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    RMT a Section | aie tS BL Glare] ic AAS eye) 5 mom er Pr Po PEP rb a POWER BOILERS A GUIDE TO SECTION I OF THE ASME BOILER AND PRESSURE VESSEL CODE Martin D. Bernstein Foster Wheeler Energy Corporation 2° Clinton, New Jersey and Lloyd W. Yoder Wadsworth, Ohio Copyright © 1998 by The American Sonety of Mechanical Engineers Taree Park Avenue, New York, NY 10016 Library of Congress Cataloging tn Publication Data Bernstein, Martin D., 1928— ‘Power Boilers: A Guide to Section [of the ASME Boiler and Pressure ‘Vessel Code by Martin D. Bernstein and Lioyd W. Yoder. Boom Includes index. ISBN 0-7918-0056-3 1, Stear-bollers—Standards—United States. 2. Preseure vessels—Standards—United Sues. L. Yoder, Lloyd W., 1930— American Society of Mechanical Engineers. Boilec and Pressure ‘Vessel Committee. ASME Boiler and Pressure Vessel Code. ml. Tite, THARBBAT 1998 98-43261 621 83'021873—Ae2 cP Al sights reserved, Printed in the United Staes of America. Except sx permitted ‘under the United States Copyright Act af 1976, no past of this publication may be reproduced or distributed in any form or by any means, or sored in dttabese or retrieval syste, without the prior weten permssion of the publisher. ASME shal not be responsible for stavzments or opinions advanced in papers for... printed im its publications (B7.1.3) Statement from the Bylaws ‘Authorization to photocopy material for internal r personal use under citeumstanees. ‘not falling within the fair use provisions of the Copyright Act is granted by ASME to libraries and other users registered with Copyright Clearance Center (CCC) Trans- ‘etional Reporting Service provided the base fee ef $4.00 per page is paid directly to the CCC, 222 Rosewood Drive, Danvers, MA.01923. ‘Cover figure courtesy of Foster Wheeler Energy Corporation. DEDICATION The authors dedicate this book to their distinguished colleague on Subcommittee 1, the late Walter Harding of Combustion Engineering. From the 1950s untit his retirement in the 1980s, Walter Harding served with distinction on the ASME Boiler and Pressure Vessel Committee in many capacities, including Chairman of the Main Committee. An engineer of the greatest integrity, Harding was an inspiring role model jor younger committee members, extremely knowledgeable, ever helpful, cheerful, and the possessor of a fine sense of humor. We were fortunate to have had the privilege of serving with him, [ cha Fada Pa Pa Pe ba Pa Pa Pe Pe Pa Pw Pe ba babs Po ML Table of Contents Chapter 4 Boller Design 35 Design Life - 35 Design Methods sevens 36 Design Loads 37 Distinsion Betwoen Boiler Proper Piping and Boiler Extemal Piping 39 ‘Some Design Differences: Section I Versus B31.1 0 Rend Design sss - 4 Openings and Compensation a Ligament Design 52 Interpretations on Openings, Compensation, and Ligaments 35 Nozzle Antachment Rules 37 Dished Heads 6 Flat Heads . - @ Interpretations on Heads 1 Stayed Surfaces. - : n Supports and Attachment LUZS oem. cm 16 Losing on Structural Anachments.. 16 Design of Safety Valve Nozzles B ‘Thermocouple Installations... Bp Chapter 5 Piping Design... 2 Tatroduetion ~ . a ‘Shock Service for Feedwater and Blowoff Piping a Pump Discharge Head 34 ‘Unusually High Piping Design Pressure. sine 4 ‘Short-Term Overstess in Boiler Extemal Piping 85 Hydrostatic Test of Boiler External Piping 8 Allowable Suess When Safety Valves Are Discharging 89 Focdwater Piping ss 90 Main Steam Piping 90 Blowoff and Blowdown Piping 93 Design Conditions for Blowoff and Blowdown Piping 95 Drains 95 Design Conditions for Drain Piping 98 Pipe Connections to the Boiler 98 ‘Aduition of Small Connections to Boiler Pin 98 Chapier 6 Fabrication and Welding 101 Fabrication —.. 101 Welding—Some History ~. 