FSO-SU-5157-A

FSO-SU-5157-A
FPSO MARINE STEAM PLANTS — GENERAL
APPLICATION: FPSO MARINE AND HULL
This document is the confidential property of Chevron U.S.A. Inc. Neither

the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron U.S.A. Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system, or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording, or otherwise) without the prior
written consent of Chevron U.S.A. Inc.
Rev Date Description Author Sponsor

— 09/08 Document number change only.
Formerly CIV-SC-5157
A 12/11 General revision. Updated references. GJAD MCXI
December 2011 © 2008–2011 Chevron U.S.A. Inc. All rights reserved. 1 of 54

54
FPSO Marine Steam Plants — General FSO-SU-5157-A
CONTENTS
1.0 Scope ..........................................................................................................................5

2.0 References ..................................................................................................................5
2.1 Purchaser Standards ........................................................................................5
2.2 Industry Standards ...........................................................................................5
2.3 Conflict Resolution ...........................................................................................5
3.0 Terminology ................................................................................................................5
3.1 Acronyms .........................................................................................................5
3.2 Definitions .........................................................................................................6
4.0 General ........................................................................................................................6
5.0 Documentation ...........................................................................................................7
5.1 General .............................................................................................................7
5.2 Analysis and Test Documentation ....................................................................7
5.3 Quality Assurance/Quality Control Documentation ..........................................8
5.4 Purchasing Documentation ..............................................................................8
5.5 Equipment Documentation ...............................................................................8
5.6 Connection Drawings .......................................................................................9
5.7 Piping and Valve Documentation .....................................................................9
5.8 Ducting and Insulation ....................................................................................10
5.9 Boiler Documentation .....................................................................................10
5.10 Instrumentation Documentation .....................................................................10
5.11 Expansion Calculations ..................................................................................10
5.12 Equipment Operation Manuals .......................................................................11
6.0 Steam System ...........................................................................................................11
6.1 General ...........................................................................................................11
6.2 Isolation Valves ..............................................................................................12
6.3 Configuration ..................................................................................................12
7.0 Steam System Piping ...............................................................................................12
7.1 General ...........................................................................................................12
7.2 Materials .........................................................................................................13
7.3 Connections ...................................................................................................13
7.4 Sizing ..............................................................................................................14
7.5 Expansion Loops ............................................................................................14
7.6 Steam Strainers ..............................................................................................14
7.7 Fasteners .......................................................................................................14
7.8 Gaskets ..........................................................................................................14
7.9 Drains .............................................................................................................14
7.10 Steam Traps and Separators .........................................................................14
7.11 Stop and Drain Valves ....................................................................................15
7.12 Insulation ........................................................................................................15

8.0 Condensate System .................................................................................................15

8.1 Condensate Discharge ...................................................................................15
8.2 Makeup Lines .................................................................................................16
8.3 Salinity Monitoring ..........................................................................................16
8.4 Protection for Topsides Condensate Return Lines .........................................16
9.0 Valves ........................................................................................................................16
9.1 General ...........................................................................................................16
9.2 Control Valves ................................................................................................18
9.3 Safety Valves .................................................................................................18
9.4 Valve Mountings—General ............................................................................19
10.0 Instrumentation ........................................................................................................19
10.1 General ...........................................................................................................19
10.2 Water Level ....................................................................................................20
10.3 Draft Gauges ..................................................................................................21
10.4 Furnace Draft .................................................................................................22
10.5 Smoke Indicators ............................................................................................22
11.0 Tanks .........................................................................................................................22
11.1 General ...........................................................................................................22
11.2 Drain Inspection Tank ....................................................................................22
11.3 Atmospheric Drain Tank .................................................................................23
11.4 Cascade Tanks ..............................................................................................23
11.5 Distilled Water Tanks .....................................................................................24
12.0 Boiler Chemical Feed System .................................................................................25
12.1 General ...........................................................................................................25
12.2 Chemical Handling Safety ..............................................................................25
12.3 Boiler Chemicals Storage ...............................................................................26
13.0 Superheaters, Atemperators, Deaerators, and Low Pressure
Steam Generators (LPSGs) .....................................................................................26
13.1 Superheaters ..................................................................................................26
13.2 Attemperators .................................................................................................27
13.3 Deaerators ......................................................................................................27
14.0 Soot Blowers ............................................................................................................30
15.0 Steam Smothering System ......................................................................................31
16.0 Ducting ......................................................................................................................31
16.1 General ...........................................................................................................31
16.2 Exhaust Gas Ducts and Uptakes ...................................................................32
17.0 Water and Flue Gas Testing ....................................................................................33
17.1 Water Testing Station .....................................................................................33
17.2 Flue Gas Testing Analyzer .............................................................................34

18.0 Spare Parts and Tools .............................................................................................35

18.1 General ...........................................................................................................35
18.2 Expansion Joints ............................................................................................35
18.3 Valves .............................................................................................................35
18.4 Burners ...........................................................................................................35
18.5 Soot Blowers ..................................................................................................36
18.6 Boiler Feedwater Pumps ................................................................................36
18.7 Forced Draft Fans ..........................................................................................36
18.8 Motors and Electrical Components ................................................................36
18.9 Bearings .........................................................................................................36
18.10 Instrumentation ...............................................................................................37
18.11 Tools ...............................................................................................................37
18.12 Storage ...........................................................................................................37
19.0 Shipping and Storage ..............................................................................................37
20.0 Testing ......................................................................................................................38
20.1 General ...........................................................................................................38
20.2 Factory Acceptance Tests ..............................................................................39
21.0 Commissioning ........................................................................................................42
21.1 Mechanical Completion Checks (A-Scope Commissioning) ..........................42
21.2 Energized Completion Checks (B-Scope Commissioning) ............................50
21.3 Operational Tests (C-Scope Commissioning) ................................................52
22.0 72 Hour Running Test ..............................................................................................54

1.0 SCOPE
1. This specification defines minimum technical requirements for the design, materials,
fabrication, testing and inspection, and documentation of Floating Production, Storage, and
Offloading (FPSO) steam generation plants.
2. This document provides general requirements that apply to both steam generation systems
using new build FPSO boilers and boiler systems converted from existing trading tankers to
FPSO service.
3. This document does not include the following:
a. Requirements specific only to new build FPSO steam boilers (refer to FSO-SU-5188).
b. Requirements specific only to tanker vessel steam plant conversions for FPSO service
(refer to FSO-SU-5187).
c. Requirements for steam generation plant boiler auxiliary systems (refer to FSO-SU-5189).
2.0 REFERENCES
1. The following documents are referenced herein and are considered part of this specification.
2. Use the edition of each referenced document in effect on the date of the publication of this
specification.
2.1 Purchaser Standards

FSO-SU-5187 FPSO Marine Steam Plants—Steam Plant Conversion
FSO-SU-5188 FPSO Marine Steam Plants—New Build Steam Boilers
FSO-SU-5189 FPSO Marine Steam Plants—Boiler Auxiliary Systems
2.2 Industry Standards

American Petroleum Institute (API)
610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries
Services
Det Norske Veritas (DNV)
Rules for Classification of Ships—Part 6 Ch. 4, Additional Fire Protection (F-AMC) (Ships)
2.3 Conflict Resolution

Supplier shall submit any conflicts among the inquiry documents in writing to Purchaser for
resolution.
3.0 TERMINOLOGY
3.1 Acronyms
CAPEX—Capital Expenditure
DFT—Dry Film Thickness
FAT—Factory Acceptance Test
FMEA—Failure Mode and Effects Analysis
FO—Fuel Oil

FPSO—Floating Production Storage and Offloading

HAZOP—Hazard and Operability
Hi-Pot—High Potential
HP—Horsepower
IP—Ingress Protection
LP—Low Pressure
LPG—Low Pressure Generator
MGO—Marine Gas Oil
NDE—Nondestructive Examination
NPSH—Net Positive Suction Head
NPT—National Pipe Thread
OD—Outer Diameter
P&ID—Piping and Instrumentation Diagram
PPE—Personal Protective Equipment
PSV—Pressure Safety Valve
PT—Test Pressure
ST—Stress value of the piping material at the hydrostatic test temperature
QA—Quality Assurance
QC—Quality Control
RTD—Resistance Temperature Devices
SUS—Stainless Steel
TDS—Total Dissolved Solids
3.2 Definitions
Blackout—Loss of essential electrical power.
Deadship—Loss of emergency and electrical power.
4.0 GENERAL
1. New build Floating Production Storage and Offloading (FPSO) steam generation boilers shall
comply with requirements in this document and in FSO-SU-5188.
2. Conversion FPSO steam generation plants shall comply with requirements in this document
and in FSO-SU-5187.
3. FPSO steam generation boiler auxiliary systems shall comply with requirements in this
document and in FSO-SU-5189.
4. Purchaser review of and comment on plans, drawings, calculations, or other documents shall
in no way relieve the Supplier or Sub-Suppliers of any obligation, responsibility, or liability.
5. Purchaser review and/or comment shall not in any way be construed to constitute Supplier’s
assumption of responsibility for the accuracy or adequacy of any information or work.

5.0 DOCUMENTATION
5.1 General
1. Equipment and system drawings, plans, drawings, calculations, and other relevant documents,
shall be submitted for Purchaser review and comment prior to the start of vessel hull
construction.
2. Copies of all correspondence between the Supplier and the following shall be provided to
Purchaser:
a. Sub-Suppliers
b. Marine Classification Societies
5.2 Analysis and Test Documentation
5.2.1 Failure Mode and Effects Analysis Study

1. A complete failure mode and effects analysis (FMEA) study of the entire steam
generating plant shall be performed.
2. Analysis shall account for all possible scenarios.
3. In addition to possible component failures, the following additional failure modes
shall be considered:
a. Blackout—loss of essential electrical power
b. Deadship—loss of emergency and electrical power
c. Loss of nitrogen supply pressure (for purging)
d. Forced draft fan failure
e. Blower damper failure
f. Control valve failure—all possible cases (steam, fuel, feedwater, etc.)
4. For control systems, the FMEA study shall evaluate various failure modes of
components such as:
a. Signal failure
b. Process faults
c. Memory faults
d. Relay/contact failure
e. Timer failure
5.2.2 Steam and Heat Balances

1. A steam balance for the system shall be submitted for Purchaser review and comment.
2. A heat balance for the cascade tanks shall be submitted to show that the steam supply
piping is properly sized.
3. A heat balance shall be provided for the deaerator and external superheater, if fitted.
5.2.3 Hazard and Operability Documentation

A hazard and operability (HAZOP) study shall be performed for the steam generation
system.

5.2.4 Test Results Documentation

1. Test report results from the following shall be provided to Purchaser:
a. Factory Acceptance Test (FAT)
b. On-board installation checks/tests
c. Onsite commissioning tests
2. Factory acceptance test procedures and on-board test procedures shall be provided to
Purchaser for all equipment as appropriate. Documents shall be submitted at least 60
days prior to the performance of any tests to allow Purchaser to review and comment
on the procedures.
5.3 Quality Assurance/Quality Control Documentation

1. Quality assurance (QA) and quality control (QC) documents shall be submitted by all
equipment manufacturers to Purchaser for review and acceptance.
2. As part of the QA/QC documentation covering coating specifications, details of surface
preparation, application, final dry film thickness (DFT), etc., for coatings applied by
equipment suppliers or the Supplier shall be provided.
3. Class Certificates shall be provided as appropriate.
5.4 Purchasing Documentation

1. Prior to ordering equipment and before purchase orders are issued, the following items shall be
submitted to the Purchaser:
a. A reference list of key equipment from previous marine installations (for the same models
being proposed) to ensure that only well-proven equipment is being offered
b. Purchase orders for steam system equipment to ensure that technical requirements are
included to potential suppliers for cost/schedule indications.
2. Operating, servicing, and parts ordering information shall be provided for all equipment.
3. Lists of spare parts to be provided with equipment shall be provided. This list shall meet
requirements of Section 18.0.
5.5 Equipment Documentation
5.5.1 General
1. Sizing calculations shall be provided for all equipment for Purchaser verification that
the selected capacities, pressures, etc., are correct.
2. Lifting points and component weights shall be shown on all equipment diagrams.
3. For key equipment such as boilers, manufacturer shall provide lay up and preservation
instructions, recommendations, and requirements.
5.5.2 Cascade Tanks

1. For cascade tanks, structural calculations shall be provided to ensure that the design is
acceptable for expected stresses and pressures.
2. The natural frequency of the tank panels in air and with fluid on one side shall be
calculated to ensure no vibration problems will occur after FPSO is in service.

