CONSTRUCTION STANDARD

ETHANE FURNACE ERECTION SEQUENCE

MB5-2CS-BASE

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 5
NOTE: BEFORE USING ON A PROJECT, THIS BASE SPEC MUST BE REVISED AS A PROJECT SPEC WITH APPLICABLE
PROJECT DETAILS.
TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
2. MATERIAL SUPPLY .....................................................................................................................1
3. ERECTION SCOPE........................................................................................................................2
3.1 Radiant modules and Transition Section Erection Procedure .......................................................2
3.2 Convection Modules and Miscellaneous Steel Erection Procedure ...............................................3
3.3 Radiant Coil and Crossover Piping and Balancing Procedure ......................................................3
4. ERECTION COMPLETION INSPECTION .....................................................................................5

1. GENERAL

1.1 This sequence is to serve as a guide for planning and does not include all work (scaffolding, rigging,
material handling, etc.) normally handled by Construction-contractor performing the work. The Client or
Construction-contractor performing the work is responsible for all work needed to complete the requirements of
this procedure, per Design Drawings and Job Specifications.

1.2 Construction schedule, actual sequence and planning of crews and manpower must be verified to suit local
and existing conditions. In addition to KBR drawings, also refer to the erection and assembly drawings
furnished by module/steel fabricator and equipment suppliers.

2. MATERIAL SUPPLY

2.1 The Construction-contractor performing the work shall ensure that all items are received and are received
without any damage. It is also essential to verify that all the items are per construction issue of KBR drawings.

2.2 Radiant and transition sections will be shipped to the field as six prefabricated modules (SFM) and seven
prefabricated pieces(SFP). The prefabricated components are :

SFM-1A, SFM-1B, SFM-2A, SFM-2B, SFM-3A, SFM-3B,

SFP-3C, SFP-3D, SFP-3E, SFP-3F, SFP-3G, SFP-3H, SFP-3J.

Four modules (SFM-2A, SFM-2B, SFM-3A, SFM-3B) shall be complete with shop installed insulation anchors.
All other insulation anchors and insulation shall be field installed.

2.3 Convection Section and Breeching will be shipped as four pre-fabricated modules (SFM) complete with
shop installed insulation and coils. These prefabricated modules are: SFM-4, SFM-5, SFM-6, and SFM-7.

2.4 Stack and Stack Transition will be shipped to the field as two prefabricated modules(SFM) to be externally
insulated in the field.

2.5 Structural steel will be shipped as loose material to the field.

2.6 Platforms will be shop fabricated in maximum shippable pieces for field erection. Stairs and handrails are
shipped loose for field erection. Stairways will be shop assembled for field erection.

2.7 Radiant Tube Assembly will be shipped to the field in four sets. Each set consists of 13 radiant tubes
welded to 12 return bends.

2.8 Quench Exchanger will be shipped to the field as a complete unit consisting of two quench exchangers and
the steam drum.

2.9 Crossover and Jumpover Piping will be shipped in spool pieces, sized per practical shipping and handling
requirements. Both ends beveled for field welding.

2.10 I.D. Fan, Motor Driver, and Bearings are shipped to the field as one unit.
 CONSTRUCTION STANDARD

ETHANE FURNACE ERECTION SEQUENCE

MB5-2CS-BASE

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 5
NOTE: BEFORE USING ON A PROJECT, THIS BASE SPEC MUST BE REVISED AS A PROJECT SPEC WITH APPLICABLE
PROJECT DETAILS.
2.11 Fields installation refractories: Ceramic fiber modules, insulating firebricks, ceramic fiber blankets, H-tie
back anchors, gasket tapes, etc.

2.12 Miscellaneous Items: Slide plates, terminal seals (by Class P), crossover insulation, asphaltic coating,
bolts, nuts, washers, etc.

3. ERECTION SCOPE

3.1 Radiant modules and Transition Section Erection Procedure

3.1.1 All radiant modules will be shipped to the field unlined. (Note: The Client or Construction-contractor to
check burner openings and burner dimensions for fit-up.)

3.1.2 Establish location of centerlines and elevations of exchanger foundations.

3.1.3 Locate Exchangers, Steam Drum and related piping assembly on foundations, ensuring that slide plates
are installed.