101 Welding Rules 102 Qualification of Welding Procedures - 103 Qualification of Welder Performance 103 Expiration and Renewal of Welding, Qualifications ur 104 105 Transfec of Procedures and Welders to Another Organization Welding Documentation .. . ‘Welding Nonductile Materials Welding Variables TABLE OF CONTENTS bes tee bee lem le le le Pressure Range of Section I Boilers .. Fired Versus Unfired Boilers ‘The Use of Section VENI Vessels in a Section Standards Referenced by Section £ a... Chapter 2 How ané Where Section Is Bnforeed and Eetive Dates United States and Canada .. International Acceptance Uniform Boiler and Pressure Vessel Laws Society ‘National Board Inspection Code a Effective Dates of the Code and Code Revisions .. Chapter 3 Materials... How Material Is Ordered Using Section I Finding and Using Design Stesscs in Seen Ml, Past D Marking of Materials Use of Non-ASME Material Specifications and Material Not Fully Identified Special Concems ... Material Requirements for Boiler Exterral Piping Electric Resistance Weided (ERW) Materials Nonpressure Part Material .... Material Test Reports ne Strength of Materials After Fabrication Does New Material Get O14? Use of Materias in Inventory .. Code Guidance on the Use of Old Materials SVRBRRIREe 32 PP = siil_Table of Contents ‘Establishing aad Certifying Relieving Capacitis ... 173 ‘Qualification of Pressure-Relief Valve Manufacturers 176 Installation Guidelines... 7 Safety Valves in Service m Summary — 178 Chapter 13 Feedwater Supply an¢ Water Level Indication 179 Importance of Feedwater . one I Rules for Feedwater Supply - 179 182 Forced-Flow Steam Generators Low Water Level Fuel Cutoffs, un Water Level Indication nn Water Columns... ‘Chapter 14 ‘Creep and Fatigue Damage Dering Boller Life . 182 182 187 187 187 190 192 ‘Chapter 15 Determination of Allowable Stresses son 195 ‘General Philosophy .. 195 Establishing Allowable Stresses... 196 Penalties on Allowable Stresses... 196 Design Stresses: Past, Present, and Future .. 197 198 ‘Appendix 1 of Section Il, Part D Chapter 16 Rales Covering Boilers in Service Fetroduction .. [ASME Code Edition Applicable to Repairs and Alterations Jurisdictional Requirements ‘The National Board. 7 Reptirs and Alterations Under the NBIC ‘The National Board Repair Stamp Program Pressure Tests Following Repairs and Alterations .. Repait Documentation and Stamping : Routine Repairs Alteration Documentation and Stamping, Advantages of Following the NBIC Postconsinietion Activities of the AS! References Appendix 1 Evolution of the ASME Boiler and Pressure Vessel Code Appendix It ‘Organization and Operation of the Boiler and Pressure Vessel Committee .. Organization and Responsibility sn Table of Contents vii 109 ut 112 112 113 HS ts 16 P-Numbers, S-Numbers, F-Numbers, and A-Numbers ... Weldability Design of Welded Joints Bending Stress on Welds . ‘Acceptance Criteria for Welds Tube-to-Ticader Attachment Using Partial Penetration Welds Alignment Tolerance Backing Rings .. Preheating 116 Postweld Heat ‘Treatment . 117 Test Plates 120 Interpretations on Welding .. 120 Radiographic Examination of Welds 123 126 Ultrasonic Examination of Welds .. (Chapter 7 Nondestructive Examination and Hydrostatic Testing ‘Nondestructive Examination Qualification and Certification of NDE Personne Hydrostatic Testing Welaing After Hydrostatic Test... Interpretations on Hydrostatic Testing Chapter & 127 127 127 128 131 13 139 141 141 142 142 14 us 145 146 147 148 Manufacturers’ Data Report Forms ‘The Ten Section { Manufacturers’ Data Report Forms Completing the Data Report Focms ‘Comments on the Data Report Forms Distribution of the Data Report Forms Interpretations on Use of Manufacturers’ Data Report Forms ~. Code Symbol Stamps and How They Are Obtsned ‘What the Code Symbol Stamps Cover Interpretations on Code Symbol Stamping .. Chapter 10 Quality Control System nnn Chapter 11 Standard Prossre Pars, Valves, and Valve Ratings Standard Pressure Parts Valves and Valve Ratings Chapter 12 Safety Valve Requirements Inoduction . Overpressure Protection - Selection of Pressure-Relieving Devices «. Design of Pressure-Relief Valves 187 © Jo eS edd erat es et et ed et © Code Inquiries and Interpretations... Publication of Interpretations of the Code —.m. ‘Additions and Revisions (0 the Code Code Cases ... — Design Exercise No. 1, Design of a Header Design Exercise No. 2, Design of a Head Design Exercise No. 3, Choice of Feedwater Stop Design Enerae No.4 Design o Tbe for Lag Loating PG-27 Cylindrical Components Under Internal Pressure... PG-29 Dished Heads . ‘Appendix V Blustrations of Various Types of Boilers Index of Interpretations Referenced in Text, Their Major Subjects and Abstracts .. TdeX asnineanninannnn | PF... Po bs Pe Po bai ti Pai Peto to be boob bob Pe bt. Chapter 2 Fig.21 Chapter 4 Fig, PG-36 Fig. PG-52.1 Fig. PW16 Fig, PW.16.1 Fig, PG-3L Chapter 5 Fig. PO-583.1 Chapter 14 Fig. 141 Fig. 142 Fig63 ‘Appendix I Fig. AILL Fig. AMZ Fig. ATI Appendix Fig. AVI Fig, AV2 Fig AVS. List OF FIGURES Map of States and Provinces With Boiler and Pressure Vessel Laws (Courtesy of the Uniform Boller and Pressure Vesse! Laws Society. In. rr Limits of Reingorcertent for Typical Openings (Reprocuced Fiom ASME Section 1) Diagram for Determining the Efficiency of Longitudinal and Diegonal Ligements Between COperings in Cylindrical Shells (Repfoduced From ASME Section 1) LLoad-Camying Paths in Welded Nozzle Auachments (Reproduced Prom ASME Section 3) ‘Some Acceptable Types of Welded Norzles and Other Connestions to Shells, Prums, and Headers (Reproduced From ASME Section 1) Some Accepuble Types of Unstyed iat Head a Covers (Reprodoced From ASME Section 1). 