1 การตรวจสอบการสร้างหม้อน้ำตามมาตรฐานASME2013

09Feb
Sect. I Course 1
LR INSURANCE, INC.
Working together for a safer world
LR INSURANCE INC
ASME Boiler and Pressure Vessel Code
General Requirements of
ASME Section I 2013
Rules For The Construction Of
Power Boilers
LR Insurance, Inc.
09Feb
Sect. I Course 2
LR Insurance, Inc.
Content
1. Introduction, LR and LR Insurance Inc
2. Organisation, Content and Structure of Section I
3. General Requirements for all Methods of Construction
4. Requirements for Methods of Fabrication
Welding---Riveting---Brazing
5. Requirements for Types of Boilers
Watertube---Firetube---Feedwater Heater---
Miniature---Electric---Organic Fluid Vaporizer---
Heat Recovery Steam Generator
6. Mandatory and Nonmandatory Appendices
LR Insurance, Inc.
Lloyds Register.
The worlds first ship classification
Society - founded in 1760
We are not an insurance company and
do not have any connections with
Lloyds of London
We are a not for profit organisation
we do not have any shareholders
Our business is governed by our
General Committee, the members of
which are drawn from the industries
which we serve
Our purpose is to
to promote safety of life and
property
to improve overall business
performance in the industries we
serve
We achieve this by securing high
technical standards of design,
construction, maintenance and
operation
09Feb
Sect. I Course 3
LR Insurance, Inc.
LR Insurance, Inc.
Working
together
for a safer world
Working
together
for a safer world
ASME Section I General Information
2013 Edition
5 June 2014
09Feb
Sect. I Course 4
Boilex Exhibition 5 June 2014
ASME Certification Mark and Designators
LR Insurance, Inc.
General Requirements for all Methods of Construction - PG
Organisation, Content and Structure of Section I
General requirements for all methods of
construction (PG)
Requirements for methods of fabrication
Welding (PW), Riveting (PR), Brazing (PB)
Requirements for types of boilers
Watertube Boilers - PWT
Firetube Boilers - PFT
Feedwater Heater - PFH
Miniature Boiler - PMB
Electric Boilers - PEB
Organic Fluid Vaporizer - PVG
Heat Recovery Steam Generators - PHRSG
Mandatory and Nonmandatory Appendices
09Feb
Sect. I Course 5
LR Insurance, Inc.
General Requirements for all Methods of Construction
Service Limitations
Boilers in which steam or vapour
is generated at a pressure of more
than 15 psig
High temperature water boilers
intended for operation at
pressures exceeding 160 psig (1.1
Mpa) and / or temperatures
exceeding 120 C
LR Insurance, Inc.
Materials
Shall conform to one of the specifications given
in Section II and shall be limited to those that
are listed in the Tables of Section II, Part D.
Further limitations are given in PG-5 General,
PG-6 to PG-14 for plates, forgings, castings, pipes
and tubes, miscellaneous pressure parts, gage
glass body, stays and rivets
09Feb
Sect. I Course 6
LR Insurance, Inc.
Design
Shall conform to the general design requirements and in
addition to the specific requirements given in the applicable
parts pertaining to the methods of construction
Minimum thickness of any boiler plate under pressure shall be
inch (6 mm) except for electric boilers constructed under
PEB
Minimum thickness of plates to which stays may be applied in
other than cylindrical outer shell plates shall be 5/16 inch (8
mm)
When pipe larger than NPS 5 (DN 125) is used in lieu of
plate for the shell of cylindrical components under
pressure, its minimum wall shall not be less than the
smaller of 1/4 in. (6 mm) or the minimum wall thickness of
Standard wall pipe listed in ASME B36.10M, Table 1.
When no rules are given and it is impossible to calculate, this
may be done by appropriate analytical methods, the
appropriate use of rules from other design codes or, as
permitted by PG-18, by proof test.
LR Insurance, Inc.
Design
Loadings are to be considered
Hydrostatic head
Other stresses that increase the average stress by more than 10 % including
Weight of component and its content
Method of support
Quality factors for steel castings to be considered
Design formulas are given for
Cylindrical components under internal pressure
Dished heads (stayed and unstayed)
Unstayed flat heads and covers
Openings and compensations
Stayed surfaces
Ligaments (definite or not definite patterns)
09Feb
Sect. I Course 7
LR Insurance, Inc.
