Training Programme on Code Awareness ASME Section I

Introduction:Evolution of Codes:

Process Industries came up in the wake up rapid industrialization in European countries

during 19th century.

No guidelines and no common standard available.

The boilers and pressure vessels operate at high pressure / high temperature with critical

operating medium such as chemicals, steam etc.

Failures were taking place, some of them fatal and caused concern to several

government..

Several committees were instituted in different countries to recommend safety features in

design and construction of boilers and pressure vessels.

In 1911, ASME set up committee for formulating standard rules.

In 1915, ASME brought out rules for Boilers and in 1925 , brought rules for Pressure

vessels.

Concept of Codes:

Safety in design and construction

Specify minimum requirements

System of principles or rules

Mandated by state laws

It is not a design handbook

Revise periodically based on feedback and developments

Code Contents:

Permitted materials

Design

Fabrication/Workmanship

Welding and Heat treatment

Non Destructive Examination

Testing & Inspection

Documentation

Certification and Data reports( if applicable)

ASMEBOILER AND PRESSURE VESSEL CODESECTIONSI Rules for Construction of Power Boilers

II MaterialsPart A — Ferrous Material SpecificationsPart B — Nonferrous Material SpecificationsPart C — Specifications for Welding Rods, Electrodes, and Filler MetalsPart D — Properties

III Subsection NCA — General Requirements for Division 1 and Division 2III Division 1Subsection NB — Class 1 ComponentsSubsection NC — Class 2 ComponentsSubsection ND — Class 3 ComponentsSubsection NE — Class MC ComponentsSubsection NF — SupportsSubsection NG — Core Support StructuresSubsection NH — Class 1 Components in Elevated Temperature ServiceAppendicesIII Division 2 — Code for Concrete Reactor Vessels and ContainmentsIII Division 3 — Containment Systems for Storage and Transport Packagings of Spent Nuclear Fueland High Level Radioactive Material and Waste

IV Rules for Construction of Heating Boilers

V Nondestructive Examination

VI Recommended Rules for the Care and Operation of Heating Boilers

VII Recommended Guidelines for the Care of Power Boilers

VIII Rules for Construction of Pressure VesselsDivision 1Division 2 — Alternative RulesDivision 3 — Alternative Rules for Construction of High Pressure Vessels

IX Welding and Brazing Qualifications

X Fiber-Reinforced Plastic Pressure VesselsXI Rules for Inservice Inspection of Nuclear Power Plant Components

ADDENDAColored-sheet Addenda, which include additions and revisions to individual Sections of the Code, arepublished annually. ASME 2004 code will have addenda for 05 and 06 and new revised code will be published in 2007.INTERPRETATIONSASME issues written replies to inquiries concerning interpretation of technical aspects of the Code.The Interpretations for each individual Section will be published separately and will be included aspart of the update service to that Section. They will be issued semiannually (July and December).CODE CASESThe Boiler and Pressure Vessel Committee meets regularly to consider proposed additions and revisionsto the Code and to formulate Cases to clarify the intent of existing requirements or provide, when theneed is urgent, rules for materials or constructions not covered by existing Code rules. Those Caseswhich have been adopted will appear in the appropriate Code Cases book: (1) Boilers and PressureVessels and (2) Nuclear Components. Supplements will be sent automatically to the purchasers of theCode Cases books upto the publication of next revised code.

ASME Section I : Rules for construction of Power BoilersCONTENTSA Detailed Contents Precedes Each Part, the Appendix, and the Forms

Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statements of Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preamble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part PG General Requirements for All Methods of Construction . . . . . . . . . . . . . . . . . Part PW Requirements for Boilers Fabricated by Welding. . . . . . . . . . . . . . . . . . . . . . . Part PR Requirements for Boilers Fabricated by Riveting. . . . . . . . . . . . . . . . . . . . . . . Part PB Requirements for Boilers Fabricated by Brazing . . . . . . . . . . . . . . . . . . . . . . . Part PWT Requirements for Watertube Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part PFT Requirements for Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part PFH Optional Requirements for Feedwater Heater (When Located WithinScope of Section I Rules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part PMB Requirements for Miniature Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Part PEB Requirements for Electric Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part PVG Requirements for Organic Fluid Vaporizers . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix I Mandatory — Preparation of Technical Inquiries to the Boiler andPressure Vessel Committee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Explanation of the Code Containing Matter Not Mandatory UnlessSpecifically Referred to in the Rules of the Code . Data Report Forms and Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Codes, Standards, and Specifications Referenced in Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guide to Information Appearing on Certificate of Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Calculations for External Pressure Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SI Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index

Scope of Section I

Boiler Proper---- Drum, Economiser, Superheater, Waterwalls etc.

Boiler Exteranl Piping: Boiler Proper & Boiler external ( termination)

Boiler external piping shall be considered as that piping which begins where the boiler

proper or separately fired superheater terminates at:

a) the first circ. Joint for wekding end connections;or

b) the face of the first flange in bolted flanged construction;or

c) the first threaded joint in that type of conncetion; and which extends upto and

including the valve or valves required by this code.

Boiler External Piping technical rules governed by ASME B 31.1 covered under

Section I.

Non boiler external piping is not covered under Section I . It comes under ASME B 31.1

See fig PG 58.3.1 for Drum Type Boiler – Limits for Piping

Definitions:

Power Boiler – a boiler in which steam or other vapor is generated at a pressure more

than 15psi for use external to itself.

High temperature water boiler – a water boiler intended for operation at pressure in

excess of 160 psi and / or temperatures in excess of 250 deg F.

A pressure vessel in which steam is generated by the application of heat resulting from

the combustion of fuel (solid, liquid. Or gaseous) shall be considered as a fired steam

boiler.

Unfired pressure vessels in which steam is generated shall be classed as unfired steam

boilers with the following exceptions:

a) vessels known as evaporators or heat exchangers

b) vessels in which steam is generated by the use of heat resulting from the operation

of a processing system.

Unfired steam boilers shall be constructed under the provision of section I or VIII

Expansion tanks required in connection with high temperature water boilers shall be

constructed to the requirements of Section I or VIII

A pressure vessel in which an organic fluid is vaporized by the application of heat

resulting form combustion of fuel shall be constructed under the provisions of Section I

Boiler using waste heat is termed as fired if it stems from combustion of fuel or otherwise

it is termed as unfired. Boilers running on turbine exhaust is considered as unfired boiler.

Presence of auxillary burner in boiler using waste heat is generally considered as fired

boiler.

Unfired steam boiler constructed to Section VIII must meet additional requirements

UW-2(C), U-1(g), UG-16(b)3, UG 125(b), UCS- 25

Inspection mandated in Section VIII is much larger compared to Section I.

Annual inspection of Section I boiler is more compared to Section VIII .

Safety valves are to be furnished to Section I requirements.

For pressure > 50psi radiography of all butt joints is required except for circ seam in

nozzles exempted as per para UW – 11(a)4 for Section I boilers.

PWHT is required for vessels constructed of Carbon Steel and Low alloy steel with some

exemptions.

Minimum thickness of shell and head shall be 6.25mm.

MDMT(mean design metal temperature) needs to be considered when constructed to

Section VIII . UCS – 66 curve for exemption of impact for material and thickness to be

used. Sometime it may become necessary to include impact testing. Exemption of

radiography available under para PW – 41.1 is not available when boiler is constructed to

Section VIII.

Code stamping of boilers are mandatory when it is installed in U.S.A. and Canada.

Boiler has to be registered with National Boiler Board.

Section I is to be used for making new boilers to ensure safety. Repair to boilers are

governed by NBIC.

Authorized Inspector( AI ) and Authorized Inspection Agency are involved for code

stamping.

Manufacturer has to get accreditation from ASME for use of stamps based on the quality

system renewed every three year.

Boilers could be constructed to Section I with third party inspection without code

stamping.

