GP-07!02!01 Industrial Boilers

GP 07-02-01 Industrial Boilers August 2005
Industrial Boilers
GP 07-02-01
Scope
1) [I] This Global Practice (GP) covers the design, fabrication, and inspection of gas and oil fired water
tube (membrane or tangent tube) industrial boilers (other than gas turbine exhaust boilers) having
steam outlet conditions not exceeding 1700 psig (117221 kPa-g) and 960°F (515°C).
2) [I] An asterisk (*) indicates that a decision by Purchaser is required or that additional information is
specified by Purchaser.
Refining/Chemicals, Downstream
For ExxonMobil Use Only Version 2.0.0
Imperial Oil
Page 1 of 33 ExxonMobil Development Company

Table of Contents
Table of Tables .............................................................................................................. 4
1. Required References ............................................................................................ 5

1.1. Global Practices–ExxonMobil Engineering Practices ................................... 5
1.2. AMCA–Air Movement and Control Association ............................................ 6
1.3. ASME–American Society of Mechanical Engineers ..................................... 6
1.4. ASTM–American Society for Testing and Materials ..................................... 6
1.5. NFPA–National Fire Protection Association ................................................. 7
1.6. SSPC–Society for Protective Coatings ......................................................... 7
2. Additional Requirements ...................................................................................... 7
2.1. Global Practices–ExxonMobil Engineering Practices ................................... 7
2.2. ASME–American Society of Mechanical Engineers ..................................... 7
2.3. ASTM–American Society for Testing and Materials ..................................... 8
3. Definitions.............................................................................................................. 8
4. Documentation ...................................................................................................... 9
4.1. Proposal information .................................................................................... 9
4.2. Post Award Review .................................................................................... 10
4.3. Final Records ............................................................................................. 11
5. Materials............................................................................................................... 11
5.1. Drums and Headers ................................................................................... 11
6. Design .................................................................................................................. 12
6.1. General....................................................................................................... 12
6.2. Drums and Headers ................................................................................... 12
6.3. Superheater................................................................................................ 13
6.4. Convection Surface Cleaning ..................................................................... 14
6.5. Structure and Casing .................................................................................. 14
6.6. Observation and Access Doors .................................................................. 15
6.7. Platforms and Stairs ................................................................................... 15
6.8. Stack .......................................................................................................... 15
6.9. Burners ....................................................................................................... 16
6.10. Ducting and Windbox ................................................................................. 16
RFCH, DIOL For ExxonMobil Use Only Version 2.0.0

6.11. Forced Draft Fans ...................................................................................... 17

6.12. Instrumentation and Controls ..................................................................... 17
6.13. Burner Management System ...................................................................... 19
6.14. Facilities and Logic Programming for Burner Lightoff ................................. 21
6.15. Boiler Shutdown, Shutdown Valves, and Test Facilities ............................. 22
6.16. Combustion Control System ....................................................................... 24
6.17. Pressure Relief Valves ............................................................................... 25
6.18. Piping Systems........................................................................................... 26
7. Inspection Standards and Acceptance Criteria ................................................ 27
8. Testing ................................................................................................................. 28
9. Guarantee ............................................................................................................ 29
Record of Change ....................................................................................................... 32
Attachment: Purpose Codes Definitions.................................................................. 33

Table of Tables
Table 1: Limits for Maximum Continuous Rating (MCR) ........................................ 12
Table 2: Criteria for Convection Surface Cleaning Facilities Selection................. 14
Table 3: Maximum Radial Coverage of Sootblower ................................................ 14
Table 4: Solids Content Limits .................................................................................. 29
Table 5: Performance Checklist ................................................................................ 30

1. Required References
[I] This Section lists the Practices, codes, standards, and specifications which shall be used with this
Practice.
1.1. Global Practices–ExxonMobil Engineering Practices

GP 01-01-01 Drawings, Diagrams, and Line Lists
GP 02-01-01 Plant Noise Design Criteria
GP 03-04-01 Piping for Fired Equipment
GP 03-06-01 Piping for Instruments
GP 03-06-02 Piping at Control and Protective System Valve Stations
GP 03-12-01 Valve Selection
GP 03-16-01 Flanged Joints, Gaskets, and Bolting
GP 03-18-01 Piping Fabrication Shop or Field
GP 04-01-02 Structural Steel Design
GP 04-01-03 Design Loads for Structures
GP 04-02-01 Auxiliary Structures for Operation and Maintenance
GP 07-05-01 Coils for Fired Heaters and Boilers
GP 07-08-01 Dampers and Guillotines for Fired Equipment
GP 10-13-01 Special Purpose Centrifugal Fans
GP 14-01-01 External Insulation
GP 15-02-01 Temperature Instruments
GP 15-03-01 Pressure Instruments
GP 15-04-01 Flow Instruments
GP 15-05-01 Level Instruments
GP 15-06-02 Environmental Protection for Instrumentation
GP 15-07-02 Protective Systems
GP 15-09-01 Control Valves
GP 15-11-01 Instrument Control Panels
GP 18-07-01 Welding Procedures
GP 18-08-01 Precommission Cleaning of Steam Generating Equipment and Piping
Systems for Rotating Equipment

GP 18-10-01 Additional Requirements for Materials

GP 18-12-01 Positive Material Identification
GP 19-01-01 Paint and Protective Coatings
GP 19-03-03 Linings for Fired Heaters
GP 20-01-01 Inspection of Equipment and Materials
1.2. AMCA–Air Movement and Control Association

AMCA 210 Laboratory Methods of Testing Fans for Rating
1.3. ASME–American Society of Mechanical Engineers

Unless specific references to the ASME Code are listed, an IHS link to the Introduction is provided to
facilitate accessing the relevant parts of the Code.
ASME SEC I BPVC Section I - Rules for Construction of Power Boilers
ASME SEC II A BPVC Section II A - Materials Part A - Ferrous Material Specifications
ASME SEC II B BPVC Section II B - Materials Part B - Nonferrous Material
Specifications
ASME SEC II C BPVC Section II C - Materials Part C - Specifications for Welding Rods,
Electrodes, and Filler Metals
ASME SEC II D BPVC Section II D - Materials Part D - Properties
ASME SEC V BPVC Section V - Nondestructive Examination
ASME SEC V A-2 Article 2 Radiographic Examination
ASME B1.20.1 Pipe Threads, General Purpose (Inch)
ASME B31.3 Process Piping
ASME PTC 4 Fire Steam Generators
ASME PTC 19.11 Steam and Water Sampling, Conditioning, and Analysis in the Power
Cycle (Performance Test Codes)
1.4. ASTM–American Society for Testing and Materials

ASTM C 680 Standard Practice for Determination of Heat Gain or Loss and the
Surface Temperatures of Insulated Pipe and Equipment Systems by the
Use of a Computer Program

1.5. NFPA–National Fire Protection Association

NFPA 85 Boiler and Combustion Systems Hazards Code
1.6. SSPC–Society for Protective Coatings

SSPC SP 7 Joint Surface Preparation Standard Brush-Off Blast Cleaning (NACE
NO. 4)
2. Additional Requirements
1) * [I] This Section lists the Practices, code, and standards which shall be used with this Practice as
specified by Purchaser.
2) * [I] Proposals to use codes other than listed in Section 1 shall be submitted to Purchaser for approval
by Purchaser. To be considered for acceptance, the code must be acceptable to the inspecting
authority of the country in which the boiler will be installed.
2.1. Global Practices–ExxonMobil Engineering Practices

GP 04-05-01 Steel Stacks
GP 04-05-02 Reinforced Concrete Chimneys
GP 05-01-02 Additional Requirements for Special Criteria Pressure Vessels
GP 07-03-01 Sootblowers for Fired Equipment
GP 07-09-01 Expansion Joints for Fired Equipment
GP 10-07-02 Special Purpose Steam Turbines
GP 15-08-01 Process Analyzers
GP 16-09-01 Low Voltage AC Motors Up to 200 HP (150 kW)
GP 18-03-02 Statically Cast Steel and Alloy Pressure Containing Parts and Tube
Supports for Fired Heaters
2.2. ASME–American Society of Mechanical Engineers

