TECHNICAL STANDARD

SHOP FABRICATED FURNACE STEEL

MB15-2TS

DATE: 01 AUG 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 7

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 KBR Documents, Codes and Industry Standards ..........................................................................1
2. STEEL FABRICATION ..................................................................................................................2
2.1 General ...........................................................................................................................................2
2.2 Radiant Steel ..................................................................................................................................3
2.3 Convection Steel.............................................................................................................................4
2.4 Breeching........................................................................................................................................4
2.5 Platform Steel .................................................................................................................................4
2.6 Miscellaneous Steel........................................................................................................................4
2.7 Low Chrome, Stainless, and High Alloy Steel ................................................................................4
3. SHOP WELDING OF STRUCTURAL STEEL TO CASING PLATE .............................................4
3.1 General ...........................................................................................................................................4
3.2 Minimum Welding Requirements....................................................................................................5
4. BOLTING........................................................................................................................................5
4.1 General ...........................................................................................................................................5
5. PROTECTIVE COATINGS.............................................................................................................6
5.1 General ...........................................................................................................................................6
6. INSPECTION ..................................................................................................................................6
7. FABRICATION TOLERANCES .....................................................................................................7
7.1 Shop Fabricated Module or Piece ..................................................................................................7
7.2 Field Erected Modules or Pieces ....................................................................................................7
7.3 Shop Fabricated Structural Steel....................................................................................................7

1. GENERAL

1.1 Scope

This technical standard, KBR Technical Specification S15-1F, Purchasing Standards MB2-1PS and SDR-
2MB-2 cover the requirements for shop fabricated furnace steel. In case of conflict between these
specifications, this Technical Standard MB15-2TS shall govern. Exceptions, if any, and abbreviations are in
accordance with KBR Technical Standard MB15-1TS (Note: KBR will be referred to as the Purchaser).

1.2 KBR Documents, Codes and Industry Standards

The following documents are referenced herein and form part of the Order. Additional Purchaser
documents, when applicable, will be listed in the Requisition. Applicable dates of issue of codes, industry
standards and Purchaser documents shall be as indicated in the Purchaser Technical Standard MB15-1TS.

KBR DOCUMENTS
4-7TS, "General Welding Requirements"
GDS-10, "Coating Requirements for Furnaces and Associated Equipment" (Data Sheet)
MB2-1PS, "Purchasing Requirements for Furnace Materials, Components, and Equipment"
MB15-1TS, "General Furnace Specification"
SDR-2MB-2, "Supplier Data Requirements, Fabricated Furnace Components"
S15-1F, "Shop Fabricated Structural Steel with High Strength Bolted Field Connections"
S15-1PS, "Purchasing Requirements for Shop Fabricated Structural Steel with High Strength
Bolted Field Connections"
V42-6TS, "Galvanizing Requirements for Structural Steel"
 TECHNICAL STANDARD

SHOP FABRICATED FURNACE STEEL

MB15-2TS

DATE: 01 AUG 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 7

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

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

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A36, "Carbon Structural Steel"
ASTM A307, "Carbon Steel Bolts and Studs, 60 000 psi Tensile Strength"

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

SOCIETY OF PROTECTIVE COATINGS (SSPC)

SSPC SP 2, "Hand Tool Cleaning"
SSPC SP 3, "Power Tool Cleaning"

2. STEEL FABRICATION

2.1 General

2.1.1 All structural steel shall be new and conform to ASTM A36 and material shall be furnished in
accordance with Purchaser Technical Specification S15-1F.

2.1.2 When a framing member is suffixed by a (+) or a (-) number, this number signifies the distance the top
of this member is above (+) or below (-) the reference level. Platform elevations are referenced to the
underside of flooring.

2.1.3 Detailing and fabrication of the steel shall be such as to assure a minimum amount of air infiltration
into the furnace and minimum warping of members and casing plates being welded.

2.1.4 All framing and stiffener members shall be coped to fit into the web sections of the main structural
columns and beams and shall be continuously welded.

2.1.5 Fabricator shall provide erection clips, line-up bolts or other suitable positioning devices for field
welded connections (Supplied by Fabricator).

2.1.6 Fabricator shall design and locate all lifting and handling lugs for furnace components over 70 lb
(30 kg), unless noted otherwise on Purchaser drawings. Minimum of (2) lugs shall be furnished. Removable
panels or header box panels shall also be provided with lugs.

