CODES & STANDARDS

PIPING
Codes, Standards & Regulations
ASME DIN TRD BS IBR

 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 Codes and Standards on piping are given below:

1. 2. 3. 4.
5. 6. 7. 8.

ASME B31.1 ASME B31.2 ASME B31.3 ASME B31.4

ASME B31.5 ASME B31.8 ASME B31.9 ASME B31.11

Power Piping Fuel Gas Piping Process Piping Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids. - Refrigeration Piping - Gas Transmission and Distribution Piping Systems - Building Services Piping - Slurry Transportation Piping Systems.

 Through the use of codes and standards, safety and uniform economy are obtained. 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.

 Even though the use of codes and standards is not a legal requirement the same becomes a legal requirement in a contractual situation. Certain regulations are legally binding. The Indian Boiler Regulations, 1950 (IBR) is binding on the Indian Boiler-makers and Boiler-users, of certain kind of boilers. The codes and standards do not cover all aspects of the piping. The codes and standards are not textbooks. They do not cover the theory. They provide answers to the following aspects: 1. Know what 2. Know how

 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 of Know 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.

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

 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. Note that 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.

 Schedule of Pipes: The schedule of pipes is an ASME method of indicating the pressure carrying 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.

 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.

REFERENCES
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.

COMPARISON OF BOILER CODES

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 by comparing 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. The following codes have been considered for the study:1.IBR 1950 2.ASME Section-I 3.BS 1113 4.DIN TRD 300.

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 ASME Section-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 be designed for drum design pressure. 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 actual metal temperatures.

3)

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 a place 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.

COMPARISON OF BOILER CODES

Sl.No. 01. 02. 03. 04. 05. 06. 07. 08. 09. Applicability of Code Regulations Maximum Allowable Working Pressure Design Pressures & Design Temperatures Comparison of Codes Design Stresses - Factors of Safety Comparison of Material Grades Temperature Limits for various Steel Grades Design - Calculation of Thickness Required Openings in Shell Item Description

10.
11. 12. 13. 14. 15. 16. 17.

Ligament Efficiency
Drum / Headers comparison - 2 sheets Tubes comparison Relationship between Allowable Stress, Weight Savings IBR Regulations - Clauses - 2 sheets IBR Regulation Numbers - Ascending Order - 8 sheets Requirements as per ASME Section-I - 3 sheets Salient Clauses of BS1113 - 3 sheets

APPLICABILITY OF CODE REGULATIONS

IBR Applicable to boiler that is a closed vessel exceeding 22.75 litres in capacity which is used to generate steam under pressure.

ASME Sec. I

Applicable to boilers in which the steam or any other vapour is generated at a pressure more than 15 PSI (g).
The rules specify the requirements for the water tube steam generating plant subject to internal pressure.

BS 1113

TRD 300

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

MAXIMUM ALLOWABLE WORKING PRESSURE

IBR It is the working pressure of any component of the boiler. It is the maximum pressure to which any part of the boiler is subjected to except when SV or SRV or Valves are discharging at which time the MAWP shall not be exceeded by more than 6%. It is the highest set pressure on any SV mounted on the steam drum. For steam generators, the design pressure shall be the allowable pressure.

ASME Sec. I

BS 1113

TRD 300

DESIGN PRESSURES & DESIGN TEMPERATURES ALLOWANCES USED IN VARIOUS CODES

AREA IBR
Drum design pressure with pressure drop

ASME SEC.I
Drum design pressure

BS 1113
Drum design pressure

DIN TRD 300

Drum design pressure

DESIGN PRESSURE

RADIATION
CONVECTION ECONOMISER

50C
ACTUAL METAL TEMPERATURE 371C (MIN) FOR GAS TOUCHED PORTION

50C

50C

39C

35C

35C

11C

25C

15+2xAct. wall thick) C Max. 50C

WATER WALLS / SH WALLS

GAS TOUCHED DRUMS/HEADERS

28C

50C

50C

28C

25C

20C

COMPARISON OF CODES
IBR 1950 ASME SEC.I BS 1113 DIN TRD 300 REMARKS DESIGN PRESSURE DESIGN PRESSURE WITH PRESSURE DROP 50C DRUM DESIGN PRESSURE DRUM DESIGN PERSSURE DRUM DESIGN PRESSURE

DESIGN TEMPERATUE ALLOWANCE RADIATION CONVECTION

50C

50C

39C

ACTUAL METAL TEMPERATURE 371C (MIN)

35C

35C

ECONOMISER

11C

25C

(15 + 2 Se) C Max. 50C

Se - ACTUAL WALL THICKNESS in mm.

