NUMBER Q06-E04

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ENGINEERING STANDARD DATE NOV 2000
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Boiler Support Systems: Design

This document is issued by Engineering Standards Section, SABIC R&D Complex, PO Box 42503, Riyadh 11551, Kingdom of Saudi Arabia.
The information contained in this document is the confidential property of SABIC. It can not be disclosed, copied or used for any purpose
without prior approval from SABIC If you are not authorized to posses this document please destroy it immediately
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DATE NOV 2000
ENGINEERING STANDARD
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7. Design
7.1 Water and Steam Quality Monitoring System
A reliable water and steam quality monitoring and analyzing system shall be required, to make all
necessary parameters measurements, record data, and alert operators when limits are exceeded.
Moreover, this monitoring system shall be efficient at very low levels of impurity concentrations.
7.1.1 Water and steam quality should be monitored at locations shown in Figure 2. Sampling points shall
include the following:
a. BFW make up and condensate return to deaerator
b. Deaerator pump discharge to boiler economizer
c. Steam from boiler drum
d. Steam from superheater coil outlet
e. Steam from desuperheater station
7.1.2 Monitoring system shall be designed to obtain representative samples, provide adequate sample
flow to sample room or local sample panel, and properly condition the sample's temperature and pressure.
See Figure 4 for general system arrangement. Also, it shall analyze the sample for different parameters
listed in 7.1.8.
7.1.3 As shown in Figure 3A, each complete sample line shall consist as a minimum, a sample probe, two
double block valves (root valves) immediately following it, a double block valve branch line to local sample
tap, main line to sample panel, block valve at panel inlet, purge (blow down) line, valve downstream of the
panel, primary sample cooler, pressure tap, pressure control valve, pressure relieve valve, secondary
sample cooler, temperature indicator before entering analyzing system, and block valve and line to grab
the sample.
7.1.4 In general, orientation of sample probe in vertical and horizontal steam lines is shown in Figure 3B.
Sample probe shall not be installed on the top or bottom of the line.
7.1.5 Two-stage sample cooling system shall be used for high-temperature samples. Primary sample
cooler shall be designed to cool sample temperature to approximately 38 C. Secondary cooler shall be
designed to cool sample to 25 C.
7.1.6 For sample temperature below 38 C, a single stage cooling may be used. Sample temperature out
of cooler shall be 25 C, or within the tolerance of water quality monitoring instrument.
7.1.7 Sample cooling can be provided through refrigeration chiller, isothermal bath or a closed-circuit
cooling water system. Selection of cooling system shall be based on consideration of fouling, availability of
cooling medium, controllability, and ease of operation and maintenance.
7.1.8 As a minimum, analyzing instruments shall be provided to measure the following:
a. Sample conductivity
b. Sodium and chloride content in the sample
c. TDS
d. Silica content in the sample
e. PH
f. Oxygen and CO2 concentrations
7.1.9 Monitoring instruments shall be designed for high accuracy, sensitivity, and reliability.
7.2 Water and Steam Quality Improvement
7.2.1 Presence of impurities and dissolved gases, for example oxygen and carbon dioxide, in boiler feed
water system are causes of many corrosion problems. Therefore, a system for removal of gases, salts,
and solids from boiler feed water shall be provided for efficient boiler performance, and to extend
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Boiler Support Systems: Design
DATE NOV 2000
ENGINEERING STANDARD PAGE 6 OF 17