Unless specific references to the ASME Code are listed, an IHS link to the Introduction is provided to
facilitate accessing the relevant parts of the Code.
ASME SEC VIII D1 BPVC Section VIII - Rules for Construction of Pressure Vessels -
Division 1

ASME SEC VIII D1 Mandatory Appendix 6 Methods for Magnetic Particle Examination
MA APP 6 (MT)
ASME SEC VIII D1 Mandatory Appendix 12 Ultrasonic Examination of Welds (UT)
MA APP 12
2.3. ASTM–American Society for Testing and Materials

ASTM A 276 Standard Specification for Stainless Steel Bars and Shapes
ASTM A 578/A 578M Standard Specification for Straight-Beam Ultrasonic Examination of
Plain and Clad Steel Plates for Special Applications
3. Definitions
Term [I] Description
Effective projected radiant [I] In the furnace, this shall be calculated as the flat projected
surface area of exposed tubes and exposed extended surface integral
with tubes. Refractory covered surfaces shall not be included.
Calculation of furnace heat absorption is to be based on this
definition.
Radiant heating surface [I] In the furnace, this is defined as the flat projected area of
all surfaces enclosing the furnace volume exclusive of
superheater cavity opening. Calculation of furnace heat
release is to be based on this definition.
BMS - Supervised Automatic [I] This is an ExxonMobil term used to describe a burner
management system by which a boiler is purged and a burner
is started (ignited) automatically, as defined by NFPA 85, but
with specific hold points added for operator verification and
confirmation.
SIS - Safety Instrumented [I] Protective system designed per requirements of GP 15-07-
System 02. For boilers, the Burner Management System (BMS)
usually handles all protective functions and is the SIS.
Pilot [I] Burner main flame ignition device.
Igniter [I] Device to ignite pilot

4. Documentation
4.1. Proposal information
[I] A technical description, including the following information for the boiler and auxiliaries, shall be
supplied:
1) An itemized descriptive list of valves, instruments, controls, piping, and other boiler accessories
included in the scope of supply.
2) The system resistance curve, overplotted on the fan characteristic curve for all FD and ID fans, for
each operating combination.
3) Guaranteed ramp rates (load change) through entire range for:
a) Cold startup
b) Upward load charge
c) Downward load charge
4) A functional logic diagram showing the light-off and shutdown sequence for the burners.
5) Heat transfer surface in the furnace and boiler bank reported according to the definitions given in this
Practice.
6) The applicable performance data shown in Table 5 for the maximum continuous rating and other
specified operating points.
7) Dimensional drawing or drawings showing drum internals, drum and header material, outside
diameter, plate thickness; water and steam circuit arrangement, furnace configuration, burner
locations, flue and duct arrangements, and dimensions and material of expansion joints, size location
of observation, access and inspection doors, and sizes and locations of vents and drains.
8) Materials of construction.
9) Extent of platforming, ladders, and stairways to be supplied.
10) A list of exceptions to this Practice or, if there are no exceptions, a statement to this effect in the
proposal.
11) Maximum boiler turndown with all burners in operation and minimum recommended excess air for
the specified design fuel and fuel pressure.
12) The maximum capacity of liquid fuel guns—these shall be stated in lb/hr (kg/h).
13) The minimum load obtainable with combination firing.
14) A curve showing the variation of superheater outlet temperature with boiler load over the range of
operation of the boiler.
15) Method of tube replacement/plugging for each coil.
16) Complete description of all field work required—Drawings shall show all break points and weights of
individual shop assembled items.
17) A curve showing circulation rate versus steam production over the range of boiler operation.

18) One copy of Vendor's quality control manual.

19) Proposed chemical cleaning arrangement/procedure—procedures shall show nozzle/line sizes and
locations, blinds, circulation paths, and flow rates through each section of the boiler, including
superheater coils.
20) Estimated emissions including NOx, CO, and VOCs.
4.2. Post Award Review

[I] As a minimum, Vendor shall provide for review by the Owner's Engineer the following design details:
1) All changes to proposal information.
2) Burners including general arrangement, air/fuel capacity curves, and pilot details including pilot and
burner front piping.
3) Air and flue gas ducting including dampers, expansion joints, turning vanes, blinds, pressure drop,
and heat loss calculations.
4) Tubesheets and tube supports including stress calculations.
5) Castable Manufacturer's recommended procedure for refractory dryout.
6) Complete tube to drum/header installation procedures.
7) Foundation loading diagram and steel structure and casing.
8) Calculations showing steam/water side pressure drop, superheater metal temperature, and circulation
results.
9) Lining details including material selection, anchor details, heat loss calculations, installation
procedures, and expansion provision.
10) Observation and access doors.
11) Thermocouple details and installation procedure for non-drainable superheater.
12) All attemperator design criteria and heat transfer calculations.
13) Pressure relief valve calculations.
14) Tube vibrational analysis.
15) Combustion control, air flow measurement device, and feed water control.
16) Code calculations for all pressure parts.
17) Auxiliary equipment such as air preheaters, induced and forced draft fans, sootblowers, and fuel
filters.
18) Burner management system, including P&ID, logic diagrams/narrative and Cause & Effect diagrams.
19) Guaranteed emissions including NO x , CO, and VOCs.

4.3. Final Records

Final records to be submitted to Purchaser shall include:
1) Operating manuals shall be written specifically for the unit being supplied. Manuals shall include all
details necessary for commissioning, startup, and operation without the need for Vendor assistance.
2) All as-built assembly and shop detail drawings and instructions necessary for fabrication, erection,
and continued maintenance of the boiler, including adequate details and specifications for fabricating
and installing any and all replacement parts.
3) All proposal information, corrected to the as-built conditions.
4) Approved procedure for refractory dryout.
5) Vendor recommendations and detailed procedure for both boil-out and chemical cleaning.
6) Vendor detailed procedure to plug tubes and tube holes. Provide mechanical features of plugs and
details of tube expanding equipment required.
7) An outline drawing shall be furnished for each significant pressure part. This drawing will be used as
an overall summary drawing for in-plant inspection and maintenance tasks. This drawing shall show
the size and orientation of all nozzles and connections, layout of all appendages to the pressure part,
and sufficient data to adequately describe the part. The location of vessel marking or nameplate shall
be indicated on this drawing.
8) Fabrication drawings shall show weld details and materials, and shall reference applicable welding
procedures. When impact testing is required, the drawings shall include:
a) Component
b) Material Specification
c) Critical Exposure Temperature (CET)
d) Appropriate Charpy Impact Requirements (Average/Minimum Values)
9) Additional information shall be supplied as follows:
a) Certified Material Mill Test Reports from the mill of manufacture for all pressure parts
b) Nameplate Rubbings
c) Code Calculations
10) P&ID of the BMS.
5. Materials
5.1. Drums and Headers
1) * [S] Material with a maximum tensile strength in excess of 112,500 psi (775 MPa) is not acceptable.
Proposals to use proprietary alloy material shall be submitted for approval by the Owner's Engineer.
2) [R] A corrosion allowance of 1/ 16 in. shall be used for drums, headers, and crossover piping.

6. Design
6.1. General
1) * [R] Boiler design and fuel combination shall be commercially demonstrated in a similar service,
and operating range, including fuel transitions, to the satisfaction of the Owner's Engineer.
2) * [O], [R] Based on design fuel higher heating value, the maximum heat release at Maximum
Continuous Rating (MCR) in the furnace shall not exceed the limits shown in Table 1.
Table 1: Limits for Maximum Continuous Rating (MCR)
Heat Release (HHV)

Fuel Fired Furnace Volume Furnace Radiant Heating Surface
Btu/hr-ft3 kW/m3 Btu/hr-ft2 kW/m2
Gaseous fuels and liquid fuels 80,000 828 150,000 473
lighter than 15° API (0.966
relative density)
Liquid fuels 15° API and 60,000 620 150,000 473
heavier
3) [O] Boiler and auxiliary equipment, with the exception of the forced draft fans and drivers, shall be
designed for at least 10 percent excess air for firing gas fuel and 15 percent excess air for firing oil
fuel or combination gas and oil fuel.
4) [O] All circuits and coils shall be drainable. For superheater exception, see Section 6.3, Item (1).
6.2. Drums and Headers

1) [O] The maximum boiler operating pressure must be a minimum of 5 percent below the setpoint of
any pressure relief valve.
a) Owner will specify the maximum required operating pressure downstream of the non-return
valve.
b) Vendor is responsible to determine maximum operating pressure at relief valve inlet points based
on boiler component pressure drops at MCR.
2) [R] Steam/Mud drum internal piping shall be designed for even distribution with no functional
interference along the length of the drum.
3) * [I] The size of blowdown nozzles shall be determined based on the blowdown rate and back
pressure specified.

