Sp-Me-Me-022-Steam Generators

DOCUMENT NO. REV.
PT Caltex Pacific Indonesia SP-ME-ME-022 1

DATE : October 9, 2001 SHEET : 1 OF 57
SPECIFICATION PREPARED BY Nurhasan NHS

CHECKED BY Nurhasan NHS
APPROVED BY Shawn SPD
STEAM GENERATORS
PT. CALTEX PACIFIC INDONESIA
REV DATE PAGES DESCRIPTION PREP’D CHK’D APP’D
0 10/9/01 ALL ISSUED FOR IMPLEMENTATION NHS NHS SPD

1 15/5/02 ALL CPI SPEC REVIEW TEAM (TRB, TOTO, FIB, SKMT, BBA, TJG, MIRS) Team Team Team
TABLE OF CONTENT
1. GENERAL .......................................................................................................................... 3
1.1. Scope........................................................................................................................ 3
1.2. Terminology.............................................................................................................. 3
1.3. References................................................................................................................. 4
1.4. Conflicting Requirements ........................................................................................... 4
2. BASIC DESIGN .................................................................................................................. 5
2.1. Casing...................................................................................................................... 5
2.2. Radiant Section ......................................................................................................... 5
2.3. Transition Section...................................................................................................... 7
2.4. Convection Section.................................................................................................... 8
2.5. Refractory............................................................................................................... 10
2.6. Radiant Section Refractory Requirement................................................................... 12
2.7. Transition Section Refractory Requirements.............................................................. 13
2.8. Convection Section Refractory Requirements............................................................. 13
2.9. Refractory Gasketing ............................................................................................... 13
2.10. Fuel Burning Equipment.......................................................................................... 14
2.11. Piping System.......................................................................................................... 20
2.12. Instrument Air Supply System................................................................................... 25
2.13. Electrical System..................................................................................................... 25
2.14. Control System........................................................................................................ 30
2.15. Programmable Logic Controller System (PLC).......................................................... 33
2.16. Automatic Combustion Control (A.C.C).................................................................... 33
2.17. Safety System........................................................................................................... 35
2.18. Control Panel.......................................................................................................... 37
2.19. Operator Panel ....................................................................................................... 38
2.20. Skid Structure.......................................................................................................... 39
2.21. Control Cab............................................................................................................ 41
3. FABRICATION................................................................................................................. 41
3.1. Welding .................................................................................................................. 41

3.2. Heat Treatment ....................................................................................................... 41
3.3. Insulation................................................................................................................ 41
4. COATING AND PAINTING............................................................................................. 43
4.1. General................................................................................................................... 43
4.2. Additional Requirement : ......................................................................................... 43
PT. CALTEX PACIFIC INDONESIA Steam Generators
SP-ME-ME-022 Rev. 1
5. INSPECTION AND TESTING.......................................................................................... 46
6. PREPARATION FOR SHIPMENT................................................................................... 48
7. INSTALLATION , START UP AND COMMISSIONING................................................ 50
8. VENDOR’S GUARANTEE............................................................................................... 51
9. DESIGN DATA AND SITE CONDITIONS....................................................................... 51
10. INFORMATION TO BE FURNISHED WITH QUOTATION.......................................... 51
11. BASIS OF BIDS................................................................................................................. 54
12. INFORMATION PROVIDED BY SUCCESSFUL BIDDER............................................. 54
OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1: “Project Specific Clarifications & Requirements”
October 9, 2001 Page 2 of 57

SP-ME-ME-022 Rev. 1
1. GENERAL
1.1. Scope
1.1.1. This specification defines minimum requirements for the design, materials,
fabrication, testing and inspection for Steam Generator. The type of Steam
Generator shall be Fire Tube Boiler with once through and force flow water
circuit design.
1.1.2. The equipment specified herein is subject to the execution by the bidder and the
principle/designer of CONTRACTOR's Guarantee Agreement.
1.1.3. This specification supplements the data sheets which contain the operating
conditions.
1.1.4. Compliance by Vendor with this specification does not relieve Vendor’s
responsibility of furnishing the package and accessories at the minimum
requirement of proper design, mechanically suited to meet operating guarantees
at specified condition on the applicable data sheet.
1.1.5. This specification is intended to be a general performance type specification.
Therefore, if the bidder feels an exception to the materials, components, or
mechanical details specified herein will be to the COMPANY's advantage, the
exception may be quoted as an alternate. Where Vendor takes exception to the
specifications, he may offer additional bids for alternative designs, clearly
showing:
?? How the alternative differs from the original specification.
?? Life cycle cost benefit to COMPANY resulting from the proposed change.
?? Why proposals are equal or superior to the provisions of this specification.
?? Operating experience of existing installations in similar service from which
COMPANY may evaluate reliability of the proposed change.
1.2. Terminology
In this specification, the following words and terms shall have the meanings indicated when
used herein:
1.2.1. COMPANY
Refers to PT. CALTEX PACIFIC INDONESIA, as the ultimate user and owner,
the authorized representative of COMPANY or COMPANY third party
inspection.
1.2.2. CONTRACTOR
Refers to company selected by COMPANY, which may be responsible for the
detailed engineering design, material and equipment procurement, and
construction as specified in Contract, Scope of Work, or Work Order.

SP-ME-ME-022 Rev. 1
1.2.3. Vendor
Refers to company selected by COMPANY or CONTRACTOR, which is
responsible for the purchase agreement or purchase order of goods or services
specified in this specification.
Note:
?? For EPC (Engineering, Procurement and Construction) project purposes:
The terminology shall have the meaning as above.
?? For “ Direct Procurement “ by COMPANY purposes:
Vendor shall also be responsible as CONTRACTOR.
1.3. References
The references listed below form part of this specification. Each publication shall be the
latest revision and addendum in effect on the date this specification is issued for
construction unless noted otherwise. Except as modified by the requirements specified
herein or the details of the drawings, work included in this specification shall conform to
the applicable provisions of these publications :
1.3.1. Related Specification
?? SP-ME-ME-025 Coating and Painting Specification”
?? PP-PC-GG-003 Shipping instruction Procedure
?? PP-PC-GG-004 Packing and Marking Instruction
?? PP-QC-GG-003 Inspection and Test Plan at Shop”
?? PP-QC-GG-004 Inspection and Test Plan at Field”
?? SP-IN-II-006 Programmable Logic Controller (PLC)” Specification
1.3.2. Standards and Codes
?? ASME Boiler and Pressure Vessel Code, Section I
?? ASME Boiler and Pressure Vessel Code, Section VIII
?? ASME Power Test Code
?? ANSI B31.1 Power Piping
?? ANSI B31.3 Chemical Plant and Petroleum Refinery Piping
?? AISC Manual of Steel Construction
?? Standard for Prevention of Furnace Explosions in Fuel Oil - and Natural Gas-
Fired Single Burner Boiler-Furnaces (ANSI/NFPA 85A)
?? National Electrical Code (ANSI/NFPA 70)
?? Steel Structure Painting Council Code
?? Caltex Safety in Designs Field Manual
?? American Welding Society (AWS) D1.1 (Structural Steel Fabrication)
1.4. Conflicting Requirements

SP-ME-ME-022 Rev. 1
1.4.1. In case of conflict between this Specification and its associated Specifications
and the above Codes and Standards, the Vendor shall bring the matter to the
COMPANY’s attention for resolution and approval in writing. However, the
most stringent requirement shall govern.
1.4.2. Should conflicts exist between this specification and other documents, the
following order of precedence shall a govern:
?? Purchase Order.
?? Data sheets.
?? This Specification
?? Other COMPANY Specifications
?? Other Referenced Publications
?? Approved for Construction Drawings
?? Vendor’s Code
2. BASIC DESIGN
2.1. Casing
2.1.1. Casing of the boiler shall be so designed as to attain gas tightness against positive
internal pressure.
2.1.2. Maximum deflection of the external casing surface shall be smaller than 1 : 360
(deflection/span) within total deflection of 25 mm in a single span, based on the
maximum operating furnace pressure.
2.1.3. Furnace bottom shall be provided with drain to permit removal of flue gas
deposits by water washing.
2.1.4. Thickness of skin casing shall be 3.2 mm or more, if used.
2.2. Radiant Section

2.2.1. General
The radiant section, with a long cylindrical shape, shall be of steel plate, ASTM
A-36, and lined with ceramic fiber and castable refractory as described in this
specification. There shall be a minimum of 1/16-inch corrosion allowance in
addition to that thickness required for structural strength.
2.2.1.1 The radiant section shall be designed with horizontal tube transposed
around for equalized heat pick up. All radiant tubes shall be removable
without dismantling of economizer or burner end components. The entire
radiant tube, including return bends, shall be enclosed in the radiant
shell. Two (2) inches of space shall be provided between the burner wall
and target wall refractory surface to allow tube expansion.
2.2.1.2 Structural angle for attaching radiant section end plates shall be
seal-welded to the outside diameter of the radiant shell and skip-welded

SP-ME-ME-022 Rev. 1
(min skip-weld length is 2 inch) to the inside of shell. Shell sections

shall be joined with full-penetration butt welds.
2.2.2. Radiant Section Cradles
Radiant section shall be supported by cradles seal welded to the shell and located
as required to provide an integral structure with the wide flange skid beams.
Cradles shall be offset from tube hanger rows to eliminate any heat transfer from
hanger pads welded to the radiant shell. The radiant section shell and support
structure shall be designed for thermal-induced expansion for shell temperature
100 deg F above maximum operating temperature.
2.2.3. Burner Wall Construction
Front (burner) wall shall be provided with a steel plate, ASTM A-36, of not less
than 1/4-inch thickness, adequately reinforced to provide rigidity, prevent
buckling and support the burner .
2.2.4. Tube Penetrations
Water and steam tube and 1" NPT drain, from the bottom tube shell, penetrations
in the radiant section shell shall have a sleeve, minimum 2" larger than pipe size,
completed with adjustable packing glands suitable for use at operating
temperatures (1800 deg F minimum) and gland plate.
2.2.5. Spare Connection for Gauge
A spare 1-inch NPT threadolet with pipe plug shall be provided on the radiant
shell at mid-section for measuring pressure or temperature of firebox.
2.2.6. Manway
The radiant section shall have a lightweight door at the burner end for entry and
inspection. The door shall have a beveled, 316 stainless steel-supported sealing
surface of minimum 12 gage stainle ss steel thickness. The manway door shall be
insulated with ceramic fiber and equipped with a davit or hinge assembly for ease
of opening and closing. Minimum diameter shall be 20 inches. A positive
restraining device is to be provided for keeping the manway door open during
maintenance operations. Door cover shall be secured with threaded studs and
nuts.
2.2.7. Sight Port
One air-cooled view window, Tate-Jones SAF-T-EYE, shall be provided in the
radiant section on the burner end wall. It shall not be higher than 4'-6" above the
top of skid grating. The view window shutter shall have a positive lock-close
device for use while cleaning the window. Provide cooling air to the window
through NPS 1 galvanized pipe. Final connection to the window shall be 1/2" SS
tubing. Provide a ball valve to regulate air flow to the window. Cooling air
source shall be from the air blower.
2.2.8. Combustion Chamber Pressure Indicator
A Magnehelic Pressure Gauge, Dwyer Instruments Inc., or COMPANY-
approved equal, 0 - 15 iwc shall be provided for measurement of combustion
chamber pressure. The gauge shall be mounted on the burner end wall of the

SP-ME-ME-022 Rev. 1
radiant section. Pressure connection to combustion chamber shall be with 1/2"

stainless steel tubing.
2.2.9. Tube Temperature Indicator
Radiant section steam discharge tube temperature shall be monitored by two (one
standby) thermocouples mounted inside the radiant section to eliminate
atmospheric interference with the true skin reading. Thermocouples shall be
mounted in a 310 stainless steel pad which is to be covered with a piece of
channel 6 inches long. Thermocouple junction box shall be easily accessible.
Weld thermocouple boxes onto the last tube of the steam coil and cover with
ceramic fiber fastened to the tube with 304 stainless steel wire. Any loop of
stainless steel tubing for thermocouples shall not be installed inside the radiant
section.
2.2.10. Drain Connection
The radiant section shall be provided with two NPS 4 flanged drain connections
installed at the bottom of the shell. Each drain nozzle shall have a 6-inch high
internal riser with at least 4 equally spaced holes to drain moisture which has
accumulated next to the shell. Drain nozzles shall be equipped with 4" knifegate
valves, Slimslide Mosser or COMPANY-approved equal. A mechanism shall be
installed on each valve to facilitate valve operation from outside of the generator
skid. Each drain shall be provided with drain plug made from stainless steel.
2.3. Transition Section

2.3.1. General
The transition section shall be of plate steel, with minimum 1/16” corrosion
allowance in addition to that thickness required for structural strength, and lined
with castable and ceramic fiber refractory as described in Section 10.
2.3.2. Dowel Pin
Transition section shall be provided with dowel pin guides, at least four pie ces at
each corner, for rapid installation of convection section at the top of it.
2.3.3. Drainage
The interior shell bottom shall be sloped for full drainage to a central size NPS 6
flanged drain nozzle during washdown operations. The lower surface of the
transition section refractory shall be contoured from the radiant section outlet to
prevent water from entering the radiant section during convection section
washdown. The drain nozzle shall have an internal riser 8 inches high with 4
equally spaced holes to drain moisture that collects next to the shell. The nozzle
shall have a 6"-150# knifegate valve, Slimslide Mosser or COMPANY-approved
equal, that can be operated easily from the skid's edge. Drain plug made from
stainless steel shall be provided.
2.3.4. Support Structural
Full-width support legs with reinforcing saddle plates shall be used for load
distribution. Seal welds shall be used on all welds to the transition section shell.

