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Sect. I Course 1

LR INSURANCE, INC.Working together for a safer world

LR INSURANCE INC

ASME Boiler and Pressure Vessel Code

General Requirements of

ASME Section I 2013

Rules For The Construction Of

Power Boilers

LR Insurance, Inc.Working together for a safer world

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Sect. I Course 2


Content

1. Introduction, LR and LR Insurance Inc

2. Organisation, Content and Structure of Section I

3. General Requirements for all Methods of Construction

4. Requirements for Methods of Fabrication

Welding---Riveting---Brazing

5. Requirements for Types of Boilers

Watertube---Firetube---Feedwater Heater---Miniature---Electric---Organic Fluid Vaporizer---

Heat Recovery Steam Generator

6. Mandatory and Nonmandatory Appendices


Lloyds Register.

The worlds first ship classificationSociety - founded in 1760

We are not an insurance company anddo not have any connections with

Lloyds of London

We are a not for profit organisation we do not have any shareholders

Our business is governed by ourGeneral Committee, the members of

which are drawn from the industries

which we serve

Our purpose is to to promote safety of life and

property

to improve overall businessperformance in the industries we

serve

We achieve this by securing hightechnical standards of design,

construction, maintenance and

operation

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Sect. I Course 3


LR Insurance, Inc.

Workingtogetherfor a safer world

Workingtogetherfor a safer world

ASME Section I General Information

2013 Edition

5 June 2014

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Sect. I Course 4

Boilex Exhibition 5 June 2014

ASME Certification Mark and Designators


General Requirements for all Methods of Construction - PG

Organisation, Content and Structure of Section I

General requirements for all methods of

construction (PG)

Requirements for methods of fabrication

Welding (PW), Riveting (PR), Brazing (PB)

Requirements for types of boilers Watertube Boilers - PWT Firetube Boilers - PFT Feedwater Heater - PFH Miniature Boiler - PMB Electric Boilers - PEB Organic Fluid Vaporizer - PVG Heat Recovery Steam Generators - PHRSG

Mandatory and Nonmandatory Appendices

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Sect. I Course 5


General Requirements for all Methods of Construction

Service Limitations

Boilers in which steam or vapouris generated at a pressure of more

than 15 psig

High temperature water boilersintended for operation at

pressures exceeding 160 psig (1.1

Mpa) and / or temperatures

exceeding 120 C



Materials

Shall conform to one of the specifications givenin Section II and shall be limited to those that

are listed in the Tables of Section II, Part D.

Further limitations are given in PG-5 General,PG-6 to PG-14 for plates, forgings, castings, pipes

and tubes, miscellaneous pressure parts, gage

glass body, stays and rivets

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Sect. I Course 6



Design

Shall conform to the general design requirements and in

addition to the specific requirements given in the applicable

parts pertaining to the methods of construction

Minimum thickness of any boiler plate under pressure shall be

inch (6 mm) except for electric boilers constructed under

PEB

Minimum thickness of plates to which stays may be applied in

other than cylindrical outer shell plates shall be 5/16 inch (8

mm)

When pipe larger than NPS 5 (DN 125) is used in lieu of

plate for the shell of cylindrical components under

pressure, its minimum wall shall not be less than the

smaller of 1/4 in. (6 mm) or the minimum wall thickness of

Standard wall pipe listed in ASME B36.10M, Table 1.

When no rules are given and it is impossible to calculate, this

may be done by appropriate analytical methods, the

appropriate use of rules from other design codes or, as

permitted by PG-18, by proof test.



Design

Loadings are to be considered

Hydrostatic head

Other stresses that increase the average stress by more than 10 including

Weight of component and its content

Method of support

Quality factors for steel castings to be considered

Design formulas are given for

Cylindrical components under internal pressure

Dished heads (stayed and unstayed)

Unstayed flat heads and covers

Openings and compensations

Stayed surfaces

Ligaments (definite or not definite patterns)

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Sect. I Course 7



Boiler external piping and boiler proper connections

Boiler external piping

Materials, design, fabrication, installation and testing :defined in ASME B 31.1 , Power Piping

Boiler proper

Common to steam, feedwater, blow-off and drain systems

Requirements for miscellaneous pipe, valves and fittings

Water level indicators

Water columns Connections

Pressure gauges



Overpressure Protection Requirements

Boiler (PG-67)

each boiler shall have at least one pressure relief valve If more than 500 ft (47m) of bare tube water-heating

surface, or an electric boiler has a power input of more than

1,100 kW, it shall have two or more pressure relief valves

Capacity of pressure relief valve(s) shall not allow the boiler

to rise the pressure more than 6 above the highest

pressure at which any valve is set and in no case to more

than 6 above the MAWP

Minimum relieving capacity for all type of boilers shall notbe less than the maximum designed steaming capacity at the