Boiler external piping and boiler proper connections
Boiler external piping
Materials, design, fabrication, installation and testing :
defined in ASME B 31.1 , Power Piping
Boiler proper
Common to steam, feedwater, blow-off and drain systems
Requirements for miscellaneous pipe, valves and fittings
Water level indicators
Water columns
Connections
Pressure gauges
LR Insurance, Inc.
Overpressure Protection Requirements
Boiler (PG-67)
each boiler shall have at least one pressure relief valve
If more than 500 ft (47m) of bare tube water-heating
surface, or an electric boiler has a power input of more than
1,100 kW, it shall have two or more pressure relief valves
Capacity of pressure relief valve(s) shall not allow the boiler
to rise the pressure more than 6% above the highest
pressure at which any valve is set and in no case to more
than 6% above the MAWP
Minimum relieving capacity for all type of boilers shall not
be less than the maximum designed steaming capacity at the
MAWP of the boiler
One or more pressure relief valves shall be set at or below
the MAWP. Additional valves: setting shall not exceed the
MAWP by more than 3%
09Feb
Sect. I Course 8
LR Insurance, Inc.
Superheater and Reheater (PG-68)
Every attached superheater shall have one or more
pressure relief valves in the steam flow path between the
superheater outlet and the first stop valve
Discharge capacity may be included in determining the
number and size of the safety valves for the boiler
Every separately fired superheater shall have one or more
safety valves having a discharge capacity equal to 6 lb/ft
(29 kg/m) of steam per hour of superheater surface
Every reheater shall have one or more safety valves with
relieving capacity of at least equal to the maximum steam
flow for which the heater is designed
LR Insurance, Inc.
Certification of Capacity of Safety and Safety Relief Valves
Manufacturer of safety and safety relief valves need to
demonstrate to ASME a QC Programme and to test and receive
certification on the relieving capacity for each type of valve
Capacity test are to be conducted at authorized places by the
manufacturer and an ASME authorized observer
Following tests by the manufacturer all tests will be repeated at
the test labs of the National Board in Ohio
Agreement between the results of the 2 labs shall be within 2%
Upon completion of satisfactory tests and certification the
manufacturer may stamp each valve with the V Code Symbol
A Certified Individual of the manufacturer shall be
responsible to verify the documentation and to sign the
applicable Certificate of Conformance (Form P-8) for each safety
or safety relief valve
09Feb
Sect. I Course 9
LR Insurance, Inc.
MINIMUM REQUIREMENTS FOR PRESSURE RELIEF VALVES (PG-73)
Pressure relief valves shall be either direct spring-loaded
safety valves, direct spring-loaded safety relief valves, or
pilot-operated pressure relief valves.
Power-actuated pressure relieving valves shall only be used
for applications specified in PG-67.4.1.
Deadweight or weighted lever safety valves or safety relief
valves shall not be used.
LR Insurance, Inc.
Fabrication, Inspection and Test
Fabrication of all boilers shall conform to the general
fabrication requirements in PG and in addition to the specific
requirements that pertain to the methods of construction
used
Plate identification to be kept or coded system to be
used
Out of roundness of cylindrical shell within a limit of 1%
Requirements for tube holes and holes for stays to be
considered
Corner joints to be MT or PT tested
Each boiler, superheater, waterwall, economizer, any other
Code stamped item or component and boiler external piping
to be inspected by an AI
Duties of the AI are identified in PG-90.1
Hydrostatic pressure tests
09Feb
Sect. I Course 10
LR Insurance, Inc.
Certification and
Stamping
Guide to information
appearing on Certificate
of Authorization
S Designator for Power Boiler
A Designator for Assembly
PP Designator for Power Piping
M Designator for Miniature Boiler
E Designator for Electric Boiler
V Designator for Pressure Relief
Valve for Boiler
LR Insurance, Inc.
