Power BoilerDesign,

Inspection,and Repair

ASME Code Simplified

Mohammad A. Malek, Ph.D., P.E.

McGraw-HillNew York Chicago San Francisco Lisbon London Madrid

Mexico City Milan New Delhi San Juan SeoulSingapore Sydney Toronto

Contents

ice xvii>duction xix

ipter 1. Boiler Fundamentals

1.1 Definition1.2 Steam Generation

1.2.1 Boiler flow diagram1.2.2 Thermodynamics1.2.3 Heat transfer

1.3 Boiler Classifications1.3.1 Classification based on ASME code1.3.2 Classification based on pressure1.3.3 Classification based on output1.3.4 Classification based on fuel1.3.5 Classification based on materials1.3.6 Classification based on use1.3.7 Classification based on tube type1.3.8 Miscellaneous boilers

1.4 Power Boilers1.4.1 Power boiler1.4.2 High-temperature water boiler1.4.3 Miniature boiler1.4.4 Electric boiler1.4.5 Organic fluid vaporizer

1.5 Boiler Performance1.6 Selection of a Boiler1.7 International Code1.8 Power Boiler Life Analysis

1.8.1 Useful life1.8.2 Code requirements

1.9 Jurisdictional Authority

2. Materials

2.1 Production2.1.1 Steel making process2.1.2 Ferrous metals and alloys

2223466788899

1111111213131414151618181819

21

222224

vi Contents

2.1.3 Steel2.1.4 Nonferrous metal and alloys2.1.5 Forming shapes

2.2 Properties2.2.1 Physical properties2.2.2 Mechanical properties2.2.3 Chemical properties

2.3 Application of Materials2.3.1 Pressure parts2.3.2 Nonpressure parts

2.4 Ordering2.4.1 Standard2.4.2 Size and tolerances2.4.3 Code requirements2.4.4 Purchase order

2.5 Receiving2.5.1 Identification of materials2.5.2 Receiving inspection reports2.5.3 Mill test reports

2.6 Inspection2.6.1 Markings2.6.2 Transfer of markings

Chapter 3. Boiler Design

3.1 Design Methods3.2 Design Factors

3.2.1 Definitions3.2.2 Design load

3.3 Cylindrical Parts under Stress3.3.1 Longitudinal stress in a cylinder3.3.2 Circumferential stress in a cylinder

3.4 Design of Boiler Components3.4.1 Cylindrical parts3.4.2 Dished heads3.4.3 Unstayed flat heads and covers

3.5 Openings and Compensations3.5.1 Small openings3.5.2 Medium openings3.5.3 Large openings3.5.4 Compensation for openings3.5.5 Steps in solving compensation problems

3.6 Stayed Surfaces3.6.1 Stayed flat plates3.6.2 Staybolts

3.7 Ligaments3.7.1 Ligaments for definite pattern3.7.2 Ligaments for indefinite pattern

3.8 Designer's Responsibilities3.8.1 Operating conditions3.8.2 Specifications

Contents vii

3.8.3 Design calculations 1003.8.4 Design Process 101

Chapter 4. Boiler Piping 103

} 4.1 Pipe Classifications 104- 4.2 Power Boiler Piping 105

4.2.1 Boiler proper piping 1084.2.2 Boiler external piping 108

t 4.2.3 Nonboiler external piping 110->' 4.3 Design Requirements 1101 4.3.1 Piping under internal pressure 111*"• 4.3.2 Specific piping systems 115*" 4.4 Materials 122%̂ 4.4.1 American piping standard 123*•'* 4.4.2 International standards 123*'• 4.5 Fabrication and Assembly 124| 4.6 Shop Inspection and Testing 125

4.6.1 Stamping of pressure piping 1254.6.2 Code symbol stamp 1264.6.3 Manufacturer's data reports 126

4.7 Operation and Maintenance 1274.8 In-service Inspection and Repair 127

ipter 5. Safety and Safety Relief Valves 129

5.1 Working Principle 1305.2 Classifications 1305.3 Materials 1325.4 Capacity Requirements 134

5.4.1 Relieving capacity 1345.4.2 Capacity checking 140

5.5 Design Requirements 1435.5.1 Mechanical requirements 1435.5.2 Boiler safety valves 1445.5.3 Superheater and reheater

safety valves 1455.5.4 Organic fluid vaporizer

safety valves 1465.6 Safety Valve Manufacturing 147

5.6.1 Manufacturers 1475.6.2 Capacity certification 1485.6.3 Testing by manufacturers 1525.6.4 Inspection and stamping 1525.6.5 Certificate of conformance 154

