Power Boiler Design, Inspection, and Repair

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1 Power Boiler Design, Inspection, and Repair ASME Code Simplified Mohammad A. Malek, Ph.D., P.E. McGraw-Hill New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto

2 ice xvii >duction xix ipter 1. Boiler Fundamentals 1.1 Definition 1.2 Steam Generation Boiler flow diagram Thermodynamics Heat transfer 1.3 Boiler Classifications Classification based on ASME code Classification based on pressure Classification based on output Classification based on fuel Classification based on materials Classification based on use Classification based on tube type Miscellaneous boilers 1.4 Power Boilers Power boiler High-temperature water boiler Miniature boiler Electric boiler Organic fluid vaporizer 1.5 Boiler Performance 1.6 Selection of a Boiler 1.7 International Code 1.8 Power Boiler Life Analysis Useful life Code requirements 1.9 Jurisdictional Authority 2. Materials 2.1 Production Steel making process Ferrous metals and alloys

3 vi Contents Steel Nonferrous metal and alloys Forming shapes 2.2 Properties Physical properties Mechanical properties Chemical properties 2.3 Application of Materials Pressure parts Nonpressure parts 2.4 Ordering Standard Size and tolerances Code requirements Purchase order 2.5 Receiving Identification of materials Receiving inspection reports Mill test reports 2.6 Inspection Markings Transfer of markings Chapter 3. Boiler Design 3.1 Design Methods 3.2 Design Factors Definitions Design load 3.3 Cylindrical Parts under Stress Longitudinal stress in a cylinder Circumferential stress in a cylinder 3.4 Design of Boiler Components Cylindrical parts Dished heads Unstayed flat heads and covers 3.5 Openings and Compensations Small openings Medium openings Large openings Compensation for openings Steps in solving compensation problems 3.6 Stayed Surfaces Stayed flat plates Staybolts 3.7 Ligaments Ligaments for definite pattern Ligaments for indefinite pattern 3.8 Designer's Responsibilities Operating conditions Specifications

4 vii Design calculations Design Process 101 Chapter 4. Boiler Piping 103 } 4.1 Pipe Classifications Power Boiler Piping Boiler proper piping Boiler external piping 108 t Nonboiler external piping 110 ->' 4.3 Design Requirements Piping under internal pressure 111 *" Specific piping systems 115 *" 4.4 Materials 122 %^ American piping standard 123 * '* International standards 123 *' 4.5 Fabrication and Assembly Shop Inspection and Testing Stamping of pressure piping Code symbol stamp Manufacturer's data reports Operation and Maintenance In-service Inspection and Repair 127 ipter 5. Safety and Safety Relief Valves Working Principle Classifications Materials Capacity Requirements Relieving capacity Capacity checking Design Requirements Mechanical requirements Boiler safety valves Superheater and reheater safety valves Organic fluid vaporizer safety valves Safety Valve Manufacturing Manufacturers Capacity certification Testing by manufacturers Inspection and stamping Certificate of conformance Installation Requirements Operation and Maintenance Inspection and Repair Inspection Repairs 159

5 viii Contents Chapter 6. Fabrication Preparation Plates Cylindrical shells Formed heads Tube holes Holes for stays Repair of defective materials Fabrication by Welding Design Fabrication welding process Loading on structural attachments Inspection and tests Fabrication by Brazing Materials Design Fabrication Inspection and tests Assembly of Boiler Shop-assembled boilers Field-assembled boilers Production of a Firetube Package Boiler 195 Chapter 7. Watertube Boilers Working Principle Classifications Classification based on tubes' and drums' (structural) configurations Classification based on use Classification based on water circulation Classification based on output Classification based on erection Classification based on special purpose Main Components Design Features Construction of a Package Watertube Boiler Specifying a Package Watertube Boiler 230 Chapter 8. Firetube Boilers Working Principle Classifications Classification based on layout position Classification based on type of firebox Classification based on output Classification based on type of erection Classification based on special purpose Main Components Design Features Shell and tubesheet thickness Attachment of heads and tubesheets Tubes 256

6 ix : Combustion chamber tubesheet f Furnaces l Fireboxes and waterlegs r Stayed surfaces i'-' Doors and openings Domes f Setting 1" Piping, fittings, and appliances t' MAWP for furnaces and tubes t" 8.5 Construction of a Firetube Boiler?* 8.6 Specifying a Firetube Boiler Npter 9. Feedwater Heaters f 9.1 Working Principle I* 9.2 Classifications i Closed feedwater heater ^ Open feedwater heater I 9.3 Materials Sv 9.4 Design Features ** 9.5 Operation ^ 9.6 Maintenance 9.7 Specifying a Feedwater Heater ttapter 10. Miniature Boilers It «f 10.1 Classification m 10.2 Design Features s« Washout openings?i Feeding devices Blowoff connections Gage glasses p Safety valves ' Stop valves ^ Pressure gages w Inspection and Stamping k 10.4 Controls and Safety Devices kj Automatic low water fuel cutoff I: Electrical f 10.5 Specifying a Miniature Boiler Mpterii. Electric Boilers Ci1.1 Working Principle ^ 11.2 Classifications If 11.3 Design Features C Sizing L Pressure vessel l[f Inspection openings C Feedwater supply L Blowoff piping r Water gages F Pioina

