TECHNICAL SPECIFICATION

FABRICATION REQUIREMENTS FOR BOILER

COILS AND JUMPOVERS
(ASME SECTION I) MB21-4F

DATE: 01 JUL 2004 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
2. COMPONENTS AND MATERIALS ...............................................................................................2
2.1 Tubes and Fittings ..........................................................................................................................2
2.2 Intermediate Tube Supports ...........................................................................................................2
2.3 End Tube Sheets and Coil Lifting Beams.......................................................................................2
3. FABRICATION ...............................................................................................................................2
3.1 General ...........................................................................................................................................2
3.2 Welding ...........................................................................................................................................2
3.3 Examination of Welds .....................................................................................................................4
3.4 Preheat and Postweld Heat Treatment ..........................................................................................4
3.5 Tolerances ......................................................................................................................................4
3.6 Bending...........................................................................................................................................4
4. TESTING AND INSPECTION ........................................................................................................6
4.1 Hydrotest.........................................................................................................................................6
4.2 Inspection........................................................................................................................................6
4.3 Alloy Verification .............................................................................................................................6
5. CODE STAMPING AND MANUFACTURER'S DATA REPORTS ................................................6
5.1 Complete Fabricated Coils and Jumpovers....................................................................................6
5.2 Partial Fabricated Coils and Jumpovers ........................................................................................7

1. GENERAL

1.1 Scope

This Specification, KBR Purchasing Standards MB2-1PS and SDR-2MB-2, cover the requirements for
fabrication, testing, inspection, stamping, and certification of boiler coils and jumpovers designed in
accordance with ASME Section I. Mandatory codes, governmental rules, and regulations specified in the
Purchase Order are referred to in this specification as the Code. Any modifications to this specification and
applicable abbreviations are in accordance with KBR Technical Standard MB15-1TS. (Note: KBR will be
referred to as the Purchaser.)

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 for Industry Standards and Codes
shall be as indicated in KBR Technical Standard MB15-1TS.

KBR DOCUMENTS
2-1TS, "Alloy Verification"
4-7TS, "General Welding Requirements"
MB2-1PS, "Purchasing Requirements for Furnace Materials, Components and Equipment"
MB11-1TS, "Installation of Furnace Castable Linings (Shop or Field)"
MB15-1TS, "General Furnace Specification"
SDR-2MB-2, "Supplier Data Requirements - Fabricated Furnace Components"

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Boiler and Pressure Vessel Code

Section I, "Power Boilers"

 TECHNICAL SPECIFICATION
FABRICATION REQUIREMENTS FOR BOILER
COILS AND JUMPOVERS
(ASME SECTION I) MB21-4F

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 7

Section II, "Material Specifications"

Part A - "Ferrous Materials"

ASME SA-370, "Test Methods and Definitions for Mechanical Testing of Steel Products"

Section VIII, "Pressure Vessels, Division 1"

2. COMPONENTS AND MATERIALS

2.1 Tubes and Fittings

Unless otherwise noted on the Purchase Order, all materials designated by mark numbers on Purchaser
Design Drawings and listed in the Bill of Material, will be supplied by the Purchaser and shipped to the
fabricator. Balance of materials needed to complete the scope shall be supplied by the fabricator. Material
supplied shall conform to the specifications listed under Article 1.2 and on the Purchaser Design Drawings.

2.2 Intermediate Tube Supports

Unless otherwise noted on the Purchase Order, intermediate tube supports, when shown and specified on
Purchaser Design Drawings will be supplied by the Purchaser and shipped to the fabricator.

2.3 End Tube Sheets and Coil Lifting Beams

2.3.1 End tube sheets including insulation and coil lifting beams when shown and specified on Purchaser
Design Drawings shall be supplied by the fabricator.

2.3.2 The insulation and anchorage for end tube sheets shall be furnished by the fabricator as specified on
the Purchaser Design Drawings. Technical data sheets of the proposed proprietary castables must be
submitted to the Purchaser for approval prior to using the material.

3. FABRICATION

3.1 General

3.1.1 Coils, including end tube sheets and intermediate tube supports, and jumpovers shall be fabricated
into assemblies or modules as detailed on Purchaser Design Drawings.