5.7 Installation Requirements 1555.8 Operation and Maintenance 1565.9 Inspection and Repair 157

5.9.1 Inspection 1575.9.2 Repairs 159

viii Contents

Chapter 6. Fabrication 161

6.1 Preparation 1616.1.1 Plates 1626.1.2 Cylindrical shells 1626.1.3 Formed heads 1626.1.4 Tube holes 1626.1.5 Holes for stays 1626.1.6 Repair of defective materials 163

6.2 Fabrication by Welding 1646.2.1 Design 1656.2.2 Fabrication welding process 1706.2.3 Loading on structural attachments 1786.2.4 Inspection and tests 184

6.3 Fabrication by Brazing 1866.3.1 Materials 1896.3.2 Design 1896.3.3 Fabrication 1926.3.4 Inspection and tests 193

6.4 Assembly of Boiler 1946.4.1 Shop-assembled boilers 1946.4.2 Field-assembled boilers 194

6.5 Production of a Firetube Package Boiler 195

Chapter 7. Watertube Boilers 201

7.1 Working Principle 2027.2 Classifications 203

7.2.1 Classification based on tubes' and drums'(structural) configurations 203

7.2.2 Classification based on use 2067.2.3 Classification based on water circulation 2087.2.4 Classification based on output 2117.2.5 Classification based on erection 2117.2.6 Classification based on special purpose 211

7.3 Main Components 2157.4 Design Features 2187.5 Construction of a Package Watertube Boiler 2237.6 Specifying a Package Watertube Boiler 230

Chapter 8. Firetube Boilers 241

8.1 Working Principle 2428.2 Classifications 242

8.2.1 Classification based on layout position 2428.2.2 Classification based on type of firebox 2478.2.3 Classification based on output 2498.2.4 Classification based on type of erection 2498.2.5 Classification based on special purpose 251

8.3 Main Components 2518.4 Design Features 253

8.4.1 Shell and tubesheet thickness 2568.4.2 Attachment of heads and tubesheets 2568.4.3 Tubes 256

• : 8.4.4 Combustion chamber tubesheetf 8.4.5 Furnacesl + 8.4.6 Fireboxes and waterlegsr 8.4.7 Stayed surfacesi'-' 8.4.8 Doors and openings

8.4.9 Domesf 8.4.10 Setting1" 8.4.11 Piping, fittings, and appliancest' 8.4.12 MAWP for furnaces and tubest" 8.5 Construction of a Firetube Boiler?* 8.6 Specifying a Firetube Boiler

Npter 9. Feedwater Heaters

f 9.1 Working PrincipleI* 9.2 Classifications| i 9.2.1 Closed feedwater heater^ 9.2.2 Open feedwater heaterI 9.3 MaterialsSv 9.4 Design Features** 9.5 Operation^ 9.6 Maintenance

9.7 Specifying a Feedwater Heater

ttapter 10. Miniature BoilersIt« f 10.1 Classificationm 10.2 Design Featuress« 10.2.1 Washout openings?i 10.2.2 Feeding devices

10.2.3 Blowoff connections10.2.4 Gage glasses

p 10.2.5 Safety valves' 10.2.6 Stop valves|^ 10.2.7 Pressure gagesw. 10.3 Inspection and Stampingk 10.4 Controls and Safety Deviceskj. 10.4.1 Automatic low water fuel cutoffI : 10.4.2 Electrical|f 10.5 Specifying a Miniature Boiler

M p t e r i i . Electric Boilers

Ci1.1 Working Principle^ 11.2 ClassificationsI f 11.3 Design FeaturesC 11.3.1 SizingL 11.3.2 Pressure vessell[f 11.3.3 Inspection openingsC 11.3.4 Feedwater supplyL. 11.3.5 Blowoff pipingr 11.3.6 Water gagesF 11.3.7 Pioina

Contents ix

258258265266271273273274275284285

289

289289290292295295297298298

301

302303304304305305305305305305306306306307

309

309310312313314314314315315315

Contents

11.4 Inspection and Stamping 31611.4.1 Inspection 31611.4.2 Hydrostatic test 31611.4.3 Stamp holder 31611.4.4 Stamping 31711.4.5 Manufacturer's data reports 317