7 11.4 Inspection and Stamping Inspection Hydrostatic test Stamp holder Stamping Manufacturer's data reports Controls and Safety Devices Safety valves Automatic devices Low water fuel cutoff Specifying an Electric Boiler 318 Chapter 12. Organic Fluid Vaporizers Organic Fluids Working Principle Classifications Design Features Vaporizer shell Gage glass Drain valves Hartford loop Code reference Inspection and Stamping Controls and Safety Devices Safety valve Rupture disks Level control Temperature control Operation Specifying an Organic Fluid Vaporizer 331 Chapter 13. Shop Inspection Boiler Fabrication Shop Manufacturer Manufacturer's responsibility Authorized Inspection Agency Qualification Duties Accreditation certificate Authorized Inspectors Qualification Authorized inspector's responsibility Inspection Tools Inspections The traveler Code inspection Field inspection Visual inspection Welding inspection Nondestructive Examination Hydrostatic Test Hydrostatic Deformation Test 347

8 xi ipter 14. Stamping and Data Reports 14.1 Stamp Holders Certificate of authorization Agreement with authorized inspection agency Quality control system 14.2 Code Symbol Stamps 14.3 Stamping Shop assembled boilers Field assembled boilers 14.4 Manufacturer's Data Reports Types of data reports 14.5 Selection of Data Report Forms ipter 15. Auxiliaries and Appurtenances 15.1 Boiler Auxiliaries Air system Fuel systems Steam system Feedwater system Draft system 15.2 Boiler Appurtenances Safety and safety relief valves Pressure gages Water columns Blowdown apparatus Fusible plugs Soot blowers Boiler vents 15.3 Boiler Accessories Blowoff tanks Sample coolers Flash economizers Mist separators Inline separators Temperature regulating valves Exhaust silencers pter16. FuelI Systems f 18.3 Fuels Gas Liquefied petroleum gas Fuel oils Coal Electricity Combustion Types of combustion Combustion process Chemical reaction Combustion air Fuel-Burning Systems Burners Pilots

9 xii Contents 16.4 Gas-Burning Equipment 16.5 Oil-Burning Equipment 16.6 Coal-Burning Equipment 16.7 NOx Control NOx control technologies Chapter 17. Boiler Controls pter 18. Boiler Installation Basic Boiler Controls Control loops Application to boiler Burner Management Control Standards Controls and Safety Devices Types Minimum controls Systems for multiple burners Installation Periodic Testing Boiler Installers Installation Code Boiler Room Water and drain connections Fire protection Housekeeping Posting the certificates Record keeping Safety Combustion Air Venting Boiler Placement Operation Tests Documentation Chapter 19. Boiler Operation 19.1 Operating Personnel Boiler operators Boiler engineers Training QFO-1 standard 19.2 Filling a New Boiler 19.3 Boiling Out Simple boilout method Stubborn boilout 19.4 Starting a Boiler 19.5 Condensation 19.6 Cutting in an Additional Boiler 19.7 Normal Operation

10 xiii 19.8 Boiler Shutdown 19.9 Periodic Tests Boiler Room Emergency Operation Logsheet ^Chapter 20. In-service Inspection 20.1 Authorized Inspectors Qualification Authorized inspector's responsibility 20.2 Boiler and Machinery Insurance 20.3 Inspection Tools 20.4 Boiler Inspection First inspection Routine inspection 20.5 Preparation for Inspection Preparation for internal inspection Preparation for external inspection 20.6 Inspection Types Internal inspection External inspection 20.7 Inspector's Calculations 20.8 Controls and Safety Devices Inspection 20.9 Repair Inspection Certificates Certificate of competency Certificate of compliance tapter 21. Boiler Maintenance Maintenance Personnel Maintenance Program Routine maintenance Preventive maintenance Shutdown maintenance Spare parts inventories Personnel training Boiler improvement Trouble-Shooting Maintenance Tools Tube Cleaning Mechanical cleaning Chemical cleaning Tube Expansion Preparing for Inspection Maintenance Logsheet ipter 22. Boiler Repairs 22.1 Repair Organizations 22.2 Repairs Routine repairs Major repairs

11 xiv Contents 22.3 Alterations Rerating and Derating MAWP for existing boilers Repair Calculations Repair Steps Preparation Authorization Repair work Welding Heat treatment Nondestructive examination Materials Repair inspection Hydrostatic test Repair nameplate Repair Methods Drum repair Tube repair Waterleg repair Handhole repair Stay repairs Welded crack repairs Seal welding of tubes Reversed flange (ogee) repair Documentation 512 Chapter 23. Water Treatment Boiler Water Water types Formation of scale Quantity of scale Boiler Water Problems Deposit problems Corrosion problems Foaming and priming Testing of Water Testing types Recommended limits Treatment Methods External treatment Internal treatment Condensate treatment Boiler Storage Wet method Dry method 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

12 xv idix D. Dimension of Heads Appendix E. Pipe Thickness I Ifcppendix F. Tube Thickness i )pendix G. Charts for Components under External 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 Organic Fluid 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 Procedure Specifications (WPS) idix R. Unit Conversions Bibliography 607 Index 611

2007 ASME Boiler & Pressure Vessel Code 2007 Edition July 1, 2007

AN INTERNATIONAL CODE 2007 ASME Boiler & Pressure Vessel Code 2007 Edition July 1, 2007 VI RECOMMENDED RULES FOR THE CARE AND OPERATION OF HEATING BOILERS ASME Boiler and Pressure Vessel Committee Subcommittee