SP-ME-ME-022 Rev. 1
The transition section shall be designed for thermal-induced expansion for

temperatures 100°F above maximum operating temperature.
2.3.5. Manway
A 24-inch square bolt-on lightweight entrance manway into the transition section
shall be provided for inspecting the lower convection section tubes and entering
the radiant section. The manway shall be beveled, 316 stainless steel-supported
sealing surface. The stainless steel minimum thickness is 16 gage. The manway
door shall be insulated with ceramic fiber and equipped with a davit or hinge
assembly for ease of opening and closing. A positive restraining device is to be
provided for keeping the manway door open during maintenance operations. The
bottom of the manway shall be 3 inches above the refractory surface in the
transition section bottom to prevent water from running out the door during
convection section washdown.
2.3.6. Sight Port
One air-cooled view window, Tate-Jones SAF-T-EYE or COMPANY-approved
equal, shall be provided for inspecting flame pattern and radiant section tubes. It
shall be located on the end wall on the burner centerline. It shall not be higher
than 4'-6" above the skid top. The view window shutter shall have a positive
lock-close device for use while cleaning the window. Provide cooling air to the
window through size NPS 1 galvanized pipe completed with 1-inch ball valve.
Final connections to the window shall be 1/2" SS tubing. This tubing shall be
easily removed. Provide a globe valve to regulate air flow to the window.
Cooling air source shall be from the air blower.
2.3.7. Sample Connection
One sample connection shall be installed on the side of the transition section.
The exact location for the connection will be designated by COMPANY on
Vendor's drawings when submitted for approval.
2.3.7.1 Transition section sample port shall be a size NPS 1 schedule 80 pipe
nipple welded in the horizontal position slopped 10° to provide drainage,
with a threaded pipe cap covering the nipple's external end. Pipe nipple
shall extend through the refractory and be positioned flush with the
internal face of the refractory. It shall have 4-inch external projection.
2.3.7.2 A 4-inch blinded flange sample port shall be provide for the purpose of
oxygen analyzer installation, sloped at 15 deg to provide drainage. This
port shall be installed on the feedwater preheater side of the transition
section.
2.4. Convection Section

2.4.1. Type of Convection
The convection section shall be of the “constant mass velocity” design with
interior surfaces lined with ceramic fiber and castable refractory as described in
section 10. The convection shall be steel, self-supporting, welded construction
with a minimum 1/16-inch corrosion allowance in addition to that thickness
required for structural strength. The convection shell surrounding the bare-tube

SP-ME-ME-022 Rev. 1
portion may have sloped or vertical sides. The shell sides surrounding the finned
tubes shall have sloped sides with vertical tube sheets.
2.4.2. Minimum Convection Temperature
The convection section shall be designed to provide enough flue gas exhaust
temperature to prevent the sulfuric condensation at the convection tube. The
content of H2 S on the fuel gas and fuel oil can be found in section of Design Data
and Site Conditions within this specification.
2.4.3. Tubesheet
All tube return bends shall be external to convection section tubesheets and
covered by an internally insulated solid metal cover. The space between
tubesheet and all tubes shall be sealed with packing glands. The cover is to be
bolted to the tubesheet with threaded studs and guide pins.
2.4.4. Quick Releasing Door
The convection section shall be equipped with quick-releasing and balanced
doors on two sides. Doors shall be large enough for easy access to convection
tubes for cleaning. Jack screws shall be located in each corner for breaking doors
loose for opening during washdown operations. Guide pins or other devices to
facilitate reinstallation of the doors shall be provided. Doors are to be secured
with threaded stud assemblies with a minimum diameter of 3/4-inch beveled
weld. Pin and wedge type latches are not acceptable. COMPANY shall approve
the ‘quick opening’ latches design prior to fabrication.
2.4.4.1 Door flange and other joint gaskets shall be designed to prevent leakage
under pressure up to 14-inches water column. Door flange minimum
width shall be 6-inches. Gasket material shall be 6"-wide by 1"-thick
ceramic fiber blanket. A 304 or 316 stainless steel supported sealing
surface shall be provided around the perimeter of each door and its
opening in the convection section; gaps shall be provided in the
perimeter plates to allow for thermal expansion.
2.4.4.2 An overhead rail system is to be provided for opening and suspending
doors when washing convection section. Permanent platform(s) with
ladder(s) shall be provided on both sides of the convection section to
facilitate door opening and tube cleaning.
2.4.4.3 A platform shall be provided half way up to the door to allow access to
the door fasteners along the top edge of each door. The platform design
shall comply to Caltex Safety in Design Field Manual.
2.4.5. Thermocouple
A direct reading thermocouple connection for stack temperature indication shall
be provided. This thermocouple shall be no further than 3-inches from the top
row of tubes. The thermocouple shall be installed substantially level, and well
protected from the effects of the wind.
2.4.5.1 Radiant section and transition section drains as well as those for the
steam traps, and other miscellaneous drains shall be tied into a single
drain header. The drain header shall be routed underneath the generator

SP-ME-ME-022 Rev. 1
and sloped to the convection section the end of the generator. The drain
header shall be size NPS 4, increasing to size NPS 6 where the transition
section drain enters. Major drain header sections shall be coupled with
quick removable groove/clamp joint fittings (Victaulic or
COMPANY-approved equal) for ease of disassembly and maintenance.
Gaskets shall be suitable for maximum anticipated temperature. A clean-
out shall be provided at burner end of the generator skid with a NPS 4
cap.
2.5. Refractory
2.5.1. General Requirement
2.5.1.1 The interior surface of the generators shall be insulated with a
combination of ceramic fiber and castable refractories. Exterior surface
temperatures must be no hotter than 140 deg F for 86 deg F ambient
temperature and 15 MPH wind.
2.5.1.2 All interior surfaces of radiant, transition, and convection sections
(including tubesheet covers and doors) shall be commercial sandblasted
to SSPC-SP6 with a surface profile of 1.5 mils to 2.0 mils maximum and
coated with 1/8-inch minimum thickness of Childers Stalastic CP-79 or
COMPANY-approved equal. Coating shall not be done until refractory
anchors, tube hangers, and all others welds are applied.
2.5.2. Castable Refractory System
Castable refractory shall be installed continuously; cold joints are not acceptable.
Castable refractory installation shall avoid sharp corners. Corners and joints shall
be rounded to prevent cracking.
2.5.2.1 Castable Refractory Material
Green Cast-45-L-GR or COMPANY-approved equal with maximum
temperature 2500 deg F and 80 lbs/ft3 density shall be used for all
castable refractory, unless other type is specified.
2.5.2.2 Anchor
Anchor type 310 stainless steel, 1/4-inch diameter, footed wavy vee or
long horn studs, with a length that will extend to 1-inch below the
refractory hot face, shall be used for castable refractory system. Anchors
shall be installed on 10-inch centers, except that 6-inch centers shall be
used in the tunnel between radiant and transition section.
2.5.3. Ceramic Fiber Refractory System
2.5.3.1 Anchor
Module shall be mechanically anchored with anchoring studs that are a
minimum 1/4-inch diameter and full filled welded to the shell.
The anchoring studs and all other hardware shall be 310 Stainless steel or
COMPANY approved alternative. Anchor shall be set 1-inch below the
hot face of the refractory. All anchoring hardware shall be protected from
combustion temperatures and atmosphere at all times.

SP-ME-ME-022 Rev. 1
2.5.3.2 Welding Procedure Qualification

At least three trial stud welds shall be made using the anchor material for
the job and a plate with the same thickness as the furnace shell. These
welds shall be bend tested by hitting them with a light hammer and
bending them 15 degrees from vertical and back. If any welds crack, they
fail the test, and an additional three welds must be passed.
2.5.3.3 Production Weld Testing
The actual production anchor welds shall be 100 % hammer tested, as
follows: A stud shall be considered to have a good weld if, when the stud
is hit with a light hammer it produces a ringing sound similar to that
obtained when furnace shell is struck. Any studs that do not produce
such a sound, and any studs that bend or loosen upon hitting, shall be
removed and repla ced. Care shall be used during hammer testing so that
studs are not damage.
2.5.3.4 Refractory Ceramic Fiber (RCF) Blanket
Blanket used for this specification shall be of 8 lb/ft3 minimum density.
Manufacturer’s data must show that the RCF to be used will shrink less
than 2% at the maximum operating temperature. Alternatively, the
maximum use temperature of the RCF shall be set 300 deg F lower than
the manufacturer’s maximum recommended use temperature.
2.5.3.5 RCF Module System
Module, constructed from folding blanket, system shall be used for
refractory ceramic fiber. The minimum density of the compressed
module shall be 9.3 lb/ft3. A mechanism system shall be provided to
retain the density of pre-compressed module. The size of the modules is
12 inches x 12 inches x 4 inches thickness. All refractory ceramic fiber
product shall be kept dry and protected from mechanical damage during
the course of the job.
2.5.3.6 Module Installation
Modules shall be installed using a parquet pattern where modules
oriented 90 degree to one another. The exception is for the curve plane,
such as at the burner wall, all module folds shall be oriented horizontally,
in order to get the flexibility in vertical direction.
2.5.3.7 Multi-layer Ceramic Fiber System
Multi-layer Ceramic Fiber System used in this specification shall be
comprised of blanket and modules RCF. On the cold face there shall be
two (2) layers of 1-inch thick ceramic fiber blanket of 8 lb/ft3 density.
Joints between adjacent blankets on the first layer shall be overlapped
50% by the second blanket layer to eliminate direct heat paths to the
shell. RCF module, described previously, shall be installed over the
blankets. Total insulation thickness shall be 6-inches.

SP-ME-ME-022 Rev. 1
2.5.3.8 Specific Installation

Soldier Course installation shall be done with double batten strip. Refer
to Standard Drawing installation. Joint construction between dense
refractory and modules should be filled with folded blanket.
2.6. Radiant Section Refractory Requirement

2.6.1. Cylindrical Section
Cylindrical section of shell behind the tubes shall be insulated with a multi-layer
ceramic fiber system. Clearance of 2-inches shall be maintained between radiant
section tubes and refractory surface.
2.6.2. Walk-way
A walk way, approximately 4-feet wide, of castable refractory shall be installed
in the bottom of the cylindrical section. The walk way shall extend the entire
length of the radiant section. Refractory thickness shall be 6-inches. Walk way
shall be poured prior to installation of ceramic fiber.
2.6.3. The Target End Wall and Tunnel
The target end wall and tunnel to transition section shall be insulated with high-
density castable refractory. Refractory thickness shall be a uniform 8-inches.
2.6.4. The Drip Ledge - Burner Wall
A rectangular drip ledge of castable refractory shall be formed which extends a
minimum of 6-inches on all sides of the burner throat ring and continue to
surround the burner wall manway and vertically down to the floor of the radiant
section. The thickness of this refractory shall be a uniform 6-inches.
2.6.5. The Burner Throat
A burner throat ring of 3200 deg F castable refractory, AP Green Kruzite or
COMPANY approved equal, shall be installed. It shall be concentric with the
burner centerline and circular. The throat ring shall have a minimum thickness of
4-inches. Shrinkage shall be controlled to limit the gap between drip ledge and
burner throat ring to 1/16 - inch.
All areas at the burner wall that are not insulated with castable refractory shall be
insulated with a multi layer ceramic fiber system.
2.6.6. Tube Hanger
Tube hanger shall be protected with Moist Pack tube hanger protection.
2.6.7. Sleeve
The space between sleeve and inlet/outlet tubing to radiant, also the drain from
bottom tubing, shall be filled with RCF.
2.6.8. Manway
Manway shall be covered with 8-inches thick RCF in a module system.

SP-ME-ME-022 Rev. 1
2.6.9. Drain Plug

Drain plug made from stainless steel shall be covered with RCF.
2.7. Transition Section Refractory Requirements

2.7.1. General
End wall, sides, and floor of transition section shall be insulated with castable
refractory with a minimum thickness of 8-inches.
Floor sha ll be slopped, as described in section 3.3.3, to provide complete
drainage. A water dam 4-inches high and 6-inches wide shall be formed from
castable refractory at the entrance to the transition section to prevent liquids from
entering the radiant section.
2.7.2. Manway
Manway shall be covered with 8-inches in thick of Castable Refractory.
2.7.3. Drain Plug
Drain plug made from stainless steel shall be covered with RCF.
2.8. Convection Section Refractory Requirements

2.8.1. Tubesheets and Walls
Castable refractories system of 4-inches thickness shall be install in convection
section walls and tubesheets. Carborundum Variform A shall be used as
refractory of tubesheet. Gunned installation shall be used.
2.8.2. Tubesheet Covers
Tubesheet covers shall be internally insulated with a 2-inches thickness of RCF
blankets.
2.8.3. Doors
Convection doors shall be insulated with RCF modules having 4-inches wide
folds.
2.9. Refractory Gasketing

One-inch thick RCF shall be installed as a gasket at the connection of steam generator, i.e.;
?? Between the radiant and transition section
?? Between the transition and convection section
?? Between the trolley doors and the convection section
?? At the manway flanges
Vendor shall furnish RCF and castable refractory system designs, including anchoring,
material specification, dimensions, and drawings, for COMPANY approval.

SP-ME-ME-022 Rev. 1
2.10. Fuel Burning Equipment

2.10.1. General
?? The type of burner to be applied for oil, gas or combination of them shall be
of ones well proven in comparable service conditions (type/combination of
fuel, turn-down ration, excess air, heat release and configuration).
?? Turn down ratio of each burner shall be clearly specified in Vendor’s
proposal.
?? Burner shall be so designed as not to cause flame impingement on the
heating surface up to 110% of maximum continuous rating of the boiler.
?? Dual fuel burners shall be capable of firing gaseous fuel and liquid fuel
simultaneously.
?? Three stage air register is not acceptable
?? Primary air secondary air shall be easily adjustable.
?? Gas burner shall be designed to burn the specified fuel; without incomplete
combustion at less than 10% excess air.
?? Gas burner shall be capable of operating through out the all firing range
without instability, pulsation and poor firing.
?? All parts of register shall be so arranged as not to be affected by the furnace
radiation and conducted heat.
?? Parts of the burners exposed to high temperature shall be made of heat-
resistant alloy.
?? Oil burners shall be of steam-atomizing type unless otherwise specified.
Uniform atomization shall be ensured throughout the range of the burner.
?? In case of one oil burner application, auxiliary burner gun to replace with the
main one withdrawn for maintenance during operation, shall be provided
adjacent to the main burner gun.
?? Oil burner guns shall be of quick release, withdrawable type. Burner gun
holder shall be provided with check housing.
?? Incase of field assembling boiler, moderate heating burner for drying shall be
provided
2.10.2. Combination Burner
?? In case dual fuel combustion is needed, air registers shall be capable of
providing good combustion efficiency for oil and gas.
?? In case dual fuel combustion of oil and gas is not needed, the burners shall be
designed to facilitate quick change-over from one fuel to the other. Unused
burner(s) shall be protected from overheating.
2.10.3. Pilot and Ignite rs
?? Continuos pilot firing shall not be applied.
?? Electric spark igniters shall be provided.

SP-ME-ME-022 Rev. 1
?? The igniter flame shall be extinguished automatically after main burner flame
is established.
?? Igniter shall be provided to each burner. Transfer of fire from one burner to
another is not acceptable.
2.10.4. Fuel/Pilot Gas
2.10.4.1 Vendor shall provide a piping system to keep the gas clean and free of
liquid. Sufficient volume shall be provided upstream of safety shut off
valves and inlet gas supply reducing regulator to provide a cushioning
effect and reduce pressure surges.
2.10.4.2 Both fuel gas and gas pilot shall be provided with two step pressure
regulator, double block and bleed, low and high pressure switch
complete with monitoring pressure indicator that shall be fully
interlocked with control system. Both block valve for fuel gas, shall be
of MAXON type 808 or COMPANY approved equal, shall be an
electrical trip come with manual reset.
2.10.4.3 Minimum 1/2-inch ball valves shall be used for bleed and drain valve
of the gas piping system. All valves in the gas system shall be forged
steel; cast steel is not acceptable. All piping shall be no less than
schedule 80.
2.10.4.4 Vendor shall provide the flanged end connection for all fuel gas piping
connections. This pilot gas piping shall be connected to the fuel gas
piping, completed with a check valve and a block valve to avoid back
flow to the fuel gas piping.
2.10.5. Fuel Oil
2.10.5.1 Basic Requirement
The fuel oil heating system shall be designed and built to maintain a
near constant (±5°F) temperature at the burner of 200°F (±20°F,
depending upon the fuel oil being used) over the entire range of fuel
flow rates possible during burner operation, which includes flow
through the burner bypass valve when bypassing at maximum rate with
76 SSU oil. The initial fuel oil source may be Sumatran Light, 34.6 deg
API sweet crude. The heating system shall be designed to be bypassed
if not required when this fuel is used.
2.10.5.2 Piping
Fuel oil piping shall be NPS 1 schedule 40 seamless and include
thermowells upstream of each heater and at the burner inlet. All fuel oil
lines shall be insulated in accordance with this specification.
2.10.5.3 Shut-off Valve
An electric solenoid-operated safety shutoff valve, Whitey 3/4-inch
ball valve Model S-65TF12-35C with air actuator, or COMPANY
approved equal, shall be provided in the fuel oil piping downstream of
the fuel oil meter and just upstream of the burner. The shutoff valve
shall be activated by the generator shutdown system.

