Types of Boilers Explained

BOILER 3.
Ir.Sadani
Types of Boiler
There are two main types of boilers
• Water Tube Boilers: Water tube boilers are used in large power plants. In such type of boilers the
water runs through tubes while there is fire surrounding them. These types of boilers are also ideal
for high pressure applications.
Figure 1 : water tube boiler

• Fire Tube Boilers: Fire tube boilers are usually used for the small scale applications. One
advantage that these boilers have over other types is that they are compact in size and do not
occupy much space.
Figure 2: Fire Tube Boiler

BOILER INSPECTION AND TEST PLAN
REFERENCE ACCEPTAN VERIFING ACTIVITY BY REMARK
No. INSPECTION AND TEST PLAN
DOCUMEN CE DOCUMEN
MANUF. TPI CLIENT
T CRITERIA T
1 PRE‐INSPECTION MEETING SPEC. SPEC. MOM H H H
Before Manufacturing
DWG, DESIGN, DWG,

2 ASME, SPEC. ASME, SPEC H R A
CALCULATION DOCUMENT CALCULATION
BOOK
3 WPS & PQR ASME ASME IX WELDING BOOK H R A
WELDER QUALIFICATION
4 ASME ASME IX CERTIFICATES H R ‐
CERTIFICATES
5 NDT PROCEDURE ASME ASME V,I, IX PROCEDURES H R A
6 NDE PERSONAL CERTIFICATES ASME ASME V CERTIFICATES H R ‐
7 PWHT PROCEDURE ASME ASME I PROCEDURES H R A

HYDRO‐STATIC TESTING
8 ASME ASME I PROCEDURES H R A
PROCEDURE
9 PAINTING PROCEDURE ASME SPEC. PROCEDURES H R A
Materials
Original Material
10 MATERIAL CERTIFICATES ASME ASME II H H ‐
Certificates
11 STORAGE OF RAW MATERIALS ASME ASME ‐ H SW ‐
VISUAL, DIMENTION AND

12 ASME I ASME I REPORT H SW ‐
MARKING CONTROL
During Manufacturing‐HP DRUM, C.B.D AND I.B.D TANK
MATERIAL ASME, MATERIAL
13 ‐ H H ‐ ‐
RECEIVING DRAWIN CERTIFICAT
INSPECTION G ES
MARKING, CUTTING &
14 DRAWING ‐ ‐ H SW ‐ ‐
ROLLING OF SHELL
15 VERIFY DIMENSION OF HEAD DRAWING ‐ REPORT H W ‐ ‐
16 FIT UP (HEAD TO SHELL) DRAWING ‐ REPORT H SW ‐

DRAWING,
17 WELDING INSPECTION ‐ REPORT H W ‐
WPS/ PQR
NOZZLE MARKING
18 DRAWING WITHIN TOLERANCE REPORT H SW ‐
INSPECTION BEFORE
HOLE OPENING
NON‐DESTRUCTIVE
NDE
19 EXAMINATION ASME SEC I REPORT H SW ‐
PROCEDUR
(INCL. RT
E
FILMS)
DIMENSION &
VISUAL
INSPECTION
PWHT
21 POST WELD HEAT TREATMENT ‐ REPORT H SW/R ‐
PROCEDUR
E
NDE
22 FULL R/T (ONLY STEAM DRUM) ASME SEC I REPORT H SW/R ‐
PROCEDURE
DIMENSION AND VISUAL
23 DRAWING WITHIN TOLERANCE REPORT H H ‐
INSPECTION OF
INTERNAL
HYDRO. TEST
24 HYDROSTATIC TEST (AT SHOP) NO LEAK & DEFORM REPORT H H ‐
PROCEDURE
25 PAINTWG INSPECTION PAINTING SPEC. ‐ REPORT H W ‐
FINAL INTERNATIONA
PRE‐SHIPMENT INSPECTION
(PACKING,
PACKING
27 MARKING,QUANTITY, ‐ Packing List H H ‐
PROCEDUR
VISUAL CHECK, FINAL
E
DOCUMENT, REVIEW,
LOADING)
FINNED TUBES
MATERIAL RECEIVING
28 ASME, DRAWING ‐ H H ‐
INSPECTION
DIMENSIONAL / INTERNATIONAL
29 ‐ H SW ‐
VISUAL INSPECTION STD.
30 FINNING INSPECTION DRAWINGS ‐ H SW ‐
HEADERS
MATERIAL MATERIAL
31 ASME, DRAWING ‐ H H ‐
RECEIVING CERTIFICAT
INSPECTION ES
DIMENSIONAL / VISUAL
32 DRAWING ‐ REPORT H SW ‐
INSPECTION
33 HEADER DRILLING DRAWING ‐ REPORT H SW ‐
34 MARKING & CUTTING DRAWING ‐ REPORT H SW ‐
35 FIT UP (HEADER TO TUBE) DRAWING ‐ REPORT H SW ‐

