Training Programme on Code Awareness ASME Section I Introduction: Evolution of Codes :
Process Industries came up in the wake up rapid industrialization in European countries during 19th century. No guidelines and no common standard available. The boilers and pressure vessels operate at high h igh pressure / high temperature with critical operating medium such as chemicals, steam etc. Failures were taking place, some of them fatal and caused concern to several government.. Several committees were instituted in different countries to recommend safety features in design and construction of boilers and pressure vessels. In 1911, ASME set up committee co mmittee for formulating standard rules. In 1915, ASME brought out rules for Boilers and in 1925 , brought rules for Pressure vessels. Concept of Codes :
Safety in design and construction Specify minimum requirements System of principles or rules Mandated by state laws It is not a design handbook Revise periodically periodically based on feedback and developments Code Contents:
Permitted materials Design Fabrication/Workmanship Welding and Heat treatment Non Destructive Examination Testing & Inspection Documentation Certification and Data reports( if applicable)
ASME BOILER AND PRESSURE VESSEL CODE SECTIONS I Rules for Construction of Power Boilers
II Materials Part A — Ferrous Material Specifications Part B — Nonferrous Material Specifications Part C — Specifications for Welding Rods, Electrodes, and Filler Metals Part D — Properties III Subsection NCA — General Requirements for Division 1 and Division 2 III Division 1 Subsection NB — Class 1 Components Subsection NC — Class 2 Components Subsection ND — Class 3 Components Subsection NE — Class MC Components Subsection NF — Supports Subsection NG — Core Support Structures Subsection NH — Class 1 Components in Elevated Temperature Service Appendices III Division 2 — Code for Concrete Reactor Vessels and Containments III Division 3 — Containment Systems for Storage and Transport Packagings of Spent Nuclear Fuel and High Level Radioactive Material Material and Waste IV Rules for Construction of Heating Boilers V Nondestructive Examination VI Recommended Rules for the Care and Operation of Heating Boilers VII Recommended Guidelines for the Care of Power Boilers VIII Rules for Construction of Pressure Vessels Division 1 Division 2 — Alternative Rules Division 3 — Alternative Rules for Construction of High Pressure Vessels IX Welding and Brazing Qualifications X Fiber-Reinforced Plastic Pressure Vessels XI Rules for Inservice Inspection of Nuclear Power Plant Components ADDENDA Colored-sheet Addenda, which include additions and revisions to individual Sections of the Code, are published annually. ASME ASME 2004 code will will have addenda addenda for 05 and 06 and new revised code will be published in 2007. INTERPRETATIONS ASME issues written replies to inquiries concerning interpretation of technical aspects of the Code. The Interpretations for each individual Section will be published separately and will be included as part of the update service to that Section. They will be issued semiannually (July and December). CODE CASES The Boiler and Pressure Vessel Committee meets regularly to consider proposed additions and revisions to the Code and to formulate Cases to clarify the intent of existing requirements or provide, when the need is urgent, rules for materials or constructions not covered b y existing Code rules. Those Cases which have been adopted will appear in the appropriate Code Cases book: (1) Boilers and Pressure Vessels and (2) Nuclear Components. Supplements will be sent automatically to the purchasers of the Code Cases books upto the publication of next revised code.