11.5 Controls and Safety Devices 31711.5.1 Safety valves 31711.5.2 Automatic devices 31811.5.3 Low water fuel cutoff 318

11.6 Specifying an Electric Boiler 318

Chapter 12. Organic Fluid Vaporizers 321

12.1 Organic Fluids 32112.2 Working Principle 32212.3 Classifications 32212.4 Design Features 324

12.4.1 Vaporizer shell 32412.4.2 Gage glass 32512.4.3 Drain valves 32512.4.4 Hartford loop 32512.4.5 Code reference 325

12.5 Inspection and Stamping 32512.6 Controls and Safety Devices 325

12.6.1 Safety valve 32612.6.2 Rupture disks 32812.6.3 Level control 32912.6.4 Temperature control 329

12.7 Operation 32912.8 Specifying an Organic Fluid Vaporizer 331

Chapter 13. Shop Inspection 333

13.1 Boiler Fabrication Shop 33313.1.1 Manufacturer 33413.1.2 Manufacturer's responsibility 334

13.2 Authorized Inspection Agency 33513.2.1 Qualification 33513.2.2 Duties 33613.2.3 Accreditation certificate 336

13.3 Authorized Inspectors 33613.3.1 Qualification 33713.3.2 Authorized inspector's responsibility 337

13.4 Inspection Tools 33813.5 Inspections 338

13.5.1 The traveler 34013.5.2 Code inspection 34113.5.3 Field inspection 34113.5.4 Visual inspection 34213.5.5 Welding inspection 343

13.6 Nondestructive Examination 34313.7 Hydrostatic Test 34613.8 Hydrostatic Deformation Test 347

Contents xi

ipter 14. Stamping and Data Reports

14.1 Stamp Holders14.1.1 Certificate of authorization14.1.2 Agreement with authorized inspection agency14.1.3 Quality control system

14.2 Code Symbol Stamps14.3 Stamping

14.3.1 Shop assembled boilers14.3.2 Field assembled boilers

14.4 Manufacturer's Data Reports14.4.1 Types of data reports

14.5 Selection of Data Report Forms

349

350350352352355356357359360362362

ipter 15. Auxiliaries and Appurtenances

15.1 Boiler Auxiliaries15.1.1 Air system15.1.2 Fuel systems15.1.3 Steam system15.1.4 Feedwater system15.1.5 Draft system

15.2 Boiler Appurtenances15.2.1 Safety and safety relief valves15.2.2 Pressure gages15.2.3 Water columns15.2.4 Blowdown apparatus15.2.5 Fusible plugs15.2.6 Soot blowers15.2.7 Boiler vents

15.3 Boiler Accessories15.3.115.3.215.3.315.3.415.3.515.3.615.3.7

pter16. Fuel

16.1

16.2

f

18.3

Fuels16.1.116.1.216.1.316.1.416.1.5

Blowoff tanksSample coolersFlash economizersMist separatorsInline separatorsTemperature regulating valvesExhaust silencers

I Systems

GasLiquefied petroleum gasFuel oilsCoalElectricity

Combustion16.2.116.2.216.2.316.2.4

Types of combustionCombustion processChemical reactionCombustion air

Fuel-Burning Systems16.3.116.3.2

BurnersPilots

365

365365366369372377379380380382382383383383383383385385385385386386

387

387388388389391391391393393394394395395395

xii Contents

16.4 Gas-Burning Equipment16.5 Oil-Burning Equipment16.6 Coal-Burning Equipment16.7 NOx Control

16.7.1 NOx control technologies

Chapter 17. Boiler Controls

17.1

17.217.317.4

17.517.6

pter

18.118.218.3

18.418.518.618.718.8

Basic Boiler Controls17.1.1 Control loops17.1.2 Application to boiler

Burner ManagementControl StandardsControls and Safety Devices

17.4.1 Types17.4.2 Minimum controls17.4.3 Systems for multiple burners

InstallationPeriodic Testing

18. Boiler Installation

Boiler InstallersInstallation CodeBoiler Room

18.3.1 Water and drain connections18.3.2 Fire protection18.3.3 Housekeeping18.3.4 Posting the certificates18.3.5 Record keeping18.3.6 Safety

