Boiler Design 506m1b

Power Boiler Design, Inspection, and Repair ASME Code Simplified

Mohammad A. Malek, Ph.D., P.E.

McGraw-Hill New York

Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto

Contents

ice xvii >duction xix

ipter 1. Boiler Fundamentals 1.1 1.2

1.3

1.4

1.5 1.6 1.7 1.8

1.9

Definition Steam Generation 1.2.1 Boiler flow diagram 1.2.2 Thermodynamics 1.2.3 Heat transfer Boiler Classifications 1.3.1 Classification based on ASME code 1.3.2 Classification based on pressure 1.3.3 Classification based on output 1.3.4 Classification based on fuel 1.3.5 Classification based on materials 1.3.6 Classification based on use 1.3.7 Classification based on tube type 1.3.8 Miscellaneous boilers Power Boilers 1.4.1 Power boiler 1.4.2 High-temperature water boiler 1.4.3 Miniature boiler 1.4.4 Electric boiler 1.4.5 Organic fluid vaporizer Boiler Performance Selection of a Boiler International Code Power Boiler Life Analysis 1.8.1 Useful life 1.8.2 Code requirements Jurisdictional Authority

2. Materials 2.1

Production 2.1.1 Steel making process 2.1.2 Ferrous metals and alloys

2 2 2 3 4 6 6 7 8 8 8 9 9

11 11 11 12 13

13 14 14 15 16 18 18 18 19

21 22 22 24

vi

Contents

2.1.3 Steel 2.1.4 Nonferrous metal and alloys 2.1.5 Forming shapes 2.2 Properties 2.2.1 Physical properties 2.2.2 Mechanical properties 2.2.3 Chemical properties 2.3 Application of Materials 2.3.1 Pressure parts 2.3.2 Nonpressure parts 2.4 Ordering 2.4.1 Standard 2.4.2 Size and tolerances 2.4.3 Code requirements 2.4.4 Purchase order 2.5 Receiving 2.5.1 Identification of materials 2.5.2 Receiving inspection reports 2.5.3 Mill test reports 2.6 Inspection 2.6.1 Markings 2.6.2 Transfer of markings

Chapter 3. Boiler Design 3.1 3.2

Design Methods Design Factors 3.2.1 Definitions 3.2.2 Design load 3.3 Cylindrical Parts under Stress 3.3.1 Longitudinal stress in a cylinder 3.3.2 Circumferential stress in a cylinder 3.4 Design of Boiler Components 3.4.1 Cylindrical parts 3.4.2 Dished heads 3.4.3 Unstayed flat heads and covers 3.5 Openings and Compensations 3.5.1 Small openings 3.5.2 Medium openings 3.5.3 Large openings 3.5.4 Compensation for openings 3.5.5 Steps in solving compensation problems 3.6 Stayed Surfaces 3.6.1 Stayed flat plates 3.6.2 Staybolts 3.7 Ligaments 3.7.1 Ligaments for definite pattern 3.7.2 Ligaments for indefinite pattern 3.8 Designer's Responsibilities 3.8.1 Operating conditions 3.8.2 Specifications

Contents

3.8.3 3.8.4

Design calculations Design Process

vii

100 101

Chapter 4. Boiler Piping

103

} -

104 105 108 108 110 110 111 115 122 123 123 124 125 125 126 126 127 127

t ->' 1 *"• *" %^ *•'* *'• |

4.1 Pipe Classifications 4.2 Power Boiler Piping 4.2.1 Boiler proper piping 4.2.2 Boiler external piping 4.2.3 Nonboiler external piping 4.3 Design Requirements 4.3.1 Piping under internal pressure 4.3.2 Specific piping systems 4.4 Materials 4.4.1 American piping standard 4.4.2 International standards 4.5 Fabrication and Assembly 4.6 Shop Inspection and Testing 4.6.1 Stamping of pressure piping 4.6.2 Code symbol stamp 4.6.3 Manufacturer's data reports 4.7 Operation and Maintenance 4.8 In-service Inspection and Repair

ipter 5. Safety and Safety Relief Valves

129

5.1 Working Principle 5.2 Classifications 5.3 Materials 5.4 Capacity Requirements 5.4.1 Relieving capacity 5.4.2 Capacity checking 5.5 Design Requirements 5.5.1 Mechanical requirements 5.5.2 Boiler safety valves 5.5.3 Superheater and reheater safety valves 5.5.4 Organic fluid vaporizer safety valves 5.6 Safety Valve Manufacturing 5.6.1 Manufacturers 5.6.2 Capacity certification 5.6.3 Testing by manufacturers 5.6.4 Inspection and stamping 5.6.5 Certificate of conformance 5.7 Installation Requirements 5.8 Operation and Maintenance 5.9 Inspection and Repair 5.9.1 Inspection 5.9.2 Repairs