WATER WALL

28C

50C

50C P=DESIGN PR. D=OUTSIDE DIA f=ALLOWABLE STRESS CORR. TO DESIGN METAL TEMP. R 2.4 Et = YIELD STRENGTH R = TENSILE STRENGTH SR = RUPTURE STRENGTH SC = CREEP STRENGTH

TUBE THICKNESS FORMULA tmin

PD --------- + *C 2f + P

PD --------- + 0.005D 2f + P

PD --------2f + P

PD --------2f + P

FACTOR OF SAFETY

Et 1.5 , SR 1.5

R 2.7 SC

Et 1.5 , SR 1.5

R 3.5 SC

Et 1.5 , SR 1.3

R 2.7

Et 1.5 , SR 1.0

FOR ASME MATERIALS ALLOWABLE STRESS CAN BE TAKEN DIRECTLY FROM ASME SEC.II PART-D *C = CORROSION ALLOWANCE = 0.75mm FOR P 70 bar; 0 mm FOR P > 70 bar

DESIGN STRESSES FACTORS OF SAFETY IN VARIOUS CODES

PROPERTIES IBR ASME SEC.I BS 1113 DIN TRD 300

Min. yield strength at Room Temperature

---

1.5

---

---

Min. yield strength at Design Temperature

---

---

1.5

1.5

Average yield strength at Design Temperature Min. ultimate tensile strength at Room Temperature

1.5

1.5

---

---

2.7

3.5

2.7

2.4

Average creep rupture strength for 100,000 hours life at Design Temperature

1.5

1.49

1.3

1.0

Average creep strength for 1% creep in 100,000 hours at Design Temperature

1.0

1.0

---

---

For Austenitic steels, FS = 1.35 To be used at temperature below 1500F For components without an acceptance test certificate to DIN 50049, FS shall be increased by 20%.

COMPARISON OF MATERIALS GRADES

Max. Service Temperature ASME SA 106 SA 192 SA 209 - SA 210 SA 213 - SA 335 475C 885F 500C 930F 550C 1020F 560C 1040F 575C 1065F 600C 1110F 625C 1155F

Gr.A A192

Gr.B Gr.A1

Gr.C Gr.C T1 P1 T2 / P2 T12/P 12 T11/P1 1 T22/P2 2 T9/P9

BS 3059-36023604

360

410

440460

490Nb

243

620

621

622

660

629

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

St.35. 8

St.45. 8

17 Mn4

19 Mn5

15 Mo3

1.030 5

1.040 5

1.048 1

1.0482

1.541 5

16 Mo5 1.542 3

15Ni CuM oNb 5 1.63 68

13Cr Mo44 1.7335

10Cr Mo 9 10 1.7380

(14M o V63) 1.771 5

(X12Cr MO 91) 1.7386

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

20

15 XM

12 X1 MF

(15X IMI F)

JIS (JAPAN) G3456 G3458 G3461 G3462

STPT 38 STB 35 TU37C

STPT 42 STB 42 TU42C

STPT 49

STPA 12 STBA 12 TU52C TU15 D3

STPA2 0 STBA2 0 TU15C D 2.05

STPA2 2 STBA2 2 TU13C D 4.04

STPA2 3 STBA2 3 TU10C D 5.05

STPA2 4 STBA2 4 TU10 CD 9.10

STPA2 6 STBA2 6 TU Z10 CD9

NF A 49-213 (FRENCH)

TU48C

This is indicative only. However, the actual maximum service temperature for various steels shall be limited as prescribed in the relevant codes.