MAWP of the boiler

One or more pressure relief valves shall be set at or belowthe MAWP. Additional valves: setting shall not exceed the

MAWP by more than 3

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Sect. I Course 8




Superheater and Reheater (PG-68)

Every attached superheater shall have one or morepressure relief valves in the steam flow path between the

superheater outlet and the first stop valve

Discharge capacity may be included in determining thenumber and size of the safety valves for the boiler

Every separately fired superheater shall have one or moresafety valves having a discharge capacity equal to 6 lb/ft

(29 kg/m) of steam per hour of superheater surface

Every reheater shall have one or more safety valves withrelieving capacity of at least equal to the maximum steam

flow for which the heater is designed




Certification of Capacity of Safety and Safety Relief Valves

Manufacturer of safety and safety relief valves need todemonstrate to ASME a QC Programme and to test and receive

certification on the relieving capacity for each type of valve

Capacity test are to be conducted at authorized places by themanufacturer and an ASME authorized observer

Following tests by the manufacturer all tests will be repeated atthe test labs of the National Board in Ohio

Agreement between the results of the 2 labs shall be within 2

Upon completion of satisfactory tests and certification themanufacturer may stamp each valve with the V Code Symbol

A Certified Individual of the manufacturer shall beresponsible to verify the documentation and to s ign the

applicable Certificate of Conformance (Form P-8) for each safety

or safety relief valve

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Sect. I Course 9




MINIMUM REQUIREMENTS FOR PRESSURE RELIEF VALVES (PG-73)

Pressure relief valves shall be either direct spring-loadedsafety valves, direct spring-loaded safety relief valves, or

pilot-operated pressure relief valves.

Power-actuated pressure relieving valves shall only be usedfor applications specified in PG-67.4.1.

Deadweight or weighted lever safety valves or safety reliefvalves shall not be used.



Fabrication, Inspection and Test

Fabrication of all boilers shall conform to the generalfabrication requirements in PG and in addition to the specific

requirements that pertain to the methods of construction

used

Plate identification to be kept or coded system to beused

Out of roundness of cylindrical shell within a limit of 1

Requirements for tube holes and holes for stays to beconsidered

Corner joints to be MT or PT tested

Each boiler, superheater, waterwall, economizer, any otherCode stamped item or component and boiler external piping

to be inspected by an AI

Duties of the AI are identified in PG-90.1

Hydrostatic pressure tests

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Sect. I Course 10



Certification and

Stamping

Guide to information

appearing on Certificate

of Authorization

S Designator for Power Boiler

A Designator for Assembly

PP Designator for Power Piping

M Designator for Miniature Boiler

E Designator for Electric Boiler

V Designator for Pressure Relief

Valve for Boiler



Contd Certification and Stamping

Hard stamping is required however in addition each manufacturer shall

furnish a metallic plate with the required data reproduced; this plate

shall be readily visible from the operating floor or platform

Location of stamping and required data is clearly defined

External piping > NPS 2 (DN 50) to be properly stamped with ASME

Certification Mark

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Sect. I Course 11



Manufacturers Data Report Forms

P2 - for all types of boilers except watertube and electric

P2A - for all types of electric boilers

P2B - for electric superheaters and reheaters

P3 - for watertube boilers, superheaters, waterwalls, economizer

P3A - for engineering contractors having design responsibility

P4 - for boiler parts

P4A - for fabricated piping, shop and field welded

P4B for field-installed mechanically assembled piping

P5 - for all items of field assembled process steam generators (summary)

P6 - supplementary sheet to record additional data

P7 - for safety valves

Data Reports are to be furnished to the purchaser, inspection agency and

the authority at the place of location


Requirements for Boilers fabricated by Welding Part PW

General Welding Requirements

Welding and qualification of procedures and

personnel is the responsibility of the manufacturer

and shall be in accordance with Section IX

Code welding may be done by welders employed

by the manufacturer or, under certain conditions,

by welders not employed by the manufacturer

Joints shall be full penetration butt welds, with

some exceptions

Joints between material of unequal thickness shall

be tapered

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Sect. I Course 12


Requirements for Boilers fabricated by Welding

Nondestructive Examination

Unless exempted by table PW-11 all longitudinal

and circumferential welded butt joints shall be

RT examined through their entire length

UT allowed only under special conditions

RT and UT to be in accordance with Section V

Qualification of personnel to SNT-TC-1A or CP-189



Welded Connections

Requirements for calculation of the weld strength to

be considered including stress correction factors

(PW-15)