130 130 132 134 134 140 143 143 144 145 146 147 147 148 152 152 154 155 156 157 157 159

viii

Contents

Chapter 6. Fabrication 6.1

Preparation 6.1.1 Plates 6.1.2 Cylindrical shells 6.1.3 Formed heads 6.1.4 Tube holes 6.1.5 Holes for stays 6.1.6 Repair of defective materials 6.2 Fabrication by Welding 6.2.1 Design 6.2.2 Fabrication welding process 6.2.3 Loading on structural attachments 6.2.4 Inspection and tests 6.3 Fabrication by Brazing 6.3.1 Materials 6.3.2 Design 6.3.3 Fabrication 6.3.4 Inspection and tests 6.4 Assembly of Boiler 6.4.1 Shop-assembled boilers 6.4.2 Field-assembled boilers 6.5 Production of a Firetube Package Boiler

Chapter 7. Watertube Boilers 7.1 7.2

7.3 7.4 7.5 7.6

Working Principle Classifications 7.2.1 Classification based on tubes' and drums' (structural) configurations 7.2.2 Classification based on use 7.2.3 Classification based on water circulation 7.2.4 Classification based on output 7.2.5 Classification based on erection 7.2.6 Classification based on special purpose Main Components Design Features Construction of a Package Watertube Boiler Specifying a Package Watertube Boiler

Chapter 8. Firetube Boilers 8.1 Working Principle 8.2 Classifications 8.2.1 Classification based on layout position 8.2.2 Classification based on type of firebox 8.2.3 Classification based on output 8.2.4 Classification based on type of erection 8.2.5 Classification based on special purpose 8.3 Main Components 8.4 Design Features 8.4.1 Shell and tubesheet thickness 8.4.2 Attachment of heads and tubesheets 8.4.3 Tubes

161 161 162 162 162 162 162 163 164 165 170 178 184 186 189 189 192 193 194 194 194 195

201 202 203 203 206 208 211 211 211 215 218 223 230

241 242 242 242 247 249 249 251 251 253 256 256 256

Contents

ix

•: f l+ r i'-'

8.4.4 Combustion chamber tubesheet 8.4.5 Furnaces 8.4.6 Fireboxes and waterlegs 8.4.7 Stayed surfaces 8.4.8 Doors and openings 8.4.9 Domes f 8.4.10 Setting 1" 8.4.11 Piping, fittings, and appliances t' 8.4.12 MAWP for furnaces and tubes t" 8.5 Construction of a Firetube Boiler ?* 8.6 Specifying a Firetube Boiler

258 258 265 266 271 273 273 274 275 284 285

Npter 9. Feedwater Heaters

289

f I* |i ^ I Sv ** ^

289 289 290 292 295 295 297 298 298

9.1 9.2

Working Principle Classifications 9.2.1 Closed feedwater heater 9.2.2 Open feedwater heater 9.3 Materials 9.4 Design Features 9.5 Operation 9.6 Maintenance 9.7 Specifying a Feedwater Heater

ttapter 10. Miniature Boilers

It

301

« f 10.1 m 10.2 s«

Classification Design Features 10.2.1 Washout openings 10.2.2 Feeding devices ?i 10.2.3 Blowoff connections 10.2.4 Gage glasses p 10.2.5 Safety valves ' 10.2.6 Stop valves |^ 10.2.7 Pressure gages w. 10.3 Inspection and Stamping k 10.4 Controls and Safety Devices kj. 10.4.1 Automatic low water fuel cutoff I: 10.4.2 Electrical |f 10.5 Specifying a Miniature Boiler

302 303 304 304 305 305 305 305 305 305 306 306 306 307

M p t e r i i . Electric Boilers

309

Ci1.1 Working Principle

309 310 312 313 314 314 314 315 315 315

^ 11.2 Classifications I f 11.3 Design Features C 11.3.1 Sizing L 11.3.2 Pressure vessel l[f 11.3.3 Inspection openings C 11.3.4 Feedwater supply L. 11.3.5 Blowoff piping r 11.3.6 Water gages F 11.3.7 Pioina

Contents

11.4

Inspection and Stamping 11.4.1 Inspection 11.4.2 Hydrostatic test 11.4.3 Stamp holder 11.4.4 Stamping 11.4.5 Manufacturer's data reports 11.5 Controls and Safety Devices 11.5.1 Safety valves 11.5.2 Automatic devices 11.5.3 Low water fuel cutoff 11.6 Specifying an Electric Boiler