3.1.2 Fabrication of coils and jumpovers shall be in accordance with ASME Section I.

3.1.3 When coil is furnished in a complete module, steel and refractory shall be in accordance with
Purchaser Design Drawings and specifications as listed in the Purchase Order.

3.1.4 Proprietary insulating castable for end tube supports (when applicable) shall be applied in accordance
Purchaser Technical Standard MB11-1TS and Purchaser Design Drawings.

3.2 Welding

3.2.1 Welding and selection of electrodes and weld wires shall be in accordance with Purchaser Technical
Standard 4-7TS, the fabrication Code and the following, unless otherwise noted on Purchaser Design
Drawings:

a. The root pass shall be made using the Gas-Tungsten Arc Welding (GTAW) process.
 TECHNICAL SPECIFICATION
FABRICATION REQUIREMENTS FOR BOILER
COILS AND JUMPOVERS
(ASME SECTION I) MB21-4F

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 7

b. The weld surface and the adjacent base metal shall be free of all welding slag. Slag may be removed
by stainless steel wire brushing or grinding, using tools that have not been used on other materials.

c. All buttwelds and nozzle welds shall have complete penetration.

d. Backing rings shall not be used.

e. The buttweld reinforcement shall not exceed 1/16 inch (1.6 mm) and shall blend smoothly into adjacent
surfaces.

f. Maximum internal weld protrusions shall be limited as follows unless otherwise noted on Purchaser
Drawings and in no case to exceed ASME Section I requirements of PW-35.

1. For tMW ≤ 1/4 inch (6.4 mm), protrusion ≤ 1/16 inch (1.6 mm)

2. For tMW > 1/4 inch (6.4 mm) and <1/2 inch (12.7 mm), protrusion ≤ 1/8 inch (3.2 mm)

3. For tMW ≥ 1/2 inch (12.7 mm), protrusion ≤ 1/8 inch (3.2 mm) except for limited lengths
(approximately 1/2 inch (12.7 mm) long) where 5/32 inch (4 mm) protrusion maximum is
permissible.

g. For pipes smaller than 2.5 inch O.D. or wall thickness under 1/4 inch (6.4 mm), the misalignment shall
be restricted to 1/32 inch (0.8 mm). Misalignment of the inside diameters shall not exceed 1/16 inch (1.6
mm) for pipe over 2.5 inch O.D. or wall thickness over 1/4 inch (6.4 mm). Misalignment shall be no
greater than as allowed in Table PW-33 of ASME Section I.

h. Arc strikes on the tubes shall be avoided. If any occurs, the surface shall be properly conditioned to
eliminate surface stress raisers and shall be examined by liquid penetrant or magnetic particle
examination, as applicable for the material. Repairs to the pressure parts shall not reduce thickness
below minimum required thickness.

i. Coils shall be progressively blown out as each weld is completed and care exercised to prevent
entrance of extraneous matter.

j. The weld surface shall be free of ripples and undercuts to permit examination by radiography and liquid
penetrant or magnetic particle method with unhindered interpretation of any indication of defects. Weld
contours and finish which do not comply with these requirements shall be ground to a finish of
approximately 250 µ in. Ra (6.3 µm Ra).

k. The weld metal shall be ground smooth to the outside contour of the tubes when a centerweld coincides
with an intermediate tube support.

3.2.2 Tube ends or nozzles for field welds shall be prepared in accordance with the dimensions and styles
specified on Purchaser Design Drawings.

3.2.3 The Gas Metal Arc Welding (GMAW) process utilizing the "short circuiting" metal transfer mode shall
not be used.

3.2.4 Nozzle welds shall be of a "set-on" type as shown in ASME Section I, PW-16, Fig. PW-16.1a.

3.2.5 Each reinforcing pad or separately welded portion of the pad shall have 1/4 in. (6 mm) NPT vent hole
drilled and tapped prior to installation of the pad.
 TECHNICAL SPECIFICATION
FABRICATION REQUIREMENTS FOR BOILER
COILS AND JUMPOVERS
(ASME SECTION I) MB21-4F

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 7

3.3 Examination of Welds

3.3.1 Welds shall be examined in accordance with requirements of ASME Section I.

3.3.2 Radiographic procedure and acceptance criteria shall be in accordance with Paragraph UW-51 of
ASME Section VIII, Division 1. Radiographic examination procedure shall be submitted for review and
approval by Purchaser prior to commencement of the work.

