CONSTRUCTION STANDARD

REFORMER RADIANT COIL ALIGNMENT

AND BALANCING PROCEDURE MB5-6CS

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 8

TABLE OF CONTENTS

Section Title Page No.

1. INTRODUCTION ............................................................................................................................1
2. RADIANT HARP BALANCING PROCEDURE..............................................................................1
3. END OF JOB RECORDS...............................................................................................................4
4. HOT BALANCE OF THE RADIANT COIL ....................................................................................5

1. INTRODUCTION

This procedure covers the alignment and balancing of the individual radiant coil subassemblies (harps) in the
radiant section of the reformer furnace. While the contractor has flexibility with executing the change out of the
radiant coils, the specific steps in this procedure are mandatory to ensure the proper operation of the spring
support system and ultimate longevity of the coil operation itself. The steps in this procedure shall not be
deviated from.

It is recommended that a KBR Furnace engineer be present during the balancing operation, but a client
representative who is well versed with these procedures will also serve the purpose.

The harp balancing operation is of utmost importance to determine what the operating load settings for the new
catalyst tube support springs will be for the life of the new radiant coils. Although the springs are supplied with
"calibrated" load settings, this weight figure is an estimate made early in the job to assure the springs selected
have the proper operating range. Since the individual catalyst tubes can vary in weight due to tube wall
thickness and catalyst weight variations it is necessary to "weigh-in" the coil using the new springs to determine
the actual installed weight of the coils in the furnace. The most accurate spring readings can only be obtained
when the radiant coil subassemblies have been aligned, leveled, the spring loads equalized, all prior to any field
welds being made. This spring reading or weight record becomes permanent record of the weight of each
specific harp assembly. This is why individual spring reading records and locations maps of subassembly mark
numbers are very important.

Should a problem occur in the future with the operation of the furnace such as bowed catalyst or riser tubes,
bowed or curved outlet manifolds, or excessive movement of the inlet pigtails, these initial records will provide the
clues to solving the problem and help determine what corrective action is needed. Should a metallurgical problem
occur during furnace operation such as a rupture or crack, the credibility of the material can be traced to the
manufacturers records based on the tube serial numbers, location in the furnace, etc. If there was a problem with
the metallurgy, then any other tube segments could be pinpointed in the furnace for corrective action.

2. RADIANT HARP BALANCING PROCEDURE

Before attempting to level and balance any of the 1/3 harp subassemblies, all of the following conditions should
be met:

~ Transfer line blocked and in final position

~ Catalyst tubes loaded with catalyst (or compensation thereof)

~ All flanges/bolts/gaskets installed on catalyst tubes (or compensation thereof)

~ All shipping bracing removed

~ 1/3 harp sections hanging on unblocked springs free from any obstructions or contact with steel

~ Individual spring rods plumb within 1/8 inch (3 mm) vertical tolerance
 CONSTRUCTION STANDARD
REFORMER RADIANT COIL ALIGNMENT
AND BALANCING PROCEDURE MB5-6CS

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 8

~ All spring scales positioned facing the service walkways

~ The riser transition section is welded into final position to transfer line

Leveling and Balancing Center 1/3 Harp Subassemblies

~ Begin the leveling and balancing sequence with the center harp section. This is because the end section
has to ultimately fit-up to the center section in both elevation and alignment, and the center section is set
based on the relative riser and transfer line position. If the end section is balanced before the respective
center section, it will most probably have to be redone after the center section is complete. It is best to stay
in the correct sequence and balance the center section first, it will save time in the long run.

~ Beginning with the center harp section:

~ Drop a plumb line from the corresponding riser transition and locate the center of the riser where it
connects to the outlet manifold. The vertical alignment of the riser should be to a ± 1/2 inch (12 mm)
tolerance. The plumb line should correspond to the existing holes in the floor steel for the drain and
thermowells from the outlet manifold. If there is a conflict, the plumb line position will govern location and
the floor holes will have to be modified accordingly.