5.5.3 Pumps
For all pumps, the following shall be submitted to the Purchaser for review and comment:
1. Supporting calculations such as flow, head, net positive suction head (NPSH), and
horsepower (HP).
a. Bill of materials with all items identified by ASTM or other commercial
specification.
b. Characteristic curves showing expected performance throughout the operating
range.
c. Required NPSH.
2. Curves for centrifugal pumps including plots of head, power, and efficiency versus
capacity.
3. Plots of power, efficiency, and capacity versus speed from zero-power speed to
runaway speed.
4. All pump, fan, and motor driver bearing life calculations.
5.6 Connection Drawings

1. For all equipment, interface drawings documenting all connections between Supplier supplied
equipment and other equipment installed on the FPSO shall be provided.
2. Supplier drawings shall clearly indicate all necessary information (for example, piping flange
connection sizes, and wiring connections).
5.7 Piping and Valve Documentation

1. Line sizing calculations shall be provided.
2. Maximum velocity of the fluid through each piping branch shall be shown on system piping
and instrumentation diagrams (P&IDs).
3. If equipment or system specifications include a minimum acceptable fluid velocity, the
minimum fluid velocity shall be shown on system P&IDs.
4. Line wall thickness calculations shall be provided to demonstrate that the schedule of piping
selected is adequate for the maximum system design pressure including any specified
corrosion margin as appropriate.
5. Final piping drawings shall include individual drawings of all valves, including:
a. Manufacturer’s name
b. Manufacturer’s address
c. Detailed material list
d. Part numbers for ordering spare parts
6. Orifice diameters shall be specified for orifice plates installed in system piping or as part of
Supplier supplied equipment.
7. Sizing calculations shall be provided for all relief valves.

8. For all valves in the marine steam generating plant, including valves supplied as part of skid
mounted equipment or Supplier packages, a table shall be prepared listing summary
information for all valves. At a minimum, it shall include the following as shown in Table 1.
Table 1: Valve Information Summary

Tag Number
Name
Type
Material
Location
System P&ID Drawing Number (Showing Valve System Location)
Drawing Number (E.g., Supplier Assembly Drawing, JIS Standard, etc.)
Quantity
Manufacturer
Weight
5.8 Ducting and Insulation

1. Drawings showing the forced draft fan duct arrangement and exhaust duct arrangement shall
be provided.
2. Pressure drop (draft loss) and velocity calculations for the ducting arrangement shall be
provided to confirm that the forced draft fan selected is acceptable for the proposed vessel
boilers arrangement.
3. Calculations shall be provided to confirm proposed insulation satisfies the performance
requirements of this specification.
5.9 Boiler Documentation

1. Boiler manufacturer shall provide a list of standards, codes, and design data applicable for
design and manufacture of the boilers.
2. A complete material description shall be provided for all components used for the boiler
construction. For boiler pressure containing components, the ASTM equivalent material
designation shall be included.
3. Boiler performance curves shall be submitted for operation on both gas and liquid fuel.
5.10 Instrumentation Documentation

1. A complete list of all local instrumentation fitted shall be provided. List shall include locally
mounted instrumentation provided by equipment suppliers.
2. A complete list of all sensors that provide remote readouts, along with their normal calibrated
ranges, shall be provided.
a. List shall include all signals from Supplier supplied instrumentation.
b. List shall clearly identify signals to be included in the FPSO-wide central monitoring and
control system.
5.11 Expansion Calculations

Supplier shall submit thermal expansion calculations for system piping and ducting for Purchaser
review and comment.

5.12 Equipment Operation Manuals

1. Equipment operation manuals shall be provided by all equipment manufacturers and shall be
clearly written in English. Manuals shall be submitted in both hard copy and CD-ROM
formats and shall include the following:
a. Specifications and data
b. Descriptions
c. Diagrams, including as a minimum:
1) Assembly plans
2) Sections
3) Schematics
4) Line art to identify parts
d. Electric circuit diagram of the equipment, if required
e. Installation instructions, including bolt tightening torques and tightening sequences, as
necessary
f. Clear operating instructions, including:
1) Normal operations
2) Emergency operations
3) Startup operations
4) Shutdown operations
5) Lockout procedures
g. Detailed maintenance procedures
h. Troubleshooting instructions
i. Service and repair instructions
j. Assembly drawings and part breakdowns (Parts breakdown shall include description of
materials from which parts were fabricated.)
2. Lubrication list shall include the following:
a. Description of lubrication type and schedule for lubricating components.
b. Cross-references to Purchaser product brands, whenever applicable.
c. Contact information for service engineers and parts procurement.
6.0 STEAM SYSTEM
6.1 General
1. A complete, operational steam system that can achieve 100 percent uptime on-station shall be
provided.
2. One hundred percent uptime shall mean that any failure or scheduled inspection or repair of
any single piece of system equipment, valve, or section of piping shall not result in any
downtime for the FPSO.

3. Steam system shall provide steam to steam driven equipment. Steam driven equipment may
include the following:
a. Turbogenerators
b. Cargo pumps
c. Ballast pumps
d. Other services as necessary
6.2 Isolation Valves

1. Pressurized steam and feedwater piping requiring isolation shall use double block valves to
ensure that maintenance and repairs of system equipment and piping can be safely performed.
2. Locations other than those specified in item 1 above shall use single valve isolation.
3. Isolation valves shall be fitted with suitable locking devices. Locking device types shall be
subject to Purchaser review and comment.
6.3 Configuration
1. If steam driven turbogenerators are required:
a. Exhaust from steam generators condensers shall be piped to the cascade tanks.
b. Steam discharge from each of the boilers shall be crossconnected so that any one boiler
can supply steam to any turbogenerator.
2. Piping arrangement shall have sufficient redundancy and isolation valves such that any section
of the steam system piping can be isolated for maintenance and inspection, without impacting
the uptime of the FPSO.
3. Maintaining FPSO uptime includes ensuring that the FPSO can operate continuously at full
rated production capacity while the section of piping is isolated.
4. A low pressure (LP) steam system (less than 7 bar [101.5 psi]) shall provide steam to the
secondary steam consumers including:
a. Cargo and slops tank heating
b. Cargo tank wash water heating
c. Cargo pump room bilge pump
d. Domestic hot water heater
e. Process crude oil heating
7.0 STEAM SYSTEM PIPING
7.1 General
1. Purchase or fabrication of steam system materials shall not proceed without Purchaser review
and comment.
2. Depending upon the topsides utility demands, if hazardous materials may potentially enter the
steam condensate and return to the machinery space, special safety precautions shall be
installed.

3. Arrangements that may introduce hydrocarbon gases into the machinery space shall be
properly studied and a HAZOP study shall be performed to eliminate/minimize the risk of this
from occurring.
4. Item 3 above shall also apply to cargo heating requirements. As a minimum, the following
precautions shall be provided:
a. Drain inspection tanks
b. Gas detectors
c. De-oiler
5. Design pressure for a piping system shall be a minimum of 10 percent or 4 bar (58 psi) above
the maximum operating pressure, whichever is greater.
6. For services above ambient temperature, design temperature shall be a minimum of 54°F
(30°C) above the maximum operating temperature.
7. In the steam system, double valve isolation shall be provided for isolating equipment from
pressurized system piping.
8. Valves, fittings, flanges, and unions shall include identification marks that at a minimum
a. (Stamped) nominal pressure rating
b. Nominal size
c. Arrowhead indicting direction of flow (if appropriate)
d. Manufacturer’s name or mark and month and year of manufacture
7.2 Materials
1. Seamless carbon steel pipe shall be used for all steam piping.
2. Steam system valves, flanges, and fittings shall be fabricated from steel.
3. Piping schedule shall be based upon the Class requirements including a corrosion margin of
0.012 inch (0.3 mm) for superheated steam and 0.031 inch (0.8 mm) for saturated steam.
4. Pipe immediately upstream and downstream of all control valves shall have increased wall
thickness by one schedule. Increased wall thickness shall continue for a length of 8.2 feet
(2.5 meters) in each direction.
5. As a minimum, all piping 2-1/2 inches (65 mm) and above shall be Schedule 40. Smaller
piping shall be Schedule 80, minimum.
6. Boiler blowdown piping and drain piping shall be Schedule 80 at a minimum.
7. Flexible hoses shall not be used in steam systems.
7.3 Connections
1. External steam piping downstream of the boiler to the first isolation/block valve shall comply
with the marine classification society requirements.
2. On pressurized piping, flanged connections shall be used. Threaded unions shall not be used.
3. The number of flanges in the system shall be minimized. Flanges shall be installed only where
required to maintain sections of pipe.

7.4 Sizing
1. In selecting steam piping diameter, the maximum velocity (units ft./sec.) shall not exceed the
lower value of either 200 ft./sec.(60.96m/s) or 50 d where d is the pipe internal diameter in
inches.
2. For selecting piping diameter, the maximum velocity (units ft./sec.) in exhaust steam piping
shall not exceed the lower value of either 250 ft./sec. (76.2m/s) or 75 d where d is the pipe
internal diameter in inches.
3. A surface blowoff line shall not exceed 1-1/2 inches (40 mm nominal) pipe size.
7.5 Expansion Loops

1. Expansion loops shall be used in the steam system as necessary.
2. Expansion joints shall not be fitted.
7.6 Steam Strainers

1. Steam strainers shall be fitted wherever required to protect equipment or to facilitate system
operations.
2. Steam strainers shall be fitted wherever recommended by either of the following:
a. Supplier equipment installation practices
b. Marine standards and best practices
7.7 Fasteners
Fasteners shall be made from the following materials:
1. Bolts: S45C (ASTM A108-1035)
2. Nuts: S35C (ASTM A108-1045)
7.8 Gaskets
Spiral wound gaskets shall be used.
7.9 Drains
Automatic drains shall be provided throughout the steam system to prevent water hammer.
7.10 Steam Traps and Separators

1. Steam traps shall be conveniently arranged in a common location, if practical, for ease of
operation and routine maintenance.
2. To permit safe maintenance on the unit without shutting the system, steam traps shall be fitted
with:
a. Isolation valves
b. A bypass
3. Steam traps shall be fabricated from stainless steel.
4. Inlet header and piping to steam turbines shall be fitted with steam traps and separators to
prevent condensate from entering the turbine, especially during startup operations.

7.11 Stop and Drain Valves

1. For boilers connected to a common steam main:
a. Steam piping connected from each boiler shall be fitted with two stop valves.
b. Stop valves shall each be provided with a small warm-up line around the valve.
c. A drain valve shall be located between the two stop valves.
2. Stop valves shall consist of the following:
a. One non-return stop check valve (set next to the boiler).
b. A second valve of the outside-screw-and-yoke type.
3. A drain valve shall be located upstream of the main boiler discharge non-return stop check
valve.
4. High velocity steam blowing and thermal cycling of the piping shall be performed to remove
weld spatter, mill scale, and debris.
7.12 Insulation
1. Surfaces shall be insulated such that the maximum temperature is not greater than 140°F
(60°C) under all operating conditions.
2. Main steam piping lines shall be fitted with removable insulation pads to facilitate thickness
measurements after startup on-station.
3. Removable pre-molded insulation and covers shall be provided for system flanges for piping,
valves, and fittings.
4. Steam traps and the piping immediately upstream of steam traps (within 24 inches [620 mm])
shall not be insulated. Expanded metal shields shall be provided for personnel protection.
5. Insulation for the steam system piping shall comply with the DNV F-AMC requirement that
all insulation shall be as follows:
a. Protected by steel sheet cladding.
b. Easy to dismantle and assemble whenever inspection is necessary.
6. Cladding alternatives other than those in item 5 (above) shall not be applied even if the
proposed alternative is acceptable to the marine classification society.
8.0 CONDENSATE SYSTEM
8.1 Condensate Discharge

1. Condensates that can potentially be contaminated with hydrocarbon shall be led to the cascade
tank.
2. Returns shall be discharged through the oil detector and inspection tank section of the cascade
tank, including those from the following components:
a. Oil heating systems (such as diesel oil purifier heater or lubricating oil purifier heater)
b. Drain coolers
3. Gas detectors shall be installed in the cascade tank area to ensure that hydrocarbon gases do
not accumulate in the area.

