TECHNICAL SPECIFICATION CAST FITTINGS FOR FURNACES MB20-1F PAGE 1 OF 10

DATE: 01 MAR 2006

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TABLE OF CONTENTS Section 1. 1.1 1.2 1.3 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 Title Page No. GENERAL ......................................................................................................................................1 Scope..............................................................................................................................................1 KBR Documents, Codes, and Industry Standards .........................................................................1 Definitions .......................................................................................................................................2 DESIGN AND MATERIALS ...........................................................................................................2 General ...........................................................................................................................................2 Chemical Composition....................................................................................................................3 Mechanical Properties ....................................................................................................................5 FABRICATION ...............................................................................................................................5 Casting Practice and Heat Treatment ............................................................................................5 Tolerances ......................................................................................................................................6 Joint Preparation for Welding by Others.........................................................................................6 INSPECTION, TESTING, AND REPAIRS .....................................................................................6 Inspection........................................................................................................................................6 Radiographic Examination of Austenitic Steel Castings.................................................................6 Liquid Penetrant Examination for Austenitic Steel Castings ..........................................................7 Chemical Analysis ..........................................................................................................................8 Mechanical Testing.........................................................................................................................8 Grain Size .......................................................................................................................................8 Hydrostatic Pressure Tests.............................................................................................................8 Proof Test .......................................................................................................................................9 Results ............................................................................................................................................9 Repairs............................................................................................................................................9 Dimensional Inspection...................................................................................................................9 Code Stamping and Manufacturer's Data Reports.......................................................................10

1. GENERAL 1.1 Scope This Specification, KBR Purchasing Standards MB2-1PS and SDR-2MB-3 cover the requirements for fabrication and testing of cast fittings for furnaces. Centrifugally cast fittings shall additionally meet the requirements of Technical Specification MB14-2M. Exception to this specification, if any, and abbreviations are in accordance with 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 KBR documents, when applicable, will be listed in the Requisition. Applicable dates of issue of industry standards and codes shall be as indicated in the Technical Standards MB15-1TS. KBR DOCUMENTS MB2-1PS, "Purchasing Requirements for Furnace Materials, Components, and Equipment" MB14-2M, "Furnace Tubes, Centrifugally Cast" MB15-1TS, "General Furnace Specification" SDR-2MB-3, "Supplier Data Requirements - Furnace Pressure Parts"

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DATE: 01 MAR 2006

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AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) ASME Boiler and Pressure Vessel Code Section I, "Power Boilers" Section V, "Nondestructive Examination" Section VIII, "Pressure Vessels, Division 1" ASME B31.3, ASME B46.1, "Process Piping" "Surface Texture (Surface Roughness, Waviness, and Lay)"

For all "ASTM" designations specified in this Specification, corresponding "ASME" designations shall be applicable, when the materials specified on the drawings are in accordance with "ASME". AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ASTM A216/A216M, "Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service" ASTM A217/A217M, "Steel Castings, Martensitic Stainless and Alloy, for Pressure Containing Parts, Suitable for High Temperature Service" ASTM A351/A351M, "Castings, Austenitic, Austenitic-Ferritic (Duplex), for Pressure-Containing Parts" ASTM A370, "Mechanical Testing of Steel Products" ASTM E94, "Radiographic Examination" ASTM E112, "Methods for Determining Average Grain Size" ASTM E186, "Reference Radiographs for Heavy-Walled (2 to 4 1/2 in.) (51 to 114 mm) Steel Castings" ASTM E446, "Reference Radiographs for Steel Castings up to 2 in. (51 mm) in Thickness" ASTM E1025, "Design, Manufacture, and Material Grouping Classification of Hole-Type Image Quality Indicators (IQI) Used for Radiology" MANUFACTURER'S STANDARDIZATION SOCIETY (MSS) MSS SP55, "Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components Visual Method for Evaluation of Surface Irregularities" 1.3 Definitions The following terms used in this specification shall be defined as follows: a. "Master Heat" , is a single furnace charge of refined alloy which may be poured into remelt alloy for individual melts. "Melt" , is a single furnace charge poured into castings. When master heats are used to prepare melts, a melt analysis shall be reported. "Melt analysis" , is the chemical analysis taken from a test sample obtained during the pouring of the melt.

b.

c.

