for maintenance while the boiler continues to
operate.

INSTRUMENTATION CONNECTIONS AND CONTROLS

O 6.41 Water column shall be furnished by the boiler vendor with a range that extends below low-water cut-off and
above high level alarm.
S,O 6.42 A combined oxygen/combustibles analyzer shall be provided to permit continuous analysis of the flue
gas in the stack. If a zirconia type analyzer is used, then it shall be equipped with flame arrestors to
prevent flame propagation in the event of ignition by the heated sensor.
R 6.43 Feedwater control shall be of the three-element type.
S 6.44 Fail-Action direction for the following valves shall be:

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a. Fuel - close.
b. Combustion air - open.
c. Feedwater - close.
d. Fuel gas vent - open.

BURNER MANAGEMENT SYSTEM

I 6.45 A burner management system (BMS) shall be provided based on NFPA standards for supervised manual
operation consisting of an integrated system of flame safeguarding, interrupted spark ignited gas ignitors,
shutdown devices, interlocks, combustion limits, and alarms to assure safe conditions for lightoff and prevent
unsafe conditions from developing during operation. BMS shall be in accordance with IP 15-7-2 and shall be
Fail-Action.
S 6.46 The flame safeguard systems for front or opposed fired boilers shall be designed per NFPA with the
following additional requirements:
a. Dual flame detection for each burner:
 1. Flame detector type shall be approved by the Owner’s Engineer.
2. Flame detectors shall be provided with a self-checking feature which continuously checks all
components from the scanner to the output circuit at least once every 6 seconds without affecting
the response time of the flame detector. A permanent voltmeter shall be provided on the output
circuit to facilitate aiming and monitoring the detector.
3. Facilities shall be provided to detect the pilot flame. Where this is performed by the main burner
flame detection facilities, at least one scanner shall be aligned to view the pilot flame.
4. Flame detectors shall detect their burners flame at all loads and during all load changes without
picking up radiation from other burner flames on multiple burner units.
5. Continuous pilots may not be used in place of dual flame detection except when specified by the
Purchaser.
b. 2-out-of-2 voting of the flame detectors is required to trip the associated individual burner fuel
shutdown valves.
1. A single detector flameout signal shall alarm in the main control room and on the local panel. The
local panel shall indicate which detector had the flameout signal.
2. If the BMS is implemented using relays, flame detector relays shall operate individual burner fuel
shutdown valves without intermediate relays except additional relays necessary to provide the
required number of contacts.
 c. Automated individual burner air registers which close simultaneously with individual burner fuel
shutdown valves on flameout signals from both detectors will be specified by Purchaser on multiple
burner units.
d. The time interval between loss of flame and stopping the fuel flow to the burner(s) shall be not
more than four seconds.
e. Burner lightoff facilities:
1. A startup panel consisting of lights, pushbuttons, and auto-manual (A/M) transfer stations for
boiler control loops shall be located at the firing aisle.
2. Pressure control on pilot gas manifold shall be independent for each boiler and shall maintain
proper pilot gas lightoff and operating pressure.
3. Fuel flow to the burners shall be maintained at proper rate for lightoff by an independent pressure
regulator installed in parallel with the boiler fuel control valve.

LOGIC CIRCUITRY FOR BURNER LIGHTOFF

S 6.47 Permissive interlock system for lightoff shall be per NFPA requirements. System shall include a one
minute timer to prohibit another attempt to ignite any pilot after a pilot gas valve shutdown.
S 6.48 A lightoff checklist shall be permanently mounted on local panels.
S,O 6.49 All inputs tied into burner lightoff permissive logic, including limit switches, shall be provided with individual
visual indication at the local panel to display the status.

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BOILER SHUTDOWN, SHUTDOWN VALVES AND TEST FACILITIES

S 6.50 Conditions to actuate boiler shutdown. Where local codes differ from NFPA requirements, master fuel
and pilot gas shutdown valves and individual fuel and pilot gas shutdown valves shall be tripped closed by
any one of the following conditions (forced draft fan shall not be shutdown):
a. Emergency pushbuttons on main control panel and local control panel.
b. Low combustion air rate.
c. Low oil atomizing steam pressure or pressure differential only if the liquid fuel has a flash point of
100F (38C) or less.
d. Low drum level with adjustable time delay of 0 - 10 seconds.
e. Loss of flame on all main burners (pilot flames shall be excluded) after completion of first main burner
time trial period.
f. Closure of individual burner fuel shutdown valves on more than 50% of burners if unit has four or more
burners.
g. Closure of any individual burner fuel shutdown valve on units with two or three burners that are not
equipped with automated individual burner air registers.
h. Loss of forced draft fan.
R  6.51 Low combustion air rate shall be sensed with a venturi like device which generates a pressure drop of not
less than 6 in. (150 mm) H2O at normal firing rate and excess air.
R 6.52 The preferred measurement for loss of forced draft fan is low fan speed. Other methods must be
approved by the Purchaser.
M 6.53 Block valves shall be provided:
a. Upstream and downstream of master fuel shutdown valves.
b. Upstream of individual burner fuel shutdown valves.
c. Upstream of gas vent valves.
S 6.54 Individual burner fuel shutdown valves shall have an opening time compatible with burner ignition
requirements and shall be located to achieve the minimum practical piping volume between the valve and
the burner.
S 6.55 Test facilities shall be provided in accordance with IP 15-7-2 and as clarified below:
a. Bypass valves are not required for individual burner fuel shutdown valves.
b. A test switch shall be provided for each master shutdown valve and gas vent valve.