3 8 61-64 ‘Code Jurisdictional Limits for Piping —Drum-Type Boiters (Reproduced From ASME Section D . a ‘Strain in Constant Stress Creep Tes. Progression of Microsictral Damage Dung Compovet Life (epraduced From ‘Neubauer and Wedel (1983) ae 189 2% Cr Mo—100 Percent of te Miimam See To-Rupare (Reproduced From ‘ASME Section IID vs sa 190 Organization of ASME (Condensed) eon se vevimmconane 18 orton of ASME Orgarizaton Exconpesing Suizomier ov Power Ron (Subcomunittee 1) - _— bosons 219 Lug Load on Tube (Reproduced Prom ASME Section 1) 246 Suprereat One Trough Cat Fring Seam Gaeta (Couieyof Foe Wheeler Energy Corporation) nso 259 Coat Fring Cena Staton Steam Generator (Cours of Foster Wheeler Energy Corporation} Circulating Fhidized Bed Boilee (Courtesy of Foster Wheeler Energy Corporation) aves 261 HiL_Lis of Figures Fe-AVA Kin Proves Bl Ligur Reoorey Rall (Couey of The Babcock & Wilcox Company) Fig AVS Refuse Fired Boiler (Counesy of The Babcock & Wilcox Company) Fig ANS Package Boiler (Counesy of The Rabeock & Wilcox Company). POP Perea a Pe Pa Pa Pa Pe Pa Pa Pa Pe Pa baba Pata Chapter 9 Table 9.1 Chapter 12 TebleI2.1 Tablel2.2(@) ‘Tablel2.20) ‘Teble!2Ke) ‘Tablel2.4(@) Chapter 15 Table 1-100 ‘Appendix 1 ‘Table ATLL “Appendix IV ‘Table 2 Tebte | Table 2414 List oF TABLES Capabilities Needed to Obtain Section I Code Symbol Stamps. 9 167 168 Pressure Relief Deviees Allowed by the ASME Code Section I Requirements .. Section TV Requirements ‘Section VIM Requirements .. 169 Section X Requirements .. 170 Criteria for Establishing Allowable Stress Values for Tables 1A and 1B (Repeeduced From ASME Section I). va 200 “Thc Book Sections of the ASME Boller and Pressure Vessel Code Code ma ‘Dimensions and Weights of Welded and Seamless Wrought Steel Pipe 258 256 237 OPP. Pa Pa Pa Pa Pa Pe Pa Pa Pa Pa Pa be Pa ba ba Pa rab FoREWORD In 1986 the ASME Professional Development Department approached author Martin Bemstein and asked hhim to develop and teach a two-day professional development courze on Section | of the ASME Boiler and Pressure Vessel Code, whose title is now Rulles for Construction of Power Boilers, The tack of developing ‘course notes and the prospect of teaching all day for two days with no relief was somewhat daunting, s0 Bemstein enlisted the holp of Lloyd Yoder, his long-time friend and colleague on Subcomanitice 1, the ‘ASME comumitoe that governs Section L ‘The two then collaborated on ibe preparation of appropriate notes and since 1986 have been teaching a two-day courst for the ASME at various locations within the United ‘States and overseas. During that tite they expanded and refined the course notes, covering material of interest to those who have been iaking the course—design engincers; project managers; architect engineers; ‘engineers from boiler manufacturers, boiler operators, and insurance and inspection agencies: and others involved with power boilers and the ASME Code governing their construction. "The introduction in the brochure for the two-day professional development course on Section I explains that Section I contains the rules for the construction of power boilers, but that those rules are accompanied by very litle explanation, Thus the course is intended to provide a basic understanding of those rules, their intent, and how they are applied, interpreted, and revised. This book is a greatly expanded version of the ‘course notes, with broader and more detailed coverage on various topics of interest to those involved with ‘power boilers. Both authors have spent their careers working for major boiler manufacturers, and decades Servingiin various capacities onthe ASME Boiler and Pressure Vessel Committee, This bock is acompendium ‘of the author” knowledge and experience. ‘The design and