TECHNICAL SPECIFICATION

BURNERS FOR PYROLYSIS FURNACES

MB43-1E

DATE: 01 AUG 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 7

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 KBR Documents, Codes, and Industry Standards .........................................................................1
1.3 Quotation Requirements.................................................................................................................1
1.4 Seller's Guarantee ..........................................................................................................................2
1.5 Drawings and Data to be Furnished by the Seller ..........................................................................3
2. DESIGN ..........................................................................................................................................3
2.1 General ...........................................................................................................................................3
2.2 Connections ....................................................................................................................................4
2.3 Pilot Burner .....................................................................................................................................4
2.4 Noise Suppression..........................................................................................................................4
2.5 Ganged Damper Linkage System...................................................................................................4
3. MATERIALS ...................................................................................................................................5
3.1 General ...........................................................................................................................................5
4. TESTING ........................................................................................................................................6
4.1 Shop Performance Demonstration .................................................................................................6
4.2 Field Performance Testing..............................................................................................................6
4.3 Material Testing ..............................................................................................................................7
5. INSPECTION ..................................................................................................................................7

1. GENERAL

1.1 Scope

This specification and KBR Purchasing Standard MB2-1PS cover the requirements for burners used in pyrolysis
furnaces.

1.2 KBR Documents, Codes, and Industry Standards

The following documents are referenced herein and form part of the Order. Additional KBR documents, when
applicable, will be listed in the Requisition. Applicable dates of issue of industry standards and codes shall be
as indicated in the KBR Technical Standards MB15-1TS.

KBR DOCUMENTS
MB2-1PS, "Purchasing Requirements For Furnace Materials, Components, and Equipment"
SDR-2MB-6, "Supplier Data Requirements Engineered Equipment"

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B31.3, "Process Piping"

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM C20, "Apparent Porosity, Water Absorption, Apparent Specific Gravity, and Bulk Density
of Burned Refractory Brick and Shapes by Boiling Water"
ASTM C133, "Cold Crushing Strength and Modulus of Rupture of Refractories"
ASTM C401, "Classification of Alumina and Alumina-Silicate Castable Refractories"

1.3 Quotation Requirements

1.3.1 The quotation shall specify the type of burner to be furnished, including a tabulation of unit prices for each
of the following items, when applicable:

a. burner assembly, plenum and burner tile

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BURNERS FOR PYROLYSIS FURNACES

MB43-1E

DATE: 01 AUG 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 7

b. pilot burner

c. noise suppression materials and/or equipment

d. ignitor

e. ganged damper linkage system

f. covers made of plywood (or similar) to protect the burner tile during construction.

1.3.2 The Bidders quotation shall include all drawings and data required by SDR-2MB-6, Groups A1, A4, B2,
B4 and D1, suitable for use by the Purchaser to proceed with engineering work prior to receipt of certified final
drawings.

1.3.3 The Bidder shall furnish all information required by the Purchaser to make the burners operational. In
addition, the following items are required:

a. Requirements for modifications (if any) to the Purchaser's air inlet system, or burner arrangement to comply
with Seller's Guarantees of Article 1.4.

b. Provisions for replacement of critical burner parts during operation, or in lieu of this, specific
recommendations for maintenance.

c. Noise level data as specified in the requisition documents.

1.3.4 The Seller shall be responsible for requesting additional information, not provided in the Purchaser's
requisition, necessary for Supplier to meet emissions, and all other Seller Guarantees of Article 1.4.

1.3.5 The Bidder shall provide a description of the test facility and an outline of the test program to comply with
the requirements of Article 4.1.

1.3.6 The Bidder shall provide an experience list for the proposed burner and its application.

1.3.7 The Bidder shall confirm compliance with the Seller's Guarantee as specified in Article 1.4.

1.3.8 The Bidder shall define and be responsible for field inspections by their representative to ensure that
performance guarantees will be met in the field.

1.4 Seller's Guarantee

The Seller shall guarantee the following:

a. Final acceptance of the burner shall be based upon burner performance in the Owner's furnace.

b. The burner will perform in accordance with the Data Sheet requirements.

c. Burners shall not exceed the maximum allowable emissions level, specified in the Burner Data Sheet, at
any time during the warranty period when tested in accordance with the methods referenced in Article 4.2.

d. Mechanical integrity and performance of the burner and ganged damper assembly operating in concert
when installed in accordance with the Seller's drawings for duration of warranty period.
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BURNERS FOR PYROLYSIS FURNACES

MB43-1E

DATE: 01 AUG 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 7

1.5 Drawings and Data to be Furnished by the Seller

The Seller shall furnish all drawings and data as defined in SDR-2MB-6.