3.3.3 All welds, including structural attachments on austenitic materials shall be examined by liquid
penetrant method on all accessible finished weld surfaces in accordance with ASME Section VIII, Division I,
Appendix 8.

3.3.4 Nozzle welds and structural attachments to ferritic alloy steels shall be checked by magnetic particle
method in accordance with ASME Section VIII, Division I, Appendix 6.

3.3.5 Repair welds shall be reheat treated if originally required, and re-examined by the original inspection
method.

3.3.6 For 9Cr-1M0-V material, hardness testing of all welds and heat affected zones, including structural
attachments, shall be required and shall be in accordance with ASME SA-370. Production hardness shall
not exceed 241 BHN.

3.4 Preheat and Postweld Heat Treatment

3.4.1 Preheat and postweld heat treatment (PWHT) shall be in accordance with ASME Section I. Postweld
heat treatment temperature shall not exceed the lower of the values specified in Table I, Note 1, a, b, and c.

3.4.2 Local postweld heat treatment shall not be performed without prior written agreement of the
Purchaser.

3.4.3 Nozzle welds shall be postweld heat treated.

3.4.4 Support attachments on piping to be heat treated shall be welded on prior to the heat treatment.

3.4.5 For welding, preheat and postweld heat treatment of 9Cr-1Mo-V material refer to the requirements of
Purchaser Technical Standard 4-7TS, Paragraph 4.2.2.

3.4.6 Prior to start of fabrication of 9Cr-1Mo-V material, a “Runoff” or “Duplicate” proof sample is required to
confirm that the rough thickness microhardness traverses actually meet softing criteria. The maximum
Vickers Hardness shall be 252 for weld and heat affected zone. Hold time for postweld heat treatement may
be increased beyond the 3 hours minimum to achieve specified hardness.

3.5 Tolerances

Tolerances on overall dimensions of an unrestrained completed coil assembly shall not exceed:

+1/4 inch (6 mm) - 0 inch (0 mm) for overall dimensions up to 20 feet (6 m).

+3/8 inch (9.5 mm) - 0 inch (0 mm) for overall dimensions over 20 feet (6 m).

3.6 Bending

3.6.1 The bending of the coils and jumpovers shall be done in either the hot or cold condition and shall
conform to the requirements of Table I. All bends shall be free of wrinkles, bulges, kinks, and other serious
defects (detectable by visual inspection) and shall meet out-of-roundness requirements of ASME Section I.
 TECHNICAL SPECIFICATION
FABRICATION REQUIREMENTS FOR BOILER
COILS AND JUMPOVERS
(ASME SECTION I) MB21-4F

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 7

3.6.2 Heat treatment after bending is required in accordance with Table I and it shall conform to the
requirements of Table II.

TABLE I - HEAT TREATMENT REQUIREMENTS AFTER BENDING

Type of Material Cold Bending Hot Bending
Normalize and temper to conform
1-1/4% to 9% Cr-Mo None
to mill test report heat treatment
Alloy 800 HT (UNS N08811) Solution Anneal Solution Anneal

ASME Type 310H Solution Anneal Solution Anneal

NOTES TO TABLE I:

1. Bending is defined as cold for austenitic materials when the temperature is 1100 oF (593 oC) or under.
Bending is defined as cold for ferritic materials when the temperature does not exceed the lower of the
following values:

a. Maximum temperatures for postweld heat treatment as defined in the applicable Code.

b. The tempering temperature of mill test report test pieces and components, if tempering was
performed.

c. The following temperatures for the listed materials:

1375 oF (746 oC) for 1 1/4% to 9% Cr-Mo Steel

2. Bending is defined as hot for ferritic materials when above 1600 oF (871 oC) and hot for austenitic
materials when over 1100 oF (593 oC). Bending and forming shall not be performed on ferritic materials
at temperatures between the maximum cold temperature and 1600 oF (871 oC).

