50190057 codes standards

8/6/2019 50190057 Codes Standards

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CODES & STANDARDSCODES & STANDARDS


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PIPING

Codes, Standards & Regulations

ASME

DIN

TRD

BS

IBR


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Codes and Standards:

Several groups have written codes and standards for materials,

inspection, design, stress analysis, fabrication, heat treatment,

welding and construction of pipes and piping components.

Regulations, practices, rules and laws are also available for use

of piping. Certain aspects are mandatory and certain aspects

are recommendatory. The commonly used American Codesand Standards on piping are given below:


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1. ASME B31.1 - Power Piping

2. ASME B31.2 - Fuel Gas Piping

3. ASME B31.3 - Process Piping

4. ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids.

5. ASME B31.5 - Refrigeration Piping

6. ASME B31.8 - Gas Transmission and Distribution Piping

Systems

7. ASME B31.9 - Building Services Piping 8. ASME B31.11 - Slurry Transportation Piping Systems.


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Through the use of codes and standards, safety and uniform economy areobtained. The codes and standards primarily cover the following aspects:

1. Factors safety

2. Material property

3. Thickness calculation

4. Loads

5. Load combinations

6. Stress limits

7. Stress intensification factors

8. Flexibility factors

9. Supports

10. Flexibility analysis.


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The Know why is not covered by the codes and standards. The

Know why is learned by study, experimentation, application and

experience. In most of the situations, a knowledge of Know what

and Know how is sufficient to solve the problems. A knowledge ofKnow why will help in handling the following situations:

1. Material selection

2. Applicable code and standards

3. Evaluation of the deviations

4. Use of new fabrication and inspection methods.


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Codes and Standards:

The following codes and standards are referred:

1.ASME-I : Rules for Construction of Power Boilers

2.ASME B31.1-1998 : Power Piping

3.ASME B16.5-1996 :Pipe Flanges and Flanged Fittings NPS through 24.

4.IS 1239 (Part-I)-1990 :Mild Steel Tubes, Tubular and other

Wrought Steel Fittings - Mild Steel Tubes

5.IS 1239 (Part-II)-1992 :Mild Steel Tubes, Tubular and other Wrought Steel Fittings Steel Pipe Fittings


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Nominal Pipe Size (NPS):

The Nominal Pipe Size (NPS) in an ASME method of indicating the

approximate outside diameter of the connected pipe in inches. Notethat the unit (inch) is not followed after the designation.

Class of Fittings:

The class of fittings is an ASME method of indicating the pressure

carrying capacity of the fittings.


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Schedule of Pipes:

The schedule of pipes is an ASME method of indicating the pressurecarrying capacity of the fittings.

Types of Flanges:

The following types of flanges are used:

1. Threaded

2. Socket welding

3. Blind

4. Slip-on welding

5. Lapped

6. Welding neck.


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Pressure Temperature Rating:

Ratings are maximum allowable working gauge pressure at a

given temperature. These values are given in ASME B16.5.

Selection of Flanges:

The flanges are selected based on the application, pressure,temperature and size.


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ASME Section-I PG 9 Materials Specifications List.

ASME Section-II Part-A Material Specifications.

- SA106, 192, 299, 210, 213, 234, 515.

ASME Section-II Part-D Table IA Maximum Allowable Stress

- Table Y, U

ASME Section-II Part-A

Tubes - SA450 - Specification for General Requirements for tubes.

Pipes - SA530 - Specification for General Requirements for Pipes.

Fittings - SA234 - Specification for Piping Fittings.

Drum combined bending Stress BS 1113, ANNEX-B.

REFERENCES


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Boiler Codes have been written by various nations in the past

century to ensure safety of personnel and to avoid loss of property. Boiler

codes cover the whole gamut of activities including Design, Fabrication,Testing, Construction and Operation. Although these codes are framed on a

common intent, there are variations on the degree of conservation on

different aspects. One such area where variations do exist between Boiler

Codes is the criteria stipulated for calculating the allowable stresses. In the

present day context of evolving competitive design without sacrificing the

safety needs laid down in the boiler codes, an attempt has been made bycomparing the various aspects in the design like allowable stress, Design

temperature criteria, the various formulae used to determine the thicknesses

for drums / shells, headers, tubes, dished / flat ends, etc, other aspects like

minimum design requirements for drums/headers & tubes and presented in

annexures. The various aspects of IBR Regulations are called out and

consolidated against major items like drum, headers, lines & links, etc. Thefollowing codes have been considered for the study:-

1.IBR 1950

2.ASME Section-I

3.BS 1113

4.DIN TRD 300.

COMPARISON OF BOILER CODES


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The observations made between various boiler codes in respect

of design are given below:-

1) Yield strength at room temperature is not considered in BS1113

and IBR whereas factor of safety at room temperature in ASMESection-I is 1.5 and the same in TRD is 2.4.

For tensile strength at room temperature, both IBR and BS1113

considers a factor of safety of 2.7 whereas in ASME Section-I

indicates 3.5 and not considered in TRD. In the case of rupture

strength, all codes consider factor of safety as 1.5 except

BS1113 which shows 1.3.

2) In the case of Design Pressure of the boiler IBR alone considers

pressure drop for various components inline with erstwhile ISO

R831 whereas the rest of the codes indicate the boiler to bedesigned for drum design pressure.

