DESIGN SPECIFICATION

FURNACES
MB40-1D

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 6

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 KBR Documents, Codes, and Industry Standards .........................................................................1
2. DESIGN ..........................................................................................................................................2
2.1 General ...........................................................................................................................................2
2.2 Design Codes .................................................................................................................................2
2.3 Floors, Walls, and Arches...............................................................................................................3
2.4 Tube Supports ................................................................................................................................3
2.5 Settings ...........................................................................................................................................4
2.6 Doors and Header Boxes ...............................................................................................................4
2.7 Burners ...........................................................................................................................................5
2.8 Instrument and Auxiliary Connections ............................................................................................5
2.9 Stacks, Flares, Ducts, and Dampers ..............................................................................................5
2.10 Tubing, Fittings, and Headers.........................................................................................................6
2.11 Structural Steel ...............................................................................................................................6

1. GENERAL

1.1 Scope

1.1.1 This specification covers the requirements for the design of furnaces. Exceptions to this specification, if
any, and all abbreviations used shall be in accordance with KBR Technical Standard MB15-1TS (Note: KBR will
be referred to as the Purchaser).

1.1.2 Furnaces furnished as standardized or proprietary equipment shall follow this specification, but may differ
in some details, with Purchaser agreement, by following the manufacturers and industry consensus standards
for the design conditions.

1.2 KBR Documents, Codes, and Industry Standards

The following documents are referenced herein and shall be considered mandatory as indicated herein.
Applicable issue dates of codes and industry standards and Purchaser documents shall be as indicated in the
Technical Standard MB15-1TS.

KBR DOCUMENTS
9-8D, "Structural Design"
10-1D, "Process Plant Arrangement"
MB13-1D, "Material Specifications for Furnace Tubes, Headers, and Fittings"
MB15-1TS, "General Furnace Specification"
MB42-1D, "Steel Furnace Stacks"

AMERICAN PETROLEUM INSTITUTE (API)

API STD 530, "Calculation of Heater-Tube Thickness in Petroleum Refineries"

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Boiler and Pressure Vessel Code

Section II, "Materials"

Part B, "Nonferrous Materials Specifications"
Part D, "Properties"
Section VIII, "Pressure Vessels" Division 1

ASME B31.3, "Process Piping"

 DESIGN SPECIFICATION

FURNACES
MB40-1D

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 6

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC, "Manual of Steel Construction, Allowable Stress Design"

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A216/A216M, "Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service"
ASTM A240, "Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
Vessels and for General Applications
ASTM A283/A283M, "Low and Intermediate Tensile Strength Carbon Steel Plates"
ASTM A297/A297M, "Steel Castings, Iron-Chromium and Iron-Chromium-Nickel, Heat Resistant, for General
Application"
ASTM A351/A351M, "Castings, Austenitic, Austenitic-Ferritic (Duplex), for Pressure-Containing Parts"
ASTM A387/A387M, "Pressure Vessel Plates, Alloy Steel, Chromium-Molybdenum"
ASTM A519, "Seamless Carbon and Alloy Steel Mechanical Tubing"
ASTM A536, "Ductile Iron Castings"

MILITARY SPECIFICATIONS
MIL-S-17377, "Sealing Compound, Boiler-Casing"

SOCIETY OF PROTECTIVE COATINGS (SSPC)

SSPC SP 2, "Hand Tool Cleaning"

2. DESIGN

2.1 General

2.1.1 The general arrangement of the furnace will be indicated on the drawings.

2.1.2 Furnaces shall be designed so that during normal operations, a negative pressure shall exist in all parts of
the furnace.

2.1.3 The type of furnace selected shall be suitable for the service conditions, the type of fuel, and the efficiency
as specified on the Furnace Data Sheets.

2.1.4 Platforms, access, handrailing, ladders, connecting walkways, and elevations of furnace floors shall be in
accordance with the Purchaser Design Specification 10-1D.

2.2 Design Codes

2.2.1 Steam Superheater and Boiler coils shall be designed in accordance with ASME Section VIII, Division 1.

2.2.2 Process coils inside of the furnace shall be designed in accordance with API STD 530, unless otherwise
specified. The allowable stress shall be established using the stress-rupture curves in API STD 530 based on
an elastic design or a rupture time of 100 000 hours, except that a rupture time of 50 000 hours shall be used for
millisecond and SCORE furnace radiant pressure parts.

2.2.3 Steam superheater, boiler, and process piping outside the furnace shall be designed in accordance with
ASME B31.3, unless otherwise specified.

2.2.4 Calculations for branch reinforcement of steam superheater and boiler coils shall conform to the methods
in ASME Section VIII, Division 1.

2.2.5 Calculations, if performed for branch reinforcement of process coils, shall conform to the methods in
ASME B31.3 using allowable stress values obtained from API STD 530.
 DESIGN SPECIFICATION

FURNACES
MB40-1D

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 6

2.2.6 Specific design criteria will be issued for special short term or intermittent operating conditions, if
applicable for the design of coils or external piping.