4) [O], [R] For boilers operating over 500 psig (3450 kPa), steam drum internals shall include
centrifugal type primary separators and secondary separators. Separators shall be sealed below water
level.
5) * Proposals to use other types of primary separators shall be submitted to the Owner's Engineer for
approval. To be considered for approval, Vendor must substantiate with test data from a commercial
unit that the solids content of steam entering the superheater will not exceed job specification
requirement when operating with water at high level and with specified boiler water concentration.
6) [R] Drums with wall thickness greater than 2 in. (50 mm) shall have welded connections as follows:
a) Connections greater than NPS 4 (100 mm) shall be according to Figures PW-16.1 (q-1), (q-2), (q-
3), or (q-4) of ASME SEC I.
b) Connections NPS 4 and less shall be as above or according to Figures PW-16.1 (a), (b), (c), (g),
(h). Figures PW-16.1 (y) or (z) may also be used for tube connections NPS 4 and less when the
tube wall thickness is less than 1/ 2 in. (13 mm).
7) [S], [R] Drums and headers, where both the wrapper plate and tubesheet exceed 2 in. (50 mm) in
thickness, shall be designed according to GP 05-01-02.
8) [R] The interior of the upper and lower drums shall be cleaned to SSPC SP 7 prior to tube installation.
9) [S], [R] Design of feedwater and chemical feed entry through steam drum shell shall be approved by
the Owner's Engineer. Use of a thermal sleeve is required when differential temperature between
fluids exceeds 100°F (38°C).
10) [S], [O] The steam drum shall:
a) Contain adequate volume to withstand the "shrink" and/or "swell" resulting from maximum
guaranteed ramp rates to and from MCR without reaching the high or low level alarm. For
calculation purposes, assume all steam bubbles collapse during a "shrink" occasion.
b) For boilers up to 600 psig provide minimum holdup of three minutes at MCR from low level
alarm to low level trip point, which is set just above the point where damage can occur (one inch
above level at which tubes are uncovered), unless specified otherwise.
c) * For boilers operating at over 600 psig provide minimum holdup of one minute at MCR from
low level alarm to low level trip point, which is set just above the point where damage can occur
(one inch above level at which tubes are uncovered), unless specified otherwise.
d) In calculating holdup time, Vendor shall consider only that water which can actually enter the
tubes within the stated time. Water cutoff from the tube by internal baffles or partitions must not
be considered.
11) [S] The steam drum shall be equipped with two man-ways, one at each end of the drum, with
minimum dimensions of 15 in. x 18 in.
12) If supplied, chevron drains to be piped below LWCO.
6.3. Superheater
1) [R] The superheater shall be arranged such that the inlet tubes are not located in the region of highest
flue gas temperature.
2) [R] * Boiler Vendor shall indicate whether the superheater is drainable or non-drainable. Vendor
shall have demonstrated experience with the proposed design and shall outline the proposed method
for internal cleaning of superheater coils.

6.4. Convection Surface Cleaning

1) * [O] Convection surface cleaning facilities shall be selected according to the criteria of Table 2. If
using a combination oil-gas burner, the properties of the oil shall govern selection of the cleaning
facilities.
2) [R] Sootblower shall meet the following:
a) Requirements stated in GP 07-03-01
b) For Class I fuels only retractable types are acceptable
c) For Class II, III, and IV fuels rotary sootblowers may be used in passes where the entering flue
gas temperature is below 1200°F (650°C)
Table 2: Criteria for Convection Surface Cleaning Facilities Selection
Fuel Class Fuel fired Tube Surface Convection Surface Cleaning

I Liquid fuel of less than 25° API Bare Retractable sootblowers are
(0.904 relative density) gravity and required
with more than 0.01 wt percent ash
II Liquid fuel of less than 25° API Bare or finned Retractable or rotary
gravity and with less than 0.01 wt sootblowers required. Rotary
percent ash sootblowers may be used in
cooler flue gas regions below
1200°F (650°C)
III Liquid fuel of greater than 25° API Bare or finned Sootblower space required
gravity
IV * Gas Fuel Bare or finned Provision for sootblower space
optional
3) [O], [M] Maximum radial coverage of a sootblower shall be as specified in Table 3.
Table 3: Maximum Radial Coverage of Sootblower
Type Radial Coverage

Retractable 5 ft (1500 mm) or 5 tube rows whichever is less for fuels lighter than 15°
API (0.966 relative density)
4 ft (1200 mm) or 5 tube rows whichever is less for fuels 15° API and
heavier
Rotary 3 ft (900 mm)
6.5. Structure and Casing

1) [R], [S] Welded waterwall construction shall be used to form a pressure tight envelope to protect
insulation and outer casing from flue gas contact.

2) [R] Membranes on membrane wall construction shall be welded to the adjoining tubes on the front
and back face of the membrane.
3) [O] Drains shall be furnished at the low point of the boiler furnace and bank areas to permit removal
of the flue gas deposits by water washing. Minimum opening shall be 3 in. (75 mm) diameter. Drain
openings shall be effectively sealed against flue gas bypassing and casing overheating.
4) [R] Metallic jacket covering boiler insulation shall have a minimum thickness of 0.05 in. (1.3 mm)
and shall be galvanized carbon steel sheet or corrugated aluminum sheet. Jacket shall also be
adequately reinforced to prevent buckling and vibration.
5) [S] Waterwall (flue gas path) design pressure shall be the maximum (shutoff) F.D. fan discharge
pressure if the boiler outlet flue gas path can be blocked—e.g., equipped with a flue gas damper.
6.6. Observation and Access Doors

1) [S], [R] Observation doors shall be provided to meet the following requirements:
a) Be located to permit visibility of all burners, flame envelope, furnace surfaces, and the
superheater cavity.
b) Have minimum wall opening of 2 in. x 4 in. (50 mm x 100 mm) or 3 in. (75 mm) diameter.
c) On pressurized boilers, observation doors shall have a view glass and shall be furnished with:
i) Aspirating air of sufficient pressure to prevent flue gases from blowing out when the door is
open. Warning signs shall be posted alerting operators to the dangers and procedures for
opening observation doors.
ii) Seal air to minimize flue gas leakage and prevent fogging of the view glass when the door is
closed.
2) [M] Boilers which have continuous tangent tubes or fin welded (membrane wall) furnace floor tubes
shall be elevated a minimum of 3 ft (900 mm) to permit access beneath the furnace floor.
6.7. Platforms and Stairs

1) [I] Platform, stairs, and ladders shall be provided according to GP 04-02-01 with the additions and
clarifications noted in this Section.
2) [C] Grating is acceptable for platform flooring. This is an exception to GP 04-02-01.
3) [M] Minimum clear width of platforms for access to drum manways shall be 4 ft (1200 mm).
4) [O], [M] Stairway access shall be provided to platforms serving burners, burner controls, sootblowers
and the steam drum.
5) [M] Platform access shall be provided for maintenance of the oxygen/combustibles sample probe(s).
6.8. Stack
[S] Top of stack shall be a minimum of 10 ft (3000 mm) above any equipment which is located within 50
ft (15 m) horizontally of the stack. The stack shall also be at least 10 ft (3000 mm) higher than any
working platform that is regularly used by operating or maintenance personnel (with a frequency of once
a day or greater), and is within a horizontal distance of 100 ft (30 m).