construction of power boilers involves the use of other sections of the ASME Code besides Section I, and the use of those other sections is explained in this book when appropriate. Section I, = Materials, provides detailed specifications for materials and welding consumables, as well as tabulations cof design suesses and material properties, such as yield strength and tensile strength as function of temperature, Section V, Nondestructive Examination, contains a series of standards that provide the method ‘ology for conducting the various nondestructive examinations used in Section I eonsiruction. Section IX, Welding and Brazing Qualifications, provides the information necessary to qualify the weld procedures and the welders required for Section I construction. Ina rather unusual arrangement, the construction rules for boiler piping are found party in Section | and partly in the B34.1 Power Piping Code. This bas led to considerable misunderstanding and confusion, and the authors have endeavored to provide a clear explanation ‘of these mules and the potential pitfalls to be avoi Both authors aze long-time members of the ASME committee that governs Section I, the Subcommittee ‘on Power Boilers, Subcommittee I. In the course of its duties, that committee answers 2 steady flow of {uestions from all over the world of the application and interpretation of Section I, The authors have thus participated in or are familiar with Section I interpretations and Code changes going back move than @ guarter of a century. Since 1978 the ASME has been publishing those interpretations, but they are not sridely or readily available, nor is their background known by most people. A useful feature ofthis book Jr that as a particular subject is covered, niany important interpretations dealing with that subject are cited ‘and discussed. These interpretations form a very useful body of reference information, since they explain dr clarify rales that have led o inquities from the public and provide insight into the views of Subcommittee I ‘Although Section I nominally covers only the new construction of power boilers, this book goes further and comains 2 chapter oa rules covering boilers in service, such as those found in the National Board ~ xvl_Foreword Inspection Code. The authors have also found that pevticipants in their course on Section I were interested in the subject of creep and fatigue damage during boiler life and the related subject of boiler life extension. ‘Accordingly, a chapler providing an overview of those subjects has been included, ‘When the ASME in 1911 began the development of « boiler code. it addressed a serious safety problem of that time by formulating a uniform set of rules for the construction of steem boilers, rules that couki be adopted by all the states. That se* of nules eventually became Section I. The interesting history of steam ‘power in the nineteenth century provides the background forthe development of Section 1 and is described in Appendix [. ‘The organization and operation of the ASME Boiler and Pressure Vessel Committee is a subject not likely to be found on & best-seller list, Nevertheless, some knowledge of the workings of the committee ‘may prove useful for those submitting inquiries or requests for Code changes, or for Code Cases. Appendix T provides a description of how the committee operates. ‘Those unfamiliar with the ASME Code may at first be confused by a number of terms commonly used in it. Examples include thind party inspection, Authorized Inspector, Authorized Inspection Age jurisdiction, Maximum Allowable Working Pressure (MAWP), boiler proper, boiler proper piping, boiler ‘extemal piping, interpretation, Code Case, accreditation, and Certificate of Authorization (10 use a Code ‘symbol stamp). The authors explain these terms in the text wherever appropriate. ‘Although the ASME Boiler and Pressure Vessel Code changes very slowly, it does change continuously. ‘The rate of change in recent yeers seems to have increased, pethaps due to technological innovation and international competition. Thus although this book provides a substantia! body of information and an explanation of the rules as they now exist, it can never provide the last word. The edition covered is the 1998 edition of Section I, which comprises the 1995 edition with Addenda through 1997. (In a deparure from previous practice, the 1998 edition included