3) In respect of Design Temperatures, all codes apply some fixed

temperature allowances over the medium temperature except

ASME Section-I which states that parts to be designed for actualmetal temperatures.


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4) Comparison material grades among various codes indicate

specification as common for most of the material

compositions. DIN (GERMAN) indicates a specification 12

Cr, 1 Mo, V composition (X20) which is not finding aplace in both ASME & BS1113. Also, when there is a

specification indication for austenitic steels like 18 Cr 8 Ni,

18 Cr 10 Ni Cb in both ASME & BS1113, there is no such

grade under TRD 300.

It is concluded that ASME Section-I gives the most

stringent criteria on design for deciding the allowable

stresses (Tensile / 3.5) compared to other international

codes below creep region. BS1113 & IBR are same in

respect of design criteria for allowable stresses (Tensile /

2.7). TRD 300 is in between ASME & IBR / BS1113 since

the allowable stress values of DIN falls in between them.

Above creep region, BS1113 gives more liberal criteria

(Creep rupture / 1.3) compared to other international codes.

Weight savings arising out of adopting BS1113 compared

to ASME Section-I is also illustrated in an annexure.

CO SO O O CO S


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Sl.No. Item Description

01. Applicability of Code Regulations

02. Maximum Allowable Working Pressure

03. Design Pressures & Design Temperatures

04. Comparison of Codes

05. Design Stresses - Factors of Safety

06. Comparison of Material Grades

07. Temperature Limits for various Steel Grades

08. Design - Calculation of Thickness Required

09. Openings in Shell

10. Ligament Efficiency

11. Drum / Headers comparison - 2 sheets

12. Tubes comparison

13. Relationship between Allowable Stress, Weight Savings

14. IBR Regulations - Clauses - 2 sheets

15. IBR Regulation Numbers - Ascending Order - 8 sheets

16. Requirements as per ASME Section-I - 3 sheets

17. Salient Clauses of BS1113 - 3 sheets

COMPARISON OF BOILER CODES


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APPLICABILITY OF CODE REGULATIONS

IBR

Applicable to boiler that is a closed vesselexceeding 22.75 litres in capacity which isused to generate steam under pressure.

ASMESec. I

Applicable to boilers in which the steam or anyother vapour is generated at a pressure more

than 15 PSI (g).

BS 1113

The rules specify the requirements for thewater tube steam generating plant subject tointernal pressure.

TRD 300

The rules apply to steam boilers and to feedwater preheaters, SH with shut off devices,RH, DESH, steam and hot water lines andfittings which are regarded as part of thesteam boiler installation.


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MAXIMUM ALLOWABLE WORKING PRESSURE

IBR

It is the working pressure of any componentof the boiler.

ASMESec. I

It is the maximum pressure to which any partof the boiler is subjected to except when SV

or SRV or Valves are discharging at whichtime the MAWP shall not be exceeded bymore than 6%.

BS 1113

It is the highest set pressure on any SV

mounted on the steam drum.

TRD 300

For steam generators, the design pressureshall be the allowable pressure.

DESIGN PRESSURES & DESIGN


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AREA

IBR

ASME

SEC.I

BS

1113

DIN

TRD300DESIGN PRESSURE

Drumdesign

pressurewith

pressuredrop

Drumdesign

pressure

Drumdesign

pressure

Drumdesign

pressure

RADIATION

50C 50C 50C

CONVECTION

39C 35C 35C

ECONOMISER

11C 25C 15+2xAct.wall thick)

CMax. 50C

WATER WALLS / SHWALLS

28C 50C 50C

GAS TOUCHED DRUMS/HEADERS

28C 25C 20CACTUAL

MET

ALTEMPE

RATUR

E

371C(M

IN)FORGA

S

TOUCH

ED

PORT

ION

DESIGN PRESSURES & DESIGNTEMPERATURES - ALLOWANCES USED IN

VARIOUS CODES


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IBR 1950 ASME SEC.I BS 1113 DIN TRD 300 REMARKS

DESIGN

PRESSURE

DESIGN

PRESSUREWITH

PRESSUREDROP

DRUM DESIGN

PRESSURE

DRUM DESIGN

PERSSURE

DRUM DESIGN

PRESSURE

DESIGNTEMPERATUEALLOWANCERADIATION

50C

ACTUALMETAL

TEMPERATURE371C (MIN)

50C 50C

CONVECTION

39C 35C 35C

ECONOMISER

11C

25C

(15 + 2 Se) CMax. 50C

Se - ACTUAL WALLTHICKNESS

in mm.

WATER WALL

28C 50C 50C

TUBETHICKNESS

FORMULA tmin

PD

--------- + *C

2f + P

PD--------- +

0.005D2f + P

PD---------

2f + P

PD---------

2f + P

P=DESIGN PR.D=OUTSIDE DIAf=ALLOWABLE

STRESSCORR. TODESIGN

METAL TEMP.