Some customers order boiler with code stamping even if the installation does not

mandate purely to ensure quality of material and workmanship including inspection and

testing. Data report need not be registere with NBB.

MAWP ---- 2975 psi for natural circulation boiler

4000 psi for forced circulation boiler

Fundamental of Section I construction:

1) Achieve safe boiler design

2) Materials, design ( formulae’s, loads, allowable stress, and construction details ),

fabrication techniques, welding, inspection, testing and certification by stamping

and data reports.

3) Quality control program intended to ensure that has been followed.

Materials:

Materials to ASME Section II

ASTM materials adopted by ASME will have “S” prefixed to A

Permitted materials by Section I is given in Para PG – 5 thru PG – 13.

PW – 5 adds further requirements for material used in welded construction.

Materials are to be used within the temperature range specified by the code.

Allowable stress values are provided in ASME Section II Part D.

Use of non ASME material not fully identified as per PG-10 or UG-10

Some of the international material specification has been added to Section II

PG 5.5 gives limitation to certain material usage.

Material requirements for external piping will be as per ASME B 31.1.

Miscellaneous parts as per PG-11 meeting PG-42 requirements are acceptable.

Non pressure part material attached to pressure parts should be of weldable quality.

Limits to Carbon is specified in PW-5.2.

Please refer to latest code for update

APPENDIX Table A-360TABLE A-360 01CODES, STANDARDS, AND SPECIFICATIONS REFERENCED IN TEXTASME StandardsB1.20.1-1983(R1992) Pipe Threads, General Purpose (Inch)B16.1-1989 Cast Iron Pipe Flanges and Flanged FittingsB16.3-1992 Malleable Iron Threaded Fittings, Classes 150 and 300B16.4-1992 Gray Iron Threaded Fittings, Class 125 and 250B16.5-1996 Pipe Flanges and Flanged Fittings [Note (1)]B16.9-1993 Factory-Made Wrought Steel Buttwelding FittingsB16.11-1996 Forged Fittings, Socket-Welding and ThreadedB16.15-1985(R1994) Cast Bronze Threaded Fittings, Class 125 and 250B16.20-1993 Ring-Joint Gaskets and Grooves for Steel Pipe FlangesB16.24-1991(R1995) Cast Copper Alloy Pipe Flanges and Flanged FittingsB16.25-1997 Buttwelding EndsB16.28-1994 Wrought Steel Buttwelding Short Radius Elbows and ReturnsB16.34-1996 Valves — Flanged, Threaded, and Welding End [Note (1)]B16.42-1987(R1997) Ductile Iron Pipe Flanges and Flanged Fittings, Classes 150 and 300B31.1-1998 & 2000 Addenda Power Piping [Notes (2), (3), (4), (5), and (6)]B36.10M-1996 Welded and Seamless Wrought Steel PipeQAI-1 Qualifications for Authorized InspectionASTMA 126-1995 Standard Specification for Gray Iron Castings for Valves, Flanges, andPipe FittingsB 139-1995 Standard Specification for Phosphor-Bronze Rod, Bar, and ShapesE 8-1998 Standard Test Methods of Tension Testing of Metallic MaterialsE 125-63(R1997) Reference Photographs for Magnetic Particle Indications on Ferrous CastingsE 186-98 Standard Reference Radiographs for Heavy-Walled [2 to 41⁄2 in. (51 to 114 mm)] Steel CastingsE 280-98 Standard Reference Radiographs for Heavy-Walled [41⁄2 to 12 in. (114 to 305 mm)] Steel CastingsE 446-98 Standard Reference Radiographs for Steel Casings up to 2 in. (51 mm) in ThicknessASME Performance Test CodePTC 25-1994 Pressure Relief DevicesASNT SpecificationSNT-TC-1A-1996 with the 1998 Recommended Practice for Nondestructive Testing Personnel QualificationAddenda and CertificationACCP, Revision 3, November 1997 Central Certification ProgramGENERAL NOTE: The issue date shown immediately following the hyphen after the number of the standard (e.g., B1.20.1-1983) is the effectivedate of issue (edition) of the standard.NOTES:(1) Saturated steam ratings and boiler feed and blowoff ratings for B16.5 flanges and B16.34 Standard Class valves of Material Group 1.1are given in Table A-361. For other conditions, other materials, Special Class or Limited Class valves, or intermediate rating valves, seeASME B16.5 and ASME B16.34 for pressure–temperature limitations.(2) Note 1 of Table A-1 of B31.1, Appendix A, applies to Electric Resistance Welded A-333, Grade 6 material.(3) The weld end transition of Fig. PG-42.1 is also acceptable.(4) The use of diverter valves under Section I reheater safety valves is prohibited.(5) The minimum carbon content specified in paras. 124.2(d) and 127.2.1 and in Note (18) of Table A-2 of B31.1 shall only apply to low alloysteels whose nominal composition is 21/4 Cr-1 Mo.(6) Paragraph 136.4.5 (A-5) is not applicable to Boiler External Piping.