2.2.7 All design and details of the supporting steel framework, platform, and ladders for furnaces shall be in
accordance with Purchaser Design Specification 9-8D and the AISC "Manual of Steel Construction, Allowable
Stress Design".

2.3 Floors, Walls, and Arches

Minimum casing thickness shall be 3/16 inch (5 mm) for walls and arches, and 1/4 inch (6 mm) for floors.

2.4 Tube Supports

2.4.1 Furnace tube supports shall be designed to resist the vertical reactions of the supported tubes plus the
operating contents under the normal operating conditions. They shall also be capable of sustaining the vertical
load plus any frictional forces, which may be developed and transmitted to the supports under short-time
conditions. The coefficient of friction for steel on steel shall be 0.30. For the friction load of convection tubes on
intermediate tube supports and end tubesheets, consideration may be given to the probability of non-concurrent,
non-uniform expansion of multiple tubes. However, in no case, shall a coefficient of friction less than 0.3 be
used.

2.4.2 Supports for horizontal tubes shall be spaced at a maximum distance of 40 tube outside diameters.
Consideration shall be given to the service, tube size, and wall thickness.

2.4.3 Tube supports shall have allowable stresses established using elastic criteria or stress rupture curves
based on a rupture time of 100 000 hours.

2.4.4 Tube support materials listed and defined below shall be used only within the specified temperature
range:
TABLE I
TUBE SUPPORT MATERIAL

DESIGN TEMPERATURE RANGE TUBE SUPPORT

CASTINGS * PLATE *
MATERIAL
°F °C
up to 800 up to 427 Carbon Steel A216 Gr. WCB A283 Gr. C
up to 800 up to 427 Ductile Cast Iron A536 Cl. 65-45-12 ---
800 to 1100 427 to 593 1 1/4Cr --- A387 Gr. 11
800 to 1200 427 to 649 2 1/4Cr --- A387 Gr. 22

800 to 1200 427 to 649 19Cr - 9Ni A297 Gr. HF ---

800 to 1500 427 to 815 18Cr - 8Ni --- A240 TP304H
1000 to 1800 538 to 982 50Cr - 50Ni A519 ---
1200 to 1600 649 to 871 2CS - 20Ni --- A240 T310S
1200 to 1800 649 to 982 Alloy 800H A351 Gr. CT15C ASME SB409
1200 to 2050 649 to 1121 25Cr-35Ni +Nb Proprietary ---
35Ni 26Cr 15Co 5W
Above 1900 Above 1038 Proprietary ---
or Approved Equal

* ASTM material specification, unless otherwise noted.

 DESIGN SPECIFICATION

FURNACES
MB40-1D

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 6

2.5 Settings

2.5.1 Floors, walls, and arches shall be designed so the outside surface temperature specified on the Furnace
Data Sheets is attained when the furnace is operating at design process conditions based on an ambient
temperature of 80°F (27°C) and a wind velocity of 5 mph (2.24 m/s). Floor, wall, and arch construction will be
described on the Furnace Data Sheets.

2.5.2 Header boxes and breeching sections shall be internally lined with a minimum of 2 inch (50 mm) thick
insulating castable.

2.5.3 End tube sheets for furnaces shall be designed with not less than 3 inch (75 mm) thick insulating castable
on the flue gas side.

2.5.4 Floor, wall, and arch insulation shall be designed to allow for thermal expansion or shrinkage of insulating
materials.

2.5.5 For multilayer design, splice joints shall be staggered relative to the adjacent layers.

2.5.6 The refractory and insulating material of any layer shall be suitable for a design temperature, with suitable
safety factor, above its calculated hot face temperature.

2.5.7 Minimum design temperature for refractories shall be 1800oF (982oC) in the radiant and shield sections.

2.5.8 Burner blocks shall have a minimum design temperature of 2700oF (1482oC).

2.5.9 For corrosion protection of all internal surfaces, except surfaces lined only with castable insulation, shall
be enhanced by the application of a high temperature vapor barrier. Internal surfaces lined with castable and
block or board as backup are also included in the corrosion protection. The vapor barrier coating shall meet the
requirements of Military Specification MIL-S-17377 and shall retain its integrity at continuous exposure to
temperatures up to 500°F (260°C). The coating shall be asbestos-free and shall be applied on surfaces
prepared in accordance with SSPC SP 2. Installation procedures and thicknesses shall be in accordance with
the material supplier's recommendations.

2.6 Doors and Header Boxes

2.6.1 A sufficient number of observation doors shall be installed in the furnace to provide visibility of the burner
flames. In furnaces, which require decoking, and in furnaces, which have the potential for radiant tube hot
spots, the doors shall provide visibility of the full length of all tubes in the radiant section.

2.6.2 Doors shall be designed and insulated to minimize air infiltration into the furnace.

2.6.3 Access doors shall be provided in each radiant cell, the breeching, and transition sections for all furnaces.
Access doors shall be provided in all sections of flue gas ducting.