SP-ME-ME-022 Rev. 1
2.10.6. Three-way Bypass Valve

A pneumatically operated 3/4-inch Fisher Model 528TY 3-way fuel oil bypass
valve or COMPANY approved equal, set to open (bypass/vent) on generator
shutdown shall be installed downstream the fuel oil meter. Under normal
operating conditions, the bypass (vent) port will be closed. Under shutdown
conditions, the inlet port will be closed and the bypass port open. The bypass
port shall be piped to the generator skid boundary for connection by COMPANY
to the fuel oil return line. Bypass piping shall be NPS 0.75 minimum and include
a check valve installed next to the bypass port. Air signal to the Fisher valve
shall be automatically blocked and vented by means of two ASCO 3-way
solenoid valves when the generator shuts down.
A manually operated 2-way angle valve for startup recirculation (3/8-inch
minimum), North American Bypass Sensitrol Oil Valve shall be provided.
2.10.7. Metering
The fuel oil at each generator shall be metered through a 1-inch Halliburton or
COMPANY-approved equal turbine meter with 1-inch MNPT end connections.
Block valves (1-inch full-port ball valves) and unions shall be installed upstream
and downstream of the turbine meter for easy removal and servicing. A
minimum of 20 times diameter upstream pipe and 10 times diameter downstream
pipe of meter tube are required. A NPS 0.75 manual bypass line with full-port
ball valve shall be installed around the turbine meter. The meter shall be
calibrated for a range of 0 to 210 barrels per day (BPD) of crude oil with a
viscosity of less than 44 SSU at 180°F. Accuracy shall be +0.5%. Readout shall
be in BPD. The turbine meter shall be wired to a pulse slave input module,
MODICON or equal mounted in the generator control panel. Signal wires shall
be shielded and installed in conduit from the turbine meter to the control. Signal
wires shall be kept separate from power conductors to avoid contaminating the
signal with electrical noise.
2.10.8. Heater
The heater shall utilize dry 175 psig steam from an on-plot scrubber. Heater
temperature shall be controlled by a fully modulating self-contained pressure
controller, Fisher 3/4-inch 95H-109 or COMPANY approved equal. Heater shall
be fully insulated. The steam side of the heater shall be rated for 250 psig
maximum allowable working pressure (MAWP)
2.10.9. Steam Trap
Steam condensate shall be removed from the oil heater by a Sarco OK-300 or
COMPANY approved equal, float/thermostatic steam trap installed downstream
of the heater. A line strainer with a manual drain valve shall be installed ahead
of the trap. The condensate shall be discharged to the drain system with a block
and bleed valve installed in the drain to permit checking the trap operation. The
bleed valve shall be vented to atmosphere. Steam traps, solenoid valves, manual
valves, and the strainer shall be easily accessible for maintenance. All manual
valves shall be ball valves for steam service at 250 psig operating pressure.

SP-ME-ME-022 Rev. 1
2.10.10. Pressure Relief Valve

A pressure relief valve shall be installed down stream the heater to protect
against over pressure on the fuel oil line.
2.10.11. Strainer
The fuel oil system shall be equipped with a fuel oil strainer and a duplex fuel oil
strainer, each equipped with drain valves. The fuel oil strainer shall be located
where the fuel oil piping enters the generator skid and shall be a Hayward #50
Duplex Strainer, 2-inch stainless steel baskets with 3/64-inch dia. holes, or
COMPANY approved equal. The Duplex fuel oil strainer is to be located
downstream of the fuel oil heater and shall be a Hayward #50 Duplex Strainer,
1-inch stainless steel baskets with 1/32-inch dia. holes, or COMPANY approved
equal. Strainer materials shall be carbon steel; cast iron is not acceptable.
Strainers shall be located for easy operator access. Sheet metal catch basins shall
be installed under the strainer for spillage. The basin shall have a sloped bottom
and a 2-inch drain connection. The basin drain shall be connected by Vendor to
the main drain header on the generator using a size NPS 2 drain pipe. A 2-inch
ball valve shall be installed in the drain line between the basin and the main drain
header.
2.10.12. Regulator
Fuel oil pressure at the burner shall be regulated with a 3/4-inch Fisher 95H or
COMPANY approved equal regulator (75-150 psig spring range) located
downstream of the secondary fuel oil strainer. A 3/4-inch ball valve shall be
installed between the secondary strainer and the pressure regulator. A pressure
gauge (0-200 psig range) with block valve shall be installed immediately
downstream of the 95H regulator.
Fuel oil piping shall be installed so that no piping connections have to be
disassembled to open the hinged burner door. Flexible stainless steel lines shall
be used where necessary to achieve this.
2.10.13. Atomization System
?? The generator shall use steam or air atomization alternately. Atomizing steam
at 95% quality and 175 psig will be supplied by COMPANY. A Fisher
Model 95H or COMPANY approved equal for steam atomizing pressure
regulator completed with a strainer shall be provided by Vendor.
?? ASCO or COMPANY approved equal electric solenoid-operated shutoff
valves shall be provided in the steam atomizing line at the burner. The valves
shall be suitable for high temperature operation and be activated by the
generator shutdown system.
?? A manual block valve shall be installed just upstream of the solenoid valves.
A manual drain valve shall also be installed upstream of the solenoid valves
to drain condensed water prior to start-up. The drain shall be routed to the
main drain header.

SP-ME-ME-022 Rev. 1
2.10.14. Burner
?? Furnish for crude oil or natural gas firing a Dual Fuel Burner COEN
Quantum Low Nox or equal without any Flue Gas Recirculation Technology,
with maximum input capacity of 62.5 million BTU/hr.
?? Burner shall guarantee Nox emission on natural gas firing will not exceed 30
ppmv dry at 3 % oxygen. CO emission will not exceed 200 ppmv
?? The Modulating firing range of the burner on gas fuel shall be less than 8 to 1
and on crude oil shall not be less than 6 to 1. The burner shall be capable of
firing fuel with not over 15 % excess air at full load with minimal CO and
unburned combustibles.
?? Lower Electrical Power consumed by the Blower electric motor will be
consider. Operating cost for 5 years service will be used for basic calculation
in the price evaluation.
Burner shall have the following instrumentation :
a. Fuel oil preheat temperature indicator
b. Fuel oil injection pressure indicator
c. Steam (or air) atomization pressure indicator
d. Low blower pressure shutdown switch set for 8-inch H20 column.
?? Burner throat high temperature indicating limit switch
?? Bailey flamon UW3100 or COMPANY approved equal ultraviolet flame
detector with swivel mount. Purge air shall be supplied to detector from
combustion air blower; final connection to sensor shall be with braided
stainless steel hose.
?? Any hinged or quick-release latches on the burner mount shall be provided
with interlock safety switches tied into the generator shutdown system. Any
necessary flexible hose shall be provided to allow the burner swing easily
with minimum connection to be released.
?? Adequate space for installation of additional air dampener shall be provided.
2.10.15. Blower
2.10.15.1 General
?? Boiler shall be furnished with at least one forced draft fan. Detailed
specification is shown in the attached data sheets.
?? Fans shall be of centrifugal type and shall be furnished complete
with suction damper control or variable vane control, inlet screen,
silencer, flexible coupling, coupling guard, bearings, pedestals and
supports.
?? Fan housing or inlet box shall be made of minimum 5 mm plate
and braced for rigidity. Housing shall be designed to allow
horizontal split for rotor removal without dismantling the duck
work.

SP-ME-ME-022 Rev. 1
?? Exposed shaft surface and couplings shall be covered by guard

cage.
2.10.15.2 Vendor shall provide a forced-draft combustion air blower,
Driven by a 40 HP max.TEFC 1800 RPM motor suitable for Class I
Div II Group D area classification, which meets the attached induction
motor data sheet. The motor shall have space heaters. The blower
housing shall have an observation port for looking down the burner
throat. The elevation of the observation port shall be 5 feet from the
grating. A 3/4" drain with plug shall be provided on blower housing.
2.10.15.3 Blower inlet ducting and roof opening shall be sized for full
blower suction capacity.
2.10.15.4 Vendor shall submit the air capacity calculation for approval
before proceeding with the size of the blower motor.
2.10.15.5 The blower inlet duct shall enter through the cab roof and have a
stainless steel bug screen and a rain cover. A removable section shall
be included as part of the inlet duct to allow for removing the control
cab roof. Maximum opening size of screen at blower inlet shall be
0.25".
2.10.15.6 The blower-to-burner flex hose connection shall be
soundproofed. Sound proofing material shall be covered with a
weatherproof jacket.
2.10.15.7 Blower shall have 1" NPT port for providing purge air to view ports
and ultraviolet flame detector and a 2” NPT line to pilot gas train.
?? Capability
a. Rated air flow shall be 115% of the air flow required for the
operating condition at M.C.R., firing the specified fuel at 17%
excess air for oil and at 14% excess air for gas firing.
b. Rated static head shall be sufficient at M.C.R. condition with
firing the specified fuel at 17% excess air for oil and excess air
for gas firing.
c. Fan and driver shall be so designed that there is no shortage of
shaft power in the coldest winter and no shortage of volumetric
capacity in the hottest summer.
?? Noise Control
a. For noise reduction, fan shall be furnished with a sound
absorption material covering its outer surface and with suction
stack covered with a sound absorption material. Inlet of the
suction stack shall be provided with weather hood against
snow rain shower.
b. Noise at any point 1 m or more distant from the surface of
machine shall not exceed 90 dB (AI), unless otherwise
specified.

SP-ME-ME-022 Rev. 1
?? Flow Control
Fan speed control by variable voltage or variable frequency device
may be used.
2.11. Piping System

2.11.1. General
2.11.1.1 Code and Material
Pressure piping shall be designed and constructed in accordance with
the code jurisdictional limits for piping of Section 1 ASME Boiler and
Pressure Vessel Code. Piping defined in Section 1 of the Code as
"Non-Boiler External Piping and Joint" shall be designed and
constructed in accordance with ANSI B31.3, Petroleum Refinery
Piping.
?? Flanges, valves, and fittings shall be in accordance with applicable
ANSI standards. Vendor shall provide necessary ASME P-4A
materials certificate.
?? The pipe material shall be carbon steel Grade B. Screwed and
socket weld fittings shall be 3000# minimum. Galvanized pipe
shall be A-120 gr B and galvanized fittings shall be 150# M.I.
Radiant tubes shall be SA 106 B or 53 B seamless pipe.
?? Screwed or socket-weld piping shall be used for all fuel oil piping
and other lines size NPS 1.5 and smaller. Screwed piping in
hydrocarbon service shall be seal welded. Pipe dope or tape shall
not be used on seal-welded, threaded joints.
?? Flanged valves shall be quoted as the base bid for water piping.
Weld-end valves may be quoted as an alternative.
?? Low melting temperature materials such as brass, copper and
aluminum, in addition to cast iron shall not be used for any
component which will be in contact with hydrocarbons.
COMPANY shall approve all materials proposed.
2.11.1.2 Piping Lay-out
The lateral pipeway shall be at the left side of steam generator to
connect steam generator piping to the main pipeway. All the steam
generator piping shall be installed for direct connection to the lateral
pipeway and all connections shall be on the left side of steam
generator.
?? Generator skid piping to and from the lateral pipeway shall be
routed under the generator shell wherever possible. All pipe
routing shall be approved by COMPANY prior to spool
fabrication.
?? A minimum of piping connections shall be made between skids.

SP-ME-ME-022 Rev. 1
Piping connections between skids shall be flanged, except for drain

pipe header. All piping components shall be identified and tagged
with matching permanent metallic markers.
?? Piping layout shall provide accessibility and ease of operation for
valves. Minimum clearance around valve handles, handle wheels,
etc, must be 3 inches. Valve handles located close to hot lines must
have a minimum 6 inches clearance.
?? Vendor shall refer to the related P&ID regarding the scope of
supply.
2.11.1.3 Support
All piping shall be rigidly supported from structural members. Grating
shall be cut to fit around pipe supports. Piping system design shall
include provisions for possible differential thermal expansion and
vibration-induced fatigue at small branch connections.
2.11.1.4 Drain
All the piping, except for the drain line, shall be provided with drains.
2.11.2. Feed Water System
The feedwater flow rate shall be controlled at a constant rate by a flow control
loop consisting of a turbine meter for flow rate measurement, a control valve for
flow control, and a three mode (PID) controller implemented in the steam
generator's Programmable Logic Controller (PLC).
2.11.2.1 Turbine Meter
The turbine meter shall be installed upstream of the flow control valve.
It shall be located and positioned to provide convenient access to the
test port on the meter body. To ensure metering accuracy, the meter
shall be provided with minimum 20 times diameters upstream and 10
times diameter downstream of meter tube. The inside diameter of the
pipe shall match the turbine meter bore. The meter shall be centered in
the flow stream and flange gaskets shall match the pipe bore.
The turbine meter shall be a Halliburton EZ-In, 2" x 2", with binderless
carbide bearings, or COMPANY approved equal. Turbine meter shall
be furnished complete with a magnetic pickup rated for 400°F.
2.11.2.2 Turbine Meter Input to PLC
The turbine meter shall be wired to Analog input module, Modicon
model 140-030-00, mounted in the PLC control panel. Signal wires
shall be shielded and installed in conduit from the turbine meter to
termination in the Junction Box on Steam Generator Skid. Signal
wires shall be kept separate from power conductors to avoid
contaminating the signal with electrical noise. The wire connection
shall be install in such a orientation that the wire does not offset from
the skid level.
2.11.2.3 Controller

SP-ME-ME-022 Rev. 1
The PID controller shall be programmed in the PLC software. Tuning

and set-up parameters will be accessible through an operator interface
located in the PLC control panel.
The controller will have the following features:
?? PID control modes
?? Remote set point
?? Display process measurement and set point in engineering units
?? Anti-integral wind-up
?? Auto tuning
?? Display output as 0-100%
2.11.2.4 Controller Output
The controller will drive a 4-20 mA output module. The module's
power supply for the 4-20 mA loop will be in the PLC equipment rack
inside control panel. The output will be wired to an I/P transducer
mounted on the control valve.
2.11.2.5 Control Valve
The control valve, Fisher or COMPANY approved equal, shall be
designed to control the flow of feedwater at a constant rate over the
range of process conditions. Control valve shall be furnished complete
with actuator and current to pneumatic (I/P) transducer. The control
valve shall be designed for fail-safe operation.
2.11.2.6 Vendor will be responsible for valve and actuator sizing, and valve
material selection. The valve shall be sized to throttle between 20 and
70% of the stroke range for the range of process conditions specified.
Select body style and trim to avoid cavitation. Vendor shall submit
sizing calculations and specifications for COMPANY review and
approval.
2.11.2.7 Preheater
A feedwater preheater shall be provided for heating feedwater before it
enters the convection section. The preheater shall be designed to
preheat the feedwater from 120°F to 260°F which ensures that tube
temperatures in the convection section will always be above the
exhaust gas acid dew point. A bypass manually operated globe valve
shall be provided to compensate for inlet feedwater temperature
changes and convection section tube fouling. The preheater shall be a
double pipe heat exchanger of ‘hairpin’ design (180° return bend) with
sufficient clearance to allow for maximum differential expansion
between the inner and outer strings. The preheater shall be fully
insulated.
2.11.2.8 Pressure and Temperature Gauge
Local readout pressure and temperature gauges shall be provided