4. Electrical equipment within 9.84 feet (3 m) of the cascade tank area shall be suitable for use in
hazardous areas.
5. Cascade tank vents shall be led to safe area.
8.2 Makeup Lines

1. Makeup line shall be provided from the distilled water tank to the cascade tank.
2. Makeup shall be automatic.
3. Excessive makeup water level alarms shall be provided.
8.3 Salinity Monitoring

1. Salinity indicators of the remote reading electrical type shall be provided to indicate the
salinity in the feedwater system.
2. Salinity cells shall be provided at the cascade tank outlet line.
3. High salinity levels shall initiate an alarm.
4. Salinity cells shall display as follows:
a. Locally near the cascade tank.
b. Remotely in the machinery control room.
c. Remotely in the FPSO-wide monitoring and control system.
8.4 Protection for Topsides Condensate Return Lines

To ensure hazardous gases do not accidentally enter the machinery room, condensate return lines
coming from any heated topsides process stream shall be protected with the following:
1. Flash drum located outside the machinery room.
2. Vent led to safe area.
3. Continuous online gas monitoring and suction gas detection system, employing suction
sampling.
9.0 VALVES
9.1 General
1. Valve material and type shall be suitable for the service and meet FPSO long life, low, and
easy maintenance requirements.
2. Valves shall be arranged to facilitate ease of maintenance. Special consideration shall be given
to valves installed in overhead piping or in other difficult-to-access locations.
3. Proposed Supplier and manufacturer of all valves shall require acceptance by Purchaser. This
requirement applies to valves provided by manufacturers as part of packaged equipment.
4. Unless a case-by-case written acceptance for deviations is obtained from Purchaser the
following valves shall be globe or angle type:
a. Valves in steam service.
b. Valves in the feedwater system.
5. Valves used in the steam system shall be supplied with hardened seats, Stellite or equal, in the
valve body and on the seating (sealing) surfaces of the valve disc.

6. Seat material for other valves installed in the steam system shall be fabricated from stainless
steel (SUS) 440C.
7. For cases where throttling of large steam valves (6-inch [150-mm] nominal diameter and
above) is necessary, a smaller diameter bypass valve shall be installed in parallel.
8. Valves shall have balls, seals, stuffing glands, seats, and bushings that are replaceable without
welding or cutting the valve from its line.
9. All valves except check valves shall be capable of sealing with design pressure applied from
either end of the valve.
10. Valves shall close with a clockwise motion of the handwheel or lever when facing the end of
the valve stem and be fitted with an open/close indicator.
11. Valves shall be fitted with reduction gears to facilitate operation if the required torque to
close/open the valve is greater than 50 ft-lbf (67.79N-m).
12. Globe style valves shall be of the rising stem type with stem threads external to the valve body.
13. A reduced diameter bypass with a globe valve shall be installed around valves where slow
warmup or pressurizing downstream piping is required.
14. If the potential exists for condensed water to flow through the steam system, warming up
valves shall be fitted for all large valves (4-inch [100 mm] and above).
15. Bypasses shall be installed around all control valves.
a. A valve suitable for manual throttling shall be installed in the bypass.
b. Valve shall be easily accessible.
c. The piping shall be arranged to prevent liquid from collecting in the line.
16. Double valves shall be provided upstream of all steam traps and wherever the following are
installed:
a. Drum blowdown valves.
b. Steam system vent valves.
c. Steam system drain valves.
17. Double valves shall be provided for all instrumentation installed in pressurized equipment and
steam system piping.
18. Double valve isolation shall be provided downstream of boiler feedwater pumps to isolate the
pumps from system pressure so that pump periodic maintenance can be performed safely.
19. Ball type valves shall be used as the master fuel gas trip valves and main fuel gas supply
isolation valves for each boiler.
20. Remote closure of valves located at large steam consumers shall be possible in the event of
boiler trip. This may be necessary to maintain steam pressure in the system and prevent any
other boilers operating from also tripping.
21. Valves shall be provided with a 316 stainless steel tag or band, stamped or embossed with the
valve tag number.
22. Tags shall be securely attached to the valve with stainless steel screws or rivets. Stainless steel
wire may be used in cases where stainless steel screws and rivets cannot be used.

9.2 Control Valves

1. Control valves shall be provided by a manufacturer experienced in providing similar
equipment for marine service.
2. Acceptance of all potential boiler manufacturers and Suppliers shall be obtained from
Purchaser prior to issuance of purchase orders for equipment price and schedule quotation.
3. Control valves, valve actuators, and on-valve mounted controllers shall all be provided by a
single manufacturer.
4. Valves shall be sized such that their operating range prevents them from opening as follows:
a. More than 90 percent at maximum flow
b. More than 70 percent at normal flow
c. Less than 10 percent at minimum flow
5. Sizing calculations shall be submitted for Purchaser review and comment.
6. Maximum noise under all operating conditions shall not exceed 85 dB(A) at a distance of
3.28 feet (1 m) from any control valve.
7. If the maximum allowable noise criteria cannot be achieved, HUSH trim or selected
manufacturer’s trim shall be used instead of fitting noise reduction insulation.
8. Piping within 10 pipe diameters both upstream and downstream of control valves shall be
straight.
9.3 Safety Valves

1. A minimum of two safety valves shall be installed on the boiler in compliance with
ABS SVR 4-4-1/9.
2. Boiler safety valves shall be fitted with releasing gear as required by regulatory body
requirements.
3. Boiler safety valve releasing gear mechanism shall be arranged such that the safety valves are
operable from the boiler flat.
4. Safety valves shall be tested and set in accordance with requirements of regulatory bodies.
5. High lift type safety valves shall be used.
6. Boiler and superheater safety valves shall be sized for the full rated capacity of the boiler.
7. Independent discharge piping from each boiler safety relief valve shall be provided.
a. Boiler safety valve discharge outlet piping cannot be combined for different boilers.
b. Only safety valves located on a common boiler may have discharge piping combined into
a single outlet if no other arrangement is possible and written acceptance of the
arrangement is obtained from Purchaser and Class.
c. If combined, the backpressure caused by any relieving valve shall be used in determining
the capacity of other valves installed.
8. A drain shall be installed downstream of the boiler steam drum safety valves to ensure that the
water does not accumulate in the piping.
9. Arrangement of drain in item 8 (above) shall ensure that crew safety is maintained in the event
the safety valve lifts.

9.4 Valve Mountings—General

1. Boiler valve mountings shall include, but not be limited to the following:
a. Steam stop valves
b. Feed valves
c. Blow off valves
d. Chemical feed valves
e. Water level gauge block valves
f. Steam pressure gauge valves
g. The bottom blow off valve on the water drum
2. Sufficient means of easily maintaining all valves in service shall be provided and
demonstrated to Purchaser.
3. Each type of valve shall be provided with a complete spare unit.
4. Valves shall not be installed between safety valves and boilers.
10.0 INSTRUMENTATION
10.1 General
1. A list of suppliers and manufacturers for all instrumentation shall be provided and is subject to
Purchaser review and comment.
2. Manufacturers shall use instrumentation models and suppliers that have been used for similar
instrumentation fitted in other locations on the FPSO.
3. In locations in which local pressure gauges are fitted (either in system piping or on
manufacturer-supplied equipment), gauges shall include the following:
a. Solid front design
b. SUS 304 cases
c. Glycerin-filled internals
d. 4-inch minimum diameter dials
e. Scales marked in barg or mm of water (common units shall be used throughout the FPSO)
4. Local pressure gauges shall include a scale that can read pressures up to approximately double
the pressure at which the safety valve is set for that system.
5. Pressure gauges that measure boiler pressure shall be fitted with two isolation valves on the
gauge taps. Isolation valves shall be installed as follows:
a. One valve shall be located immediately adjacent to the boiler.
b. Second valve shall be located immediately upstream of the pressure gauge.
c. No other shutoff valves shall be provided for isolating pressure gauge from the boiler.
d. Valve adjacent to the boiler shall be locked or sealed in the open position.
6. A steam pressure gauge or its connection shall contain a siphon, or Purchaser and Class
accepted equivalent device, that develops and maintains a water seal to prevent steam from
entering the gauge bourdon tube.

7. Boilers shall include a steam temperature gauge mounted at or near the boiler steam outlet
connection in a location that is easily readable.
8. Thermocouples shall be appropriate for the intended service.
9. Continuous leads shall be used for all temperature measuring instrumentation.
10. Local thermometers shall be as follows:
a. Bimetallically actuated
b. Heavy duty
c. Weatherproof
d. A dial type with 5-inch (127-mm) diameter face
e. Hermetically sealed with external micrometer pointer adjustment.
11. Thermowells shall include the following:
a. 1/2-inch national pipe thread (NPT) female connection for the measuring element
b. Flanged mounting connections
c. Constructed of SUS 316 material
12. Thermocouples, resistance temperature devices (RTDs) and thermometers shall be
interchangeable in either type thermowell, (i.e., either type sensor can be inserted in a test
well).
13. Instrumentation (including level switches) fitted to tanks shall be capable of being maintained,
replaced, and tested without the need to empty and enter tank.
14. For flow transmitters installed in horizontal pipes, the following locations for pipe taps shall
apply:
a. Steam measurement connections shall be in the horizontal plane of the pipe centerline.
b. Water measurement connections shall be in the lower half of the pipe.
10.2 Water Level

1. Each boiler shall have at least three independent means of remote indication of boiler drum
water level in addition to one flat glass-type of locally-mounted water level gauge.
2. The flat glass type local water gauge shall be Yarway brand (Tyco) glass model 4161N with a
mica shield or equal.
3. Yarway level gauge glass shall be as follows:
a. Indicator shall be internally illuminated and provide clear readings in a 180 degree
viewing arc.
b. Connections on the Yarway gauge glass shall be not less than 1/2 inch (12 mm) pipe size.
c. Gauge glasses shall be fitted with a drain cock or valve containing an unrestricted drain
opening, with an 1/4 inch (8 mm) diameter, minimum, to facilitate cleaning.
d. Gauge glass drain shall be furnished with a valve and piped to a safe discharge point.
4. Boiler steam remote reading level indicators shall comply with the following:
a. Primary display shall be in the machinery control room.
b. Secondary display shall be located at the boiler.

c. Remote water level indicators shall be:

1. Self powered
2. Differential pressure, manometer type
3. Operated by the measured fluid itself
d. Indicators shall not require any external source of energy or a secondary level of
reproduction mechanism.
e. Remote reading level transmitter sensor and alarm indicating elements shall be connected
through a magnetic coupling.
5. Connections shall be as follows:
a. From the boiler to the remote level indicators, piping or tubing connections shall be at
least 3/4 inch (20 mm) pipe size to and including isolation valve.
b. Connections from the isolation valve to the remote level indicator shall be at least 1/2 inch
(12 mm) outer diameter (OD) tubing.
c. Connections shall be completely independent of other connections for any function other
than water level indication.
6. Alarm and trip points shall be clearly marked on all water gauge level readouts.
7. Steam drums shall have two differential pressure type level transmitters to ensure a more
reliable water level control system.
8. Level transmitter used as input for drum level control logic shall be independent of level
transmitter used as input for the boiler tripping logic.
9. To eliminate condensing vapors in sensors, constant head reservoirs shall be installed for both
differential pressure transmitters fitted for remote monitoring of boiler drum level.
10. High, Low, and Low-Low water level alarms shall be provided in both the FPSO Central
Control Room and Machinery Control Room.
11. Each boiler steam drum shall be fitted with a High-High water level trip device to minimize
the potential for water carryover. Activation shall initiate boiler trip alarm.
10.3 Draft Gauges

1. Draft gauges with local readouts shall be provided in the following locations:
a. Fan outlet
b. Wind box (burner inlet)
c. Furnace
d. Uptake just prior to the inert gas suction valve
2. Three draft gauge transmitters shall be provided for each boiler, each with a separate readout
located on the boiler control console and on the FPSO-wide monitoring and control system.
3. Remote readouts shall indicate draft air pressure at the following locations:
a. Wind box
b. Furnace
c. Uptake

10.4 Furnace Draft

1. System shall be such that in the event a high furnace pressure is detected, boiler load shall
automatically be reduced.
2. If furnace pressure exceeds the high limit for a predetermined time period, boiler shall be
automatically tripped.
10.5 Smoke Indicators

1. Boilers shall be furnished with a smoke density indicator. Smoke density indicators shall be as
follows:
a. Electric type utilizing light source and receive units.
b. One indicator per boiler.
c. For continuous smoke monitoring and input to the combustion monitoring system
2. Smoke observation system shall also permit visual inspection of internal conditions inside the
exhaust duct near the same location as the electronic smoke indicator.
3. System shall include a smoke detector output that automatically initiates an excess smoke
alarm both on the machinery room boiler control consoles and FPSO-wide monitoring and
control system.
4. Excess smoke alarm point shall be adjustable by the operator.
11.0 TANKS
11.1 General
1. Tanks shall be conveniently located for operation and maintenance.
2. Local displays of tank instrumentation shall be located for convenient monitoring.
3. Tanks shall be fitted with local and remote level gauging.
4. Remote gauging shall be displayed in FPSO-wide monitoring and control system.
11.2 Drain Inspection Tank

1. One drain inspection tank shall be provided.
2. Drain inspection tank shall include the following sections:
a. Storage
b. Filter
c. Inspection
3. Drain inspection tank shall:
a. Be galvanized or coated after fabrication.
b. Have ample capacity to accommodate all heating drains at peak load conditions.
c. Be fitted with a cooling coil.
d. Include a probe which initiates an alarm on oil detection. Alarm indication shall be in both
machinery control room and FPSO-wide monitoring and control system.
4. To minimize the potential for corrosion, fresh water shall be used for cooling the drain
inspection tank. Sea water cooling shall not be acceptable.