TABLE II - HEAT TREATING REQUIREMENTS AFTER BENDING

Type of Soaking Temp. Method of
Heat Treatment o Holding Time Hours
Material F (oC) (Note 1) Cooling
Alloy 800 HT
2100 (1150)
(UNS N08811) 1 per in.(25 mm) of Water Quench
Solution Anneal
ASME thickness but not less than 1 or Air Blast
2100 (1150)
Type 310H
1 per in.(25 mm) of
1-1/4% to 9% 1650 to 1750
Normalize thickness but not less than Still Air
Cr-Mo (899 to 954)
1/2
1-1/4% to 9% 1300 to 1400 1 per in. (25 mm) of
Temper thickness but not less than 1 (Note 2)
Cr-Mo (704 to 760)

NOTES TO TABLE II:

1. Uniformity of the heat treatment temperature shall be verified by calibrated thermocouples attached to
the parts. At least two thermocouples are required. One each shall be located at the expected hottest
and coldest portion of the part or batch being heat treated. Satisfactory evidence shall be furnished by
the fabricator that the thermocouples were checked before and after heat treatment of the material and
that the thermocouples and temperature recorder were found to be properly calibrated to within 5 oF
(2.8 oC) of the actual temperature in the specified range.
 TECHNICAL SPECIFICATION
FABRICATION REQUIREMENTS FOR BOILER
COILS AND JUMPOVERS
(ASME SECTION I) MB21-4F

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 7

2. After attaining the soaking temperature and maintaining the required holding time, the cooling time to
800 oF (427 oC) shall not be less than one hour.

4. TESTING AND INSPECTION

4.1 Hydrotest

4.1.1 Upon completion of fabrication to the extent indicated on Purchaser Design Drawings, coils and
jumpovers shall be hydrostatically tested at a pressure specified on Purchaser Design Drawings. The
pressure shall be continuously maintained for a minimum of 10 minutes and shall then be reduced by a
factor of 1.5 and maintained till such time as may be necessary to conduct examination for leakage.
Examination for leakage shall be made at all joints and shall show no evidence of weeping or leakage.

4.1.2 Water used for testing shall be clean and potable. Maximum chloride content shall be 50 ppm where
the coil or jumpover is drainable. Maximum chloride content for hydrotest of austenitic steel coil shall be
5 ppm if the coil is not completely drainable.

4.1.3 After testing, coil and jumpover shall be dried out, cleaned inside and outside of all loose scale, dirt,
sand, weld splatters, etc., and capped or sealed for shipment. If air is used to dry austenitic materials, it shall
not be hot to avoid stress corrosion cracking. Desiccants or internal coating shall not be used.

4.1.4 When chemical cleaning is necessary, the requirements will be specified on Purchaser Design
Drawings or in the Purchase Order.

4.2 Inspection

4.2.1 General

All phases of fabrication are subject to observation and review by the Purchaser's Inspector. The
Purchaser's Inspector shall be allowed to witness any part of the examination and testing at his request.

4.2.2 Code Inspection

a. Equipment conforming to ASME Section I, or other codes, governmental, or state rules and regulations
within the United States or Canada, and fabricated within the United States, shall be inspected by an
authorized inspector as defined in Paragraph PG-91 of ASME Section I.

b. A National Board stamping will be done when specified depending on Client or jurisdiction requirement.
Otherwise, stamping is normally not required.

4.3 Alloy Verification

Alloy verification and its extent shall be in accordance with Purchaser Technical Standard 2-1TS and as
specified on Purchaser Design Drawings.

5. CODE STAMPING AND MANUFACTURER'S DATA REPORTS

5.1 Complete Fabricated Coils and Jumpovers

If the coil/jumpover is shop fabricated complete from inlet to outlet, the shop fabricator shall provide ASME
code stamping, when code stamping is specified on Purchaser Drawings. Code stamping shall be in
accordance with ASME Section I, Paragraph PG-106 and Manufacturer's Data Report Form P-3 as the
manufacturer.
 TECHNICAL SPECIFICATION
FABRICATION REQUIREMENTS FOR BOILER
COILS AND JUMPOVERS
(ASME SECTION I) MB21-4F

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 7

5.2 Partial Fabricated Coils and Jumpovers

If the coil/jumpover is shop fabricated in sections for field assembly, the shop fabricator shall provide ASME
"S" symbol stamping, when code stamping is specified on Purchaser drawings. Code stamping shall be in
accordance with ASME Section I, Paragraph PG 106.8 on each part and manufacturer's Data Report
Form P-4.