Chapter 12. Organic Fluid Vaporizers 12.1 Organic Fluids 12.2 Working Principle 12.3 Classifications 12.4 Design Features 12.4.1 Vaporizer shell 12.4.2 Gage glass 12.4.3 Drain valves 12.4.4 Hartford loop 12.4.5 Code reference 12.5 Inspection and Stamping 12.6 Controls and Safety Devices 12.6.1 Safety valve 12.6.2 Rupture disks 12.6.3 Level control 12.6.4 Temperature control 12.7 Operation 12.8 Specifying an Organic Fluid Vaporizer

Chapter 13. Shop Inspection 13.1

13.2

13.3

13.4 13.5

13.6 13.7 13.8

Boiler Fabrication Shop 13.1.1 Manufacturer 13.1.2 Manufacturer's responsibility Authorized Inspection Agency 13.2.1 Qualification 13.2.2 Duties 13.2.3 Accreditation certificate Authorized Inspectors 13.3.1 Qualification 13.3.2 Authorized inspector's responsibility Inspection Tools Inspections 13.5.1 The traveler 13.5.2 Code inspection 13.5.3 Field inspection 13.5.4 Visual inspection 13.5.5 Welding inspection Nondestructive Examination Hydrostatic Test Hydrostatic Deformation Test

316 316 316 316 317 317 317 317 318 318 318

321 321 322 322 324 324 325 325 325 325 325 325 326 328 329 329 329 331

333 333 334 334 335 335 336 336 336 337 337 338 338 340 341 341 342 343 343 346 347

Contents

xi

ipter 14. Stamping and Data Reports

349

14.1 Stamp Holders 14.1.1 Certificate of authorization 14.1.2 Agreement with authorized inspection agency 14.1.3 Quality control system 14.2 Code Symbol Stamps 14.3 Stamping 14.3.1 Shop assembled boilers 14.3.2 Field assembled boilers 14.4 Manufacturer's Data Reports 14.4.1 Types of data reports 14.5 Selection of Data Report Forms

350 350 352 352 355 356 357 359 360 362 362

ipter 15. Auxiliaries and Appurtenances

365

15.1 Boiler Auxiliaries 15.1.1 Air system 15.1.2 Fuel systems 15.1.3 Steam system 15.1.4 Feedwater system 15.1.5 Draft system 15.2 Boiler Appurtenances 15.2.1 Safety and safety relief valves 15.2.2 Pressure gages 15.2.3 Water columns 15.2.4 Blowdown apparatus 15.2.5 Fusible plugs 15.2.6 Soot blowers 15.2.7 Boiler vents 15.3 Boiler Accessories 15.3.1 Blowoff tanks 15.3.2 Sample coolers 15.3.3 Flash economizers 15.3.4 Mist separators 15.3.5 Inline separators 15.3.6 Temperature regulating valves 15.3.7 Exhaust silencers

365 365 366 369 372 377 379 380 380 382 382 383 383 383 383 383 385 385 385 385 386 386

pter16. FuelI Systems

387

16.1 Fuels 16.1.1 Gas 16.1.2 Liquefied petroleum gas 16.1.3 Fuel oils 16.1.4 Coal 16.1.5 Electricity 16.2 Combustion 16.2.1 Types of combustion f 16.2.2 Combustion process 16.2.3 Chemical reaction 16.2.4 Combustion air 18.3 Fuel-Burning Systems 16.3.1 Burners 16.3.2 Pilots

387 388 388 389 391 391 391 393 393 394 394 395 395 395

xii

Contents

16.4 16.5 16.6 16.7

Gas-Burning Equipment Oil-Burning Equipment Coal-Burning Equipment NOx Control 16.7.1 NOx control technologies

Chapter 17. Boiler Controls 17.1

Basic Boiler Controls 17.1.1 Control loops 17.1.2 Application to boiler 17.2 Burner Management 17.3 Control Standards 17.4 Controls and Safety Devices 17.4.1 Types 17.4.2 Minimum controls 17.4.3 Systems for multiple burners 17.5 Installation 17.6 Periodic Testing

pter 18. Boiler Installation 18.1 18.2 18.3

18.4 18.5 18.6 18.7 18.8

Boiler Installers Installation Code Boiler Room 18.3.1 Water and drain connections 18.3.2 Fire protection 18.3.3 Housekeeping 18.3.4 Posting the certificates 18.3.5 Record keeping 18.3.6 Safety Combustion Air Venting Boiler Placement Operation Tests Documentation

Chapter 19. Boiler Operation 19.1 Operating Personnel 19.1.1 Boiler operators 19.1.2 Boiler engineers 19.1.3 Training 19.1.4 QFO-1 standard 19.2 Filling a New Boiler 19.3 Boiling Out 19.3.1 Simple boilout method 19.3.2 Stubborn boilout 19.4 Starting a Boiler 19.5 Condensation 19.6 Cutting in an Additional Boiler 19.7 Normal Operation