COMBUSTION CONTROL SYSTEM

S,O 6.56 Local indicators, of significance to flameout protection, which are to be within view from the local panel
are:
a. Main fuel supply pressures.
b. Main fuel manifold pressures downstream of all control valves.
c. Pilot gas fuel pressure downstream of control valve.
d. Atomizing steam pressure.
e. Combustion air flow.
f. Boiler drum level.
S 6.57 Maintaining air-fuel ratio. Combustion control for regulation of fuel and air shall maintain air-fuel ratio at a
safe value under all conditions.
a. It shall include means for setting minimum and maximum limits in the fuel and air control systems to
prevent these systems from providing fuel and air flows beyond the stable limits of the burners.
b. Minimum firing rate set point of each fuel of a combination (dual fuel) burner shall be that required to
maintain stable combustion at 100% combustion air rate when firing each fuel alone. In no case shall
this set point be less than 10% of burner rating.
c. Loss of fuel flow signal shall be detected and alarmed and shall not cause combustion control system
to go to an unsafe state.

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PRESSURE RELIEF VALVES

S 6.58 Pressure relief (PR) valves complete with test gags shall be furnished for both the steam drum and the
superheater.

INSPECTION STANDARDS AND ACCEPTANCE CRITERIA

R 7.1 Radiographic examination of all welds shall be per ASME Code Section I, Par PW-11, except as
modified below:
a. For headers, drums, pipe, and butt welds of tubes, which the Code exempts from radiographic
examination, examination of welds shall be made as follows:
1. A minimum of 5% of the welded joints selected at random by the Inspector shall be spot
radiographed as the work progresses.
2. The length of film for each spot radiographed shall be 10 in. (250 mm) or one-half the
component circumference whichever is less.
3. At least one of each type and position of weld made by each welder shall be examined.
4. Follow up on acceptable welding. In addition to the minimum spot examination of 5% of the
welded joints, the extent of defective welding found in any joint shall be determined by taking at
least two additional radiographs. As an alternative, the complete weld may be cut out and
replaced. In addition, spot radiographs shall be made of two other welds made by the same
welder for each weld found unsatisfactory.
b. All welds of P-4 or P-5 materials shall be 100% radiographed when the pipe or header wall is 3/4 in.
(19 mm) or greater in thickness.
c. Acceptance criteria shall be per ASME Code Section I, Par. PW-51.
d. Radiography shall be per ASME Code Section V, Article 2, except that fluorescent intensifying
screens, such as calcium tungstate, shall not be used.
R 7.2 Spot examination by sectioning is prohibited, except as may be approved by the Purchaser to confirm
contentions of excessive weld projection, depressions, or lack of penetration at otherwise inaccessible joints.
R 7.3 Magnetic particle inspection of nozzle welds and a random selection of 10% of the welds joining the shell
to a tube or tube stub shall be per the ASME Code Section VIII, Division 1, Appendix 6. Both sides of the
completed weld, where accessible, shall be examined after any post weld heat treatment. If back welding is
done, the back side of the root pass shall be examined after it has been prepared for back welding. The
D- C prod method shall be used prior to post weld heat treatment and the A-C yoke or coil method after final
post weld heat treatment.
R 7.4 Ultrasonic examination. All piping welds where the wall thickness exceeds 1-1/4 in. (32 mm) shall be
100% ultrasonically inspected. Ultrasonic examination shall be per the ASME Code Section VIII, Division
1, Appendix 12.
R 7.5 When the tubesheet of a boiler drum or header exceeds 2 in. (50 mm) in thickness and the wrapper
plate is less than 2 in. in thickness, the tubesheet shall be inspected per the following:
a. Ultrasonic examination of plates. Plates (and platelike forgings such as forged shell rings) shall be
ultrasonically examined per ASTM A578/A578M. Acceptance standard shall be Level II. In addition,
the entire surface area within two plate thicknesses from the location of a major load bearing
attachment weld or corner type joint shall be examined. Acceptance standard shall be Level 1.
b. Magnetic particle examination of edges prepared for welding and openings. Prior to welding, all
edges prepared for welding and plate openings shall be examined by the magnetic particle method (D-
C prod only). Indications found shall be cleared and back welded to provide a minimum depth of 1 in.
(25 mm) of sound metal.
R 7.6 Inspection and testing per IP 5-1-2 is required for drums and headers when both the wrapper plate and
tubesheet exceed 2 in. (50 mm) in thickness (references to ASME Code radiography shall be per Section I
instead of Section VIII).