5. Hydrocarbon gas detection shall:

a. Be provided near the inspection section of the drain inspection tank.
b. Initiate an alarm in the event any low vapor pressure hydrocarbon contaminated liquids
are returned to the tank. Alarm indication shall be in both machinery control room and
FPSO-wide monitoring and control system.
11.3 Atmospheric Drain Tank

1. One atmospheric drain tank shall be provided to collect all of the low and intermittent high
pressure steam drains.
2. Atmosphere drain tank shall:
a. Be galvanized or coated after fabrication.
b. Include level control by a floatless control and valved bypass.
11.4 Cascade Tanks

1. A minimum of two cascade tanks shall be provided.
2. Cascade tanks shall be sized and arranged such that one tank can be removed for inspection
without the need to shutdown the entire system.
3. Cascade tanks shall be adequately sized to ensure that, during normal fluctuations in boiler
loads and startup and shutdown operations, the:
a. Tank does not require added make-up
b. Tank overfill does not occur.
4. Cascade tank shall be fully insulated:
a. For personnel protection
b. To minimize heat loss
5. To protect against corrosion, cascade tank shall be coated with heat resistant paint.
6. Piping within cascade tanks shall be flanged. Welded in place piping shall not be used.
7. Cascade tank shall be enclosed complete with an air vent pipe.
8. Safe access for maintenance and inspection shall be provided.
9. Access designs shall be such that the following can be easily maintained:
a. Weirs
b. Sponges
c. Fittings
d. Instruments
10. Steam injection lines shall be installed in the cascade tanks to maintain condensate water at
203°F (95°C).
11. Commercial silencers shall be:
a. Fitted on steam injection lines in the cascade tank
b. Fabricated from stainless steel (SUS 304)
c. Installed as low as possible in the cascade tanks

12. Steam injection line to each cascade tank shall be fitted with the following:
a. Isolation/stop valve at the feed line takeoff
b. Strainer
c. Vacuum breaker
d. Temperature control valve to regulate steam flow based upon cascade tank temperatures
e. Non-return valve
f. Additional isolation/stop valve installed directly on the flange connection to each
cascade tank
13. Cascade tanks shall each be fitted with the following instrumentation:
a. Local temperature sensor
b. Remote readout temperature sensor and transmitter to provide High/Low alarms and
signal to temperature control valve
c. Sight glass
d. Remote readout level sensor with High/Low alarm
14. Separate, independent float-type level control switches shall be fitted to each cascade tank if
both of the following conditions are present:
a. Steam generating plant does not include a deaerator
b. Make-up feed is automatically supplied to the cascade tanks
15. Local instruments shall be easily visible to an operator making rounds of the machinery space.
16. Cascade tanks shall be fitted with permanent means of access for internal inspection including:
a. Handrails
b. Vertical ladders
17. Design of handrails and ladders shall be consistent with other accepted arrangements used in
the FPSO machinery space.
18. Handling arrangements for heavy components shall be provided.
11.5 Distilled Water Tanks

1. Distilled water tanks shall be separate and independent of fresh water tanks.
2. Connections between domestic fresh water and the following water systems shall be through
an air gap to prevent any possibilities of contamination of the domestic water system,
including the following systems:
a. Feedwater
b. Condensate
c. Distilled water
3. Two distilled water tanks shall be provided. Capacity of each tank shall be two times the
maximum calculated amount of water required to completely fill the boilers and the feedwater
system.
4. Distilled feedwater tanks shall be provided with piping and valve system such that tanks can
be operated independently.

5. Distilled water tanks shall each be equipped with level transmitter. Level transmitter shall
provide for the following:
a. Local level readout
b. Remote level readout at FPSO-wide monitoring and control system
c. High and low level alarm indications at FPSO-wide monitoring and control system
6. Manual hand tank level gauging capabilities shall be provided.
7. Distilled water tanks shall each be fitted with independent high-high and low-low level alarm
switches that will initiate independent level alarm indications displayed on the FPSO-wide
monitoring and control system.
12.0 BOILER CHEMICAL FEED SYSTEM
12.1 General
1. A boiler compound liquid chemical feed system shall be provided and shall consist of one
chemical compound feed tank complete with all necessary piping, valves, fittings, etc.
2. Feedwater system and chemical injection system materials shall be compatible with chemicals
used.
3. Chemical injection point shall be after the feedwater recirculation offtake for each boiler.
4. Chemical feed points shall also be provided for each boiler in the following locations:
a. boiler steam drum
b. deaerating feed tank, if included
5. Redundant boiler chemical feed pumps shall be fitted.
6. Horizontal single plunger type pumps shall be installed.
12.2 Chemical Handling Safety

1. A complete chemical handling arrangement shall be provided. Handling arrangement shall
a. Loading chemical on board the FPSO from shore.
b. Handling and storing the chemicals onboard.
c. Adding chemicals to the chemical feed system.
2. The following notices shall be posted in the areas where the boiler feedwater chemicals are
added to the feedwater system:
a. Hazardous warning placard.
b. Step-by-step procedure for safely adding chemicals to the chemical feed tank.
3. Warning placard shall be written in both English and in the native language where FPSO
facility will be located.
4. A chemical transfer pump for safely filling the chemical feed tank shall be provided.
5. Fill line for the chemical feed tank shall be fitted with a pressure gauge and check valve on the
chemical filling line.
6. Chemical fill line shall be fitted with a funnel and cap.

7. The following shall be installed within ten (10) feet of the boiler chemical feed system tank:
a. Eyewash station
b. Safety shower
12.3 Boiler Chemicals Storage

1. A one year supply of boiler feedwater treatment chemicals and reagents from Drew Chemical
Corporation or other manufacturer accepted by Purchaser shall be provided.
2. Shelf life of chemicals provided shall be at least one year from the delivery of the vessel
in the field.
3. A separate enclosed space shall be provided for boiler chemical storage.
4. Boiler chemical storage space shall be subdivided into two compartments for storage of
noncombustible chemicals.
5. Boiler chemical storage space shall be located adjacent to boiler chemical injection tank.
6. The following shall be installed within ten (10) feet of the boiler chemical storage space:
a. Eyewash station
b. Safety shower
7. Boiler chemical storage space shall be fitted with two by 100 percent exhaust fans designed
for continuous operation. Each fan shall be sized for 30 air changes per hour.
8. Exhaust duct from boiler chemical storage space shall be fitted with a fire damper.
9. Fire damper closure methods shall be by the following:
a. Manual release locally.
b. Remote release based upon the FPSO fire detection system.
c. Release through action by a fusible plug restraint.
10. Exhaust duct from the boiler chemical storage space shall terminate outside of the machinery
space in a safe area away from the crew and normal traffic.
13.0 SUPERHEATERS, ATEMPERATORS, DEAERATORS, AND LOW PRESSURE

STEAM GENERATORS (LPSGS)
13.1 Superheaters
1. If superheaters are required, the superheater for each boiler shall be as follows:
a. Externally mounted.
b. Capable of dry running to permit the unit to be removed from service without having to
stop boiler operation.
c. In order to prevent damage to the superheater tubes, operating manual shall clearly state
any precautions that must be taken when firing a boiler from cold conditions.
d. A vent valve shall be installed on the outlet of the superheater so that there can be flow
through the tubes during startup.
e. Vent line shall be arranged to allow removing air from the steam system during startup.
2. Adequate soot blowers shall be fitted to eliminate accumulation of soot deposits in the unit
during operation.

3. Adequate hand holes and inspection holes shall be provided for inspection and maintenance of
the unit.
4. A method for replacement and isolation of leaking tubes shall be provided for Purchaser
review and comment. Method shall comply with specified functional requirement for easy
maintenance.
5. A high temperature alarm shall be provided on the superheater steam flow outlet.
13.2 Attemperators
1. If an attemperator is required, attemperator shall be provided by a manufacturer experienced in
providing similar equipment for marine service.
2. Acceptance by Purchaser for all potential attemperator suppliers shall be obtained prior to
issuing purchase orders for equipment price and schedule quotation.
3. An attemperator (control desuperheater) shall be provided to maintain constant superheater
outlet temperature through the range of boiler firing rates from 50 to 100 percent maximum
design firing rates on either marine gas oil (MGO) or fuel gas.
4. Redundant attemperator units shall be provided with each unit sized for approximately
50 percent of the maximum required demand (2 x 50 percent).
5. Design outlet temperature of the attemperator shall be 302°F (130°C).
6. An attemperator of proven performance in similar applications with similar ranges of firing
rates shall be provided.
7. Attemperator design, supplier, controls, and installation shall be subject to Purchaser review
and comment.
8. Attemperator shall be an external spray type desuperheater.
9. Attemperator shall be orientated in a vertical pipe with the flow direction up.
10. High temperature feedwater shall be used as spray water.
13.3 Deaerators
1. If a deaerator is required, deaerator shall be provided by a manufacturer experienced in
providing similar equipment for marine service.
2. Acceptance by Purchaser of all potential deaerator suppliers shall be obtained prior to issuing
purchase orders for equipment price and schedule quotation.
3. Deaerator shall be located high within the machinery space to ensure that the pressure head at
the feedwater pump suction exceeds the NPSHr given the feedwater temperature. Installing a
booster pump to achieve NPSHr shall not be acceptable.
4. If a booster pump is fitted:
a. Booster pump shall be located adjacent to the deaerator to minimize suction piping losses
b. Suction piping shall be straight (no bends or elbows)
c. Suction line shall be adequately vented
5. A direct contact spray scrubber type deaerator with integral storage tank shall be provided.
6. Deaerator system shall maintain a constant operating pressure and temperature within the
deaerator through all operating ranges.

7. To ensure the efficiency of the deaerator at low flow rates, two inlet feed connections shall be
provided to allow the number of nozzles in use to be reduced.
8. Deaerator shall be a pressurized vessel.
9. Deaeration shall take place in a 2 bar (29 psi) steam environment that will heat the water to
between 239°F (115°C) to 248°F (120°C).
10. Deaerator shall be reviewed for a maximum working pressure of 5 bar (72.5 psi) at 302°F
(150°C).
11. A pressure-reducing valve shall be installed in the steam line that feeds the deaerator. Sensing
line for the valve shall be inside the deaerator. The pressure-reducing valve shall be near the
deaerator.
12. A check valve shall be provided in the steam supply line to the deaerator.
13. Steam condensate and makeup water shall be blended in the piping before being supplied into
the deaerator.
14. Makeup line shall be provided from the distilled water tank to the deaerator.
a. Makeup shall be automatic
b. Excessive makeup flow alarms shall be provided
15. Steam supply piping shall be sloped to drain to the deaerator.
16. The deaerator shall have a connection for sampling feedwater quality.
17. Means for draining the deaerator to the distilled water tanks shall be provided for performing
maintenance and inspection as may be necessary.
18. An interlock shall be provided so that it is not possible to open the drain valve without first
opening the vent valve to avoid the risk of creating a vacuum in the deaerator.
19. Deaerator shall be configured and sized to maintain oxygen content in boiler feedwater at
0.005 cc per liter throughout the full firing range of the boilers and the full boiler feedwater
makeup water range of supply rates.
20. Deaerator pressure vessel shall:
a. Be ASME stamped, or Purchaser accepted equivalent
b. Be stress relieved
c. Have a minimum 0.06 inch (1.5 mm) corrosion allowance
21. Deaerator shell and some limited internals shall be fabricated from welded steel.
22. To lay up deaerator for vessel tow to site or for periods in excess of one month:
a. Unit shall be drained and dried
b. An electric warm air blower should be installed in the unit and all openings closed
c. Unit should be periodically checked to ensure that no moisture is in the unit
23. Deaerator steam baffles, spray nozzles, atomizing valve, vent condenser, etc., shall be
fabricated from stainless steel (SUS 304L).
24. Deaerator shall be fitted with a vertical swash plate to minimize the impact of vessel motions.
25. Results of nondestructive examination (NDE) tests shall be provided in a timely manner
during the construction of the deaerator for Purchaser review and comment.