2. DESIGN

2.1 General

2.1.1 Burners shall be designed to meet the requirements as specified on the Burner Data Sheet when firing
within the range of fuel compositions, combustion air compositions, excess air and draft.

2.1.2 Burner design shall consider burner spacing and clearances from furnace tubes and refractory walls
needed to prevent flame impingement on tubes. Fuel ports shall not be angled toward radiant tubes without
prior review and acceptance from KBR.

2.1.3 Burner tips shall be provided with a positive means of support.

2.1.4 Burner tiles shall be provided with adequate means of support, anchorage and positive location. A means
of correctly locating the burner tile, during and after installation, with respect to the burner tips and furnace
setting shall be provided; normally a tray is provided which holds the tile in the correct position. If a tray is
provided it should form a structural part of the burner and the burner should be supplied, and shipped, as a
one-piece pre-assembled unit with the tile mounted in the tray.

2.1.5 Burners not connected to a common combustion air duct shall be designed to minimize wind effects and
to prevent rain from entering the burner plenum. Typically, the burner air intake shall be oriented to face the
furnace casing. Ambient air intakes shall be covered with a removable metal screen to prevent debris from
entering.

2.1.6 All burner tips and the pilot burner shall be removable for maintenance during furnace operation. Burner
tip/gas gun assemblies shall be interchangeable with similar assemblies of other identical burners in the same
order. Burner tip/gas gun assemblies shall be self-locating so that burner tips will be correctly positioned with
respect to tile, wall and adjacent burner tips when installed from burner platform.

2.1.7 When ganged dampers are not required, the air plenum damper shall be controlled with a spring loaded
hand lever which positively locates the damper and accurately indicates the damper position. Dampers shall be
supported by sealed, self-lubricating bearings.

2.1.8 At design heat liberation, excess air and draft, the air plenum damper shall be no greater than 80º open.

2.1.9 Burner plenum chamber faceplate, on which burner guns are normally mounted, shall be designed to be
completely removable such that the entire cross section of the horizontal plenum is exposed when the faceplate
is removed.

2.1.10 A sight port shall be provided to verify ignition. For forced draft combustion air systems with air preheat
the sight ports shall include a glass cover.

2.1.11 A manual lighting port with cover shall be provided, independent of the sighting port.

2.1.12 An NPS 3/4 pressure tap with plug shall be provided on the face plate downstream of the inlet box
damper to balance air flows. During air flow balancing a probe of sufficient length to reach the burner-to-furnace
mounting flange will be inserted through the pressure tap. The pressure tap therefore shall be located such that
there are no obstructions, inside the plenum, which would prevent insertion of the probe to the vicinity of the
burner-to-furnace mounting flange.
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BURNERS FOR PYROLYSIS FURNACES

MB43-1E

DATE: 01 AUG 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 7

2.1.13 Internal insulation shall be provided to reduce heat leak and/or for noise suppression. Unless otherwise
noted, the insulation thickness shall be sufficient to result in a maximum casing plate temperature of 150ºF
(66ºC) based on 5 mph wind (2.25 m/sec), 80ºF (27ºC) ambient temperature and 0.95 emissivity.

2.1.14 All external carbon steel surfaces of burner housing shall be shop primed in accordance with Kellogg
Brown & Root Coating Specifications.

2.2 Connections

There shall be only one flanged Purchaser connection point for gas fuel, pilot fuel, and oil fuel per burner.
Distribution piping of fuel to burner tips, from the single Purchaser connection, is the responsibility of the burner
Supplier.

2.3 Pilot Burner

2.3.1 A pilot is required on each burner, if specified on the Burner Data Sheet. Unless otherwise noted, it shall
be a manually ignited, continuous, self-inspirating gas pilot with 25 000 kcal/hr (100 000 BTU/hr) minimum heat
release.

2.3.2 Pilot must maintain flame stability at all operating ranges of combustion air, excess air and draft specified
on the Burner Data Sheet.