Welding details for connections are given in PW-16

Full penetration from one or both sides Partial penetration from both sides

Fillet welds from both sides

Fillet and partial penetration welds on oppositesides

Special requirements for necks and tubes up to and

including NPS 6 (DN150) attached from one side only

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Sect. I Course 13



Fabrication

Alignment tolerances to be considered, see PW33

Maximum reinforcement to be considered, see PW-35

Repair of Defects

Repair welding in general is allowed, even under

special conditions without PWHT

The area is to be MT or PT examined before and after

repair welding

Limits for repair are given for the maximum depthand size of the defective area



Postweld Heat Treatment (PWHT)

Applicable to boiler proper and parts thereof - not

applicable to external piping

All welded pressure parts shall be given a PWHT at a

temperature specified for the various P-Number

groupings , see tables PW-39 and PW-39.1

Exemptions for heat treatment are given in the notes ofthe tables

Weldments may be heat treated by any of the following

methods

Heating the complete assembly as a unit

Heating sections of assemblies

Local PWHT by heating a circumferential bandaround the weldment

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Sect. I Course 14



Test Plates

Test plates are required for cylindrical pressure parts such as drums and shells

Test plates are not required for cylindrical pressure parts such as pipe, tubes and headers

and all cylindrical pressure parts of P-No 1 materials

Test plates shall be prepared from plate of the same material specification, same or

greater thickness as the weld at the joint , same welding procedure

Test plates be welded as continuation except for vessels with circumferential welds only

When noncylindrical pressure parts are not integral with the vessel, a test plate shall be

provided of a thickness not less than that of the parts

For several pressure parts of any one design welded in succession of the same material

covered by the WPS, a test plate is required for each 200 ft (60m)

t of the thinnest and thickest plate shall not differ by more than inch (6mm)

Test specimen (2 tension tests (1 transverse + 1 all weld metal) and 1 bend test

transverse to the welded joint) are to be removed as specified and tested

For plate thicknesses less than 5/8 inch (16mm) the all weld metal test may beomitted



Hydrostatic Pressure Tests

All welded parts are to be subjected to a hydrostatic test

pressure of not less than 1,5 times the MAWP

Test may be made either in the shop or field

Welding of non pressure parts to pressure parts may be

performed after hydro test without requiring another hydro

test under the following conditions :

Inspection by the AI

Pressure part material limited to P1 materials

Non pressure parts limited to carbon steel with C < 0,2or any P1 material

Welding by stud or fillet welding, the throat notexceeding the lesser of 0,7 times the thickness of the

pressure part or inch (6 mm)

Minimum of 200 F (95 C) preheat shall be appliedwhen the pressure part thickness exceeds inch (19mm)

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Sect. I Course 15


Requirements for Boilers fabricated by Riveting or Brazing

Fabrication by Riveting

Manufacturers using riveted constructions shalluse the 1971 Edition of Section I

Fabrication by Brazing

This Part is similar organized as the Part for welding

Brazing processes are specified

Service restrictions due to temperature limits

Brazing procedures and personnel to be qualified in accordance with Section IX

Design to be in accordance with the rules of this Part and in conjunction withPG as well as the Part pertaining to the method of fabrication

Joint efficiency factor for all joints shall be 1

Visual examination required


Requirements for Watertube Boilers Part PWT

This part is applicable to watertube boilers and parts thereof

Is not applicable for external piping

Design to be in accordance with PG and specific requirements of this part

Material to conform to specification in Section II and for which stress values are given

Tube wall thickness

Either to be calculated or table PWT-10 may be used in lieu of the formulafor SA-178 Gr A, SA-192 and SA- 226 provided the maximum mean wall

temperature does not exceed 700F (370C)

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Sect. I Course 16


Requirements for Watertube Boilers

Tube connections

Expanded and flared

Expanded and beaded

Expanded, flared, seal welded and re-expanded

Expanded, seal welded and re-expanded or

seal welded and expanded after welding

Firing doors shall be of the inward-opening type unless

such doors are provided with substantial and effective

latching

Minimum size of an access or fire door opening different

for furnace dimensions greater 24 inch (600 mm) or

smaller 24 inch

12 x 16 inch (300 x 410 mm) or 15 inch (380 mm)when circular

2 x 3 inch (70 x 89 mm) or 2 openings with aminimum size of 1 inch (25mm)