Please refer to latest code for update.COPYRIGHT American Society of Mechanical EngineersLicensed by Information Handling ServicesTable A-361 SECTION ITABLE A-361MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP) FOR THE USE OF ASMEB16.5 PIPE FLANGES AND FLANGED FITTINGS AND ASME/ANSI B16.34 VALVES —FLANGED, THREADED, AND WELDING END (STANDARD CLASS) Maximum Allowable Working Pressure (MAWP), Except as Noted Steam Service at Saturation Boiler Feed and Blowoff LineASME B16.5 and Temperature, psi (ksi) Service, psi (ksi)B16.34 Class [Notes (1), (4)] [Notes (1), (2), (4)]150 205 (1 400) 170 (1 200)300 605 (4 200) 490 (3 300)400 785 (5 400) 640 (4 400)600 1,135 (7 800) 935 (6 400)900 1,635 (11 200) 1,430 (9 800)1500 2,675 (18 400) 2,455 (16 900)2500 3,206 (22 100) [Note (3)] 3,206 (22 100) [Note (3)]NOTES:(1) Adjusted pressure ratings for Steel Pipe Flanges and Flanged Fittings, for steam service at saturationtemperature corresponding to the pressure, derived from Tables 1A and 2, using material group 1.1 ofASME B16.5. Adjusted pressure ratings for Steel Valves (Standard Class) for steam service at saturationtemperature corresponding to the pressure, derived from Tables 1 and 2-1.1A, using material group 1.1of ASME B16.34. For other materials or design temperatures exceeding saturation temperature, seeASME B16.5 and ASME B16.34 for pressure-temperature limitations. The pressure listed is roundedto the nearest 5 psi.(2) Pressures shown include the factor for boiler feed and blowoff line service, corrected for line designtemperature, as required by ASME B31.1. The pressure listed is rounded to the nearest 5 psi.(3) Rating exceeds critical pressure of water.(4) The pressure-temperature ratings provided herein apply to the flange and do not necessarily reflect therating of the assembled flange joint. The pressure-temperature ratings provided apply to the gasketedand bolted flange joint only when the gasket and studs conform to the recommendations of ASME B16.5.