ASME Section I : Rules for construction construction of Power Boilers Boilers CONTENTS A Detailed Contents Precedes Each Part, the Appendix, and the Forms Foreword ........................................................................... Statements of Policy ................................................................... Personnel ............................................................................ Preamble ............................................................................. Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part PG General Requirements for All Methods of Construction ................. Part PW Requirements for Boilers Fabricated by Welding ....................... Part PR Requirements for Boilers Fabricated by Riveting ....................... Part PB Requirements for Boilers Fabricated by Brazing ....................... Part PWT Requirements for Watertube Boilers .................................. Part PFT Requirements for Firetube Boilers ................................... Part PFH Optional Requirements for Feedwater Heater (When Located Within Scope of Section I Rules) ........................................ Part PMB Requirements for Miniature Boilers .................................. Part PEB Requirements for Electric Boilers .................................... Part PVG Requirements for Organic Fluid Vaporizers . .......................... Appendix I Mandatory — Preparation of Technical Inquiries to the Boiler and Pressure Vessel Committee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A Explanation of the Code Containing Matter Not Mandatory Unless Specifically Referred Referred to in the Rules of the Code . Data Report Forms and Guides. ......................................................... Codes, Standards, and Specifications Referenced in Text. ................................... Guide to Information Appearing on Certificate of Authorization ............................. Sample Calculations for External Pressure Design ......................................... SI Units ............................................................................. Index
Scope of Section I Boiler Proper---- Drum, Economiser, Superheater, Waterwalls etc. Boiler Exteranl Piping: Boiler Proper Proper & Boiler external ( termination) Boiler external piping shall be considered as that piping which begins where the boiler proper or separately fired superheater terminates at: a) the first circ. Joint for wekding end connections;or b) the face of the first flange in bolted flanged construction;or c) the first threaded joint in that type of conncetion; and which extends upto and including the valve or valves required by this code. Boiler External Piping technical rules governed by ASME B 31.1 covered under Section I. Non boiler external piping is not covered under Section I . It comes under ASME B 31.1 See fig PG 58.3.1 for Drum Type Boiler – Limits for Piping Definitions:
Power Boiler – a boiler in which steam or other vapor is generated at a pressure more than 15psi for use external to itself. High temperature water boiler – a water boiler intended for operation at pressure in excess of 160 psi and / or temperatures in excess of 250 deg F. A pressure vessel in which steam is generated by the application of heat resulting from the combustion of fuel (solid, liquid. Or gaseous) shall b e considered as a fired steam boiler. Unfired pressure vessels in which steam is generated shall be classed as unfired steam boilers with the following exceptions: a) vessels vessels known known as evapora evaporators tors or heat exchangers exchangers b) vessels vessels in which steam steam is generated generated by the use use of heat resulting resulting from from the operation operation of a processing system. Unfired steam boilers shall be constructed under the provision of section I or VIII Expansion tanks required in connection with high temperature water boilers shall be constructed to the requirements of Section I or VIII
A pressure vessel in which an organic fluid is vaporized by the application of heat resulting form combustion of fuel shall be constructed under the provisions of Section Section I Boiler using waste heat is termed as fired if it stems from combustion of fuel or otherwise it is termed as unfired. Boilers running on turbine exhaust is considered as unfired boiler. Presence of auxillary burner in boiler using waste heat is generally considered as fired boiler. Unfired steam boiler constructed to Section VIII must meet additional requirements UW-2(C), U-1(g), UG-16(b)3, UG 125(b), UCS- 25 Inspection mandated in Section VIII is much larger compared to Section I. Annual inspection of Section I boiler is more compared to Section VIII . Safety valves are to be furnished to Section I requirements. For pressure > 50psi radiography of all butt joints is required except for circ seam in nozzles exempted as per para UW – 11(a)4 for Section I boilers. PWHT is required for vessels constructed of Carbon Steel and Low alloy steel with some exemptions. Minimum thickness of shell and head shall be 6.25mm.
MDMT(mean design metal temperature) needs to be considered when constructed to
Section VIII . UCS – 66 curve for exemption of impact for material and thickness to be used. Sometime it may become necessary to include impact testing. Exemption of radiography available under para PW – 41.1 is not available when boiler is constructed to Section VIII. Code stamping of boilers are mandatory when it is installed in U.S.A. and Canada.
Boiler has to be registered with National Boiler Board. Section I is to be used for making new boilers to ensure safety. Repair to boilers are governed by NBIC. Authorized Inspector( AI ) and Authorized Inspection Ag ency are involved for code stamping. Manufacturer has to get accreditation from ASME for use of stamps based on the quality system renewed every three year.