3.1.4 Establish location of C/L and elevation of furnace foundations.

3.1.5 Locate outer furnace foundations from furnace C/L to 3 mm.

3.1.6 Erect radiant modules SFM-1A and SFM-1B ensuring that base plates are square and level.

3.1.7 Erect the remaining modules and panels of radiant cells A and B, checking each module or panel erected
for correct alignment.

a. Field to coat all bolted field splices with asphaltic coating prior to setting subsequent modules as specified
on the erection drawings (Ref. MB15-1TS Article 3.6). Do not coat field splices at column locations due to
welding requirement of column.

b. All bolted connections, located anywhere on the furnace, with oversized or slotted connections must include
washers.

c. Do not remove radiant module bracing until absolutely necessary.

d. Do not install arch seal plates at this time. If already in place, remove them prior to installing radiant coils.

e. Field welds of columns splices to be done after erection of each module (Ref. MB15-1TS Article 3.7).

3.1.8 Install Radiant Outlet Piping assemblies WC-1, OC-1, OC-2 and connect to exchangers.

3.1.9 Erect balance of beams, bracing, platforming, ladders and stairs to radiant arch level.

3.1.10 Install refractory in radiant Cells A and B and transition in accordance with refractory subcontractor's
instructions.

3.1.11 Install radiant tube assemblies through arch opening and temporarily support from radiant steel. In
addition, temporarily cover the arch opening around the radiant coil with polyethylene to prevent rain or snow
from entering.

(Note: All radiant tubes waiting to be installed in the furnace should be covered to protect them from the
environment.)

3.1.12 Install radiant burners in accordance with Supplier's instructions.

 CONSTRUCTION STANDARD

ETHANE FURNACE ERECTION SEQUENCE

MB5-2CS-BASE

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 5
NOTE: BEFORE USING ON A PROJECT, THIS BASE SPEC MUST BE REVISED AS A PROJECT SPEC WITH APPLICABLE
PROJECT DETAILS.

3.2 Convection Modules and Miscellaneous Steel Erection Procedure

3.2.1 Erect convection modules including breeching section to the top of the ID fan deck section (EL 126550).
When bolting convection modules to each other, connect the flanges on the end walls (Wall #1 and Wall #3)
before bolting the flanges on Wall #5 and Wall # 6.

a. Field to coat all bolted field splices with asphaltic coating prior to setting subsequent modules as specified
in KBR Technical Standard MB15-1TS, Article 3.6. Do not coat field splices at column locations due to
column welding requirement.

b. All bolted connections, located anywhere on the furnace, with oversized or slotted connections must include
washers.

c. Field weld all column splices per KBR Technical Standard MB15-1TS, Article 3.7 after erection of each
module.

3.2.2 Erect all remaining bracing, platforms, and support steel including fan deck platforms.

3.2.3 Match fan mounting against support steel to ensure correct orientation.

3.2.4 Pour concrete for deck and fan support in two pours. Let it set for minimum of 3 days between pours.

3.2.5 Install I.D. fan, driver, and bearing skid unit in accordance with Supplier's instructions.

3.2.6 Erect stack support steel, stack and transition assembly. Externally insulate stack per Class P
Specification.

3.2.7 Erect all remaining steel including pipe supports.

3.2.8 Complete all remaining insulation installation, including all external pipe insulation and terminal seals.

3.2.9 Install all instrumentation (Reference Class O drawings). Plug all unused openings.

3.2.10 Touch up or precoat any areas where paint has been damaged.

3.3 Radiant Coil and Crossover Piping and Balancing Procedure (Do not deviate from this procedure)

3.3.1 Install counterweight assemblies for radiant coils including filling counterweight cans with concrete per
design drawing 219-D05.

3.3.2 Lubricate rocker arm assembly, eye bolts, cables, etc. to reduce friction.

3.3.3 Calculate the ratio of each counterweight to the total counterweight for radiant coil sub-assembly, from
Table A of Drawing 219-D05.

3.3.4 Start balancing with counterweights in Table A of Drawing 219-D05.

3.3.5 Add counterweights in the proportion of the ratios in 3.3.3 until the system moves upward.

(Note the additional counterweight added at each location).

3.3.6 Remove counterweights in the same proportion as in 3.3.3 until the system moves downward. (Note the
counterweight removed at each location).

3.3.7 Add half the counterweights noted in 3.3.6.

 CONSTRUCTION STANDARD

ETHANE FURNACE ERECTION SEQUENCE

MB5-2CS-BASE

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 5
NOTE: BEFORE USING ON A PROJECT, THIS BASE SPEC MUST BE REVISED AS A PROJECT SPEC WITH APPLICABLE
PROJECT DETAILS.

3.3.8 Adjust the counterweights and balance all remaining radiant coil sub assemblies using the above
procedure. Record all final weights at each counterweight location.

3.3.9 Install arch seal plates complete installation.

3.3.10 Raise or lower the radiant coil sub-assemblies to bring them to the proper elevation per
Drawing 219-D02. Verify that the sub-assemblies are leveled.