PART PGGeneralPG-1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-2 Service Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-3 Referenced Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MaterialsPG-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-6 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-7 Forgings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-8 Castings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-9 Pipes, Tubes, and Pressure Containing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-10 Material Identified With or Produced to a Specification Not Permitted byThis Section, and Material Not Fully Identified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-11 Miscellaneous Pressure Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-12 Gage Glass Body and Connector Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-13 Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DesignPG-16 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-17 Fabrication by a Combination of Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-18 Hydrostatic Deformation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-19 Cold Forming of Austenitic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-21 Maximum Allowable Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-22 Loadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-23 Stress Values for Calculation Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-25 Quality Factors for Steel Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-27 Cylindrical Components Under Internal Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-28 Welded Access or Inspection Openings Under External Pressure . . . . . . . . . . . . . . . . . PG-29 Dished Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-30 Stayed Dished Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-31 Unstayed Flat Heads and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Openings and CompensationPG-32 Openings in Shells, Headers, and Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-33 Compensation Required for Openings in Shells and Formed Heads. . . . . . . . . . . . . . .PG-34 Flanged-in Openings in Formed Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-35 Compensation Required for Openings in Flat Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-36 Limits of Metal Available for Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-37 Strength of Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-38 Compensation for Multiple Openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-39 Methods of Attachment of Pipe and Nozzle Necks to Vessel Walls. . . . . . . . . . . . . .PG-42 General Requirements for Fittings, Flanges, and Valves . . . . . . . . . . . . . . . . . . . . . . . . . PG-43 Nozzle Neck Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-44 Inspection Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-46 Stayed Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-47 Staybolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-48 Location of Staybolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-49 Dimensions of Staybolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52 Ligaments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-53 Ligaments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-55 Supports and Attachment Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boiler External Piping and Boiler Proper ConnectionsPG-58 Outlets and External Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-59 Application Requirements for the Boiler Proper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design and ApplicationPG-60 Requirements for Miscellaneous Pipe, Valves, and Fittings . . . . . . . . . . . . . . . . . . . . . . PG-61 Feedwater Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Valves and Safety Relief ValvesPG-67 Boiler Safety Valve Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-68 Superheater and Reheater Safety Valve Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-69 Certification of Capacity of Safety and Safety Relief Valves . . . . . . . . . . . . . . . . . . . . PG-70 Capacity of Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-71 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-72 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-73 Minimum Requirements for Safety and Safety Relief Valves . . . . . . . . . . . . . . . . . . . . FabricationPG-75 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-76 Cutting Plates and Other Stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-77 Plate Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-78 Repairs of Defects in Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-79 Tube Holes and Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-80 Permissible Out-of-Roundness of Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-81 Tolerance for Formed Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-82 Holes for Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection and TestsPG-90 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-91 Qualification of Inspectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-93 Inspection and Repair of Flat Plate in Corner Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-99 Hydrostatic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-100 Hydrostatic Deformation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Certification by Stamping and Data ReportsPG-101 Heating Surface Computation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COPYRIGHT American Society of Mechanical EngineersLicensed by Information Handling ServicesPG-104 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-105 Code Symbol Stamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-106 Stamping of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-107 Field Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-108 Stamping for Field Assembled Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-109 Stamping of Pressure Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-110 Stamping of Safety Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-111 Location of Stampings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-112 Manufacturers’ Data Report Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-113 Master Data Report Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FiguresPG-19 Cold Forming Operations for Flaring, Swaging, and Upsetting of Tubing . . . . . . . . . PG-28 Maximum Internal Projection of Welded Access or Inspection Openings. . . . . . . . . . PG-31 Some Acceptable Types of Unstayed Flat Heads and Covers . . . . . . . . . . . . . . . . . . . . PG-32 Chart Showing Limits of Sizes of Openings With Inherent Compensationin Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-33 Chart for Determining Value of F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-36 Limits of Reinforcement for Typical Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-36.4 Some Representative Configurations Describing the te ReinforcementDimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-38 Illustrations of the Rule Given in PG-38.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-42.1 Welding End Transitions Maximum Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-46.2 Acceptable Proportions for Ends of Through-Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52.1 Diagram for Determining the Efficiency of Longitudinal and DiagonalLigaments Between Openings in Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52.2 Example of Tube Spacing With Pitch of Holes Equal in Every Row. . . . . . . . . . . . . PG-52.3 Example of Tube Spacing With Pitch of Holes Unequal in Every SecondRow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PG-52.4 Example of Tube Spacing With Pitch of Holes Varying in Every Secondand Third Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-52.5 Example of Tube Spacing With Tube Holes on Diagonal Lines . . . . . . . . . . . . . . . . .PG-52.6 Diagram for Determining Equivalent Longitudinal Efficiency of DiagonalLigaments Between Openings in Cylindrical Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-58.3.1 Code Jurisdictional Limits for Piping — Drum Type Boilers . . . . . . . . . . . . . . . . . . . .