SP-ME-ME-022 Rev. 1
upstream and downstream of feed water preheater, in both water and

hot steam line.
All water piping shall be insulated in accordance with the requirement
in this specification.
2.11.2.9 Code and Standard
Piping to the radiant and convection section shall include required
ASME Code Section I, inlet block and check valves. Piston check
valve, Durabla or COMPANY-approved equal shall be used as a check
valve for feed water / steam discharge application. Vendor shall install
a gate valve instead of needle valve for instrument connection in feed
water/steam discharge application.
2.11.3. Boiler Tubing
Steam Generator design shall have no heat absorbing pressure part larger than
three-inch pipe size
2.11.3.1 Radiant Tubes
The radiant tubes shall be constructed of SA-53-B or SA-106B
seamless minimum sch 80 pipe, A-234-WPB, and short radius return
bends, minimum sch 80, arranged in a once-through design. Tube butt
welds shall not utilize backup or internal chill rings. No fittings made
in China are allowed.
The radiant tubes shall be spaced for maximum heat absorption from
both direct and reflected heat. The design shall not allow flame
impingement on any tubes or tube hangers.
2.11.3.2 Radiant Tube Hanger
The radiant tubes shall be supported at intermediate positions with
free-slip type high alloy cast steel and shall be free to expand with
temperature changes. Hangers shall be of the ‘loose pin’. Clearance
between radiant section tubes and refractory shall be 2 inches. Yoke
weight shall be 9.5 lbs minimum. Yokes shall be bolted in place with 3
studs of minimum length to allow at least one-half inch projection on
either side of the hanger assembly.
Vendor shall tighten the stud bolt using a torque meter to ensure that
the bolt can hold the yoke against any vibration.
There shall be a minimum of 5 complete rings of hanger in the radiant
section. Hangers, yokes, stud, and nuts shall be made of one of the
following steel alloys.
?? ASTM A297 Grade HH (25 Cr, 12 Ni)
?? ASTM A297 Grade HK (25 Cr, 20 Ni) or
?? ASTM A447 Type II Grade HH (25 Cr, 12 Ni)
2.11.3.3 Convection Tubes
All convection tubes are to be SA-53-B or SA-106B seamless,

SP-ME-ME-022 Rev. 1
minimum schedule 80. All tube return bends are to be SA-234-WPB

short or extra-short radius, minimum schedule 80. The tubes are to be
removable trough the tube sheets.
2.11.3.4 Tube Configuration
Convection section combustion gas inlet shall have a bare tube section
(three rows minimum) ahead of the finned tube section to prevent fin
heat damage. Maximum fin tip temperature shall be 950 deg. F.
Maximum fin density on the convection tubes shall be 36 fins per foot.
Maximum fin he ight shall be 1-inch, except first row of finned tubes
which shall have a maximum fin height limit of 1/2-inch. Minimum fin
thickness shall be of 0.060-inch. Fins shall be of the continuous edge
design and be continuously welded to the tube.
2.11.4. Steam Discharge Piping
2.11.4.1 Pressure Drop
The discharge piping and valves shall be sized for minimum pressure
drop. Reduced port valves and valves sized smaller than discharge
piping are not acceptable. All steam discharge piping shall be insulated
in accordance with the requirement of this specification.
2.11.4.2 Pressure Relief Valve
Two packed-lever ASME Code Section I safety relief valves, Crosby
or COMPANY approved equal, shall be provided in the steam
discharge piping, mounted low for easy access (4 feet above skid
maximum). Relief valves should be set within design pressures under
Code requirements. Valve discs and seats shall be of suitably hard
material to resist erosion during routine testing of the valves. The
valves shall have closed bonnets, a 0.375-inch NPT minimum tapped
pipe body drain below seat level, and packed lifting levers. Body
drains and honnet vents shall be piped away to a safe location beneath
the steam generator using 1/2" stainless steel tubing. The valves shall
be sized so that during maximum firing and flow rate the generator
pressure will not exceed the limits contained in ASME Section I, Pg-67
A 3/8-inch stainless steel tube and appropriate Swagelok or
COMPANY-approved equal fitting shall be installed in safety relief
valve bonnet vent and drain. The end of the tube should be directed to
the drain header.
2.11.4.3 Block Valve
Separate ASME Code block valve on discharge line shall be installed.
2.11.4.4 Gauges
Pressure and temperature gauge shall be installed on the discharge line.
2.11.5. Boiler External Piping and Boiler Proper Connection
?? Valves and instruments on the boiler and attached pipings shall be so
arranged as to be easily operated and inspected from operator’s working area.

SP-ME-ME-022 Rev. 1
?? The boiler pipings shall be so arranged as to avoid interfering with boiler

proper or other structures.
?? Boiler pipings for hot medium (higher than 60?C) shall be provided with
thermal insulation for heat conservation and personnel protection.
?? The boiler shall be provided with pipings as specified in PG-58. F1 and Fig.
PG-58.3.1 ASME Sec. 1, as a minimum requirement, unless otherwise
specified.
?? Discharge point of vents and drains shall be so arranged as to avoid danger to
operator in the vicinity.
2.12. Instrument Air Supply System

2.12.1. A central instrument air supply will be provided by THE Vendor. Instrument air
will be dehydrated and supplied at a pressure of 100-125 psig. Vendor shall
furnish the COMPANY with the pressure, volume, and maximum moisture
requirements of air supply system with the bid submittal. The COMPANY will
provide the interconnection piping between the air compressor skid and each
generator skid.
2.12.2. Each generator shall be equipped with an instrument air system, piped by Vendor
to the edge of generator control skid at skid beam level. All instrument air piping
shall be galvanized steel. Ball valves of 0.5 inch Male x Female (MxF) shall be
furnished at each air take-off point.
2.12.3. One inlet coalescing filter/separator with a 1-micron rating shall be installed
upstream of all pressure regulators and instruments, equipped with a differential
pressure gauge or indicator.
2.13. Electrical System

2.13.1. General
2.13.1.1 Area Classification
The generator will be installed in an area classified as Class I Div II
Group D hazardous location.
2.13.1.2 Code Compliance
The generator's electrical system shall comply with the latest edition of
the National Electrical Code (NEC). All electrical material and
equipment shall have Underwriters' Laboratories (UL), or other
COMPANY-recognized testing laboratory approval for the service in
which it is to be used, and shall bear their label or listing. Equipment
and material not available under Underwriters' Laboratories label shall
be assembled from UL-approved components.
All electrical components shall have NEMA-4X enclosures.
2.13.2. Wiring
2.13.2.1 Wiring Conduit
All external wiring shall be installed in ga lvanized rigid-steel conduit,

SP-ME-ME-022 Rev. 1
except for short terminal connections (18-inches maximum length),

which shall be installed in Sealtite flexible liquid-tight conduit. All
conduit runs shall be installed in a neat and workmanlike manner,
parallel or perpendic ular to structural members. Appropriate conduit
support fittings or clamps (such as Unistrut) shall be installed on
structural members as required. Where bends or offsets are required,
they shall be made with suitable conduit bending equipment. Uniform
circular cross-section of the conduit shall be maintained at such bends.
No single bend shall be greater than 90°.
2.13.2.2 Power Cable
All wire for power and lighting circuits shall be single conductor
copper, minimum No. 12 AWG with type THWN insulation. For
control circuits wiring shall be minimum No.18 stranded AWG with
type THW insulation. All internal panel electrical wiring shall be
Class D stranded Type SIS General Electric Co. Vulkene insulated
switchboard wire, No.18 AWG minimum.
2.13.2.3 All wiring shall be neatly bundled together and supported from the
panel framework or enclosed in non-metallic raceways so that no strain
is placed upon the terminations.
2.13.2.4 All wiring shall be identified at termination points using preprinted
tubular heat shrink wire markers or preprinted tubular vinyl wire
markers such as Thomas & Betts Shur-Code. Wires shall be numbered
as shown on the point-to-point connection drawings prepared by
Vendor.
2.13.2.5 All control wiring shall be terminated with compression type ring lugs
with insulated sle eves or in tubular clamp type terminals. The
maximum number of wires connected to any terminal shall be two. All
wiring outside the panel shall be made on one side of the terminal
blocks, and all wiring inside the panel on the other side of the block.
2.13.2.6 All wiring from external devices shall enter the panel from the bottom
and be terminated on terminal blocks, except for motor & heater leads,
and annunciator field device wiring. Motor and heater leads shall be
run continuously from the motor terminals to the
starter/CONTRACTOR. All field devices which wire to the
annunciator shall be run continuously from the device to the
annunciator terminal, except for shipping splits required between skids.
2.13.3. Terminal Boxes
Skid interface terminal boxes shall be furnished for all wiring between
skids, except for motor and heater leads. The boxes shall be
NEMA-4X and large enough to accommodate all wiring and terminals
required. Terminal boxes shall be located where access is readily
available. Minimum working clearance in front of terminal boxes
shall be 3'-0".

SP-ME-ME-022 Rev. 1
Bottom of terminal boxes shall be located approximately 1'-6" above generator

skid grating and shall be properly supported from existing structure. The
terminal boxes shall be located in the burner and radiant skids near the ends
adjacent to the shipping split. All field wiring from the radiant and burner
sections shall be terminated on terminal strips in the respective terminal boxes.
All field devices on the burner skid shall be wired to the generator control panel
through the on skid terminal box. All field devices on the radiant skid shall be
wired to the radiant skid terminal box. Interwiring between the burner and
radiant skid terminal boxes will be made by COMPANY in the field after
equipment assembly. For this purpose Vendor shall provide an interconnection
wiring diagram indicating wiring terminations to be made by COMPANY. In
addition Vendor shall terminate one end of this interwiring in the radiant skid
terminal box and leave sufficient wire coile d inside this box for COMPANY to
complete interconnections. Rigid steel conduits shall be installed from terminal
boxes to shipping split as required for COMPANY field wiring. All wires and
terminals shall be numbered as shown on Vendor drawings. COMPANY is to
approve terminal box locations before installation by Vendor.
2.13.4. Motor
2.13.4.1 Motors shall be designed and fabricated in accordance with the latest
edition of NEMA Publication No.MG 1, "Motors and Generators", and
applicable sections of the National Electric al Code. All motors 1
horsepower and larger shall be 460 volt, 60 Hz, 3 phase, high
efficiency, TEFC induction motors and have a 1.15 service factor.
2.13.4.2 Motor terminal boxes shall be weatherproof, of cast iron, heavy
fabricated steel, or cast aluminum, with gasketed covers and threaded
conduit entrances.
2.13.4.3 Motors shall be provided with slingers or shaft seals to prevent dirt and
moisture from entering bearings. Balance washers shall be of
corrosion-resistant material and rotors shall be given a
corrosion-resistant coating after balancing. Motor finish and external
hardware shall be resistant to salt-water washdown and corrosive
atmospheres found in the petroleum industry. Nameplates shall be
stainless steel.
2.13.4.4 Generator mounted motors shall be TEFC Severe Duty Type. External
housings shall be cast iron or copper-free aluminum throughout,
including fan covers. Fits shall be sealed to prevent moisture entrance.
Leads shall be sealed between motor housing and terminal box. Fans
shall be non-sparking inert plastic, brass, bronze, or copper-free
aluminum.
2.13.4.5 TEFC motors shall have a 1/4-inch diameter minimum untapped drain
hole or a 1/4" NPT (minimum) tapped drain hole fitted with a pipe
plug or suitable drain fitting. The drain hole shall be located at the low
point of the motor as mounted. If necessary to completely drain all
moisture due to ribs in the lower end bell, more than one drain hole
shall be provided. Bearings and grease chambers shall be arranged to
provide adequate lubrication of both upper and lower bearings for the

SP-ME-ME-022 Rev. 1
mounting position specified, even when all grease has liquified due to
centrifugal action or high temperature.
2.13.4.6 Motor frames shall be assigned in accordance with the latest edition of
NEMA Publication No. MG 1.
2.13.4.7 Motor terminal boxes shall be of adequate size to permit terminating
motor leads and other wiring at the motor. For motors rated 600 volts
or less, terminal box shall be sized in accordance with NEMA
MG1-11.06 or MG1-20.62, as applicable. Conduit entrance shall be
adequate for rigid steel conduit required for Type THW or THWN
aluminum conductor power leads sized in accordance with the National
Electrical Code, but not smaller than 3/4-inch diameter. Separate
terminal boxes shall be provided for space heater and temperature
detector leads.
2.13.4.8 Induction motor rotor cages may be of fabricated copper or copper
alloy, fabricated aluminum, or cast aluminum construction. The rotor
cage and core construction shall have proven satisfactory performance
in the size, speed, and horsepower ranges specified.
2.13.4.9 Bearings and lubrication systems shall comply with the requirements
of subsections 3.9 and 3.10 of API RP-541, with the following
exceptions:
?? Grease-lubricated ball bearings shall be provided on all motors up
to 250 horsepower.
?? Ball bearings shall be vacuum-degassed steel, motor quality.
Bearings shall be selected for a minimum AFBMA L-10 Rating
Life of 40,000 hours continuous service at rated motor load and
40°C ambient temperature.
2.13.4.10 All motors shall be suitable for full-voltage starting. Polyphase
integral-horsepower induction motors per NEMA MG1-10.32D shall
have starting capabilities in accordance with NEMA MG1-12.50.
2.13.4.11 Motors shall be capable of accelerating actual driven load, or load
inertia in accordance with NEMA MG1-20.42 where driven load is not
known, with 80% of rated voltage applied. Vendor shall submit with
his bid the following data for motor accelerating its load under the
above conditions: line current, efficiency, power factor, and
acceleration time versus speed or slip. Data may be in the form of
plotted curves or tabular computer output.
2.13.4.12 Vendor shall specify the guaranteed minimum efficiency for each
motor per IEEE 112 Method F. The stray-load losses shall be assumed
as 1.2% for motors below 2500 horsepower.
2.13.4.13 The minimum permissible stall (locked rotor) time shall be either 150
% of, or 5 seconds more than, (whichever is greater), the time required
to accelerate the actual driven load, or load inertia in accordance with
NEMA MG1-20.42 where driven load is not known, with 80% or rated
voltage applied.