TEMPERATURE LIMITS FOR VARIOUS STEEL GRADES OF TUBES / PIPES

Sl. No. Nominal Composition ASME Section-I MATERIAL SPECIFICATION DIN TRD 300 BS 1113 Temp. Limit C

01.

Carbon Steel

SA178 Gr.C, Gr.D, SA192, SA210 Gr.A1 & Gr.C SA106 Gr.B, Gr.C SA209 T1

St 35.8 St 45.8

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

427

02.

Mo

15 Mo3

----

482

03.

1 Cr Mo

SA335 P12 SA213 T12 SA213 T11 SA335 P11 SA213 T22 SA335 P22 SA213 T91 SA335 P91 -----

13 Cr Mo 44

BS3059 P2 S2 620 BS3604 P1 620 440 BS3604 P1, 621

535

04.

1 Cr Mo

----

552

05.

2 Cr 1 Mo

10 Cr Mo 910

BS3059 P2 S2 622-490 BS3604 P1, 622 -----

577

06.

9 Cr 1 Mo V

X 10 Cr Mo V Nb91 X 20 Cr Mo V 121

635

07.

12 Cr 1 Mo V

BS3059 P2 S2 762 BS3604 P1 762 BS3059 P2 304 S51 BS3605 304 S59 E BS3059 P2 347 S51 BS3605 347 S59 E

700

08.

18 Cr 8 Ni

SA213 TP304 H

-----

704

09.

18 Cr 10 Ni Cb

SA213 TP347 H

-----

704

DESIGN - CALCULATION OF THICKNESS REQUIRED IN VARIOUS CODES

AREA

IBR

ASME SEC.I

BS 1113

DIN TRD 300

Tube thickness

PD 2f + P PR

+ C

PD 2f + P +0.005D

PD 2f + P PR fE 0.5 P PDK 2f Cd P f

PD 2f + P PR fE 0.5 PE R 1+ 2P 1 2f P P f

Shell thickness Dished end thickness Flat end thickness

PR
+ 0.75

fE 0.5 P PDK
+ 0.75

fE (1 Y) P PR 2f 0.2 P + C CP f

2f d CP f

Cd

OPENINGS IN SHELL
PD 1.82 St PD 1.82 St

IBR

8.08 [Dt (1

K)]1/3

K=

ASME Sec. I

8.08 [Dt (1

K)]1/3

K=

BS 1113

8.08 [Dt (1

K)]1/3

K=

PD
1.82 St

For dia of Opg. 50 mm, TRD 300 For dia of Opg > 50 mm,

t t

branch shell

2 opg dia shell ID opg dia shell ID t branch t shell t branch t shell

if

0.2, then

2.

if

> 0.2, then

2.

LIGAMENT EFFICIENCY
EFFICIENCY P d P PC d PC ASME P d P PC d PC IBR BS 1113 P d P PC d PC

Longitudional

Circumferential

Diagonal

J + 0.25 (1 0.01 Elong) 0.75 +J

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

2 (A B)2 + 4C2

0.00375 + 0.005 J

TRD 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 di VL = SV A0 + all A1 + all A2 all all all all

all

all

AP0 (1+cos2)+2AP1+2AP2+A1+A2

A1

A2

DRUM / HEADERS - COMPARISON WITH VARIOUS CODES

DESCRIPTION IBR ASME SEC.I BS 1113 DIN TRD 300

Min. Plate thickness for shell

6 mm

6 mm

6 mm

3 mm

Type of weld joint

Single or double U or V type.

Double welded butt type. The shape shall be such as to permit complete fusion and complete joint penetration. Any type of opening that meets the requirements for compensation may be located in a welded joint.

Double V Type or U type.

Double V type.

Position of tube holes

Allowed through welded seams, if they are radiographed and stress relieved. The ligament efficiency shall be multiplied by a factor 0.95. Difference between internal diameter of drum shall not exceed 1%.

Machining of holes through the centre of main seam welds is permitted provided the seam welds have been subjected to NDE. Maximum internal diameter of drum shall not exceed the nominal internal diameter by more than 2%.

-----

Circularity of Drum

The drum shall be circular within a limit of 1% of mean diameter based on the differences between maximum and minimum mean diameters. D max. D min.

