PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

Boiler type: Circulation: Arrangement: Number of burners: Burners type: Fuels: Firing: HRSG type: Recovery: Desuperheater type: 2 Pressure parts materials: Calculation code: TITAN M - Bidrum - Bottom supported - TAG 7V-454 A/B/C/D/E Natural circulation Horizontal 3 Macchi Low NOx burners - MHM type Fuel Gas Lean Gas/Deo Gas Single Firing Not Applicable External economizer finned type Interstage - Injection type U.N.I. AFNOR Performance test code: ASME PTC 4-2000 ASME PTC 4.4 E.N. A.S.T.M. ASME With Stamp T.R.D. ASME PTC 4.1(Abbreviated Test) D.I.N. 1942 A.S.M.E. D.I.N. ISPESL P.E.D. ASME PTC 4 N.F.E. ASME Without Stamp

MAIN DESIGN DATA Steam capacity at MCR Superheated steam temp. at B/L Steam pressure at B/L Boiler feed water temperature Boiler efficiency on LHV at MCR Steam temperature control range Boiler automatic control range Boiler design pressure Superheater design pressure Economizer design pressure Start-Up vent capacity design 25%MCR Load variation Blow down flow @1% Blow down design flow @ 5% [2] [3] [4] [1] : : : : : : : : : : : : : : 180000 355(+5 ) /-0 30 110/149 90 25110 25110 41 41 41 45000 15 1800 9000 kg/h C barg C % % MCR barg barg barg kg/h % / min kg/h kg/h COILS HEATING SURFACE Indicated quantities are for 1 ( one ) boiler SECTION Final Superheater Primary Superheater Boiler Bank #1 Boiler Bank #2 Economizer Tubes per row 10 9 17 17 26 Tubes deep 10 10 34 33 10 Tubes 60 54 578 561 260
Pitch [mm] Out. Diam. long.

Boiler heating surface

Total heating surf. (including SH + ECO)

: : : : : : : : : : [5] :

1886 4517 74,8 62,0 1,8 1,7 2,6 264,4 342,00 8000 46,0

m2 m2 m3 m3 m3 m3 m3 m2 m3 mm barg

Total water volume Water volume at normal level Volume of final superheater Volume of primary superheater E.P.R.S. geometrical Furnace volume Drums centerline Boiler feedwater pressure

% MCR Volume of economizer

thk [mm] 3,6 3,6 3,6 3,6 3,6

in parall. tr.

[mm] 50,8 50,8 63,5 63,5 50,8

Exchang. Length [m] 5,85 5,85 6,53 6,53 6,00

Fins type solid

Fins/m 157

Fins [mm] Surface h thk [m2] 180 162 752 730 2289

103 101 103 101 120 100 120 100 100 102

19 1,25

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

BOILER TUBES - MEMBRANED WALLS Indicated quantities are for 1 ( one ) boiler FURNACE Depth Volume 10443 342 mm m3 889 Width E.P.R.S. Pitch Description [mm] TUBES "D" wall Side wall Front wall Rear wall HEADERS Front wall header Rear wall header RISERS AND FEEDERS Risers Feeders [9] 4350 4000 76,1 76,1 4 4 1,0 1,0 26 20 SA 210 Gr. A1 SA 210 Gr. A1 41 41 276 276 88,5 88,5 88,5 88,5 [11] 4625 4625 219,1 219,1 18,26 18,26 3,2 3,2 2 2 SA 106 Gr. B SA 106 Gr. B 41,0 41,0 276 276 16500 7765 8050 8050 63,5 63,5 63,5 63,5 3,6 3,6 3,6 3,6 1,0 1,0 1,0 1,0 117 98 43 51 SA 210 Gr. A1 SA 210 Gr. A1 SA 210 Gr. A1 SA 210 Gr. A1 41,0 41,0 41,0 41,0 385 385 385 385 4513,5 264,4 Avg. length [mm] [7] mm m2 Outside diam. [mm] [mm] Avg. height Heat transf. Surf. 508 Thick. mmH2O Corrosion Number allowance of tubes [mm] Material Design pressure [barg] Design temp. [ C] [8] [6] 7130 280,8 mm m2 Outlet width Outlet height 1593 7175 mm mm