26. Water level in the deaerator’s integral tank shall be automatically regulated by a floatless,
modulating type level control that controls both the condensate spill valve and makeup feed
valve. These valves shall be provided with bypass valves.
27. Deaerator tank water level readouts shall be provided as follows:
a. Locally at the tank
b. In machinery room control center
c. In FPSO-wide machinery and control system
28. A manual valve shall be supplied to vent the deaerator. Vent valve shall be suitable for
throttling operation with a 1/8 inch (3.2 mm) drilled orifice to avoid complete shutoff
capability.
29. Deaerator shall be fitted with instruments to monitor and alarm for abnormal conditions. As a
minimum, the following instrumentation shall be provided:
a. Level (alarms: High, Low, and Low-Low)
b. Pressure (alarms: High and Low)
c. Temperature (alarms: High and Low)
d. Condensate/feedwater temperature supply (alarm: High)
30. Prior to the deaerator low level alarm being activated, an automatic makeup water supply
valve shall supply distilled water to the unit. The level at which makeup water shall be
supplied shall be adjustable without removing deaerator from service.
31. A low-low deaerator water level alarm shall trip the boiler feedwater pumps to prevent
damage to the pumps, and also trip that boiler.
32. Deaerator Overflow
a. Overflow from the deaerator shall discharge through a float type overflow trap and shall
be piped to the distilled water storage tanks.
b. Overflow trap body shall be constructed of cast steel.
c. Inside the body, a stainless steel ball float shall automatically operate a double-seated
brass valve.
d. Overflow trap body shall be bolted together in order to be disassembled for inspection and
maintenance of valve assembly.
e. A manually operated butterfly valve shall be supplied between the deaerator and the
overflow trap to allow inspection without having to shut down the deaerator.
33. Deaerator shall be fitted with a pressure safety relief valve.
34. Deaerator shall be fitted with a vacuum breaker to protect the vessel from a vacuum condition
during operation or in the event of misoperation.
35. To minimize the risk of a misoperation occurring, an interlock shall be provided so that
feedwater supply to the deaerator cannot be opened without adequate heating steam supply to
the deaerator.
36. A local pressure gauge temperature gauge and water level gauge glass shall be supplied on the
deaerator unit.
a. Gauges shall be sized suitable for the operation and design range of the deaerator.

b. Gauge glass shall cover the water level range from low-low level to overflow level.
c. Gauge glass shall be:
1) Enclosed with a protective metal shield to protect against damage from getting hit by
outside objects;
2) Mounted for protection from being accidentally broken.
37. Remote readouts of deaerator operating pressure, temperature and water level shall be
provided in the FPSO-wide monitoring and control system.
14.0 SOOT BLOWERS

1. Steam soot blowers shall be provided.
2. Soot blowers shall be provided complete with all necessary:
a. Controls
b. Air control equipment
c. Piping
d. Valves
e. Fittings
3. Soot blowers may also be the electric motor driven type.
4. Soot blowers shall be of sufficient number to adequately clean the external surfaces of the
main tube banks.
5. Depending on their position in the boilers, tube banks shall be cleaned by electric motor driven
long retractable or rotary type soot blowers containing manual operated equipment for element
withdrawal in the event of drive failure.
6. Manual operation of soot blowers shall be possible by a suitable handle in the event the soot
blower electric motor fails.
7. Soot blowers shall be provided with pressurized, air cooled floating stuffing boxes to
minimize gas leakage.
8. A pressurizing air scavenging system shall be provided for the soot blower steam supply
piping on each boiler.
9. Control panels containing the necessary pushbuttons and individual indicating lights for
remote control of each soot blower shall be provided. Controls shall include but not be limited
to the following:
a. Boiler select
b. Steam supply valve (Open/Close)
c. Steam blowing
d. Drain valve (Open/Close)
e. Running line (one for each soot blower fitted)
f. Soot blower bypass (one for each soot blower fitted)
g. Emergency top
h. Motor overload alarm

i. Time exceeded alarm

j. Soot blower abnormal alarm
k. Lamp test
l. Buzzer Stop
m. Lamp reset
10. One main soot blower control panel shall be conveniently located in the machinery control
room.
11. A local control panel shall be provided on the boiler flat at a location where individual soot
blowers can be observed by an operator.
12. Remote soot blower panels shall be capable of manual operation and automatic sequential
operation of the soot blowers.
13. Soot blower control panel shall have a mimic based graphical interface.
14. Automatic sequential blowing shall be provided. Recommended sequence shall be provided
by the boiler manufacturer.
15. An emergency stop pushbutton shall be provided to stop the sequence.
15.0 STEAM SMOTHERING SYSTEM

1. A steam smothering system for each boiler uptake shall be provided and installed.
2. The steam smothering system discharge location shall be above the boiler convection tubes.
3. Steam smothering system shall be remotely operated from a panel mounted adjacent to the
boiler control mimic panel.
4. Each boiler shall be fitted with an independent steam smothering release valve. Steam supply
shall be from the main steam header.
5. The steam smothering release valve shall be located at least 50 feet from the boiler. The valve
location shall be clearly visible, readily accessible and accepted by Purchaser and Class.
16.0 DUCTING
16.1 General
1. Minimum mean gas velocity of the boiler exhaust shall be 15 m/s.
2. Inlet ducting shall be fabricated of 0.2 inch (5.0 mm) thick steel plate construction.
3. Ducting shall be braced to prevent warping or distortion during operation.
4. Draft measurement capability shall be provided along various points between air intake
ducting and the boiler exhaust casing.
5. Inlet ducting shall be protected against corrosion. Ducting shall be galvanized and fully coated
(internally and externally).
6. If allowable based on pressure drop considerations, mitered ducting may be used.
7. If sharp 90 degree bends are necessary on the inlet side of the boiler, turning vanes shall be
installed to ensure uniform gas flow velocities into the boiler.

16.2 Exhaust Gas Ducts and Uptakes

1. Boiler exhausts shall be lead to a safe location away from the following:
a. Hydrocarbon gas sources
b. Helideck
c. Personnel
d. Accommodations
2. An exhaust gas dispersion study shall be performed to ensure the following is avoided:
a. Smoke nuisance in the accommodation area
b. Recycling exhaust gas into ventilation system intakes
3. An exhaust gas dispersion study shall be performed to determine the thermal profile around
the helideck to avoid any unacceptable thermal currents. Either of the following conditions
shall indicate an unacceptable thermal current:
a. Air temperature in area around the helideck is more than 18°F (10°C) above ambient
conditions.
b. Air temperature in the normal approach path to the helideck is more than 18°F (10°C)
above ambient conditions.
4. Effect of machinery exhaust on helideck shall be analyzed by wind tunnel model test.
5. Inner stack shall be:
a. Circular in cross-section
b. Fitted with a division plate to provide passages of equal area for each boiler;
c. Have the outlet section sized to provide an exit gas velocity at 80 percent of maximum
power of not less than 25 m/s to avoid smoke nuisance.
6. Uptakes and inner stack shall be:
a. At least 0.2 inch (5 mm) Corten steel (Type B) plate
b. Suitably stiffened
7. Uptakes and inner stack shall be supported independently of the boilers with suitable
expansion joints at the boiler gas outlet and elsewhere as may be required.
8. A high temperature alarm shall be fitted on the exhaust ducting from each boiler.
9. A local temperature gauge shall be fitted on the exhaust gas duct downstream of the external
superheater.
10. Exhaust gas duct thermal expansion calculations shall be performed to determine axial and
lateral movements to be accommodated by expansion bellows. Calculations shall be submitted
to Purchaser for review and comment.
11. For equipment such as boilers, calculated loads shall be confirmed to not exceed allowable
loads as specified by manufacturers.
12. As part of the design calculations for supports design, consideration of loads imposed by all
expansion bellows shall be verified.
13. For boilers not in service during heavy rainfalls, shielding shall be provided to prevent water
entering the exhaust gas ducts.

14. Drains
a. Exhaust gas ducts shall be fitted with drains in the event rainfall enters the duct.
b. Exhaust gas duct drains shall be fitted with a drain pot.
c. Easy access shall be provided for filling the drain pots with water.
15. Exhaust pipe drain outlets shall be fitted with flame screens.
16. Exhaust pipe outlet flame screens shall be fabricated from SUS 304 mesh (2-Mesh; minimum
wire diameter of 0.1 inch [2 mm]).
17. Wire mesh shall be adequately supported by flat bar (minimum thickness 1/4 inch [6 mm]), as
necessary.
18. Flame screen shall be bolted for easy replacement on site.
19. Surfaces shall be insulated so that maximum temperature is not greater than 140°F (60°C)
under all operating conditions.
20. Insulation for boiler uptakes shall be protected with hot dipped galvanized sheet steel.
Galvanized coating shall not be less than 0.03 inch. (0.8 mm) thick.
21. With regard to galvanized coatings, it may be beneficial to refer to the requirements specified
in ASTM A653 as part of the drawing review process.
22. Uptake arrangement shall allow access so that all internal surfaces can be periodically washed
onsite to remove any soot accumulation.
17.0 WATER AND FLUE GAS TESTING
17.1 Water Testing Station

1. A boiler water test station shall be provided by the boiler water chemical manufacturer.
2. Test station shall be:
a. Conveniently located
b. Complete with boiler water test outfit in a metal cabinet with sink
3. Complete necessary supplies shall be provided including, but not limited to:
a. Chemicals
b. Glassware
c. Sample coolers
d. Gauges
e. Thermometers
f. Additional supplies, as required
4. Sampling points shall be included in the boiler water and steam systems to test water and
steam quality at the following locations:
a. Makeup supply connection
b. Discharge from condensate pump
c. Feedwater pump discharge (at least 10 meters after the chemical injection point)
d. Boiler steam drum

5. If a deaerator is fitted, sample points shall also be provided at both the inlet and outlet of the
deaerator.
6. Boiler water test station shall be located in a separate enclosed air conditioned compartment.
7. Air from compartment space shall not be recirculated to any other compartment.
8. Cabinet sink shall be located adjacent to the testing station workbench.
9. A suitable water test kit shall be provided to test for the following:
a. Oxygen, sulfite, alkalinity, phosphate, chlorides, and hardness in the boiler water
b. Amine and pH in the condensate
10. Test kit shall be provided in accordance with the boiler water chemical manufacturer
recommendation.
11. Water treatment test cabinet shall be equipped to perform the usual tests on central supply of
fresh water cooling water (alkalinity, total dissolved solid [TDS], chlorides, free nitrite, etc.).
12. Design intent of this water treatment test kit shall be for all tests to be simply performed using
pre-measured ampules and colorimetric comparators.
13. A metal locker shall be provided for storing reagents and glassware in a manner to prevent
breakage in rough weather (including FPSO tow to site).
14. Test cabinets, manifolds, and sample coolers shall be conveniently located to the water test
station work bench.
15. The testing arrangement shall be arranged to permit simultaneously sampling from all boilers.
To provide for this capability, one complete set of primary and secondary feedwater sample
coolers for each boiler shall be provided.
16. Primary coolers shall be connected in series with secondary coolers.
17. Sampling connections shall be provided over the sink from:
a. Each boiler
b. Feedwater piping at the inlet to the boiler
18. Sample connections from each boiler to the steam drum and water drum shall be made.
19. Eyewash stations shall be installed within ten (10) feet of the boiler water testing station.
17.2 Flue Gas Testing Analyzer

1. For flue gas testing, the following shall be provided:
a. Purchaser accepted portable gas analysis set, complete with a one year supply of
chemicals, shall be furnished.
b. Set shall be capable of measuring O2, CO, and CO2 in boiler flue gases.
2. Flue gas analyzer shall be Fyrite or equal.
3. Sampling tubes for flue gas testing shall be piped from each boiler to the boiler water testing
station.
4. An aspirator shall be furnished for drawing flue gases from the boilers.