2.6.4 Convection section bends shall be installed inside header boxes. Header boxes shall allow for the total
tube expansion. A minimum clearance of 2 inches (50 mm) shall be provided, in the hot position, between the
header box refractory and the edge of return bend, internal crossover, or header.

2.6.5 Header boxes shall be designed with splices at tube penetrations with sufficient allowance for expansion.

2.6.6 Header boxes shall not cross-field splices.

 DESIGN SPECIFICATION

FURNACES
MB40-1D

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 6

2.7 Burners

2.7.1 Burners shall be designed for maximum heat liberation of 120% of normal operating requirements.

2.7.2 Burners shall be designed for the fuel(s), turndown ratio, excess air, air preheat, draft, and flame
characteristics as required for start-up and operation.

2.7.3 Burners shall be designed to comply with emission requirements.

2.7.4 Furnace design shall consider burner spacing and clearances from furnace tubes and refractory walls
required to prevent flame impingement on tubes.

2.7.5 Burner design shall provide means for burner ignition.

2.7.6 All burner components required for operation such as fuel connections, sight and lighting ports, and
damper operating handles shall be arranged and oriented to accommodate conditions at the burner location.

2.7.7 Burner design shall provide for burner tip and/or oil gun removal for maintenance during furnace
operation.

2.8 Instrument and Auxiliary Connections

2.8.1 Instrumentation and service connections shall be provided throughout the furnace to enable full control of
the furnace process and combustion.

2.8.2 For Purchaser furnace designs, instrumentation shall be provided in accordance with Process and
Instrumentation Drawing (P&ID) requirements.

2.8.3 A flue gas thermocouple connection shall be provided at the exit of each radiant section and at the exit of
the convection section.

2.8.4 All instrument and auxiliary connections shall be plugged, capped, or provided with a blind flange equal to
the connection size and rating.

2.9 Stacks, Flares, Ducts, and Dampers

2.9.1 Stacks and flares mounted at grade or within the furnace structure shall conform to Purchaser Design
Specification MB42-1D. The height of the stack shall be governed by the local and national air quality standards
of the area and in accordance with Purchaser Design Specification 10-1D. External or internal lining
requirements, and stack instrument requirements, will be in accordance with Furnace API Data Sheets and
P&ID's.

2.9.2 Furnace stacks and ducts may be internally lined to protect casing from excessive heat or to dampen
wind excited vibrations. They may also be externally insulated to increase metal temperature to preclude
internal corrosion due to condensation. Where internal linings are specified, insulating castable shall be used
with a minimum thickness of 1 1/2 inches (40 mm) reinforced with chain link fencing, hexagonal carbon steel
mesh, or V-clips. Where external insulation is specified, weatherproofed mineral wool or equal shall be used.
For gas temperatures less than 450°F (232°C), and where corrosion of the casing plate is not a factor, the
linings may be omitted and replaced by expanded metal personnel protection where required.

2.9.3 Configuration of the flue gas system shall account for the need to isolate sections of the system for
maintenance where practical.

2.9.4 Flue gas ducts shall be fabricated from weldable carbon steel of structural quality plate and sheet, with a
minimum thickness of 3/16 inch (5 mm).
 DESIGN SPECIFICATION

FURNACES
MB40-1D

DATE: 01 JUN 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 6

2.9.5 Dampers with design temperatures up to 650°F (343°C) shall be made from carbon steel.

2.9.6 Damper material shall be selected in accordance with the following table:

TABLE II
DAMPER MATERIAL
DESIGN TEMPERATURE DAMPER MATERIAL

650oF (343oC) through

18Cr-8Ni Stainless Steel
1200oF (649oC)

Above 1200oF 25Cr-20Ni Stainless Steel

2.10 Tubing, Fittings, and Headers

2.10.1 All tubes, headers, and return bends for process streams shall be provided with suitable allowances for
erosion, corrosion, and oxidation depending upon material and applicable design conditions.

2.10.2 Removable plug fittings shall be provided only in services requiring mechanical cleaning and then on
only one end of the tubes. Removable plug fittings shall be used at the tube pulling end.

2.10.3 Buttwelded return bends shall have the inside and outside contours taper-blended to provide a smooth
transition.

2.10.4 Material Specifications for Furnace Tubes, Headers, and Fittings shall be in accordance with Purchaser
Design Specification MB13-1D.

2.11 Structural Steel

2.11.1 Furnace structural steel shall be designed in accordance with the AISC Manual, except as indicated
otherwise in Purchaser Design Specification 9-8D and this specification.

2.11.2 Box panels, casing plate, and other members supporting refractory materials shall be proportioned so
that the maximum deflection does not exceed 1/360 of the span.

2.11.3 Platform flooring shall be open type steel floor grating with 1 inch deep x 3/16 inch thick (25 mm deep x
5 mm thick) bearing bars with non-skid cross bars, pressure welded in a rectangular pattern.

2.11.4 All tubes, headers and burners shall be supported from the structural steel framework independent of the
insulation or refractory lining.

2.11.5 Roofing and gable end siding shall be of weather resistant roofing material.

2.11.6 Full reinforcement shall be provided for openings in casing plate.