TESTING
R  8.1 Hydrostatic testing of the completed boiler shall be per ASME Code Section I except that the maximum
hydrotest pressure shall be held for one hour per in. (per 25 mm) of metal thickness, and in no case for less
than one hour or more than three hours. The minimum permissible test temperature per IP 18-10-1 shall be
stamped on the boiler nameplate and noted on the manufacturer's data report. Test to be witnessed by
Inspector.

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EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 Industrial Boilers IP 7-2-1
Page 11 of 13
(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

R 8.2 Pneumatic leak testing shall be performed for the boiler casing before external insulation is applied. The
test pressure shall be one and a half times the maximum furnace operating pressure. If the boiler is to be
equipped with isolating dampers, the test pressure shall be the maximum F.D. fan discharge pressure. The
duration of the test shall be ten minutes, during which time the furnace pressure may not decrease by more
than 10%. All leaks which are detected shall be repaired and the unit retested.
R 8.3 Forced draft fan performance test shall be required if:
a. The manufacturer's prototype has not been tested per AMCA 210 using the test setup specified by the
code most similar to the actual installation.

b. Non-standard duct work (such as an inlet silencer) is supplied. The test setup requires Purchaser’s
approval.
I 8.4 Within 12 months after mechanical completion or 6 months after start-up, the Owner shall have option
to performance test the boiler per ASME Power Test Code PTC 4.1 as mutually agreed by Owner and
Vendor.

GUARANTEE
I 9.1 The following performance guarantees, at maximum continuous steam flow, shall be included:
a. Maximum continuous steam flow.
 b. Efficiency. The conditions at which efficiency is guaranteed shall be specified by the manufacturer.
c. Steam temperature leaving the superheater (  10F or  5C). If steam temperature control
equipment is furnished, this equipment shall be guaranteed for a specified load and temperature range.
d. Steam purity entering the superheater. The solids content in the steam shall not exceed requirements
with boiler water at high level alarm and concentrations as specified in the table, following, for the
operating pressure:

TOTAL ALKALINITY SUSPENDED SOLIDS

BOILER PRESSURE AT OUTLET SOLIDS (TOTAL) SOLIDS IN STEAM
psig kPa ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm max.
0 - 300 0 - 2100 3500 700 15 1.0
> 300 - 450 > 2100 - 3100 3000 600 10 1.0
> 450 - 600 > 3100 - 4200 2500 500 8 1.0
> 600 - 750 > 4200 - 5200 1000 200 3 0.5
> 750 - 900 > 5200 - 6200 750 150 2 0.5
> 900 - 1000 > 6200 - 6900 625 125 1 0.5
> 1000 - 1700 > 6900 - 11700 100 — 1 0.1

e. If an air heater is provided, the temperature of the air leaving the air heater ( 30F) ( 17C).
f. Water/steam pressure drop, psi from upstream of boiler feedwater valve to downstream of steam
stop/non-return valve.
 g. Ramp rates:
1. Cold Start Up.
2. Upward load change.
3. Downward load change.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 IP 7-2-1 Industrial Boilers
Page 12 of 13
Rev. 1 March 1998 (This practice is appropriate for attachment to Inquiry or Purchase Document)

TABLE 3

PREDICTED PERFORMANCE

ITEM VALUE
Steam Flow Rate, lb/hr
Fuel
Quantity fuel, lb/hr
Quantity combustion air, lb/hr
Excess air leaving boiler, %
Efficiency, % (LHV Basis)
Quality of Steam leaving drum, ppm
Drum pressure, psig
Superheater pressure drop, psi
Water temperature leaving economizer, F
Economizer pressure drop, psi
Economizer inlet pressure, psig
Gas temperature leaving furnace, F
Gas temperature entering superheater, F
Gas temperature entering boiler section, F
Gas temperature entering economizer, F
Economizer outlet gas temperature, F
Gas temperature entering air preheater, F
Gas temperature leaving air preheater, F
Air temperature leaving air preheater, F
Forced draft fan discharge press, in. W. G.
Burner wind box inlet pressure in. W. G.
Furnace pressure, in. W. G.
Superheater outlet gas pressure, in. W. G.
Boiler section outlet gas pressure, in. W. G.
Economizer section outlet gas pressure, in. W. G.
Air pressure drop across air preheater, in. H2O
Gas pressure drop across air preheater, in. H2O
Heat release in furnace, Btu/ft3 -hr
Heat release in furnace, Btu/ft2 -hr
Heat absorption in furnace, Btu/ft2 -hr
Heat absorption in boiler section, Btu/ft2 -hr
Gas velocities through unit, ft/sec
a. F. D. Fan duct
b. Windbox
c. Superheater
d. Boiler passes
e. Economizer
f. Exhaust duct