~ After centering the riser, adjust all of the center section springs either side of the riser to get the manifold
level across the length of the outlet manifold. The tolerance of the manifold levelness should be within
± 3/8 inch (10 mm) per each 10 feet (3 m) of length.

~ The elevation of the outlet manifold should be set at approximately 3/4 inch (19 mm) below the intended
final elevation for the outlet manifold. This position will require raising the entire harp to final elevation and
proper weld gap for welding the riser (later). At this point, the clearance between the top of floor steel and
the underside of the outlet manifold should be checked. You must take into account the floor brick
insulation and the outlet manifold insulation which are probably not installed at this time, and the gap at the
riser weld 3/4 inch (19 mm). The "net" clearance below the bottom manifold insulation should be a
minimum of 8 inch (200 mm) to accommodate riser expansion during operation. Sufficient clearance below
the entire length of manifold is critical to compensate for the downward thermal expansion of radiant coil
during furnace operation. The outlet manifold should be temporarily blocked in position to prevent any
movement sideways and temporarily supported from below to hold its elevation.

~ Read the springs and record individual spring numbers, calibrated spring load, spring constant rate, and
the spring indicator readings. (The spring indicator reading is the position of the indicator above or below
the calibrated load mark. Above the calibrated load mark subtracts weight from the calibrated load, and
below the calibrated load mark adds weight to the calibrated weight. To obtain the ultimate spring reading
you record the position above or below the calibrated load, measured in 1/10 inch (1 mm) increments on
the spring scale, multiply the reading by the spring constant rate, and add or subtract this number to the
spring calibrated load.

Example:

Spring number 101-B/A

Calibrated spring load is 1913 lb (868 kg)
Spring constant rate is 225 lb/in (4 kg/mm)
Spring reading is + 0.1 inch (2.5 mm below the calibrated load mark)

1913 (868 kg) calibrated load

+22.5 ( 10 kg) [0.1 inch (2.5 mm) deflection below cal'b load times 225 lb/in (4 kg/mm)]
1936 (878 kg) total spring weight indication

~ Record all spring weights and readings on the radiant harp weigh-in tabulation sheets.
 CONSTRUCTION STANDARD
REFORMER RADIANT COIL ALIGNMENT
AND BALANCING PROCEDURE MB5-6CS

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 8

~ Readjust the springs to equalize the overall harp subassemblies weight as recorded in the last step. Each
of the springs supporting the center harp section is carrying an equal portion of the total weight of this
section.

~ Recheck the riser vertical plumb, the manifold elevation and levelness, and the spring balance, if all are
within the stated tolerances, then the center manifold is ready for welding.

Leveling and Balancing the End 1/3 Harp Subassemblies

Leveling and balancing the end harp subassemblies is very much like doing the center section except there is
no riser, but end sections have to be set-up based on the existing position of the center section.

~ Plumb all spring hangers rods to a vertical tolerance of 1/8 inch (3 mm) tolerance.

~ Adjust all of the end section springs to level the manifold level across the length of the end section of outlet
manifold. The tolerance of the manifold levelness should be within ± 1/4 inch (6 mm) in 10 feet (3 m) of
length.

~ The elevation of the end section of harp manifold should be set slightly below the intended final elevation
for the outlet manifold and correspond to the elevation of the center section manifold. This position will
later require raising the entire harp to final elevation and proper weld gap to make the riser weld. At this
point, the clearance between the top of floor steel and the underside of the outlet manifold should be
checked. You must take into account the floor brick insulation and the outlet manifold insulation which may
not be installed at this time. The "net" clearance below the bottom manifold insulation should be a
minimum of 8 inches (203 mm) to accommodate riser expansion during operation.