DRAWING
36 WELDING INSPECTION ‐ REPORT H W ‐
, WPS/
PQR
NON‐DESTRUCTIVE
37 NDE PROCEDURE ‐ REPORT H SW ‐
EXAMINATION
FINAL DIMENSIONAL / INTERNATIONA
38 ‐ REPORT H H ‐
VISUAL INSPECTION L STD.
TUBE BUNDLE ASSEMBLY WITH CASING
VERIFY PROPER
39 ASME, DRAWING REPORT H R ‐
SPECIFIED PARTS
FOR ASS'Y
MATERIAL MATERIAL
40 DRAWING H H ‐
INSPECTION ES
41 VERIFY LENGTH OF HARPS DRAWING REPORT H SW ‐
FIT‐UP INSPECTION (TUBE TO
42 DRAWING REPORT H SW ‐
HEADER)
WPS/PQR,
43 WELDING INSPECTlON REPORT H W ‐
DRAWING
NON‐DESTRUCTIVE
44 NDE PROCEDURE ASME SEC. I REPORT H SW ‐
EXAMINATION (MT/PT,RT)
DIMENSIONAL / VISUAL
45 DRAWING WITHIN TOLERANCE REPORT H W ‐
INSPECTION
PWHT
46 POST WELD HEAT TREATMENT REPORT H R ‐
PROCEDURE
HYDRO. TEST
47 HYDROSTATIC TEST (AT SHOP) NO LEAK & DEFORM REPORT H H ‐
PROCEDURE
48 CASING FIT‐UP INSPECTION DRAWING REPORT H SW ‐
WPS/PQR,
49 CASING WELDING INSPECTION REPORT H SW ‐
DRAWIN
G
50 INSULATION DRAWING REPORT H SW ‐
51 PAINTING (MODULE BOX) PAINTING SPEC. REPORT H W ‐

FINAL DIMENSIONAL
52 & VISUAL INSEPCTION DRAWING WITHIN TOLERANCE REPORT H H ‐
(MODU LE BOX)
(PACKING, MARKING,
PACKING
53 QUANTITY, VISUAL CHECK, PACKING LIST H H ‐
PROCEDUR
INLET DUCT, BYPASS STACK & MAIN STACK
MATERIAL MATERIAL
54 DRAWING H H ‐
INSPECTION ES
DIMENSIONAL /
VISUAL
INSPECTION
INTERFACE OPENING
DIMENSION
INSPECTION
57 FIT‐UP INSPECTION DRAWING REPORT H SW ‐
WPS/
58 WELDING INSPECTION REPORT H W ‐
PQR,
DRAWING
NON‐DESTRUCTIVE
59 NDE PROCEDURE REPORT H SW ‐
EXAMINATION (IF
ANY)
60 INSULATION DRAWING REPORT H SW ‐
61 PAINTING INSPECTION PAINTING SPEC. REPORT H W ‐

FINAL DIMENSIONAL
& VISUAL
INSEPCTION
(PACKING, MARKING,
PACKING
PROCEDUR
FINAL DOCUMENT
E
REVIEW AND LOADING)
DIVERTER DAMPER, BLANKING PLATE & SEAL AIR FAN
DOCUMENT STATUS
64 DOCUMENTS REPORT H R ‐
WITH APPROVAL STATUS
MATERIAL RECEIVING DOCUMENTS / MATERIAL
65 H H ‐
INSPECTION DRAWING CERTIFICATES
DIMENSIONAL /
FINAL DIMENSIONAL &
VISUAL INSEPCTION
(PACKING, MARKING,
PACKING
PROCEDUR
FINAL DOCUMENT REVIEW
E
AND LOADING)
STEAM VENT SILENCER
MATERIAL DOCUMENTS / MATERIAL

71 H H ‐
RECEIVING DRAWING CERTIFICAT
INSPECTION ES
DIMENSIONAL /
VISUAL
INSPECTION
WPS/PQR,
73 WELDING INSPECTION (IF ANY) REPORT H W ‐
DRAWIN
G
NON‐DESTRUCTIVE
EXAMINATION (IF ANY)
75 NOISE ABSORPTION TEST PROCEDURE REPORT H H ‐

FINAL DIMENSIONAL
77 DRAWING REPORT H H ‐
& VISUAL
INSPECTION
(PACKING, MARKING,
PACKING
PROCEDUR
FINAL DOCUMENT REVIEW E
AND LOADING)
GAS SILENCER