6.9. Burners
1) [R] Burners shall meet one of the following:
a) A burner which has been commercially proven in comparable service (service conditions, fuel,
orientations, turndown excess air, and heat release, fuel transitions, and individual fuel trips for a
multi-fuel burner).
b) A demonstration (of the burner being provided) under simulated field conditions to the
satisfaction of the Owner's Engineer.
2) [O] For liquid fuel only burners, there shall be a minimum of two fuel guns per boiler to facilitate
burner changes without loss of combustion. Operating procedures with recommended fuel conditions
shall be provided and demonstrated for such fuel gun transitions.
3) [O] Dual fuel burners shall be:
a) Capable of firing the gas and liquid fuels specified, both separately and simultaneously.
b) Dual rated—i.e., must be capable of meeting design requirements on each fuel, fired separately, if
specified.
c) [R] A boiler firing two primary fuels shall be designed to continue to operate when either primary
fuel trips. This shall be true over the entire operating window. Burner stability, during a switch
from two fuels to one fuel while at high excess air, shall be demonstrated at initial startup.
4) [S] A device shall be provided to prevent pressurized furnace gases from blowing out through burner
gun openings when guns are removed.
5) [S] Oil gun heads for liquid fuel shall be designed so that no fuel or steam will escape if head is
removed without first blocking fuel and steam lines.
6) [S], [M] All burners shall have interrupted spark ignited gas pilots (NFPA 85 Class 3). All pilots and
ignition sources shall be removable with burner in operation. * In special cases when gaseous fuel is
not available, NFPA 85 Class 3 direct electrical pilots may be used if approval is given by Owner.
7) [S] The burner vendor shall state the minimum to maximum level of excess combustion air where
burner stability is guaranteed.
a) These limits shall be confirmed in the field through rigorous testing for all specified fuels,
operating conditions and transitional fuel switches.
b) Air/fuel controls must be configured and tuned to keep the boiler within guaranteed burner
stability limits for all specified fuels, operating conditions and transitional fuel switches.
8) [S] All burner piping designs supplying fuel to more than two burners shall be analyzed for equal
distribution to each burner.
6.10. Ducting and Windbox

1) [O], [R] Ducting for flue gas and air shall be 3/ 16 in. (5 mm) minimum plate thickness of continuous
seal welded construction, with flanged connections for field assembly, to ensure air tightness.
2) [R] Flue gas ducting shall be insulated to maintain the bulk flue gas temperature above its acid
dewpoint. Ducting upstream of flue gas heat recovery shall be insulated to produce a calculated cold
face temperature of no more than 180°F (82°C) based on an ambient still air temperature of 80°F
(27°C). Physical barriers, per GP 14-01-01, shall be provided for all surfaces located within 1 ft. (300
mm) horizontally or 7 ft. (2100 mm) vertically of a normal access, walkway or work area.

3) [O], [R] Combustion air ducting shall be:

a) Designed to provide uniform flow distribution to all burners.
b) Insulated, if an air preheater is provided, to produce a calculated cold face temperature of 150°F
(65°C) based on an ambient, still, air temperature of 80°F (27°C).
4) [O] A dynamic flow model, CFD or cold flow, shall be performed for all windbox designs supplying
combustion air to more than two burners to confirm equal distribution of combustion air to each
burner.
5) If perforated plates are to be provided for achieving uniform air distribution, perforated plate hole size
should be limited to 1/ 4 in. to avoid plugging.
6) [S] For boilers with flue gas recirculation (FGR), the FGR duct shall be equipped with a damper with
open and closed position switches.
6.11. Forced Draft Fans

1) [R] Forced and induced draft fans shall meet the following requirements at their rated points:
a) Rated airflow shall be 110 percent of the airflow required by the unit operating at MCR and firing
design fuel at 20 percent excess air for oil fuel and 15 percent excess air for gas fuel.
For boilers with flue gas recirculation (FGR) returning to the FD fan inlet, 110 percent of the
maximum FGR rate at MCR (at design stack temperature plus 20°F/10°C) shall be added to the
fresh air flow rate calculated as described above.
b) Rated static head shall be 120 percent of the head required at MCR and firing design fuel at 20
percent excess air for oil fuel and 15 percent excess air for gas fuel.
For boilers with FGR, the FGR rate shall be included in determining head required.
c) Forced draft fans shall be rated at summer design air temperature, summer design relative
humidity, and altitude at site of installation. Induced draft fans shall be capable of maintaining
design capacity and head at inlet design temperature, ±25°F (14°C).
2) [O], [R] Fan blading design shall be either of the airfoil or backward curved non-overloading type.
3) [S] Discharge dampers shall be provided for parallel fans discharging into a common duct.
a) Dampers shall be actuator or counterweight operated to prevent backflow through any non-
operating fan.
b) Discharge isolation facilities, guillotine blanks that can be slipped between flanged sections of
duct on the upstream side of the discharge damper, shall be provided on any fan that can be
shutdown for maintenance while the boiler continues to operate.
c) A position switch shall be provided to indicate discharge damper closed position.
d) Tight shutoff dampers shall be provided with a minimum of 98 percent shut-off on area.
6.12. Instrumentation and Controls

1) [O] Water column shall be furnished by Boiler Vendor with a range that extends below low-water
cut-off and above high level alarm.
2) [S], [O] A combined oxygen/combustibles analyzer shall be provided to permit continuous analysis of
the flue gas in the stack.

a) [S] If a zirconia type analyzer is used, then it shall be equipped with a flame arrestor to prevent
flame propagation in the event of ignition by the heated sensor.
b) [S] The power to the zirconia type analyzer shall also be removed automatically in the event of a
boiler trip. The analyzer power reset shall be performed automatically by the BMS. The
following alternatives to power shutoff are acceptable with Owner's Engineer approval:
i) For extractive systems, block the flue gas sample flow and replace with ambient or
instrument air.
ii) Flood the analyzer probe with calibration air.
In all cases, reset of the analyzer following a boiler trip shall not occur until after completion of
the subsequent firebox purge.
3) [R] Feedwater control shall be of the three-element type.
4) [S] Fail-Action direction for the following valves/dampers shall be:
a) Fuel-close
b) Fuel gas vent–open
c) Combustion air–remain stationary (tend to open on air bleed down)
d) Feedwater (steam drum level control)–remain stationary (tend to close on air bleed down)
e) Blowdown-close
f) Desuperheater water (steam temperature control) - remain stationary (tend to close on air bleed
down)
g) Atomizing medium remain stationary (tend to open on air bleed down)
h) FGR damper - remain stationary (tend to close on air bleed down)
5) [S] Combustion air flowrate measurement shall be by a venturi type meter. Where a venturi is not
possible because of construction reasons, pitot arrays may be used subject to Owner's approval. Pitot
array should allow for on-line removal of the array element to facilitate cleaning in case of nozzle
fouling.
a) Either type shall be sized to generate a pressure differential of not less than 6 in. (150 mm) H2O at
normal firing rate and excess air. This provides adequate turndown capability.
b) A single primary measuring element is acceptable for both control and protective system
requirements provided each input has a separate transmitter with its own root valves and there are
no intermediate valves which could isolate more than a single transmitter.
6) [S] Measurement method for loss of forced draft fan shall be low fan speed (measured by fan shaft or
wheel RPM).
7) [R] Firebox pressure taps shall be 2" minimum to prevent potential restriction/plugging.
8) [S] Where flow measurement requires two or more inputs (e.g., fuel, steam), a single orifice plate or
wedge meter is acceptable; however, separate taps shall be used for each transmitter.
9) [R] The use of bridle assemblies to reduce the number of vessel connections is permitted per GP 15-
05-01 Section 7.1. Owner shall approve the final configuration.
a) All pairs of taps for level transmitters shall span the same range of drum level.
b) The level control transmitter can share a bridle with the gauge glass. Each shall have separate
root valves so they can be maintained independently.