Contents

19.8 19.9 19.10 19.11

Boiler Shutdown Periodic Tests Boiler Room Emergency Operation Logsheet

^Chapter 20. In-service Inspection 20.1 Authorized Inspectors 20.1.1 Qualification 20.1.2 Authorized inspector's responsibility 20.2 Boiler and Machinery Insurance 20.3 Inspection Tools 20.4 Boiler Inspection 20.4.1 First inspection 20.4.2 Routine inspection 20.5 Preparation for Inspection 20.5.1 Preparation for internal inspection 20.5.2 Preparation for external inspection 20.6 Inspection Types 20.6.1 Internal inspection 20.6.2 External inspection 20.7 Inspector's Calculations 20.8 Controls and Safety Devices Inspection 20.9 Repair Inspection 20.10 Certificates 20.10.1 Certificate of competency 20.10.2 Certificate of compliance

tapter 21. Boiler Maintenance

xiii

450 451 453 455 457 457 458 458 458 460 461 462 463 463 463 465 465 465 468 470 473 475 475 475 475 477

21.1 Maintenance Personnel 21.2 Maintenance Program 21.2.1 Routine maintenance 21.2.2 Preventive maintenance 21.2.3 Shutdown maintenance 21.2.4 Spare parts inventories 21.2.5 Personnel training 21.2.6 Boiler improvement 21.3 Trouble-Shooting 21.4 Maintenance Tools 21.5 Tube Cleaning 21.5.1 Mechanical cleaning 21.5.2 Chemical cleaning 21.6 Tube Expansion 21.7 Preparing for Inspection 21.8 Maintenance Logsheet

477 478 478 481 481 483 483 484 484 484 485 486 488 489 492 493

ipter 22. Boiler Repairs

495

22.1 Repair Organizations 22.2 Repairs 22.2.1 Routine repairs 22.2.2 Major repairs

495 496 496 497

xiv

Contents

22.3 22.4

Alterations Rerating and Derating 22.4.1 MAWP for existing boilers 22.5 Repair Calculations 22.6 Repair Steps 22.6.1 Preparation 22.6.2 Authorization 22.6.3 Repair work 22.6.4 Welding 22.6.5 Heat treatment 22.6.6 Nondestructive examination 22.6.7 Materials 22.6.8 Repair inspection 22.6.9 Hydrostatic test 22.6.10 Repair nameplate 22.7 Repair Methods 22.7.1 Drum repair 22.7.2 Tube repair 22.7.3 Waterleg repair 22.7.4 Handhole repair 22.7.5 Stay repairs 22.7.6 Welded crack repairs 22.7.7 Seal welding of tubes 22.7.8 Reversed flange (ogee) repair 22.8 Documentation

Chapter 23. Water Treatment 23.1

498 498 500 501 502 502 503 503 503 504 505 505 505 505 505 506 506 508 509 510 510 510 511 511 512

515

Boiler Water 23.1.1 Water types 23.1.2 Formation of scale 23.1.3 Quantity of scale 23.2 Boiler Water Problems 23.2.1 Deposit problems 23.2.2 Corrosion problems 23.2.3 Foaming and priming 23.3 Testing of Water 23.3.1 Testing types 23.3.2 Recommended limits 23.4 Treatment Methods 23.4.1 External treatment 23.4.2 Internal treatment 23.4.3 Condensate treatment 23.5 Boiler Storage 23.5.1 Wet method 23.5.2 Dry method

516 516 517 518 518 518 520 521 521 522 523 523 525 530 532 533 533 534

23.6

535

Conclusion

Appendix A. Maximum Stress Values for Ferrous Materials

537

Appendix B. Maximum Stress Values for Nonferrous Materials

545

Appendix C. Dimensions of Plates

549

Contents idix D. Dimension of Heads Appendix E. Pipe Thickness

I Ifpendix F. Tube Thickness

xv

551 555 557

i

)pendix G. Charts for Components under External Pressure

559

mdix H. MAWP for Watertubes

563

mdix I. Manufacturers' Data Report for Watertube Boilers

565

mdix J. Manufacturers' Data Report for Firetube Boilers

569

mdix K. Manufacturers' Data Report for Miniature Boilers

573

mdix L. Manufacturers' Data Report for Electric Boilers

577

spendix M. Manufacturers' Data Report for Organic Fluid Vaporizer

581

mdix N. Manufacturers' Data Report for Pressure Piping

585

mdix O. Installing Contractor's Report for CSD-1

589

mdix P. First Inspection Report

593

mdix Q. Suggested Format for Welding Procedure Specifications (WPS)

597

idix R. Unit Conversions

Bibliography Index 611

607

601