the first Addenda to that edition, the 1998 Addenda, as ‘explained further in Chapter 2.) The avthors are confident that the book wil provide the industry with a very useful reference and guide to Section I. - INTRODUCTION It is helpful to begin the study of Power Boilers, Section I of the ASME Boiler & Pressure Vessel Code, ‘with some discussion of its character and philosophy. According tothe dictionary, the term code has several meanings: a system of principles or rules; a body of laws acrenged systematically for easy reference. Section I is primarily a system of rulss. When the ASME it 1911 decided that the country reeded a boiler code, it sssigned a committee and gave it a mandate to formulate standard rules fur the construction of steam boilers end other pressure vesseis. The first edition of what is now known as Section L was finally approved by the ASME in 1915 and incorporated what was considered the best curreat practice in boiler construction. However, the guiding principle then, as now, was that these be safety rules. ‘Pant of the toreword of Section I explains the guiding principles and philosophy of Section I, and also of the Boiler and Pressure Vessel Commitee, which continues to administer the Code: ‘The American Society of Mechanical Engineers set up a comminee in 1911 for the purpose ‘af formulating ssandard rules for the construction of steam boilers and other pressure vessels. This commitie is now called the Boiler and Pressure Vessel Committee. ‘The Committee's function is 10 establish rules of safety governing the design, fabrication, and inspection durig consiriction of boilers and pressure vessels, and to interpret these rules when questions arise regarding their intent. In formulating the rules, the Committee considers the needs of users, manufacturers, and inspectors of pressure vessels. The objective ofthe rules 1s to afford reasonably certain protection of life and property and to provide a margin for deterioration inservice so as 10 give a reasonably long, safe period of usefulness. Advancements in design and material and the evidence of experience have been recognized. Tris Code contains mandatory requirements, specific prohibitions, and nonmandatory guid- ance for construction activities. The Code does not address all aspects ofthese activities, and those aspects which ere not specifically addressed should not be considered prohibited. The Code is not a handbook and cannot replace education, experience, and the use of engineering judgment. The phrase engineering judgment refers to technical judgments made by knowledge- ‘able designers experienced in the application of the Code, Engineering judginents must be ‘consistent with Code philosophy and suck judgments must never be used to overrule mandatory requirements or specific prohibitions of the Cade. ‘The Boiler and Pressure Vessel Committee deals with the care and inspection of boilers and pressure vessels in service only to the extent of providing suggested rales of good practice as fan aid to owners and their inspectors. ‘The rules established by the Committee are not tobe interpreted as approving, recommending, cor endorsing any proprietary or specific design or as limiting in any way the manufacturer's freedom to chonse any method of design or any form of consiruction that conforms to the ‘Code rules. ‘Certain points in these paragraphs should be stressed. Section I covers the design, fabrication, and inspection of boilers during construction, ie. it covers new construction only. (Rules covering boilers in service will be discussed later, in Chapter 16.) Although there is general agreement that Section I should apply to new replacenient parts, and such parts are usually specified that way, until the appearance of the xsi 2vit_Ineduction 1996 Addenda, Section I had no clear provisions dealing with parts other than how they should be documented. Those addenda included changes to PG-106.8 and PG-112.2.4, which require the manufacturer of replacement parts to state on the data Teport form (the documentation that accompanies the part: see Chapter 9) whether or not the company is assuming design responsibility for a replacement pressure part. ‘Also mentioned in the Foreword is the objective of the rules: reasonably certain protection of life and property, with a margin for deterioration in service, s0 4s to provide a reasonably long, safe period of