6.13. Burner Management System

1) [I] A burner management system (BMS) shall be provided, based on NFPA 85 standards, consisting
of an integrated system of flame safeguarding, interrupted spark ignited gas pilots, shutdown devices,
interlocks, combustion limits, and alarms to assure safe conditions for lightoff and prevent unsafe
conditions from developing during operation. BMS shall preferably use a Programmable Electronic
System (PES) as defined by GP 15-07-02. Proposals to use relay based logic require Owner's
approval.
2) [S] The BMS shall be designed consistent with a "supervised automatic" operation. The intent for the
"supervised automatic" requirement is that an ExxonMobil operator be present at the boiler and
responsible for initiating various steps in the automated light-off sequence. This shall be
accomplished by providing the following minimum hold points in the NFPA 85 automated (non-
recycling) light-off sequence, with appropriate pushbuttons on the local panel:
a) Boiler reset/start purge.
b) Pilot start.
Normally this step will advance the sequence through burner light-off. (Alternatively, if "pilot
alone" operation is required before light off of main burners, a separate "Burner Start" pushbutton
must be provided. The BMS logic must ensure that the minimum air purge rate [25% of MCR air
rate] is maintained during pilot only operation.)
3) [S] The BMS shall be designed according to GP 15-07-02 and shall be Fail-Action (i.e., Fail Safe).
a) With the exception of the flame detectors, input sensor signal bypassing is allowable for testing or
maintenance purposes per GP 15-07-02 provisions. This is an exception to NFPA 85 standards.
b) Output defeats are prohibited for sequential logic systems, such as the BMS.
c) Sensors or switches that have a selectable failure direction shall be set to fail-action. Note that
this is an exception to GP 15-07-02 for single sensor (1oo1) systems.
d) Single channel I/O modules shall not be used for BMS functions. This is an exception to GP 15-
07-02.
e) A BMS time delay of up to 3 seconds is acceptable for process variable trip initiators. No BMS
time delay is allowed for flame detectors or for manual shutdown pushbuttons.
f) [S] All process variable inputs to the BMS shall be transmitters.
4) [S] The flame safeguard systems for all boilers shall be designed according to NFPA 85 with the
following additional requirements:
a) Flame detector type shall be approved by the Owner's Engineer.
b) Flame detectors shall be provided with a self-checking feature which continuously checks all
components from the scanner to the output circuit at least once every 6 seconds without affecting
the response time of the flame detector. The flame detector built-in time delay, if provided, shall
be at the minimum setting.
c) A permanent voltmeter shall be provided on the output circuit to facilitate aiming and monitoring
the detector. This readout shall be located at the burner deck.
d) Facilities shall be provided to detect the pilot flame. Where this is performed by the main burner
flame detection facilities, at least one scanner shall be aligned to view the pilot flame. If the
burner configuration compromises seeing both the pilot flame and main flame, the pilot shall
have a dedicated flame detection device.

e) Flame detectors shall detect their burner's flame at all loads and during all load changes without
picking up radiation from other burner flames on multiple burner units.
f) Continuous pilots may not be used in place of flame detection except when specified by
Purchaser.
g) The time interval between loss of flame and stopping the fuel flow to the burner(s) shall be not
more than five seconds.
h) For high FGR applications (greater than 10%), flame scanner purge air source should be fresh air
only.
5) [S] The flame safeguard systems for front or opposed fired boilers shall be designed according to
NFPA 85 with the following additional requirements:
a) Dual flame detection shall be provided for each burner.
b) To trip the associated individual burner fuel shutdown valves (or main shutdown valves for single
burner units), 2-out-of-2 voting of the flame detectors is required for boiler reliability purposes.
i) A single detector flameout signal shall alarm in the main control room and on the local panel.
The local panel shall indicate which detector had the flameout signal.
ii) If the BMS is implemented using relays, flame detector relays shall operate individual burner
fuel shutdown valves without intermediate relays except additional relays necessary to
provide the required number of contacts.
iii) [S] For one burner units, two outputs from each detector shall be independently wired to the
BMS with 1oo2 trip voting logic for each scanner's dual inputs.
c) Single flame detectors for each burner are acceptable for multiple burner units with 8 or more
burners, with Owner's Engineer approval, and provided the following conditions are met:
i) The type of flame detector selected is capable of reliable detection over the entire operating
window, including the range of fuels, excess air levels and boiler loads.
ii) The burner vendor has confirmed that MCR steam production is feasible with any two
detectors out of service and the associated burners off-line.
6) [S] Tangentially fired boilers shall meet the requirements in Item (4) above, with the exception or
addition of the following:
a) The flame detectors must be designed/positioned such that an individual burner flame can be
detected without picking up radiation from other burners at firing rates up to the initiation of
"fireball" conditions. (e.g., 30% MCR)
Once the boiler is in "fireball" conditions individual burner light-offs shall be allowed to proceed
even if flame is sensed.
b) At firing rates below "fireball" conditions, individual burners shall be tripped based on the
individual flame scanner(s).
c) At firing rates above initiation of "fireball" conditions, a flame scanner voting scheme shall be
used to initiate a master fuel trip. The voting scheme shall be determined by the burner vendor
and approved by the Owner's Engineer.
d) Steam flow shall be used to determine when the boiler reaches "fireball" load conditions.
Three transmitters shall be used for this input to the BMS for 2oo3 voting logic.
e) [R] Single flame scanners are acceptable for single gun burners as long as there are a sufficient
number of burners such that loss of signal from any two detectors will not result in a boiler
shutdown.

7) [S] Input to the BMS for the steam drum low level boiler trip shall consist of three level transmitters
for 2oo3 voting logic.
6.14. Facilities and Logic Programming for Burner Lightoff

1) [S] Burner light-off facilities:
a) A startup panel consisting of lights, pushbuttons, and auto-manual (A/M) transfer stations for
boiler control loops shall be located at the firing aisle.
b) Pressure control on pilot gas manifold shall be independent for each boiler and shall maintain
proper pilot gas light-off and operating pressure.
c) Fuel flow to the burners shall be maintained at proper rate for light-off by an independent
pressure controller installed in parallel with the boiler fuel control valve. For single burner boiler
designs, a positive means of ensuring that the main fuel control valve is in the proper light-off
position is an acceptable alternative (e.g., position transmitter or limit switch, measuring actual
valve position, with input to the BMS).
d) Light-off bypass pressure regulator sizing or light-off position setting on the main fuel control
valve shall limit the fuel flow to less than 10% boiler MCR fuel rate at maximum possible
upstream pressure conditions and maximum fuel density.
e) The main fuel control bypass valve shall be equipped with a limit switch located at the closed
position which will input to the BMS to alarm and prohibit light-off (i.e., permissive input) when
the control valve is not fully closed. The BMS shall automatically remove this permissive inhibit
signal once light-off has been achieved.
2) [S] Permissive interlock system for light-off shall be consistent with NFPA 85 requirements with the
following additions, clarifications and exceptions:
Additions:
a) The BMS shall verify "no flame" from all flame detectors as a permissive condition to allow
boiler reset.
b) The BMS shall be programmed to prohibit light-off of any individual burner if that burner's flame
detector senses flame.
If a burner has multiple detectors any one sensing flame shall prohibit light-off.
c) All input bypasses must be removed as part of the boiler reset before each light-off attempt.
d) The BMS shall be programmed to limit the time between purge and light-off of the first burner to
a maximum of thirty (30) minutes, at which point a master fuel trip will be initiated.
Clarifications:
a) System shall include a one-minute timer to prohibit another attempt to ignite any pilot after a pilot
gas valve shutdown.
Exceptions:
a) Pilot fuel gas high and low pressure trips are not required.
3) [S] Direct air flow measurement shall be used for proof of purge.
a) Three transmitters shall be used for this input to the BMS for 2oo3 voting logic. These inputs can
also be used for the combustion air low flow trip.
b) For boilers with parallel FD fans discharging into a common duct, the closed discharge damper
position switch on idle fans shall be a purge permissive.

c) For boilers with flue gas recirculation (FGR), the FGR damper closed position switch shall be a
purge permissive.
The open position switch shall be utilized to prove the FGR duct has been purged at the end of
the firebox purge cycle.
4) [S] A light-off checklist shall be permanently mounted on local panels.
5) [S], [O] All inputs tied into burner light-off permissive logic, including limit switches, shall be
provided with individual visual indication at the local panel to display the status.
6.15. Boiler Shutdown, Shutdown Valves, and Test Facilities