2.1.7 Fabricator shall provide drain holes of minimum 9/16 inch (14 mm) diameter in areas, which would trap
water. Drain holes shall not be located over manways, peep doors, instrument connections, or areas leading
to these locations.

2.1.8 The direction of the channel or angle stiffener toe is at the Fabricator's discretion for vertical stiffeners.
However, for horizontal stiffeners, toes must be turned downward unless shown otherwise on Purchaser
drawings.

2.1.9 Fabricator shall ensure proper fit-up of all components prior to shipment.

2.1.10 Each shipment of shop fabricated module (SFM) or shop fabricated panel (SFP) must have sufficient
lifting devices to handle all items in the shipment for both handling and erection.
 TECHNICAL STANDARD

SHOP FABRICATED FURNACE STEEL

MB15-2TS

DATE: 01 AUG 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 7

2.1.11 All insulation retaining plates shall be a minimum 3/16 inch (5 mm) thick and of the same depth as
the insulation thickness specified on the furnace insulation schedule (Ref. DWG. 215 series).

2.1.12 Insulation retainer plates greater than 2 inches (50 mm) in depth shall have 1/8 inch (3 mm) wide saw
cuts on 9 inch (230 mm) centers. The depth of cut shall be 1 inch (25 mm) less than the plate depth.
Retainer plates shall be attached to casing plate with a 1/8 inch (3 mm) by 2 inch (50 mm) long fillet weld
staggered on 8 inch (200 mm) centers.

2.1.13 Fabricator is required to install insulation anchors and internal coating of the casing plate as noted on
Reference 215 Drawing Series. Special provision shall be made to protect the anchors from damage during
shipment, storage, and erection.

2.1.14 All doors, burners and removable panels shall be provided with 1/8 inch (3 mm) thick ceramic fiber or
fiberglass or silica tape suitable for exposure to the outdoor environment without deterioration even after
multiple uses. The tape shall be drop-wrap type of minimum 2 inches (50 mm) width and centered on bolt
line.

2.1.15 All components must be properly protected during shipment and storage in accordance with
Purchaser Technical Standard MB1-4TS with special attention being paid to the protection of high alloy
materials (stainless steel etc.) from salt water and other detrimental substances.

2.1.16 The following items shall be furnished by the furnace steel fabricator and shipped to the field:

a. All field bolts, nuts and washers including all equipment mounting bolts, bolts at field splices, etc., (plus
Field Excess = 10%).

b. Gasket tape for doors, header boxes, seal plates, pig tail boxes (if applicable), removable panels, etc., in
accordance with Paragraph 2.1.14 (plus Field Excess = 10%).

c. Asphalt coating for all field splices, except where gasket tape is provided for item b. above and as
required for Paragraph 5.1.7 below (plus Field Excess = 10%).

d. Touch-up paint for field welded and galvanized areas.

2.1.17 For instrument connection designations and location, see Purchaser drawings. Location of
instrument connections shown on general arrangement drawings can be adjusted to clear structural
interference as required.

2.1.18 All structural steel and subassemblies shall be clearly marked with 2-inch (50-mm) minimum high
letters or numbers for field identification. All loose items such as rods, turnbuckles, clevises, bolts, nuts, and
washers shall be shipped in bags, kegs, or crates. Bags, kegs, or crates shall be tagged as to size, diameter
and length of contents such that tags for each item are individually identifiable. Tags used for marking shall
be metal and markings shall be applied by stamping.

2.2 Radiant Steel

2.2.1 Radiant steel (containing steel, peep doors, access doors, tube removal doors, instrument
connections, retainer bars, lintels, insulation anchorage, ceramic fiber modules, etc.) shall be shop fabricated
and shipped to the field in shop fabricated modules (SFM's) or shop fabricated pieces (SFP's), unless noted
otherwise on the Purchaser Drawings.

2.2.2 Pigtail boxes for millisecond furnace containing steel, instrument connections, retainer bars, and
insulation shall be shop assembled, match marked and shipped to the field in one SFM, for field disassembly
and erection.
 TECHNICAL STANDARD

SHOP FABRICATED FURNACE STEEL

MB15-2TS

DATE: 01 AUG 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 7

2.3 Convection Steel

2.3.1 Convection steel shall be shop fabricated and shipped to the field in SFM's.

a. Convection modules shall contain structural steel, insulation and insulation anchorage, end tube
supports, intermediate tube supports, bearing block, and guides, coils and fittings, header boxes,
instrument connections, gaskets, packing and other materials as specified on Purchaser drawings.

b. Convection module fabricator must block convection coils to prevent any shifting during shipment (field
to remove blocks prior to start-up).