usefulness, This is an acknowledgment of the fact that no equipment lasts ferever and that boilers do heve 1 finite life. The mechanisms by which a boiler wears out and the means by which remaining life may be estimated are discussed in Chapter 14, ‘The Section I rules were based on the best design practice known when they were written and have continued to evolve on the same basis. They have worked well over many years. Ruie changes have been made that recognize advances in design and materials, 2s well as evidence of satisfactory experience. The needs of the users, manufacturers, and inspectors are considered, but safety is always the primary concera. ‘Another basis forthe success of Section I is its committee's insistonce thatthe rules be general, and not be interpreted as approving, recommending, or endorsing any proprietary or specific design, or Hmiting a ‘manufacturer's freedom to choose any design cr construction that conforms to the Code rules. The committee considers that a manufacturer is ultimately responsible for the boiler design and leaves certain aspects not explicitly covered by Section I to the manufacturer. Traditionally, the manufacturer has recognized and bome this responsibilty for such things as Functional performance, providing for thermal expansion and support of the boiler and its associated piping, and for consideration of thermal stress, wind, and seismic loading. ‘The useful advice that Section I is not a handbook and cannot replace education, experience, and the use of engineering judgment was added to the Foreword of all sectioas of the Code in the 1992 Addenda. This ‘overdue advice was added in an attempt to limit the ASME’s entanglement in certain disputes among manufacturers, owners, and regulatory authorities regarding the application of the Code. Further evidence of the flexibly and reasonableness of Section and another Key (0 its success as a living document is found in the second paragraph of the Preamble: The Code does not contain rules to cover all details of design and construction. Where complete details are not given, itis intended that the manufacturer, subject 10 the acceptance of the ‘Authorized Inspector, shall provide details of design and construction which will be as safe as ‘otherwise provided by the rules in the Code. This important paragraph provides a way to aocept new or special designs for which no rules are given, by allowing the designer to prove to the satisfaction of an Authorized Inspector thatthe safety of the new design is equivalent to that usually supplied. ‘According to one of the definitions cited above, a code is a body of laws arranged systematically for ‘easy reference. Although this may be ue of Section I it is nol at first easy to use or understand, because it is neither a textbook nor an engineering design manual. Its rather a collection of rutes that have been revised and expanded over the years with very little accompanying explanation. These rules mandate the ‘fundamental construction features considered necessary fora safe boiler (one that isa safe pressure container), but typically do not provide any advice on how to design a boiler from the standpoint of what size or arrangement of components should be used. There are no provisions dealing with the thermal performance and efficiency of the boiler or how much steam it wil produce (other than for some approximate guidelines for judging the adequacy of the safety valve discharge capacity). Itis assumed that the boiler manufacturer ‘or designer already has this knowledge, presumably from experience or available technical literature. Many rules seem, and indeed are, arbitrary; but as explained before, they were originally written to incorporate ‘what was considered good practice in the industry. Section I's method of achieving safe boiler design is a rolatively simple one. It requires all those features ‘considered necessary for safety (eg., water gage glass, safety valve, pressure gage, check valve, drain) and then provides detailed rules governing the construction of the various components comprising the boiler, be beet bee be hee ame te tee le teen beth le le lms PPP rr Por Por rf bor ro ro ror bebo ro re re Introduction xix such as tubes, piping, headers, shells, and heads. This approach is analogous to the old saying that a chain is no stronger than its weakest link. For a boiles, the links ofthe figurative chain can