FACTOR OFSAFETY

Et R

1.5 , 2.7SR SC1.5

Et R

1.5 , 3.5SR SC1.5

Et R

1.5 , 2.7SR1.3

Et R

1.5 , 2.4SR1.0

Et = YIELDSTRENGTHR = TENSILESTRENGTHSR = RUPTURESTRENGTHSC = CREEPSTRENGTH

FOR ASME MATERIALS ALLOWABLE STRESS CAN BE TAKEN DIRECTLY FROM ASME SEC.II PART-D

COMPARISON OF CODES

*C = CORROSION ALLOWANCE = 0.75mm FOR P 70 bar; 0 mm FOR P > 70 bar


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PROPERTIES

IBR

ASMESEC.I

BS 1113

DIN TRD

300

Min. yield strength at RoomTemperature

---

1.5

---

---

Min. yield strength at DesignTemperature

---

---

1.5

1.5

Average yield strength at DesignTemperature

1.5

1.5

---

---

Min. ultimate tensile strength at RoomTemperature

2.7

3.5

2.7

2.4

Average creep rupture strength for100,000 hours life at DesignTemperature

1.5

1.49

1.3

1.0

Average creep strength for 1% creep in100,000 hours at Design Temperature

1.0

1.0

---

---

For Austenitic steels, FS = 1.35

To be used at temperature below 1500FFor components without an acceptance test certificate to DIN 50049, FS shall be increas

DESIGN STRESSES FACTORS OF SAFETY IN VARIOUS CODES


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Max.ServiceTemperature

475C885F 500C930F 550C

1020F

560C

1040F

575C1065F 600C1110F 625C

1155F

Gr.A

A192

Gr.B

Gr.A1

Gr.C

Gr.C

T1P1

T2 /P2

T12/P 12

T11/P11

T22/P22

T9/P9

BS3059-3602-

3604

360

410

440-

460

490Nb

243

620

621

622

660

629

DIN(GERMANY)17175VdTUV.B1(Werkstoff-Nr.)

St.35.81.0305

St.45.81.0405

17Mn41.0481

19Mn51.0482

15Mo31.5415

16Mo51.5423

15NiCuMoNb51.6368

13CrMo441.7335

10CrMo9 101.7380

(14MoV63)1.7715

(X12CrMO91)1.7386

GOST(RUSSIAN)TY 14-3-460-75

20

15XM

12X1MF

(15XIMIF)

JIS(JAPAN)G3456G3458G3461G3462

STPT38STB35

STPT42STB42

STPT49

STPA12STBA12

STPA20STBA20

STPA22STBA22

STPA23STBA23

STPA24STBA24

STPA26STBA26

NF A 49-213(FRENCH)

TU37-C

TU42-C

TU48-C

TU52-C

TU15D3

TU15CD2.05

TU13CD4.04

TU10CD5.05

TU10CD9.10

TUZ10CD9

ASMESA 106SA 192SA 209 - SA 210SA 213 - SA 335

cative only. However, the actual maximum service temperature for various steels shall be limited as prescribed in the relevant

COMPARISON OF MATERIALS GRADES


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Sl. Nominal MATERIAL SPECIFICATION Temp.

No. Composition ASME Section-I DIN TRD 300 BS 1113 LimitC

01.

Carbon Steel

SA178 Gr.C, Gr.D,SA192, SA210Gr.A1& Gr.CSA106 Gr.B, Gr.C

St 35.8St 45.8

BS3059 P2 S2 360, 440BS3602 P1 360, 430,500 Nb

427

02. Mo

SA209 T1

15 Mo3

----

482

03.

1 Cr Mo

SA335 P12SA213 T12

13 Cr Mo 44

BS3059 P2 S2 620BS3604 P1 620 440

535

04.

1 Cr Mo

SA213 T11SA335 P11

----

BS3604 P1, 621

552

05.

2 Cr 1 Mo

SA213 T22SA335 P22

10 Cr Mo 910

BS3059 P2 S2 622-490BS3604 P1, 622

577

06.

9 Cr 1 Mo V

SA213 T91

SA335 P91

X 10 Cr Mo V

Nb91

-----

635

07.

12 Cr 1 Mo V

-----

X 20 Cr Mo V121

BS3059 P2 S2 762BS3604 P1 762

700

08.

18 Cr 8 Ni

SA213 TP304 H

-----

BS3059 P2 304 S51BS3605 304 S59 E

704

09.

18 Cr 10 Ni Cb

SA213 TP347 H

-----

BS3059 P2 347 S51BS3605 347 S59 E

704

TEMPERATURE LIMITS FOR VARIOUS STEEL GRADES OF TUBES / PIPES


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AREA

IBR

ASME SEC.I

BS 1113

DIN TRD 300

Tubethickness

PD

+ C

2f + P

PD

+0.005D

2f + P

PD

2f + P

PD

2f + P

Shellthickness

PR + 0.75

fE 0.5 PPR

fE (1Y) PPR

fE 0.5 PPR

fE 0.5 PE

Dished end

thickness

PDK + 0.75

2f

PR

2f 0.2 PPDK

2f

2PR 1+

1 2fP

Flat endthickness

CPd + C

f

CPd

f

PCd

f

PCd

f

DESIGN - CALCULATION OF THICKNESS REQUIRED IN VARIOUS CODE


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IBRPD

8.08 [Dt (1 K)]1/3 K =1.82 St

ASME Sec. IPD

8.08 [Dt (1 K)]1/3 K =1.82 St

BS 1113

PD

8.08 [Dt (1 K)]1/3 K =1.82 St

TRD 300

tbranch

For dia of Opg. 50 mm, 2t

shell

For dia of Opg > 50 mm,

opg dia tbranch

if 0.2, then 2.shell ID t

shellopg dia t

branch

if > 0.2, then 2.