Design pressure

mmH2O Test pressure

BOILER BANK SIDE WALLS Depth Volume 10443 147 mm m3 Width E.P.R.S. Pitch Description [mm] TUBES Side wall Double side wall SH Front Wall Screen [10] 88,5 100 120 354/100 8050 7667 7000 7500 63,5 76,1 76,1 63,5 3,6 4 4 3,6 1,0 1,0 1,0 1 111 26 17 6 SA 210 Gr. A1 SA 210 Gr. A1 SA 210 Gr. A1 SA 210 Gr. A1 41 41 41 41 385 385 385 385 2160 140 Avg. length [mm] mm m2 Outside diam. [mm] [mm] Avg. height Heat transf. Surf. Thick. 6525 147,1 mm m2 Design Material pressure [barg] Design temp. [ C]

Corrosion Number allowance of tubes [mm]

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

BOILER TUBES - SUPERHEATER Indicated quantities are for 1 ( one ) boiler

FINAL SUPERHEATER
Arrangement Tubes per row In line 10 Number of rows Pitch Description TUBES SH tubes 103 96 9400 [11] 1061,5 1061,5 400 300 355,6 355,6 355,6 355,6 23,83 23,83 27,79 27,79 3,2 3,2 3,2 3,2 1 1 1 1 SA 335 Gr. P11 SA 335 Gr. P11 SA 335 Gr. P11 SA 335 Gr. P11 41 41 41 41 352 385 352 385 50,8 3,6 1,3 120 SA 213 Gr. T22 41 490 tr. long [mm] Avg. length [mm] [7] Staggered 10 Flow Outside diam. [mm] [mm] Thick. Parallel 60 Corrosion Number allowance of tubes [mm] Material Counter Avg. exchanging height Cross 5850 Design pressure [barg] mm Design temp. [ C] [8] Tubes in parallel

HEADERS / NOZZLES / JUMPERS Inlet header Outlet header 1 Inlet Nozzle 1 Outlet Nozzle

INLET HEADER Saturated steam diaphragm Superheated steam to DSH OUTLET HEADER Superheated steam from DSH

Superheated steam outlet to BL

refractory

INLET HEADER OUTLET HEADER

Tubes to be protected

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/11

BOILER DATA SHEET

BOILER TUBES - SUPERHEATER Indicated quantities are for 1 ( one ) boiler

PRIMARY SUPERHEATER
Arrangement Tubes per row In line 9 Number of rows Pitch tr. long [mm] TUBES SH tubes 103 96 9400 [11] 1010 1010 400 750 355,6 355,6 355,6 355,6 23,83 23,83 27,79 27,79 3,2 3,2 3,2 3,2 1 1 1 1 SA 335 Gr. P11 SA 335 Gr. P11 SA 335 Gr. P11 SA 335 Gr. P11 41 41 41 41 352 385 352 385 50,8 3,6 1,3 108 SA 213 Gr. T22 41 465 Avg. length [mm] [7] Staggered 10 Flow Outside diam. [mm] Thick. [mm] Parallel 54 Corrosion Number allowance of tubes [mm] Counter Avg. exchanging height Material Cross 5850 Design pressure [barg] mm Design temp. [ C] [8] Tubes in parallel

Description

HEADERS / NOZZLES / JUMPERS Inlet header Outlet header 1 Inlet Nozzle 1 Outlet Nozzle

FURNACE

PRIMARY SUPERHEATER

FINAL SUPERHEATER

BOILER BANK #1

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

BOILER TUBES - EVAPORATOR Indicated quantities are for 1 ( one ) boiler

BOILER BANK #1
Arrangement 1 Tubes per row 17 In line Number of rows Pitch Description TUBES Tubes 120 100 7000 63,5 3,6 1,0 578 SA 210 Gr. A1 41 385 tr. long [mm] Staggered 34 Avg. length [mm] [7] Tubes in parallel Outside diam. [mm] [mm] Thick. 578 Avg. exchanging length Material 6525 Design pressure [barg] mm Design temp. [ C] [8] Corrosion Number allowance of tubes [mm]