The average bore shall not deviate by more than 1% from the nominal diameter.

Percentage deviation from circularity

2 (d max. d min.)

D max. D min.

2 (d max. d min.)

X 100
d max. + d min. DS

X 100
DS

X 100
d max. + d min.

X 100

Hand hole size in Headers

89 x 63.5

89 x 70

-----

------

DESCRIPTION

IBR

ASME SEC.I

BS 1113

DIN TRD 300

Hydraulic test point - Shop & test pressure.

Drums & Headers greater than 1000 mm shall be hydraulic tested at shop to 1.5 times the Design Pressure.

-----

Drums & Headers greater than 600 mm shall be hydraulic tested at shop to 1.5 times the max. permissible working pressure. + 10% 10%

-----

Wall thickness tolerance for pipes / headers.

+ 15% 5%

12.5%

+ 12.5% 10.0%

Hydraulic test pressure at site.

1.5 times the Drum Design Pressure.

1.5 times the maximum allowable Working Pressure.

1.5 times the maximum permissible Working Pressure.

1.3 times the maximum allowable Working Pressure.

Requirement of Safety Valves.

Two safety valves - the bore not less than 19mm.

Two or more safety valves.

Two safety valves. Minimum bore 20 mm.

Two or more safety valves.

Water level indication.

Two means of indicating water leve.

Two numbers of gauge glass. Two independent remote level indicators instead of one gauge glass.

Two independent means of water level indication.

Two means of indicating water level.

TUBES - COMPARISON WITH VARIOUS CODES

DESCRIPTION IBR ASME SEC.I BS 1113 DIN TRD 300

TYPE

Cold drawn or hot finished seamless or ERW

Cold drawn or hot finished seamless or ERW

Cold drawn or hot finished seamless or ERW

Cold drawn or hot finished seamless or Longitudinally welded Min. - 3 mm Max. - 6.3 mm for Water wall tubes

Minimum thickness allowed for various tube Diameters Seamless.

Up to D32 Up to D51 D51 to D76 D76 to D89 D89 to D114

2.03 2.34 2.64 3.25 3.66

Up to D32 Up to D51 D51 to D76 D76 to D102 D102 to D127

2.41 2.67 3.05 3.43 3.81

Up to D38 D38 to D51 D51 to D70 D70 to D76 D76 to D95 D95 to D102 D102 to D127

- 1.7 - 2.2 - 2.4 - 2.6 - 3.0 - 3.3 - 3.5

Ovality (Deviation from circularity)

D Max. D Min.
x 100

D D Min.

D shall not exceed 20D R

D shall not be more than 50D R

x 100

2(DMax.DMin.) DMax + DMin

x100

Provides calculation for wall thickness for inside & outside of bend as per TRD301 Annex-2.

Wall thickness tolerance

+ 10% 5%

+ 22% 0%

+ 10% 10%

+ 15% 10%

RELATIONSHIP BETWEEN ALLOWABLE STRESS, WEIGHT AND SAVINGS IN WEIGHT

(TYPICAL 250 MW)
Sl. No Item Material Specn. Design Temp. C Allowable Stress Kg/mm2
% increase

in allowable Stress

in allowable Stress

Correspond -ing

ASME

BS 1113

01.

Water Walls

SA210 Gr.C SA106 Gr.C SA106 Gr.B SA210 A1 SA210 A1

385

11.038

13.228

19.8

11.4

02.

Downcomers

357

11.993

13.570

13.0

9.8

03

Riser Pipes

357

10.339

11.859

14.7

9.8

04.

Economiser

311

10.546

12.896

22.3

16.0

05.

