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Ministry of Labor, Peoples Republic of China

Steam Boiler Safety Technology Supervisory Regulations

China Labor Publishing House The Chinese version of standards has precedence to their English translations which are only for internal reference. ========================================2 2 ========================================

 Document of the Ministry of Labor LaoBuFa [1996] No.276 Notice about issuing of Steam Boiler Safety Technology Supervisory Regulation To: Departments (Bureaus) of Labor (Labor and Personnel) of all the provinces, a utonomous regions, and the municipalities under central authority, Ministries and Committe es relevant under the State Council and Organizations directly under it, the Supreme Peoples Procur atorate, the Supreme Peoples Court, General Logistics Department of the PLA and Xinjiang Produ ction and Construction Corps: Along with the development of our national economy, the advancement of science a nd technology, and the improvement of management level, great changes have taken pl ace in the boiler industry of our country in the design, manufacture and operation level. Therefor e, the Steam Boiler Safety Technology Supervisory Regulations (LaoRenGuo [1987] No.4) issued by the f ormer Ministry of Labor and Personnel cannot meet current requirements for the supervi sory of safety and technology. Therefore, we have revised the original regulations thoroughly on th e basis of making extensive investigations and soliciting experts opinions. Now, the newly revised S team Boiler Safety Technology Supervisory Regulation is issued to you and it will be implemen ted from January 1, 1997, and the original Steam Boiler Safety Technology Supervisory Regu lation (LaoRenGuo [1987] No.4) will be annulled on the same date. If the existing regul ations of our ministry are in conflict with the new regulations, the new regulations shall gov ern. The labor departments at all levels and the units relevant shall organize the pe rsonnel concerned to study and implement conscientiously the new regulations. Any proble m occurred during the implementation, please inform the Supervisory Bureau of Occupational Safety and Health and Boiler Pressure Vessels of our Ministry.

Ministry of Labor August 19, 1996 ========================================3 3 Contents ========================================

1. General4 2. General requirements 5 3. Materials7 4. Structures14 5. Welding of pressure elements 21 6. Expanded Tube Joint34 7. Main Accessories and Instruments35 8. Boiler House45 9. Operation Management47 10. Testing and Inspection49 11. Supplementary Provisions52 Appendix I. Qualification of Welding Procedure53 II. Specimens for Welding Joint Tensile Test and Bend Test65 ========================================4 4 Steam Boiler Safety Technology Supervisory Regulation Chapter 1 General Article 1 This regulation is made, on the basis of the stipulations of the Tentative Regul ations for the Supervision of Safety of Boiler Pressure Vessels, to ensure boiler safety operation, protect human safety, and promote the development of the national economy. Article 2 This regulation applies to stationary pressure steam boilers with water as thei r medium, and to the design, manufacture, installation, handling, inspection, repa ir and modification of pipes within the boiler scope. Steam-water dual-purpose boilers shall conform to the related stipulations in Sup ervisory Regulation for Safety and Technology of Hot Water Boilers, in addition to conform ing to the stipulations in this Regulation. This Regulation does not apply to stationary pressure steam boilers with water v olume less than 30L and nuclear steam generators. Article 3 All the related units and their responsible departments must implement stipulat ions in this Regulation. The labor administrative departments of the peoples governments above the county level shall be responsible for the boiler safety supervisory. The safety supervisory agency of boiler pressure vessel of labor administrative departments at all levels (hereinafter referred to as the safety supervisory agency) shall be res ponsible for supervisory of the implementation of this Regulation. ========================================

Article 4 The stipulations in this Regulation are the basic requirements in the field of boiler safety management and safety technology. If the requirements in other related te chnical standards are not in conformity with the stipulations in this Regulation, this Regulation shall govern. Article 5 The imported stationary steam boiler or the stationary steam boiler manufacture d by domestic enterprises (including enterprises invested by foreign investors) that have imported foreign technology and followed foreign standards in manufacturing and used domestically shall also be in conformity with this Regulation. If it is not in conformity with this Regulation under special cases, pre-approval shall be obtained from the safety supervisory agency of the Ministr y of Labor. Article 6 If new technology, such as, new structure, new process, new material, etc. are used by related units, if they are not in conformity with this Regulation, the test c ondition and data or related technical information and grounds shall be submitted to the safety super visory agency at province level for approval and submitted to the safety supervisory agency of th e Ministry of Labor for approval. ========================================5 ======================================== 5 Chapter 2 General requirements

Article 7 The design of boilers shall conform to the requirements of safety and reliabili ty. The structure of boilers shall conform to the requirements in Chapter 4 of this Regu lation. The strength of boiler pressure elements shall be calculated and verified according to Strengt h Calculation of Pressure Elements of Water-tube Boilers or Strength Calculation of Pressure Elemen ts of Drum Boilers. Article 8 When boiler is delivered from factory, it must be accompanied by technical data related to safety, including: 1. Boiler drawings (including general drawings, installation drawings and main p ressure parts drawings); 2. Strength calculation sheets of pressure elements or summary of calculation re sults; 3. Calculation sheets of relieving capacity of relief valves or summary of calcu lation results; 4. Boiler quality certificate (including ex-work certificate, metal material cer tificate, welding

quality certificate and hydraulic test certificate); 5. Boiler installation instructions and operation instructions; 6. Information of major design modification of pressure elements. For boilers with rated steam pressure greater than or equal to 3.8Mpa, at least the following technical information have to be provided: 1. Thermal calculation sheets or summary of thermal calculation results of boile r; 2. Calculation sheets or summary of calculation results of superheater wall temp erature; 3. Calculation sheets or summary of calculation results of fume and air resistan ce; 4. Thermal expansion system drawings. For boilers with rated steam pressure greater than or equal to 9.8Mpa, the follo wing additional technical information has to be provided: 1. Calculation sheets or summary of calculation results of reheater wall tempera ture; 2. Calculation sheets or summary of calculation results of boiler water circulat ion (including steam-water resistance); 3. Steam-water system drawings; 4. Set values of all protection devices. Article 9 Metal nameplate shall be provided at obvious place when boiler product delivere d from factory and shall be carried with the following items: 1. Boiler model; 2. Serial number of boiler products of manufacturer; 3. Rated evaporative capacity (t/h) or rated power (MW); 4. Rated steam pressure (MPa); 5. Rated steam temperature ( ); 6. Inlet and outlet temperature ( ) and inlet and outlet pressure (MPa) of reheat steam; ========================================6 ======================================== 6 7. Name of manufacturer; 8. Class and number of license of boiler manufacture; 9. Name of supervision and inspection unit and mark of supervision and inspectio n of boiler manufacture; 10. Year of manufacture. For boilers delivered from factory in bulk, embossed stamp shall be stamped on t he head or end of major pressure parts, such as drum, superheater header, reheater header, water wall header, economizer header and attemperator and startup separator, and product serial num ber of this part shall be indicated. Article 10 For boilers with rated steam pressure lower than or equal to 2.5Mpa, the relate d stipulations in Volume 6 TJ231 (six) Installation of Crushing and Pulverizing Pla

nts, Hoisters, Stationary Diesels, Industrial Boilers of Code for Installation Construction and A cceptance of Mechanical Equipment may be referred to, in addition to conforming to this Regula tion. For boilers with rated steam pressure greater than 2.5Mpa, related stipulations in S DJ245 Technical Specifications for Construction and Acceptance of Electrical Power Construction (Boiler Section) may be referred to. Article 11 If the installation company found quality problem existed in pressure parts, wh ich will impact the safety operation of boiler before and during installation, the c ompany shall stop the installation and report to local safety supervisory agency, and the safety super visory agency shall give its instructions for the raised quality problem as early as possible. Article 12 Sectional acceptance of boiler installation quality and hydraulic test shall be carried out jointly by the installation company and operation unit. During general accep tance, usually, the safety supervisory agency shall send person to take part in, in addition to the boiler installation company and operation unit. After boiler installation acceptance, the installation company shall handover th e technical documents and construction quality certificate, etc related to boiler installati on to the operation unit for placing on file. Article 13 Boiler operation unit shall handle the registration formalities for each boiler according to Boiler Operation Registration Measures issued by the former Ministry of Labor and Personnel. Those not registered are not allowed to put into operation. Article 14 Boiler operation unit shall conduct the firemen management according to Management Measures for Safety and Skill Examination of Boiler Firemen issued by t he former Ministry of Labor and Personnel. Boilers without firemen who are qualified for th e corresponding boilers, are not allowed to be put into operation. Article 15 Operation management for boilers used for power generation in electrical power system and management examination of the operators shall be conducted according to the related stipulations in Supervisory Regulations for Electrical Industrial Boilers. ========================================7 ======================================== 7 Article 16 Boiler operation unit and its management department shall assign special or part-time personnel to be in charge of the safety management of boiler equipment and do a good job in the boiler operation management based on the requirements in this Regulation.

