TECHNICAL SPECIFICATION

FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 8

TABLE OF CONTENTS

Section Title Page No.

INTRODUCTION ............................................................................................................................1
1. General...........................................................................................................................................1
2. Design Considerations.................................................................................................................2
3. Tubes .............................................................................................................................................3
5. Piping, Terminals, and Manifolds................................................................................................3
6. Tube Supports...............................................................................................................................3
7. Refractories and Insulation .........................................................................................................3
8. Structures and Appurtenances ...................................................................................................4
9. Stacks, Ducts and Breeching ......................................................................................................5
10. Burners, Sootblowers and Damper Controls.............................................................................6
12. Instrument and Auxiliary Connections.......................................................................................7
13. Shop Fabrication and Field Erection ..........................................................................................7
14. Inspection, Examination, and Testing ........................................................................................7

INTRODUCTION

KBR requirements for fired heaters for general refinery service correspond to those of API Standard 560
Fired Heaters for General Refinery Services, Third Edition, May 2001, with the specific (Add), (Substitute),
(Revise), (New), and (Delete) listed herein. (Note: KBR will be referred to as the Purchaser.)

The paragraph numbers in this specification correspond to those used in API Standard 560. Paragraph
numbers may not be consecutive. All API paragraphs not addressed herein shall be considered verbatim
requirements of this specification.

Instructions contained in this specification shall be interpreted as follows:

"(Add)" denotes requirements which shall be added to the referenced API STD 560 paragraph and shall be
read as a continuation of the API paragraph.

"(Substitute)" denotes requirements which shall replace the referenced API STD 560 paragraph in its
entirety.

"(Revise)" denotes a slight revision to the referenced API STD 560 paragraph. A single sentence in the
paragraph may be revised; the remainder of the paragraph shall be read verbatim.

"(New)" denotes an added KBR requirement. The existing API STD 560 makes no reference to this
paragraph number.

"(Delete)" denotes an API STD 560 paragraph which may be deleted; KBR does not require compliance to
these paragraphs.

NOTE: U.S. customary units shall be regarded as standard. Metric units are referenced in API STD 560;
this supplement shall be used for convenience only and shall not be interpreted as precise conversions.

1. General

1.6 NORMATIVE CODES AND STANDARDS

1.6.2 (Substitute first paragraph) The Supplier shall be responsible for complying with the mandatory
requirements of all codes, regulations, ordinances, and statutes of all municipal, provincial, state, and
national bodies having jurisdiction at the location where the items are to be installed.
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FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 8

1.8 PROPOSALS

1.8.2 Vendor's Responsibilities

h. (Add) Agreed upon, firm shipping dates for shipment of multiple sections.

j. (New) Lists from which Subcontractors for steel fabrication, coil fabrication, refractory installation, and
heater erection (if included in scope of supply) will be selected by the manufacturer after Purchaser's
acceptance.

k. (New) For component fabrication to conform to the ASME Code, the Bidder shall confirm compliance
with the following:

1. Bidder has authorization and is taking responsibility for applicable codes/stamps.

2. If the complete unit is required to be stamped "National Board", Bidder shall also be registered with
the "National Board".

1.9 DOCUMENTATION

(Add) Supplier shall submit all documents in accordance with Purchaser's Supplier Data Requirements as
listed in SDR-1MB and SDR-2MB-8. (Their issue dates listed in attachment index and included in the
Requisition.)

1.9.3 Documents for Purchaser’s Review

l. (New) Supplier shall submit procedure for radiant tube replacement.

2. Design Considerations

2.1 PROCESS

2.1.5 (New) Where vapor and liquid phases coexist in the heater coil, Supplier shall advise purchaser of
predicted flow regimes. Supplier shall design the heater for stable flow conditions over the complete range
of predicted operating flow rates and heat inputs. In quotation, Supplier shall state heater outlet velocity (as
a % of sonic) used in proposed design.

2.1.6 (New) Collection and distribution manifolds on multipass heaters shall be sized so that the frictional
head loss over the total manifold length, based on a constant velocity equal to the maximum (inlet) velocity,
does not exceed 10% of the individual pass pressure drop.

2.2 COMBUSTION

2.2.2 (Add) Heater efficiency shall be based on 60 oF (15.6 oC) ambient air temperature at 50% relative
humidity.

2.3 MECHANICAL

2.3.4 (Add) When the convection section has more than one service, the location of the additional rows
shall be selected to give maximum flexibility in future modifications. Header boxes shall be accordingly
designed and provided. Plugs for future rows end tube sheets shall be easily removable.