DIMENSIONAL /
VISUAL
INSPECTION
WPS/
81 WELDING INSPECTION (IF ANY) REPORT H W ‐
PQR,
DRAWING
NON‐DESTRUCTIVE
EXAMINATION (IF
ANY)
FINAL DIMENSIONAL &
VISUAL INSPECTION
(PACKING, MARKING,
PACKING
PROCEDUR
AND LOADING)
DEAERATOR & STORAGE TANK
MATERIAL RECEIVING DOCUMENTS / MATERIAL
86 H H ‐
INSPECTION DRAWING CERTIFICATES
MARKING, CUTTING
& BENDING OF
SHELL
88 VERIFY DIMENSION OF HEAD DRAWING REPORT H W ‐
89 FIT UP (HEAD TO SHELL) DRAWING REPORT H SW ‐

DRAWING
,
WPS/PQ
R
NOZZLE MARKING DRAWING
91 WITHIN TOLERANCE REPORT H W ‐
INSPECTION BEFORE & ASME
HOLE OPENING SEC.I
NON‐DESTRUCTIVE
92 NDE PROCEDURE ASME SEC VIII REPORT H SW ‐
DIMENSION &
VISUAL
INSPECTION
POST WELD HEAT PWHT
94 REPORT H SW/R ‐
TREATMENT (IF PROCEDUR
REQUIRED) E
DIMENSION AND VISUAL
INSPECTION OF
INTERNAL
HYDRO.
96 HYDRO STATIC TEST (AT SHOP) NO LEAK & DEFORM REPORT H H ‐
TEST
PROCEDURE
FINAL DIMENSIONAL
& VISUAL
INSPECTION
(PACKING, MARKING, PACKING
99 PACKING LIST H H ‐
QUANTITY, VISUAL CHECK, PROCEDUR
AND
CHEMICAL DOSING AND SAMPLING SYSTEM
100 H H ‐
INSPECTION ES
DIMENSIONAL /
VISUAL INSPECTION
DRAWING
,
WPS/PQ
R
NON‐DESTRUCTIVE
103 NDE PROCEDURE ASME SEC VIII REPORT H SW ‐
EXAMINATION (IF
REQUIRED)
DIMENSION &
VISUAL INSPECTION
FINAL DIMENSIONAL
& VISUAL
INSPECTION
(PACKING, MARKING,
PACKING
PROCEDUR
E
AND LOADING
EXPANSION JOINT
110 H H ‐
INSPECTION ES
DIMENSIONAL /
VISUAL
INSPECTION
DRAWING
,
WPS/PQ
R
FINAL DIMENSIONAL
& VISUAL
INSPECTION
(PACKING, MARKING,
PACKING
PROCEDUR
E
AND LOADING
PIPING
MATERIAL RECEIVING MATERIAL
116 ASTM, DRAWING H H ‐
INSPECTION CERTIFICATES
WPS/
117 FIT‐UP & WELDING REPORT H SW ‐
PQR,
DRAWING
118 NDE (MT/ PT, RT) (ONLY NDE PROCEDURE REPORT SW ‐
(PACKING, MARKING,
PACKING
PROCEDUR
E
AND LOADING
MANUAL VALVES
MATERIAL MATERIAL
122 ASTM, DRAWING H H ‐
INSPECTION ES
123 NDE (IF REQUIRED) NDE PROCEDURE REPORT H SW ‐
PRESSURE TEST (HYDRO : SHELL
124 ASME B 31.1 NO LEAKAGE REPORT H H ‐
& SEAT, AIR: SEAT)
DIMENSIONAL /
VISUAL
INSPECTION
(PACKING, MARKING,
PACKING
PROCEDUR
E
AND LOADING
SIB PIPING & PIPING SUPPORT, SPRING SUPPORT,HANGER AND SPECIAL FmING

128 H H ‐
INSPECTION ES
129 QC DOSSIER REPORT H R ‐
INSULATION (INCLUDED ACC'Y) & LAGGING SHEET

MATERIAL MATERIAL
130 ASME, DRAWING H H ‐
INSPECTION ES
MAKER's
131 QC DOSSIER REPORT H R ‐
STANDARD
ELECTRICAL PANEL
DRAWING,
132 WIRING INSPECTION REPORT H SW ‐
DOCUMENTS
DIMENSIONAL / DRAWING,
133 REPORT H SW ‐
VISUAL DOCUMENT
INSPECTION S
134 INSULATION RESISTANCE TEST IEC REPORT H W ‐
DRAWING,
135 FUNCTION TEST REPORT H H ‐
DOCUMENT
S
(PACKING, MARKING,
PACKING
PROCEDUR
E
AND LOADING
ELECTRICAL BULK MATERIAL
MATERIAL RECEIVING DRAWING, MATERIAL
138 H H ‐
INSPECTION DOCUMENTS CERTIFICATES
139 WITHIN TOLERANCE REPORT H SW ‐
VISUAL DOCUMENT
INSPECTION S
DRAWING,
140 QUANTITY TEST REPORT H SW ‐
DOCUMENT
S
(PACKING, MARKING,
PACKING
PROCEDUR
E
AND LOADING
MATERIAL DRAWING, MATERIAL
143 H H ‐
RECEIVING DOCUMENT CERTIFICAT
INSPECTION S ES
144 WITHIN TOLERANCE REPORT H SW ‐
VISUAL DOCUMENT
INSPECTION S
DRAWING,
145 FUNCTION TEST REPORT H H ‐
DOCUMENT
S
DRAWING,
146 LEAK TEST REPORT H W ‐
DOCUMENT
S
147 CALIBRATION SPECIFICATION REPORT H W ‐