2. DESIGN AND MATERIALS 2.1 General 2.1.1 In general, the Purchaser will specify the details of design or design basis, the materials to be used for pressure parts, and any code requirements. When detailed information is not furnished, the manufacturer's design will be acceptable, providing the interconnecting passages in a fitting have the following minimum area:

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DATE: 01 MAR 2006

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a. b.

For the areas passing the flow of one tube: 100% of the internal flow area of one (1) tube. For the areas passing the flow of two or more tubes: 85% of the total internal flow area of the tubes.

2.1.2 The thickness of fittings for process coils shall be based on specified temperatures, the design allowable stresses, and casting quality factors given for the type of material used. The finished thickness shall include an allowance for corrosion, erosion, and oxidation as specified on the drawing. a. b. c. d. The basic allowable stress for fittings shall be specified on the drawings. To obtain the design allowable stress, a casting quality factor shall be applied to the basic allowable stress. At bevel ends, the required casting quality factor shall be 100%. Except at bevel ends the casting quality shall be 80%, for ferritic alloys unless otherwise noted on the drawings. The casting quality factor for austenitic alloys, shall be 100% throughout the fitting, unless otherwise noted on drawings.

e.

2.1.3 The thickness and casting quality factors of fittings for boiler and steam superheater coils shall conform to the requirements of ASME Section VIII, Division I, unless otherwise noted on drawings. 2.1.4 The material for the pressure parts of fittings will be specified in the Order. 2.1.5 All materials of construction shall be new. 2.2 Chemical Composition 2.2.1 An analysis of each heat of steel shall be made to determine that the chemical composition conforms to the requirements of Table I, except for ASTM A216/A216M and ASTM A217/A217M, the chemical analysis shall be in accordance with ASTM. The analysis shall be performed on material taken from at least 0.25 inch (6 mm) beneath the surface of a test ingot made during the pouring of the melt. To ensure that the chemical composition of the test ingot is representative of the composition of the heat as whole, the manufacturer shall ensure that the time between the pouring of the test ingot and the fitting from the heat is minimized. 2.2.2 The manufacturer shall submit records of analysis, methods of analysis, and descriptions of the proposed quality control methods, which will ensure that the lead (Pb), tin (Sn) and zinc (Zn) content of the steel will be below the limit specified herein.

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DATE: 01 MAR 2006

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TABLE I CHEMICAL COMPOSITION

HK40 (Note 3) A351/A351M Gr. CT15C (20Cr-32Ni+Nb) (800H Cast Equiv.) HP modified + Nb (25Cr-35Ni+Nb) Nominal Composition Low Carbon HP modified (25Cr-35Ni+Nb)

C Mn Si P S Cr Ni Mo Pb Sn Zn Nb Ti and Others

0.38 to 0.45% 1.50% max. 1.5 to 2.0% 0.040% max. 0.040% max. 25.0 to 27.0% 19.0 to 22.0% 0.5% max. 0.01% max. 0.01% max. 0.01% max. -

0.10 - 0.15% (Note 1) (Note 1) (Note 1) (Note 1) (Note 1) (Note 1) 0.01% max. 0.01% max. 0.01% max. (Note 1) -

0.40% 1.5% max. 25.0% 35.0% 0.01% max. 0.01% max. 0.01% max. 1.25% max. -

(Note 2) 1.5% max 25.0% 35.0% 0.01% max. 0.01% max. 0.01% max. (Note 2) -

NOTES TO TABLE I: 1. 2. 3. Except where noted above, composition shall be in accordance with ASTM A351/A351M Gr. CT15C. Nominal content shall be specified and submitted by the Bidder. a. b. Chrome for ethylene service shall be 25% minimum and for reforming service shall be 23% minimum. Silicon for ethylene service shall be between 1.5% and 2% and for reforming service shall be 1.75% maximum.