Low temp. SH

373

10.087

12.442

23.7

17.6

IBR REGULATIONS I)
a) b) c) d) E f) g) h) I j) K l) M) n) o) p) q) r) s)

DRUM
Circularity of drum Drawing preparation Type of weld joint Long seam intersection )Position of tube holes Hydro Test Maximum working pressure for shell Stress factors )Ligament efficiency Longitudinal stress Shape of Dished end plate Dished end with openings Dished end maximum working pressure Reinforcement calculation Attachment of Branch pipes Mountings on the drum Attachment (SV) to dru Water gauges Uncompensated hole 243 (a)256 (b) 249 253 254 255 268 270 271 272 (215) 273 275 277 278 279 280 281 296 320 187

II)
a) b) c) d) e) f) g) h) i) j) k) l) m)

HEADERS
Header shapes and Process Hand holes Uncompensated hole Maximum working pressure Stress factors Ligament efficiency Shape of Dished end Dished end opening Dished end maximum working pressure Reinforcement calculation Attachment of Branch pipes Flat ends maximum working pressure Headers for boiler & SH 154 (a) 164 (a) 187 270 271 272 (215) 275 277 278 279 280 340 (f) 342

III)
a) b) c) d)

TUBES
Process Tubes Maximum working pressure Percentage ovality 151 (a), (b), (c) 244 (a) 338 (a) 338 (b), (c)

IV)
a) b) c) d) e) f) g) h) i) j) k)

LINES & LINKS (BOILER INTEGRAL PIPING)

Integral boiler piping Process Material, permissible stress Hydraulic Test Temperature limits for Pipes, Tees, Branches Maximum working pressure Steam pipe bending thinning Butt welding fittings Branch welded to pipes External Reinforcement Hydraulic Test 244 (b) 343 (1) 343 (2) 343 (3) 349 350 361 (a) 361 (A) 249 to 253 362 (b) 374

V)
A. a) b) c) d)

BOILER MOUNTINGS
SAFETY VALVES Discharge capacity Over pressure of safety valve Pressure drop Attachment to boiler 293 294 295 296

B. a)

WATER GUAGES Requirements 320 a, b.

VI)
1) 2) 3) 4)

GENERAL
Procedure of Hydro test of boiler Registration Fee Submission of plans of boilers Submission of plans of steam pipes 379 385 393 395

BOILER & SH TUBES Regn. 151: a) Tubes

IBR
Cold drawn or hot finished

Seamless or ERW tubes

b)

Tubes < 5 dia - can be used inside the boiler > 5 dia - can be used outside the boiler
Flash welding allowed.

c)

HEADERS MUD BOXES, ETC. OF WATER TUBE BOILERS

Regn. 154: a) i) Headers Seamless or Welded steel or cast steel.

Where welded, the welding shall be stress relieved, radiographed or UT. Headers may be closed by forging, bolting, screening or welding.

ii)

MAIN HOLES Regn. 164 (a): Regn. 187: Hole size not less than 3 x 2 in. PD Uncompensated hole - Maximum 203 mm = 1.82 fe FUSION WELDED DRUMS Regn. 244 (a): Regn.244 (b): Tubes Pipes of boiler shall comply with Chapter VIII.

Regn.243 (a):
Regn. 243 (b):

Circularity of drum 1%.

Percentage deviation = from circularity

2 (d max. d min.) x 100 (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 be furnished.

Regn. 253:

Drum - type of welded joint - Single or double U or V type. Longitudinal seams in successive rigs shall not fall in line except where the rigs of drum are in two halves of unequal thickness. Position of tube holes:Tube holes through welded seams, if they are radiographed and stress relieved - The efficiency and ligament multiplied by a factor 0.95 except the distance from edge hole to edge of weld > 13mm ().

Regn. 254:

Regn. 255:

Regn. 256:

Circularity of drum:The difference between internal diameter of drum shall not exceed 1%. Hydro test - 1 times the maximum permissible working pressure after completion of welding and heat treatment of drum (internal dia > 1000 mm).

Regn. 268:

2 f E (T 0.03)

Regn.270:

The working pressure - WP =

Weld factor 0.95.

D + T 0.03

Regn. 271:

For temperature at or below 454C Et (or) R

1.5 2.7 For temperature above 454C Et SR (or) (or) SC 1.5 1.5 In case SC valves are not available, the allowable stress may be Et SR lower of (or) 1.5 1.5 Regn. 272: The ligament efficiency as per Regn. 215. Pd P nd P P1 Diagonal and Curve P P d P Circumferential ligament.