PG-58.3.2 Code Jurisdictional Limits for Piping — Forced-Flow Steam GeneratorWith No Fixed Steam or Waterline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-59.1 Typical Boiler Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-60 Typical Arrangement of Steam and Water Connections for a WaterColumn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-67.4 Requirements for Pressure Relief Forced-Flow Steam Generator. . . . . . . . . . . . . . . . . . PG-80 Maximum Permissible Deviation From a Circular Form e for CylindricalParts Under External Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.1 Official Symbols for Stamps to Denote The American Society ofMechanical Engineers’ Standard for Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.2 Official Symbol for Stamp to Denote The American Society ofMechanical Engineers’ Standard for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.3 Official Symbol for Stamp to Denote The American Society ofMechanical Engineers’ Standard for Welded Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . PG-105.4 Official Symbol for Stamp to Denote The American Society ofMechanical Engineers’ Standard for Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . PG-106 Form of Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TablesPG-19 Post Cold-Forming Strain Limits and Heat-Treatment Requirements . . . . . . . . . . . . . . PG-39 Minimum Number of Threads per Connection .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PART PWGeneralPW-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MaterialsPW-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DesignPW-8 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-9 Design of Welded Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-10 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PW-11 Radiographic and Ultrasonic Examination of Welded Butt Joints . . . . . . . . . . . . . . . . . PW-13 Head-to-Flange Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-14 Openings in or Adjacent to Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-15 Welded Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-16 Minimum Requirements for Attachment Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PW-19 Welded-in Stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FabricationPW-26 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-27 Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-28 Welding Qualification and Weld Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-29 Base Metal Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-33 Alignment Tolerance, Shells and Vessels (Including Pipe or Tube Used as aShell). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-34 Alignment, Tube and Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-35 Finished Longitudinal and Circumferential Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PW-36 Miscellaneous Welding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-38 Preheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PW-39 Requirements for Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-40 Repair of Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-41 Circumferential Joints in Pipes, Tubes, and Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . .PW-42 Joints in Valves and Other Boiler Appurtenances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-43 Loading on Structural Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and TestsPW-46 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-47 Check of Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-48 Check of Welder and Welding Operator Performance Qualifications . . . . . . . . . . . . . . PW-49 Check of Heat Treatment Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-51 Acceptance Standards for Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PW-52 Acceptance Standards for Ultrasonic Examination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-53 Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-54 Hydrostatic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FiguresPW-9.1 Buttwelding of Plates of Unequal Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-9.2 Prohibited Welded Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PW-16 Load-Carrying Paths in Welded Nozzle Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-16.1 Some Acceptable Types of Welded Nozzles and Other Connections toShells, Drums, and Headers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-16.2 Some Acceptable Forms of Welds for Lugs, Hangers, and Brackets onShells, Drums, and Headers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-19.4(a) Some Acceptable Types of Diagonal Braces for Installation by Welding. . . . . . . . . . PW-19.4(b) Unacceptable Types of Diagonal Braces for Installation by Welding. . . . . . . . . . . . . . PW-43.1 Chart for Determining Load Factor, Lf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-43.2 Method of Computation of Attachments to Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-53.1 Test Specimens From Longitudinal Welded Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . PW-53.2 Method of Forming Longitudinal Test Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-53.3 Details of Test Specimens

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TablesPW-11 Required Radiographic and Ultrasonic Examination of Welded Butt Joints . . . . . . . . PW-33 Alignment Tolerance of Sections to Be Buttwelded. . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-39 Mandatory Requirements for Postweld Heat Treatment of Pressure Partsand Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-39.1 Alternate Postweld Heat Treatment Requirements for Carbon and LowAlloy Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PW-43.1 Tube Attachment Angle Design Factor, K

COPYRIGHT American Society of Mechanical EngineersLicensed by Information Handling Services

COPYRIGHT American Society of Mechanical EngineersLicensed by Information Handling Services

COPYRIGHT American Society of Mechanical EngineersLicensed by Information Handling ServicesCOPYRIGHT American Society of Mechanical EngineersLicensed

by Information Handling ServicesMechAnica

l EngineersLicensed by Information Handling Services

Design: Design by rules: a process requiring the determination of loads, the choice of design

formula and selection of appropriate design stress for material used.(PG 16 thru 55).