1) [S] Conditions to actuate boiler shutdown shall be consistent with NFPA 85 requirements with the
following additions, clarifications, and exceptions:
Additions:
a) Low steam drum level shall initiate master fuel trip on multiple burner boilers as well as single
burner boilers.
b) Low combustion air flow shall initiate a master fuel trip on single burner boilers as well as
multiple burner boilers.
c) High firebox pressure trip is required for all boilers.
Clarifications:
a) Emergency pushbuttons shall be located at a continuously manned control center panel and at the
local control panel.
b) Loss of flame on all main burners (pilot flames shall be excluded), after completion of first main
burner time trial period, shall initiate master fuel trip.
c) In the absence of vendor specific criteria, a "partial loss of flame" for multi-burner boilers
(defined as sudden closure of individual burner fuel shutdown valves on more than 50 percent of
operating burners) shall initiate a master fuel trip as per NFPA 85.
i) Detection of a closed valve by either of the two shutdown valve position sensors on an
individual burner shall indicate a tripped burner.
ii) Sudden closure is defined as within 15 seconds of one another.
d) High and low fuel gas pressure and low fuel oil pressure trips shall be activated at the expiration
of the ignition trial period for the first burner.
Exceptions:
a) Under the following conditions the boiler flame safeguard system is judged to provide adequate
assurance that the boiler shutdown will be initiated by loss of flame, such that the trip valves will
not reopen prior to a reset, purge and restart. As such, independent trip initiators are not required
for these conditions:
i) Closure of fuel trip and/or control valves (as indicated by actuation of the closed limit switch)
ii) Loss of instrument air
iii) Loss of instrument power
b) Boiler trips under the following conditions are judged unnecessary from a safety standpoint:
i) High steam pressure
ii) High fuel oil temperature.

Alarms are considered adequate for these conditions.

c) The manual emergency pushbutton trips shall be hard-wired as an input to the BMS to initiate a
master fuel shutdown, consistent with GP 15-07-02 protective system requirements. Independent
and direct wiring to the master trip relay, as specified in NFPA 85, is judged less reliable and is
not required. These shutdown circuits shall be configured as "open-to-trip."
2) Automated individual burner air registers are required on boilers with less than four burners. The
individual air register will close simultaneously with that burner's fuel shutdown valves when a flame
is not detected at that burner.
a) Automated burner air registers shall be designed to remain stationary on a master fuel trip (i.e.,
total boiler trip).
3) [S] For boilers with two or three burners, flame failure on any individual burner shall initiate a
complete boiler shutdown, unless the burners are equipped with individual automated air registers
that close on shutdown of that burner.
4) [S] Dual shutdown valves are required for individual burners of multiple burner liquid fuel boilers as
well as gas fired units.
5) [S] On boiler shutdown the forced draft fan shall not be shutdown.
6) [M] Block valves shall be provided:
a) Upstream and downstream of main fuel shutdown valves on multi-burner boilers. Block valves
are not required for single burner boilers.
b) Upstream and downstream of burner fuel shutdown valves on multi-burner boilers.
c) Upstream of main fuel gas vent valve.
i) [S] Note that this block valve shall be CSO and provided with a closed limit switch to alarm,
and to prohibit purge and/or light-off (i.e., permissive input), when not fully open.
ii) On multiple burner boilers, block valves are not required upstream of the individual burner
vent valve since the burner can be shutdown if valve maintenance is required.
7) [S] Main, individual, and pilot burner fuel shutdown and vent valves shall be designed per GP 15-07-
02 with the following added requirements:
a) Shutdown valves shall be designed to close fully within the time required to comply with the 5
second overall timing requirement from loss of flame to fuel out.
b) Individual burner fuel shutdown valves shall have an opening time compatible with burner
ignition requirements.
c) For multiple burner boilers, the individual burner fuel shutdown valves/vents, and for single
burner boilers, the main fuel shutdown valves/vent, shall be equipped with a limit switch for safe
valve position proving. These limit switches shall alarm and prohibit light-off (i.e. permissive
input), when not in the safe position.
d) Each individual trip valve shall be equipped with an independent solenoid. Use of a single
solenoid to trip one of the block valves and the vent valve is permitted. Proposals to use a single
approved self diagnosing SIL-3 (or higher) solenoid package for double block and vent actuation
shall require Owner's approval. Vent capacity of such a single solenoid package shall be a key
design consideration.

e) Fuel shutdown and vent trip valves shall not be equipped with manual reset solenoids. These
solenoids shall be reset after a boiler trip and before initiating a boiler light-off sequence by a
Master Reset pushbutton on the local panel.
f) [R] Main fuel shutdown valves shall also be equipped with open limit switches, with a
discrepancy alarm only, for additional error detection and advance warning of drifting closed for
reliability.
8) [S] For boiler liquid fuel systems equipped with recycle downstream of the main shutdown valve
(e.g., high viscosity, heated fuels), a separate shutdown valve shall be provided on the recycle line. A
check valve alone is not considered adequate for this service.
9) [S] Main, individual and pilot burner fuel shutdown valves shall be located to achieve the minimum
practical piping volume between the valve and the burner.
10) [S] The fuel gas and pilot gas vent trip valve shall be provided for all types of fuel gas.
The NFPA 85 exception for heavier-than-air gases shall not apply.
11) [S] Fuel shutdown bypass valves shall be provided when the required boiler run length exceeds the
required protective system test interval as per GP 15-07-02.
a) On multiple burner boilers, bypass valves shall not be provided for individual burner fuel
shutdown valves, as individual burners can be shutdown for testing.
b) Bypass valves provided around the main fuel shutdown valves shall be CSC and provided with
limit switches initiating an alarm when the bypass valves are not fully closed. The fully closed
position of the bypass valves shall be included as a purge/lightoff permissive. In addition, these
valves shall also be provided with a warning sign as per GP 15-07-02, Section 4.3, stating
"CAUTION - THIS VALVE TO BE USED ONLY FOR CHECKING PROTECTIVE
SYSTEMS."
c) For dual shutdown valve installations, each shutdown valve shall be equipped with a separate
bypass valve to allow testing one shutdown valve at a time. This prevents loss of complete
protection during testing.
d) The entire BMS must be designed/programmed to provide for on-line testing, one shutdown valve
at a time, in this case.
12) [S] Facilities shall be provided to allow nitrogen leak testing of fuel trip valves/vent combinations, as
well as fuel trip valve bypasses if equipped, during maintenance downtimes.
Exception: Automated leak testing prior to each light-off, as defined by NFPA 85, is not required,
unless specified by the Owner's Engineer based on leakage experience with a fouling/dirty fuel or as
required by local codes.
6.16. Combustion Control System

1) [S], [O] Local indicators—of significance to flameout protection—which are to be within view from
the local panel are:
a) Main fuel supply pressures
b) Main fuel manifold pressures downstream of all control valves
c) Pilot gas fuel pressure downstream of control valve
d) Atomizing steam pressure
e) Combustion air flow

f) Boiler drum level

g) O2/combustibles
2) [S] Maintaining air-fuel ratio—Combustion control for regulation of fuel and air shall maintain air-
fuel ratio at a safe value under all conditions.
a) It shall include means for setting minimum and maximum limits in the fuel and air control
systems to prevent these systems from providing fuel and air flows beyond the stable limits of the
burners. Hardware and software locks shall be provided to prevent these limits from being
exceeded. ExxonMobil Management of Change process must be used to change these limits.
b) Minimum firing rate set point of each fuel of a combination (dual fuel) burner shall be that
required to maintain stable combustion at 100 percent combustion air rate when firing each fuel
alone. In no case shall this set point be less than 10 percent of burner rating.
c) Loss of fuel flow signal shall be detected and alarmed and shall not cause combustion control
system to go to an unsafe state.
d) Dual fuel flow meters (fully redundant with same range) shall be provided and equipped with a
high signal select and a discrepancy alarm.
3) [S] For boilers with parallel FD fans discharging into a common duct, the "not closed" damper
position switch on idle fans shall generate an alarm during normal operation.
4) [S] For boilers with flue gas recirculation (FGR), facilities shall be provided to confirm forward flow
through the FGR duct at all times. An alarm shall be generated if backflow is detected.
6.17. Pressure Relief Valves