BOILER BANK #2
Arrangement 1 Tubes per row 17 In line Number of rows Pitch Description TUBES Tubes 120 100 7000 63,5 3,6 1,0 561 SA 210 Gr. A1 41 385 tr. long [mm] Staggered 33 Avg. length [mm] Tubes in parallel Outside diam. [mm] [mm] Thick. 561 Avg. exchanging length Material 6525 Design pressure [barg] mm Design temp. [ C] [8] Corrosion Number allowance of tubes [mm]

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

BOILER TUBES - ECONOMIZER Indicated quantities are for 1 ( one ) boiler

ECONOMIZER
Arrangement Tubes per row In line 26 Number of rows Pitch Description TUBES Tubes 100 102 6150 [11] 2950 2950 219,1 219,1 15,09 15,09 3,2 3,2 1 1 SA 106 Gr. B SA 106 Gr. B 41 41 276 276 50,8 3,6 1,0 260 SA 210 Gr. A1 41 385 tr. long [mm] Avg. length [mm] [7] Staggered 10 Flow Outside diam. [mm] [mm] Thick. Parallel 26 Corrosion Number allowance of tubes [mm] Material Counter Avg. exchanging length Cross 5997 Design pressure [barg] mm Design temp. [ C] [8] Tubes in parallel

HEADERS / NOZZLES / JUMPERS Inlet header Outlet header

FINS Finned Description Type length [mm] Tubes

solid

Fins x meter [fins/m] 157

Height [mm] 19

Thick. [mm] 1,25

Segment Material [23] [mm] EN 10130 DC04

Max Fin Temperature [ C] 454

5997

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

PRESSURE PARTS Indicated quantities are for 1 ( one ) boiler

STEAM DRUM
Outside diameter Shell thickness Cylindrical length Corr. allowance Shell material Levels from centerline High-High level High level Normal level Low level Low-Low level Internal details Cyclones number 42 Dryers number 30 Dryers type 6 [14] 200 100 0 -150 -300 mm mm mm mm mm 1800 60 11000 3,2 mm mm mm mm Heads type Heads outside diam. Heads thickness Heads corr. allow. Heads material Water volumes Full of water High-High level High level Normal level Low level Low-Low level 25,63 16,7 14,8 12,8 9,9 7,1 Spherical 1800 55 3,2

[12] Manhole mm mm mm Hold up m3 m3 m3 m3 m3 m3 From HL to HHL From NL to HL From NL to LL From LL to LLL [14] From NL to HHL Form NL to LLL 31,2 31,8 47,5 46 63 93,3 257x762x313 sec sec sec sec sec sec mm Design pressure Design temperature [13] 20"x24" inch 41 253+25 barg C

SA 516 Gr. 70

SA 516 Gr. 70

Dryers dimensions HxLxW

WATER DRUM
Outside diameter Shell thickness Cylindrical length Corr. allowance Shell material 1150 45 11000 3,2 mm mm mm mm Heads type Heads outside diam. Heads thickness Heads corr. allow. Heads material Spherical 1150 35 3,2 mm mm mm Manhole Design pressure Design temperature [13] 16"x20" inch 41 253+25 barg C

SA 516 Gr. 70

SA 516 Gr. 70

SAFETY VALVES Set Description Number pressure [barg] Superheater Steam drum Steam drum 1 1 1 34,5 41,0 42,0 Over pressure [%] 3 3 3 Blow down pressure [%] 4 4 4 Spring Loaded Spring Loaded Spring Loaded Total [15] Type Capacity [t/h] 52,00 78,00 78,00 208,0 [%] 25 37,5 37,5 100