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DATE: 01 MAR 2006

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2.3 Mechanical Properties The mechanical properties of the specified alloys shall conform to Table II. TABLE II MECHANICAL PROPERTIES
MATERIAL PROPERTY HK40 ASTM A351/A351M Gr. CT15C (20Cr+32NI+Nb) HP Modified (25Cr+35Ni+Nb)

Low Carbon HP modified (25Cr+35Ni+Nb) 65 000 psi (448 MPa) 26 000 psi (179 MPa) 20% 15%

Tensile Strength (min) Yield Strength (min) Elongation - As cast in 2 in. (50 mm)(min.) Aged Ductility after aging 1000 hrs at Design Temp. 3. FABRICATION

65 000 psi (448 MPa) 35 000 psi (241 MPa) 10% -

63 000 psi (434 MPa) 25 000 psi (172 MPa) 20% -

65 000 psi (448 MPa) 35 000 psi (241 MPa) 6% -

3.1 Casting Practice and Heat Treatment 3.1.1 The manufacturer's foundry procedure for his standard fittings shall apply to the production of castings under this specification. However, the following shall also be observed: a. Internal "chills" (metallic device placed in a mold cavity to increase the rate of heat removal at that location) shall not be used. "Chaplets" (metallic support placed in a mold cavity to maintain the spacing between a core and the mold) shall not be used unless unavoidable, in which case they shall be subsequently removed and repairs made in accordance with Article 4.10.

b.

3.1.2 Heat treatment of castings shall be in accordance with the applicable ASTM or ASME specification, or as otherwise specified in the Order. The manufacturer may submit for acceptance other heat treatment based on experience in the production of sound castings. 3.1.3 Pyrolysis furnace radiant fittings, including tetra and wye fittings, shall be cast using a suitable casting method to ensure a smooth internal surface finish. The internal surface finish of the casting shall be in the range of 150-200 inch (3.8 - 5.1 m) Ra in accordance with ASME B46.1. All internal imperfections shall be ground smooth. 3.1.4 Cast fittings other than for pyrolysis furnace shall have "as cast" finish of 250 inch (6.35 m) for all internal surfaces. 3.1.5 All machined internal surfaces shall have a finish of 125 inch (3.2 m), unless otherwise noted on drawings.

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DATE: 01 MAR 2006 3.2 Tolerances

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3.2.1 Tolerances stated on the drawing shall take precedence over this Specification. 3.2.2 Unless otherwise specified in the Order, the manufacturer's standard tolerances will be acceptable, except as follows: a. Warpage of casting shall not exceed 1/16 inch per foot (1.6 mm per 300 mm) of the distance between tube or plug holes, measured from a common reference plane containing one or more axes of tube holes. Tube holes and plug holes shall not vary from their correct location by more than 1/16 inch (1.6 mm). Deviation from the maximum "out" to "out" dimensions shall not exceed r 1/8 inch (3.2 mm). Fittings shall be machined such that the beveled faces of the openings are in plane, within 1/32 inch (0.8 mm) of the perpendicular to the vertical axis of the fitting. Outside diameter and inside diameter shall be concentric within 0.03 in. (0.8 mm).

b. c. d.

e.

3.3 Joint Preparation for Welding by Others Joints prepared for welding by others shall be as shown on the Purchaser's drawings. 4. INSPECTION, TESTING, AND REPAIRS 4.1 Inspection 4.1.1 All castings shall be subject to a visual examination in accordance with MSS SP-55 and as required by the applicable material specification. At machined bevel ends where a quality factor of 100% is utilized, examination shall be in accordance with ASME B31.3, Table 302.3.3C. 4.1.2 Cast fittings of austenitic alloy steel shall be examined by both the radiographic and liquid penetrant methods of examination in accordance with the following Articles 4.2 and 4.3. 4.2 Radiographic Examination of Austenitic Steel Castings 4.2.1 All castings, except those for SCORE furnace inlet manifold assemblies, produced for this order shall be completely radiographed. 4.2.2 The Seller shall supply a radiograph map and procedure of the proposed radiography for review and acceptance. 4.2.3 Radiographic examination shall be in accordance with Supplementary Requirement S5 of ASTM A351/A351M except as modified in this Article 4.2. The radiographic technique employed shall be single wall at open ends; and elsewhere, if practicable. 4.2.4 Where X-ray equipment is used, the maximum peak voltage for the metal thickness radiographed shall comply with Figure T-372.1 (b) Article 3, of ASME Section V. 4.2.5 Penetrameter designs shall comply with Figure 1 of ASTM E1025. Use of wire penetrameter is acceptable.