(PACKING, MARKING,
PACKING
PROCEDUR
E
AND LOADING
STRUCTURAL STEEL
MATERIAL MATERIAL
150 DRAWING H H ‐
RECEIVING‐ CERTIFICAT
INSPECTION ES
DIMENSIONAL /
VISUAL INSPECTION
VERIFY BOLT HOLE SIZE
& LOCATION
153 WELDING INSPECTION DRAWING REPORT H W ‐
154 PAINTING PAINTING SPEC. REPORT H W ‐

(PACKING, MARKING, PACKING
PROCEDUR
AND LOADING

156 DOCUMENT REVIEW REPORT H R R
157 RELEASE FOR SHIPMENT REPORT NOTE H R R
Abbreviations:
H: Hold Point = Hold on the production till TPI Inspector performs inspection and supervise the required test
W: Witness Point = Manufacture shall notify client and TPI Inspector but there is no hold on the production;
Client can waive this inspection based on his discretion and informs TPI Inspector accordingly.
R: Document Review = Review means Review document, which includes of material test certificates, WPS, PQR, NDT Procedures
and etc.
A: Approval
SW: Spot Witness = for items with spot witness manufacture shall notify TPI inspector as fulfilling the monitoring;
For example one random visit for whole UT tests or one or two visits for whole surface preparation works for painting.
MOM: Minute of Meeting
P.O: Purchase Order