3.3.11 Check the alignment, orientation and location of the radiant coils with respect to the radiant arch seal
plates and floor guide sleeves. Measure and record all dimensions. The dimension from radiant coil guide
extension RP-8 to floor plate should be 25 mm per Drawings 219-D03 and 219-D08 Detail #5.

3.3.12 Field weld shop assembly WC-1 to radiant coils and outlet piping.

(Note: It is essential to ensure and verify that all sub-assemblies are clean of debris such as metal shavings,
weld flux, etc.

3.3.13 Tack-weld the wye fittings OF-3 to the radiant coil sub-assemblies and outlet piping to exchangers.

3.3.14 Verify all flange fit-ups of outlet piping up to exchangers. Also, verify outlet piping support and slide
plates per Drawing 219-D08.

3.3.15 Block the radiant coil sub-assemblies, wye fittings and outlet piping. Weld wye fittings to the radiant coil
sub-assemblies and to the outlet piping after all clearances and fit-ups are verified. Remove all blocking
materials.

3.3.16 Mark all tube penetrations through radiant arch, 125 mm from penetration sleeves, with a water insoluble
material that contains no harmful substance, e.g. metallic pigments, sulfur or chlorides which would attack or
harmfully affect the material at ambient or elevated temperatures. Also, mark radiant coil guide extension RP-8
in line with the floor guide sleeve with the same marker.

3.3.17 Install bulk ceramic fiber insulation at floor guides.

3.3.18 Install crossover piping with temporary supports as required, beginning at the mixed feed outlet and
radiant inlets. (Do not weld crossovers to mixed feed outlet and radiant inlets at this time.)

3.3.19 Make necessary intermediate field welds in crossover piping, ensuring that the pipe is clean and free of
debris.

3.3.20 Install counterweight assemblies for the crossovers including filling counterweight cans with concrete per
design drawing 219-D06 ensuring that sheaves are correctly aligned with cables and are free to rotate.

3.3.21 The following guideline is provided for crossovers balancing and counterweight for each crossover.

a. Provide temporary support for the horizontal section of the crossover. Also, use safety ropes to prevent the
crossover from dropping.

b. Tie approximately 28 kg per linear meter to the crossover to simulate the uniformly distributed weight of the
crossover insulation. The calculated counterweight loads were based on a 25 mm thick inner layer of
ceramic fiber blanket with an assumed density of 192 kg/m3 covered with a 125 mm thick layer of calcium
silicate insulation with an assumed density of 240 kg/m3.

c. Lubricate cables, etc. to reduce friction.

d. Calculate the ratio of each counterweight to the total for each counterweight from Table I of Drawing
219-D06.
 CONSTRUCTION STANDARD

ETHANE FURNACE ERECTION SEQUENCE

MB5-2CS-BASE

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 5
NOTE: BEFORE USING ON A PROJECT, THIS BASE SPEC MUST BE REVISED AS A PROJECT SPEC WITH APPLICABLE
PROJECT DETAILS.

e. Start balancing the counterweights as shown in Table I of Drawing 219-D06.

f. Add counterweights in the proportion of the ratios calculated in Step d until the system moves upward.
(Note the additional counterweights added at each location.)

g. Remove the counterweights in the same proportion as in Step f until the system moves downward. (Note
the counterweight removed at each location.)

h. Add half the counterweights noted in step g.

i. Check crossover to ensure it moves up and down with an equal amount of force applied. This completes
the crossover balancing.

j. Adjust counterweights and balance all the remaining crossovers using the above procedure. Record all
final weights at each counterweight location.

k. Raise or lower the crossovers to align them with mixed feed outlets and radiant inlets. Verify that the
crossovers are leveled and the crossover stops are in correct position per Drawing 219-D06 details 1 and
1A. Block the crossovers in place.

l. Weld crossovers to mixed feed outlets and radiant inlets ensuring that the crossovers are clean and free of
debris.

m. Remove simulated crossover insulation after temporarily supporting crossovers and their counterweights.

n. Install the crossover insulation per Class P Specification.

o. Field weld crossovers to radiant inlets.

3.3.22 Remove any temporary supports for crossovers and radiant tubes.

3.3.23 Pneumatically test radiant coil, crossover piping, and associated piping in accordance with drawing
220-D101 and KBR Construction Standard 8-2CS.

3.3.24 Insulate exchanger piping, radiant outlet piping and crossovers.

3.3.25 Install seals at the arch and the floor of the radiant box. Install so that all specified clearances are
maintained.

4. ERECTION COMPLETION INSPECTION

The Construction-contractor shall complete finish and touch-up painting, carry out inspection and site clearing
as necessary and as specified in the contract.