18.0 SPARE PARTS AND TOOLS
18.1 General
1. Spare parts and tools for all machinery and equipment shall be furnished as recommended by
the manufacturers and marine classification societies for three year service, including
maintenance.
a. Equipment parts recommended to be replaced within the three years of continuous
operation by original manufacturer’s Operating Manual for the equipment shall be
provided as spares.
b. The three year requirement shall assume that all machinery will operate continuously,
regardless of whether the equipment is spared or operates only intermittently.
2. If two or more units of the same model of machinery or equipment are installed for the same
duty, only one set of common spare parts shall be supplied.
3. Commissioning parts shall be provided. Commissioning parts are in addition to the
recommended spare parts for three years of service.
4. Spare parts used to correct guarantee deficiencies shall be replaced.
5. Spare parts for items that could curtail FPSO operations in case of failure shall also be
provided, even if these items are normally expected to last more than three years.
6. Spare gaskets and parts shall be provided for boiler water level gauges.
7. In addition to spare parts required in this section, any critical components identified by FMEA
studies shall be provided.
8. A minimum quantity of five (5) percent spare refractory material shall be provided.
18.2 Expansion Joints

A complete spare unit, or 10 percent of the number installed, whichever is greater, shall be
provided for each size, type and pressure rating of all mechanical expansion joints.
18.3 Valves
1. A complete spare valve or 10 percent of the full number installed rounded up, whichever is
greater, shall be provided for each size, type, and pressure rating of all valves fitted on board,
including control valves and remote operated valves. Complete valve shall include manual or
automatic power actuation device.
2. A minimum of one complete set of relief valves for a single boiler shall be provided.
3. In addition to the requirement for spare valves, additional applicable soft good sets, seats, trim
and stem, packing, seals, O-rings, etc., shall be provided for all installed valves for the first
three years of vessel operation.
18.4 Burners
1. For each boiler, at least one spare burner for each fuel type shall be provided.
2. As a minimum, 10 percent spare burner tips shall be provided based upon the total installed
quantity for all boilers.

18.5 Soot Blowers

1. A spare motor shall be provided for boiler retractable soot blowers.
2. Spare lances shall be provided for boiler retractable soot blowers.
18.6 Boiler Feedwater Pumps

1. For boiler feedwater pumps, at least one spare shaft, spare coupling and impeller shall be
provided.
2. As a minimum for boiler feedwater pumps, sufficient spare wear rings, bearings, seals,
gaskets, etc., shall be provided for three years of spares.
3. Even if not required in the manufacturer’s list of recommended spare parts for three years of
continuous operation, a minimum of two complete sets of spares (including wear rings,
bearings, seals, gaskets, fasteners, couplings, stage pieces, etc.) for all working parts in one
feedwater pump shall be provided.
18.7 Forced Draft Fans

1. As a minimum for forced draft fans, one of each of the following shall be provided:
a. Spare shaft
b. Spare impeller
c. Spare coupling
2. For forced draft fans, spare wear rings, a complete set of spare bearings, etc., shall be provided
as required for a minimum for three years of continuous operation. Spares shall be provided
even if not required in the manufacturer’s list of recommended spare parts for three years of
operation.
3. A complete spare forced draft fan assembly including motor shall be provided.
4. Spare forced draft fan shall be located in an area adjacent to the installed forced draft fans to
minimize transportation/handling distances.
18.8 Motors and Electrical Components

1. One spare motor shall be provided of each frame size for all equipment installed on the FPSO.
2. Spare packings and gaskets shall be provided sufficient for three years of use or at least
10 percent spares, whichever is larger.
3. Spare parts for electrical components such as starters, etc., shall be provided.
18.9 Bearings
1. For bearings installed on board, whichever is greater of the following shall be provided:
a. One full set of spare bearings for each common pump, fan, etc., installed on the FPSO
b. Ten percent of each bearing type (model) installed on the FPSO
c. Sufficient spare bearings for three year service
2. A “full set of bearings” shall be defined as a complete set of all bearings installed in related
equipment. For example, if a pump has three (same or different) bearings, and its motor has
two bearings, a full set would include all five bearings (assuming all bearings are replaced at
the same time.)

18.10 Instrumentation
1. One complete set of spare flame eyes installed on a single boiler shall be provided.
2. One or 10 percent (whichever is greater) spare shall be provided for each part or component of
measurement devices or system instrumentation.
18.11 Tools
1. Any special tools required for disassembly, assembly, and maintenance of steam plant
equipment shall be provided.
2. Boiler burner cleaning tools shall be provided.
3. Bearing pullers shall be provided.
18.12 Storage
1. A complete inventory, complete with their stowed locations, of all spare parts boxes and
spares not in boxes, shall be provided.
2. Spare parts shall be clearly marked or tagged with description, purchase order number,
model/part numbers, make, bar code, etc.
3. Boxes containing spare parts shall be securely locked.
4. Spare parts shall be protected from the environment and damage.
5. Spare parts stowage areas shall be well lighted, ventilated, and provided with adequate
handling equipment to move heavy boxes and parts.
6. Spare parts shall be easily transportable to work areas and equipment areas.
7. In addition to the normal supply of tools and testing equipment, all special tools required by
manufacturer’s recommendations shall be supplied and stored.
19.0 SHIPPING AND STORAGE

1. A system shall be developed and implemented for the receipt, inspection, storage,
preservation, and control of equipment and materials received at the shipyard.
2. For heavy equipment that is transported to the shipyard by barge, transportation lashing
arrangement, route, and condition of the barge vessel prior to shipping shall be subject to
Purchaser review and comment.
3. Material and equipment shall be substantially secured to prevent damage due to weather,
handling, transportation, installation, or FPSO tow to site.
4. Material and equipment arriving at the shipyard shall be examined against the shipping
invoice for the following:
a. Quantity
b. Description
c. Shortage
d. Damage
e. Other variations to shipping invoice

5. Within 48 hours, material and equipment shall be examined and the following shall be
completed:
a. Material received record
b. Report of any visual damage
6. Main equipment accessories that are stored separately from the main equipment shall be
properly marked.
7. Equipment, piping, fittings, components, and spare parts shall be properly preserved during
the construction and fabrication phases to ensure that all items are ready for commissioning in
accordance with project schedule.
8. Through agreed reporting procedures, Purchaser shall be kept fully appraised on the status of
material and equipment on site.
9. Storage of equipment shall comply with manufacturer recommendations concerning storage in
controlled environments.
10. Purchaser’s site supervisors shall have the right to carry out physical spot checks on all
material held in storage.
11. Sandblasting and painting of the FPSO internal structure and pipe shall be done before
equipment is installed, if possible.
12. Sandblasting shall not be performed around electrical equipment or instrumentation after
installation.
13. Equipment shall be covered with fire resistant tarps or wrapped with plastic during the
painting of the structure, pipe, vessels, tanks, and other equipment.
14. Equipment shall be protected from damage due to welding or other fabrication or installation
operations.
15. For boilers, all burner and pilot tips shall be wrapped to keep them clean during shipment and
storage.
16. Exposed flanges or threaded connections shall be adequately protected during shipment and
storage.
17. Pumps shall be protected internally against corrosion during shipment.
18. Equipment, components, and systems shall be properly preserved for the vessel tow to site.
19. Equipment, components, and systems shall be brought out of preservation after transportation
of the FPSO to site. The vessel status shall be brought to “ready for operation.”
20.0 TESTING
20.1 General
1. Test agendas shall be submitted at least two months prior to testing of any equipment.
2. Test documents shall be as follows:
a. Stand alone documents (not combined with any other test document)
b. Comprehensive
c. Logically formatted/organized to include all parameters and expected results for each
piece of equipment tested

3. Test agenda shall include a description of the test setup, instrumentation, and a specific step by
step test program.
4. Manufacturer Representatives
a. Manufacturer representatives shall attend all tests performed at the shipyard and onsite for
critical equipment.
b. As a minimum, representatives from the boiler, burner, and boiler control system suppliers
shall be in attendance to witness tests and make equipment adjustments and calibrations as
may be required.
5. Operational tests shall not be performed before the installation and checkout of all safeguards
and instrumentation systems have been successfully completed.
6. Supplier representatives who operate equipment as part of the commissioning work scope
shall be suitably qualified.
7. Instructions for operating equipment in Supplier provided equipment operating manuals shall
be verified during commissioning. Discrepancies found shall be corrected and operating
manuals updated accordingly as required.
8. Orifices shall be free of deposits.
9. Bolted or threaded connections shall be checked for tightness.
20.2 Factory Acceptance Tests
20.2.1 General
1. Complete, up-to-date and organized records shall be maintained. For all equipment
and systems, the following data shall be included:
a. Tests
b. Inspections
c. Reports
2. Purchaser shall be invited to attend all factory acceptance tests performed for
equipment as required by regulatory body requirements.
3. In the event Purchaser representatives do not witness the tests, a copy of the test report
shall be provided to Purchaser following the test.
4. Before shipping boilers from manufacturer to shipyard, Purchaser representatives will
perform a final inspection of the boiler.
20.2.2 Preparation for Factory Acceptance Test (FAT)

1. Quality assurance records for equipment to be tested shall be reviewed before
performing FATs.
2. For equipment such as fans, verification that minimum clearances between fixed and
moving parts are within acceptable criteria limits shall be performed. Clearances
below acceptance criteria shall be corrected to minimize the risk of contact between
moving and fixed parts as well as to avoid the generation of high pitch noised during
operations.
3. Material records shall be reviewed before performing FATs.

4. Before performing FATs, nondestructive test records that have been performed by the
manufacturer as part of quality control for equipment fabrication shall be reviewed.
5. Deficiencies discovered during the FAT shall be corrected prior to shipping equipment
to the shipyard.
6. FATs shall verify overall appearance and quality of construction of the equipment.
7. If coatings have been provided, DFT thickness shall be measured and confirmed as
part of the Factory Acceptance Tests.
8. If multiple units of the same equipment are provided, all units shall be Factory
Acceptance Tested.
20.2.3 Combustion Control and Burner Factory Acceptance Tests

1. Proper functioning of the boiler automatic combustion control system and burner
management system shall be verified by simulation during the FAT.
2. Burner parts shall be inspected to confirm conformation with Purchaser accepted
Supplier drawings and data sheets.
3. Orifice sizes and burner tips shall be checked to ensure the proper gas tip are being
used.
20.2.4 Pump, Fan, and Motor Factory Acceptance Tests

1. For pumps and fans, FATs shall be performed with the motors that will be installed on
the FPSO.
2. For forced draft fans:
a. characteristic curves shall be confirmed;
b. FAT test shall confirm that the rated motor output shall not be exceeded under all
operating conditions.
3. FATs shall include an overhaul inspection as necessary to confirm the condition of
bearings, shafts, etc.
a. Condition of all bearings shall be photographed by the equipment supplier.
b. Photographs shall be included in the official shop test report.
4. If damage to a bearing is observed, operating conditions should be documented
(periods of load, speed change, vibration data, bearing temperature data, etc.) and the
condition of the lubrication and any lubricating oil filters should be checked.
5. During FATs, alignment of couplings shall be measured to ensure alignment is within
recommended limits. Values shall be recorded and checked against the FAT alignment
calculations after final on board installation is performed.
6. FATs of pumps and fans shall include the following:
a. Check the amplitude of any pump or fan vibration on applicable casing, motor,
and bearings. Vibrations shall be less than 0.14 inch/s (rms) (3.5 mm/s [rms]).
b. Operating noise levels of the equipment shall be measured. Noise levels shall not
exceed 90 dB(A).
c. Temperature rise of all bearings shall be measured and recorded during FATs.
Temperature rise shall not exceed 72°F (40°C).

d. Insulation resistance of motor windings as well as other insulated parts shall be

measured by megger testing. Insulation resistances measured shall comply with
manufacturer data sheet and marine industry standard practice.
7. Rotor and stator winding resistances shall be measured and recorded. Values measured
shall comply with manufacturer data sheets and marine industry standard practice.
8. As a minimum, the following items shall be measured and determined as part of FATs
for electric motors:
a. Voltage
b. Frequency
c. Duty
d. Efficiency
e. Power factor
f. Service factor
g. Full load torque
h. Locked rotor torque
i. Breakdown (maximum) torque
j. Locked Rotor Current
k. Temperature tests
l. Ambient temperature
m. High potential tests
n. Motor reactances and time constants
9. An extended two hour mechanical run test shall be performed for all motor driven
pumps and fans.
10. Pump and fan two hour performance test shall include a minimum run time of 30-min.
at each test point except shut-off.
11. During the performance test, all vibration measurements shall be taken and the results
recorded on the test log at each performance point except shutoff.
12. Name, model number, and current calibration data of the vibration transducers and
analyzer used for vibration measurements shall be recorded on the test log. If
proximity probes are used, Supplier shall measure and record the slow roll runout at
each probe.
13. For pumps provided with pressurized lube oil systems, lube oil flow rate, pressure,
and bearing inlet and drain temperatures shall be recorded at each mechanical test data
point at 15-minute intervals. If tilt pad thrust bearings (Kingsbury type) are provided,
as a minimum the temperature of one pad on each side (active and inactive) of the
bearing shall be recorded at each data point.
14. Lube oil inlet temperatures shall be varied during the performance and mechanical
tests from the minimum to the maximum allowable operating lube oil temperature.
Temperature range shall not be less than that allowed in the operating manual for the
particular pump or hydraulic power recovery turbine.