Design loads to be based on the anticipated weight and other loads to be carried.

Hydrostatic Deformation or Proof Test( PG -18, Appendix A22 ): experience based

method used to establish a safe design pressure for component for which no rules are

given or when strength cannot be calculated with satisfactory assurance of accuracy.

Allowable Design Stress: Factor is 3.5 ie UTS divided by 3.5 ( from 1999 addenda )

Design Loads: Initially only it was internal working pressure. Now we have to take

additional loading as per PG-22 such as weight of boiler and its contents, seismic loads,

wind loads, thermal loads etc.

MAWP (maximum allowable working pressure ) is the term used in Section I

Designer has to select the MAWP and the design temperature. Only MAWP is stamped

on the boiler.

PG-27 is to be reffered for tube and pipe design.

Bend thinning allowance need to be added to ensure finished bend will meet the

minimum thickness required as per calculation.( table 102.4.5 of B31.1)

Corrosion/erosion allowance are to be added to minimum thickness requirement.

Safety valve requirements are covered under PG 67 thru PG 73

Fabrication: this aspect is covered under Para PG 75 thru PG 82. Welding aspects are

covered under PW chapter of Section I.

Tolerances for drums and ellipsoidal heads are given.

Fabrication process should not injure the material. Effect if any should be removed.

Transition for unequal thickness shall be provided by means of taper of 1:3 minimum

All welding shall be carried out as per ASME Section IX.

WPS, PQR, WPQ will be approved by AI.

Welder or welding operator has to identify the seam welded by him by stamping or

recorded in documents.

PWHT shall be carried out as per PW-39

Weld acceptance criteria for reinforcement as PW 35, 41.2.2, 35.1

Preheating as per non mandatory appendix A100 to be followed

Production Test plates to be provided and tested to the requirements of code. CS

material P no.1 is exempted. Refer para PW 53

Non Destructive Examination:

RT, UT(alternate or supplement), MPI, LPT (DPT) are the various NDT methods

employed . It is covred in detail in ASME Section V

Visual Inspection is must for piping to B31.1

PW11 calls for extent of examination . Acceptance standard is given in PW 51 & PW 52.

NDT procedures are to be prepared to meet SNT-TC-1A published by ASNT or to CP189

of ACCP

NDT operators have three levels of qualification Level I, II, III

Radiographs are to retained for five years.

Exemption for radiography as per PW 41.

Hydrostatic Testing:

Requirements are given in PG 99 and PW 54.

Only water is to be used for testing.

Temperature of water 70deg F to 120 deg F. Below 70deg F not permitted as material can

fail due to brittleness.

Test pressure will be 1.5 times MAWP.

Overpressure not to exceed 6%

For forced flow steam generator initially test for hydro at 1.5 times MAWP and then

reduce to 1.25 times MAWP for closer examination.

Attachments may be welded after PWHT on P no.1 materialif thickness is below 19.6mm

and if 200deg f preheat is applied when thickness exceeds 19.6mm. This is as per para

PW 54.

AI is the independent third party.

AIA is the firm employing AI.

AI is qualified by NB B&PV I

PG 90 stipulates duties of AI and manufacturer for constructing coded equipment.

Certification is done by stamping and signing of data reports. Refer para PG 104, PG

112, PG 113

Data report is to be registered with National Boiler Board

Code Stamps under Section I

S : Power Boiler

V : Safety Valve

A ; Boiler assembly

E : Electric Boiler

PP: Pressure piping

Quality Control System : Description is given in para PG 105.4

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PYRIGHT American Society of Mechanical EngineersLicense