Requirements for Firetube Boilers Part PFT

Design to be in accordance with PG and specific requirements of this part

Material to conform to specification in Section II and for which stress values are given

Attachment of heads and tubesheets

By flanging and butt welding

By fillet welding an outwardly or inwardly flanged tubesheet to the shell

By welding an unflanged tubesheet to the shell

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Sect. I Course 18


Requirements for Firetube Boilers

Fireside Access and Inspection Openings

Size and types of access or fire door openings Size and types of inspection openings for the various boiler

types

Domes

Welding, location and size to be considered

Method of Support

Design and attachment according to PG-22.1 + PG-55

Piping, Fittings and Appliances

Requirements for water level indicators, feed- and blow-offpiping to be considered

Thickness of Furnaces and tubes under external pressureand MAWP

Design temperature is a critical factor MAWP to be determined with PFT-51


Requirements for Feedwater Heater - PFH

Design requirements

If located within the limits of Section I piping, then

Section I rules are applicable

Construction to Section VIII Div.1 nevertheless possible,

provided :

Section VIII Div. 1 rules (UW-2c) are applied

MAWP of the primary (feedwater) side limited

Design temperature of tubes specified

Heater to be stamped with U symbol and U-1Data Report required

Nameplate per UG-119 with additional information

Master Data Report with additional information

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Sect. I Course 19


Requirements for Miniature Boilers- Part PMB

Limits of miniature boilers

16 inch (400 mm) inside diameter of shell

20 ft (1.9 m) heating surface

5 ft (o.14 m) gross volume

100 psig (7oo KPa) MAWP

The rules in this part shall supplement PG requirements and take precedence over them

when there is a conflict when any of the limits are exceeded, the rules for power boilers

shall apply

Materials and thickness requirements

Materials to conform to specifications in Section II

Seamless and welded shell from pipe not less than 3/16 inch (5.0 mm)

Shells or heads made from plate not less than inch (6.0 mm) Heads used as tubesheets, with tubes expanded, not less than 5/16 (8.0mm)

Due to small size, requirements for identification of material need not be met


Requirements for Miniature Boilers

Design requirements

Washout or inspection openings required depending on size

Feedwater and blow-off connections required

Water gage(s) to be attached at defined level

All valves, pipe fittings and appliances connected shall be equal at least toclass 125 (PN 20) or class 150 (PN 20)

Each boiler to be equipped with a sealed spring loaded safety valve of not

less than NPS inch (DN 15)

Steam stop valve required

Hydrostatic pressure test

Each boiler shall be subjected to a hydrostatic pressure test of 3 times theMAWP and shall be inspected while under pressure

Different test pressures required for boilers with mechanically assembledboiler external piping or trim

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Sect. I Course 20


Requirements for Electric Boilers Part PEB

This part contains special rules for construction of

Electrode type boiler, in which heat is generatedby the passage of an electric current using water

as the conductor

Immersion resistance element type boiler in whichthe heat is generated by passage of an electric

current through a resistance heating element

immersed in water

Not included are electric boilers where the heat is

applied externally to the boiler pressure vessel by

electric resistance heating elements, induction coils, or

other electrical means


Requirements for Electric Boilers

Electric boilers and parts thereof that do not exceed the limits of PMBs may be

constructed using the applicable paragraphs of PMB in conjunction with this part

The boiler pressure vessel may be constructed to Section VIII Div.1 provided

Material of construction is clearly defined and as allowed in this part

Inspection openings are provided

Vessel shall be stamped with the Code Symbol Stamp U and the lettersUB

Special entry on the Master Data Report P-2A

Material and thickness requirements

Materials are limited to certain specifications only

Seamless or welded shell, plates or heads shall not be less than 3/16 (5mm)

Welding

If limits of PMB are not exceeded then PWHT , RT and remaining NDEdescribed in PG-93.1 are not required

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Sect. I Course 21


Requirements for Electric Boilers

Design requirements

Inspection openings required, except when a removable cover or internalelectric heating element is available

Feedwater and blow-off piping size to be considered

Water level indicators (gage glasses) to be provided

Number and size of safety valves required depending on the power input

Hydrostatic tests required

Inspection and stamping of electric boilers is different for size, power input, typeof construction

Under certain conditions AI need not to witness final examination orhydrostatic pressure test


Requirements for Organic Fluid Vaporizers Part PVG

Material requirements

Materials shall conform to specifications in Section II and the requirements inPart PG shall apply in all respects