1) [S] Pressure relief (PR) valves complete with test gags shall be furnished for both the steam drum and
the superheater.
2) [S] For boilers with superheaters, the set pressure of the steam drum PR valve must be sufficiently
above the superheater PR valve set pressure to ensure uninterrupted flow through the superheater.
Use the following formula to determine the steam drum PR valve set pressure:
SDOP + f (SHOP)
SDSP =
0.95
 SHSP 
f = − 1
 SHOP 
Where:
SDSP = Steam Drum Set Pressure
SDOP = Steam Drum Operating Pressure
SHSP = Superheater Set Pressure
SHOP = Superheater Operating Pressure

6.18. Piping Systems

1) [S] The fuel gas vent trip valve outlet line shall discharge at a safe location defined as follows:
a) The discharge point shall be located at least 50 ft (15 m) horizontally or vertically from any
combustion air intake.
b) The discharge elevation shall be at least 10 ft (3 m) above any platform within a 50 ft (15 m)
radius from the discharge point.
c) The discharge pipe shall exit vertically with no obstructions. A "P-trap" arrangement at the exit
point, with a 1/ 2 in. (13 mm) drain hole, can be used to drain rain water.
d) Alternative vent discharge locations are acceptable if confirmed safe by dispersion modeling.
e) Vents shall not be routed to the boiler stack, plant flare system or any other closed system.
2) [O] The steam startup vent and discharge stack shall be sized for not less than 35 percent MCR steam
flow and shall be provided with a silencer. The silencer shall be provided with drains for condensate
removal. The discharge stack height shall be not less than 10 ft (3 m) above the highest platform
within 50 ft (15 m) radius of the stack.
a) The silencer shall be mechanically designed for continuous operation.
b) [S] The discharge stack height shall be not less than 10 ft (3 m) above the highest platform within
50 ft (15 m) radius of the stack.
c) [S] The silencer shall be provided with drains for condensate removal. Drains shall be routed to a
safe location at grade.
d) [S] Piping to vent valves and silencer shall be designed with condensate removal traps sized for
"closed vent" conditions and located at all low points, and on both sides of vent throttling valves.
e) [S] For manually operated vents, valve locations and vent line routing shall be determined based
on the following considerations:
i) Valves to be operated during venting shall not be located directly below the silencer.
ii) Valves to be operated during venting shall be located in a place that will reduce noise
exposure from the superheater pressure relief valve.
f) [R] Carbon steel vents shall be galvanized on the O.D. and I.D. downstream of the vent valve.
g) [M] Vent control valves shall be flanged design.
3) [S] Emergency Block Valves shall be provided for isolation of all fuel streams to each boiler.
a) EBVs shall be located at least 40 ft (12m) from the edge of the firebox.
b) For boilers with multiple fuels, the EBVs shall be grouped together for ease of access in an
emergency.
c) For multiple boiler installations, the EBVs for all boilers shall be grouped together in a logical
fashion consistent with a "battery limits" isolation philosophy.
d) EBV requirements are not satisfied by the protective system/BMS fuel trip or shutdown valves.
4) [O] Piping supply systems for atomizing and soot-blower steam shall be designed with adequate
traps, drains and vents to establish and maintain dry superheated conditions.
a) A manual atomizing steam warm-up vent shall be provided for startup purposes.
b) Automatic warm-up vents and drains shall be provided for intermittent soot-blower steam.
Manual vents are acceptable with Owner's Engineer approval.

5) [S] A common steam condensate/disengaging drum, discharging to the sewer and vented to a safe
location, shall be provided for the following vents and drains:
a) Economizer, steam generation and superheater drains
b) Level gauge drains
c) Atomizing steam warm-up vents
d) Soot-blower warm-up vents
e) Any other services expected to discharge hot flashing condensate or steam during boiler start-up,
shutdown or re-start.
f) All vent and drain connections to this closed system shall be provided with a manual bleeder at
the source takeoff point for flow verification purposes.
6) [R] Boiler outlet steam piping shall be considered to be in "process induced vibrating service" for the
purpose of designing small bore piping support per GP 03-18-01. High vibration is likely during
steam blowing activities.
7) [S] All burner piping designs supplying fuel and, if applicable, atomizing media to two or more
burners shall confirm, by calculation, equal distribution to each burner.
7. Inspection Standards and Acceptance Criteria

1) [R] Radiographic examination of all welds shall be according to ASME SEC I, Par. PW-11, except as
modified below:
a) For headers, drums, pipe, and butt welds of tubes (which the Code exempts from radiographic
examination), examination of welds shall be made as follows:
i) A minimum of 5 percent of the welded joints selected at random by the Inspector shall be
spot radiographed as the work progresses.
ii) The length of film for each spot radiographed shall be 10 in. (250 mm) or one-half the
component circumference whichever is less.
iii) At least one of each type and position of weld made by each welder shall be examined.
iv) Follow up on acceptable welding—In addition to the minimum spot examination of 5 percent
of the welded joints, the extent of defective welding found in any joint shall be determined by
taking at least two additional radiographs. As an alternative, the complete weld may be cut
out and replaced. In addition, spot radiographs shall be made of two other welds made by the
same welder for each weld found unsatisfactory.
b) All welds of P-4 or P-5 material shall be 100 percent radiographed when the pipe or header wall
is 3/ 4 in. (19 mm) or greater in thickness.
c) Acceptance criteria shall be according to ASME SEC I, Par. PW-51.
d) Radiography shall be according to ASME SEC V A-2, except that fluorescent intensifying
screens, such as calcium tungstate, shall not be used.
2) [R] Spot examination by sectioning is prohibited, except as may be approved by Purchaser to confirm
contentions of excessive weld projection, depressions, or lack of penetration at otherwise inaccessible
joints.

3) [R] Magnetic particle inspection of nozzle welds and a random selection of 10 percent of the welds
joining the shell to a tube or tube stub shall be according to the ASME SEC VIII D1 MA APP 6.
Both sides of the completed weld, where accessible, shall be examined after any post weld heat
treatment. If back welding is done, the back side of the root pass shall be examined after it has been
prepared for back welding. The D-C prod method shall be used prior to post weld heat treatment and
the A-C yoke or coil method after final post weld heat treatment.
4) [R] Ultrasonic examination. All piping welds where the wall thickness exceeds 11/ 4 in. (32 mm) shall
be 100 percent ultrasonically inspected. Ultrasonic examination shall be according to ASME SEC
VIII D1 MA APP 12.
5) [R] When the tubesheet of a boiler drum or header exceeds 2 in. (50 mm) in thickness and the
wrapper plate is less than 2 in. in thickness, the tubesheet shall be inspected according to the
following:
a) Ultrasonic examination of plates—Plates (and plate-like forgings such as forged shell rings) shall
be ultrasonically examined according to ASTM A 578/A 578M. Acceptance standard shall be
Level II. In addition, the entire surface area within two plate thicknesses from the location of a
major load bearing attachment weld or corner type joint shall be examined. Acceptance standard
shall be Level 1.
b) Magnetic particle examination of edges prepared for welding and openings—Prior to welding, all
edges prepared for welding and plate openings shall be examined by the magnetic particle method
(D-C prod only). Indications found shall be cleared and back welded to provide a minimum
depth of 1 in. (25 mm) of sound metal.
6) [R] Inspection and testing according to GP 05-01-02 is required for drums and headers when both the
wrapper plate and tubesheet exceed 2 in. (50 mm) in thickness (references ASME Code radiography
shall be according to ASME SEC I instead of ASME SEC VIII D1).
8. Testing
1) [R] Hydrostatic testing of the completed boiler shall be according to ASME SEC I except that the
maximum hydrotest pressure shall be held for 1 hr/in. (1 hr/25 mm) of metal thickness, and in no case
for less than one hour or more than three hours. The minimum permissible test temperature according
to GP 18-10-01 shall be stamped on the boiler nameplate and noted on the Manufacturer's data report.
Test to be witnessed by Inspector.
a) Hydrotest water for testing boilers with non-drainable superheaters shall be treated with an
oxygen scavenger.
2) [R] Pneumatic leak testing shall be performed for the boiler casing before external insulation is
applied. The test pressure shall be one and a half times the maximum furnace operating pressure. If
the boiler is to be equipped with isolating dampers, the test pressure shall be the maximum FD fan
discharge pressure. The duration of the test shall be ten minutes, during which time the furnace
pressure may not decrease by more than 10 percent. All leaks which are detected shall be repaired
and the unit retested.
3) [R] Forced draft fan performance test shall be required if:
a) Manufacturer's prototype has not been tested according to AMCA 210 using the test setup
specified by the code most similar to the actual installation.