Contd Certification and Stamping
Hard stamping is required however in addition each manufacturer shall
furnish a metallic plate with the required data reproduced; this plate
shall be readily visible from the operating floor or platform
Location of stamping and required data is clearly defined
External piping > NPS 2 (DN 50) to be properly stamped with ASME
Certification Mark
09Feb
Sect. I Course 11
LR Insurance, Inc.
Manufacturers Data Report Forms
P2 - for all types of boilers except watertube and electric
P2A - for all types of electric boilers
P2B - for electric superheaters and reheaters
P3 - for watertube boilers, superheaters, waterwalls, economizer
P3A - for engineering contractors having design responsibility
P4 - for boiler parts
P4A - for fabricated piping, shop and field welded
P4B for field-installed mechanically assembled piping
P5 - for all items of field assembled process steam generators (summary)
P6 - supplementary sheet to record additional data
P7 - for safety valves
Data Reports are to be furnished to the purchaser, inspection agency and
the authority at the place of location
LR Insurance, Inc.
Requirements for Boilers fabricated by Welding Part PW
General Welding Requirements
Welding and qualification of procedures and
personnel is the responsibility of the manufacturer
and shall be in accordance with Section IX
Code welding may be done by welders employed
by the manufacturer or, under certain conditions,
by welders not employed by the manufacturer
Joints shall be full penetration butt welds, with
some exceptions
Joints between material of unequal thickness shall
be tapered
09Feb
Sect. I Course 12
LR Insurance, Inc.
Requirements for Boilers fabricated by Welding
Nondestructive Examination
Unless exempted by table PW-11 all longitudinal
and circumferential welded butt joints shall be
RT examined through their entire length
UT allowed only under special conditions
RT and UT to be in accordance with Section V
Qualification of personnel to SNT-TC-1A or CP-
189
LR Insurance, Inc.
Welded Connections
Requirements for calculation of the weld strength to
be considered including stress correction factors
(PW-15)
Welding details for connections are given in PW-16
Full penetration from one or both sides
Partial penetration from both sides
Fillet welds from both sides
Fillet and partial penetration welds on opposite
sides
Special requirements for necks and tubes up to and
including NPS 6 (DN150) attached from one side only
09Feb
Sect. I Course 13
LR Insurance, Inc.
Fabrication
Alignment tolerances to be considered, see PW33
Maximum reinforcement to be considered, see PW-35
Repair of Defects
Repair welding in general is allowed, even under
special conditions without PWHT
The area is to be MT or PT examined before and after
repair welding
Limits for repair are given for the maximum depth
and size of the defective area
LR Insurance, Inc.
Postweld Heat Treatment (PWHT)
Applicable to boiler proper and parts thereof - not
applicable to external piping
All welded pressure parts shall be given a PWHT at a
temperature specified for the various P-Number
groupings , see tables PW-39 and PW-39.1
Exemptions for heat treatment are given in the notes of
the tables
Weldments may be heat treated by any of the following
methods
Heating the complete assembly as a unit
Heating sections of assemblies
Local PWHT by heating a circumferential band
around the weldment
09Feb
Sect. I Course 14
LR Insurance, Inc.
Test Plates
Test plates are required for cylindrical pressure parts such as drums and shells
Test plates are not required for cylindrical pressure parts such as pipe, tubes and headers
and all cylindrical pressure parts of P-No 1 materials
Test plates shall be prepared from plate of the same material specification, same or
greater thickness as the weld at the joint , same welding procedure
Test plates be welded as continuation except for vessels with circumferential welds only
When noncylindrical pressure parts are not integral with the vessel, a test plate shall be
provided of a thickness not less than that of the parts
For several pressure parts of any one design welded in succession of the same material
covered by the WPS, a test plate is required for each 200 ft (60m)
t of the thinnest and thickest plate shall not differ by more than inch (6mm)
Test specimen (2 tension tests (1 transverse + 1 all weld metal) and 1 bend test
transverse to the welded joint) are to be removed as specified and tested
For plate thicknesses less than 5/8 inch (16mm) the all weld metal test may be
omitted
LR Insurance, Inc.