shell ID tshell

OPENINGS IN SHELL

LIGAMENT EFFICIENCY


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EFFICIENCY

ASME

IBR

BS 1113

Longitudional

P dP

P dP

P dP

Circumferential

PC d

PC

PC d

PC

PC d

PC

Diagonal

J + 0.25 (1 0.01 Elong

) 0.75 +J

0.00375 + 0.005 J

2

A + B+ (A B)2 + 4C22

A + B+ (A B)2 + 4C2

D 300 gives lengthy equations for calculating the ligament efficiency factors. For a single opening,

all

di

A + A

all

VA = and for multiple openings,

all

SV

2 AP+ A A

all

all

all

di

A 0 + A 1 + A 2 all all

VL =

all

all

LIGAMENT EFFICIENCY


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DESCRIPTION

IBR

ASME SEC.I

BS 1113

DIN TRD 300

Min. Plate thicknessfor shell

6 mm

6 mm

6 mm

3 mm

Type of weld joint

Single or double Uor V type.

Double welded butttype. The shapeshall be such as topermit completefusion andcomplete jointpenetration.

Double V Type orU type.

Double V type.

Position of tube

holes

Allowed through

welded seams, ifthey areradiographed andstress relieved.The ligamentefficiency shall bemultiplied by afactor 0.95.

Any type of opening

that meets therequirements forcompensation maybe located in awelded joint.

Machining of holes

through the centreof main seam weldsis permittedprovided the seamwelds have beensubjected to NDE.

-----

Circularity of Drum

Difference betweeninternal diameter ofdrum shall notexceed 1%.

The drum shall becircular within alimit of 1% of meandiameter based onthe differences

between maximumand minimum meandiameters.

Maximum internaldiameter of drumshall not exceed thenominal internaldiameter by more

than 2%.

The average boreshall not deviate bymore than 1% fromthe nominaldiameter.

Percentagedeviation fromcircularity

2 (d max. d min.)X 100

d max. + d min.

D max. D min.X 100

DS

D max. D min.

X 100

DS

2 (d max. d min.)

X 100d max. + d min.

Hand hole size inHeaders

89 x 63.5

89 x 70

-----

------

DRUM / HEADERS - COMPARISON WITH VARIOUS CODES


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DESCRIPTION

IBR

ASME SEC.I

BS 1113

DIN TRD 300

Hydraulic testpoint - Shop & testpressure.

Drums & Headersgreater than 1000mm shall behydraulic tested atshop to 1.5 timesthe DesignPressure.

-----

Drums & Headersgreater than 600mm shall behydraulic tested atshop to 1.5 timesthe max.permissibleworking pressure.

-----

Wall thicknesstolerance for pipes

/ headers.

+ 15%5%

12.5% + 10%10%

+ 12.5%10.0%

Hydraulic testpressure at site.

1.5 times the DrumDesign Pressure.

1.5 times themaximumallowable WorkingPressure.

1.5 times themaximumpermissibleWorking Pressure.

1.3 times themaximumallowable WorkingPressure.

Requirement ofSafety Valves.

Two safety valves -the bore not less

than 19mm.

Two or more safetyvalves.

Two safety valves.Minimum bore 20

mm.

Two or more safetyvalves.

Water levelindication.

Two means ofindicating waterleve.

Two numbers ofgauge glass. Twoindependentremote levelindicators insteadof one gauge

glass.

Two independentmeans of waterlevel indication.

Two means ofindicating waterlevel.


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DESCRIPTION

IBR

ASME SEC.I

BS 1113

DIN TRD 300

TYPECold drawn or hotfinished seamlessor ERW

Cold drawn orhot finishedseamless or ERW

Cold drawn or hotfinished seamlessor ERW

Cold drawn or hotfinished seamlessor Longitudinallywelded

Minimumthicknessallowed forvarious tubeDiameters -Seamless.

Up to D32 -2.03Up to D51 -2.34D51 to D76 -2.64D76 to D89 -3.25D89 to D114 -3.66

Up to D32 -2.41

Up to D51 -2.67D51 to D76 -3.05D76 to D102 -3.43D102 to D127 -3.81

Up to D38 -1.7D38 to D51 -2.2D51 to D70 -2.4D70 to D76 -2.6D76 to D95 -3.0D95 to D102 -3.3

D102 to D127 -3.5

Min. - 3 mmMax. - 6.3 mmfor Water walltubes

Ovality(Deviation fromcircularity)

D Max. D Min. x100

D

shall not exceed

20D

R

D D Min.x

100

D

shall not bemore than50D

%R

2(DMax.DMin.)x100

DMax + DMin

Providescalculation forwall thickness for

inside & outsideof bend as perTRD301 Annex-2.

Wall thicknesstolerance

+ 10% 5%

+ 22% 0%

+ 10% 10%

+ 15% 10%

TUBES - COMPARISON WITH VARIOUS CODES

RELATIONSHIP BETWEEN ALLOWABLE STRESS WEIGHT


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Sl.

No

Materia

lSpecn.