Material
Material
WPS and PQR
PROCEDURE SPECIFICATION
A WPS used by an organization that will have responsible operational control of production
welding shall be a WPS that has been qualified by that organization in accordance with Article II.
PERFORMANCE QUALIFICATION
In performance qualification, the basic criterion established for welder qualification is to
determine the welder’s ability to deposit sound weld metal
RESPONSIBILITY
Welding. Each organization shall conduct the tests required in this Section to qualify the welding procedures used
in the construction of the weldments built under this Code and the performance of welders and welding operators
who apply these procedures.
Records. Each organization shall maintain a record of the results obtained in welding procedure and welder and
welding operator performance qualifications. Refer to recommended Forms in Nonmandatory Appendix B.
TEST POSITIONS FOR GROOVE WELDS
TYPES AND PURPOSES OF TESTS AND EXAMINATIONS
MECHANICAL TESTS
Tension Tests. Tension tests as described in QW-150 are used to determine the ultimate strength of
groove‐weld joints.
Guided-Bend Tests. Guided‐bend tests as described in QW-160 are used to determine the degree of
soundness and ductility of groove‐weld joints.
Fillet-Weld Tests. Tests as described in QW-180 are used to determine the size, contour, and degree
of soundness of fillet welds.
Toughness Tests. Tests as described in QW-171 and QW-172 are used to determine the toughness
of the weldment.
Stud-Weld Test. Deflection bend, hammering, torque, or tension tests as shown in Figures QW-
466.4, QW-466.5, and QW-466.6, and a macro‐ examination performed in accordance with QW-
202.5, respectively, are used to determine acceptability of stud welds
SPECIAL EXAMINATIONS FOR WELDERS
Radiographic or Ultrasonic examination per QW-191 may be substituted for mechanical testing
of QW-141 for groove‐weld performance qualification as permitted in QW-304 to prove the ability
of welders to make sound welds.
VISUAL EXAMINATION
Visual examination as described in QW-194 is used to determine that the final weld surfaces
meet specified quality standards
WELDING VARIABLES
Essential Variables. Essential variables are those in which a change, as described in the specific
variables, is considered to affect the mechanical properties of the weldment, and shall require
requalification of the WPS.
Supplementary essential variables are required for metals for which other Sections specify
toughness tests and are in addition to the essential variables for each welding process.
Nonessential Variables. Nonessential variables are those in which a change, as described in the
specific variables, may be made in the WPS without requalification.
TESTS
Intent of Tests. The performance qualification tests are intended to determine the ability of
welders and welding operators to make sound welds.
Qualification Tests. Each organization shall qualify each welder or welding operator for each
welding process to be used in production welding.
Identification of Welders and Welding Operators. Each qualified welder and welding operator
shall be assigned an identifying number, letter, or symbol by the organization, which shall be
used to identify the work of that welder or welding operator.
Record of Tests. The record of Welder or Welding Operator Performance Qualification (WPQ)
tests shall include the essential variables (QW-350 or QW-360), the type of test and test results,
and the ranges qualified in accordance with QW-452 for each welder and welding operator.
TYPE OF TEST REQUIRED
Mechanical Tests. Except as may be specified for special processes (QW-380), the type and
number of test specimens required for mechanical testing shall be in accordance with QW-452.
Volumetric NDE. When the welder or welding operator is qualified by volumetric NDE, as permitted
in QW-304 for welders and QW-305 for welding operators, the minimum length of coupon(s) to be
examined shall be 6 in. (150 mm) and shall include the entire weld circumference for pipe(s),
WELDING VARIABLES FOR WELDER
BASE METAL GROUPINGS
ALTERNATE BASE MATERIALS FOR WELDER QUALIFICATION
F-NUMBERS
WELD METAL CHEMICAL COMPOSITION
PROCEDURE QUALIFICATION THICKNESS LIMITS AND TEST SPECIMENS
INSPECTION AND TESTS
Each boiler, superheater, waterwall, or economizer shall be inspected during construction and
after completion by an Authorized Inspector (AI).
Duties of the AI are described elsewhere in this Section and include the following:
1. Verifying that the Manufacturer or Assembler has a valid ASME Certificate of Authorization
covering the scope of his Code activities
2. Monitoring compliance with the accepted Quality Control Program and verifying that any
changes meet the requirements of this Section
3. Verifying that the Certificate Holder has the necessary Code books, Addenda, and Code Cases
to cover the work being performed
4. Reviewing a selected number of the Manufacturer’s design calculations to verify compliance
with Section I
5. Witnessing and approving proof tests to establish Maximum Allowable Working Pressure
(MAWP)
6. Verifying that the Certificate Holder has sufficient material control to assure that material
used for construction complies with the applicable requirements of this Section
7. When cutting plate material into two or more pieces is necessary, verifying that the
Certificate Holder’s controls provide a positive means of identification to maintain traceability of
materials
8. Verifying that the Certificate Holder’s personnel are examining cut edges before welding
9. Verifying that all welding procedure specifications, procedure qualification records, welder
and welding operator qualification records conform to the requirements of this Section
10. If welded repairs are necessary, accepting the method and extent of repairs and verifying
that only qualified welding procedures, welders, and welding operators are used
11. Verifying that all required heat treatments have been performed and are properly
documented
12. Verifying that required nondestructive examinations and tests have been performed by
qualified personnel and that the results are properly documented
13. Performing the required inspections and witnessing hydrostatic tests
14. Verifying that the responsible representative of the Certificate Holder has signed the Data
Report and that it is correct before being signed
15. Prior to stamping, verifying that the item is in compliance with the requirements of this
Section. After stamping, verifying that the stamping is correct and that the nameplate, if used,
has been properly attached
16. The Manufacturer is responsible for the preparation of design calculations to show
compliance with the rules of Section I and his signature on the Manufacturers’ Data Report Form
shall be considered to include certification that has been done
17. The Authorized Inspector has the duty to review a selected number of the Manufacturer’s
design calculations to verify compliance with Section I.
QUALIFICATION OF INSPECTORS
The inspection required by this Section shall be by an Inspector employed by an ASME
accredited Authorized Inspection Agency. These Inspectors shall have been qualified in
accordance with ASME QAI-1.
EXAMINATION AND REPAIR OF FLAT PLATE IN CORNER JOINTS
1. When flat plate greater than 1 /2 in. (13 mm) thickness is welded to other pressure parts to
form a corner joint, such as in flat heads, and the exposed edges of the plate are closer to the