Boilers could be constructed to Section I with third party inspection without code stamping. Some customers order boiler with code stamping even if the installation does not mandate purely to ensure quality of material and workmanship including inspection and testing. Data report need not be registere with NBB. MAWP ---- 2975 psi for natural circulation boiler boiler 4000 psi for forced circulation boiler
Fundamental of Section I construction :
1) Achiev Achievee safe safe boiler boiler design design 2) Materials Materials,, design ( formulae’s, formulae’s, loads, loads, allowable allowable stress, stress, and constructio construction n details ), fabrication techniques, welding, inspection, testing and certification by stamping and data reports. 3) Quality Quality control control program program intended intended to ensure ensure that that has been followe followed. d.
Materials:
Materials to ASME Section II ASTM materials adopted by ASME will have “S” prefixed to A Permitted materials by Section I is given in Para PG – 5 thru PG – 13. PW – 5 adds further requirements for material used in welded construction. Materials are to be used within the temperature range specified by the code. Allowable stress values are provided in ASME Section II Part D. Use of non ASME material not fully identified as per PG-10 or UG-10 Some of the international material specification has been added to Section II PG 5.5 gives limitation to certain material usage. Material requirements for external piping will be as per ASME B 31.1. Miscellaneous parts as per PG-11 meeting PG-42 requirements are acceptable. Non pressure part material attached to pressure parts should should be of weldable quality. Limits to Carbon is specified in PW-5.2.
Please refer to latest code for update APPENDIX Table A-360
TABLE A-360 01 CODES, STANDARDS, AND SPECIFICATIONS REFERENCED IN TEXT ASME Standards B1.20.1-1983(R1992) B1.20.1-1983(R1992) Pipe Threads, General Purpose (Inch) B16.1-1989 Cast Iron Pipe Flanges and Flanged Fittings B16.3-1992 Malleable Iron Threaded Fittings, Classes 150 and 300 B16.4-1992 Gray Iron Threaded Fittings, Class 125 and 250 B16.5-1996 Pipe Flanges and Flanged Fittings [Note (1)] B16.9-1993 Factory-Made Wrought Steel Buttwelding Fittings B16.11-1996 Forged Fittings, Socket-Welding and Threaded B16.15-1985(R1994) Cast Bronze Threaded Fittings, Class 125 and 250 B16.20-1993 Ring-Joint Gaskets and Grooves for Steel Pipe Flanges B16.24-1991(R1995) Cast Copper Alloy Pipe Flanges and Flanged Fittings B16.25-1997 Buttwelding Ends B16.28-1994 Wrought Steel Buttwelding Short Radius Elbows and Returns B16.34-1996 Valves — Flanged, Threaded, and Welding End [Note (1)] B16.42-1987(R1997) Ductile Iron Pipe Flanges and Flanged Fittings, Classes 150 and 300 B31.1-1998 & 2000 Addenda Power Piping [Notes (2), (3), (4), (5), and (6)] B36.10M-1996 Welded and Seamless Wrought Steel Pipe QAI-1 Qualifications for Authorized Inspection ASTM A 126-1995 Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings B 139-1995 Standard Specification for Phosphor-Bronze Rod, Bar, and Shapes E 8-1998 Standard Test Methods of Tension Testing of Metallic Materials E 125-63(R1997) Reference Photographs for Magnetic Particle Indications on Ferrous Castings E 186-98 Standard Reference Radiographs for Heavy-Walled [2 to 4 1 ⁄ 2 in. (51 to 114 mm)] Steel Castings E 280-98 Standard Reference Radiographs for Heavy-Walled [4 1 ⁄ 2 to 12 in. (114 to 305 mm)] Steel Castings E 446-98 Standard Reference Radiographs for Steel Casings up to 2 in. (51 mm) in Thickness ASME Performance Test Code PTC 25-1994 Pressure Relief Devices ASNT Specification SNT-TC-1A-1996 with the 1998 Recommended Practice for Nondestructive Testing Personnel Qualification Addenda and Certification ACCP, Revision 3, November 1997 Central Certification Program GENERAL NOTE: The issue date shown immediately following the hyphen after the number of the standard (e.g., B1.20.1-1983) is the effective effective date of issue (edition) of the standard. NOTES: (1) Saturated steam ratings and boiler feed and blowoff ratings for B16.5 flanges and B16.34 Standard Class valves of Material Group 1.1 are given in Table A-361. For other conditions, other materials, Special Class or Limited Class valves, or intermediate rating valves, see ASME B16.5 and ASME B16.34 for pressure–temperature limitations. (2) Note 1 of Table A-1 of B31.1, Appendix A, applies to Electric Resistance Welded A-333, Grade 6 material. (3) The weld end transition of Fig. PG-42.1 is also acceptable. (4) The use of diverter valves under Section I reheater safety valves is prohibited. (5) The minimum carbon content specified in paras. 124.2(d) and 127.2.1 and in Note (18) of Table A-2 of B31.1 shall only apply to low alloy steels whose nominal composition is 2 1/4 Cr-1 Mo. (6) Paragraph 136.4.5 (A-5) is not applicable to Boiler External Piping.
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Table A-361
SECTION I
TABLE A-361 MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP) FOR THE USE OF ASME B16.5 PIPE FLANGES AND FLANGED FITTINGS AND ASME/ANSI B16.34 VALVES — FLANGED, THREADED, AND WELDING END (STANDARD CLASS) Maximum Allowable Working Pressure (MAWP), Except as Noted Steam Service at Saturation Boiler Feed and Blowoff Line Temperature, psi (ksi) Service, psi (ksi) [Notes (1), (4)] [Notes (1), (2), (4)] 205 (1 400) 170 (1 200) 605 (4 200) 490 (3 300) 785 (5 400) 640 (4 400) 1,135 (7 800) 935 (6 400) 1,635 (11 200) 1,430 (9 800) 2,675 (18 400) 2,455 (16 900) 3,206 (22 100) [Note (3)] 3,206 (22 100) [Note (3)]
ASME B16.5 and B16.34 Class 150 300 400 600 900 1500 2500 NOTES: (1) Adjusted pressure ratings for Steel Pipe Flanges and Flanged Fittings, for steam service at saturation temperature corresponding to the pressure, derived from Tables 1A and 2, using material group 1.1 of ASME B16.5. Adjusted pressure ratings for Steel Valves (Standard Class) for steam service at saturation temperature corresponding to the pressure, derived from Tables 1 and 2-1.1A, using material group 1.1 of ASME B16.34. For other materials or design temperatures exceeding saturation temperature, see ASME B16.5 and ASME B16.34 for pressure-temperature limitations. The pressure listed is rounded to the nearest 5 psi. (2) Pressures shown include the factor for boiler feed and blowoff line service, corrected for line design temperature, as required by ASME B31.1. The pressure listed is rounded to the nearest 5 psi. (3) Rating exceeds critical pressure of water. (4) The pressure-temperature ratings provided herein apply to the flange and do not necessarily reflect the rating of the assembled flange joint. The pressure-temperature ratings provided apply to the gasketed and bolted flange joint only when the gasket and studs conform to the recommendations of ASME B16.5.