2.3.9 (Add) Provide adequate clearance beneath heater to permit safe operation and maintenance.
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FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 8

3. Tubes

3.1 GENERAL

3.1.1 (Add) Creep rupture allowable stress values shall be determined based on 100,000 hour design life,
unless otherwise stated in the API data sheet.

3.1.4 (Add) Where helical or circular coils are formed from more than one tube length, the tube length shall
be buttwelded prior to bending to the final shape.

3.2 EXTENDED SURFACE

3.2.1 (Add) Only high-frequency resistance welding shall be used for attaching fins to the tubes.

3.2.4 (New) Extended surfaces shall be studs or fins. Tube spacings providing less than 1 inch (25 mm)
minimum clear space between extended surfaces of adjacent tubes or between extended surface and
refractory require Purchaser's review and acceptance.

5. Piping, Terminals, and Manifolds

5.1 GENERAL

5.1.2 (Add) All flanges shall have a minimum ASME B16.5 Class 150 rating.

6. Tube Supports

6.1 GENERAL

6.1.3 (Add) Maximum overhang inside the firebox on intermediate tube supports shall be 12 times the
outside tube diameter.

6.1.5.1 (Add) The design temperature of the insulated end tube sheets in the radiant and convection
sections shall be equal to at least 100 oF (56 oC) above the maximum temperature of the process fluid in the
tubes that they are supporting.

6.1.7 (New) Tube supports shall be designed to prevent tubes from being dislodged from the support during
operations. Bottom supported tubes shall be provided with top guide. If tubes are more than 20 feet (6 m)
long, an intermediate guide shall also be provided for each tube. Top supported tubes shall be provided with
bottom guides.

7. Refractories and Insulation

7.1 GENERAL

7.1.3 (Add) (New) Insulating castable for end tube sheets shall have hot face rating equal to that of
adjacent unshielded refractory.

7.1.10 (Revise) Maximum temperature for TP 316 stainless steel anchor material is 1200 oF (650 oC).

7.2 BRICK AND TILE CONSTRUCTION

7.2.2 (Add) The structural integrity of the wall shall be designed for mechanical and thermal requirements.
 TECHNICAL SPECIFICATION

FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 8

7.4 CERAMIC FIBER CONSTRUCTION

7.4.12 (Substitute) Ceramic fiber system design and installation shall be such that no packing shall be
required for shrinkage gaps for a minimum of one full year of operation.

7.5 MULTICOMPONENT LINING CONSTRUCTION

7.5.6 (Revise) Block insulation shall have a temperature rating of 1900 oF (1040 oC). Mineral wool block is
not acceptable.

7.5.9 (Substitute) Minimum density of ceramic fiber used as back-up materials shall be 8 lb/ft3 (128 kg/m3).
Mineral wool block is not acceptable.

8. Structures and Appurtenances

8.1 GENERAL

8.1.1 (Add)

e. Purchaser Design Specification 9-4D, "Design Requirements for Wind Loads"

f. Purchaser Design Specification 9-5D, "Design Requirements for Earthquake Loads for Non-LNG
Facilities"

8.2 STRUCTURES

8.2.4 (Add) Horizontal external welds between plates and structural members shall have a continuous fillet
weld on the top side and 2 inch (50 mm) long fillet welds on 9 inch (230 mm) centers on the bottom side.
Diagonal and vertical exterior welds shall have continuous fillet welds on both sides. Fillet welds shall be
uniform and with full throat and legs of size that is consistent with the mechanical design requirement.

8.3 HEADER BOXES, DOORS, AND PORTS

8.3.1.3 (Add) Provide lifting lugs for all sections weighing more than 70 lbs (32 kg).

8.3.2.3 (Add) Access doors with 24 x 24 inch (610 x 610 mm) minimum clear opening shall be provided in
ducts, plenums, and at duct connections to air preheaters and control dampers. Provide adequate number
of 24 x 24 inch (610 x 610 mm) size construction doors to facilitate field installation and/or maintenance.

8.3.2.4 (Substitute) Each radiant chamber of vertical tube heaters requires at least two doors, minimum
18 by 24 inches (460 x 610 mm) each in the arch sized to allow coil removal in single hairpin assemblies.
Provide the doors on angle frames to eliminate water infiltration.

8.4 LADDERS, PLATFORMS, AND STAIRWAYS

8.4.1 (Add)

f. At all instrument and stack sample connections.