SP-ME-ME-022 Rev. 1
2.13.4.14 Random-wound motor insulation shall be Class F. Motor lead

insulation shall be oil-resistant. Form-wound sealed insulation shall be
Class F with Class E temperature rise and shall consist of mica
insulation with glass and/or other tapes and/or wrappers. The
completely wound stator shall be vacuum-pressure impregnated with
epoxy resin after connections are made and leads attached.
Impregnation process shall ensure complete penetration of epoxy resin
into interslices in stator slots to provide void-free insulation.
Completed form-wound stators including all connections shall be
capable of passing immersion test in accordance with subsection 6.3 of
API RP-541. Additionally, stators shall be capable of thermal cycling
and thermal shock tests. Moisture-sealed insulation shall be
impervious to salt water and hydrocarbons.
2.13.4.15 Where built-in thermal protection is required, protective devices shall
be set to prevent dangerous overheating of the motors due to overload
or failure to start. Devices shall not operate below 120% of full load
current for 1.15 service factor motors at an ambient temperature of
40°C.
2.13.4.16 All motors 50 horsepower and larger shall be provided with space
heaters. Space heaters shall be for 120 volt operation and be
completely wired, with leads brought to a terminal box separate from
the power lead terminal box. Surface temperature of space heaters
shall not exceed 200°C when operating at rated voltage. Where a
motor may be exposed to a gas or vapor with ignition point less than
250°C, the surface temperature of the space heaters shall not exceed
80% of the gas/vapor ignition temperature.
2.13.4.17 Vendor shall quote their standard designed motor as base bid and state
expected noise level in dBa 3-feet from the motor. If expected noise
level at this distance is greater than 85 dBa, Vendor shall offer an
alternate bid for a motor not exceeding 85 dBa at 3-feet.
2.13.4.18 For shipment, shaft extensions shall be coated for corrosion protection.
Shaft extensions greater than 5 inches shall be protected against
mechanical damage by full-length wood slats strapped to the shaft.
2.13.5. Electrical Conduit System
?? All conduit and conduit fittings shall be rigid steel, hot-dipped galvanized or
zinc electroplated, UL-approved. Minimum conduit size shall be 3/4-inch
diameter. All conduit connections to couplings, fitting boxes, or devices
shall be threaded and with at least 5 full threads of engagement. Myers Type
"STG" Scrutite hubs shall be used for conduit connections to sheet metal
enclosures in all outdoor applications.
?? All conduits 3-inch diameter and larger are required to have manufactured
bends or use condulets.
?? Aluminum threading dies shall not be used on steel conduits. Continuous
running threads are not acceptable. Threaded joints shall be made-up wrench
tight using proper tools. Hand-tight or channelock plier assembly is not

SP-ME-ME-022 Rev. 1
acceptable. Crouse-Hinds type ST-L, HT-L Compound or

COMPANY-approved equal shall be applied to conduit threads before being
made-up.
?? Conduits shall be installed so as to prevent flow of water from conduit to
device. In no case shall they be laid on the skid where they can become a
tripping hazard. Conduits shall be supported at such intervals as required to
prevent sag, but in no case shall intervals exceed 10 feet.
?? A run of conduit containing 600 volt and less insulated wire shall contain no
more than 3.5 quarter bends (315° total) between fittings, including offsets
and bends located immediately adjacent to the fittings. No single bend shall
be greater than 90°.
?? Liquid-tight flexible metallic conduit with PVC jacket shall be used only at
locations where vibration is present, where flexibility is required, and at all
motor conduit boxes. Terminations of flexible metallic conduit shall be
made using liquid-tight type connectors with integral threads and positive
ground connections. Bonding jumpers shall be installed in flexible metal
conduit larger than 1.25-inch diameter and in all sizes located in classified
areas. Appropriate grounding fittings shall be used in terminating bonding
jumpers. Ground conductors shall be located inside conduit except where
ground currents can interfere with sensitive electrical signals. In such cases,
the ground conductor may be located outside of the conduit. Maximum
length of flexib le conduit shall be 24 inches for conduit less than 2-inch
diamter, 30 inches for conduit 2-inch diameter and greater.
?? In areas classified as non-hazardous, metallic junction boxes and electrical
equipment enclosures shall have integral, threaded, conduit hubs.
Non-metallic enclosures (Rostite) shall have UL-listed threaded conduit
hubs.
2.14. Control System

2.14.1. Instrument Air Lines
2.14.1.1 Instrument take-off
All instrument take-off (gas, air, oil, steam) which lead to a gauge or
other instrument are required to have a block valve and bleed valve, or
a multiport completed with a bleeder valve, to facilitate maintenance.
The valve shall be located that the operator can readily operate the
valve when necessary. 1/2-inch male by female (MxF) ball valves shall
be furnished where insulation is less than or equal to 1-1/2-inch thick.
1/2-inch ball valves, female by female (FxF), with appropriate nipple
shall be used when insulation is greater than or equal to 1.5-inches
thick. The nipple shall be seal welded to the threadolet. Branch
connections for pressure gauges on feedwater and steam piping shall
use a 3000# 1/2-inch NPT threadolet and a full penetration weld to the
main line. Use a NPS 1/2 Schedule 160 pipe nipple between isolation
valve and threadolet when line has more than 1-1/2 inch insulation.
2.14.1.2 Air Lines Tubing

SP-ME-ME-022 Rev. 1
All instrument air lines outside the control console shall be stainless
steel tubing, of 3/8-inch diameter and 0.035-inch wall thickness
minimum. 1/4 inch diameter tubing may be used inside the control
panel. Fittings shall be Swagelok or COMPANY approved equal.
Instrument air lines shall be installed in a neat and workmanlike
manner, parallel or perpendicular to structural members. Appropriate
support fittings shall be installed on structural members as needed.
Where bends are required, they shall be made with suitable tube
bending equipment. Uniform circular cross section of the tubing shall
be maintained at such bends. No single bend shall be greater than 90°.
2.14.1.3 Air Lines End Connection
The connection for instrument air system shall be provided by Vendor
on the generator at skid beam level on the control cab end. It shall be
equipped with pressure gauge and block valve. The instrument air
system shall include an inlet filter/separator. COMPANY will supply
instrument air to the generator skid boundary at 100-125 psig. Vendor
shall provide all necessary pressure regulators and gauges.
2.14.2. Instrumentation
2.14.2.1 General
Instrument ranges shall be selected such that the normal operating
range is between 35% and 75% of the instruments total range.
Instruments shall be approved by an independent testing laboratory
(UL, FM, CSA, or BASEEFA) for the service in which it is used and
shall bear their label or listing. Use of instruments without agency
listing will require written approval from COMPANY.
??Instrument components exposed to the environment shall be
weatherproof and of suitable design to withstand environmental
conditions as described in data sheets.
??All safety devices shall be set fairly close to the operating
conditions. Vendor shall submit the setting proposal for approval.
??Instrument drafting symbols and identification shall be per
COMPANY’s Drawing Standards.
2.14.2.2 Gages Installation
The gages shall be perpendicular to the process pipe flow. For steam
application it shall be installed at the top of the pipe. The gages shall be
located in a straight section of the pipe that contain streamline flow.
All Pressure gauges shall have Root connection, 2-way valve manifold
to block and bleed the pressure from the system. Root valve size shall
½ inch FNPT
2.14.2.3 Pressure Gauge
All pressure gauges in water/steam service shall be glycerineor silicone
oil-filled or other type that has a dampening effects. All pressure
gauges shall have a 4 1/2-inch dial face (0-2000 psi) with blowout plug

SP-ME-ME-022 Rev. 1
in the case, 1/2-inch NPT stem, stainless steel bourdon tube mounted
locally. Pressure gauges in steam service shall be equipped with steel
siphons. Gauges will have shatterproof glass and safety blowouts and
shall be of the safety front design. Dials will be white with black
markings.
2.14.2.4 Pressure Switches
Pressure switches will be of the snap-acting type, utilizing DPDT rated
not less than 4 amps at 120 VAC. All switches will be field adjustable
and will have a proof pressure at least 1-1/2 times the maximum
operating pressure to which they will be subjected. The operating
pressure shall be no more than 70 % of the maximum range.
Each pressure switch shall has its own root connection, not connected
from the same root valve connection that is made for other instrument.
Root valve shall be used with a plug tee to bleed the process pressure
to the atmosphere. Union connection shall be provided downstream the
switches for maintenance purpose.
Syphon shall be installed for steam application. Locking device shall
be provided in the pressure switch.
2.14.2.5 Thermowell
Protective wells manufactured from drilled 316 SS barstock shall be
used with all temperature elements. All wells shall be bored to 0.260-
inch and designed for use with bi-metallic thermometers. All test wells
shall be provided with a suitable plug and chain.
Thermowells shall be located in a downstream of Pressure Indicator
root connection at 2 - 5 diameter distance.
2.14.2.6 Thermometer
Thermometer will be of the 5-inch dial bi-metallic type, every-angle.
The number of ranges shall be kept to a minimum. It shall be of filled
system or has other type of dampener.
2.14.2.7 Electronic Instruments
Electronic instruments will be moisture and fungus proof and will
utilize a standard 4-20 mA DC transmission level. All Transmitter shall
be Smart Type.Thermocouples may be run directly to a receiver in the
control panel.
2.14.2.8 Pressure Regulators
Pressure regulators for instruments shall be filter/separator type, Fisher
67FR or COMPANY approved equal.
2.14.2.9 Safety-Relief Valves
Safety-relief valves shall be provided in accordance with ASME Boiler
and Pressure Vessel Code and the ANSI Code for Pressure Piping, as
applicable. Valve body material shall conform to piping specification.
Bellows seal or balanced-type valves shall be used.

SP-ME-ME-022 Rev. 1
All safety-relief valves will be of the spring loaded type with metal-to-
metal seats. Valve leakage shall conform to API RP-527 for
commercial tightness. Lifting levers shall be provided on thermal relief
valves.
2.14.2.10 Alarm and Shutdown System
Alarm and shutdown systems is shown on COMPANY P&ID drawing.
In general, shut down systems shall be design for maximum protection
of the operating personnel and equipment. Where applicable, shutdown
systems will be energized during normal plant operation, i.e., de-
energized to trip. Shutdown functions will be alarmed, and where
practical, an alarm will actuate prior to the shutdown. Alarm devices in
transmitter outputs are acceptable.
2.14.2.11 Solenoid Valve
All solenoid valves shall have Group 1, Class F coils that are moisture
and fungus proof and epoxy molded construction. The enclosure shall
meet the NEMA type 4 classification; i.e., watertight and dust tight or
explosion proof if required by area classification.
2.14.2.12 Announciator
An announciator shall have “First Out” capability with a choice of
N.O./N.C. signal contact. The unit shall contain an audible alarm, 120
V 60 Hz power supply. The display shall have two lamps per position.
2.14.2.13 Thermocouple
Thermocouple extension wire type "JX" shall be run in rigid steel
conduit separate from power cables. Vendor shall minimize wire
splices. All extension wire runs from thermocouple heads to recording
or indicating instruments in the generator control panel shall be made
without splices, except where wires are terminated on iron-constant
terminal strips provided in terminal boxes for this purpose. Extension
wires originating from thermocouples in the radiant section shall be
terminated in the radiant skid terminal box. Vendor shall provide
sufficient extension wire coiled in this terminal box for purchaser to
complete interconnection in the field. Extension wires originating
from thermocouples in the burner section shall be terminated in the
generator control panel through the burner skid terminal box. Rigid
steel conduits shall be installed from terminal boxes to shipping split as
required for CONTRACTOR's field wiring.
2.15. Programmable Logic Controller System (PLC)

Refer to SP-IN-II-006 “Programmable Logic Controller (PLC)” Specification
2.16. Automatic Combustion Control (A.C.C)

2.16.1. General
?? A complete automatic combustion control system shall be provided for the
boiler.

SP-ME-ME-022 Rev. 1
?? Control, indication, recording and alarm functions of the A.C.C. system shall
be integrated in the boiler control panel installed in control room
2.16.2. Master signal
?? Unless otherwise specified, pressure of the main steam shall be employed as
the master signal for the A.C.C. system
?? In case it is specified on the data sheet that both of the steam pressure and
steam flow are to be employed as master signal, change-over station shall be
provided in the boiler control panel.
?? Change-over of the master signal shall be done without causing any bumping
due to switching.
?? Auto/manual change-over switch shall be provided.
?? In case multiple boiler are connected to a common header, a common master
signal generator (at the main header) may be employed. In such case, load
distributing station shall be provided for respective boiler.
2.16.3. Control of Fuel
?? Flow quantity of fuel (gas or oil) shall be controlled by A.C.C.
?? If fuel (gas or oil) pressure at supply point is too high to be reduced by a flow
control valve, a pressure control system shall be provided.
?? For limiting maximum opening of fuel control valves, adjustable mechanical
stopper shall be provided.
?? Atomizing steam pressure for liquid fuel firing shall be controlled by a
differential pressure controller or a constant pressure controller. Diagram of
differential pressure pick-up cell shall be made of corrosion resistant
material.
?? In case multiple fuels are to be automatically controlled simultaneously, sum
of the fuel flow as the feed back signal to the A.C.C. system shall be
converted into the value of amount of heat.
?? In case of multiple fuel control, “auto-manual” switch-over station shall be
provided for each fuel.
?? In case of multiple fuel control, “bumpless” switch-over system for selecting
automatically controlled fuel from one fuel to another shall be provided.
2.16.4. Control of Air
?? Flow rate of air shall be controlled by the A.C.C. system by regulating inlet
vane of the forced draft fan.
?? Variable fan speed control by changing the electric frequency may be used.
?? An air-rich control system shall be provided for fuel/air control circuit.
?? Air flow shall be measured and feed-back.
?? In case a tandem driving system with automatic driver change-over is applied
for the forced draft fan, temporary automatic fuel reduction system shall be
applied. Whereas air flow shall be controlled keeping ‘air rich’ condition.
2.16.4.1 Burner fire shall be kept stable at the specified turned-down condition. ‘ON-
OFF’ control of fire is not acceptable.
2.16.4.2 Minimum sustainable firing rate shall be specified by Vendor.
2.16.5. Feed Water Control

SP-ME-ME-022 Rev. 1
?? The feed water flow to the boiler shall be controlled by a three element
control which rations water flow to steam flow and is reset by drum level,
unless otherwise specified.
?? Signal for water level control shall be raised by differential pressure type
transmitter. Signal for boiler trip by extremely low water level shall be raised
by displacement type transmitter. Each function mentioned above shall be
extracted from each individual column.
2
?? Trip-triggering primary element for boilers of 100 kg/cm G class and over
may be of differential pressure type instead of displacement type.
2.16.6. Steam Temperature Control
?? In case of superheated steam boiler, steam temperature control shall be
provided.
?? In the S.T.C control range, steam temperature fluctuation shall be within
+3?C of the rated steam temperature
?? In case a high response is needed, S.T.C. loop configuration shall be as
specified in the attached data sheet.
2.17. Safety System

2.17.1. The boiler shall be provided with a master fuel trip (M.F.T.) system to avoid
explosion, overheating and other hazards.
The M.F.T. system shall be designed to be triggered by the following reason ;
?? Loss of flame in operation and failure of ignition.
?? Extremely low water level.
?? Other reason specified in the succeeding paragraphs.
2.17.2. Summary of alarm and trip items
Alarm and trip items whose instruments are mounted on the instrument panel
shall be as followings : *1
?? Low drum water level (alarm)
?? High drum water level (alarm)
?? Extreme low drum water level (alarm and trip)
?? High steam pressure (alarm)
?? Low steam pressure (alarm)
?? High steam temperature (alarm)
?? Low fuel pressure (alarm)
?? Extremely low fuel pressure (alarm and trip)
?? Low feed water pressure (alarm)
?? Electric power failure (alarm and trip)
?? Low instrument air pressure (alarm)
?? Instrument power failure (alarm)

SP-ME-ME-022 Rev. 1
?? F.D.F. trouble (alarm and trip)*2

?? Flame extinguishing (alarm and trip)*3
?? Emergency shut valve closing (alarm)
?? Fuel gas emergency blow off valve open (alarm)
?? Low differential press. Of atomizing steam and fuel oil (alarm)
?? Manual push button for stop (alarm)
Note : *1 Alarm window expressing the first reason of trip shall be kept flickering
*2 In case F.D.F. stopped, ignition must not be established.
*3 Number of extinguished burner(s) out of the total equipped number, which is to
initiate the trip condition of the boiler, shall be defined by Vendor’s option.
2.17.3. The flame safeguard system shall be designed as follows :
?? Flame detection for each burner :
a. Flame detector must be positioned so that they detect the flame at all
loads and during all load changes.
b. Flame detector shall be provided with self-checking feature which
continuously check all components, from the scanner to the output
relay, at least once every 6 seconds without affecting the response time
of the flame detector.
?? Fuel cut-off time shall not exceed 2 seconds.
?? Response time shall not exceed 1 second. However, response time for fuel
may be lengthened up to a total of 3 seconds by means of an external time
delay
?? Adjustable time delay relay with a range of 0 to 2 second shall be provided in
the fuel cut-off valve trip circuit and shall be car-sealed after initial setting.
?? Flame-out signals from detectors shall automatically trip-shut the associated
individual burner fuel cut-off valves.
?? Flame detector relays shall operate cut-off valves directly without
intermediate relays, except for the time delay in the fuel cut-off valve trip
circuit.
?? Individual burner fuel cut-off valves shall be provided with locally mounted
reset devices consisting of either electric pushbuttons with self-sealing
relays or latch type-type solenoids.
?? Cut-off valves closure time shall not exceed 1 second and valve opening time
shall be compatible with burner light-off requirements.
?? Burner light-off facilities:
a. Ignition control station, consisting of panel with lamps and pushbuttons,
shall be located at the burner floor.
b. Pressure controller on pilot gas line shall maintain proper pilot gas
operating pressure.