2.3.3 Pilot shall be located to reliably light all burner tips at all operating ranges of combustion air, excess air
and draft specified on the Burner Data Sheet.

2.4 Noise Suppression

Unless otherwise noted, the maximum A-weighted sound level shall be 85 dBA 1 m (3 feet) from the burners.
The sound level shall be based on the resultant level with multiple burners in the installed configuration. When
this cannot be obtained, Seller shall recommend noise suppression devices to be provided and the noise level
to be attained by this recommendation.

2.5 Ganged Damper Linkage System

2.5.1 When specified on the Burner Data Sheet, the dampers on each side of a furnace shall be ganged
together and controlled with a pneumatic actuator. The following are specific requirements for ganged dampers:

a. A separate pneumatic actuator is required on each side of a furnace with sidewall mounted burners, i.e.,
two (2) actuators per furnace.

b. The damper actuator shall hold last position upon loss of plant air supply.

c. The damper actuator shall fail closed on loss of signal air.

d. The damper actuator shall be supplied with a field adjustable mechanical minimum stop.

e. The actuator positioner shall be supplied with a position transmitter. Output shall be 4-20 mA signal
(open-close).

f. The actuator shall be bolted to the furnace vertical column at a location approved by the Purchaser,
preferably at the centerline of the furnace.

g. The actuator shall be connected to the jackshaft with an adjustable linkage. This linkage shall be NPS 1/2
(minimum) carbon steel pipe.
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BURNERS FOR PYROLYSIS FURNACES

MB43-1E

DATE: 01 AUG 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 7

h. The jackshaft shall be 75 mm (3 inch) OD (minimum) carbon steel tube with sealed ends. Individual
jackshaft sections shall be connected with heavy duty universal joints to minimize problems with
misalignment.

i. The jackshaft sections shall be supported with split sleeve grease lubricated bearings in two-piece pillow
blocks. Pillow blocks shall be bolted to furnace columns. Pillow blocks shall have slotted mounting holes to
accommodate vertical adjustment.

j. The linkage from the jackshaft to the burner damper shall be NPS 1/4 (minimum) carbon steel pipe
complete with rod end ball joints capable of a quick disconnect from the burner. This linkage shall be
designed to permit individual burner damper adjustment without disconnecting the linkage.

k. Dampers shall be supported by sealed, self-lubricating bearings.

2.5.2 The pneumatic actuator shall be the following model or an approved equivalent:

Manufacturer Catalog Reference Model No.

Bailey Control Systems P81-20 (1984) UP20-1-1-1-1-* (* - by Supplier)

2.5.3 Unless otherwise noted, the actuators, positioners and all linkages, shafts, bearings, shims and mounting
hardware shall be supplied by the Seller.

3. MATERIALS

3.1 General

3.1.1 All materials shall be of the Seller's selection, suitable for the imposed temperature and operating
conditions except as noted herein. Materials of construction, with the applicable ASTM or equivalent material
specification, shall be specified on the drawings.

3.1.2 Burner tiles shall be cast from a refractory castable with a minimum temperature rating of 3000ºF
(1650ºC), a nominal 60% by weight alumina content. Burner tiles shall be shop cured and dried. Supplier to
submit time and temperature for shop curing and drying of tiles.

3.1.3 Burner tile pieces used as lintels shall contain UNS N08330 (Type 330) stainless steel needles. The
needle content shall be 3% minimum to 4% maximum by weight.

3.1.4 External piping materials shall be supplied in accordance with Kellogg Brown & Root Piping Material
Specifications or other specifications supplied by Purchaser. External piping shall be supplied, fabricated,
tested, and inspected in accordance with ASME B31.3.

3.1.5 Internal piping such as burner tip leads, risers, etc., shall be, as a minimum, pipe Schedule 80 or
equivalent. Supplier shall specifically note any exceptions in the proposal.