2.4 Breeching

Breeching shall be shop assembled and shipped to the field in one SFM containing steel, access door,
instrument connections, retainer bars, insulation, etc.

2.5 Platform Steel

All platforms, handrails, ladders, stairs, stair treads, grating, etc., shall be fabricated in accordance with
Purchaser Drawings.

2.6 Miscellaneous Steel

2.6.1 Miscellaneous steel includes all steel that is not described in Articles 2.2 through 2.5 above.

2.6.2 The miscellaneous steel fabricator shall design and furnish all tie-in connections to the steel covered in
Articles 2.2 through 2.5 in accordance with Purchaser Technical Specification S15-1F.

2.6.3 Fabricator shall fabricate miscellaneous steel into shop fabricated pieces (SFP's) up to the maximum
shippable size.

2.7 Low Chrome, Stainless, and High Alloy Steel

Low chrome, stainless, and high alloy steels used in fabrication of baffles, end tube supports, lintels,
retainers, etc., shall be furnished and fabricated in compliance with this specification and as shown on
Purchaser drawings.

3. SHOP WELDING OF STRUCTURAL STEEL TO CASING PLATE

3.1 General

3.1.1 All column and beam flanges shall have full penetration welds.

3.1.2 Material subject to welding shall be of weldable quality; all material shall be new.

3.1.3 Fillet welds shall be of uniform size with full throat and legs unless otherwise detailed on the
Purchaser drawings.

3.1.4 Welding filler materials shall have a chemical composition matching that of the base materials being
welded.

3.1.5 For structural beams that connect between columns, the fabricator shall use double clip angles at both
ends of the beam with slotted holes to allow for field adjustment.

3.1.6 Weld electrode selection shall be based on Purchaser Technical Standard 4-7TS.
 TECHNICAL STANDARD

SHOP FABRICATED FURNACE STEEL

MB15-2TS

DATE: 01 AUG 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 7

3.2 Minimum Welding Requirements

3.2.1 Floors

a. Inside: 3/16 in. (5 mm) continuous fillet

b. Outside: 3/16 in. (5 mm) 2 in. (50 mm) at 8 in. (200 mm) staggered fillet

3.2.2 Walls

a. Inside: 3/16 in. (5 mm) 2 in. (50 mm) at 8 in. (200 mm) fillet

b. Outside: 3/16 in. (5 mm) continuous fillet

c. Columns: 3/16 in. (5 mm) continuous Fillet

d. Vertical and Diagonal Stiffeners: 3/16 in. (5 mm) continuous fillet

e. Horizontal Stiffeners: 3/16 in. (5 mm) continuous fillet at top

3/16 in. (5 mm) 2 in. (50 mm) at 8 in. (200 mm) fillet at bottom

f. Horizontal splice members at top and bottom of SFM's and SFP's:

Inside: 3/16 in. (5 mm) 2 in. (50 mm) at 8 in. (200 mm) fillet

Outside: 3/16 in. (5 mm) continuous fillet

g. Vertical splice members: 3/16 in. (5 mm) continuous fillet

3.2.3 Arches

a. Inside: 3/16 in. (5 mm) 2 in. (50 mm) at 8 in. (200 mm) fillet
b. Outside: 3/16 in. (5 mm) continuous fillet

3.2.4 Columns at Field Splices

All column splices shall be shop prepared for full strength field welds.

4. BOLTING

4.1 General

4.1.1 The erection drawings and a bolt list shall be furnished prior to the shipping of furnace steel. The bolt
list shall specify the number, diameter, length, and material for each connection.

4.1.2 All bolted field splices shall be covered with asphaltic coating (high temperature rated at 500 oF
(260 oC). The mating faces shall be covered with 1/8 inch (3 mm) thick coating, except 1 inch (25 mm) from
outside face (coating material supplied by steel fabricator).

Note: Do not coat column splice plates.

4.1.3 Where bolts extend into linings, nuts are tack welded to the inside of the furnace. The bolts shall be
threaded through and given a coat of grease (to prevent bonding) before the installation of lining.
 TECHNICAL STANDARD

SHOP FABRICATED FURNACE STEEL

MB15-2TS

DATE: 01 AUG 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 7

4.1.4 All slotted or oversized holes shall be provided with washers. Washers for channel flanges and "S"
shape flanges shall be of bevelled type.