SP-ME-ME-022 Rev. 1
Ignition interlock for light-off shall include the following sequence:

?? Main shut-off valve are closed, and no flame is present.
?? Prepurge of furnace
?? Not less than five times of furnace volume but, in any event, for a continuous
period of not less than five minutes at a rate equal to or greater than 25% of
full load volumetric air flow.
?? Opening of main pilot gas shut-off and individual ignitor gas valves, only
after pre-purge is completed.
?? Ignition and providing the pilot fla me
?? If pilot does light within 10-15 seconds, it shall be shut down. The spark
shall be sustained for not longer than 10 second. Establishment of ignitor
torch shall be proven by the flame scanner during this period.
?? Ignitor of the first main burner
?? Ignitor to main burner shall be done within 5 second after opening of the
burner fuel valve. If ignition to main burner fails, individual burner fuel and
pilot gas cut-off valves shall be closed.
?? Then repurge and reignition of pilot shall be required.
?? A light-off caution plate shall be permanently mounted on the local ignition
control panel.
2.18. Control Panel

2.18.1. The panel shall be equipped with two ground buses for connection of
COMPANY's No.2 AWG minimum copper grounding conductor. One ground
bus for Power Grounding system and the other for Instrumentation wiring
system. Instrumentation Grounding system shall be isolated. NEC-sized
grounding conductors shall be installed in the power lead conduits for equipment
such as motors, heaters, and transformer case and neutral. Grounding jumpers of
No.2 AWG copper shall be installed across all skid shipping splits so that the
exposed metal of the entire steam generator package is electrically continuous.
2.18.2. The panel shall be equipped with space heaters and thermostats to maintain
inside panel temperature above dew point. Vendor shall provide the panel with
an extra terminal connection for external power supply to energize space heaters
during storage or fabrication. Vendor shall be responsible to provide the external
power supply.
All equipment and devices within the panel, including all pushbuttons, selector
switches, and indicating lights, shall be identified with bakelite/laminated plastic,
nameplates and/or stainless steel tags. Nameplates shall be 1/8-inch thick, black,
with minimum 1/4-inch high engraved white lettering and attached with stainless
steel screws. The identification, including terminal block points, shall conform
to that shown on the wiring diagrams.
2.18.3. All 3-Phase motors shall be controlled by combination starters employing motor
circuit protectors and magnetic contactors with ambient-compensated thermal

SP-ME-ME-022 Rev. 1
overloads in each motor lead. All starters shall be provided with circuit
breaker/disconnects. All starters and breaker/disconnects shall be Square D or
COMPANY- approved equal.
2.18.4. Circuit breakers rather than fused switches shall be used for protection of all
power, lighting and control circuits.
2.18.5. All shutdown and control circuits shall be 120-volt, single phase, 60 Hz.
2.18.6. The generator shall have a control console to facilitate monitoring pressures,
temperatures, flows, control functions, and alarms. It shall be installed out of the
cab area and shall have at least the minimum access clearances specified by the
National Electrical Code.
2.18.7. The control console shall be a free-standing ventilated NEMA 4X enclosure of
minimum 7 gauge hot-rolled steel plate. It shall contain all electrical controls
mounted for ease of monitoring pressures, temperatures, flows, and control/alarm
functions in a single location.
2.18.8. All pane l-mounted select switches, pushbuttons, and indicating lamps shall be
Allen-Bradley 800H or COMPANY-approved equal.
2.18.9. Lighting transformer shall be encapsulated dry type of weatherproof construction
for outdoor installation. Transformers shall have type H (220°C ultimate
temperature) insulation and have a 115°C or less temperature rise at full-rated
load. The transformer shall have a rated capacity of at least 125% the initial
connected load.
2.18.10. A branch circuit panel shall be provided for all lighting, single phase power and
control loads.
2.18.11. The control areas shall be provided with manually- controlled fluorescent
lighting using enclosed, industrial type luminaries.
2.18.12. A 115-volt, 20 amp weatherproof receptacle with ground fault protection shall be
provided at the control console exterior for maintenance hand tool operation.
2.18.13. Electrical items shall be furnished as described on the attached Electrical Bill of
Material. The quantities as shown in the Bill of Materials are for the minimum
requirement only. Vendor shall be responsible to provide all necessary materials
in conformance with this specification.
2.18.14. A start-up procedure/caution written on the plate shall be posted closed to control
panel.
2.19. Operator Panel

2.19.1. The start up panel shall be equipment with the following function and hardware.
?? Button for ‘OPEN’ of fuel valves
?? Buttons for ‘START’ of ignition
?? Indication lamps by which operator can acknowledge necessary information
in light-off operation (purge condition, etc.)
?? Buttons for ‘Boiler Trip’

SP-ME-ME-022 Rev. 1
?? Ignition transformer.
?? Flame scanner controller
?? Power switch
2.19.2. The start-up panel shall have grounding earth connection.
2.19.3. The start-up panel shall be of weather-proof, corrosion resistant type.
2.19.4. Control panel shall be equipped with all control, indication, recording and
annunciating equipment.
2.19.5. All supervision and control of the boiler under any kind of operation shall be
possible from control panel, except for light-off operation.
2.19.6. Remote light-off operation is not acceptable.
2.19.7. Function of each panel shall be as follows.
Location Control Room Local

Panel Boiler Control Panel Local Panel
Mode
Start x o
Stop o o
Supervision o w
LEGEND : o : Possible
w : Possible (partially)
x : Impossible
2.20. Skid Structure

2.20.1. Code and Materials
All structural steel shall be designed and fabricated in accordance with the latest
edition of the AISC Manual of Steel Construction and AWS D1.1 and shall be of
ASTM A36 or JIS SS41 material.
2.20.2. All wide flange beams shall be of adequate size and will be used for full bearing
on a concrete foundation. Individual skids shall be constructed with welded
connections. Completed skids will be connected to one another with bolted,
doweled connections.
2.20.3. Skid Separation
The generator shall be designed for separation into 4 major skids for ease of
shipment and off-loading. All points of separation shall be marked and furnished
with guide pins and bolted connections for ease of reassembly. The 4 major

SP-ME-ME-022 Rev. 1
components are the burner and control, radiant, transition, and convection
sections. Vendor shall supply all gasketing material required to reassemble the
sections after delivery. Skid size and shape shall be in accordance with the
following dimensions and drawing. Any deviation from these dimensions shall
be disqualified by COMPANY.
Approximately Skid Dimension

Width Length Height Weight
Burner & Control 17'-8" 11'-0" 8'-3"
Radiant 45'-4" 11'-0" 12'-9"
Convection & Transition 11'-0" 15'-0" 10'-1"
Convection Section 15'-3" 11'-0" 12'-6"
Misc.Piping & Parts
Total overall assembled length 78'-3"
Maximum total overall assembled 175,000
weight lbs
Radiant's out side burner end plate to end 3'-6"
skid
Radiant's out side convection end plate to 1'-4"

end skid
Maximum projection beyond skid 8"
2.20.4. Grating
All areas requiring clean-up (under burner, etc.) shall be fully covered with
removable safety grating. Other personnel access area shall be covered with
safety grating. All grating shall be serrated, hot dipped galvanized and fastened
with clips spaced at maximum 3-foot intervals, and at each corner. Grating shall
be trimmed to fit around pipe supports and other penetrations.
2.20.5. Sleeve for Pipe Penetrations
Where penetrations through structural components are required for routing piping
or conduit, a sleeve shall be installed to ensure structural integrity. Sleeves shall
consist of schedule 40 pipe one size larger than the pipe (or outside diameter of
insulation, if insulated) or conduit passing through the structural member, and
seal welded on each side of the sleeve.

SP-ME-ME-022 Rev. 1
2.20.6. Others
Skids shall be of adequate strength to maintain alignment of equipment during
shipment, to minimize vibrations during generator operation, and to distribute
loads to the concrete generator foundation. Lifting lugs shall be provided as
necessary to facilitate field installation. Any special spreader bars or apparatus
necessary for lifting and setting the skids shall be furnished by Vendor.
2.21. Control Cab

2.21.1. The control cab, equipped with metal roof, shall be mounted on the burner end of
the generator. The cab shall be sufficiently strong to prevent shipping damage.
Minimum clearance between control panel and cab roof shall be 6 inches.
Minimum head clearance in the control cab shall be 7 feet.
2.21.2. A removable roof shall be installed over the control cabinet and burner assembly.
Hang down panels are not acceptable. The cab roofs shall be designed so that
water cannot run off into motors or other electrical equipment. The roof over the
control/power panel and burner assembly shall extend to the burner end wall on
the radiant section. Roofing material shall not be corrugated. All roof plate
joints shall be seal welded on the top (outside) and to the roof framing.
3. FABRICATION
3.1. Welding
The profile of welding grooves shall conform to the requirements of the manufacturer’s
qualified procedure. Any welding of pressure holding parts shall be done by qualified
welder.
3.2. Heat Treatment

All heat treatment work shall be done in accordance with applicable code. All attachment
of pressure holding parts shall be welded before heat treatment. Records of all heat
treatment shall be kept available.
3.3. Insulation
3.3.1. Insulation Requirements
3.3.2. Material
Mineral wool, Bradford Enercon ‘Enerok 1200’ or COMPANY-approved equal
shall be installed on all hot lines, heat exchangers, and heater. For the line that is
subject to be stepped by, the weatherproofed, preformed, hydrous calcium
silicate insulation, John-Manville “Thermo 12” or COMPANY-approved equal
shall be used. The insulation will be of sufficient thickness to only allow a
maximum 100 deg F outside surface temperature at design conditions. Use 2-1/2-
inches minimum of insulation for high pressure steam lines. All insulation
materials shall be asbestos-free.

SP-ME-ME-022 Rev. 1
3.3.3. Insulation shall be secured with 16-gage galvanized wire spaced on 9-inch
centers. See detail 1 of Standard Drawing GD-N99783-5
3.3.4. Metal End-Cap
All insulated piping shall use a metal end-cap where the insulation terminates and
the pipe continues onward, uninsulated. A metal end-cap shall also be used
adjacent to flanges. The end of the insulation shall be covered by seal lap with
1/8-inch thick coating of weatherproof mastic that laps the pipe two inches. See
detail 6 of Standard Drawing GD-N99783-5. Clearance between the flange and
metal end-cap shall be provided to allow insertion and removal of stud bolts.
3.3.5. Ring Supports
Insulation on vertical piping shall have ring supports installed at the bottom of
the pipe run and above interruptions in the pipe run such as at flanges and valves.
See detail 3 and 4 of Standard Drawing GD-N99783-5
3.3.6. Expansion joints shall be provided at the tangent points of elbows when the pipe
temperature exceeds 425 deg F, and at the following spacing between tangent
points:
Pipe Operating Temperature (deg F) Maximum Spacing (ft)
below 425 None
425 - 459 36
460 – 650 24
See detail 5 of Standard Drawing GD-N99783.

3.3.7. Structural Steel Surface Isolation
Structural steel surfaces exceeding 100 deg F and exposed to operating personnel
shall be isolated from operator contact by insulation or expanded metal guards. If
insulation is used, covered steel temperature shall not exceed 250 deg F during
all phases of operation
3.3.8. Weatherjacketing Requirements
3.3.8.1 Material
Metal jacket shall be 0.016-inch thick corrugated T-3003-H14 aluminum
with a moisture barrier of epoxy, plastic, or 50-pound kraft paper using a
1 mil thick polyethylene film on the inside surface. No adhesive shall be
used to attach the moisture barrier to the metal. Childers jacketing or
COMPANY-approved equal shall be used.
3.3.8.2 Weather jacket attachment fixtures
Fixtures shall be stainless steel, except that sheet metal screws, pop rivets
and stud caps may be aluminum (0.40% maximum Cu). Clips used to
support weather jacket panels and bands shall be 0.040-inch minimum
thickness stainless steel. Pop rivets shall be of the type where the
mandrel is retained after setting.