Boiler operation unit shall work out the operation procedure to ensure boiler sa fety operation and safety management system of explosion-proof, fire-proof, poison-proof, etc a nd accident handling methods based on boiler structure, combustion pattern and operation req uirements, and implement them earnestly. Boiler operation unit shall work out and implement the system of maintenance and repair and period maintenance for boilers and their safety accessories. For boilers with au tomatic control system, system to calibrate and maintain the automatic instruments periodically shall be set up. Article 17 Drawings and relative technical specifications shall be available for major rep airs of boiler pressure elements, such as replacing and mending by replacing the damaged parts of barrel (drum), flue, return-firing chamber, head, flue top, tube sheet, bottom belt, an d header, patch weld of major welding, expansion joint of tubes changed to welding joint, and replaci ng large amount of heating tubes. Technical specification for repair may refer to the technical sta ndard of boiler speciality and the relative technical stipulations. After repairing, the boiler operation unit shall place the technical data, such as drawings, material quality certificate, repairing qu ality inspection certificate on boiler technical file. Article 18 When repairing the operating boiler, it is strictly forbidden to repair pressur e element under pressure or high boiler water temperature. When welding is used to repair pressure element, it is strictly forbidden to weld while there is water inside. Article 19 The technical requirements for modification of boilers and their pressure eleme nts may refer to the technical standard of boiler speciality and the relative techni cal stipulations. For modifications to improve boiler operation parameters, the modification schem e shall include the necessary calculation data. Since the structure and operation parame ters are changed, water treatment measures and safety accessories shall match the new parameters. Article 20 After completion of boiler modification, boiler operation unit shall place the technical data, such as drawings, material quality certificate, construction qua lity inspection certificate, on boiler technical file. Chapter 3 Materials

Article 21 Metal materials and welding materials, etc. used in boiler pressure elements sh all conform to the relative national standard and industrial standard. The material production units shall ensure the material quality and provide quality certificate. Metal materials and

weld metal shall have the specified strength, ductility, elongation and good fatigue resistance a nd corrosion resistance under operation conditions. Steel plates, steel tubes and welding materials used for repairing boiler pressu re elements shall ========================================8 ======================================== 8 be the same material brand or with the same property as the original material in the repair parts. Article 22 Metal materials used for manufacturing boiler pressure elements shall be of kill ed steel. The elongation 5 of plates at 20 shall not be less than 18%. For Charpy of carbon steel and carbon manganese steel under room temperature (V type notch sample) shock abso rption power shall not be less than 27J. Article 23 Metal materials used in boiler pressure elements shall be selected according to the following requirements: 1. Steel plate Table 3-1 Boiler steel plate Note: When used for boiler pressure elements with rated steam pressure exceeding 0.1MP a, the components shall not contact flame. Aging shock test shall be performed and qualified. Operation pressure shall not be limited when manufacturing the drum not exposed to radiation heat. Type of steel Steel grade Standard No. Applicable range Operation P (MPa) Wall T ( ) Carbon steel Q235-A, Q235-B GB700 GB3274 1.0 See note

Q235-C, Q235-D -15, 20 GB710, GB711 GB13237 1.0 -20R GB6654 YB (T) 40 5.9 450 20g 22g GB713 YB (T) 41 5.9 450 Alloy steel 12Mng, 16Mng GB713 YB (T) 41 5.9 400 16MnR GB6654 TB (T) 40 5.9 400 ========================================9 9 2. Steel tubes Table 3-2 Boiler steel tubes Type of steel Steel grade Standard No. Applicable range Usage Operation P (MPa)

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Wall T ( ) Carbon steel 10, 20 GB8163 Heating surface tubes 1.0 Headers, steam pipes 10, 20 GB3087 YB (T) 33 Heating surface tubes 5.9 480 Headers, steam pipes 430 20G GB5310 YB (T) 32 Heating surface tubes Not limited 480 Headers, steam pipes 430 Alloy steel 12CrMoG 15CrMoG GB5310 Heating surface tubes Not limited 560 Headers, steam pipes 550 12CrlMoVG Heating surface tubes 580 Headers, steam pipes 565 12Cr2MoWVT iB GB5310 Heating surface tubes 600

12Cr3MoVSiTi B Note: It may be increased to 450 , when service life is requested to be within 20 years. When oxidation losses is considered during strength calculation, it may be rais ed to 620 . 3. Forge piece Table 3-3 Boiler forge pieces Type of steel Steel grade Standard No. Applicable range Operation P (MPa) Wall T ( ) Carbon steel Q235-A, Q235-B Q235-C, Q235-D GB700 2.5 350 20, 25 GB699 5.9 450 Alloy steel 12CrMo ZBJ98016 Not limited 540 15CrMo 550 12CrlMoV 565 30CrMo 35CrMo Not limited 450 25Cr2MoVA Not limited

 510 Note: Operation pressure shall not be limited for forge pieces not exposed to flame. ========================================10 ======================================== 10 Hollow cylinder type fittings meeting the following requirements may be machine d with rolled or forged round steel of corresponding steel grade except various types o f flanges; a. Outer diameter of carbon steel fittings not greater than 160mm, outer diamete r of alloy steel fittings or pipe cap ranges fittings not greater than 114mm; b. Machined pipe fittings are qualified after non destructive test; c. Longitudinal axis of fittings in parallel with that of round steel. 4. Cast steel Table 3-4 Boiler cast steel Type of steel Steel grade Standard No. Applicable range Nominal Pressure (MPa) Wall T ( ) Carbon steel ZG200 - 400 GB11352 ZBJ98015 6.3 450 ZG230 - 450 Not limited 450 Alloy steel ZG20CrMo ZBJ98015 Not limited 510 ZG20CrMoV Not limited 540 ZG15CrlMolV Not limited 570 5. Cast iron Table 3-5 Type of cast iron Boiler cast iron

Brand Standard No. Applicable range Accessory nominal latus rectum (mm) Nominal P (MPa) Medium T ( ) Gray cast iron Not lower than HT150 GB9439 JB/T2639 300 0.8 230 200 1.6 230 Ductile cast iron KTH300-06 KTH300-08 KTH300-10 KTH350-12 GB9440 100 1.6 300 Spheroidal graphite iron QT400-18 GB1348 JB/T2637 150 1.6 300 100 2.5

QT450-10 GB1348 150 1.6 300 100 2.5 Note: Blow down valve and blow down elbow shall not be made of gray cast iron. Boiler with rated steam pressure less than or equal to 1.6Mpa and superheater w ith steam temperature lower than or equal to 300 , valve casing of water drain valve and blow down valve may be made of ductile cast iron or spheroidal graphite iron listed in above Tab le. ========================================11 ======================================== 11 Square cast iron economizer and elbows for boiler with rated steam pressure low er than or equal to 1.6MPa, gray cast iron with brand not lower than HT150 will be acceptab le, square cast iron economizer and elbows for boiler with rated steam pressure lower than or eq ual to 2.5MPa, gray cast iron with brand not lower than HT200 will be acceptable. Hydraulic tes t shall be carried out in factory for cast iron part used in economizer, its test pressure shall be 2.5 times of boiler operation pressure. Patch weld is not allowed for cast iron used in pressure parts. 6. Fastening parts Table 3-6 Boiler fastening parts Type of steel Steel grade Standard No. Applicable range Operation P (MPa) Medium T ( ) Carbon steel Q235-A, 235-B Q235-c, Q235-D GB700 1.6 350

20, 25 GB699 Not limited 350 35 420 Alloy steel 40Cr GB3077 Not limited 450 35CrMo JB/T74 Not limited 500 25Cr2MoVA 25Cr2MolVA Not limited 500 20CrlMolVNiTiB 20CrlMolVTiB Not limited 570 2Cr12WMoVNbB Not limited 600 Note: Hardness of nut material shall be lower than that of bolt material. 7. Braces Steel products used for braces shall be of killed steel and conform to the stipu lations in GB715 Carbon Steel Hot Rolled Round Steel for Standard Parts, or the stipulations of Ste el 20 in GB699 Technical Specifications of Quality Carbon Steel and Structural Steel. Plate brace s shall be made of boiler steel. 8. Welding rods used for welding pressure elements shall conform to the stipulat ions in GB/T5117 Carbon Steel Welding Rods, GB/T5118 Low Alloy Steel Welding Rods, GB983 Stainless Steel Welding Rods; welding wire shall conform to the stipulations in GB 4242 Stainless Steel Wires for Welding, GB/T8110 Carbon Steel, Low Alloy Steel Welding W ires for Gas Shielded Arc Welding, GB10045 Carbon Steel Flux-cored Wires, GB/T14957 Steel Wir es for Melting Welding, GB/T14958 Steel Wires for Gas Shielded Welding; welding flux s hall conform to the stipulations in GB5293 Welding Flux for Submerged Arc Welding of C arbon Steel, GB12470 Welding Flux for Submerged Arc Welding of Low Alloy Steel. ========================================12 ======================================== 12

Article 24 Replacement steel plates and pipes of boiler pressure elements shall be of the boiler steel material with the similar chemical property and mechanical property. Replacement of material of boiler pressure elements and important load-carrying components shall meet the requirements of strength and structure and shall be approved by t he technical department of material replacement unit (including design and process department ). When the replacement materials, which are not listed in the national standard an d industrial standard, are used, the replacement unit shall provide the technical ground and submit it to the safety supervisory agency at province level for approval. Article 25 When the replacement material of boiler pressure elements encountered one of th e following cases, it has to be reported to the original drawing approval unit for the record, in addition to getting approval from the original design unit. 1. Replace the material of high strength with the material of low strength; 2. Replace the material of high thickness with the material of low thickness (Wi th the exception of heating surface tubes of boiler with rated steam pressure less than or equal to 1.6MPa); 3. Nominal outer diameter of the replaced steel pipes is different from that of the original. Article 26 Before using newly developed material of new steel grade for boiler trial manufacture, steel product manufacturer must organize a technical evaluation of this new material, the related departments and units, such as metallurgy, manufacture, operation, s afety supervisory agency, standard, must take part in the evaluation. The evaluation shall include at least the following items: 1. Chemical compositions. Provide the test and research data used to determine t he upper and lower limits of chemical compositions. 2. Mechanical property and structural stability. Provide the tensile strength t b , yield point t 0.2 within the operation temperature (up to exceeding the maximum allowable operatio n temperature of 50 ) with a temperature interval of 20 (50 may be used if there is a difficulty), and provide the elongation 5