PART PG General PG-1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-2 Service Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-3 Referenced Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials PG-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-6 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-7 Forgings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-8 Castings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-9 Pipes, Tubes, and Pressure Containing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-10 Material Identified With or Produced to a Specification Not Permitted by This Section, and Material Not Fully Identified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-11 Miscellaneous Pressure Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-12 Gage Glass Body and Connector Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-13 Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design PG-16 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-17 Fabrication by a Combination of Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-18 Hydrostatic Deformation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-19 Cold Forming of Austenitic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-21 Maximum Allowable Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-22 Loadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-23 Stress Values for Calculation Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-25 Quality Factors for Steel Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-27 Cylindrical Components Under Internal Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-28 Welded Access or Inspection Openings Under External Pressure . . . . . . . . . . . . . . . . . PG-29 Dished Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-30 Stayed Dished Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-31 Unstayed Flat Heads and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Openings and Compensation PG-32 Openings in Shells, Headers, and Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-33 Compensation Required for Openings in Shells and Formed Heads. . . . . . . . . . . . . . . PG-34 Flanged-in Openings in Formed Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-35 Compensation Required for Openings in Flat Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-36 Limits of Metal Available for Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-37 Strength of Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-38 Compensation for Multiple Openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-39 Methods of Attachment of Pipe and Nozzle Necks to Vessel Walls. . . . . . . . . . . . . . PG-42 General Requirements for Fittings, Flanges, and Valves . . . . . . . . . . . . . . . . . . . . . . . . . PG-43 Nozzle Neck Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-44 Inspection Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-46 Stayed Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-47 Staybolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-48 Location of Staybolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-49 Dimensions of Staybolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52 Ligaments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-53 Ligaments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-55 Supports and Attachment Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boiler External Piping and Boiler Proper Connections PG-58 Outlets and External Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-59 Application Requirements for the Boiler Proper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design and Application PG-60 Requirements for Miscellaneous Pipe, Valves, and Fittings . . . . . . . . . . . . . . . . . . . . . . PG-61 Feedwater Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Valves and Safety Relief Valves PG-67 Boiler Safety Valve Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-68 Superheater and Reheater Safety Valve Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-69 Certification of Capacity of Safety and Safety Relief Valves . . . . . . . . . . . . . . . . . . . . PG-70 Capacity of Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-71 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-72 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-73 Minimum Requirements for Safety and Safety Relief Valves . . . . . . . . . . . . . . . . . . . . Fabrication PG-75 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-76 Cutting Plates and Other Stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-77 Plate Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-78 Repairs of Defects in Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-79 Tube Holes and Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-80 Permissible Out-of-Roundness of Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-81 Tolerance for Formed Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-82 Holes for Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Tests PG-90 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-91 Qualification of Inspectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-93 Inspection and Repair of Flat Plate in Corner Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-99 Hydrostatic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-100 Hydrostatic Deformation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Certification by Stamping and Data Reports PG-101 Heating Surface Computation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COPYRIGHT American Society of Mechanical Engineers Licensed by Information Handling Services
PG-104 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105 Code Symbol Stamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-106 Stamping of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-107 Field Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-108 Stamping for Field Assembled Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-109 Stamping of Pressure Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-110 Stamping of Safety Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-111 Location of Stampings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-112 Manufacturers’ Data Report Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-113 Master Data Report Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figures PG-19 Cold Forming Operations for Flaring, Swaging, and Upsetting of Tubing . . . . . . . . . PG-28 Maximum Internal Projection of Welded Access or Inspection Openings. . . . . . . . . . PG-31 Some Acceptable Types of Unstayed Flat Heads and Covers . . . . . . . . . . . . . . . . . . . . PG-32 Chart Showing Limits of Sizes of Openings With Inherent Compensation in Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-33 Chart for Determining Value of F . F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-36 Limits of Reinforcement for Typical Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-36.4 Some Representative Configurations Describing the t e Reinforcement Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-38 Illustrations of the Rule Given in PG-38.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-42.1 Welding End Transitions Maximum Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-46.2 Acceptable Proportions for Ends of Through-Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52.1 Diagram for Determining the Efficiency of Longitudinal and Diagonal Ligaments Between Openings in Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52.2 Example of Tube Spacing With Pitch of Holes Equal in Every Row. . . . . . . . . . . . . PG-52.3 Example of Tube Spacing With Pitch of Holes Unequal in Every Second Row. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52.4 Example of Tube Spacing With Pitch of Holes Varying in Every Second and Third Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52.5 Example of Tube Spacing With Tube Holes on Diagonal Lines . . . . . . . . . . . . . . . . . PG-52.6 Diagram for Determining Equivalent Longitudinal Efficiency of Diagonal Ligaments Between Openings in Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-58.3.1 Code Jurisdictional Limits for Piping — Drum Type Boilers . . . . . . . . . . . . . . . . . . . .