General Note: For data reporting in SI units: Flow rate, (mass basis) in kg/s, Flow rate (volume basis) in m3/s,
Throughput (mass basis) in kg/h, Pressure in kPa, Temperature in C, Heat Release (Absorption) in
kW/m2 or kW/m3 as applicable, Velocity in m/s.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 Industrial Boilers IP 7-2-1
Page 13 of 13
(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

Revision Memo
9/68 Original Issue of Basic Practice
1/70 Revision 1
6/70 Revision 2
1/72 Revision 3
1/73 Revision 4
6/75 Revision 5
6/81 Revision 6
12/94 Revision 0 - Original Issue of International Practice
3/98 Revision 1
Complete editorial revision to rationalize this practice with the referenced standards and other IPs. Significant
changes include: Par. 2.1 IP 18-10-1 replaced IP 18-6-1. Deleted IPs 3-12-5, 3-12-7, 3-13-1, 3-14-2, 4-1-5 since
combined with other IPs and added IP 3-12-1 in Table 1. Par. 2.2 added IP 7-3-1 and deleted IPs 2-1-2, 4-1-6 and
18-1-1 in Table 2. Old Par. 2.3c deleted since IP 18-1-1 no longer exists. Par. 4.1g Added requirement to show
access and observation doors on proposed drawing. Par. 6.1 reworded to require proven designs. Par. 6.46a
deleted specific requirement for UV type detector. Par. 6.5 reworded to clarify intent; changed pressure requirement
to avoid potential for safety valve chattering. Par. 6.17 rewritten to reflect addition of IP 7-3-1 to Table 2. Old Pars.
11.2 & 11.3 deleted and requirement added to Paragraph 4.1g. Par. 6.28 asterisk added and also changed 200 ft to
100ft. Par. 6.35 second sentence deleted due to low value. Par. 6.51 - old Par. 17.6 deleted and requirement added
to Par. 6.51. Par. 8.1 replaced IP 18-6-1 with IP 18-10-1 and added maximum three hour hydrotest hold. Par. 9.1b
deleted specific efficiency guarantee conditions. Par. 9.1g added conditions for which ramp rates shall be guaranteed.
Deleted the following paragraphs from IP 7-2-1, Revision 0 due to commonly accepted practice or no justification: 1.4,
2.4, 3.1, 3.2, 3.3, 3.4, 3.7-13, 4.1a, 4.3i3, 5.1, 5.2, 5.4, 6.3, 6.6, 7.2, 7.3, 7.4, 7.6, 7.9, 7.10, 8.2 to 8.7, 9.4, 9.5, 10.3,
11.2, 11.3, 12.4, 14.6, 14.8, 14.9, 15.3, 15.4, 15.5b&c, 16.3, 17.1, 17.3, 17.6, 24.1, 24.2, 24.3, 24.4, Figures 1
through 3.
Paragraphs Renumbered
Old. Par. No. New Par. No. Old Par. No. New Par. No.
1.3 1.2 12.5 6.27
2.5 2.4 13.1 6.28
3.5 3.1 14.1 to 14.7 6.29 to 6.34
3.6 3.2 15.1 to 15.2 6.35 to 6.36
5.3 5.1 15.5 6.37
6.4 6.3 16.1 to 16.2 6.38 to 6.39
6.5 6.4 16.4 6.40
7.1 6.5 17.2 6.41
7.5 6.6 17.4 6.42
7.7 6.7 17.5 6.43
7.8 6.8 17.7 6.44
7.11 6.9 18.1 6.45
7.12 to 7.15 6.10 to 6.13 19.1 6.46
8.1 6.14 20.1 to 20.3 6.47 to 6.49
9.1 to 9.3 6.16 to 6.18 21.1 to 21.6 6.50 to 6.55
10.1 to 10.2 6.19 to 6.20 22.1 to 22.2 6.56 to 6.57
11.1 6.21 23.1 6.58
11.4 6.22 25.1 to 25.6 7.1 to 7.6
12.1 6.23 26.1 to 26.4 8.1 to 8.4
12.2 to 12.3 6.25 to 6.26 27.1 9.1

 Exxon Research and Engineering Company, 1994, 1998

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.