Design

Temp.C

Allowable StressKg/mm2

%

increasein

allowableStress

Correspond-ing

in

allowableStress

ASME BS 1113

01.

Water Walls

SA210Gr.C

385

11.038

13.228 19.8

11.4

02.

Downcomers

SA106Gr.C

357

11.993

13.570 13.0

9.8

03

Riser Pipes

SA106Gr.B

357

10.339

11.859 14.7

9.8

04.

Economiser

SA210

A1

311

10.546

12.896 22.3

16.0

05.

Low temp.SH

SA210

A1

373

10.087

12.442 23.7

17.6

Item

RELATIONSHIP BETWEEN ALLOWABLE STRESS, WEIGHTAND SAVINGS IN WEIGHT

(TYPICAL 250 MW)

IBR REGULATIONS


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a) Circularity of drum 243 (a)256 (b)

b) Drawing preparation 249

c) Type of weld joint 253

d) Long seam intersection 254

E )Position of tube holes 255

f) Hydro Test 268

g) Maximum working pressure for shell 270

h) Stress factors 271I )Ligament efficiency 272 (215)

j) Longitudinal stress 273

K Shape of Dished end plate 275

l) Dished end with openings 277

M) Dished end maximum working pressure 278n) Reinforcement calculation 279

o) Attachment of Branch pipes 280

p) Mountings on the drum 281

q) Attachment (SV) to dru 296

r) Water gauges 320s) Uncompensated hole 187

I) DRUM

IBR REGULATIONS


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a) Header shapes and Process 154 (a)

b) Hand holes 164 (a)c) Uncompensated hole 187

d) Maximum working pressure 270

e) Stress factors 271

f) Ligament efficiency 272 (215)g) Shape of Dished end 275

h) Dished end opening 277

i) Dished end maximum working pressure 278

j) Reinforcement calculation 279

k) Attachment of Branch pipes 280

l) Flat ends maximum working pressure 340 (f)

m) Headers for boiler & SH 342

II) HEADERS


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a) Process 151 (a), (b), (c)

b) Tubes 244 (a)

c) Maximum working pressure 338 (a)d) Percentage ovality 338 (b), (c)

a) Integral boiler piping 244 (b)b) Process 343 (1)

c) Material, permissible stress 343 (2)

d) Hydraulic Test 343 (3)

e) Temperature limits for Pipes, Tees, Branches 349

f) Maximum working pressure 350

g) Steam pipe bending thinning 361 (a)h) Butt welding fittings 361 (A)

i) Branch welded to pipes 249 to 253

j) External Reinforcement 362 (b)

k) Hydraulic Test 374

III) TUBES

IV) LINES & LINKS (BOILER INTEGRAL PIPING)


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a) Discharge capacity 293

b) Over pressure of safety valve 294

c) Pressure drop 295

d) Attachment to boiler 296

1) Procedure of Hydro test of boiler 379

2) Registration Fee 385

3) Submission of plans of boilers 393

4) Submission of plans of steam pipes 395

a) Requirements 320 a, b.

V) BOILER MOUNTINGS

A. SAFETY VALVES

B. WATER GUAGES

VI) GENERAL


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BOILER & SH TUBES

Regn. 151: Tubes Cold drawn or hot finished

a) Seamless or ERW tubes

b) Tubes < 5 dia - can be used inside the boiler

> 5 dia - can be used outside the boiler

c) Flash welding allowed.

HEADERS MUD BOXES, ETC. OF WATER TUBE BOILERS

Regn. 154:

a) Headers Seamless or Welded steel or cast steel.

i) Where welded, the welding shall be stress relieved, radiographed or

UT.

ii) Headers may be closed by forging, bolting, screening or welding.

IBR


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MAIN HOLES

Regn. 164 (a): Hole size not less than 3 x 2 in.

PD

Regn. 187: Uncompensated hole - Maximum 203 mm =

1.82 fe

FUSION WELDED DRUMS

Regn. 244 (a): Tubes

Regn.244 (b): Pipes of boiler shall comply with Chapter VIII.

Regn.243 (a): Circularity of drum 1%.

2 (d max. d min.)Regn. 243 (b): Percentage deviation = x 100

from circularity (d max. + d min.)

d = internal dia

Regn. 249: Fully dimensioned sectional drawing showing in full

detail the construction of drum - Fully dimensioned

drawings of the proposed weld preparation of the main

seams to a scale - attachment, seatings, etc. to befurnished.


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Regn. 253: Drum - type of welded joint - Single or double U or

V type.

Regn. 254: Longitudinal seams in successive rigs shall not fall

in line except where the rigs of drum are in twohalves of unequal thickness.

Regn. 255: Position of tube holes:-

Tube holes through welded seams, if they are

radiographed and stress relieved - The efficiencyand ligament multiplied by a factor 0.95 except the

distance from edge hole to edge of weld > 13mm

().

Regn. 256: Circularity of drum:-

The difference between internal diameter of drumshall not exceed 1%.

Regn. 268: Hydro test - 1 times the maximum permissible

working pressure after completion of welding and

heat treatment of drum (internal dia > 1000 mm).


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2 f E (T 0.03)Regn.270: The working pressure - WP =

D + T 0.03Weld factor 0.95.