SP-ME-ME-022 Rev. 1
3.3.8.3 Installation
Weather jacket shall be overlap 2-inches longitudinally and
circumferentially. Longitudinal joints shall be staggered between the
three o’clock and nine o’clock positions. Longitudinal seams on
aluminum jacket shall have a 1/4-inch rolled hem.
3.3.8.4 Secure the jacket with 1/2-inch x 0.015-inch straps and buckles. Joints in
weather jacket shall be caulked with sealant.
3.3.8.5 Weather jacket on vertical piping shall have S-clips, spaced 180 degrees
apart, to maintain it in position. See detail 3 of Standard Drawing GD-
N99783.
3.3.9. Surface Conditions
All surfaces to be insulated shall be clean and dry. The surface operating below
200 deg F shall be prime with coating. No insulation shall be installed until
completion of any stress-relieving and chemical cleaning and hydrotest
inspection and release in writing.
3.3.10. Flexible Removable Insulation Covers
All carbon steel or low alloy valve bodies, pipe flanges, manways, and exchanger
body flanges that operate at temperature over 100 deg F shall be insulated.
Flexible, reusable insulation covers shall be provided except for screwed and
welded fitting/valves where permanent insulation prefers.
4. COATING AND PAINTING
4.1. General
Unless otherwise specified, Coating and Painting shall be in accordance with SP-ME-ME-
025 “Coating and Painting Specification”.
4.2. Additional Requirement :

4.2.1. Codes and Standards
The following NACE standards and SSPC written specification, latest edition,
are part of this specification.
NACE No.2 (SSPC-SP-10) “Near-White Blast Cleaning
NACE No.3 (SSPC-SP-6) “Commercial Blast Cleaning
SSPC-SP-1 “Solvent Cleaning
4.2.2. Coating System 1.0 (Inhibited Alkyd/Alkyd Enamel)
This system shall be applied on radiant, transition, and convection exterior
surfaces include area within 6-inches surround them.
Surface Preparation : SSPC-SP6 Commercial blast finish
Anchor Pattern : 1.5 mils (maximum)

SP-ME-ME-022 Rev. 1
Paint:
Primer : Inhibited Alkyd, 2.0 - 3.0 mils DFT
(Hempalin Primer 1205 Red 5041 or equal)
Topcoat : Alkyd Enamel, 2.0 - 3.0 mils DFT
(Hempalin Enamel 5214 Green 410 RS or equal)
Touch-up : use this system, the color shall be Caltex Forest Green or COMPANY
approved equal.
4.2.3. Coating System 2.0 (Self-Cured Inorganic Zinc/Pure Silicone)
This system shall be applied on :
?? All stairs, walkways, platform, guards
?? All structural steel not within 6-inches of the radiant, transition, or
convection section
?? Cab roofs and supports
?? Blower ducting
Surface Preparation : SSPC-SP10 Near-white blast finish
Anchor Pattern : 1.5 - 2.5 mils
Paint:
Primer : Self-cured Inorganic Zinc, 3.0 - 4.0 mils DFT
(Ameron “Dimetcote 6 or 9” or equal)
Topcoat : High temperature Silicone 1, 1.5 - 2.5 mils DFT
(Ameron “Amercoat 878 “ or equal)
Touch-up : Pure silicon topcoat only, 2 coats. The color shall be Caltex
Forest Green or equal.
4.2.4. The electrical/control panel shall be primed on the external surface with one coat
of polymide-catalyzed epoxy coating applied to a minimum dry film thickness of
2 mils. After priming the exterior, apply two coats of polyamide-catalyzed epoxy
green finish on all outside surfaces, a minimum of 2 mils dry film thickness per
coat. Paint dry film thickness after completion shall be at least 6 mils. The
internal surfaces shall have one primer coat and two topcoats of white, with final
minimum dry film thickness of 6 mils.
4.2.5. Vendor shall propose the brand and color of the paint for COMPANY approval.
Each multi-coat system shall use materials from a single manufacturer.
4.2.6. Surface Preparation
4.2.6.1 Solvent Cleaning
All surfaces to be coated shall be clean of all contaminants that would
affect the integrity of the coating system. Detergent or solvent cleaning
shall be performed as outlined in SSPC-SP-1.
4.2.6.2 Abrasive Blasting

SP-ME-ME-022 Rev. 1
Weld areas shall be ground, chipped or wire brushed as necessary prior

to blasting to remove rust, residual flux and weld spatter. Only dry, grit-
type abrasives shall be used. The abrasive shall comply with government
regulations.
4.2.6.3 Any carbon steel surfaces not primed shall be reblasted if any rust
develops before priming regardless of the length of time since
sandblasting.
4.2.6.4 A minimum area of 4 inches around the edge of blasted areas shall be left
unprimed unless the area adjoins a coated surface. Subsequent blasting
shall continue a minimum of 1 inch into the primed surfaces. This is to
ensure that no coating is applied over unblasted steel.
4.2.6.5 The surface preparation specified shall be achieved using blasting
equipment approved by the coating manufacturer. The air supply to the
blasting equipment shall contain suitable oil and water removal devices
to prevent their impingement onto the blasted surfaces.
4.2.6.6 Abrasive material shall be clean, dry, and of proper size to provide the
surface cleanliness and profile specified.
4.2.7. Coating Application
4.2.7.1 Surface Preparation
Surface preparation shall be accomplished before priming. The specified
coating system primer shall be applied on the same day that surfaces are
cleaned.
4.2.7.2 Coating shall be applied under the environmental conditions shown in
the coating manufacturer’s data sheets. No coating shall be applied:
?? On wet surfaces
?? When the relative humidity exceeds the manufacturer’s written
recommendation
?? When the surface temperature is less than 5 deg F above the dew
point.
?? When the ambient or surface temperatures are below the
manufacturer’s recommended temperature for application and
curing.
?? When the wind speed exceeds 15 miles per hour.
4.2.7.3 Both primer and finish paints shall be capable of withstanding maximum
expected temperatures and shall be chemically compatible. Paint top coat
shall produce a semi gloss finish to allow easy cleaning of steam
generator
4.2.7.4 All coating film thickness shall be free of defects such as pinholes, voids,
and bubbles. Prior to the application of any coat, all damage and defects
in previous coats shall be repaired.
4.2.8. Inspection

SP-ME-ME-022 Rev. 1
Vendor shall perform all inspection necessary to ensure that surface preparation
and coating application complies with the requirements of this specification. All
work shall be subject to COMPANY inspection.
4.2.8.1 Surface Preparation
4.2.8.2 Immediately prior to priming, blasted surfaces shall be inspected by the
following methods to verify that the specified surface preparation has
been achieved.
4.2.8.3 The anchor pattern shall be verified using Testex Inc. “Press-O-Film”
tape or COMPANY approved equal. The measurement shall be recorded
on the Coating Inspection Record.
4.2.8.4 The degree of cleanliness shall be verified by comparison to the
appropriate visual standard included in SSPC-VIS 1-67. Surface profile
shall be visually inspected using the Keane-Tator Surface Profile
Comparator.
4.2.8.5 Coating Application
Dry film thickness shall be measured using a “Microtest” magnetic film
thickness gage or COMPANY approved equal. Dry film thickness shall
be recorded on the Coating Inspection Record for each coat as work
proceed as well as for the total thickness of each finished coating system.
5. INSPECTION AND TESTING

5.1. General
5.1.1. Unless otherwise specified, Vendor shall be responsible for all inspection and
testing in accordance with PP-QC-GG-003, "Inspection and Test Plan at Shop",
PP-QC-GG-004, "Inspection and Test Plan at Field"
5.1.2. Vendor shall furnish CONTRACTOR/COMPANY with copies of Vendor's
Inspection and Quality Control Plan.
5.1.3. Vendor shall submit all manufacturing, fabrication, inspection and testing
procedures for CONTRACTOR/COMPANY approval at least three (3) weeks in
advance of implementing the procedure. Manufacturing and fabrication shall not
proceed until Vendor’s material inspection has been approved by
CONTRACTOR/COMPANY.
5.1.4. Materials and workmanship shall be subjected to inspection by
CONTRACTOR/COMPANY in the shop.
5.1.5. Vendor shall be responsible for Factory Acceptance Test (FAT). All equipment,
materials, consumables, utilities, and facilities for the test shall be furnished by
Vendor.
5.1.6. Welded piping shall be tested with a system hydrostatic test at 1.5 times MAWP.
5.1.7. Instrumentation system shall be shop pressure tested, functional/operational
tested, and calibrated
5.2. Data List

SP-ME-ME-022 Rev. 1
Vendor shall furnish all necessary data listed on the attached Vendor Data Requirements
List in accordance with quantities, type, and timing specified in the list.
5.3. Inspection Data Report and Certificate
Vendor shall also furnish necessary pressure vessel inspection data reports and safety relief
valve certificates as required by COMPANY, including:
5.3.1. Engineering dimensional drawings
5.3.2. Material specifications
5.3.3. Spring specification showing spring range and number
5.3.4. Manufacturer's Test Certificate
5.3.5. ASME Form U-1 Manufacturer's Data Report for Pressure Vessels
5.4. Radiographic
Radiographic inspection requirements are as follows:
5.4.1. Piping for which the applicable code is ASME Section I shall have 10 % of
welds radiographed. Acceptance criteria shall be per ASME Section I.
5.4.2. Piping for which the applicable code is ANSI B31.3 shall have 10 % of welds
radiographed. Acceptance criteria shall be ANSI B31.3 standards for 100 %
radiography.
5.4.3. Tube hangers radiography
5.4.4. Tube hangers shall be subjected to 10% radiography, to detect casting defect
before being installed, witnessed by COMPANY’s Inspector.
5.4.5. Dye Penetrant Test shall be applied on 10% weld of tube hangers and shells
witnessed by COMPANY Inspector.
5.4.6. Selection of welds for radiographic inspection shall be made with agreement of
COMPANY inspector.
5.4.7. Vendor shall quote unit price per NDT film. COMPANY may elect to perform
radiographic inspection more than the required 10% at COMPANY’s expense.
5.4.8. Any welds that fail to pass radiographic test shall be repair and be re-
radiographed at Vendor’s expense. For any failure Vendor will be penaltied to
radiograph additional welds in amount that grows exponentially at Vendor’s
expense. Example: if there is one failure weld, in addition to repair and to re-
radiograph, Vendor shall radiograph other two welds (number of failure times
two) that is not included in 10% provision. If this penaltied-radiography fail
Vendor shall radiograph additional four times number of failure and so forth.
5.5. Hydrotest
All the piping, except for the drain line, shall be hydrotested at 1.5 times allowable working
pressure (MAWP). All gas and pneumatic piping shall be tested with dry air at 1.1 times
MAWP. After hydrotest, piping shall be purged with dry air to ensure removal of all scales,
slag, and debris from piping. This hydrotest does not release Vendor from the responsibility
for any leakages found during COMPANY’s hydrotest after unit being installed in
COMPANY’s site.

SP-ME-ME-022 Rev. 1
5.6. Pre-assembling
Vendor shall pre-assemble every generator at his plant before shipment to COMPANY.
Subsequent disassembly should be done only as necessary to ensure safe shipment of the
component skids.
Compliance to this obligation does not release Vendor from the responsibility for any
mismatch during field assembly caused by any deterioration occurred during the shipment.
5.7. COMPANY’s Inspector
While work on this purchase order contract is being performed, Inspector(s) designated by
COMPANY shall have free duty entry to all parts of Vendor's premises involving the
manufacture, inspection, and testing of material to be supplied to COMPANY. The Vendor
shall afford the inspector(s), free of cost, all necessary and reasonable use of facilities for
determining that the material is being furnished in accordance with this specification. All
tests and inspections by said inspector(s) shall be made at the place of manufacture before
shipment and shall be so conducted to minimize interference with operation of Vendor's
plant.
5.8. Inspection by COMPANY shall not relieve the manufacturer of complying with any
expressed or implied specification or Vendor's guarantee.
No change arising out of inspection shall be made to this contract until such change has
been approved by COMPANY representative in writing.
5.9. Subcontractor
Vendor shall notify any subcontractors of COMPANY's inspection requirements, and
obtain their consent to comply with these requirements.
5.10. COMPANY shall approve all subcontractors in writing prior to Vendor entering into legal
agreements with said subcontractor(s).
5.11. Steam Generator Test
The first generator completed shall be given a low-fire test run at the Vendor's plant. All
other units shall be given a complete, documented, functional mechanical, electrical, and
pneumatic tests and check-out before shipment to COMPANY. These tests may be
witnessed by COMPANY representatives.
5.12. DEPNAKER Approval
The Vendor shall arrange and obtain wet stamped from "Departemen Tenaga Kerja
(DEPNAKER)" on the fabrication drawings and ASME Code calculations for the steam
generators.
6. PREPARATION FOR SHIPMENT

6.1. Unless otherwise noted in the COMPANY’s Request for Proposal and/or Purchase Order,
Preparation for shipment shall be in accordance with PP-PC-GG-003, “Transportation and
Traffic Instructions”, PP-PC-GG-004 “Packing and Marking Instruction”.
6.2. Assembly and preparation for shipment shall be in accordance with Vendor’s standards and
as noted herein. Vendor shall be solely responsible for the adequacy of the preparation for
shipment provisions with respect to materials and application, and to provide equipment at

SP-ME-ME-022 Rev. 1
the destination in ex-works condition when handled by commercial carriers.

6.3. Each major component shall be properly identified with item and serial numbers. All
material shipped separately shall be properly tagged or marked with the item and serial
number for which it is intended.
6.4. Immediately after final testing and prior to shipment, equipment shall be drained, dried and
cleaned thoroughly of all grease, loose scale, rust, flux, weld splatter and rubble, both
internally and externally.
6.5. Adequate protection shall be provided against mechanical damage and atmospheric
corrosion in transit, and for mutually acceptable period of outdoor storage at jobsite before
installation.
6.6. Preparation for shipment and packing will be subject to inspection and rejection by
COMPANY inspectors. All costs occasioned by such rejection shall be to the account of
the CONTRACTOR.
6.7. After inspection and test, equipment shall be completely free of water, dried, and prepared
for shipment.
6.8. Equipment shall be packed, securely anchored, and skid mounted when required.
6.9. All items, which can be damaged by water, shall be securely wrapped in waterproof paper
or plastic before placed in wooden crates.
6.10. Bracing, support, and rigging connections shall be provided to prevent damage during
transit, lifting, or unloading.
6.11. Flanged openings shall be protected with metal coverplate to prevent damage during
shipment. Covers shall be a minimum of ¼” thick and shall be installed with full size
gasket using minimum of 4 full diameter bolts. Large diameter flanges will require enough
full diameter bolts to set the cover all around. The cover and flange shall be taped for
waterproof protection.
6.12. Open end of pipe shall be capped for protection. The cap shall be removable.
6.13. Female threaded connection shall be plugged with solid metal pipe plugs, and male
threaded connections shall be protected with full metal pipe caps.
6.14. Separate, loose and spare parts shall be completely boxed. Piece of equipment's and spare
parts shall be identified by item number and service and marked with COMPANY’s order
number, tag number, and weight, both inside and outside of each individual package or
container.
6.15. Exposed finished and machined surfaces, including bolting, shall be given a coating of rust
inhibiting compound. Internal metal surfaces shall be sprayed or coated with a suitable rust
preventive prior for shipment. Opening shall be suitably tagged to indicate the rust
preventive applied.
6.16. Mechanical seal assemblies shall be fully protected from rusting and entry of moisture and
dirt.
6.17. One complete set of the installation, operation, and maintenance instructions shall be
packed in the boxes or crate with equipment. A recommended spare part list for 2 years
operation shall be included also.

SP-ME-ME-022 Rev. 1
6.17.1. Shipping Agency

Vendor shall propose the kind of shipping, packaging, and the agency in charge
completed with the data of transportation and support facilities and all pertinent
documentation for COMPANY approval. The shipping destination will be
Caltex’s dock in Rumbai, Pakanbaru, Riau, Sumatera, Indonesia.
6.17.2. Packaging
Packaging shall include theft proof protection of all controls, gauges, small
valves, etc. If necessary, separate packaging shall be provided in locked boxes.
All flanged openings shall be gasketted and blind flanges installed. Threaded
openings shall be plugged. All other opening shall have watertight seals for
ocean shipment.
6.17.3. Shipping Papers
Each shipment shall be accompanied by a shipping list, identifying each piece on
that shipment by piecemark number, along with the ship order number, and the
weight of each piece.
Shipments arriving at COMPANY area without proper shipping list and mark
numbers on the fabricated pieces will not be received until Vendor properly
identified all of the components.
7. INSTALLATION , START UP AND COMMISSIONING

7.1. Vendor shall present his representatives to assist start up and commissioning upon request
by COMPANY.
7.2. Vendor shall submit complete parts lists for all equipment and accessories supplied. The
lists shall include Manufacturer's unique part numbers, materials of construction, and
delivery time.
7.3. Well in advance of shipping, VENDOR shall prepare detailed installation instructions, pre-
commissioning checklists, and job site test agendas for COMPANY approval. These step-
by-step instructions, checklists and test agendas shall be comprehensive and describe all
steps necessary for: 1) COMPANY to install the complete unit to the foundation, 2)
COMPANY and VENDOR commissioning engineer to verify completion of all pre-
commissioning procedures, and 3) COMPANY and VENDOR commissioning engineer to
verify that all hydraulic, mechanical, vibration, and electrical performance criteria are met.
The preparation of these documents shall be included in the Lump Sum Amount.
VENDOR is responsible for any deficiencies in hydraulic, mechanical, vibration, or
electrical performance at the job site.
7.4. If specified, COMPANY will prepare a Supplemental Agreement to the Purchase Order for
the services of VENDOR's commissioning engineer. The basis for this Agreement will be
VENDOR's proposal received with his Base Proposal. All commissioning engineers
contracted under a Supplemental Agreement shall be competent, experienced (5¸ years
minimum), factory trained, and certifie d.
7.5. The commissioning engineer shall come equipped with all special tools and information
required to expeditiously perform his work per the COMPANY -approved pre-
commissioning checklist and job site test agenda. Special tools may include.