Design requirements

General requirements of Part PG and specific requirements of this Part apply

Design working pressure shall be at least 40 psi (280 KPa) above the operatingpressure at which it will be used

Gage glasses shall be of the flat glass type with forged steel frames Suitable drain valves of the globe or angle type may be used

Safety valves shall be of a totally enclosed type and shall not have a liftinglever

The discharge capacity and minimum relieving capacity to be determined

Testing and certification as under PG-69

a rupture disc may be installed between the safety valve and the vaporizer special conditions to be considered

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Sect. I Course 22


Requirements for Heat Recovery Steam Generators Part PHRSG

Scope

HRSG has as its principle source of thermal energy a hot gas stream suchas the exhaust of gas or combustion turbine (considered synonymous andcover turbines burning liquid or gaseous fuels).

Requirements For Superheater And Reheater Condensate Removal

Connections

Each superheater and reheater shall be equipped with at least one automatedcondensate removal connection.

Shall be designed so that when discharching, a high pressure is not developedwithin the collection device.

Such piping shall extend through and include the second valve.

Desuperheater Drain Spots

Drain pot connection size shall be no smaller than one NPS less than the pipe

is attached to. Certification

Manufacturers Data Report in accordance with Part PG


APPENDICES

Mandatory Appendices

Mandatory Appendix I : Deleted

Mandatory Appendix II : Standard Units For Use In Equations

Mandatory Appendix III : Criteria for Reapplication of a Certification Mark

Mandatory Appendix IV : Local Thin Areas in Cylindrical Shells and in

Spherical Segments of Heads

Mandatory Appendix V: Additional Rules for Boilers Fabricated byRiveting

Mandatory Appendix VI: Establishing Governing Code Editions, Addenda,and Cases for Boilers and Replacement PartsApp.

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APPENDICES

Nonmandatory Appendices

App. A : Explanation Of Code Containing Matter Not Mandatory UnlessSpecifically Referred To In The Rules Of The Code

Efficiency of Joints (Riveted)

Braced and Stayed surfaces

METHOD OF CHECKING PRESSURE RELIEF VALVE CAPACITY BY MEASURINGMAXIMUM AMOUNT OF FUEL THAT CAN BE BURNED

AUTOMATIC WATER GAGES

FUSIBLE PLUGS

PROOF TESTS TO ESTABLISH MAXIMUM ALLOWABLE WORKING PRESSURE

PRESSURE RELIEF VALVES FOR POWER BOILERS

EXAMPLES OF METHODS OF COMPUTATION OF OPENINGS IN VESSEL SHELLS

EXAMPLES OF COMPUTATION OF ALLOWABLE LOADING ON STRUCTURALATTACHMENTS TO TUBES

PREHEATING (A-100) , HEATING AND COOLING RATES FOR POSTWELD HEATTREATMENT (A-101)

ROUNDED INDICATION CHARTS

METHODS FOR MAGNETIC PARTICLE EXAMINATION (MT)


APPENDICES

Nonmandatory Appendices

Appendix A : Explanation Of Code Containing Matter Not Mandatory UnlessSpecifically Referred To In The Rules Of The Code (continued)

METHODS FOR LIQUID PENETRANT EXAMINATION (PT)

QUALITY CONTROL SYSTEM

ACCEPTANCE OF TESTING LABORATORIES AND AUTHORIZED OBSERVERS FORCAPACITY CERTIFICATION OF PRESSURE RELIEF VALVES

DATA REPORT FORMS AND GUIDES

CODES, STANDARDS, AND SPECIFICATIONS REFERENCED IN TEXT (A-360) Guide to Information Appearing on Certificate of Authorization (A-370)

SAMPLE CALCULATIONS FOR EXTERNAL PRESSURE DESIGN

GUIDANCE FOR THE USE OF U.S. CUSTOMARY AND SI UNITS IN THEASME BOILER AND PRESSURE VESSEL CODE

Appendix B : Positive Material Identification Practice

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MANY THANKS FOR YOUR ATTENTION

LR INSURANCE, INC.Working together for a safer world

The Lloyds Register Groupworks to enhance safety andapprove assets and systems atsea, on land and in the air because life matters.

Services are provided by members of the Lloyds Register Group LloydsRegister, Lloyds Register EMEA and Lloyds Register Asia are exemptcharities under the UK Charities Act 1993.

For more information, please contact:

Chamni Mosagul

LR Insurance, Inc.

66 81 9352069

Chamni.mosagul

@lr.org

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