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

BURNERS Indicated quantities are for 1 ( one ) boiler FUELS: Burners duty at Burners duty at Burners duty at Burners duty at Burners turn-down Single Burner Design 56 100 110 81 25 %MCR %MCR %MCR %MCR 1 : Fuel Gas/Lean Gas/Deo Gas 147,1 162,7 117,9 36,6 5 MW MW MW MW MW (126450000 (139866000 (101389596 (31435150 Kcal/h) Kcal/h) Kcal/h) Kcal/h)

with all fuel gas ( 48150000 Kcal/h)

MECHANICAL DATA Furnace average height Furnace depth Furnace width Number of burners ds-bottom h1 dp h2 dp average height h2 depth h1 ds-bottom width Furnace peephole 6" 7130 10443,0 4513,5 3 1405,0 2050 2050 2179,75 mm mm mm mm mm mm mm

Sheet

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

PIPING AND DUCTs Indicated quantities are for 1 ( one ) boiler MAIN PIPEWORK WITHIN ASME JURISDICTION Line description Outside diam. [mm] Boiler feed water line (from check to eco) Economizer - steam drum line (from eco) Saturated steam drum nozzle Steam drum - primary superheater line Primary superheater - desuperheater line Desuperheater - final superheater line Main steam line 168,3 168,3 273,0 323,9 355,6 355,6 355,6 [mm] 10,97 10,97 12,7 9,52 9,52 9,52 19,05 Thick. Corrosion Number allowance of tubes [mm] 1,6 1,6 3,2 1,6 1,6 1,6 1,6 1 1 3 1 1 1 1 SA 106 Gr. B SA 106 Gr. B SA 106 Gr. B SA 106 Gr. B SA 106 Gr. B SA 106 Gr. B SA 106 Gr. B 600 600 600 600 600 600 600 Material Rating Design pressure [barg] 51,25 41 41 41 41 41 41 Design temp. [ C] 276 276 276 276 352 352 385

AIR AND GAS DUCTS Max Velocity Duct description [17] [m/s] Air duct single fan Air duct delivery Windbox Gas duct from boiler to economizer Gas duct from economizer to stack [18] [18] 11 11 7 15 12 Cross Area [m2] 2,50 4,80 7,60 8,00 7,25 Design Design Temp. [ C] [16] 111 111 111 427 270 pressure [mmH2O] 1470 1470 1470 200 50 5 5 5 6 6 S275 JR [21] S275 JR [21] S275 JR [21] S275 JR [21] S275 JR [21] Min.Thick. [mm] Material

MAIN STACK Base diameter Height Insulation type Design pressure Corrosion allowance 2600 40 mm Base thickness m Material Thickness mmH2O 3 mm 20 60 S275 JR [21]

[19] [20] 2600 mm Top thickness 8 mm

mm Top diameter mm Material 270

Internal lining 50

refractory with anchor C

Design temperature :

Sheet

10

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

INTERNAL INSULATION Indicated quantities are for 1 ( one ) boiler INTERNAL TYPE INSULATION GAS DUCT FROM BOILER TO ECONOMIZER INTERNAL LINING Material Thickness type density refractory 50 1340 mm kg/m 3 Insulating castable Layer 2 Material Thickness HES cement 1 mm Casing [22] Material Thickness Design pressure Design temperature GAS DUCT FROM ECONOMIZER TO STACK INTERNAL LINING Material Thickness type density refractory 50 1340 mm kg/m 3 Insulating castable Layer 2 Material Thickness HES cement 1 mm Casing [22] Material Thickness Design pressure Design temperature 6 50 270 S275 JR [21] mm mmH2O C S275 JR [21] 6 200 427 mm mmH2O C

Sheet

11

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET

CASING AND EXTERNAL INSULATION Indicated quantities are for 1 ( one ) boiler EXTERNAL TYPE INSULATION AIR DUCT -ACOUSTIC INSULATION Hot wall 1 Material Thickness 2 Design pressure Design temperature S275 JR [21] 5 1470 111 mm C WINDBOX-ACOUSTIC INSULATION Hot wall 1 Material Thickness 2 Design pressure Design temperature S275 JR [21] 5 1470 111 mm C BOILER Boiler wall 1 Material Design pressure
SA 210 Gr. A1 / A696