PG-58.3.2 Code Jurisdictional Limits for Piping — Forced-Flow Steam Generator With No Fixed Steam or Waterline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-59.1 Typical Boiler Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-60 Typical Arrangement of Steam and Water Connections for a Water Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-67.4 Requirements for Pressure Relief Forced-Flow Steam Generator. . . . . . . . . . . . . . . . . . PG-80 Maximum Permissible Deviation From a Circular Form e for Cylindrical Parts Under External Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.1 Official Symbols for Stamps to Denote The American Society of Mechanical Engineers’ Standard for Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.2 Official Symbol for Stamp to Denote The American Society of Mechanical Engineers’ Standard for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.3 Official Symbol for Stamp to Denote The American Society of Mechanical Engineers’ Standard for Welded Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.4 Official Symbol for Stamp to Denote The American Society of Mechanical Engineers’ Standard for Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-106 Form of Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tables PG-19 Post Cold-Forming Strain Limits and Heat-Treatment Requirements . . . . . . . . . . . . . . PG-39 Minimum Number of Threads per Connection .
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PART PW General PW-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials PW-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design PW-8 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-9 Design of Welded Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-10 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-11 Radiographic and Ultrasonic Examination of Welded Butt Joints . . . . . . . . . . . . . . . . . PW-13 Head-to-Flange Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-14 Openings in or Adjacent to Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-15 Welded Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-16 Minimum Requirements for Attachment Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-19 Welded-in Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fabrication PW-26 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-27 Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-28 Welding Qualification and Weld Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-29 Base Metal Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-33 Alignment Tolerance, Shells and Vessels (Including Pipe or Tube Used as a Shell). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-34 Alignment, Tube and Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-35 Finished Longitudinal and Circumferential Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-36 Miscellaneous Welding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-38 Preheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-39 Requirements for Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-40 Repair of Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-41 Circumferential Joints in Pipes, Tubes, and Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-42 Joints in Valves and Other Boiler Appurtenances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-43 Loading on Structural Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Tests PW-46 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-47 Check of Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-48 Check of Welder and Welding Operator Performance Qualifications . . . . . . . . . . . . . . PW-49 Check of Heat Treatment Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-51 Acceptance Standards for Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-52 Acceptance Standards for Ultrasonic Examination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-53 Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-54 Hydrostatic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figures PW-9.1 Buttwelding of Plates of Unequal Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-9.2 Prohibited Welded Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-16 Load-Carrying Paths in Welded Nozzle Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-16.1 Some Acceptable Types of Welded Nozzles and Other Connections to Shells, Drums, and Headers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-16.2 Some Acceptable Forms of Welds for Lugs, Hangers, and Brackets on Shells, Drums, and Headers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-19.4(a) Some Acceptable Types of Diagonal Braces for Installation by Welding. . . . . . . . . . PW-19.4(b) Unacceptable Types of Diagonal Braces for Installation by Welding. . . . . . . . . . . . . . PW-43.1 Chart for Determining Load Factor, L Factor, L f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-43.2 Method of Computation of Attachments to Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-53.1 Test Specimens From Longitudinal Welded Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . PW-53.2 Method of Forming Longitudinal Test Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-53.3 Details of Test Specimens