SP-ME-ME-022 Rev. 1
8. VENDOR’S GUARANTEE
8.1. Vendor guarantees that the equipment specified herein is free from fault in design,
workmanship, and material. Vendor guarantees that these items are of sufficient size and
capacity and proper material to fulfill satisfactorily the operating conditions specified by
COMPANY.
8.2. Should any defect in design, material, or operating characteristics develop during the first
year of equipment operation, Vendor agrees to make all necessary repairs, alterations, and
replacements free of charge. If the defect or failure to function properly cannot be
corrected, Vendor agrees to replace promptly without charge said equipment.
8.3. Vendor guarantees that each steam generator package is complete and in a good condition
as COMPANY receives it in the delivery point. Any discrepancies of materials and
structural damages happened during the shipment is the responsibility of Vendor.
8.4. Vendor Performance Requirement
The Vendor’s steam generator design must have demonstrated at least 10 years of proven
oil field operation in wet steam (i.e. 80% steam quality) service for reliability and
efficiency. Vendor shall submit the experienced-user list for reference.
8.5. Efficiency Guarantee
8.5.1. The steam generators, in new and clean condition, shall be designed to operate at
a minimum 88 % gross thermal efficiency (percentage of gross BTU input of
fuel that is realized as useful BTU output) based on 20 % excess air for crude oil-
fired operation or 84 % gross thermal efficiency based on 10 % excess air for
fuel gas-fired operation.
8.5.2. Efficiency must be guaranteed in the new and clean condition. Vendor must
submit full efficiency testing procedure for review and acceptance.
8.5.3. Guarantee for efficiency must include all repairs or additions to be made to
achieve the minimum efficiency at no cost to the COMPANY.
9. DESIGN DATA AND SITE CONDITIONS

Design data and site conditions are as per intended data sheet.
10. INFORMATION TO BE FURNISHED WITH QUOTATION

NOTE: FAILURE TO SUPPLY ALL REQUESTED DATA MAY RESULT IN
DISQUALIFICATION OF VENDOR'S BID.
All information listed on the Vendor Data Requirements List VDRL-LOSF1-MNAS shall be
submitted by the bidder. The following clarifies these requirements as well as request additional
information:
10.1. Process flow diagram
Process flow diagram showing detailed thermodynamic heat balance, design flow rates,
pressures, temperatures, and steam qualities.
10.2. Electrical Drawing

SP-ME-ME-022 Rev. 1
Electrical one line and control (ladder) diagrams. Instrument identification on the control
Diagram shall correspond to identification on the P&ID.
10.3. Outline Drawing

Outline dimensional drawings, showing plan, elevation, and end views of the generator.
Drawings shall include general layout of the proposed piping arrangement showing line
sizes, flange, valve, exchanger, and instrument locations. Drawings shall include
component lengths, thickness, height, gross weights, and shipping weights.
10.4. End-connection Lay-Out
A drawing showing the location and sizes of all piping connections, flanges, and controls.
Include tie -in points for field piping and electrical conduit.
10.5. Cross Sectional Drawing
A cross sectional drawing of each major component with dimensions and showing all
pertinent accessories.
10.6. Ceramic Fibre and Castable Refractory Installation
Detailed drawings for ceramic fiber and castable refractory installation. Include type
installation, material specification such as brand name, type, density, temperature
limitations, permanent linear change, modulus of rupture, thermal conductivity of
insulation quoted, and also type and metallurgy of anchors.
10.7. Coating Specification
Brand , type and technical data of shell coating.
10.8. Hot Face Temperature Distribution Data
Provide the data of hot face temperature distribution in the burner, combustion chamber,
target end wall, radiant section behind tubes, transition section, and convection doors.
Include the gas temperature and velocity in radiant and convection section.
Based on hot face temperature distribution data, provide the following information of the
ceramic fiber and castable refractory system quoted. Assume 80 deg F ambient air
temperature and wind at 5 mph.
10.8.1. Heat loss, Btu/ft3/hr
10.8.2. Overall heat transfer coefficient, U, for radiant and convection section
10.8.3. Cold face temperature for emissivity of 0.95
10.8.4. Thermal resistance of each component of the insulation system.
10.8.5. Temperature at each insulation barrier
10.9. Power Test Code Sheet
Complete the Power Test Code summary and calculation sheet for abbreviated efficiency
test.

SP-ME-ME-022 Rev. 1
Convection section temperature and velocity profile showing water temperature

entering and leaving each row of tubes, heat absorbed by water in each tube row, and
average heat transfer coefficient in each row of tubes.
10.10. Tube Specification

Tube size, wall thickness and surface area of radiant section, convection section, feedwater
preheater, and fuel oil heaters.
10.11. Tube Hanger Drawing
Detail drawing of tube hanger assembly, including material specifications and installation
details.
10.12. Pressure Drop Calculation
Pressure drop at design condition and at maximum rated firing rate from inlet to outlet
flanges of the generator
10.13. Maximum and average heat flux values.
Guaranteed thermal efficiency at design pressure. Expected thermal efficiency at operating
pressure. Expected combustion efficiency at design pressure. Expected combustion
efficiency at operating pressure.
10.14. Design % excess air, 02, and CO2 at design pressure. Design excess air, 02, CO2 at
operating pressure.
10.15. Completed equipment data sheets for the steam oil heater, the feedwater preheater if
required, combustion air blower, and motors.
10.16. Exterior Surface Area
Exterior surface areas of radiant section, convection section, feedwater preheater and
steam-oil preheater.
10.17. Bill of Material Listing
Bill of Material listing, describing and quantifying all items to be supplied by Vendor. The
list shall be keyed to the related P&ID, so specific items can be identified. BOM shall also
include materials of construction, manufacturer's data sheets (including noise), catalog data,
recommended spare parts for commissioning and start-up, as well as a recommended spare
parts list for 2-years operation.
10.18. Project Schedule
Schedule showing design, procurement, fabrication and expected delivery date of each unit
from date of contract award. Include procurement and delivery of sub-vendor equipment.
10.19. Name of COMPANY supplying design, including where engineering will be done.
10.20. Experience Reference
Previous experience in design and fabrication of oil-field steam generators producing 80%
quality steam using a once through coil design. Include number of units previously

SP-ME-ME-022 Rev. 1
supplied in Indonesia, number of units fabricated in Indonesia and year, as well as a world-
wide user's list for similar equipment.
10.21. Major Components Supplier
Define extent of Indonesian and foreign supply of major components, including: control
panel, control valves, instruments, exchanger/generator coils, insulation, and structural
components.
10.22. Fabrication Site Facilities
Indonesian domestic fabrication site, including: covered shop area, open yard area, paint
shop area, wharf frontage area, water depth and crane lift capacity (tons), proposed method
of load-out of completed units, number and types of employees.
10.23. Number of welders qualified to ASME Code. Define Code category to which they are
qualified. Fabrication yard ASME Code authorized to use "U" or "S" stamp (answer Yes
or No).
10.24. Service personnel available and their location for providing start-up/commissioning
assistance. Include their perdiem rate
11. BASIS OF BIDS

11.1. Bids shall state the firm lump-sum price per Vendor's delivery schedule and COMPANY'S
payment terms for all equipment DDU Minas site, Sumatra.
11.2. Bids shall include all information as requested in Request for Quotation and on the attached
"QUOTATION DATA SHEET", including:
11.2.1. Lump-sum price
11.2.2. Unit price per NDT radiographic film for additional radiographs in accordance
with this specification
11.2.3. Bids for any Vendor proposed alternatives shall state the firm lump-sum price for
each alternative.
11.2.4. Bids shall clearly state all exceptions or deviations from this specification and the
resultant cost effect.
11.3. Bid shall state delivery time from date of purchase contract award and time required to
produce approval documents after receipt of order. Assume COMPANY will return
approval documents within 15 working days from date received by COMPANY in Minas.
12. INFORMATION PROVIDED B Y SUCCESSFUL BIDDER

12.1. Vendor shall provide one reproducible and three prints of each of the following items for
COMPANY review and approval. Purchasing and fabrication shall not be started until
Vendor has received COMPANY-reviewed/approved documents. COMP ANY will return
approval documents within 15 working days from date received by COMPANY in Jakarta.
COMPANY approval of any documents does not imply that Vendor has satisfied the
requirements of this specification.
12.1.1. Project Schedule

SP-ME-ME-022 Rev. 1
Design, material, procurement, fabrication, assembly and testing schedule for

each generator as well as a composite schedule for the entire purchase order.
12.1.2. Bill of Materials
Bill of Materials listing, describing and quantifying all items to be supplied by
Vendor. Include materials of construction, manufacturer's data sheets (including
noise), catalog data, recommended spare parts for commissioning and start-up, as
well as a recommended spare parts list for 2 years operation.
12.1.3. Equipment Weights
Equipment weights: empty, operating, shipping, and water-filled. Heaviest
component to be handled during erection or maintenance.
12.1.4. Calculation
ASME Code calculation.
Pressure, volume, and maximum moisture requirement of air supply requirement.
Blower capacity calculation
Heat balance performance data sheet (refer to API RP11T last edition)
Mechanical data sheet (refer to API RP11T last edition)
12.1.5. Drawing
Drawing set includes OUTLINE DRAWING, with all dimensions needed for
layout, access, maintenance and component parts removal/replacement, SHOP
DETAIL DRAWING, and ASSEMBLY DRAWING, showing relative location
and dimensions of all components, connection descriptions, and required
clearances.
12.1.6. Inspection Test Procedure
Hydrostatic and Pneumatic test procedure.
Radiographic, dye penetrant, and magnetic particle test procedure.
Welding Procedure Specifications for all welding.
Welding Procedure Qualification certificate.
Weld repair procedure.
12.1.7. Acceptance test procedure - Manufacturer's procedure to verify equipment
operates according to purchase requirements.
?? Mill Test Certificate
?? Surface preparation procedure
?? Shop painting procedure and color samples
?? Installation/Erection procedure
?? Code Data Report
?? Pressure Vessel Code calculations
?? Stress analysis calculations

SP-ME-ME-022 Rev. 1
?? Structural steel calculations

?? Noise Data Sheet
12.2. One reproducible (mylar) set of final, Certified, "As-Built" drawings shall be transmitted to
COMPANY on or before shipment of the first generator. Two sets of blue-line copies of
these "As-Built" drawings shall be shipped with the first generator.
12.3. Vendor shall furnish six sets of Operating and Maintenance (O&M) Manuals for the
generators on or before the shipment of the first generator. Manuals shall provide
recommended operating and maintenance procedures for all furnished equipment, spare
parts lists, catalog data, bills of material referenced to the P&ID, certified copies of P&ID,
electrical one-line, and generator outline drawings, manufacturer's data sheets, lubrication
recommendations, etc.
12.4. Vendor shall furnish a reproducible set and two copies of the following data sheets,
completed to reflect "As-Built" instrumentation and equipment information. In addition,
one copy of each shall be included in each O&M Manuals.
12.4.1. Instrument summary
?? Temperature transmitters
?? Thermocouples
?? Thermocouple extension lead wire
?? Thermometers
?? Temperature wells
?? Pressure transmitters
?? Control valves
?? Miscellaneous instruments
?? Flow meters
?? Pressure safety valves
?? Switches - pressure, temperature, flow
?? Heat exchangers
?? Electric motor data sheets
?? Fired-Heater data sheet
12.4.2. Master parts list with part numbers and serial numbers. This list shall be tied to
identification numbers used on the generator P&ID for easy cross reference by
field personnel.
12.4.3. Oils and lubricants required, standard description and grade including alternate
suppliers with their designations.
12.4.4. Nameplate rubbings or photographs.
12.5. Progress Schedule Report

SP-ME-ME-022 Rev. 1
Vendor shall provide a project schedule showing design, material procurement, fabrication,
assembly, and testing activities. The schedule shall be of sufficient detail to allow accurate
progress monitoring for each generator purchased as well as overall project progress. The
schedule shall be updated regularly, at least once each month, and transmitted to
COMPANY.

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DOCUMENT NO. REV.

PT Caltex Pacific Indonesia SP-ME-ME-022 1

SPECIFICATION PREPARED BY Nurhasan NHS

PT. CALTEX PACIFIC INDONESIA

REV DATE PAGES DESCRIPTION PREP’D CHK’D APP’D

0 10/9/01 ALL ISSUED FOR IMPLEMENTATION NHS NHS SPD

2. BASIC DESIGN .................................................................................................................. 5

3.1. Welding .................................................................................................................. 41

4. COATING AND PAINTING............................................................................................. 43

5. INSPECTION AND TESTING.......................................................................................... 46

6. PREPARATION FOR SHIPMENT................................................................................... 48

7. INSTALLATION , START UP AND COMMISSIONING................................................ 50

9. DESIGN DATA AND SITE CONDITIONS....................................................................... 51

10. INFORMATION TO BE FURNISHED WITH QUOTATION.......................................... 51

11. BASIS OF BIDS................................................................................................................. 54

12. INFORMATION PROVIDED BY SUCCESSFUL BIDDER............................................. 54

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

October 9, 2001 Page 2 of 57

October 9, 2001 Page 3 of 57

1.4. Conflicting Requirements

October 9, 2001 Page 4 of 57

2.2. Radiant Section

October 9, 2001 Page 5 of 57

(min skip-weld length is 2 inch) to the inside of shell. Shell sections

October 9, 2001 Page 6 of 57

radiant section. Pressure connection to combustion chamber shall be with 1/2"

2.3. Transition Section

October 9, 2001 Page 7 of 57

The transition section shall be designed for thermal-induced expansion for

2.4. Convection Section

October 9, 2001 Page 8 of 57

October 9, 2001 Page 9 of 57

October 9, 2001 Page 10 of 57

2.5.3.2 Welding Procedure Qualification

October 9, 2001 Page 11 of 57

2.5.3.8 Specific Installation

2.6. Radiant Section Refractory Requirement

October 9, 2001 Page 12 of 57

2.6.9. Drain Plug

2.7. Transition Section Refractory Requirements

2.8. Convection Section Refractory Requirements

2.9. Refractory Gasketing

October 9, 2001 Page 13 of 57

2.10. Fuel Burning Equipment

October 9, 2001 Page 14 of 57

October 9, 2001 Page 15 of 57

2.10.6. Three-way Bypass Valve

October 9, 2001 Page 16 of 57

2.10.10. Pressure Relief Valve

October 9, 2001 Page 17 of 57

October 9, 2001 Page 18 of 57

?? Exposed shaft surface and couplings shall be covered by guard

October 9, 2001 Page 19 of 57

2.11. Piping System

October 9, 2001 Page 20 of 57

Piping connections between skids shall be flanged, except for drain

October 9, 2001 Page 21 of 57

The PID controller shall be programmed in the PLC software. Tuning