edge of the weld than a distance equal to the thickness of the plate, the peripheral plate edges
and any remaining exposed surface of the weld joint preparation shall be examined after
welding by either the magnetic particle or liquid penetrant method.
2. Laminations, cracks, or other imperfections found during the examination required by PG-
93.1 that would affect the safety of the vessel shall be repaired in accordance with PG-78. The
imperfection(s) may be pursued by any suitable method (grinding, chipping, etc.). The repaired
area shall be subjected to the same examination that first revealed the imperfection.
3. Methods and acceptance criteria for magnetic particle and liquid penetrant examination shall
be in accordance with A-260 or A-270, respectively.
Inspection During Fabrication.
The Manufacturer shall submit the vessel or other pressure part for inspection at such stages
of the work as may be designated by the Inspector.
CUTTING PLATES AND OTHER STOCK
1. Plates may be cut by machining, punching, shearing, or cutting by the electric arc or gas
process, providing enough metal is left at any unfinished edges to meet the requirements
2. When end faces of nozzle or manhole necks are to remain unwelded in the completed
vessel, these end faces shall not be cut by shearing unless at least 1 /8 in. (3 mm) of additional
metal is removed by any method that will produce a smooth finish.
MATERIAL IDENTIFICATION
1. Material identification shall be maintained until the data report (Partial Data Report or Master
Data Report) for the item containing the materials is complete.
2. When the boiler is completed, there shall remain visible on shell plates, furnace sheets, and
heads, one group of the plate manufacturer’s stamps, consisting of the manufacturer’s name,
plate identification number, material specification number with grade, class, and type as
appropriate, except that heads containing tube holes and butt straps shall have visible at least a
sufficient portion of such stamps for identification.
3. It is permissible for an authorized representative of the boiler Manufacturer to transfer the
markings on the plate provided a record is made of such transfer.
The procedure for making such transfer shall be acceptable to the Authorized Inspector.
4. An authorized representative of the plate manufacturer may duplicate the required stamping
on any material wherever located.
5. The fabricator shall also show by a supplement to the appropriate Mill Test Report that the
specified heat treatment has been performed.
6. For other than plate material, the maintenance of identification shall be at least to the type of
material. This can be achieved through any suitable method found acceptable to the Inspector,
such as color coding, abbreviated marking, written record, etc.
REPAIRS OF DEFECTS IN MATERIALS
Defects in material may be repaired by the boiler Manufacturer provided acceptance by the
Inspector is first obtained for the method and extent of repairs. Material that cannot be
satisfactorily repaired shall be rejected.
PERMISSIBLE OUT-OF-ROUNDNESS OF CYLINDRICAL SHELLS
Internal Pressure. Finished cylindrical sections of headers, shells, drums, and similar
components shall be circular at any section within a limit of 1% of the mean diameter, based on
the differences between the maximum and minimum mean diameters at any section.
External Pressure. Welded cylindrical furnaces and other cylindrical parts subjected to
external pressure shall be rolled to practically a true circle with a maximum plus or minus
deviation not to exceed the following:
(a) For components greater than 24 in. (600 mm) O.D., the maximum permissible deviation, “e”
Value for Fig. PG-80.
(b) For components equal to or less than 24 in. (600 mm) O.D., the maximum deviation shall not
exceed 1% of the O.D.
TOLERANCE FOR FORMED HEADS
The maximum variation from this true ellipse shall not exceed 0.0125 times the inside diameter
of the head.
WELDING PROCESSES
The following welding processes may be used for any Section I construction: shielded metal
arc, submerged arc, gas metal arc, hybrid plasma-gas metal arc, flux cored arc, gas tungsten
arc, plasma arc, atomic hydrogen arc, oxyhydrogen, oxyacetylene, laser beam, electron beam,
flash, induction, pressure thermit, pressure gas, and inertia and continuous drive friction
welding.
Definitions are given in Section IX, which include variations of these processes.
WELDING QUALIFICATION AND WELD RECORDS
Requirements for Qualification of Welding Procedures, Welders, and Welding Operators.
1. The Welding Procedure Specifications, the welders, and the welding operators used in welding
pressure parts and in joining load‐carrying non pressure parts, such as all permanent or
temporary clips and lugs, to pressure parts shall be qualified in accordance with Section IX.
2. When the welding process is automatic, welding procedure and performance qualification
testing is not required.
3. Welding of all test coupons shall be conducted by the Manufacturer.
4. No production work shall be undertaken until the procedures, the welders, and the welding
operators have been qualified, except that performance qualification by volumetric NDE, in
conformance with Section IX,(QW-304 and QW-305)
5. The Manufacturer shall maintain qualification records of the welding procedures, welders, and
welding operators employed, showing the date, results of the tests, and the identification mark
assigned to each welder.
6. The Manufacturer shall also establish a procedure whereby all welded joints,
7. the Manufacturer’s Quality Control System includes a procedure whereby the identity of the
welders or welding operators that made such welds on each pressure part will be maintained so
that the Inspector can verify that the welders or welding operators were all properly qualified
8. the welds are all the same type and configuration and are welded with the same welding
procedure specification
9. the Manufacturer includes a procedure to permit the Inspector to verify that such tack welds
were made by qualified welders or welding operators.
10. This weld test shall consist of five studs, welded and subjected to either the bend or torque
stud weld testing described in Section IX.
BASE METAL PREPARATION
1. The preparation of joints prior to welding may involve any of the conventional methods in use
such as machining, thermal cutting, chipping, grinding, or combinations of these.
2. The method of base metal preparation used shall leave the welding groove with reasonably
smooth surfaces and free from deep notches, striations, or irregularities. The surfaces for
welding shall be free of all scale, rust, oil, grease, or other foreign materials.
3. Cast surfaces to be welded shall be machined, chipped, or ground where necessary to
remove foundry scale and to expose sound metal.
ASSEMBLY
1. Parts that are being welded shall be fitted, aligned, and retained in position during the welding
operation within the tolerance specified in PW-33.
2. Bars, jacks, clamps, tack welds, or other appropriate means may be used to hold the edges
of the parts to be welded in alignment.
3. Tack welds, whether removed or left in place, shall be made using a fillet weld or butt weld
procedure qualified in accordance with Section IX. Tack welds to be left in place shall be made
by welders qualified in accordance with Section IX and shall be examined visually for defects