, contraction of sectional area , aging shock value, room temperature Charp (V t pe notch sample) shock absorption power, brittle transition temperature. Carbon steel, low-carbon manganese steel, low-carbon manganese vana ium steel wi th operation temperature higher than 350 , and other alloy steel with operation temperature higher than 400 , shall be provided with data of long-time strength, creep resistance property a nd long-term aging stability. Austenitic steel shall also be provided with data of anti-intercrystalline corrosion data. 3. Oxidation resistance. Boiler steel with operation temperature higher than 500 , shall be provided with oxidation resistance data under operation temperature (including e xceeding the maximum allowable operation temperature of 20 ). 4. Thermal fatigue resistance. Elastic modular ( E ), average linear expansion factor ( ) nd he t-tr nsfer coefficient ( ), etc. under the corresponding temper ture sh be provided. 5. We ding perform nce. We ding perform nce nd mech nic property d t of we d ing joints of the stee sh be provided. 6. M nuf cturing process of stee . Corresponding technic inform tion sh be provided, such ========================================13 ======================================== 13 s inform tion of sme ting, c sting, forging nd product he t tre tment. 7. Hot-working ch r cter of stee . Corresponding technic inform tion sh be provided, such s inform tion of drop st mping, hot ro ing, hot bending nd he t-tre tment. Artic e 27 On y fter the new stee gr de m teri is pproved through the technic ev u tion, c n the boi er m nuf cturer h nd e the form ities of tri m nuf cturing the pr essure e ements of boi er ccording to the stipu tions in Artic e 6 of this Regu tion. Boi er m nuf ctures, who t ke p rt in the tri m nuf cture, sh report the pr operty report, retest report, process test report of th t stee gr de m teri nd the tri m nuf cturing to s fety supervisory gency of Ministry of L bor for the record. Artic e 28

Production ev u ting sh be conducted before m ss production of new stee gr de m teri . Represent tives from dep rtments of met urgy, m nuf cture, oper tion , s fety supervisory gency, st nd rd, etc. sh t ke p rt in the ev u tion. M nuf cturer of new stee gr de m teri sh report the inform tion of ev u t ion comments, tri pp ic tion nd qu ity st bi ity of m ss production m teri to the s fet y supervisory gency of Ministry of L bor for the record. Artic e 29 Boi er pressure e ements sh conform to the fo owing requirements when foreig n stee products re used: 1. The stee gr de sh be the gr de isted in the st nd rd of foreign boi er s tee , or the chemic property, mech nic property, we ding perform nce re simi r to the s tee products domestic y owed to be used in boi er. 2. Accept nce sh be c rried out ccording to the technic st nd rds nd cond itions specified in purch se contr ct. If the inspection items re not comp ete by checking the d omestic stee st nd rd, the missed item sh be inspected when necess ry nd c n be used on y when they re qu ified. 3. We ding process ev u tion nd mo ding process test sh be c rried out befo re first pp ic tion, nd the m teri c n on y be used when technic specific tions re s tisfied. 4. Boi er strength sh be c cu ted b sed on the perform nce d t specified i n technic st nd rds nd conditions of this stee product. 5. Stee products not isted in the st nd rd or resist nce we d boi er tubes is ted in the st nd rd sh be pproved by the s fety supervisory gency of the Ministry of L bor. Artic e 30 When production unit produce stee product of foreign stee gr de, the productio n nd ccept nce sh be c rried out comp ete y ccording to the stipu tions of foreign st nd rd of this stee gr de, nd production ev u tion sh be p ssed through before putti ng into m ss production. Artic e 31 For m in m teri s used for boi ers, such s boi er stee p tes, boi er stee pipes nd we ding m teri s, boi er m nuf cturer sh check them before ccept nce, nd c n on y be ccepted when they re qu ified. M in m teri s used for boi er with r ted ste m pressure ower th n or equ to 0.4MP , c n be ========================================14 ======================================== 14

exempted from re-inspection provided th t the origin

qu ity certific tes re

comp ete, m teri m rks c e r nd comp ete. M teri s with st b e qu ity nd obt ined the product s fety qu ity pprov f rom the s fety supervisory gency of the Ministry of L bor c n be exempted from re-inspection. Otherwise, they c nnot be exempted from re-inspection. Artic e 32 Boi er m nuf cturing, inst tion nd rep ir units must set up the m n gement system of m teri stor ge nd h nd ing. Stee products used for boi er pressure e ements sh be m rked out. Before cutting of stee p te for pressure e ement, the m rks sh be tr nsp nted nd they must be e sy for identific tion. Artic e 33 The units using we ding m teri s for boi er pressure e ements sh set up stri ct m n gement system for stor ge, drying, distribution, recovery nd reuse. Ch pter 4 Structures

Artic e 34 Boi er structure sh conform to the fo owing b sic requirements: 1. E ch p rt c n exp nd free y b sed on the preset direction in design during op er tion; 2. Ensure w ter circu tion of e ch circu tion circuit norm , nd he ting surf ces c n get re i b e coo ing; 3. E ch pressure p rt h s sufficient strength; 4. Type of pressure e ements nd pressure p rts, rr ngement of openings nd we ding se ms sh void or reduce s much s possib e the combined stresses or stress concen tr tion; 5. Structure of w ter w furn ce sh h ve sufficient o d-be ring c p city; 6. Furn ce w sh h ve good tightness; 7. Lo d-c rrying members sh h ve sufficient strength, rigid, st bi ity nd co rrosion resist nce when c rrying design o ds; 8. Convenient for inst tion, oper tion, m inten nce nd intern nd extern c e ning; 9. For boi ers firing pu verized co , their structure of furn ce nd burners n d rr ngement sh m tch the designed co type nd protect the furn ce from s g-off nd cok ing. Artic e 35 Boi ers with r ted ste m pressure gre ter th n or equ to 3.8MP , b rre nd he der sh be provided with exp nsion indic tor. The exp nsion center determined duri ng design of suspended type boi er proper sh be fixed. Artic e 36 For w ter-tube boi er, the w thickness of b rre sh not be ess th n 6mm i n ny c se; when he ting surf ce tubes nd b rre re exp nsion jointed, the w thic kness of b rre sh not be ess th n 12mm. Artic e 37 For drum boi er, the w thickness of drum she sh not be ess th n 6mm whe n inner di meter of the drum is gre ter th n 1000mm; nd the w thickness of dru

m she sh not be ess th n 4mm when inner di meter of the drum is within 1000mm. ========================================15 ======================================== 15 Artic e 38 Inner di meter of furn ce f ue of drum boi er sh not exceed 1800mm, its w thickness sh not be ess th n 8mm nd not gre ter th n 22mm; when the inner d i meter of furn ce f ue is ess th n or equ to 400mm, its w thickness sh not be ess th n 6 mm; for return-firing ch mber of horizont intern y fired boi er, the w thickness of its she p te sh not be ess th n 10mm nd not gre ter th n 35mm. The c cu tion ength of f t furn ce f ue of horizont drum boi er sh not exceed 2000mm, if both ends of furn ce f ue re f nging butt jointed with tube sheet, the c c u tion ength of f t furn ce f ue c n be en rged to 3000mm. Artic e 39 The fixing m nner between he der of w ter spr y ttemper tor nd inner bushing nd between w ter spr y tubes nd he der sh be b e to ensure their re tive exp nsion, nd to void reson nce vibr tion. Their structure nd rr ngement sh be convenient f or m inten nce. Artic e 40 The minimum s fety w ter eve of w ter-tube boi er b rre sh be b e to ensu re the re i b e w ter supp y of donwcomers. The minimum w ter eve of drum boi er sh be 100mm higher th n the highest py rosphere. The minimum w ter eve of horizont drum boi er with di meter ess th n or e qu to 1500mm sh be 75mm higher th n th t of the highest pyrosphere. The minimum s fety w ter eve of boi er sh be indic ted in the dr wings. Artic e 41 For non-he ting surf ce components, if their w temper ture exceeded the ow b e temper ture of the component m teri due to insufficient coo ing, the rm insu tion sh be provided. Artic e 42 For h ndho e on he der nd nti-coking he der, when ho e cover nd ho e circ e re not jointed by we ding, they sh void to be exposed direct y to f me. Artic e 43 Oi fired boi er equipped with ir prehe ter sh be provided with re i b e soo t b owers nd extinguishers t its t i . For pu verized co fired boi er, the furn ce nd convection p ss rr nged with superhe ter nd rehe ter sh be provided with soot b owers. Artic e 44 Boi er equipped with section c st iron economizer shou d use byp ss f ue or ot her effective me sures, nd byp ss w ter oop sh be provided s we . Boi er equipped with non-section economizer sh be provided with re-circu t

ing pipes or other me sures to prevent the economizer being burnt out during boi er ignition. Artic e 45 The exp nsion coefficient of membr ne w fins nd tube m teri sh be simi r, the m nuf cture nd inspection of fin tubes (p ne s) sh conform to JB/T5255 Te chnic Specific tions for We ding Fin Tubes (P ne s), fin width sh ensure the temper ture t p rts of the fins not exceeding the ow b e temper ture of the using m teri during bo i er oper tion. Artic e 46 To ensure the coo ing of superhe ter, rehe ter during st rt up nd o d rejecti on, me sures to vent ste m, inst ste m byp ss ine or imit smoke temper ture, et c. sh be provided. ========================================16 ======================================== 16 Artic e 47 Butt-we ding of comp ete penetr tion sh be used for m jor we ding se ms of boi er pressure e ements [ ongitudin nd circumferenti se ms of b rre (drum ), furn ce f ue, return-firing ch mber nd he der, sp icing se ms of he d, tube sheet, furn ce f ue top nd bottom be t, etc.] Artic e 48 For horizont intern fired boi er with r ted ste m pressure ess th n or equ to 1.6MP , tube sheet nd furn ce f ue nd drum c n be butt-jointed with T joint wh en fo owing requirements re met, however, p joint sh not be used with the exception of the joint of furn ce f ue nd return-firing ch mber (wet-b ck type), furn ce f ue nd re r tube sheet (dry-b ck type), furn ce f ue nd front tube sheet (return-firing type) (shown in Fig. 4-1): 1. Joint p ttern of comp ete penetr tion sh be used nd beve s re m chined; 2. We d se ms sh be oc ted t the she of drum nd furn ce f ue for the joint of tube sheet nd drum nd furn ce f ue; 1. Front tube sheet 2. Drum 3.

Re r tube sheet 5.