~ Read the springs and record individual spring numbers, calibrated spring load, spring constant rates, and
the spring indicator readings. The spring indicator reading is the position of the indicator above or below
the calibrated load mark. Above the calibrated load mark subtracts weight from the calibrated load, and
below the calibrated load mark adds weight to the calibrated weight. To obtain the ultimate spring reading
you record the position above or below the calibrated load on the spring scale, multiply the reading times
the spring constant rate, and add or subtract this number to the spring calibrated load. This will be the
same procedure as used on the center section springs.

~ Record all spring weights and readings on the radiant harp weigh-in tabulation sheets.

~ Readjust the springs to equalize the overall harp subassemblies weight as recorded in the last step. Each
of the springs supporting the end harp section is carrying an equal portion of the total weight of this section.

~ Adjust the spring hanger rods by moving them at the top clevis laterally in the slotted holes as required to
position the end manifold bevel end at the correct weld gap to the center manifold bevel ends. It should
require no more than 25 lb (12 kg) of force to pull the manifold sections together to obtain the proper weld
gap.

~ Check the alignment between the center and end sections of manifold so that both sections are in a
straight line, as if looking at them from above to a tolerance of ±1/4 inch (6 mm) in 10 feet (3 m) of length.

~ Recheck the weld gap, the manifold elevation and levelness, the spring balance, and the alignment to the
center section, if all are within the stated tolerances, then the end and center sections are ready for
welding. The outlet manifold should be blocked into position to prevent any sideways movement, and
temporarily supported from below the manifold to hold the elevation in the event the springs settle during
the welding of the manifolds.

The above procedure should be followed for the opposite end harp section.
 CONSTRUCTION STANDARD
REFORMER RADIANT COIL ALIGNMENT
AND BALANCING PROCEDURE MB5-6CS

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 8

After welding the outlet manifold sections, the entire harp assembly is ready to be raised to close the gap
between the Incoloy riser transition and the top of the riser tube Incoloy 800HT transition to achieve proper weld
gap. The harp shall be raised systematically by adjusting the individual catalyst tube springs by 2 turns at a
time on each spring to eventually raise the entire harp assembly to the required elevation. The spring
adjustments shall be done simultaneously and symmetrically about the riser, so as to not disturb the levelness
and the balance of the harp.

3. END OF JOB RECORDS

Records that KBR field engineer or the client representative will generate is as follows:

a. Balancing records that record the initial coil weigh-in, calculation of the operating load spring settings,
records of any additional weights added which were included in the initial weigh-in of the coils.

These records provide essential recording of the coil weights taken during the coil installation and provide
the basis of any future adjustments or modifications to the coil support system. Note that during the
installation of the coil, the subassemblies are weighed while they are free hanging prior to any weld being
made of the outlet manifold, riser, or pigtails to determine the static weight of the coil assembly. Further
adjustments can then be made for items which were not connected during the initial weigh-in such as
insulation, bolts, and a portion of the inlet pigtail intended to be supported by the individual springs.

b. Radiant coil subassembly locations in the furnace by fabrication shop assigned mark numbers, i.e., 1A, 2B,
8C, etc.

The location of the individual coil assembly mark numbers for their installed position in the furnace. This
information is essential to quickly locate serial numbers for cast tube segments or correlate to shop
radiograph records and quality control records should the need arise.

c. Cold position measurements of the outlet manifold drains taken from below the furnace floor.

The relative cold measurements taken during the initial coil installation will allow the user to track the
movement of the coil based on the subsequent measurement of the drain displacement as the riser tube
and coil expand with the furnace operation.

d. Measurement taken from the underside of the outlet manifolds insulation to the top of the floor brick.

These measurements of the outlet manifold ensure the sufficient clearance exist below the outlet manifold
so that no damage occurs to the outlet manifold insulation as the manifold moves downward and that the
manifold is in no danger of resting on top of the floor bricks.

e. Tube top readings from cold to hot position.