Regn. 271: For temperature at or below 454CE t R

(or)

1.5 2.7

For temperature above 454CE t SR

(or) (or) SC

1.5 1.5

In case SC

valves are not available, the allowable stress may be

E t SR

lower of (or)1.5 1.5

Regn. 272: The ligament efficiency as per Regn. 215.

P d P nd P P1Diagonal and Curve

P P d P

Circumferential ligament.


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PD2

Regn. 273: Longitudinal Stress = fd =

1.273A

PD2

M =1.273

MRY

The stress due to bending f b =

Ia

Regn. 275: Shape of Dished end plate

a) Hemispherical

b) Elliptical heads -H 0.2D

c) Partial spherical heads - H 0.18D.

Figures 23A, B, C.


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Regn. 276: Gradual thinning up to a maximum of 10% of thickness

where the corner radius joins the dishing radius.

Regn. 277: Dished end with opening (inline with ISO).

d A

d1 = d DT TRegn. 278: Dished end plate maximum working pressure

2f (T C)WP =

DK (Shape factor)

Minimum head thickness - 5 mm.

Regn. 279: Reinforcement calculation.

Regn. 280: Attachments of Branch Pipes by welding.

Figures 24A to D, 26A to E, 27A to D.


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VALVES, GAUGES AND AUXILIARIES

Regn. 281: Every boiler shall be provided.

Two safety valves - one of which may be a high steam

and low water type, the bore not less than 19mm.

Two means of indicating water level.

a steam pressure gauge.

a steam stop valve.

a feed check valve.

one feed apparatus.

A blow down cock valve.

A manhole - A safety valve at the end of SH outlet.

New Regn 281A:Water level and or firing control


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New Regn.281A:Water level and or firing control.

SAFETY VALVES

Regn. 293: Discharge capacity.

Saturated steam E = CAP

E

Superheat steam ES

=

1 + 2.7 TS

1000

Regn. 294: Over pressure of safety valves:

Where discharge area < 80% - Over pressure shall not exceed10% of set pressure.

Where discharge area > 80% - Over pressure shall not exceed

5%.


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Regn. 295: Pressure drop:

Reset at a pressure at least 2.5 below but not more than

5% below safety valve set pressure. The 5% limitincreased to 10% for valves having seat bore less than 32

mm and or having a set pressure of 2 bar gauge or less.

Regn. 296: Attachment to Boiler:

The axis valve shall be vertical. Branches shall be as shortas possible.

Regn. 320: Water Gauges:

Every boiler shall have two means of indicating the water

in it of which one shall be conventional gauge glass.

Minimum length of visible portion of gauge glass 200 mm.

b) For boilers > 10,000 lb/hr., one of water gauges may be of

remote water level indicator type.


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BOILER AND SH TUBES, HEADERS

Regn. 338(a): 2f (T C) C = 0.75 for P 70 Kg/m2WP =

(D T + C) = 0 for P > 70 Kg/m2

The working metal temperature.

ECO

= The maximum water temperature + 11C.

Furnace & boiler tubes = Sat. temperature + 28C.

Convection SH =Maximum steam temperature + 39C.

Radiant SH = Maximum steam temperature + 50C.


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For temperature at or below 454C.

TS Et

(or)2.7 1.5

For temperature above 454C

SR or SC

1.5

If SC

not available

E t SR

(or)1.5 1.5

b) % Ovality = D max. D min.x 100

D


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Regn. 340 (f): Flat ends for headers -

f (t C)2WP =

d2 K

Regn. 342: Cylindrical headers - As per Regn. 270.

End attachments - As per Regn. 340(f).

STEAM PIPES AND FITTINGS

Regn.343(1): Carbon steel, Cast steel, Alloy steel, cold or hot

finished, butt welded or ERW.

Regn. 343(2): Material used, the permissible stress figures

specified in the code may be accepted.

Regn 343(3): The hydraulic test may be dispensed with if id


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Regn. 343(3): The hydraulic test may be dispensed with if id 600 mm.

Regn. 349: The temperature limits for pipes, Tees, branches,

etc. shall be as per Table-2.

Regn. 350: Working Pressure.

2fe (t C)WP = C = 0.75.

D t + C

STEAM PIPE FITTINGS

Regn. 361(a): Pipe bends thinning 12.5%.

Regn. 361(A): Butt welding fittings.

Regn. 362(a): Branch welded to pipe Regn. 249 to 253. Angle notless than 60.

Regn. 362(b): External Reinforcement :

Multiple radial plates of horse shoe form or the form

of collars applied to or around the junction betweenbranch and main.


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Regn. 374: Hydro test pressure in the piping system - 1.5 times the

design pressure.

REGULATIONS FOR THE REGISTRATION AND INSPECTION OF BOILERS

Regn. 379: Procedure of Hydro test.

Test pressure 1.5 times the maximum working pressure.

Temperature of water > 20 < 50C.Not exceeding 6% of the required pressure.

Regn. 385: Registration Fee:

Regn. 393: Submission of plans of boilers:

a) Drawing Approval.

b) & c) Boilers made outside India, Technical Advisor (Boilers)

and then CIB user state.


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d) Scrutiny fees as per Regn. 385 subject to a

maximum of Rs. 20,000.

Alteration fee at 10% of the fee of the first

scrutiny fee.

Regn. 395: Submission of plans of steam pipes:

Rs. 30 for 30 meters minimum of Rs. 50.