Furn ce f ue 4.

nd return-firing ch mber

Furn ce f ue 6. Front tube sheet 7. Wet-b ck type 8. Re r tube sheet 9.

Re r smoke-box 11. Furn ce f ue 12. Dry-b ck type 13. Front tube sheet 14. Drum 15.

Re r tube sheet 17. Furn ce f ue 18. Return-firing type

3. Se m thickness t joint p rt of T joint sh not be ess th n w thickness of tube sheet nd its se m b ck sh be se we ded where possib e. The p rts which c nnot be se we ded, they ========================================17 ========================================

Fig. 4-1 P rts where T joint is not

Furn ce f ue 16.

nd front tube sheet

Furn ce f ue 10.

nd re r tube sheet

owed

 17 sh be b cked with rgon- rc we d nd ensure the comp ete penetr tion. 4. Se ms t joint p rt of T joint sh be u tr sonic ex mined s per the re te d stipu tions. Boi er m nuf cturers using T joint for jointing, they h ve to be pproved by the s fety supervisory gency t province eve if they ho d the icense of boi er m nuf ct ure of c ss D nd bove; they h ve to be pproved by the s fety supervisory gency of the Ministry of L bor if they ho d the icense of boi er m nuf cture of c ss E 1 or E 2 . Artic e 49 When jointing downcomer nd he der of boi er, comp ete penetr tion type beve sh be m de t tube end or he der. When the outer di meter of downcomer is es s th n or equ to 108mm nd insert-type is used, beve m y not be m de. For boi er with r ted ste m pressure gre ter th n or equ to 3.8MP , connection of fittings of centr ized downcomer nd she nd he der sh be the type of comp ete penetr tion we ding. Comp ete penetr tion nd fusion in we ding sh be ensured during we ding. For boi er with r ted ste m pressure gre ter th n or equ to 9.8MP , when connecting tubes or fittings to b rre , he der, pipes, beve s for comp ete penet r tion we ding sh be m de on tube end or b rre , he der nd pipes (except ong pipe fittings). Artic e 50 Any connection pipes (feed w ter pipes, desuperhe t w ter pipes, etc.), which wi c use oc therm f tigue on b rre (drum) w or he der w , j cket sh b e provided t the p ce where b rre (drum) w or he der w wi p ss through. For boi er with r ted ste m pressure ess th n or equ to 1.0MP , nd r ted c p city ess th n or equ to 1t/h, w ter j cket m y not be provided. Artic e 51 Arr ngement of ho es on pressure e ements sh conform to the fo owing requirements: 1. The dist nce between center of exp nsion joint tube ho e nd we d edge nd f nging st rt point of tube sheet sh not be ess th n 0.8 d ( d refers to ho e di meter), nd not ess th n 0.5 d +12mm. Exp nsion joint tube ho e sh not be m de on the ongitudin we d of d rum she , nd sh void to be opened on the circumferenti we d. If it is un void b e d ue to structure design, ho e c n on y be m de on circumferenti we d when the fo owing conditions re

s tisfied: we ding se ms within 60mm round the tube ho e (if the di meter of tube ho e is gre ter th n 60mm, t ke the v ue of tube di meter) p ssed r diogr phic ex min tion nd qu ified, no s g existed on we ding se m on tube ho e edge, inside nd outside surf ces of we ding se m t o pening p rt ground f t nd he t tre tment for the who e pressure p rt m de. 2. Tube ho e of centr ized downcomer sh not be m de on we ding se m. Other w e ding tube ho es sh void to be m de on we ding se m nd its he t- ffected zone. If it i s un void b e, ho es c n on y be m de on we ding se m nd he t- ffected zone when the fo owing condi tions re s tisfied: we ding se ms within 60mm round the tube ho e (if the di meter of tu be ho e is gre ter th n 60mm, t ke the v ue of tube di meter) p ssed r diogr phic ex min tion or u tr sonic ex min tion nd qu ified, nd no s g existed on we ding se m on tube ho e edge , postwe d he t tre tment h s been performed for fittings nd stress h s been re ived. Artic e 52 Longitudin we ding se m of the dj cent two sections of b rre (unequ she w thickness exc uded), drum nd furn ce f ue, sp ice we ding se m of he d, tube sh eet, furn ce f ue ========================================18 ======================================== 18

top or bottom be t nd ongitudin we ding se m of dj cent sections sh not be jointed e ch other. The ex-circ e rc ength between we d center ines sh be t e st 3 times of the thickness of the thicker stee p te nd not ess th n 100mm. Artic e 53 When f nged components (i.e. he d, tube sheet, furn ce f ue top, etc.) re but t we ded with cy indric components, the dist nce (L) from the st rt point of f nged bending to we d center ine sh conform to the v ues in T b e 4-1. T b e 4-1 Dist nce from st rt point of f nged bending to we d center ine W thickness of f nged components t (mm) Dist nce L (mm) t 10 25 10<t 20 t+15 20<t 50

0.5t+25 t>50 50 Note: L=0 m y be t ken for spheric he d. Artic e 54 Dist nce between butt we ded se ms on str ight section of boi er he ting surf ce tubes sh not be ess th n 150mm. The dist nce from butt we d center ine of he ting surf ce tubes to tube bending st rt point, b rre (drum) nd he der outer w , edge of tube supports nd hungers sh be t e st 50mm, except coi s nd e bows without str ight ength; for boi er with r ted ste m pre ssure gre ter th n 3.8MP , it sh be t e st 70mm. For pipes, the bove dist nce sh not be ess th n outer di meter of pipes nd sh not be ess th n 100mm. If e bow without str ight ength sh be used for he ting surf ce tubes nd boi er ste m-w ter pipes, the e bow without str ight ength sh meet the re ted requirements in GB12459 Stee Butt We d Se m ess Pipe Fittings, nd the butt se m of e bow without str ight ength nd pipes sh be 100% r diogr phic ex mined nd qu ified. Bending p rt of e bow without str ight ength on he ting surf ce tubes shou d not be we ded with ny component. Artic e 55 M jor we ding se ms of pressure e ements nd their dj cent re s sh not be we ded with p rts. If it is un void b e, the we ding se m of the p rt sh p ss through the m jor we d nd never termin ted t the we ding se m or its dj cent re , so s to vo id stress concentr tion in these re s. Artic e 56 Br ces for drum boi er sh not be sp iced. Artic e 57 Stee p te center ines on both side of b rre (drum) ongitudin nd circumfer enti we ds sh be in ignment. When the thickness of stee p te on both side of b rre (drum) circumferenti we d is not the s me, usu y, center ine ignment wi be dop ted, edge ignment on one side wi so be ccept b e. When two components or stee p tes with different thickness re butt jointed, i f the difference ========================================19 ======================================== 19 of nomin edge thickness of ny one of the two sides exceeds the edge differenc e stipu ted in Artic e 74, then the edge of thicker p te sh be ch mfered to f ush with the edge of thinner p te, the ch mfered p ne sh be smooth nd the s ope r tio sh not be gre ter th n 1:4, width of we d

m y be within the ch mfered p ne if necess ry, see Fig. 4-2. Artic e 58 W ter-tube boi er with r ted c p city ess th n or equ to 75t/h sh usu y be provided with exp osion-proof door t the exp osive p rt, such s furn ce, f ue, when pu verized co , oi or g s re used s fue . The inst tion of exp osion-proof door sh not bring ny risk to person s fety. Artic e 59 Furn ce w , f ue nd doors nd ho es t p rts sh be secure y irtight for boi ers with combustion under micro-positive pressure. F me eye sh be provid ed with inter ock device to prevent f me b owing out. Artic e 60 The number nd oc tion of m nho e, he dho e, h ndho e, c e ning ho e, m inten nce ho e, observ tion ho e provided for boi er sh meet the dem nds of inst tion, m inten nce, oper tion monitoring nd c e ning.

[P.024 ] 1.

Minimum L=4 3. Plate centerline 4. Longitu inal wel ing seam 5. Minimum L=4 (wel wi th ma be inclu e 6. Minimum L=4 7. Plate centerline 8. Minimum L=4

when necessar )

Minimum L=4 (wel wi th ma be inclu e 2.

when necessar )

Minimum L=4 10. Circumferential wel ing seam

nominal e ge ifference; t 1 thickness of thinner plate; t 2 thickness of thicker plate; L chamfere length. Fig. 4-2 Butt joint of steel plates (elements) with ifferent thickness ========================================20 ======================================== 20 The structure of manhole cover, hea hole cover an han hole cover of boiler pres sure elements shall be internall closing t pe. The structure of manhole cover, hea hole cover an han hole cover of pressure elements of boiler with rate steam pressure less than or equal to 1 .6MPa shoul be flange connection; the structure of han hole cover of pressure elements of boile r with rate steam pressure greater than 3.8MPa shoul be wel connection. Soli oor bar shall be provi e for the manhole oor on furnace wall; cover for monitoring hole on furnace wall shall en sure not to be blown-off b flue gas. Article 61 Manhole shall be provi e on shell or hea (tube sheet) for water-tube boiler w ith barrel inner iameter greater then or equal to 800mm an rum boiler with rum i nner iameter greater than 1000mm. Water-tube boiler with barrel inner iameter less than 800mm an rum boiler wit h rum inner iameter of 800 ~ 1000mm shall at least be provi e with one hea hole on barrel or hea (tube sheet). Article 62 Dimensions of openings shall be as follows:

(wel wi th ma be inclu e 9.

when necessar )

1. Dimension of elliptical manhole on boiler pressure elements shall not be less than 280380mm, iameter of roun manhole shall not be less than 380mm. The minimum sea l plane wi th of manhole circle shall be 18mm. Total gap between shoul er of manhole cov er an manhole circle shall not excee 3mm (not excee ing 1.5mm along the points on the circle) , an the epth of slot shall be able to contain the whole sealing gasket. 2. Dimension of elliptical hea hole on boiler pressure elements shall not be les s than 220320mm, height of neck or hole circle shall not excee 100mm. 3. Dimension of han hole stub on boiler pressure elements shall not be less than 80mm, height of neck or hole circle shall not excee 65mm. 4. Dimension of inner iameter of cleaning hole on boiler pressure elements shal l not be less than 50mm, height of neck shall not excee 50mm. 5. Dimension of elliptical manhole on furnace wall shall not be less than 400450m m, iameter of roun manhole shall not be less than 450mm in usual, imension of re ctangular opening shall not be less than 300400mm generall . If height of neck or hole circle excee s the above value, hole imension shall b e enlarge properl . Article 63 Platform, staircase, han rail, etc. shall be provi e for boiler with the heigh t between operator stan ing place an the floor (or operation floor) excee ing 300 0mm. Boiler platform an staircase shall conform to the following stipulations: 1. The arrangement of platform an staircase shall be convenient for operators t o get to the place where frequent operation an inspection are require . 2. Staircase an platform shall be slip-proof an platform shall be provi e wit h firefighting facilities. 3. Staircase, platform an roof surroun ings where operation an inspection are require shall be provi e with han rail with vertical height not less than 1000mm an foot pro tection boar with ========================================21 ======================================== 21 a height not less than 80mm. 4. Sloping angle of staircase shoul be 45 o ~ 50 o . If there is ifficult in arrangement, the sloping angle ma be increase properl . 5. The vertical height from the platform in front of water level gauge to mi le of the gauge shall be 1000 ~ 1500mm.