Insulation 1 Material Density Mineral Wool 100 75 kg/m3 mm

Insulation 2 Material Density Thickness N.A. N.A. N.A. kg/m3 mm

Cladding Material
Alluminium 3003-H14

mmH2O Thickness

Insulation 1 Material Density Mineral Wool 100 75 kg/m3 mm

Insualtion 2 Material Density Thickness N.A. N.A. N.A. kg/m3 mm

Cladding Material
Alluminium 3003-H14

mmH2O Thickness

Insulation 1 Material Thickness Mineral Wool 100 150 kg/m3 mm 889 mmH2O Density

Insulation 2 Material Density Thickness N.A. N.A. N.A. kg/m3 mm

Cladding Material
Alluminium 3003-H14

GAS DUCT FROM BOILER TO ECONOMIZER Casing 1 Material Thickness Design pressure Design temperature S275 JR [21] 6 200 427 mm C GAS DUCT FROM ECONOMIZER TO STACK Casing 1 Material Thickness Design pressure Design temperature S275 JR [21] 6 50 270 mm C Insulation 1 Material Density Mineral Wool 100 100 kg/m3 mm Insualtion 2 Material Density Thickness N.A. N.A. N.A. kg/m3 mm Cladding Material
Alluminium 3003-H14

Insulation 1 Material Density Mineral Wool 100 150 kg/m3 mm

Insualtion 2 Material Density Thickness N.A. N.A. N.A. kg/m3 mm

Cladding Material
Alluminium 3003-H14

mmH2O Thickness

mmH2O Thickness

Sheet

12

of

13

PETROFAC - GS JV RUWAIS 4TH NGL TRAIN

RUWAIS, UAE Gallarate - Italy Basic Engineering DEPT N 5 TITAN M 180 t/h, 30 barg, 355 C

Doc No. Rev. Date

1015-C-310 2 05/12/2011

BOILER DATA SHEET NOTES [1] [2] [3] [4] Peak load 110%MCR only 2hrs/24hrs. Normal steam demand is 81%MCR. Void Design Temperature: 183 C Based on design ambient condition 25 C/60%RH @ MCR with all fuel gas and T BFW equal to 110 C.During Molecular sieve regeneration efficiency is 89%@MCR on design ambient condition 25 C/60%RH with all fue l gas and T BFW equal to 149 C. Minimum BFW pressure @ BL. Boiler feedwater is variable pressure. Access door 600x600mm for Furnace, Superheater and Economizer Approximate lenght. Design temperature according DGS-0000-020, par.4.1 and Macchi Standard. Headers: Design Temperature = maximum ( Tsat @ Pdesign; T @ maximum continuous operating + 30 C) Superheater tubes: Design Temperature = Maximum(Metal Temperature at MCR + 30 Metal temperature in unbalanced C; condition) Design temperature of Boiler tubes is 385 instea d of 371 according DIP sec.3 (Company Comments, C C mail 23/12/09) External to flue gas path Membraned wall. Headers shall be seamless, of the same material as connecting tubes, and shall have flanged 6" inch diameter handholes to permit inspection of internal surfaces (DGS 0150 001,par.10.7.19). The minimum size for all steam drum connection is 2" inches. Two Manholes for each drum According DGS 0150-001 rev.1 par. 10.7.5 Based on 5% margin on peak load (110%MCR) Design temperature for duct: Air duct: Maximum operating temperature + 56 C Flue Gas duct: The calculated metal temperature + 56 based on the maximum flue gas temperature C Maximum velocity according DGS 0150 001 rev.1, par.10.18.2 and 10.18.3 The flue gas ducts shall be refractory-lined and externally insulated. The stack shall be refractory-lined. No external insulation only personnel protection. Stack mechanical and structural design shall be compatible with 45m height. Equivalent to ASTM A36 Acid proof high strength cement. Material Equivalent to ASTM 1008 DDS

[5] [6] [7] [8]

[9] [10] [11]

[12] [13] [14] [15] [16]

1 1 1 1

[17] [18] [19] [20] [21] [22] [23]

Sheet

13

of

13