Hydrostatic Pressure Tests
All welded parts are to be subjected to a hydrostatic test
pressure of not less than 1,5 times the MAWP
Test may be made either in the shop or field
Welding of non pressure parts to pressure parts may be
performed after hydro test without requiring another hydro
test under the following conditions :
Inspection by the AI
Pressure part material limited to P1 materials
Non pressure parts limited to carbon steel with C < 0,2 %
or any P1 material
Welding by stud or fillet welding, the throat not
exceeding the lesser of 0,7 times the thickness of the
pressure part or inch (6 mm)
Minimum of 200 F (95 C) preheat shall be applied
when the pressure part thickness exceeds inch (19mm)
09Feb
Sect. I Course 15
LR Insurance, Inc.
Requirements for Boilers fabricated by Riveting or Brazing
Fabrication by Riveting
Manufacturers using riveted constructions shall
use the 1971 Edition of Section I
Fabrication by Brazing
This Part is similar organized as the Part for welding
Brazing processes are specified
Service restrictions due to temperature limits
Brazing procedures and personnel to be qualified in accordance with Section IX
Design to be in accordance with the rules of this Part and in conjunction with
PG as well as the Part pertaining to the method of fabrication
Joint efficiency factor for all joints shall be 1
Visual examination required
LR Insurance, Inc.
Requirements for Watertube Boilers Part PWT
This part is applicable to watertube boilers and parts thereof
Is not applicable for external piping
Design to be in accordance with PG and specific requirements of this part
Material to conform to specification in Section II and for which stress values are given
Tube wall thickness
Either to be calculated or table PWT-10 may be used in lieu of the formula
for SA-178 Gr A, SA-192 and SA- 226 provided the maximum mean wall
temperature does not exceed 700F (370C)
09Feb
Sect. I Course 16
LR Insurance, Inc.
Requirements for Watertube Boilers
Tube connections
Expanded and flared
Expanded and beaded
Expanded, flared, seal welded and re-expanded
Expanded, seal welded and re-expanded or
seal welded and expanded after welding
Firing doors shall be of the inward-opening type unless
such doors are provided with substantial and effective
latching
Minimum size of an access or fire door opening different
for furnace dimensions greater 24 inch (600 mm) or
smaller 24 inch
12 x 16 inch (300 x 410 mm) or 15 inch (380 mm)
when circular
2 x 3 inch (70 x 89 mm) or 2 openings with a
minimum size of 1 inch (25mm)
LR Insurance, Inc.
Requirements for Firetube Boilers Part PFT
Design to be in accordance with PG and specific requirements of this part
Material to conform to specification in Section II and for which stress values are given
Attachment of heads and tubesheets
By flanging and butt welding
By fillet welding an outwardly or inwardly flanged tubesheet to the shell
By welding an unflanged tubesheet to the shell
09Feb
Sect. I Course 17
LR Insurance, Inc.
Requirements for Firetube Boilers
Attachment of Tubes
Expanded and beaded (a, b, d)
Expanded and beaded and seal welded (c)
Expanded and seal welded (e)
Welded (f, g)
Furnaces
Plain circular furnaces
Ring reinforced type
Corrugated Furnaces
Combined plain circular and corrugated type
Attachment of furnaces
LR Insurance, Inc.
Stayed Surfaces and Stays
Rules of PG and PW to be considered in addition to PFT requirements
Formulas are given to establish MAWP for various furnace types
Segments of heads shall be stayed
Tubesheets to be stayed, special conditions to be considered
Area supported by stays, maximum spacing of stays, maximum allowable
stress and length between supports of stays to be considered
Tubes may be used as stays in multitubular boilers
09Feb
Sect. I Course 18
LR Insurance, Inc.
Fireside Access and Inspection Openings
Size and types of access or fire door openings
Size and types of inspection openings for the various boiler
types
Domes
Welding, location and size to be considered
Method of Support
Design and attachment according to PG-22.1 + PG-55
Piping, Fittings and Appliances
Requirements for water level indicators, feed- and blow-off
piping to be considered
Thickness of Furnaces and tubes under external pressure
and MAWP
Design temperature is a critical factor
MAWP to be determined with PFT-51
LR Insurance, Inc.