I General requirements Article 64 When manufacturing, erecting, repairing an mo if ing boiler pressure elements b wel ing, wel -performing unit shall work out wel ing proce ure instructions an carr out wel ing proce ure evaluation. The can onl be use in pro uction when the meet the req uirements. Article 65 Wel er who will wel boiler pressure elements shall be examine accor ing to Examination Rules for Wel ers of Boiler Pressure Vessels issue b the former Mini str of Labor an Personnel. When he/she has passe the examination an obtaine a wel ers qual ification certificate, he/she can perform the wel ing work of the same items as that he/sh e has been proven qualifie in the examination. Wel er shall perform wel ing accor ing to the wel ing proce ure instructions or wel ing proce ure chart. Article 66 Embosse stamp of low stress with wel ers co e number shall be stampe nearb the wel ing seam of boiler pressure elements. Article 67 Instruments, apparatus, such as ampere meter, voltage meter, gas flowmeter an stan ar parameter a justment evices for wel ing equipment shall be calibrate perio icall . When above-mentione meters, evices are fault, wel ing shall not be performe . Article 68 The following inspections an tests shall be carrie out for wel ing joint quali t of boiler pressure elements: 1. Visual inspection; 2. Non- estructive test; 3. Mechanical propert test; 4. Metallographic examination an fracture examination; 5. H raulic test. Article 69 Wel certificate of qualification of each boiler shall recor the metho of pos twel heat treatment of the pro uct, the specifications an patch wel of the wel ing seam, etc. in a ition to the inspection items an results carrie in Article 68. Article 70 Wel ing qualit inspection reports an non- estructive test recor s (inclu ing f ilms), shall be kept properl b the wel -performing unit for at least 5 ears or han over to the operation unit for long-term storage. ========================================22 ======================================== 22 II Wel ing proce ure requirements an postwel heat treatment Article 71

Chapter 5

Wel ing of pressure elements

Wel ing proce ure evaluation of the following wel ing joints shall be carrie ou t b wel -performing unit as per the stipulations in Appen ix I before wel ing boiler pro uct: 1. Butt-wel e joint between pressure elements; 2. T joint or corner joint requeste complete penetration in wel ing between pre ssure elements or pressure elements an loa -bearing non-pressure elements. Article 72 During boiler manufacture, wel ing shall not be performe when wel ing ambient temperature is below 0 and there is no preheating measures. When performing welding in boiler erecting, repairing field, if ambient temperature is below 0 , the welding shall conform to the stipulations in welding procedure document. Welding in open air in raining, snowing day is not allowed. Article 73 Alignment by force during weldment assembling is not allowed except design specified cold drawn welding joint. Welding can only be started when the quality of weldment assembling and tack welding conforms to the requirements of welding procedure. Article 74 Assembly of longitudinal, circumferential welding seam of barrel (drum) and spli ce welding seam of head (tube sheet) or assembling welding seam of two elements sha ll conform to the following stipulations: 1. The actual edge deviation value of steel plates on both sides of longitudinal welding seam or head (tube sheet) splice welding seam shall not be greater than 10% of the nomin al plate thickness and not exceed 3mm; when plate thickness is over 100mm, not exceed 6mm. 2. The actual edge deviation value of steel plates on both sides of circumferent ial welding seam (plate thickness difference included) shall not be greater than 15% plus 1mm of the nominal plate thickness and not exceed 6mm; when plate thickness is over 100mm, not exceed 10m m. When two elements or steel plates with different thickness are butt jointed and the edge has been chamfered, they will be treated as with the same thickness, the above-menti oned nominal plate thickness refers to thinner plate; when steel plates with different thickness ar e butt jointed without chamfering, then the above-mentioned nominal thickness refers to thicker plate. Article 75 The difference between any maximum inner diameter and outer diameter on the same cross section of barrel (drum) shall not be greater than 1% of the nominal inner diameter. The angularity of longitudinal welding seam of barrel (drum) shall not be over 4 mm. Article 76 Composite welds of fittings of boiler with rated steam pressure greater than or equal to 9.8MPa, barrel and header and manual weld butt joints of tubes and fittings s hall be backed with argon-arc weld or other welding method, which will ensure complete penetration. Article 77

Postweld heat treatment of boiler pressure elements shall conform to the followi ng stipulations: 1. Butt joints of low carbon steel pressure elements with wall thickness greater than 30mm or T joints of shell or tube sheet of internally fired boiler with wall thickness gre ater than 20mm shall perform postweld heat treatment. The thickness limit for alloy steel pressure el ements, which need ========================================23 ======================================== 23 postweld heat treatment, shall follow the stipulations in the technical standard of boiler speciality. 2. When dissimilar steel joint requires stress-relieving heat treatment after we lding, its temperature shall not exceed the lower critical point A c1 of any steel type on both sides of welding joint. 3. Steel liable to cause delayed cracking after welding shall perform postheat h ydrogen elimination or heat treatment immediately after welding. 4. Boiler pressure elements shall be treated as a whole when performing postweld heat treatment. If the heat treatment is performed in section, each heated section mu st have an overlap of at least 1500mm and the parts projected from furnace shall have thermal insulati on measures to reduce temperature gradient. When local heat treatment is performed for circumfe rential welding seam, the heated width on both sides of welding seam shall not be less than 3 ti mes of wall thickness respectively. 5. When heat treatment is performed for weldment and its examination test piece (product test plate), its equipment and specifications shall be the same. 6. Record in detail all the parameters of heat treatment specifications during p ostweld heat treatment. Article 78 For pressure elements requiring postweld heat treatment, all the welding of connectors, tube sockets, bed plates and non-pressure elements, etc. to be joint ed shall be completed before final heat treatment. For boiler pressure elements, which already performed heat treatment, such as, b arrel and header shall be avoided to weld directly the non-pressure elements on them. If i t is unavoidable, heat treatment may not be performed after welding if the following conditions ar e satisfied at the same time: 1. Material of pressure elements is of carbon steel or carbon manganese steel; 2. Calculation thickness of fillet weld not over 10mm; 3. Weld according to the welding procedure evaluated as qualified; 4. Conduct 100% surface inspection of fillet welds.

In addition, boiler manufacturer shall put forward inspection method and quality insurance measures for field welding joints of pressure elements. III Visual inspection Article 79 Visual inspection shall be carried out for all the welding seams of boiler pres sure elements (including the joints of non-pressure elements and pressure elements), surface equality shall conform to the following requirements: 1. Overall dimensions of welding seam shall meet the requirements in drawings an d process documents, height of seam shall not be higher than the surface of base material, transition of seam and base material shall be smooth; 2. No cracks, slag, pits and voids on the surface of weld or its heat-affected z one; 3. No under cut on longitudinal, circumferential welding seam of barrel (drum), furnace flue and header and on the splice welding seam of head (tube sheet), under cut depth of other welding ========================================24 ======================================== 24 seam shall not exceed 0.5mm, total length of under cut on both sides of tube wel ding seam shall not exceed 20% of tube circumference and not exceed 40mm. Article 80 Through ball test shall be performed for butt-weld jointed heating surface tube s as per JB/T1611 Technical Specifications of Boiler Tubes. IV Non-destructive test Article 81 Personnel engaged in non-destructive test shall be examined as per Qualification Examination Rules for Non-destructive Test Personnel of Boiler Pressure Vessels i ssued by the Ministry of Labor. When he/she has passed the examination and obtained a qualifi cation certificate, he/she can perform non-destructive test of the same items as that he/she has bee n proven qualified in the examination and is entitled to do within his technical scope. Article 82 The numbers need perform non-destructive test for longitudinal, circumferential butt-welded seams of barrel (drum), splice welding seams of head (tube sheet), b ottom belt, and longitudinal butt-welded seams of header are specified as follows: 1. 10% radiographic examination shall be performed for each welding seam (cross part of welding seam must be included) of boiler with rated steam pressure greater than or equal to 0.1MPa. 2. 25% radiographic examination shall be performed for each welding seam (cross