15. Lube oil outlet temperatures during running tests shall not exceed normal
temperatures. If the temperature exceeds the normal value, the cause shall be
corrected and entire test repeated. Minimum run time shall be one hour.
16. If dismantling and inspection of the pump is specified, and internal rubbing wear or
sleeve bearing damage exists:
a. The cause of the problem shall be corrected.
b. The pump shall be rerun, dismantled, and reinspected.
c. The process shall be repeated until there is no measurable dimensional change or
metal transfer in the bearings or close clearance parts.
d. if upon disassembly, no evidence of rubbing or other defects is found, pumps need
not be run again.
17. A NPSH test shall be required for all previously untested impeller patterns. An NPSH
test shall also be required if the difference between NPSH available and NPSH
required is 1 meter or less.
18. If hydrodynamic thrust bearings are supplied on pumps with three or more stages, it
shall be demonstrated during test that thrust loading does not exceed 50 percent of
bearings’ continuous rating over full operating range. Load cells or other method
accepted by Purchaser shall be used to measure thrust loading.
19. Pump test results shall be plotted with the test fluid and corrected for the actual fluid
density.
21.0 COMMISSIONING
21.1 Mechanical Completion Checks (A-Scope Commissioning)
21.1.1 General
1. Prior to performing mechanical completion inspections, confirmation shall be made
that all punch list deficiencies from equipment FAT and receiving inspections are
closed.
2. Air registers and dampers shall be checked for freedom of movement.
3. Primary air control devices shall be tested for full movement.
4. Ensure expansion joint materials around the burners have been installed properly.
21.1.2 Pump Mechanical Completion Inspection

1. A mechanical completion inspection shall be performed on all pumps.
2. As a minimum, the following items shall be checked for all pump installations:
a. Confirm nameplate is correct, securely attached by screws, readily visible, and
fabricated from stainless steel.
b. Confirm the equipment has been installed in accordance with manufacturer
installation recommendations.
c. Pump foundation has been fully welded to the deck.
d. Suction strainers, where fitted, are correct and the mesh size has been recorded.

e. Piping is correctly installed consistent with accepted system diagrams and

installation practices.
f. Pump and motor are solidly mounted to the baseplate.
g. Hold down bolts are tightened to the correct torque.
h. No gaps are between equipment foot and base plate that a 0.002 inch (0.04 mm)
filler gauge cannot go through.
i. Coupling guards are correctly fitted.
j. Lube oil system is complete.
k. Seal oil system is complete.
l. Earth bonding has been correctly installed.
m. For centrifugal pumps, bonding straps shall be provided to provide electrical
continuity between pipe and pump if specified on the accepted Supplier drawing.
n. Preservation measures are intact and effective.
o. Pump skid is clean of all debris, contaminants, etc.
p. Shaft turns smoothly by hand.
q. There is no damage to the pump and accessories.
r. Pump coating has not been damaged.
s. There is no rust or damage on the side and ends of the shaft coupling.
t. Eyebolts and lifting lugs are fitted where required.
u. Easy and sufficient accessibility to the pumps for maintenance is provided.
v. Access to valves and gauges is adequate.
w. Units on instrumentation gauges are correct.
x. Safety signs and marks are posted.
21.1.3 Fan Mechanical Inspection

1. A mechanical completion inspection shall be performed on all fans.
2. As a minimum, the following items shall be checked for all fan installations:
a. Verify that ABS reviewed drawings for equipment and installation have been
received.
b. Confirm nameplate is correct, securely attached by screws, readily visible, and
fabricated from stainless steel.
c. Equipment is installed properly.
d. Setting bolt nuts seating and duct connections are installed correctly.
e. Fan housing is clean and clear of any debris.
f. Verify that fan direction of rotation is clearly marked and correct.
g. Examine if there are any pieces of cloth or other material which may be easily
sucked in near fan suction.
h. Inspect rotating parts for any contact with fixed parts.

i. Move impeller by hand, to check for easy movement.

j. Adequate access is provided for maintenance.
k. Confirm safe access is provided to fan area, as required.
l. Lubrication points are clean and the correct amount of grease has been added per
the instruction manual.
m. Earth bonding has been correctly installed.
n. Safety signs and marks are posted.
o. There is no visible coating damage to fan assembly.
p. There is no visible equipment damage or defects.
q. Coupling guards are properly installed.
r. All welded joints for the base plate structure are fully seal welded to minimize
corrosion.
21.1.4 Coupling Installations Check

1. For each pump and fan, a coupling centering check and misalignment check shall be
performed.
2. As a minimum, the following shall be checked for all coupling installations:
a. Before checking coupling alignment, check that all piping connections have been
completed.
b. Manufacturer tolerances for the coupling alignment are correct.
c. Check flange alignments for parallelism and side offset.
d. Check condition of all hold down and jacking bolts.
e. Check that there are no gaps between the pump bedplate and the liner plates.
f. Bolts and guards are in good condition and in place.
g. Check the radial concentricity of each half coupling.
h. Alignment and a record of reading is completed.
i. On completion, ensure all jacking bolts are loose and coupling guards have been
refitted.
21.1.5 Piping Mechanical Completion Inspection

1. A mechanical completion inspection shall be performed on all piping.
2. As a minimum, the following items shall be checked for all piping installations:
a. Piping is correctly installed in accordance with piping diagrams.
b. Installation of components and fastenings comply with accepted piping practice.
c. Pipe penetrations filled through nonwatertight flats, integral hull tank tops, flats,
and decks are fitted in accordance with marine piping practice.
d. Piping requirements such as slope have been accomplished.
e. Piping has no high or low points as far as practical.

f. Eccentric reducers are installed where appropriate and with the correct
orientation.
g. Piping is supported to prevent vibration and allow expansion where necessary.
h. Any temporary pieces have been removed.
i. Any strainers in the system have been cleaned after flushing.
j. Relief valves have been correctly installed.
k. Outlets from all pressure relief valves are arranged properly to avoid any possible
injury to operators.
l. Inline equipment such as valves, strainers, expansion joints, etc., is correctly
installed with the flow direction as shown on the piping diagrams and items.
m. Spectacle flanges (if fitted) are in the correct flow position.
n. Any disconnected instrumentation has been correctly restored.
o. Piping has been satisfactorily painted as applicable with no visual damage to
piping or coatings.
p. Insulation and lagging, including personnel protection, has been completed and
has no visual damage.
q. Piping marking and identification is correct and adequate.
r. Correct material of valve label plates has been used (brass valve name plate or tag
attached with SUS 316 wire).
s. Oil spray shield covers are provided for fuel oil piping flange connections.
t. Check that arrangement of valves permits ease of operation.
u. Check that arrangement of piping allows easy removal and maintenance of piping
sections, valves, and equipment.
v. Check that the spacing between piping, including flanges and insulation, is
adequate for performing maintenance.
w. Check that piping does not restrict the required minimum overhead clearances
required.
x. Check that all control valve actuators are oriented in the vertical position unless
specifically recommended otherwise by the valve manufacturer.
y. Check that installed orifice plates are:
1) Correct type
2) Correct bore size as shown on the piping diagram
3) Installed correctly
z. Check that valves that are either specified as “Locked open” or “Locked closed”
on the piping diagram are in the correct position and locked correctly.
21.1.6 Hydrostatic Piping Test

1. Inspection test records for piping hydrotested in shops shall be checked.
2. Piping pressure tested in the shop shall be identified on the flange circumference with
an ABS surveyor’s stamp provided during testing and the pressure rating.

3. Prior to pressure testing of piping, relief valves shall be removed. Special equipment
and instruments shall be bypassed.
4. Piping Hydrostatic Test Pressures
a. Piping hydrostatic test pressures shall be continuously maintained for a minimum
of one hour to detect any leakage.
b. Pressure gauges shall be placed at two locations:
1) Near the pump
2) As far away from pump as is practicable
5. Pressure testing of piping shall require the following to be recorded:
a. Test medium
b. Design pressure
c. Design temperature (steam piping)
d. Test pressure
e. Test temperature (steam piping correction factor)
f. Pressure gauge instrumentation numbers (verify calibration records)
g. Duration of test
6. System piping diagrams shall be marked to clearly show which sections have been
hydrotested and shall be continually updated to reflect the current status of hydrotests
performed to date.
21.1.7 Ducting Mechanical Completion Inspection

1. A mechanical completion inspection shall be performed on all ducting.
2. As a minimum, the following shall be checked for all ducting installations:
a. Duct installation is complete and there is no damage.
b. Ensure that all ducting is internally clean and free of foreign matter.
c. Flanges are secure and all bolts are tight.
d. Antivibration and resilient supports are secure.
e. Inlet and outlet louvers have been correctly installed in accordance with
installation diagrams.
f. Access door locations are correct and each door is fastened and sealed.
g. Earth bonding has been correctly installed.
h. If wire mesh is required on inlet/outlet flanges, installation shall comply with
accepted drawings and correctly fastened.
21.1.8 Cable Connections

1. Visual inspections shall be performed on all cable connections.
2. As a minimum, the following items shall be inspected for compliance with the
accepted fabrication drawings:
a. Proper connection and identifications of all terminals

b. Proper securing of all terminal connections (made tight)

c. Proper identification of cables including phasing
d. Correct conductor (size and type) in compliance with the drawings
3. After visual inspection of cable ends, cable continuity shall be checked at both ends of
the cable for each conductor by using a circuit tester. The section where this work is
performed shall be marked on the fabrication wiring diagram and cable inspection
records by the commissioning electrician.
4. During continuity checks, insulation resistance of the cables shall be measured.
a. Power and lighting cables shall be measured from conductor to ground.
b. For other cables, such as control, communication, instrumentation, radio, etc., the
insulation resistance test shall not be applied unless any electronic equipment can
be isolated.
5. Acceptance criteria for minimum insulation resistance shall be:
a. Over 5°M for low voltage cables
b. Over 10°M for medium voltage cables
6. A high potential (Hi-Pot) dielectric test shall be performed for medium voltage cables
only. Test voltage and time shall comply with marine classification society
requirements.
21.1.9 Motors
1. Prior to startup the following shall occur:
a. A visual inspection of all motors shall be performed.
b. Supplier requirements specified in the equipment installation manuals shall be
confirmed.
2. As a minimum, all motor installations shall be checked for the following:
a. Nameplate data
b. Area classification
c. Shaft blocking has been removed
d. Rotate motor
e. Inspect bearings (confirm properly lubricated)
f. Check grades and level of oil/grease
g. Inspect terminal box and connections
h. Terminal connections are secure
i. Protective devices
j. Operate motor heaters
k. Inspect equipment grounding arrangement
l. Measure grounding resistance
m. Measure insulation resistance of windings