8.4.3 (Add)

d. Where wider platforms are needed, such as for samplers or analyzers, the Purchaser shall specify
special platform requirements.

8.4.5 (Add) Slide poles are not permitted.

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FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 8

8.4.7 (Add) Ladders shall be located to provide side-step access from platforms and landings. Ladders
located less than 4 feet (1220 mm) from the edge of a platform shall have the ladder vertical cage bars flared
and extended to the top of the handrailing.

8.4.8 (Add) Riser height and tread width shall be uniform throughout any flight of stairs including any
foundation structure used as one or more treads of the stairs.

8.4.10 (Substitute) Handrails and toe plates meeting local code requirements shall be provided on all
platforms, walkways, and stairways.

8.4.11 (Add) Removable sections shall not exceed 8 feet (2400 mm) in length.

9. Stacks, Ducts, and Breeching

9.1 GENERAL

9.1.11 (New) Stacks with floors shall be lined and provided with a 2 inch (50 mm) drain as a minimum. The
castable insulation shall be sloped towards the drain.

9.1.12 (New) Grade mounted stacks shall have an inspection opening not less than 24 x 24 inch
(610 x 610 mm) accessible at grade. For elevated floors, provide an access door 24 x 24 inch
(610 x 610 mm).

9.1.13 (New) All bolted connections for stacks, ducts, header boxes, plenums, etc., shall be provided with
suitable gasketing to prevent air leakage.

9.2 DESIGN CONSIDERATIONS

9.2.1 (Add)

e. Purchaser Design Specification 9-4D, "Design Requirements for Wind Loads"

f. Purchaser Design Specification 9-5D, "Design Requirements for Earthquake Loads for Non-LNG
Facilities"

9.2.7 (Add) Stacks having field welded splices shall be furnished with jackscrews and clip angles welded to
the outside of the stack plate spaced at maximum 3 ft. 3 in. (991 mm) to facilitate erection.

9.2.17 (New) Fan inlet and outlet duct design shall be reviewed and approved by the fan Supplier.

9.2.18 (New) Air and flue gas ducts, particularly transitions and bends, shall be designed to provide uniform
flow distribution to air preheater elements. Duct design at the preheater is to be reviewed and approved by
the preheater Supplier.

1. Cold flue gas duct connecting to the bottom of the air preheater shall be provided with a floor slightly
sloped to a 2 inch (50 mm) flanged drain.

2. Hot combustion air ducts shall be supplied with natural draft air doors to achieve uniform flow distribution
of cold air to all the burners in the event of fan failure. For personnel protection, a fence should be
provided all around these doors, and the location designated as a "restricted area."

3. Isolation blinds or guillotines shall be provided in the ducts to permit isolation of the air preheater, fans
and the heater for maintenance.
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FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 8

4. Provide a birdscreen, 1.5 in. (38 mm) mesh size, at the suction inlet of the forced draft fan to prevent
entry of foreign material which could potentially damage the fan.

5. Provide a rainhood at air inlet.

9.2.19 (New) Where tube pulling interference could occur, ducts shall have a flanged removable section,
and duct shall be braced so that temporary support is not required when such a section is removed.

9.2.20 (New) Flanged, blinded NPS 2 drain connections shall be provided at low points of horizontal ducts.
Such connections shall be provided on the topside of all non-vertically oriented guillotine blinds.

9.2.21 (New) Plenums (air ducts) shall be designed to provide proper distribution of combustion air to the
burners. Plenums shall be designed so that oil spills from burners will not damage internal lining, or soak the
lining and cause fire hazard. Plenums shall be designed for ready access to burners, pilots, and any
accessory control or safety equipment mounted on burners. Plenums shall not obstruct peepsight views of
burner flames, tubes, and tube supports.

10. Burners, Sootblowers and Damper Controls

10.1 BURNERS

10.1.6 (Add) The locations of the pilot ignition port, pilot, and burner piping connection must allow
unimpaired and complete view of the pilot while lighting and during operation. The same port shall not be
used for simultaneous pilot ignition and viewing, i.e., two ports are required at the pilot when ignition at the
burner front (not via side view port) is specified.

10.1.19 (New) Oil burners for firing vertically in a plenum mounting shall be designed to provide positive
visible drainage of oil spills.

10.1.20 (New) Burner tile for floor-mounted burners shall extend at least 2 inches (50 mm) above the floor
refractory for combination or oil burners.