part of welding seam must be included) of boiler with rated steam pressure greater than 0.1MPa, but less than or equal to 0.4MPa. 3. 100% radiographic examination shall be performed for each welding seam of boi ler with rated steam pressure greater than 0.4MPa, but less than 2.5MPa. 4. 100% ultrasonic examination plus at least 25% radiographic examination or 100 % radiographic examination shall be performed for each welding seam of boiler with rated steam pressure greater than or equal to 2.5MPa, but less than 3.8MPa. Cross part of we lding seam and quality doubted part found during ultrasonic examination must be examined by rad iographic examination. 5. 100% ultrasonic examination plus at least 25% radiographic examination shall be performed for each welding seam of boiler with rated steam pressure greater than or equal to 3.8MPa. Cross part of welding seam and quality doubted part found during ultrasonic examinatio n must be examined by radiographic examination. Non-destructive test of splice welding seam of head (tube sheet), bottom belt sh all be carried out after machine-shaped. Ultrasonic examination of electric slag welding seam shall be carried out after normalizing heat treatment of welding seam. Article 83 Numbers of non-destructive test for longitudinal, circumferential butt jointed s eam of furnace flue, butt jointed seam of return-firing chamber and splice welding s eam of furnace flue top are specified as follows: 1. 10% radiographic examination shall be performed for each welding seam (cross part of ========================================25 ======================================== 25 welding seam must be included) of boiler with rated steam pressure less than or equal to 0.1MPa. 2. 25% radiographic examination shall be performed for each welding seam (cross part of welding seam must be included) of boiler with rated steam pressure greater than 0.1MPa. Article 84 For internally fired drum boiler with rated stream pressure less than or equal t o 1.6MPa, numbers of examination for corner joint welding of tube sheet and furnac e flue, drum are specified as follows: 1. 100% ultrasonic examination for each welding seam at T joint part of tube she et and drum shall be performed; 2. 50% ultrasonic examination for welding seams at tube sheet and furnace flue,

return-firing chamber and its T joint part shall be performed. Article 85 Numbers for radiographic examination or ultrasonic examination of circumferenti al welding seams of header, tubes, pipes and other fittings (contact welding of hea ting surface tubes excluded) are specified as follows: 1. 100% shall be examined for each welding seams when outer diameter is over 159 mm, or wall thickness over or equal to 20mm. 2. For circumferential welding seam of header with OD less than or equal to 159m m, 25% shall be examined for each welding seam length, it may also not be less than 25% of th e seam numbers of header circumferential welding seams of each boiler. 3. Tubes with operation pressure higher than or equal to 9.8MPa and their OD les s than or equal to 159mm, 100% of joints numbers shall be examined in factory, and at leas t 25% shall be examined at installation field. 4. Tubes with operation pressure higher than or equal to 3.8MPa, but less than 9 .8MPa, and their OD less than or equal to 159mm, at least 50% of joint numbers shall be exa mined in factory, and at least 25% of joint numbers shall be examined at installation field. 5. Tubes with operation pressure higher than or equal to 0.10MPa, but less than 3.8MPa, and their OD less than or equal to 159mm, at least 10% of joint numbers shall be ran dom examined in factory and installation field respectively. Article 86 100% radiographic examination or ultrasonic examination shall be performed for corner joint of centralized downcomers of boiler with rated steam pressure great er than or equal to 3.8MPa; at least 10% non-destructive test shall be random performed for corner j oint of other fittings of each drum and header. Article 87 Radiographic examination of butt joints shall be carried out as per the stipulat ions in GB3323 Steel Fusion Welding Butt Joints Radiographic Examination and Quality Clas sification. Quality requirements for radiographic examination shall not be lower than class AB. For boiler with rated steam pressure greater than 0.1MPa, butt joint shall be qu alified if quality is not lower than class II; For boiler with rated steam pressure less than or eq ual to 0.1MPa, butt joint shall be qualified if quality is not lower than class III. Article 88 Ultrasonic examination of butt joints shall be carried out according to the ========================================26 ======================================== 26 stipulations in JB1152 Ultrasonic Examination of Butt-welded Joints of Boiler and

Steel Pressure Vessels when wall thickness is less than or equal to 120mm; it may be carried out according to the stipulations in GB11345 Manual Ultrasonic Examination Methods of Steel Welds and Examination Results Classification when wall thickness exceeding 120mm; ultrasonic examinatio n of tubes and pipes may be carried out according to the stipulations in SDJ67 Technical Specifi cations for Construction and Acceptance of Electrical Power Construction (Section of Ultraso nic Examination of Pipe Welds); enterprise standard shall be implemented when out of the applicab le limits of SDJ67. When ultrasonic examination is employed, butt joint shall be qualified if qualit y is not lower than class I. Article 89 Ultrasonic examination of corner joint of centralized downcomers may be carried out according to the stipulations in JB3144 Ultrasonic Examination of Fillet Weld s of Large Diameter Tube Sockets of Boiler. Ultrasonic examination of tube sheet and furnace flue, drum and T joint of horiz ontal internal-fired drum boiler shall be carried out according to the appropriate sti pulations. Article 90 When welding seam is examined by both radiographic examination and ultrasonic examination, the seam can only be deemed as qualified when it is in conformity w ith the standard of both examinations. Article 91 For welding seam, which is partially radiographic examined or ultrasonic examine d, if defect liable to extend is found at any end of the examined part, supplement radiographic examination or ultrasonic examination shall be performed at defect extending dir ection. If unqualified defect is found in random examination or supplement examination at d efect extending direction, double number of the random examined welding seams shall be examined in supplement examination. After supplement examination, if there are still some not qualified , the complete seam has to be examined. When random examination is performed for butt joint of pressure pipes and tubes, if unqualified defect is found, double number of the random examined welding seams shall be examined in supplement examination. If the supplement examination is still not q ualified, all the welding seams welded by that welder must be examined. V Mechanical property test of welding joints Article 92 To examine the mechanical property of welding seam joint of product, product examination test piece (plate-shaped test piece is referred to as examination te st plate) shall be welded, so as to carry out tensile test, cold bending test and necessary impact

flexibility test. Article 93 Number and requirements of product examination test piece are as follows: 1. One examination test plate shall be prepared respectively for longitudinal, c ircumferential welding seam of each barrel (drum). 2. For boilers of mass production with rated steam pressure less than or equal t o 1.6MPa, it is permitted to make one examination test plate respectively for longitudinal and c ircumferential ========================================27 ======================================== 27 welding seams of every 10 barrels (drums), which are made in the same batch (sam e steel grade, same welding material and procedure) and one examination test plate has to be ma de respectively for longitudinal and circumferential welding seams if number of barrels (drums) are below 10, provided that the quality is stable. 3. When the base material and welding procedure of longitudinal welding seam is the same as that of circumferential welding seam, you may make examination test plate only f or the longitudinal welding seam, not for circumferential welding seam. 4. For splice welding seam of head, tube sheet, when its base material is the sa me as that of barrel (drum), it may not be necessary to make examination test plate, otherwise , the number of examination test plate shall be the same as that of shell of barrel (drum). 5. For furnace flue, return-firing chamber, when its base material, welding proc edure are the same as that of drum, it may not be necessary to make examination test plate, ot herwise, the number of examination test plate shall be same as that of shell of drum. 6. For butt joints of header and pipes, when the material is of carbon steel, it may not be necessary to make examination test plate; when the material is of alloy steel, m ake 1% simulating examination test piece of welding joints for each batch with the preconditions o f the same steel grade, same welding material, same welding procedure, same heat treatment device s and specifications. However, never be less than one. 7. For butt joints of heating surface tubes, when the material is of carbon stee l (butt joint of contact welding excluded), it may not be necessary to make examination test piec e; when the material is of alloy steel, cut 0.5% of the joint from each batch of product as examination test piece with the preconditions of the same steel grade, same welding material, same weld ing procedure, same heat treatment devices and specifications. However, never be less than the joint umber required by one set of specimen. When it is really difficult to cut directly the test piece from product

joint, i.e. butt joint of fittings on barrel and header and tubes, butt joint of membrane wall tubes, etc., simulating examination test piece may be welded. 8. It may not be necessary to make product examination test piece for splice wel ding seam of drum and head, tube sheet and bottom belt on boiler with rated steam pressure le ss than 0.1MPa. 9. Examination test plate of longitudinal welding seam shall be welded as extens ion part of the product longitudinal welding seam (electric slag welding excluded), examination test plate of circumferential welding seam may be welded separately. 10. Product examination test piece shall be welded by the welder who welded the product. Test piece material, welding material, welding equipment, and process conditions, etc . shall be the same as that of the representative product. When the test piece if finished welding, stamp the embossed stamp of welders code on it. 11. The number, dimension of examination test piece shall satisfy the requiremen ts of preparing mechanical property specimen for inspection and re-inspection. Base ma terial used to weld product examination test piece at the installation field shall be provided by the manufacturer. Article 94 Take specimen from the qualified part of the test piece, which had been visually inspected and non-destructive tested. When weld of examination test piece has to be repaired, its ========================================28 ======================================== 28 welding procedure has to be the same as that of product welding repair. Article 95 To examine tensile strength of the whole thickness of the welding joint, cut lat erally the tensile force specimen of full section of the welding joint along the weldin g seam on the examination test plate. For sampling dimension and number of the specimen, see i tem 1 of Appendix II. Article 96 When the plate thickness is greater than 20mm, less than or equal to 70mm, cut longitudinally one all-welded metal tensile specimen from the longitudinal weldi ng seam examination test plate; when the plate thickness is greater than 70mm, cut two a ll-welded metal tensile specimens. For sampling part and dimension of the specimen, see item 2 o f Appendix II. Article 97 Two tensile specimens for tube butt joint shall be cut from the examination test piece, a full length of examination test piece may also be used as a tensile spe cimen instead of tow tensile specimens of the split tubes. For sampling part and dimension of the spe

cimen, see item 3 and 4 of Appendix II. Article 98 Tensile force test of the specimen shall be performed according to the methods specified in GB228 Methods of Metal Tension Test, its qualification standard is as follows: 1. Tensile strength of welding joint shall not be lower than the specified lower limit of base material. 2. The tensile strength and yield point of all-welded metal specimen shall not b e lower than the specified lower limit of base material. If the specified lower limit tensile str ength of base material is over 490MPa, and the yield point of seam metal is higher than that specified for base material, it is allowed that the tensile strength of seam metal is 19.6MPa lower than that of sp ecified lower limit of base material. 3. The elongation rate of all-welded metal specimen shall not be lower than 80% of specified value of the elongation rate ( 5 ) of base material. Article 99 Cut laterall two ben ing specimens of wel ing joint along the wel ing seam on examination test plate, one is face-ben specimen, another is root-ben specimen . For the joint of ifferent steel gra e, longitu inal ben ing specimen ma be use to replace the lateral ben ing specimen. For imension an sampling part of the ben ing specimen, see item 5 of Appen ix II. Article 100 Cut two ben ing specimens of tube butt-wel e joint from the examination test piece, one is face-ben , another is root-ben . For part of sampling an imension of specimen, see item 3, 6 of Appen ix II. Article 101 Ben ing test of the specimen shall be carrie out accor ing to the metho s specifie in GB232 Metho s of Metal Ben ing Test. Wel centerline of the specimen must be aligne with center of ben axis. For specifie specimen ben ing angle, see Tabl e 5-1. When ben ing specimen is bent to the angle specifie in Table 5-1 b col ben in g, it will be qualifie when the maximum efect length at an irection of the specimen is not greater than 3mm. E ge crack of the specimen is ignore . ========================================29 ======================================== 29 Table 5-1 Specimen ben ing angle t : specimen thickness Steel t pe Ben ing ia. D Pivot point istance