Fittings like DESH, Separators, etc. Rs. 150

each.

Sl DESCRIPTIO CLAUS REQUIREMENT AS PER ASME REMARKS


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Sl.No.

DESCRIPTION

CLAUSE

REQUIREMENT AS PER ASMESEC.I 2001

REMARKS

1. ServiceLimitations

PG-2 a)Boilers in whichsteam/vapour is generatedat a pr. more than 15 PSIG

b)High temp. water boilers >160 PSIG or 250 Deg.F

2. Platematerial

PG-6 Shall be of pressure vesselquality SA202; SA204;SA240(Type 405 only) SA302;387(A.S) SA285; SA299;SA515; SA516 (C.S), SA / EN -

10028 - 2

3. Pipes, Tubesmaterials

PG-9 PG 9.1 for boiler partsmaterialsPG 9.1 & 9.2 for superheater

matrials

4. Boiler platemin.thick

PG-16.3

The min. thickness of anyboiler plate under pressureshall be 1/4 in (6 mm)

5. Tubingcalculation

PG-27.2.1

"Upto and including 5 inchesoutside dia" (127mm)t(inch)=PD/2S+P +0.005D+e

e = 0 for tubes strengthwelded to headersP = Max. allowable working

pressure(psi) D= Outside dia in

Sl DESCRIPTIO CLAU REQUIREMENT AS PER REMARK


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Sl.No.

DESCRIPTION

CLAUSE

REQUIREMENT AS PERASME SEC.I 2001

REMARKS

6. Piping,Drums and

headerscalculation

PG-27.2.2

t =PD / 2SE+2YP + C (or) t= PR / SE - (1-y)P+ C E

= efficiency of liagamentof weld jointsY = temperature co-

efficientC = Min.

allowance for threadingand structural stability (0)

R = Insideradius in

7. Hemispherical head

PG-29.11

t = PL / 1.6SL

= radius to which formedhead measured on concaveside

8. 2:1 Semi-ellipsoidal

PG-29.7&

PG-

27.2.2

t = PR / SE - (1-y)P + C

R = Inside radius ofend cover

9. Max. Dia of

opening inshell

PG-

32.1.2&

PG-32.1.3.2

K Factor = PD / 1.82 St

Max. dia of openingwithout compensation asper Fig PG 32

10. CompensationCalulation

PG -37 &PW -

15

Limits of reinforcement

X = greater of 2d or 2(t

+ tn) but not greater thanpitch Y = the smaller of 2

Sl.No

DESCRIPTION CLAUSE

REQUIREMENT AS PER ASMESEC I 2001

REMARKS


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o. E SEC.I 2001

11. Max.allowablestress fordrum

(Bending andLongi stress)

PG - 22&

Sec.3.3.4

of BS-1113

Total stress = fb + fdfb =

stress due to bendingfd =

Direct longitudinal stress

12. Hydraulictest pr.

PG99.1

1.5 times the max. allowableworking pr. Calculate stressat hydraulic test bysubstituting in thickformula.Stress at hydro to beleser than 90% yield stress at100 deg. F.

13. Min. weldsize

PW -16.1

Check as per Fig. PW 16.1

14. Min. weldsize

PG - 37

PW -15

Combined strength of eachpath >min. weld strengthrequired

15. Feed waterconnection

PG -59.2

Boiler pr. 400 PSI or over thefeed water inlet shall befitted with sleeves.

16. Blow - off PG -59.3.3

Boiler shall have a bottomblow off outlet in the lowestwater space.

17. Water levelindicator

PG -60.1.1

a) Two nos. gauge glass over aboiler pr. Of 400 PSI b) Twoindependent remote levelindicators instead of one gaugeglass in case of pr. above 900 PSI

c) The lowest visible part ofgauge shall be at least 2 in. above


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Sl.No.

DESCRIPTION

CLAUSE

REQUIREMENT AS PERASME SEC.I 2001

REMARKS

18. Water level

indicator

PG -

60.1.6

a) Connection to the gauge

glass shall not be less than1/2" pipe size

b) Water gauge glass drainnot less than 1/4 in.Above 100 PSI pr. Drainconnects to safe dischargepoint

19. Pressure

gauges

PG -

60.6.1

Pr. Gauge connection to

the boiler shall not be lessthan 1/2 in. Inside dia. forsteel pipe.

20. Test pr.Gauges

PG-60.6.3

Connection to the test pr.gauge shall be at least 1/4in. pipe size

21. Feed watersupply

PG-61 a)Boiler having more than500 sq. ft. of waterheating surface shall havetwo means of feedingwater b) The feedconnection shall not beless than 3/4" pipe size forwater heating surface

Sl DESCRIPTIO CLAUS REQUIREMENT AS PER ASME REMARKS


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Sl.No.

DESCRIPTION

CLAUSE

REQUIREMENT AS PER ASMESEC.I 2001

REMARKS

22. Boiler safetyvalve reqts

PG-67.1

Boiler with water heatingsurface exceeding 500 sq.

ft. and steam generatingcapacity exceeding 4000lb/hr two or more safetyvalves are required.

PG-67.3

a) one or more safety valvesshall be set at or belowmax. allowable working pr.