be considered to be the material, the design (formulas, loads, allowable stresses, construction details), fabrication techniques including welding, inspection, testing, and certification by stamping and data reports. If each of these ‘clements meets the appropriate Section I rules, a safe boiler results. The boiler can then be described as 2 ‘Section I boiler, meaning one constructed to meet all the requirements of Section | of the ASME Boiler & Pressure Vessel Code. An important element of this construction process is a quality control program, intended to assure that the Code has been followed. Each aspect of the process is discussed in this book. ‘Code construction under the rules of Section Itakes place as follows: The ASME socredits a manufacturer (ie after appropriate review and acceptance of the manufacturer's facilities, organization, and quality control system, authorizes the manufacturer to engage in Code construction). The manufacturer then constructs, documents, certifies, and stamps the boiler in compliance with the rales of Section I, The manofacturer's activities ave monitored and inspected by a third party (the Authorized Inspector, see Chapter 8). The boiler is then acceptable to jurisdicions with laws stipolaing ASME consruction of boilers. Section “Viti construction (of pressure vessels) and Section IV construction (of heating boilers) is carved out in siwilar fashion, De ee ett Dome Be Be fe eet Seas Pt u LO ACKNOWLEDGMENT ‘We wish to acknowledge first the generous support of our companiss, Foster Wheeler Energy Corporation. and the Babcock and Wilcox Company, support which for so many years has provided us the opportunity and the honor of serving on the ASME Boiler and Pressure Vessel Commitee. ‘The material presented in this book is based on knowledge we have gained ducing our careers in the industry and from oor fong participation on the Code committees. Much of what we have learned tas come from present ard former colleagues at our companies and on those committees. We have sought the assistance of many of them in reviewing this book. Although itis not possible to name them all, we do acknowledge with thanks the particular assistance and helpful suggestions of the following: Chuck Recht 1V, Jeff Blough, Joe Breuszkiewicz, D'or Doty, Jim Farr, Joel Feldstein, Joha Fishburn, Ron Friend, Roo ‘Haupt, Bd Kistner, Tom McGough, Bob McLaughlin, Peter Molvie, Kim Morrison, T.V. Narayanan, Everett Rodabaugh, Blaine Roberts, Bob Schueler, Mark Sheehan, Will Somers, and Mitch Stanko. Pebu bo ba Po Pa Pa Po Pa Pa te Pe be Pe Pe Poe Pe Pe Pa ‘ CHAPTER 1 Score oF SECTION I, ORGANIZATION, AND Service Limits SCOPE Section I applies to several types of boilers and components of boilers, such as economizers, superheaters, Teheaters, and in some circumstances feedwater heaters. Although its tile is Power Boilers, its scope is ‘somewhat broader. The Preamble to Section [ explains that it covers electric boilers, miniature boilers, high-temperature water boilers, and organic fluid vaporizers. Since the precise definitions of these various types of boilers are not generally known, the following deiintions, found in footnotes to the Preamble, are helpfal: Power boller—e boiler in which steam or other vapor is generated at a pressure of more than 15 psi for use external to itself Eleetriec boiler.—a power boiler or a high-temperature water boiler in which the source of heat is electricity. ‘Miniature boiler—e power boiler or high-temperature water boiler in whitch the limits in PMB-2 are not exceeded. (PMB-2 establishes limits on shell diameter, heating surface, gross volume, and ‘maximum allowable working pressure. See further discussion under Part PMB later in this chapter.) ‘High-temperature water boiler —a watcr boiler intended for operation at pressures in excess of 160 psi end/or temperatures in excess of 250°P. Ithappens that Section I doesn't provide an explicit definition of an organic fluid vaporizer. An organic fluid vaporizer is a boilerike dovice that uses an organic fluid instead of steam as the working fluid. The fast paragraph of the Preamble states that a pressure vessel in which an organic fluid is vaporized by the application of heat resulting from the combustion of fuel shall be constructed under the provisions of Section I, (Those provisions are found in Part PVG.) Thus, so far as Section I is concemed, an organic