Ben ing angle, o Double-wel e Carbon steel, Austenitic steel 3 t 5.2 t 180 Other allo steel 3 t 5.2 t 100 Single-wel e Carbon steel, Austenitic steel 3 t 5.2 t 90 Other allo steel 3 t 5.2 t 50 Note: Joint ben ing angle of contact wel ing shall follow the stipulations for ouble -si e wel ing. Joint ben ing angle of single-si e wel ing with backing shall follow the stipul ations for ouble-si e wel ing. Article 102 Three shock specimen of wel ing joint shall be cut from its examination test pie ce when boiler with operation pressure greater than or equal to 3.8MPa, or barrel a n hea er an butt joint pipes of allo steel with wall temperature greater than or equal to 450 , if wall thickness is over or equal to 12mm (single-welded weldment thickness is over or equal to 16mm ). Specimen notch shall be made inside the welding side face of the last pass, it may be mad e within fusion line or heat-affected zone if required. Pattern, dimension, machining and test method of the specimen shall conform to the stipulations for V shape notch in GB/T229 Methods for Metal Charpy-type Test. Article 103

The average value of shock absorption power of the three specimens under normal temperature shall not be lower than the specified value of base material, if the re is no specified base material value, they shall not be lower than 27J (section dimension of the speci men 1010mm), and at most only one specimen is permitted to be with a shock absorption power lower than the above-mentioned index value, but not lower than 70% of the above-mentioned index value. Article 104 When an item in mechanical property test is unqualified, double of that unqualif ied specimen shall be cut from the original welded examination test piece to retest (additional three specimens shall be cut for retesting for shock test), or carry out an all-round retest after re-heat treatment of the original examination test piece and product. Article 105 If the test result of each tensile and bending retest specimen is qualified, the average value of shock absorption power of the six shock specimens (including th ree initial test specimens and three retest specimens) is not lower than that of specified value of base material, and not lower than 27J (section dimension of the specimen 1010mm) if there is no spec ified value of base material, and the shock absorption power of at most two specimens lower tha n the above-mentioned index value, and only one of the specimens with the value lower than 70% of the above-mentioned index value, then the retest is qualified. Otherwise the retest is not qualified. ========================================30 ======================================== 30 VI Metallographic examination and fracture examination Article 106 When the weldment material is of alloy steel, metallographic examination shall be carried out for the following welding seams: 1. Butt jointed seam for barrel with operation pressure greater than or equal to 3.8MPa, butt jointed seam for header with operation pressure greater than or equal to 9.8MPa or header, heating surface tubes and pipes with wall temperature over 450 ; 2. Corner welding seam for fittings on barrel, header with operation pressure gr eater than or equal to 3.8MPa. Article 107 Specimen for metallographic examination shall be taken according to the following stipulations: 1. For barrel and header, cut one specimen from each examination test piece;

2. For pipes, heating surface tubes within boiler scope, cut one specimen from e ach (set) examination test piece; 3. For corner welding seam of fittings on barrel and header, the fittings must b e divided into two categories (wall thickness greater than 6mm and wall thickness less than or equal to 6mm), weld one examination test piece for every 200 fittings of each type, and weld on e examination test piece for fittings less than 200, and cut along the centerline of the examinatio n test piece for metallographic examination. Article 108 Criteria of qualification of metallographic examination shall be: 1. No cracking, not loose; 2. No burnt structure; 3. No martensitic structure of hardenability. Article 109 Retest is not permitted if any one of crack, burnt, loose exists, then the metallographic examination is not qualified. If it is not qualified only due to martensitic structure of hardenability, it is permitted to have another heat treatment for the examination test piece and the product, then take double of the specimen to retest (retest of mechanical property is still required when it is q ualified), it can only be deemed as qualified when retest of each retest specimen is qualified. Article 110 Fracture examination shall be carried out for butt-welded joints of boiler, heat ing surface tubes with rated steam pressure greater than or equal to 3.8MPa. One joi nt out of 200 joints shall be fracture examined in random, and one joint has to be examined for joint s less than 200. Fracture examination may not be performed for butt-welded joint, which is qualif ied by 100% examination or argon-arc welded (welding covered by manual arc welding and backe d by argon-arc welding included). Fracture examination includes the whole fracture of welding. For criteria of qua lification of fracture examination, see Table 5-2. ========================================31 ======================================== 31 Table 5-2 Criteria of qualification of fracture examination Defects Wall thickness t 6 Wall thickness t >6 Crack No Not fused No

Not completed penetrated Depth 15% t , and 1.5mm, total length 10% circumference Internal concave (sag waist) Depth 25% t , and 1mm, Depth 20% t , and 2mm, Single porosity Radial 30% t , and 1.5mm, 25% t , and 4mm, Axial, radial 2mm 30% t , and 6mm Single porosity and slag Radial 25% t 20% t , and

4mm Axial, radial 30% t 25% t , and 4mm Concentrated porosities and slag No Porosity and slag not exceed 5 within every 1cm 2 and total area of porosity and slag not exceed 3mm 2 within every 1cm 2 Total length of porosity and slag along circumference direction The accumulated length of porosity and slag not exceed the wall thickness in the scope of 10 times of the wall thickness along the circumference direction, Total length of various defects on the same straight line along wall thickness direction 30% t , and 1.5mm 25% t , and 4mm Any item not in conformity with any value in Table 5-2, it is deemed as unqualif ied, and it is permitted to retest with double of the specimen. If every examination result of each retest specimen is qualified, then the retest is qualified, otherwise, it is not qualified, acco rdingly, the welding represented by this specimen is not qualified. VII Hydraulic test Article 111 Hydraulic test of pressure weldment shall be carried out after non-destructive test

and heat treatment. 1. Single barrel and welded boiler delivered from factory as a whole shall be hy draulically tested in boiler manufacturer according to the test pressure in Article 207 of t his Regulation. 2. Header and their similar elements for boiler delivered from factory in bulk s hall be hydraulically tested in boiler manufacturer with a pressure of 1.5 times of the element operation pressure and keep for 5 minutes under the test pressure. Header of boiler with p ressure less than or ========================================32 ======================================== 32 equal to 2.5MPa and without fitting may not be hydraulically tested separately. 3. Butt-welded heating surface tubes and their pressure fittings shall be hydrau lically tested one by one in boiler manufacturer with the test pressure of 2 times of the element o peration pressure (This test pressure may be 1.5 times for boiler with rated steam pressure greate r than or equal to 13.7MPa), and keep at this test pressure for 10 ~ 20 seconds. This hydraulic tes t may not be carried out in boiler manufacturer provided that the butt jointed seams are backed with argon-arc weld and are qualified through 100% non-destructive test, and welding quality is ensured. Welding joints of heating surface tubes and pipes assembled at site may be hydraulically tested to gether with body. Hydraulic test method shall follow the stipulations in Article 208 of this Regul ation. Hydraulic test results shall be in conformity with the stipulations in Article 2 09 of this Regulation. VIII Repair of welding joints Article 112 If welding joint of pressure elements has defect found during non-destructive t est, the weld-performing unit has to find out the cause and work out practical repair ing scheme before repairing. Before patch welding, clear thoroughly the defect. After patch weldin g, visual inspection and non-destructive test shall be carried out for the patch weld zone. Element r equires postweld heat treatment, must perform the postweld heat treatment after welding. Repairing on the same position shall not exceed three times. IX Repairing with welding method Article 113 When welding method has to be used for boiler pressure elements with large damaged area caused by stress corrosion, creep, fatigue, method of removing-mend ing, or replacing has to be employed usually. Patch welding method should not be employed. Article 114

When removing-mending method is used to repair boiler pressure elements, the mending plate must be in regular shape, if square mending plate is used, four co rners must be round corners with radius not less than 100mm (if one side of the mending plate is coi ncident with the original weld, the two corners of this side may not be included). Boiler pressure elements shall not be repaired with the method of pasting-mendin g. Article 115 Before removing-mending and patch welding the barrel (drum), the repair unit must carry out welding procedure evaluation. The procedure test piece must be we lded by the repair unit. Chemical constitution analysis and mechanical property test of the procedu re test piece may be authorized to other unit to do. Article 116 Welders who take part in the T joint welding of centralized downcomer and barrel of operating boiler or similar welding seam repairing work shall exercise simula ting welding according to the welding procedure and meet the welding requirements before perf orming patch welding, in addition to obtaining the welder certificate of qualification. Article 117 Oil whiting test or magnetic powder inspection shall be performed after build-u p welding when build-up welding is used for barrel (drum) repairing. ========================================33 ======================================== 33 Article 118 It is necessary to weld simulating examination test piece to perform mechanical property test when boiler, barrel (drum) with rated steam pressure greater than or equal to 0.1MPa change head (tube sheet) or shell sections. Article 119 Mechanical property test may not be performed for butt joint of tubes when changing or repairing heating surface tubes. Article 120 Non-destructive test shall be carried out for welding seams of replacing, removing-mending, patch welding of main weld of pressure elements according to t he related stipulations in this Regulation. Article 121 When repairing boiler pressure elements, which had heat treatment before, postweld heat treatment shall be performed basically according to the original h eat treatment specifications after welding. ========================================34 34 ========================================