3.1.6 Minimum plate thickness for the plenum chamber or wind box shall be 3.42 mm (10 gage).

3.1.7 Minimum plate thickness for the plenum damper shall be 3.42 mm (10 gage).
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BURNERS FOR PYROLYSIS FURNACES

MB43-1E

DATE: 01 AUG 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 7

3.1.8 Internal insulation shall consist of mineral fiber material covered by flattened expanded metal in all
locations except within one half damper blade width of the air plenum damper which shall be internally lined with
sheet metal. The expanded metal may be a galvanized steel up to 260ºC (500ºF) and shall be stainless steel
above 260ºC (500ºF). Minimum thickness, after flattening, shall be 0.76 mm (22 Gage). The maximum slot
width of the expanded metal (measured from center to center of bonds) shall be 12.7 mm (1/2 inch). Insulation
anchors shall be welded pins with an integral, non-removable, washer head of 25 mm (1 inch) minimum
diameter. Anchor material shall be stainless steel. Anchors shall be located on a maximum of 225 mm (9 inch)
centers.

3.1.9 Burner tips shall be of 310 stainless steel or Purchaser approved alternate material.

4. TESTING

4.1 Shop Performance Demonstration

4.1.1 A burner performance demonstration shall be conducted by the Seller in the presence of a KBR Furnace
Engineer and the Purchaser at the Seller's facility. The demonstration shall quantify operating characteristics
and verify compliance with design guidelines. An outline of the demonstration program requirements is as
follows:

a. The design heat release shall be verified for the fuels specified on the Burner Data Sheet.

b. NOx emissions, excess oxygen and CO in the flue gas shall be recorded.

c. The flame size, stability, and characteristics shall be demonstrated for the full range of operation. Flame
stability shall be demonstrated at a pressure which is a minimum of 0.7 kg/cm2g (10 psig) higher than that
required for the design heat release.

d. Turndown capability shall be verified.

e. Fuel and air pressure drops and damper position shall be recorded.

f. The minimum acceptable level of excess oxygen shall be determined.

g. Pilot lighting and stability shall be verified.

4.1.2 Performance demonstration shall be conducted as near to installed furnace conditions as possible. A
high velocity thermocouple shall be used to measure the temperature of the recirculated flue gas within the
Seller's furnace. Temperature measurements shall be taken at the floor and radiant box outlet.

4.1.3 The demonstration burner shall be instrumented to separately measure pressure drop across the damper
and across the burner throat.

4.2 Field Performance Testing

4.2.1 Burner performance testing will be conducted after installation in the Owner's facility. Burner
characteristics demonstrated at the Seller's facility will be confirmed in the field performance test.
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BURNERS FOR PYROLYSIS FURNACES

MB43-1E

DATE: 01 AUG 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 7

4.2.2 Emissions compliance stack testing, if specified on the Burner Data Sheet, shall be performed at the
Owner's facility after furnace operations have stabilized. Details of the testing procedure will be given in the
Burner Data Sheet. The compliance test shall be conducted at, or as close as practical to, the maximum design
capacity and normal operational load when burning the "Normal" plant fuel gas. Refer to the Burner Data Sheet
for composition of the "Normal" plant fuel gas as given in the Burner Data Sheet. The compliance tests will be
conducted over a range of excess air levels encountered during normal furnace operations.

4.3 Material Testing

4.3.1 Supplier shall quote acceptance criteria. During manufacture of the burner tile the following tests shall be
performed at the frequencies indicated:

a. Density - ASTM C20, one test per batch.

b. Cold Crushing Strength - ASTM C133, one test per batch.

c. The allowable deviations from the published information are as follows:

Deviation
Density ± 5%
Cold Crushing Strength -10%

4.3.2 If material testing indicates a failed sample, the material represented by that sample is not acceptable.

5. INSPECTION

Burners shall be subject to the following shop inspections. The fit-up inspection shall be witnessed by a
KBR representative prior to acceptance/shipment.

a. Dimensional check on 100% of burner tiles.

b. Dimensional check on 50% of burner connection bolting pattern layouts. If any discrepancies arise out of
this check, all 100% must be checked.

c. Shop fit-up on 100% of burner assemblies. Burner assemblies refers to gas burner tips and leads, pilot
burner tips and leads, oil guns and any additional assemblies mounted on the burner plenum chamber face
plate and protruding into the burner plenum. Shop fit-up to check burner assemblies within a dimensionally
accurate tile and burner plenum representing the installed furnace dimensions.

d. Flow test on 100% of assembled burners. Permissible flow variation shall be ± 2% when complete burner
assemblies are tested at the same, constant supply pressure.

e. Demonstrate removal and re-installation of burner tip assemblies and confirm re-installed burner tips are
correctly located with respect to tile, wall and adjacent burner tips.