These readings are taken from a wire datum line to the top of the catalyst tube tops at 500 degree
increments from ambient to full furnace operating load. The individual measurements are plotted and will
provide an indicator of coil movements as the furnace heats up. A problem with a spring, excessive
expansion of an individual tube, tube binding, or other abnormal coil movement will be indicated with this
activity. It can also indicate burner firing imbalances between individual tube rows. This activity is normally
only done after a major furnace retubing to ensure that all of the newly installed components have been
installed properly and are functioning as intended.
 CONSTRUCTION STANDARD
REFORMER RADIANT COIL ALIGNMENT
AND BALANCING PROCEDURE MB5-6CS

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 8

4. HOT BALANCE OF THE RADIANT COIL

Hot balancing of the radiant coil spring support system is required after the furnace operating conditions are
stabilized, usually within a few weeks after the coil installation is completed. The purpose of this activity is to
systematically adjust the catalyst tube support springs to eliminate thermal loads created from the coil components
being at furnace operating temperature. This activity basically readjusts the springs back to the operating load
settings determined during the coil balancing and alignment procedure. It is highly recommended that a KBR field
engineer supervise this activity which usually takes one to two days. Subsequent catalyst tube spring adjustments
are not usually required unless specific circumstances occur and warrant such adjustments. Information regarding
online spring adjustments is covered in the furnace maintenance manual provided during the original installation of
the furnace. Questions regarding spring adjustments can be directed to the Furnace Technology Group at KBR,
Houston, Texas.
COMMENTS:
CENTER SECTION (
END SECTION ( C) END SECTION ( A) ROW No. __________
B)

--
--
SPRING NO.

;N

TOTAL (G)
TOTAL (G)

TOTAL (G)
SUPPLIER SPRING I.D. NO.

--
--
FROM SPRING
DATE: 01 JUN 2003

ACTUAL SPRING
3

lb/in
CONSTANT FROM SPRING

kg/mm
lb
CALIBRATED LOAD
4

kg
FROM SPRING
SPRING SCALE READING
(DISTANCE FROM
5

in
mm
CALIBRATED LOAD) FROM
SPRING
LOAD DEVIATION FROM
6

lb
kg
CALIBRATED LOAD (3X5)

ACTUAL LOAD
7

lb
DETERMINED BY SPRING

kg
(4 ± 6)
INITIAL BALANCED LOAD
8

lb
kg
PER SPRING
G7 X(4 / G4)
INITIAL BALANCED LOAD
9

in

SETTING
mm

(8-4)/3
AND BALANCING PROCEDURE

ADDITIONAL PER SPRING

lb
kg
10

WEIGHT (PIGTAILS, CAT.,

REFORMER RADIANT COIL ALIGNMENT

ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.

INSUL., ETC.) CALCULATED

RISER WEIGHT PER
lb
kg
11

SPRING (-)
CALCULATED
FINAL CALCULATED
RADIANT HARP WEIGH-IN TABULATION SHEET

lb
kg
12

OPERATING LOAD
8+10+11
FINAL CALCULATED LOAD
in
13

SETTING
mm

(12 - 4)/3
DISTANCE FROM 9 PRIOR
MB5-6CS

in

TO READJUSTMENT
14

mm

(13 ± 9)
PAGE 6 OF 8
CONSTRUCTION STANDARD
 CONSTRUCTION STANDARD
REFORMER RADIANT COIL ALIGNMENT
AND BALANCING PROCEDURE MB5-6CS

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 8

The following instructions are to be used in conjunction with the Tabulation Sheet Form on Page 6.

Column 1:

This column relates to the relative spring position reading from one end of the tube row to the opposite end.
Each row would be numbered the same for all of the rows of springs, i.e., the west wall begins with spring
number 1 and the east wall ends with spring number 26, then repeated on all remaining rows.

Column 2:

List each manufacturers spring number as taken directly from each spring scale after the springs are installed.