Requirements for Feedwater Heater - PFH
Design requirements
If located within the limits of Section I piping, then
Section I rules are applicable
Construction to Section VIII Div.1 nevertheless possible,
provided :
Section VIII Div. 1 rules (UW-2c) are applied
MAWP of the primary (feedwater) side limited
Design temperature of tubes specified
Heater to be stamped with U symbol and U-1
Data Report required
Nameplate per UG-119 with additional information
Master Data Report with additional information
09Feb
Sect. I Course 19
LR Insurance, Inc.
Requirements for Miniature Boilers- Part PMB
Limits of miniature boilers
16 inch (400 mm) inside diameter of shell
20 ft (1.9 m) heating surface
5 ft (o.14 m) gross volume
100 psig (7oo KPa) MAWP
The rules in this part shall supplement PG requirements and take precedence over them
when there is a conflict when any of the limits are exceeded, the rules for power boilers
shall apply
Materials and thickness requirements
Materials to conform to specifications in Section II
Seamless and welded shell from pipe not less than 3/16 inch (5.0 mm)
Shells or heads made from plate not less than inch (6.0 mm)
Heads used as tubesheets, with tubes expanded, not less than 5/16 (8.0mm)
Due to small size, requirements for identification of material need not be met
LR Insurance, Inc.
Requirements for Miniature Boilers
Design requirements
Washout or inspection openings required depending on size
Feedwater and blow-off connections required
Water gage(s) to be attached at defined level
All valves, pipe fittings and appliances connected shall be equal at least to
class 125 (PN 20) or class 150 (PN 20)
Each boiler to be equipped with a sealed spring loaded safety valve of not
less than NPS inch (DN 15)
Steam stop valve required
Hydrostatic pressure test
Each boiler shall be subjected to a hydrostatic pressure test of 3 times the
MAWP and shall be inspected while under pressure
Different test pressures required for boilers with mechanically assembled
boiler external piping or trim
09Feb
Sect. I Course 20
LR Insurance, Inc.
Requirements for Electric Boilers Part PEB
This part contains special rules for construction of
Electrode type boiler, in which heat is generated
by the passage of an electric current using water
as the conductor
Immersion resistance element type boiler in which
the heat is generated by passage of an electric
current through a resistance heating element
immersed in water
Not included are electric boilers where the heat is
applied externally to the boiler pressure vessel by
electric resistance heating elements, induction coils, or
other electrical means
LR Insurance, Inc.
Requirements for Electric Boilers
Electric boilers and parts thereof that do not exceed the limits of PMBs may be
constructed using the applicable paragraphs of PMB in conjunction with this part
The boiler pressure vessel may be constructed to Section VIII Div.1 provided
Material of construction is clearly defined and as allowed in this part
Inspection openings are provided
Vessel shall be stamped with the Code Symbol Stamp U and the letters
UB
Special entry on the Master Data Report P-2A
Material and thickness requirements
Materials are limited to certain specifications only
Seamless or welded shell, plates or heads shall not be less than 3/16 (5mm)
Welding
If limits of PMB are not exceeded then PWHT , RT and remaining NDE
described in PG-93.1 are not required
09Feb
Sect. I Course 21
LR Insurance, Inc.
Requirements for Electric Boilers
Design requirements
Inspection openings required, except when a removable cover or internal
electric heating element is available
Feedwater and blow-off piping size to be considered
Water level indicators (gage glasses) to be provided
Number and size of safety valves required depending on the power input
Hydrostatic tests required
Inspection and stamping of electric boilers is different for size, power input, type
of construction
Under certain conditions AI need not to witness final examination or
hydrostatic pressure test
LR Insurance, Inc.
Requirements for Organic Fluid Vaporizers Part PVG
Material requirements
Materials shall conform to specifications in Section II and the requirements in
Part PG shall apply in all respects
Design requirements
General requirements of Part PG and specific requirements of this Part apply
Design working pressure shall be at least 40 psi (280 KPa) above the operating
pressure at which it will be used
Gage glasses shall be of the flat glass type with forged steel frames
Suitable drain valves of the globe or angle type may be used
Safety valves shall be of a totally enclosed type and shall not have a lifting
lever
The discharge capacity and minimum relieving capacity to be determined
Testing and certification as under PG-69
a rupture disc may be installed between the safety valve and the vaporizer
special conditions to be considered
09Feb
Sect. I Course 22
LR Insurance, Inc.