PD2 Regn. 273: Longitudinal Stress = fd =

1.273A PD2 M= 1.273

MRY

The stress due to bending f b =

Ia Regn. 275: a) b) c) Shape of Dished end plate

Hemispherical Elliptical heads -H 0.2D Partial spherical heads - H 0.18D.

Figures 23A, B, C.

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 DT d1 = d A T

Regn. 278:

Dished end plate maximum working pressure 2f (T C) WP = DK (Shape factor) Minimum head thickness - 5 mm. Reinforcement calculation. Attachments of Branch Pipes by welding.

Regn. 279: Regn. 280:

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

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. 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 exceed 10% of set pressure. Where discharge area > 80% - Over pressure shall not exceed 5%.

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% limit increased 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 short as 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.

BOILER AND SH TUBES, HEADERS

Regn. 338(a): WP = 2f (T C) (D T + C) C = 0.75 for P 70 Kg/m2 = 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.

For temperature at or below 454C. TS (or) 2.7 1.5 For temperature above 454C SR 1.5 or SC Et

If SC not available Et (or) SR

1.5
b)

1.5

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

Regn. 340 (f):

Flat ends for headers f (t C)2

WP =
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.
Material used, the permissible stress figures specified in the code may be accepted.

Regn. 343(2):

Regn. 343(3):

The hydraulic test may be dispensed with if 600 mm.

id

Regn. 349:

The temperature limits for pipes, Tees, branches, etc. shall be as per Table-2.

Regn. 350:

Working Pressure. 2fe (t C) WP = Dt+C STEAM PIPE FITTINGS

C = 0.75.

Regn. 361(a):
Regn. 361(A): Regn. 362(a):

Pipe bends thinning 12.5%.

Butt welding fittings. Branch welded to pipe Regn. 249 to 253. Angle not less than 60. External Reinforcement : Multiple radial plates of horse shoe form or the form of collars applied to or around the junction between branch and main.

Regn. 362(b):

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: Regn. 393: Registration Fee: Submission of plans of boilers:

a)
b) & c)

Drawing Approval.
Boilers made outside India, Technical Advisor (Boilers) and then CIB user state.

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.No . 1.

DESCRIPTION

CLAUSE

REQUIREMENT AS PER ASME SEC.I 2001

REMARKS

Service Limitations

PG-2

a)Boilers in which steam/vapour is generated at a pr. more than 15 PSIG b)High temp. water boilers > 160 PSIG or 250 Deg.F Shall be of pressure vessel quality SA202; SA204; SA240(Type 405 only) SA302; 387(A.S) SA285; SA299; SA515; SA516 (C.S), SA / EN - 10028 - 2 PG 9.1 for boiler parts materials PG 9.1 & 9.2 for superheater matrials

2.

Plate material

PG-6

3.

Pipes, Tubes materials

PG-9

4.

Boiler plate min.thick

PG-16.3

The min. thickness of any boiler plate under pressure shall be 1/4 in (6 mm)

5.

Tubing calculation

PG-27.2.1

"Upto and including 5 inches outside dia" (127mm) t(inch)=PD/2S+P +0.005D+e e = 0 for tubes strength welded to headers P = Max. allowable working pressure(psi) D = Outside dia(in) S = Max. allowable stress (psi)

Sl.No . 6.

DESCRIPTION Piping, Drums and headers calculation

CLAUSE PG27.2.2

REQUIREMENT AS PER ASME SEC.I 2001 t =PD / 2SE+2YP + C (or) t = PR / SE (1-y)P+ C E = efficiency of liagament of weld joints Y = temperature co-efficient C = Min. allowance for threading and structural stability (0) R Inside radius in t ==PL / 1.6S L = radius to which formed head measured on concave side

REMARKS

7.

Hemispherical head

PG-29.11

8.

2:1 Semiellipsoidal

9.

Max. Dia of opening in shell

PG-29.7 & PG27.2.2 PG32.1.2 &

PG-32.1.3.2

t = PR / SE - (1-y)P + C R = Inside radius of end cover

K Factor = PD / 1.82 St Max. dia of opening without compensation as per Fig PG 32 Limits of reinforcement X = greater of 2d or 2(t + tn) but not greater than pitch Y = the smaller of 2 1/2t or 2 1/2 tn

10.