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DATE: 01 MAR 2006

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4.2.6 Penetrameter designations and essential holes shall be in accordance with Table T-333.1 and T-62.2 of Article 3, ASME Section V based on single wall thicknesses. 4.2.7 Radiographic film shall be of the fine grain, non-screen type possessing high contrast and definition, and in accordance with ASTM E94. For any lot of film examined, the film density shall be in accordance with ASME Section V, Paragraph T 382.1, except the maximum density shall be limited to 3 1/2. 4.2.8 Lead screens shall be used on both sides of the film. Fluorescent type screens shall not be used. 4.2.9 Variable intensity viewing equipment shall be used. As a maximum, the brightness at the oval glass shall register 1/100 second at +10 on photographic exposure meter set for a film speed of ASA 100. 4.2.10 The acceptability of castings based on radiographic examination shall be judged by the Reference Radiographic standards ASTM E446 or ASTM E186, as applicable. Except for chills and chaplets (see Paragraph 3.1.1), the acceptability for all categories of discontinuity types throughout the body of the casting shall be severity level 2 except that within a distance of 2T from the edge of the weld bevel (T being the minimum thickness at the weld bevel) the minimum acceptability of internal shrinkage shall be severity Level 1. 4.2.11 Radiography by single shot, single wall panoramic technique with source at center is acceptable. 4.2.12 SCORE furnace inlet manifold fittings: All types of cast fittings shall have random radiographic examination. 10% of cast fittings of each type from each melt shall be 100% examined. If the fitting being tested found rejectable, two (2) additional fittings from the same melt shall be examined. If any of these two fittings is also found rejectable, then 100% of castings from that melt shall be examined or rejected. All additional costs after the initial 10% shall be the responsibility of Supplier. 4.3 Liquid Penetrant Examination for Austenitic Steel Castings 4.3.1 All castings shall be examined by the liquid penetrant method for the detection of surface discontinuities. All accessible as-cast, machined, or ground outside and inside surfaces including final machined flanges or welding ends shall be completely examined. 4.3.2 All completed weld bevels, all machined external surfaces adjacent to the bevel, and 1 inch (25 mm) minimum on the adjacent machined inside surface shall be examined by the liquid penetrant method to ensure that these surfaces exhibit zero indications and defects, and that all porosity has been removed. 4.3.3 For the purpose of determining if the liquid penetrant test is effective on as cast surfaces, one casting from every pattern for every melt shall have all accessible outside and inside surfaces examined by the liquid penetrant method both before and after grinding the accessible surface to a finish of at least 250 inch (6.35 m) Ra. a. If defects are revealed on the ground surfaces which were not detected during inspection of the as-cast surfaces, all other castings from the same pattern and melt shall be similarly ground before inspection. If the inspection of the as-cast surfaces proves to be sufficient as verified by examination of the ground surfaces, all other castings of the same pattern and melt need not be ground, except to remove surface defects.

b.

4.3.4 Castings for orders of 5 or less of the same pattern shall have all accessible outside and inside surfaces ground to a finish of at least 250 inch (6.35 m) Ra before liquid penetrant examination.