................................................... Tables PW-11 Required Radiographic and Ultrasonic Examination of Welded Butt Joints . . . . . . . . PW-33 Alignment Tolerance of Sections to Be Buttwelded. . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-39 Mandatory Requirements for Postweld Heat Treatment of Pressure Parts and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-39.1 Alternate Postweld Heat Treatment Requirements for Carbon and Low Alloy Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-43.1 Tube Attachment Angle Design Factor, K Factor, K
COPYRIGHT American Society of Mechanical Engineers Licensed by Information Handling Services COPYRIGHT American Society of Mechanical Engineers Licensed by Information Handling Services COPYRIGHT American Society of Mechanical Engineers Licensed by Information Handling Services COPYRIGHT American Society of Mechanical Engineers Licensed
by Information Handling Services Mech Anica
l Engineers Licensed by Information Handling Services
Design: Design by rules: a process process requiring the determination determination of loads, the choice of design
formula and selection of appropriate design stress for material used.(PG 16 thru 55). Design loads to be based on the anticipated weight and other loads to be carried. Hydrostatic Deformation or Proof Test( PG -18, Appendix A22 ): experience based method used to establish a safe design pressure for component for which no rules are given or when strength cannot be calculated with satisfactory assurance of accuracy. Allowable Design Stress: Stress: Factor is 3.5 ie UTS divided divided by 3.5 ( from 1999 addenda ) Design Loads: Initially only it was internal working pressure. Now we have to take additional loading as per PG-22 such as weight of boiler boiler and its contents, seismic seismic loads, wind loads, thermal loads etc. MAWP (maximum allowable working pressure ) is the term used in Section I Designer has to select the MAWP and the design temperature. Only MAWP is stamped on the boiler. PG-27 is to be reffered for tube and pipe design. Bend thinning allowance need to be added to ensure finished bend will meet the minimum thickness required as per calculation.( table 102.4.5 of B31.1) Corrosion/erosion allowance are to be added to minimum thickness requirement. Safety valve requirements are covered under PG 67 thru PG 73 Fabrication: this aspect is covered under Para PG 75 thru PG 82. Welding aspects are
covered under PW chapter of Section I. Tolerances for drums and ellipsoidal heads are given. Fabrication process should not injure the material. Effect if any shou ld be removed. Transition for unequal thickness shall be provided by means of taper of 1:3 minimum All welding shall be carried out as per ASME Section IX. WPS, PQR, WPQ will be approved by AI. Welder or welding operator has to identify identify the seam welded by him by stamping or recorded in documents.
PWHT shall be carried out as per PW-39 Weld acceptance criteria for reinforcement as PW 35, 41.2.2, 35.1 Preheating as per non mandatory appendix A100 to be followed Production Test plates to be provided and tested to the requirements of code. CS material P no.1 is exempted. Refer para PW 53 Non Destructive Examination:
RT, UT(alternate or supplement), MPI, LPT (DPT) are the various NDT methods employed . It is covred in detail in ASME Section V Visual Inspection is must for piping to B31.1 PW11 calls for extent of examination . Acceptance Ac ceptance standard is given in PW 51 & PW 52. NDT procedures are to be prepared to meet SNT-TC-1A published by ASNT or to CP189 of ACCP NDT operators have three levels of qualification Level I, II, III Radiographs are to retained for five years. Exemption for radiography as per PW 41. Hydrostatic Testing:
Requirements are given in PG 99 and PW 54. Only water is to be used for testing. Temperature of water 70deg F to 120 deg F. Below 70deg F not permitted as material can fail due to brittleness. Test pressure will be 1.5 times MAWP. Overpressure not to exceed 6% For forced flow steam generator initially test for hydro at 1.5 times MAWP and then reduce to 1.25 times MAWP for closer examination. Attachments may be welded after PWHT on P no.1 materialif thickness is below 19.6mm and if 200deg f preheat is applied applied when thickness exceeds 19.6mm. This is as per para PW 54.
AI is the independent third party. AIA is the firm employing AI.
AI is qualified by NB B&PV I
PG 90 stipulates duties of AI and manufacturer for constructing coded equipment. Certification is done by stamping and signing of data reports. reports. Refer para PG 104, PG 112, PG 113 Data report is to be registered with National Boiler Board Code Stamps under Section I S : Power Boiler V : Safety Valve A ; Boiler assembly E : Electric Boiler PP: Pressure piping
Quality Control System : Description is given in para PG 105 .4 COPYRIGHT American Society of Mechanical Engineers Licensed by Information Handling Services
PYRIGHT American Society of Mechanical Engineers License