B)The

highest pr. Setting shall notexceed 3% of the max.allowable working pressure

PG -67.2

c) The safety valve willdischarge all the steamgenerated by the boilerwithout allowing the pr. torise more than 6% abovemax. allowable workingpressure.PG-68.2 The discharge capacity ofthe safety valve on theboiler is at least 75% of theaggregate value capacityrequired

23. Drain, ventsprovisions

PG -58.3.7

Piping connections for itemssuch as drains, vents for ahigh temp. Boiler.

SALIENT CLAUSES OF BS-1113-1990


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2..1.2 MATERIALS FOR PP.BS MATERIALS OR AGREED BETWEEN MANUFACTURERAND PURCHASER

2.2 DESIGN STRESSES2.2.3 FOR C, C-Mn AND LOW ALLOY STEELS

FE= R

e(T)/1.5 OR R

m/2.7 WHICHEVER GIVES A LOWER

VALUE.

2.2.4 FOR AUSTENTIC STEEL

FE= R

e(T)/1.35 OR R

m/2.7 WHICHEVER GIVES A

LOWER VALUE.

SALIENT CLAUSES OF BS 1113 1990SECTION 2 MATERIALS AND DESIGN STRESSES

2.2.7 DESIGN TEMPERATURE


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2.2.7.1 DRUMS AND HEADERS

NOT HEATED BY GAS - EQUALS FLUID TEMP.HEATED BY GAS - ADD 25 C.

2.2.7.2 BOILER TUBES

SUBJECT TO RADIANT HEAT -- SAT TEMP. + 50 C.

NOT SUBJECT TO RADIANT HEAT -- SAT TEMP. + 25 C.

2.2.7.3 SH & RH TUBES

SUBJECT TO RADIANT HEAT -- SAT TEMP. + 50 C.

NOT SUBJECT TO RADIANT HEAT -- SAT TEMP. + 35 C.

2.2.7.4 ECONOMIZER TUBES

SECTION 3 DESIGN


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SECTION 3 DESIGN

3.3.4 COMBINED STRESSES IN DRUMS AND HEADERS.

TO BE BROUGHT IN PLACE OF REG.73 OF IBR

3.3.1 MINIMUM 9.5 mm THICK FOR HEADERS OF OD 300 mm AND

ABOVE.

3.3.2 MINIMUM 6 mm THICK FOR HEADERS UPTO OD 300 mm

t = PDi

/ 2 fn

- P

3.3.3.1. MAX DIA OF UNREINFORCED OPENING 200 mm.

3.6.1 DISHED ENDS

TORI AND SEMI ELLIPSOIDAL DISHED ENDS.

3.6.1.2 t= PDOK/2f

MINIMUM THICKNESS OF DISHED ENDS TO BE 9.5 mm.

3 6 1 3 1 UNREINFORCED OPENINGS


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3.6.1.3.1 UNREINFORCED OPENINGS

OPENINGS NOT TO BE GIVEN IN D/10

AREA.

3.7.2 TUBES AND PIPES

3.7.2.1 t = P do/2f + P.

MINIMUM THICKNESS TO AS UNDER

UPTO 38 MM OD 1.7

38 TO 51 MM OD 2.2

51 TO 70 MM OD 2.4

70 TO 76 MM OD 2.6

76 TO 95 MM OD 3.0

95 TO 102 MM OD 3.3

102 TO 127 MM OD 3.5


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SECTION 4 MANUFACTURE AND WORKMANSHIP

4.2.2.5.1 PLATES CAN BE BUTT WELDED PRIOR TO

FORMING PROVIDED WELD IS NDT EXAMINED.

4.2.2.5.2 OUT OF ROUNDNESS NOT TO EXCEED 1 % OF

NOM INTERNAL DIA.

4.3.1.1.6 LONGITUDINAL DRUM SEAMS TO BE WELDED

BEFORE CIRCUMFERENTIAL SEAMS AND WHRE

PRACTICABLE THE LONGITUDINAL SEAMS OF

ADJACENT COURSES SHALL BE STAGGERED.

4.3.1.1.7 HOLES CAN BE MACHINED THROUGH THE SEAMS

AFTER SEAM HAS BEEN NDT EXAMINE PRIOR TO

PWHT.


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SECTION 5 INSPECTION AND TESTING

5.10.1.1 HYDROSTATIC TEST PRESSURE

5.10.2.1 HYDRO TEST PRESSURE OF BOILER 1.5 TIMES

THE MAX WORKING PRESSURE.

DRUMS AND CYLINDRICAL HEADERS GREATER

THAN 600 MM SHALL BE HYDROSTATICALLY

TESTED AT SHOP.

5.10.3.1 ALL COMPONENTS NOT REASONABLYACESSIBLE TO INSPECTION AFTER ASSEMBLY

TO BE HYDROTESTED AT SHOP.


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SECTION 7 VALVES, GUAGES AND FITTINGS

7.2 SAFETY VALVES

7.2.1.1 MINIMUM BORE 20 mm

7.2.1.2 FOR EVAPOTATION UPTO 3700 KG/H ONE

SAFETY VALVE FOR GREATEREVAPORATION TWO SAFETY VALVES

7.2 WATER LEVEL GUAGE

EACH BOILER TO HAVE TWO INDEPENDENT

MEANS OF WATER LEVEL INDICATION.

50190057 codes standards

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