Requirements for Heat Recovery Steam Generators Part PHRSG
Scope
HRSG has as its principle source of thermal energy a hot gas stream such
as the exhaust of gas or combustion turbine (considered synonymous and
cover turbines burning liquid or gaseous fuels).
Requirements For Superheater And Reheater Condensate Removal
Connections
Each superheater and reheater shall be equipped with at least one automated
condensate removal connection.
Shall be designed so that when discharching, a high pressure is not developed
within the collection device.
Such piping shall extend through and include the second valve.
Desuperheater Drain Spots
Drain pot connection size shall be no smaller than one NPS less than the pipe
is attached to.
Certification
Manufacturers Data Report in accordance with Part PG
LR Insurance, Inc.
APPENDICES
Mandatory Appendices
Mandatory Appendix I : Deleted
Mandatory Appendix II : Standard Units For Use In Equations
Mandatory Appendix III : Criteria for Reapplication of a Certification Mark
Mandatory Appendix IV : Local Thin Areas in Cylindrical Shells and in
Spherical Segments of Heads
Mandatory Appendix V: Additional Rules for Boilers Fabricated by
Riveting
Mandatory Appendix VI: Establishing Governing Code Editions, Addenda,
and Cases for Boilers and Replacement PartsApp.
09Feb
Sect. I Course 23
LR Insurance, Inc.
APPENDICES
Nonmandatory Appendices
App. A : Explanation Of Code Containing Matter Not Mandatory Unless
Specifically Referred To In The Rules Of The Code
Efficiency of Joints (Riveted)
Braced and Stayed surfaces
METHOD OF CHECKING PRESSURE RELIEF VALVE CAPACITY BY MEASURING
MAXIMUM AMOUNT OF FUEL THAT CAN BE BURNED
AUTOMATIC WATER GAGES
FUSIBLE PLUGS
PROOF TESTS TO ESTABLISH MAXIMUM ALLOWABLE WORKING PRESSURE
PRESSURE RELIEF VALVES FOR POWER BOILERS
EXAMPLES OF METHODS OF COMPUTATION OF OPENINGS IN VESSEL SHELLS
EXAMPLES OF COMPUTATION OF ALLOWABLE LOADING ON STRUCTURAL
ATTACHMENTS TO TUBES
PREHEATING (A-100) , HEATING AND COOLING RATES FOR POSTWELD HEAT
TREATMENT (A-101)
ROUNDED INDICATION CHARTS
METHODS FOR MAGNETIC PARTICLE EXAMINATION (MT)
LR Insurance, Inc.
APPENDICES
Nonmandatory Appendices
Appendix A : Explanation Of Code Containing Matter Not Mandatory Unless
Specifically Referred To In The Rules Of The Code (continued)
METHODS FOR LIQUID PENETRANT EXAMINATION (PT)
QUALITY CONTROL SYSTEM
ACCEPTANCE OF TESTING LABORATORIES AND AUTHORIZED OBSERVERS FOR
CAPACITY CERTIFICATION OF PRESSURE RELIEF VALVES
DATA REPORT FORMS AND GUIDES
CODES, STANDARDS, AND SPECIFICATIONS REFERENCED IN TEXT (A-360)
Guide to Information Appearing on Certificate of Authorization (A-370)
SAMPLE CALCULATIONS FOR EXTERNAL PRESSURE DESIGN
GUIDANCE FOR THE USE OF U.S. CUSTOMARY AND SI UNITS IN THE
ASME BOILER AND PRESSURE VESSEL CODE
Appendix B : Positive Material Identification Practice
09Feb
Sect. I Course 24
LR Insurance, Inc.
MANY THANKS FOR YOUR ATTENTION
LR INSURANCE, INC.
The Lloyds Register Group
works to enhance safety and
approve assets and systems at
sea, on land and in the air
because life matters.
Services are provided by members of the Lloyds Register Group Lloyds
Register, Lloyds Register EMEA and Lloyds Register Asia are exempt
charities under the UK Charities Act 1993.
For more information, please contact:
Chamni Mosagul
LR Insurance, Inc.
+66 81 9352069
[email protected]

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09Feb

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