and, if found to be defective, shall be removed.
4. When joining two parts by the inertia and continuous drive friction welding processes, one of
the two parts must be held in a fixed position and the other part rotated.
ALIGNMENT TOLERANCE, SHELLS AND VESSELS (INCLUDING PIPE OR TUBE USED AS A
SHELL)
Any offset within the allowable tolerance provided above shall be faired at a 3 to 1 taper over the
width of the finished weld, or if necessary, by adding additional weld metal beyond what would
otherwise be the edge of the weld.
ALIGNMENT, TUBE AND PIPE
When tubes or pipes are welded together, the alignment shall be such that the inside surfaces
provide for complete weld penetration. The weld shall meet the reinforcement requirements of
PW-35.
FINISHED LONGITUDINAL AND CIRCUMFERENTIAL JOINTS
Butt welds shall have complete joint penetration. To assure that the weld grooves are completely
filled so that the surface of the weld metal at any point is not below the surface of the adjoining
base materials, weld metal may be added as reinforcement on each face of the weld. The
thickness of the weld reinforcement on each face shall not exceed the following:
Undercuts shall not exceed 1 /32 in. (0.8 mm) or 10%
of the wall thickness, whichever is less, and shall not
encroach on the required section thickness.
MISCELLANEOUS WELDING REQUIREMENTS
1. Before applying weld metal on the second side to be welded, the root of double ‐welded butt
joints shall be prepared by suitable methods such as chipping, grinding, or thermal gouging, so
as to secure sound metal at the base of weld metal deposited on the face side, except for those
processes of welding by which proper fusion and penetration are otherwise obtained and by
which the root of the weld remains free from impurities.
2. Fillet Welds. In making fillet welds, the weld metal shall be deposited in such a way as to
secure adequate penetration into the base metal at the root of the weld.
PREHEATING AND INTERPASS TEMPERATURES
1. The Welding Procedure Specification for the material being welded shall specify the minimum
preheating and maximum inter-pass requirements in accordance with the rules of this Section and
Section IX.
2. If preheating is performed using electric resistance heating pads, it is recommended that it be
performed in accordance with the requirement
3. No welding or thermal cutting operations shall be carried out on boiler components when the
temperature of the base metal in the welding or cutting zone is below 50°F (10°C).
4. The base metal temperature for the parts to be welded or thermally cut shall be at or above the
minimum required temperature as specified in the Welding Procedure Specification.
For tubes and pipes with an outside diameter and wall thickness not exceeding 10 in. (250 mm)
and 1 in. (25 mm) respectively, minimum preheat is to be established for a distance not less
than 3 times the thickness of the weld on either side of the weld. For all other welds, preheat
temperature is to be established in all directions from the point of welding for a distance of 3 in.
(75 mm) or 1.5 times the larger thickness of the pressure parts being joined, whichever is
greater.
5. For tack welds the base metal temperature shall be at or above the minimum temperature
specified in the Welding Procedure Specification for a distance not less than 1 in. (25 mm) in all
directions from the point of welding.
6. When welding two different P-Number materials, the minimum preheat temperature shall be
the higher temperature for the materials to be welded.
7. The temperature shall be verified by use of temperature-indicating crayons, thermocouple
pyrometers,
8. Except as detailed in the following or otherwise demonstrated by qualification of the Welding
Procedure Specification in accordance with the rules of Section IX, interpass temperature shall be
controlled to a maximum of 800°F (425°C).
HYDROSTATIC TEST
Hydrostatic testing of the completed boiler unit shall be conducted in accordance with the
following requirements:
1. After a boiler has been completed (see PG-104), it shall be subjected to pressure tests using
water at not less than ambient temperature, but in no case less than 70°F (20°C).
2. Hydrostatic pressure tests shall be applied by raising the pressure gradually to not less than
1-1 /2 times the maximum allowable working pressure as shown on the data report to be
stamped on the boiler.
3. The metal temperature shall not exceed 120°F (50°C) during the close visual examination.
4. But no less than 1-1 /4 times the maximum allowable working pressure of any part of the
boiler, excluding the boiler external piping.
Test Gages.
1. An indicating gage, visible to the operator controlling the pressure applied, shall be connected to
the pressure parts.
2. It is preferred that the range of the gage be double the intended maximum test pressure, but in
no case shall the range be less than 1-1 /2 nor more than 4 times that test pressure.
3. Digital pressure gages having a wider range of pressure readings may be used provided the
readings give the same or greater degree of accuracy as obtained with dial pressure gages.
4. Calibration certificate of the equipment that it’s used hydrostatic test pressure
REQUIREMENTS FOR POSTWELD HEAT TREATMENT
Before applying the detailed requirements and exemptions in these paragraphs, satisfactory
weld procedure qualifications of the procedures to be used shall be performed in accordance
with all the essential variables of Section IX including conditions of post weld heat treatment or
lack of post-weld heat treatment and including other restrictions listed below.
1. When pressure parts of two different P‐Number groups are joined by welding, the post-weld
heat treatment shall be that specified
2. Pressure part welds and attachment welds using ferritic filler metals that have a specified
chromium content of more than 3% shall receive a post-weld heat treatment.
MANUFACTURER’S DATA REPORT FORMS
1. When the certification of the complete boiler unit is accomplished by more than one Data
Report, the principal Data Report (Form P-2, P-2A, P-3, P-3A, or PL-1) shall be designated as the
Master Data Report (see PG-113).
2. Supporting Data Reports, such as Form P-4 and, when used as a Partial Data Report, Form
P-3, shall be attached to and referenced in the Master Data Report.
3. Requirements for completing multiple pages of Data Report Forms are shown in A-350.1.
MASTER DATA REPORT FORM
1. When a field‐assembled boiler unit is documented by Data Forms from manufacturers other
than the Manufacturer [see PG-104.1, Note (1)] responsible for the complete boiler unit, the
boiler Manufacturer shall complete the applicable Master Data Report Form by recording the
required data from all supporting Data Report Forms that are required for the complete boiler
unit. All Data Forms shall be securely attached to the Master Data Report
2. The Manufacturer’s written quality control system shall include requirements for completion
of Manufacturer’s Data Reports. The Manufacturer shall retain the Manufacturer’s Data Reports
for a minimum of 5 years.
REFERENCE CODE AND STANDARD
CODE
ASME Section 1, Boiler code
ASME section IX, Welding and brazing code
ASME section V, Non destructive examination
ASME Section II A specification Ferritic Materials
ASME Section II B Specification Non ferritic Materials
ASME Section II C Specification Material Consumable
ASME Section II D Specification Allowable stress Materials