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4.3.5 The liquid penetrant examination shall be performed and the results interpreted in accordance with Appendix 8 of ASME Section VIII Division I on all accessible weld surfaces and bevels. The liquid penetrant materials shall be analyzed for sulfur and chlorine content in accordance with Paragraph T-641 of ASME Section V. Liquid penetrant materials shall meet the requirements of T-641 of ASME Section V. After completion of examination, the surface shall be completely cleaned with "Alconox" (manufactured by Alconox Incorporated, 30 Glenn Street, Suite 309, White Plains, NY 10603). Cleaning after completion of examination by water is acceptable only for water soluble penetrant. Chloride content of water shall be limited to 50 ppm. 4.3.6 Liquid penetrant examination shall be subject to review by the Purchaser's representative. If agreement is reached with the Purchaser's representative, the examination of cast surfaces may be conducted as part of the foundry control prior to final submittal of the machined fittings for inspection and acceptance. 4.4 Chemical Analysis A melt analysis as defined in Article 1.3 c shall be performed on each melt. The chemical composition thus determined shall conform to the requirements in the specification. For proprietary alloys, the composition shall conform to that submitted by the Seller in the quotation. 4.5 Mechanical Testing Material shall be taken from the thickest section of a production casting from the first melt poured; thereafter from a production casting of each fifth melt. The axis of these test specimens shall be located midway between the surface and the center of the casting wherever permitted by the wall thickness. The tensile and yield strength shall not be less than that specified in the applicable ASTM Standards, this specification, the Design Drawings or Purchase Order. If the wall thickness does not permit standard size specimens to be taken, the small size specimens of ASTM A370 may be used. If the tensile and yield strength of the test specimens do not meet the minimum requirements then one fitting from each adjacent melt shall also be tested as stated above. If both of these fittings pass then all fittings represented by these tests pass, but if either fail, then all fail. 4.6 Grain Size Grain size shall be Number 5 or coarser in accordance with ASTM E112. Cast fittings shall have minimum of two (2) grains through the wall thickness. This should be verified on each casting used for destructive testing of Article 4.5. The verification procedure shall be specified by the Supplier for the Purchaser acceptance. 4.7 Hydrostatic Pressure Tests 4.7.1 After all heat treating and machining has been completed, each fitting shall be hydrostatically tested with water, oil, or kerosene at 1 1/2 times the design pressure multiplied by the ratio of the allowable stress at the test temperature to the allowable design stress at design metal temperature, or to that pressure which will produce a stress of 60% of the minimum specified yield stress, whichever is greater. The test pressure shall not be allowed to exceed that which would produce a stress of 90% of the minimum specified yield stress. The testing medium shall not contain more than 50 ppm chlorides. 4.7.2 The pressure shall be continuously maintained for a minimum of 10 minutes and shall then be reduced by a factor of 1.3 till such time as necessary to conduct examination for leakage. Examination for leakage shall be made at all joints and shall show no evidence of weeping or leakage. 4.7.3 Defects, extending through the wall, detected as a result of the pressure tests shall not be repaired. The fitting shall be considered unacceptable.

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4.8 Proof Test A proof test (bursting test) shall be performed on one fitting per each type or pattern, when required by the Order. This test shall be performed in accordance with ASME Section VIII, Division 1, Paragraph UG-101. Bursting test procedure UG-101(M) shall be performed and the M.A.W.P. at the specified design metal temperature shall be determined in accordance with UG-101(K). Test procedures shall be subject to the approval of Purchaser. A representative of Purchaser shall be present during the proof test. The results of this test will be used to qualify the pattern and design of the Seller's fittings. Only one successful test need be performed per fitting supplier. 4.9 Results 4.9.1 Results from tests previously submitted and accepted by Purchaser may be used in lieu of the performance of new tests for the following: a. b. Aged elongation. Proof test

4.10 Repairs 4.10.1 Defects, as used herein, shall mean discontinuities which result in the casting failing to satisfy the acceptance standards referenced in this specification. 4.10.2 Minor defects, within the limits established below, in otherwise sound castings may be weld repaired in accordance with the procedure of the applicable ASTM or ASME specification. a. In plug or tube seats of removable cleanout fittings, defects considered minor shall not exceed a depth of 1/8 inch (3 mm) nor a length of 5/8 inch (16 mm) or 50% of the height of the contact surface, whichever, is less. After repair welding the fitting shall be heat treated again before final machining. Weld repairs of minor defects, in other locations in carbon and austenitic steel castings need not be heat treated. Defects considered minor at other locations on the fittings shall not exceed 1/5 the thickness of the casting in the area of the defect.

b.

4.10.3 Weld repairs of major defects require prior acceptance of the Purchaser. a. Weld repairs shall be considered major when the depth of the cavity after preparation for repair exceeds 20% of the actual wall thickness. Depth of the cavity after preparation for repair shall not exceed 50% of the actual wall thickness. Fittings with defects greater than 50% of the depth of the actual wall thickness shall be considered unacceptable.

b.

4.11 Dimensional Inspection Dimensions of all cast fittings shall be in compliance with the dimensions specified on drawings. No dimension may be altered without prior acceptance by Purchaser.

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DATE: 01 MAR 2006

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4.12 Code Stamping and Manufacturer's Data Reports Cast Fitting Supplier shall provide ASME Code Stamping. If specified on drawings, code stamping on each fitting shall be in accordance with ASME Section VIII, Division I, Paragraph UG-115 and the manufacturer's data report to be submitted shall be in accordance with Form U-2. Only when ASME Section I is specified on drawing, code stamping shall be in accordance with ASME Section I, Paragraph PG-106.8 and the manufacturer's data report to be submitted shall be in accordance with Form P-4.