equipment service life. As a general, BFW and steam quality monitoring and control (improvement) system
shall be arranged as per Figure 4.
7.2.2 Non-condensable gases, for example oxygen and carbon dioxide can be removed by steam
stripping, and scrubbing through a de-gas section of a deaerator. The design, performance, material
selection and construction of a deaerator shall be in accordance with SES Q06-S02. Combination of
deaeration and chemical dosing may be required to achieve the required steam purity, especially at high
pressure level.
7.3 Continuous Blow Down System
Continuous blow down system shall remove excessive solid concentrations from boiler feed water in the
steam drum. Also, the continuous blow down system shall recover energy from high pressure let down
liquid and convert it into low pressure steam for deaeration. A simplified schematic flow diagram is shown
in Figure 5.
7.3.1 Boiler continuous blow down system shall effectively and safely remove high pressure liquid during
normal operation and start-up. Components shall be designed for handling two-phase flow in a controlled,
depressurizing condition.
7.3.2 Boiler blow down system shall comprise the following components and features:
a. A normally open blow down block valve (provided by boiler manufacturer)
b. A main control valve with gate valves, and by-pass line to flash tank
c. A flash tank to separate steam from liquid
d. A blow down tank
e. A sample line with block valves, sample coolers, flow control valve, conductivity cell and
grab-sample connection
f. Sample analyzer system connected to DCS
g. Blow down system shall be designed to operate manually and automatically
7.3.3 Flash tank and blow down tank shall be designed in accordance with ASME Section VIII, Div 1.
7.3.4 Piping in continuous blow down system shall be designed in accordance with ASME B31.3.
7.3.5 Valves and trim shall conform to SES X01-S03.
7.3.6 Blow down piping shall be routed as directly as possible, and shall avoid pockets. Five-diameter
bends, instead of forged elbows, shall be used to streamline flow and minimize flow resistance.
7.4 Steam De-superheating
Steam desuperheaters shall be used to control super heated steam temperature to safe limits of equipment
design conditions and to prevent process fluid from overheating.
7.4.1 The criteria for selecting proper type of desuperheating device shall be based on the following
considerations:
a. Steam cooling range and required variation
b. Sensitivity of control
c. Steam flow or boiler load variation
d. Available water quality
e. Available water pressure
f. Allowable steam side pressure drop
7.4.2 Desuperheater package shall include the suitable desuperheating device, the actuator (if required),
and the provisions for instrumentation hook-ups.
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7.4.3 Design requirements for steam desuperheaters shall be in accordance with SES Q06-S03. Supplied
desuperheater shall be suitable for steam quality and turndown requirements specified in data sheets or
purchase documents.
7.5 Fuel Gas Filter and Coalescer
7.5.1 Fuel gas filter and coalescer shall be either a horizontal or vertical pressure vessel, complete with
cartridge filter and liquid-gas separating compartment, process and instrument nozzles, internals, support,
access and removal head. A typical filter-coalescer package is shown in Figure 6.
7.5.2 The replaceable filter elements shall be properly supported and sealed.
7.5.3 By-pass of the filter-coalescer unit shall be provided. By-pass line shall be sized for full capacity with
on/off valve controlled by the filter differential pressure.
7.5.4 The following connections and instrumentation shall be provided by supplier:
a. Differential pressure (signal to control room) across the filter unit, with local indicator and alarm
b. Local level gage and indicator
c. Level transducer for remote control
7.5.5 Vessel for fuel gas filter and coalescer shall be designed and fabricated in accordance with
ASME Section VIII, Div 1, SES Q01-E01 and Q01-F07.
7.5.6 Material selection for filter elements and internals shall be in accordance with design engineer's
purchase documents.
7.6 Flue Gas Sampling and Monitoring System
7.6.1 All boiler stacks, shall be equipped with Continuous Emission Rate Monitoring (CERM) system.
CERM is a comprehensively instrumented system capable of continuously measuring, analyzing, and
recording the constituents of exhaust gases from stationary sources.
7.6.2 There are two types of flue gas sampling systems: extractive or in-situ. The terms refer to the way
the gas sample is delivered into the analyzer. In extractive sampling, a gas sample is drawn out of the duct
or stack, conditioned, then transported to a remotely located site for analysis. In-situ analysis features an
analyzer mounted on the stack, with its sampling apparatus directly in contact with the flue gas.
7.6.3 In extractive sampling, gas drawn out of stack shall pass through a sample conditioner before
entering the measuring instrument. Sample conditioning shall consist of:
a. Filtration to remove particulates
b. Refrigeration to remove water vapor
c. Heating or insulation of lines to maintain proper processing temperatures
d. Introduction of standard composition gases for calibration, so that zero and span adjustments for
scaling and calibration can be made
7.6.4 There shall be sufficient working clearance and access for operator and equipment.
7.6.5 Design engineer shall specify the instrumental flow measurement method based on consideration of
monitoring equipment location, flow pattern, process flow condition and acceptable degree of accuracy.
7.6.6 When specified, CERM shall include the following:
a. CERM sampling probe, sampling line and analyzer
b. Programmable logic controller (PLC)
c. Data concentrator connected to PLC, where plant wide or area wide information is gathered
d. TDC or DCS control unit connected to concentrator via data high way
e. Parallel data archiving and data recorder report printing
f. Spare parts list for 2 years of operation
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7.7.5 Provisions for adding additional layers in future of catalyst into reactor housing shall be incorporated
into system design.
7.7.6 Catalyst shall be guaranteed for at least three years continuous operation at specified conditions in
purchase document.
7.7.7 Responsibility of disposal of spent catalyst at end of catalyst life shall be agreed upon mutually by
SABIC and supplier.

FIGURE 1
Boiler Support Systems Scope of Work
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DATE NOV 2000
ENGINEERING STANDARD
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FIGURE 2
BFW and Steam Quality Monitoring Points
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DATE NOV 2000
ENGINEERING STANDARD PAGE 12 OF 17

FIGURE 3
Collecting and Cooling System

Figure 3A. Sample Panel

Figure 3B. Sample Probe

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DATE NOV 2000
ENGINEERING STANDARD
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FIGURE 4
Monitoring and Control System - General Arrangement