Types of Boilers Explained

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Types of Boilers Explained

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BOILER 3.

Figure 1 : water tube boiler

Figure 2: Fire Tube Boiler

DWG, DESIGN, DWG,

6 NDE PERSONAL CERTIFICATES ASME ASME V CERTIFICATES H R ‐

7 PWHT PROCEDURE ASME ASME I PROCEDURES H R A

VISUAL, DIMENTION AND

15 VERIFY DIMENSION OF HEAD DRAWING ‐ REPORT H W ‐ ‐

16 FIT UP (HEAD TO SHELL) DRAWING ‐ REPORT H SW ‐

25 PAINTWG INSPECTION PAINTING SPEC. ‐ REPORT H W ‐

34 MARKING & CUTTING DRAWING ‐ REPORT H SW ‐

35 FIT UP (HEADER TO TUBE) DRAWING ‐ REPORT H SW ‐

51 PAINTING (MODULE BOX) PAINTING SPEC. REPORT H W ‐

61 PAINTING INSPECTION PAINTING SPEC. REPORT H W ‐

STEAM VENT SILENCER

MATERIAL DOCUMENTS / MATERIAL

76 PAINTING INSPECTION PAINTING SPEC. REPORT H W ‐

MATERIAL DOCUMENTS / MATERIAL

89 FIT UP (HEAD TO SHELL) DRAWING REPORT H SW ‐

MATERIAL DOCUMENTS / MATERIAL

INSULATION (INCLUDED ACC'Y) & LAGGING SHEET

148 PAINTING INSPECTION PAINTING SPEC. REPORT H W ‐

153 WELDING INSPECTION DRAWING REPORT H W ‐

154 PAINTING PAINTING SPEC. REPORT H W ‐

FINAL DOCUMENT REVIEW

157 RELEASE FOR SHIPMENT REPORT NOTE H R R

MOM: Minute of Meeting

P.O: Purchase Order

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