Compensation Calulation

PG - 37 & PW 15

Sl.No. 11.

DESCRIPTION Max. allowable stress for drum (Bending and Longi stress) Hydraulic test pr.

CLAUSE PG - 22 & Sec.3.3.4 of BS1113 PG 99.1

REQUIREMENT AS PER ASME SEC.I 2001 Total stress = fb + fd fb = stress due to bending fd = Direct longitudinal stress 1.5 times the max. allowable working pr. Calculate stress at hydraulic test by substituting in thick formula.Stress at hydro to be leser than 90% yield stress at 100 deg. F. Check as per Fig. PW 16.1 Combined strength of each path >min. weld strength required Boiler pr. 400 PSI or over the feed water inlet shall be fitted with sleeves. Boiler shall have a bottom blow off outlet in the lowest water space.
a) Two nos. gauge glass over a boiler pr. Of 400 PSI b) Two independent remote level indicators instead of one gauge glass in case of pr. above 900 PSI c) The lowest visible part of gauge shall be at least 2 in. above lowest water level

REMARKS

12.

13. 14.

Min. weld size Min. weld size

PW - 16.1 PG - 37 PW - 15 water PG - 59.2

15.

Feed connection Blow - off

16.

PG 59.3.3 level PG 60.1.1

17.

Water indicator

Sl.No .

DESCRIPTION

CLAUSE

REQUIREMENT AS PER ASME SEC.I 2001

REMARKS

18.

Water indicator

level

PG 60.1.6

a) Connection to the gauge glass shall not be less than 1/2" pipe size b) Water gauge glass drain not less than 1/4 in. Above 100 PSI pr. Drain connects to safe discharge point
Pr. Gauge connection to the boiler shall not be less than 1/2 in. Inside dia. for steel pipe. Connection to the test pr. gauge shall be at least 1/4 in. pipe size a)Boiler having more than 500 sq. ft. of water heating surface shall have two means of feeding water b) The feed connection shall not be less than 3/4" pipe size for water heating surface more than 100 sq. ft.

19.

Pressure gauges

PG 60.6.1 PG60.6.3 PG-61

20.

Test pr. Gauges

21.

Feed supply

water

Sl.No .

DESCRIPTION

CLAUSE

REQUIREMENT AS PER ASME SEC.I 2001

REMARKS

22.

Boiler safety valve reqts

PG-67.1

Boiler with water heating surface exceeding 500 sq. ft. and steam generating capacity exceeding 4000 lb/hr two or more safety valves are required.
a) one or more safety valves shall be set at or below max. allowable working pr. B)The highest pr. Setting shall not exceed 3% of the max. allowable working pressure c) The safety valve will discharge all the steam generated by the boiler without allowing the pr. to rise more than 6% above max. allowable working pressure.

PG-67.3

PG - 67.2

PG-68.2

The discharge capacity of the safety valve on the boiler is at least 75% of the aggregate value capacity required
Piping connections for items such as drains, vents for a high temp. Boiler.

23.

Drain, provisions

vents

PG 58.3.7

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

2..1.2 MATERIALS FOR PP. BS MATERIALS OR AGREED BETWEEN MANUFACTURER AND PURCHASER 2.2 2.2.3 DESIGN STRESSES FOR C, C-Mn AND LOW ALLOY STEELS FE = Re (T)/1.5 VALUE. 2.2.4 OR Rm /2.7 WHICHEVER GIVES A LOWER

FOR AUSTENTIC STEEL FE = Re (T)/1.35 VALUE. OR Rm /2.7 WHICHEVER GIVES A LOWER

2.2.7

DESIGN TEMPERATURE

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. -- SAT TEMP. + 25 C.

NOT SUBJECT TO RADIANT HEAT

2.2.7.3 SH & RH TUBES SUBJECT TO RADIANT HEAT -- SAT TEMP. + 50 C. -- SAT TEMP. + 35 C.

NOT SUBJECT TO RADIANT HEAT 2.2.7.4 ECONOMIZER TUBES MAX FLUID TEMP + 25 C.