fluid vaporizer is a boilerlike device in which an organic Fuid is vaporized as just described. (Note that a key factor is the vaporization of the organic fluid. Ifthe organic fuid is merely heated without vaporizing, the device does not fall within the scope of Section I; it might fall instead under the scope of Section VITT a5 1 pressure vessel) The Preamble then provides a notable exception to the Section I definition of an ‘organic fuid vaporize: ‘*Vessels in which vapor is generated incidental to the operation of a processing System, containing number of pressure vessels such as are used in chemical and petroleum manufacture, are not covered by the cules of Section 1.” Again, if Section I rules don’t cover these vessels, what rules 1 2 Chapter do? The answer is, the rules of Section VIEL Pressure Vessels. Those rules cover all kinds of pressure vessels, including in some cases fired pressure vessels. ‘Although the origin of the above exception to Section I coverage is uncertain, a possible explanation can bbe offered. Note that the vessel in question would probably be used in a chemical plant or petroleum fefinery. Such plants are normally owned and operated by large companies with capable engineering staffs and well-trained operators. Those companies can sully demonstrate a good record of maintenance and safety. Furthermore, vaporizing organic liquids inside pressure vessels is a routine matter for them. They might also argue that it really doesn’t make much difference whether « properly designed vessel is built 10 the rules of Section I or Section VEIL, nor does it matter whether the source of heat is from direct firing, from hot gases that may have given up some of thei heat by having passed over heat-transfer surface ‘upstream, or from a hot liquid that is being processed. There are also economic reasons why an owner ‘might prefer a Section VIN vessel over # Section I vessel, as explained later in the discussion of fired versus unfired boilers. ‘The Preamble doesn't expliin the precise meaning of “‘vapor generation incidental to the operation of 1 processing system."” It apparently means the generation of vapor in a vessel or heat exchanger that is part of # processing system in a chemical plant or petroleum refinery where this vapor generation is oaly 8 minor o secondary aspect of the principal business of the plant, such as refining oil. Thus, cestain ‘equipment normally constructed to Section I rales could, under this exception, be constructed instead (0 the rules of Section VIII, provided the appropriate authorities in the jurisdiction where the equipment it to be installed have no objection. As will be explained later, these so-called jurisdictional authorities have the last word in deciding which Code section applies (See How and Where Section I Is Enforced in Chapter 2). ‘There is also some imprecision in the use and meaning of the term power boller. That term is sometimes ‘understood to mean a boiler whose steam is used forthe generation of power, as opposed, for example, to ‘boiler whose steam is used for chemical processing or high-pressure steam heating, However, according 10 the definition in the Preamble, a boiler that generates steam or other vapor at a pressure greater than 15 psi for external use is considered by Section I to be & power boiler, irrespective of how the steam might ‘be used. Although exceptions exis, must jurisdictional authorities follow the ASME Code in defining and ‘categorizing boilers and pressure vessels. ‘Note from the definition of a power boiler that the steain ot other vapor generated is for use external to the boiler. This is supposed to distinguish a power boiler from certain other pressure vessels such as autoclaves, which may similarly generate steam or vapor ata pressure greater than 15 psi, but not generally for extemal use. These pressure vessels, oftea used as process equipment in the chemical and petroleum ‘tidastries, and for cooking or sterilizaticn in other industries, are designed to meet the rules of Section VILL * From the Preamble lefinitions, it is apparent that @ high-temperature water boiler, which generally ‘produces pressurized bot water for beating or process tse, is not considered a power boiler. However, 28, ‘practical matter, the particular characterization of a device by Section I as a power boiler or something

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