21.1.10 Panels and Motor Starters

1. For all electrical panels and motor starters, a visual inspection shall be performed in
accordance with Supplier drawings, installation manuals, and accepted Supplier
fabrication drawings.
2. As a minimum, panels and motor starter installations shall be checked for the
following:
a. Nameplate data
b. Area classification
c. Check enclosure
d. Inspect assembly for damage and missing items
e. Breaker and fuse rating
f. Overload relay sized correctly (setting/adjustment)
g. Inspect cables and cable glands
h. Inspect bolted connections
i. Remove blocking and binding material
j. Inspect equipment grounding
k. Measure insulation resistance and resistance to ground
l. Securing of all terminal connections
m. Securing to foundation/support
n. Interior is clean
21.1.11 Electrical Cable

1. A visual inspection shall be performed for each electrical cable installed.
2. As a minimum, each cable should be checked for the following:
a. Cable number
b. Cable fixing interval
c. Cable bend radius
d. Cable jacket for damage
e. Mechanical protection installed
f. Cable separation distance is correct
g. Cable laying (no more than two layers)
h. Cable fixing strap condition
i. Cable gland completed (including bulkhead penetrations)
j. Cable penetrations (coaming) completed
k. Cables not painted

21.1.12 Electrical Cable Trays

1. A visual inspection shall be performed for all installed electrical cable trays.
2. As a minimum, each cable tray should be checked for the following:
a. Cable ladder routing correct
b. Width of ladder size correct
c. Separation distance between trays correct
d. Routing—no clashes
e. Ladder supported at correct intervals
f. Correct hardware used
g. Clamps tight—proper fixing to supports
h. Cable tray—proper identification
i. Sufficient margin remaining to install new cables in service
j. No sharp edges (each cable tray installations should be checked against the
drawings reviewed and accepted by Purchaser.)
k. Cable trays are correctly grounded
21.1.13 Instrumentation
1. A visual check shall be performed for all installed instrumentation.
2. As a minimum, the following items shall be checked:
a. Confirm manufacturer’s calibration sheet is complete.
b. Confirm instrument is not damaged.
c. Instrument is accessible for maintenance and clear of obstructions (local display is
visible).
d. Equipment fixings and mountings are secure.
e. Confirm all cables are correctly sized.
f. Spare entries are plugged correctly.
g. Instrument grounded in accordance with grounding practice drawing.
h. End-of-Line device are fitted and correctly rated where applicable.
i. Tag No. and labeling is correct.
j. Ingress protection (IP) rating is suitable for the area.
k. Confirm instrument installation tapping point is correct.
l. Confirm instrument tubing support and routing is adequate.
m. Instrument range is per the accepted drawing or data sheet.
n. Instrument material is appropriate for the location.

21.2 Energized Completion Checks (B-Scope Commissioning)
21.2.1 General
1. Prior to initial firing of the boiler, the following items shall be checked:
a. Ventilate N2 gas from inside boiler.
b. Inspect inside of steam drum, water drum and each header.
c. Prepare boiler filling water (water quality shall be meet required standards).
d. Prepare fuel oil for boiler start.
e. Prepare chemicals for soda boiling.
f. Confirm stable electric source.
g. Confirm proper operation of feedwater pump.
h. Confirm proper operation of forced draft fans.
i. Prepare necessary parts for initial firing (atomizers, etc.).
2. As part of B-Scope commissioning, boiler manufacturer representatives shall make all
boiler adjustments as necessary. Manufacturer data sheets and standard procedures
shall be used.
3. Items that the service engineer shall confirm prior to soda boiling include but are not
limited to the following:
a. Confirm wiring and signal loops for all sensors.
b. Calibrate pressure transmitters and temperature sensors.
c. Confirm operation of remote operated valves.
d. Confirm correct operation of control valves and actuators.
e. Confirm operation of burner fittings.
f. Check burner ignition/extinguishing sequence.
g. Adjust boiler safety devices (roughly without boiler operating):
1) Flame eye failure
2) Steam drum level low-low alarm and trip
3) Electric power failure trip
4) Manual trip
h. Participate in job risk assessments prior to starting work.
i. Read and initial chemical product data sheets.
j. Confirm that boiler is properly installed in compliance with equipment installation
drawings and instructions.
k. Verify that all instrumentation and loose equipment provided by the boiler
manufacturer are properly installed.
4. Prior to boiler initial firing, chemical cleaning of the boiler shall be performed.
5. Chemical cleaning procedure to be used on boilers shall be subject to Purchaser
review and comment.

6. Soda boiling shall be performed on board after boiler installation and completion of
all hydrotesting. Key items in the procedure include:
a. Ensure proper ventilation. Proper ventilation is critical for safety.
b. Close root valves for gauges and meters (including remote water level indicators)
except for drum-side water level gauge and pressure gauge.
c. Partially fill the boiler with water (50–75 percent) prior to introducing chemicals.
d. Dissolve chemicals in water prior to introduction.
e. Monitor the boiler so it does not exceed a maximum temperature (e.g., 122°F
[50°C]).
f. Monitor the boiler so it does not exceed a maximum pressure (e.g., 7 bar).
g. Circulate the chemicals for minimum of 8 hr.
h. Regularly check chemical acid level (maximum pH 5).
i. Drain the boiler.
j. Wash down with high pressure water jet and inspect all cleaned surfaces.
k. Refill boiler and neutralize any remaining chemicals.
l. Chemical suppliers such as Unitor, Ashland, etc., have written procedures for
safely removing scale from boilers using chemical acid cleaning.
7. Boiler manufacturer representatives shall witness the soda-boiling operation.
8. Safety precautions shall be taken during soda-boiling operation.
9. Prior to firing the boiler, an acid wash shall be performed.
21.2.2 Pump Hydrostatic Test

1. Gaskets used during hydrostatic tests shall be identical to those supplied with the
pump (i.e., use “in-service” type gaskets). Leaks of any gasketed areas or any joint
connections shall be unacceptable.
2. Pump hydrostatic test liquid shall include a wetting agent if any of the conditions
listed in API 610 exist, or if 11 to 13 percent chrome steel is used for any pressure
containing part.
21.2.3 Steam System Piping Hydrostatic Test

1. Foreign matter such as welding beads, chips, scale, dust, and debris shall be removed
from the gas and steam piping.
2. Steam system piping shall be hydrostatically tested prior to being insulated.
3. Markups of the piping and instrument diagrams shall be prepared for the steam system
to clearly identify boundaries and piping to be hydrostatically tested.
4. Steam system piping shall be hydrostatically tested at 1.5 times the design pressure
(P). Test pressure (PT) shall be correct for the difference between the stress value of
the piping material at the hydrostatic test temperature (ST) and the stress value (S) of
the piping material at the design temperature. The required hydrostatic test pressure is
given by the formula:
PT=1.5P(ST/S).

21.3 Operational Tests (C-Scope Commissioning)

1. Prior to performing onboard tests, confirmation that all safety devices are properly functioning
shall be recorded.
2. Prior to start of boiler tests, the correct fan damper setting shall be confirmed.
3. Before performing onboard tests, a walk through shall be performed to verify that all valve
positions (open/closed) are correct. Check shall include confirmation that all root valves on
local instrumentation and sensors are open.
4. All operational test data shall be recorded during commissioning tests. Purchaser shall review
for comment the test data sheets prior to the start of the commissioning tests.
5. Boiler commissioning shall be performed based upon fuel oil firing first prior to dual fuel and
fuel gas operation.
6. Tests required by Class shall be performed and witnessed by Purchaser representative.
7. For the boilers the following shall be checked:
a. remote monitoring, alarm, and trip functions
b. burner management system to confirm the operational sequence is correct according to
accepted drawings
c. operational items to include, but not be limited to:
1) Fuel oil shutoff valve open
2) Fuel oil shutoff valve close
3) Base fuel oil (FO) burner ignition
4) Additional FO burner ignitions
5) Additional FO burner extinguish
6) Base FO burner extinguish
7) Master gas valve open
8) Master gas valve close
9) Master N2 purge sequence (auto)
10) Master N2 purge sequence (manual)
11) Boiler gas valve open
12) Boiler gas valve close
13) Header N2 purge sequence (auto)
14) Header N2 purge sequence (manual)
15) Furnace purge
d. A burner control test shall be performed to include, but not limited to the following:
1) automatic control test to confirm that burners automatically ignite and extinguish
according to increasing/decreasing boiler load; along with verifying that the force
draft fan speed changes as designed
2) Remote control test
3) Fuel oil flow control test

4) Atomizing steam pressure control test

5) Air flow control test
6) Feedwater flow control test
8. Prior to firing the boilers, a fuel oil analysis and boiler feedwater analysis shall be performed
and provided to Purchaser and the boiler manufacturer representative.
9. Functionality of the master boiler controls shall be verified and shall include confirmation of
the following:
a. Master boiler load bias set (each boiler)
b. Master pressure control test
c. Master boiler trip control test
10. Measurements shall be recorded to monitor the movement of the boiler sliding feet under cold
and hot conditions. Results shall be compared to the design values.
11. For boilers, operating position changeover tests shall be performed. As part of this test,
confirmation of the boiler operation on manual control (from machinery room control center
and locally) shall be performed.
12. For the boilers and superheaters, if installed, a soot blower operation test shall be performed.
13. Operational demonstrations shall be performed to verify the following:
a. Emergency operation of the boiler (following Manufacturer recommended procedure)
b. Boiler steam drum blow down valve operation
c. Drum drain valve operation
d. Chemical feed system operation
e. Manual changeover steam/air fuel atomizing
14. After initial firing of the boiler, an internal inspection of the furnace shall be performed.
15. During boiler operation tests, the following shall be verified:
a. Boiler surface temperature check
b. Burner flame check from peep hole
c. Operation of boiler fuel oil pumps to include:
1) Pumps automatically starting/stopping with boiler load change
2) Stand-by pump starts in event of a main pump trip
16. If equipment is provided with automatic and manual control, both operations shall be tested to
demonstrate the correct functioning of each.
17. Prior to initial boiler firing on fuel gas, leak tests shall be performed on the fuel gas system
piping and all gas safety shutoff valves.
18. As part of onboard tests, the proper functioning of all motor accessories (e.g., space heaters)
shall be confirmed.

22.0 72 HOUR RUNNING TEST

1. Prior to the FPSO leaving the shipyard, machinery for the marine steam generating system
shall be fully operated continuously for a reasonable duration of not less than 72 hr.
2. A 72 hr test shall be performed with equipment operating at full capacity within the normal
operating range to confirm compliance with the technical requirements.
3. If redundant equipment is installed, each unit shall be operated for a minimum of 24 hours.
4. Temperatures within electronic panels fitted in the open machinery spaces shall be measured
to ensure that internal temperatures are less than 131°F (55°C) under all operating conditions.

FSO-SU-5157-A - FPSO Marine Steam Plants - General

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FPSO MARINE STEAM PLANTS — GENERAL

APPLICATION: FPSO MARINE AND HULL

This document is the confidential property of Chevron U.S.A. Inc. Neither

Rev Date Description Author Sponsor

December 2011 © 2008–2011 Chevron U.S.A. Inc. All rights reserved. 1 of 54

1.0 Scope ..........................................................................................................................5

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8.0 Condensate System .................................................................................................15

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18.0 Spare Parts and Tools .............................................................................................35

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2.1 Purchaser Standards

2.2 Industry Standards

2.3 Conflict Resolution

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FPSO—Floating Production Storage and Offloading

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5.2 Analysis and Test Documentation

5.2.1 Failure Mode and Effects Analysis Study

5.2.2 Steam and Heat Balances

5.2.3 Hazard and Operability Documentation

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5.2.4 Test Results Documentation

5.3 Quality Assurance/Quality Control Documentation

5.4 Purchasing Documentation

5.5 Equipment Documentation

5.5.2 Cascade Tanks

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5.6 Connection Drawings

5.7 Piping and Valve Documentation

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Table 1: Valve Information Summary

5.8 Ducting and Insulation

5.9 Boiler Documentation

5.10 Instrumentation Documentation

5.11 Expansion Calculations

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5.12 Equipment Operation Manuals

6.0 STEAM SYSTEM

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6.2 Isolation Valves

7.0 STEAM SYSTEM PIPING

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7.5 Expansion Loops

7.6 Steam Strainers

7.10 Steam Traps and Separators

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7.11 Stop and Drain Valves

8.0 CONDENSATE SYSTEM

8.1 Condensate Discharge

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8.2 Makeup Lines

8.3 Salinity Monitoring

8.4 Protection for Topsides Condensate Return Lines

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9.2 Control Valves