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. MINIMUM 6 mm THICK FOR HEADERS UPTO OD 300 mm t = PDi / 2 f n - P

3.3.2

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 OPENINGS NOT TO BE GIVEN IN D/10

AREA. 3.7.2 3.7.2.1 TUBES AND PIPES 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

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.

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 REASONABLY ACESSIBLE TO INSPECTION AFTER ASSEMBLY TO BE HYDROTESTED AT SHOP.

SECTION 7 VALVES, GUAGES AND FITTINGS 7.2 SAFETY VALVES

7.2.1.1 7.2.1.2

MINIMUM BORE 20 mm FOR EVAPOTATION UPTO 3700 KG/H ONE SAFETY VALVE FOR GREATER EVAPORATION TWO SAFETY VALVES

7.2

WATER LEVEL GUAGE

EACH BOILER TO HAVE TWO INDEPENDENT MEANS OF WATER LEVEL INDICATION.

BOILER PRESSURE PARTS COMPARISON BETWEEN BHEL & MBEL (500 MW)
Sl.No.

Page 01 of 02

Description

BHEL

MBEL

01.

BOILER DRUM - Shell Material

CARBON STEEL to SA299

ALLOY STEEL to Specification BS EN 10028-2 1993 Grade NC 271

Thickness in mm Internals
02. 03. DOWNCOMERS WATERWALLS

195 / 165 Turbo Separators (92 Nos)

6 Nos. of D368 SA106 Gr.C D51 at 63.5 Centres Rifled SA210 Gr.C Tangential firing.

111/111 Cyclone Separators (168 Nos)

4 Nos. of D508 BS 3602 500Nb Supply pipes - 48 Nos. of D139.7 D66.7 at 92 Centres Rifled - BS 3059 243 S2 Calls for optimisation with headers. Front / Rear wall firing.

04.

RISERS

68 Nos. of D159 - SA106 Gr.C Risers are connected to the top of drum.

48 Nos. of D168.3 - BS 3602 500 Nb The rear and bottom of drum. Armchair support with hanger tubes. BS 1563 - 620 - 440.

05.

PRIMARY SUPERHEATER

Strap type support with hanger tubes. SA240 Type 310/304.

Page 02 of 02

Sl.No. 06.

Description PLATEN SH / FINAL SH

BHEL
Flex connectors for spacing between tubes. Tangent Flex tie at close spacings. Common Header for inlet & outlet of all assemblies.

MBEL
Wraparounds for spacing between tubes. Only 2 DAGS of Material BS 3059 622 S2 & T91 - Half the horizontal bottom portion of platen membraned. Individual headers for both inlet & outlet of each Coil Assembly (Calls for optimisation).

07.

REHEATER

Front RH - Flex connectors for spacing. Rear RH - Alignment band for spacing.

Tube strap support for both Front & Rear Reheater.

08.

ECONOMISER

Two loop D51 - SA210 Gr.A1

Not covered in the scope.

09.

ATTEMPERATOR

Liner is positioned with shell support screws.

Liner is positioned with shell by support bar welded to liner out side and support ring.

10.

STEAM COOLED WALLS

D63.5 / D51 at 152.4 Centres SA210 Gr.C

D44.5 at 115 Centres - BS 3059 243 S2.

COST SAVINGS DUE TO NEW MATERIALS

Sl. No . Pipe / Tube Specification Usage Area Annual Quantum (200304) Tons 2000 Cost/T on Total Cost Increase Substitute d Material WB361 Cost Savings (%) Total Savings (in Crores)

01.

SA106 Gr.B / Gr.C

Water wall Headers, Downcomers, Risers

70,000

14

25%

3.5

02.

SA213 T22

SH / RH coils

1060

60,000

6.36

SA213 T232 SA213 T922 SA213 T922

23%

1.46

03.

SA213 T91

SH / RH coils

257

1,30,00 0

3.34

21%

0.7

04.

SA213 TP347 H

SH / RH coils

173

2,10,00 0

3.63

21%

0.76

TOTAL SAVINGS / YEAR

6.42

Cost Savings projected by M/s. V&M.

1 2

= Code case but covered in DIN. = Published in ASME.