b) Non-standard duct work (such as an inlet silencer) is supplied. The test setup requires Purchaser's
approval.
4) [I] Within 12 months after mechanical completion or 6 months after start-up, the Owner shall have
option to performance test the boiler according to ASME PTC 4 as mutually agreed by Owner and
Vendor.
5) [R] A Factory Acceptance Test is required of the BMS hardware and software.
6) [S] The safety interlock and protective devices shall be fully function tested by the Project
Management/Design Followup Team and the Manufacturing or Startup Team. These tests shall be
successfully completed before initial operation.
9. Guarantee
1) [I] The following performance guarantees, at maximum continuous steam flow, shall be included:
a) Maximum continuous steam flow.
b) Efficiency—The conditions at which efficiency is guaranteed shall be specified by Manufacturer.
c) Steam temperature leaving the superheater (± 10°F or ± 5°C)—If steam temperature control
equipment is furnished, this equipment shall be guaranteed for a specified load and temperature
range.
d) Steam purity entering the superheater—The solids content in the steam shall not exceed
requirements with boiler water at high level alarm and concentrations as specified in Table 4 for
the operating pressure:
Table 4: Solids Content Limits
Boiler Pressure at Outlet Total Solids Alkalinity Suspended Solids in

(total) Solids Steam
psig kPa ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm max.
0–300 0–2100 3500 700 15 1.0
> 300–450 > 2100–3100 3000 600 10 1.0
> 450–600 > 3100–4200 2500 500 8 1.0
> 600–750 > 4200–5200 1000 200 3 0.5
> 750–900 > 5200–6200 750 150 2 0.5
> 900–1000 > 6200–6900 625 125 1 0.5
> 1000–1700 > 6900–11700 100 — 1 0.1
2) If an air heater is provided, the temperature of the air leaving the air heater ± 30°F (± 17°C).
3) Water/steam pressure drop, psi from upstream of boiler feedwater valve to downstream of steam
stop/non-return valve.

4) Ramp rates:
a) Cold Startup
b) Upward load change
c) Downward load change
Table 5: Performance Checklist
Predicted Performance
Item Value
Steam Flow Rate, lb/hr
Fuel
Quantity fuel, lb/hr
Quantity combustion air, lb/hr
Excess air leaving boiler, %
Efficiency, % (LHV Basis)
Quality of Steam leaving drum, ppm
Drum pressure, psig
Superheater pressure drop, psi
Water temperature leaving economizer, °F
Economizer pressure drop, psi
Economizer inlet pressure, psig
Gas temperature leaving furnace, °F
Gas temperature entering superheater, °F
Gas temperature entering boiler section, °F
Gas temperature entering economizer, °F
Economizer outlet gas temperature, °F
Gas temperature entering air preheater, °F
Gas temperature leaving air preheater, °F
Air temperature leaving air preheater, °F
Forced draft fan discharge press, in. W. G.
Burner wind box inlet pressure in. W. G.
Furnace pressure, in. W. G.
Superheater outlet gas pressure, in. W. G.

Predicted Performance
Item Value
Boiler section outlet gas pressure, in. W. G.

Economizer section outlet gas pressure, in. W. G.
Air pressure drop across air preheater, in. H2O
Gas pressure drop across air preheater, in. H2O
Heat release in furnace, Btu/ft3 -hr
Heat release in furnace, Btu/ft2 -hr
Heat absorption in furnace, Btu/ft2 -hr
Heat absorption in boiler section, Btu/ft2 -hr
Gas velocities though unit, ft/sec
a. FD Fan Duct
b. Windbox
c. Superheater
d. Boiler passes
e. Economizer
f. Exhaust duct
General Note For data reporting in SI units

Flow rate (Mass basis) kg/s
Flow rate (Volume basis) m3/s
Throughput (Mass basis) kg/h
Pressure KPa
Temperature °C
Heat Release (Absorption) kW/m2 or kW/m3 (as applicable)
Velocity m/s

Record of Change
Version 1.0.0 Date: 03/02
Location Action Description
Initial Publish.

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

Major revision of GP incorporating boiler best practices changes.
Includes more detail on specific portions of NFPA 85 that XOM requires.
Upstream Owning Business Sector reviewed, updated, and advanced to Version
Only 2.0.0. Upstream maintains Version 1.0.0 until review of Owner's update.

Attachment: Purpose Codes Definitions

Code Description
C Assigned to paragraphs containing specifications whose primary purpose is reduced costs.
Reduced cost in this context refers to initial investment cost and does not include Life-Cycle
cost considerations. Life-Cycle cost considerations are captured under reliability,
maintainability, or operability purpose codes.
E Assigned to paragraphs containing specifications whose primary purpose is driven by
environmental considerations. Environmental considerations typically include specifications
intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the
specifications contained in such paragraphs require formal review and approval according to
local environmental policy.
I Assigned to paragraphs that provide only clarifying information such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs containing specifications whose primary purpose is to provide for
maintainability of equipment or systems. Maintainability provisions are those that facilitate the
performance of maintenance on equipment/systems either during downtimes or during on-
stream operations.
O Assigned to paragraphs containing specifications whose primary purpose is to assure
operability of equipment or systems. Operability is the ability of the equipment/system to
perform satisfactorily even though conditions are off-design, such as during startups, process
swings, subcomponent malfunction, etc.
R Assigned to paragraphs containing specifications whose primary purpose is to improve or
assure the reliability of equipment or systems. Reliability is a measure of the ability of
equipment/systems to operate without malfunction or failure between planned maintenance
interventions.
S Assigned to paragraphs containing specifications whose primary purpose is avoidance of
personnel or operational safety incidents. Any deviation from the specifications contained in
such designated paragraphs requires formal review and approval according to local safety
policy.
Personnel Safety: Refers to the avoidance of recordable personnel injuries; i.e., burns, cuts,
abrasions, inhalation, or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, explosions,
Safety: etc.

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Page 1 of 33 ExxonMobil Development Company

Table of Tables .............................................................................................................. 4

1. Required References ............................................................................................ 5

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6.11. Forced Draft Fans ...................................................................................... 17

Record of Change ....................................................................................................... 32

Attachment: Purpose Codes Definitions.................................................................. 33

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Table 1: Limits for Maximum Continuous Rating (MCR) ........................................ 12

Table 2: Criteria for Convection Surface Cleaning Facilities Selection................. 14

Table 3: Maximum Radial Coverage of Sootblower ................................................ 14

Table 4: Solids Content Limits .................................................................................. 29

Table 5: Performance Checklist ................................................................................ 30

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1.1. Global Practices–ExxonMobil Engineering Practices

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GP 18-10-01 Additional Requirements for Materials

1.2. AMCA–Air Movement and Control Association

1.3. ASME–American Society of Mechanical Engineers

1.4. ASTM–American Society for Testing and Materials

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1.5. NFPA–National Fire Protection Association

1.6. SSPC–Society for Protective Coatings

2.1. Global Practices–ExxonMobil Engineering Practices

2.2. ASME–American Society of Mechanical Engineers

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2.3. ASTM–American Society for Testing and Materials

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18) One copy of Vendor's quality control manual.

4.2. Post Award Review

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4.3. Final Records

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Table 1: Limits for Maximum Continuous Rating (MCR)

Heat Release (HHV)

6.2. Drums and Headers

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Page 13 of 33 ExxonMobil Development Company

6.4. Convection Surface Cleaning

Table 2: Criteria for Convection Surface Cleaning Facilities Selection

Fuel Class Fuel fired Tube Surface Convection Surface Cleaning

Table 3: Maximum Radial Coverage of Sootblower

Type Radial Coverage

6.5. Structure and Casing

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6.6. Observation and Access Doors

6.7. Platforms and Stairs

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