Column 3:

The actual spring constant is taken from each spring scale as stamped by the spring manufacturer, as in
pounds per inch or kilograms per millimeter. It is important to determine how many units the spring scale has,
be it 10 or 8 increments per inch.

Column 4:

The calibrated load is stamped on each spring scale and is usually stamped on the scale with the
accompanying letter "C". All double springs will have the same calibrated load and all single springs will have
the same load.

Column 5:

This column indicates the spring scale reading taken in units above or below the calibrated load as read from
the position of the spring indicator. If the reading is above the calibrated load it is a minus (-) since it is
subtracted from the calibrated load or below the calibrated load (+) it is added to the calibrated load to arrive at
the actual spring reading. The reading to be entered in this column would be as an example +.15 inch or
-.15 inch, or + 1.2 mm or -1.2 mm.

Column 6:

The value in this column is a function of column 3 multiplied by column 5, the deflection in inches (mm) times
the spring constant in pounds per inch (kg/mm).

Column 7:

The entry in this column is the value arrived at when either adding or subtracting column 6 to column 4.

Column 8:

This is the sum of column 7 for each one-third section divided by the number of tubes in each section. When a
single spring is present it will only carry one-half of the load as the double spring (one tube versus two), but the
sum of the spring settings must equal the recorded weight of the springs in each respective one-third section.
EXAMPLE: One end section has 6 double springs and 1 single and has a recorded weight in column 7 of
14300 lb (6486 kg) for these seven springs. To arrive at the initial balance load per spring, divide 14 300 lb
(6486 kg) by 13 (the number of tubes in the respective section) which results in 1 100 lb (499 kg) for a single
spring (1X) and 2200 lb (998 kg) load for a double spring (2X).
 CONSTRUCTION STANDARD
REFORMER RADIANT COIL ALIGNMENT
AND BALANCING PROCEDURE MB5-6CS

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 8 OF 8

The initial balanced load per spring is derived by adjusting calibrated load in column 4 by multiplying it with a
ratio of sum of actual loads (column 7) to sum of calibrated loads (column 4).

Column 9:

The entry in this column is the result of adding or subtracting the initial balance load (column 8) for each spring
to or from the calibrated load (column 4) and dividing the difference by the respective spring constant (column
3) to arrive at a distance (+/-) in inches (mm) above or below the calibrated load. These equalized spring
settings should be achieved prior to any welding of manifolds or riser tubes.

Column 10:

This column indicates the weight to be added to each spring which was not present during the weigh-in such as
1/2 of the pigtail weight, 1/2 the pigtail insulation, the outlet header insulation weight, any flange bolts or catalyst
which was not present during the initial spring reading. Each entry should include the total added weight on a
"per tube basis" shown as double for a double spring, and single for single spring hangers.

Column 11:

This applies to only the center section of manifold support springs which carry the weight of riser until the riser
is welded to the riser transition. The calculated weight of the riser should also include the appropriate section of
the outlet manifold and branch fitting and insulation, essentially all that is to be supported by the transfer line
spring support system.

EXAMPLE: The riser is calculated to weigh 985 lb (446.8 kg) and the center section is supported by 6 double
springs, the entry for the six springs in column 11 would be [985 lb/ 6 = 164.1 lb (446.8 kg/6 = 74.4 kg)]
= 164.1 lb (74.4 kg) deducted for each center section springs.

Column 12:

This column is the sum of values for columns 8, 10, and 11 on a spring by spring basis.

Column 13:

This represents the final operating load to be stamped on each spring scale which is calculated at by taking the
final calculated operating load (column 12) less the spring calibrated load (column 4) which can be either plus or
minus, and dividing by the spring constant (column 3). This provides a measured distance above (-) or below
(+) the spring calibrated load. This value is to be permanently stamped on each spring scale at the end of the
job.

Column 14:

This is for future reference and provides an indication of what the extent of readjustment was on each spring
prior to the final operating load settings.