Combustion AirVentingBoiler PlacementOperation TestsDocumentation

Chapter 19. Boiler Operation

19.1 Operating Personnel19.1.1 Boiler operators19.1.2 Boiler engineers19.1.3 Training19.1.4 QFO-1 standard

19.2 Filling a New Boiler19.3 Boiling Out

19.3.1 Simple boilout method19.3.2 Stubborn boilout

19.4 Starting a Boiler19.5 Condensation19.6 Cutting in an Additional Boiler19.7 Normal Operation

Contents xiii

19.8 Boiler Shutdown19.9 Periodic Tests

19.10 Boiler Room Emergency19.11 Operation Logsheet

^Chapter 20. In-service Inspection

20.1 Authorized Inspectors20.1.1 Qualification20.1.2 Authorized inspector's responsibility

20.2 Boiler and Machinery Insurance20.3 Inspection Tools20.4 Boiler Inspection

20.4.1 First inspection20.4.2 Routine inspection

20.5 Preparation for Inspection20.5.1 Preparation for internal inspection20.5.2 Preparation for external inspection

20.6 Inspection Types20.6.1 Internal inspection20.6.2 External inspection

20.7 Inspector's Calculations20.8 Controls and Safety Devices Inspection20.9 Repair Inspection

20.10 Certificates20.10.1 Certificate of competency20.10.2 Certificate of compliance

tapter 21. Boiler Maintenance

21.121.2

21.321.421.5

21.621.721.8

Maintenance PersonnelMaintenance Program

21.2.1 Routine maintenance21.2.2 Preventive maintenance21.2.3 Shutdown maintenance21.2.4 Spare parts inventories21.2.5 Personnel training21.2.6 Boiler improvement

Trouble-ShootingMaintenance ToolsTube Cleaning

21.5.1 Mechanical cleaning21.5.2 Chemical cleaning

Tube ExpansionPreparing for InspectionMaintenance Logsheet

ipter 22. Boiler Repairs

22.1 Repair Organizations22.2 Repairs

22.2.1 Routine repairs22.2.2 Major repairs

450

451

453

455

457

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477

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495

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xiv Contents

22.3 Alterations 49822.4 Rerating and Derating 498

22.4.1 MAWP for existing boilers 50022.5 Repair Calculations 50122.6 Repair Steps 502

22.6.1 Preparation 50222.6.2 Authorization 50322.6.3 Repair work 50322.6.4 Welding 50322.6.5 Heat treatment 50422.6.6 Nondestructive examination 50522.6.7 Materials 50522.6.8 Repair inspection 50522.6.9 Hydrostatic test 505

22.6.10 Repair nameplate 50522.7 Repair Methods 506

22.7.1 Drum repair 50622.7.2 Tube repair 50822.7.3 Waterleg repair 50922.7.4 Handhole repair 51022.7.5 Stay repairs 51022.7.6 Welded crack repairs 51022.7.7 Seal welding of tubes 51122.7.8 Reversed flange (ogee) repair 511

22.8 Documentation 512

Chapter 23. Water Treatment 515

23.1 Boiler Water 51623.1.1 Water types 51623.1.2 Formation of scale 51723.1.3 Quantity of scale 518

23.2 Boiler Water Problems 51823.2.1 Deposit problems 51823.2.2 Corrosion problems 52023.2.3 Foaming and priming 521

23.3 Testing of Water 52123.3.1 Testing types 52223.3.2 Recommended limits 523

23.4 Treatment Methods 52323.4.1 External treatment 52523.4.2 Internal treatment 53023.4.3 Condensate treatment 532

23.5 Boiler Storage 53323.5.1 Wet method 53323.5.2 Dry method 534

23.6 Conclusion 535

Appendix A. Maximum Stress Values for Ferrous Materials 537

Appendix B. Maximum Stress Values for Nonferrous Materials 545

Appendix C. Dimensions of Plates 549

Contents xv

idix D. Dimension of Heads

Appendix E. Pipe Thickness

IIfcppendix F. Tube Thicknessi

)pendix G. Charts for Components underExternal Pressure

mdix H. MAWP for Watertubes

mdix I. Manufacturers' Data Report for Watertube Boilers

mdix J. Manufacturers' Data Report for Firetube Boilers

mdix K. Manufacturers' Data Report for Miniature Boilers

mdix L. Manufacturers' Data Report for Electric Boilers

spendix M. Manufacturers' Data Report for OrganicFluid Vaporizer

mdix N. Manufacturers' Data Report for Pressure Piping

mdix O. Installing Contractor's Report for CSD-1

mdix P. First Inspection Report

mdix Q. Suggested Format for Welding ProcedureSpecifications (WPS)

idix R. Unit Conversions

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Bibliography 607Index 611