4.1.5 All field splices of SFP's and SFM's shall have field bolt hole spacing at 12 inches (300 mm) maximum
centers.

4.1.6 Holes for horizontal field splices shall be 3/4 inch (19 mm) diameter for 5/8 inch (M16) ASTM A307
bolts unless otherwise noted on the Purchaser drawings.

4.1.7 There shall be two (2) rows of bolts for C8 (C200) channel or larger member, and one (1) row of bolts
for smaller than C8 (C200) channel and any size angle.

4.1.8 All access doors removable panels and header box panels shall have bolt hole spacing at 9 inch
(225 mm) maximum centers. Holes shall be 3/4 inch (19 mm) diameter for 5/8 inch (M16) ASTM A307 bolts
unless otherwise noted on the Purchaser drawings.

4.1.9 Circular or slotted bolt holes in columns and baseplates shall be drilled or punched.

5. PROTECTIVE COATINGS

5.1 General

5.1.1 External surface of the furnace casing and structural steel shall be coated in accordance with Data
Sheet GDS-10. Furnace steel fabricator shall furnish touch-up paint for field welded and galvanized areas.

5.1.2 All platforms, grating, handrails, stairs, ladders and cages shall be galvanized in accordance with
Purchaser Technical Standard V42-6TS, except those integral to furnace casing and those noted on
Purchaser Drawings or Data Sheet GDS-10.

5.1.3 All structural bolt connections to the galvanized or shop painted steel parts shall have galvanized bolts,
nuts and washers in accordance with Purchaser Data Sheet GDS-10. All other structural bolted connections
shall have black bolts, nuts, and washers.

5.1.4 All members and assemblies warped during galvanizing shall be straightened prior to shipping to field.

5.1.5 Areas to be field welded (only if required and approved by Purchaser) are to be left unpainted and
ungalvanized.

5.1.6 Internal surfaces in contact with linings and members to be fire-proofed shall be shop cleaned of mill
scale, dirt, oil, etc., in accordance with SSPC SP 2 or SSPC SP 3 for hand or power tool cleaning.

5.1.7 For corrosion protection, all internal surfaces with the exception of externally lined stack and 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 insulation 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 oF (260 oC). 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. Furnace steel fabricator shall supply the coating for shop or field application. The
coating shall be applied in shop by the fabricator, unless otherwise noted on the Purchaser Drawings.

6. INSPECTION

Inspection requirements shall be in accordance with Purchaser Purchasing Standard S15-1PS.

 TECHNICAL STANDARD

SHOP FABRICATED FURNACE STEEL

MB15-2TS

DATE: 01 AUG 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 7

7. FABRICATION TOLERANCES

7.1 Shop Fabricated Module or Piece

7.1.1 The following maximum fabrication tolerances shall apply for each individual furnace shop fabricated
module or shop fabricated piece: (The data shall be recorded and a copy submitted to the Purchaser's
Inspector at the time of inspection).

a. Overall dimension for width: ±1/8 inch (±3.0 mm).

b. Overall dimension for height: ±1/8 inch (±3.0 mm).

c. Overall dimension for length: ±1/4 inch (±6.0 mm), with a tolerance of ±1/8 inch (±3.0 mm)
between vertical column centerlines.

d. Diagonal dimensions for each endwall, sidewall and top and bottom surface: ±1/4 inch (±6.0 mm).

e. Bolt hole pitch between center to center: ±1/16 inch (±1.6 mm).

f. Accumulated bolt hole distance against overall length: ±1/16 inch (±1.6 mm).

g. For vertical plumbness of columns: ±1/8 inch (±3.0 mm) (This shall be checked at all columns).

h. For bowing of wall casing plate between stiffeners: ±3/8 inch (±9.0 mm).

i. For further tolerances on the modules, refer to Steel Drawings, 214 Series.

7.2 Field Erected Modules or Pieces

7.2.1 For field erected modules or pieces, the following tolerances shall be maintained for the vertical
alignment:

a. Overall dimension for all radiant modules (total height): ±1/8 inch (±3.0 mm).

b. Overall dimension for all convection modules (total height): ±1/8 inch (±3.0 mm).

c. Overall dimension for combined total radiant modules and convection modules: ±1/2 inch (±12 mm).

7.3 Shop Fabricated Structural Steel

For shop fabricated structural steel, fabricator shall follow the pertinent and applicable sections of the latest
edition of the AISC "Manual of Steel Construction Allowable Stress Design".