10.1.21 (New) The burner weight shall be stated on the burner assembly drawing.

10.3 DAMPER CONTROLS

10.3.1 (Add) All hand-controlled stack dampers shall automatically move to the "open" position in the case
of failure of the operating mechanism's locking system.

10.3.5 (New) Damper position transmitter linkage is to be directly connected to the damper, not to the
actuator.

10.3.6 (New) The damper operating mechanism shall be external and provide positive control in both
directions. Counterweights in one direction are not acceptable for pneumatically positioned dampers.

10.3.7 (New) The actuating mechanism and the linkage and damper bearings shall be accessible for
servicing. The location of the actuator will be specified on the data sheet; it will normally be close to the
damper shaft and accessible from grade or a platform.

10.3.8 (New) In order to provide the required degree of damper control, the number of links in the operating
mechanism is to be minimized. The links shall be structurally rigid and designed for 3 times the maximum
actuator output force at 100 psig (7.0 kg/cm2g) (689 kPa (gage)) motive air pressure without deformation.

10.3.9 (New) Multiblade type damper blades shall not extend beyond the damper frame when damper is
fully open.
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FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 8

10.4 (New) NON-METALLIC EXPANSION JOINTS (NMEJ)

10.4.1 Specific written Purchaser approval is required for application of non-metallic expansion joints.
Information required before approval includes basic dimensions, movements, design operating conditions,
description of type, material, material temperature limits, and thermal gradient between ambient and design
temperatures.

10.4.2 Flow plate protectors shall be provided if fluid (i.e., flue gas) contains particulates or if fluid velocity
exceeds 40 ft/sec (12 m/s).

12. Instrument and Auxiliary Connections

12.3 AUXILIARY CONNECTIONS

12.3.1 Purge Steam Connections

12.3.1.2 (Revise) The openings through the refractory shall be lined with a Schedule 80 stainless steel pipe,
Type 304 for exposure temperatures to 1400 oF (760 oC) and Type 310 for higher temperatures.

12.3.2 Vent and Drain Connections

12.3.2.1 (Substitute) Manifold or piping vents and drains shall be provided with a minimum NPS 2, Class
300 or greater, WNF, with blind flanges of the same metallurgy and rating as the manifold or piping.

13. Shop Fabrication and Field Erection

13.1 GENERAL

13.1.1 (Add) All blocking and bracing used for shipping purposes shall be clearly identified, with yellow
paint, for field removal.

13.1.4 (Substitute) Coils shall be fabricated in accordance with the applicable provisions of the ASME B31.3
for piping, ASME Section I, and ASME Section VIII, Division 1 as specified in API data sheet.

13.1.5 (New) Marking with paint or ink on all metallic materials shall be with a water insoluble material that
contains no harmful substance, e.g., metallic pigments, sulfur, or chlorides, which would harm specified
materials at ambient or elevated temperatures.

13.2 STEEL FABRICATION

13.2.15 (Add) All galvanized material shall be permanently marked with embossed or engraved letters.
Metal wire tags are not acceptable.

14. Inspection, Examination, and Testing

14.2 WELD INSPECTION AND EXAMINATION

14.2.1 (Substitute) Radiographic, visual, magnetic particle, or liquid penetrant examination of welds in coils
shall be in accordance with ASME B31.3, ASME Section I, or ASME Section VIII, Division 1 as specified in
API Data Sheet.

14.2.2.2 (Substitute) Buttwelds for Class 900 and under shall be examined using 100% of 10% random
radiographic examination, i.e., complete radiography of one weld from each lot of ten (10) or fewer welds. If
a weld is found unacceptable, two additional welds from the same lot shall be examined. If either of the two
additional welds is unacceptable, each remaining weld in the lot shall be examined in the same manner.
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FIRED HEATERS
MB40-1F

DATE: 01 JUN 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 8 OF 8

Each weld of stainless and other austenitic materials of Class 900 and under shall have liquid penetrant
examination. Class ratings are in accordance with ASME B16.5. Unless otherwise specified in the order,
the required examination for Class 1500 in Section 13.2.2.3 shall be used.

14.2.2.3 (Substitute) Buttwelds for Class 1500 and over shall be examined with complete radiographic
examination (100% of 100%). Each weld of stainless and other austenitic materials of Class 1500 and over
shall have liquid penetrant examination. Class ratings are in accordance with ASME B16.5.

14.5.2 Refractory Testing

14.5.2 (Add) Selected anchors shall be bend or hammer-tested to verify attachment weld quality.