Chapter 6 Expanded Tube Joint Clause 122 Trial expanding shall be made before making expanded tube joint in order to check the quality of tube expander and the expanded tube joint property of tube materials. In expanding test, comparative check shall be made to inspect whether there is any crack at the expand, whether there is an intensified change in the transition section of expanded tub e joint, whether the condition of joint between the root of flare and the tube exterior wall is good, etc. Then inspection shall be made to the impression and engagement conditions of the contact facing of the tube port wall and the tube exterior wall. The rational expanding rate shall be determined according to the inspection results. When the boiler which is required to have the tube expanded joints made at site is delivered from the manufacturer, the boiler manufacturer shall provide a suitable quantity of the specimens of the same steel grade for making expanded tube joints shall be provided (sheet sa mples for expanded tube joint test shall be provided with the tube holes). Clause 123 Construction units shall establish the Expanded Tube Joint Procedures in accordance with the boiler design drawings and the trial expanding results. The expanding operation personnel shall be subjected to training and carry out e xpanding operations in strict accordance with the Expanding Joint Procedures. Clause 124 The thickness of boiler casings (boiler shells) and the tube sheets for the ex pand tube shall not be smaller than 12mm. The spans between the expand tube holes sha ll not be smaller than 19mm. The expanded tube joint should not be made for tubes with an outside diameter > 102mm. Clause 125 Materials with a hardness lower than that of the tube sheet should be selected f or the expended tube. In case the hardness of tube end is greater than that of the tube sheet, annealing treatment shall be made to the tube end. Coal shall not be used for directly hea ting the tube end for annealing. The annealing length at the tube end shall not be smaller than 100mm. Clause 126 When the inside diameter control method is used, the expanding rate shall be generally within a range of 1% ~ 2.1%. The following equation can be used to cal culate the expanding rate: Where: H n

= Expanding rate, %; d 1 = Inside diameter of tube actually measured after expanding, mm; t = Wall thickness of tube actually measured before expanding, mm; ========================================35 ======================================== 35 d = Diameter of tube hole actually measured before expanding, mm. Clause 127 Extension of tube end should be 6 ~ 12mm. The turn-up rims of flares at tube end shall be at an angle of 12 o ~ 15 o to the centerline of tube. The starting point of turn-up rims should be flush with the surface of tube sheet (boiler casing). For the shell boiler, the ends of flue tubes in direct contact with flame (at fl ue gas temperature > 800 o C) shall be turned up at 90 o . After turning up, the turned-up tube ends shall be in tight contact with the tube sheet and the clearance between them shall not be greater than 0.4 mm, and the length with a clearance > 0.1mm shall not be greater than 20% of the perimeter of tube. Clause 128 After expansion joint, there shall be no such defects as scaling, wrinkling, cracking, cutting, biasing, etc. During expansion joint, the quality of expanded tube joint of expands shall be controlled at any time so as to find out and eliminate any defect. Clause 129 In order to calculate the expanding rate and check the quality of expanded tub es, construction units shall maintain the records of expansion joints according to t he actual inspection and measurement results. Clause 130 After completion of expansion joints, the hydraulic test shall be performed to check the tightness of expands. Chapter 7 Main Accessories and Instruments (I). Safety Valve Clause 131 Two safety valves shall be provided for each boiler at least (excluding the sa fety valve of economizer). In case one of the following provisions is complied with, it is possible to

install only one safety valve. 1. Boilers with a rated evaporating capacity 0.5t/h; 2. Boilers with a rated evaporating capacity < 4t/h, and a reliable overpressure interlock protection device provided. Safety valves shall be installed at the outlets of dissociable type economizer a nd steam superheater, at the inlet and outlet of reheaters, and on the start up separator of once through boiler. Clause 132 Full-open type spring-loaded safety valve, lever-type safety valve and pilot safety valve (pulse type, pneumatic type, hydraulic type and solenoid type, etc. ) shall be used as the safety valves for boilers. The safety valves selected to use shall comply with t he stipulations of relevant technical standards. The dead-weight safety valves or water-sealing safety devices can used for the b oilers with a rated steam pressure 0.1MPa. The inside diameter of water sealing tubes for the water sealing device shall not be smaller than 25mm, and no valve shall be installed on the tu bes. Meanwhile antifreeze measures shall be taken. ========================================36 ======================================== 36 Clause 133 The total discharge capacity of the safety valves installed on the boiler casi ng (boiler shell) and superheaters shall be greater than the evaporating capacity o f boiler. After opening of all the safety valves installed on the boiler casing (boiler shell) and super heaters, the steam pressure in the boiler casing (boiler shell) shall not exceed 1.1 times the calc ulated pressure in design. Calculation of forced-flow boiler shall be made based on the calculated pressure of the pressure components at the outlet of boiler. Clause 134 The discharge capacity of steam safety valve shall be calculated based on one o f the following methods: 1. Calculations are made according to the equations given in GB12241 General Requirements for Safety Valves . 2. E = 0.235 A (10.2 p + 1)

K Where: E = The theoretic disch rge c p city of s fety v ve, kg/h; p = Ste m pressure(g) t the in et of s fety v ve, MP ; A = Are of f ow p ss ge of s fety v ve, mm 2 ; c n be used for c cu tion; d = Di meter of f ow p ss ge of s fety v ve, mm; K = Correction coefficient for the specific vo ume of ste m t in et of s fety v ve to be c cu ted ccording to the fo owing equ tion: K = K p K g Where: K p = Correction coefficient of pressure; K g = Correction coefficient of overhe t; K , K p nd K g sh be se ected nd c cu ted ccording to T b e 7-1.

K p (Mp ) K p K g K = K

T b e 7-1 Correction Coefficients for In et of S fety V

ve

p K g p 12 S tur ted 1 1 1 Rehe ted 1 P > 12 S tur ted 1 Rehe ted Note: c n so be rep ced by In the t b e: V g = The specific vo ume of superhe ted ste m, m 3 /kg; V b = The specific vo ume of s tur ted ste m, m 3 /kg; T g = Superhe ting temper ture, o C. 3. The c cu tion is m de b sed on the c cu tion expressions nd d t provide d by the ========================================37 ======================================== 37 m nuf cturer of s fety v ves. ========================================38 38 C use 135 The disch rge c p city of s fety v ves t out ets of superhe ters s

========================================

nd rehe ter

sh be ensured to h ve sufficient coo ing for superhe ters nd rehe ters. The disch rge c p city of s fety v ve inst ed on the st rt-up sep r tor of on ce- through boi er sh be gre ter th n the ste m gener tion c p city of the boi er during st rt up. The re of f ow p ss ge of s fety v ve for economizer sh be determined by t he design unit of boi er. C use 136 The di meter of f ow p ss ge of s fety v ves for the boi ers with r ted ste m pressure 3.8MP sh not be sm er th n 25mm. The di meter of f ow p ss ge of s fety v ves for the boi ers with r ted ste m pressure > 3.8MP sh not be sm er th n 2 0mm. C use 137 S fety v ves sh be inst ed in vertic position nd t the highest poi nt of he der of boi er c sing (boi er she ). No ste m out et pipes nd v ves th t us e the ste m sh be inst ed between the s fety v ve nd boi er c sing (boi er she ) or between s fety v ve nd he der. C use 138 In c se sever s fety v ves re inst ed together on short pipe direct y connected to the boi er c sing (boi er she ), the section re of f ow for th e short pipe sh not be sm er th n the sum of section re s of f ow p ss ges of s fety v ves. C use 139 The specific tions of screwed connection spring- o ded s fety v ves sh comp y with the requirements set in St nd rd JB2202 P r meters of Spring- o ded S fety V ves. In this c se, the s fety v ve sh be connected with short pipe with screwed ends whi e the short pipe sh be connected with the boi er c sing (boi er she ) or herders by we d ing. C use 140 S fety v ve sh be provided with ste m disch rge pipe which sh be run to s fe point with sufficient f ow section re to ensure unimpeded ste m dis ch rge f ow. Me nwhi e, the ste m disch rge pipe sh be fixed. In c se open inst tion of the ste m disch rge pipe wi ffect the norm ct ion of s fety v ve, protective hood sh be set up. The inst tion of protective hood sh not ffect the norm ction nd m inten nce of s fety v ve. Dr inpipe sh be inst ed t the bottom of ste m disch rge pipe of s fety v ve nd connected to s fe point. It is not owed to provide ny v ve in the ste m d isch rge pipe nd dr inpipe. Dr inpipe sh be provided for the s fety v ve of economizer nd connected to s fe point. It is not owed to provide ny v ve in the dr inpipe. C use 141 In c se ny si encer is inst ed in the ste m disch rge pipe, it sh h ve

sufficient section re for f ow so s to prevent the norm ction nd disch rge c p city of s fety v ves from being ffected by the b ck pressure gener ted during venting of s fe ty v ves. Reduce in the ste m f ow section re due to fou ing in the structures of si encer bo rd or the other components sh be voided. ========================================39 ======================================== 39

C use 142 S fety v ves sh be provided with the fo owing devices: 1. Lever s fety v ves sh be provided with devices to prevent weights from se f-movement nd guide br ckets to imit overrun of evers. 2. Spring- o ded s fety v ve sh be provided with ifting h nd e nd devi ce to prevent the djustment screw from being tempered with. 3. De d-weight s fety v ve sh be provided with the devices to prevent the br e k-off of weight pieces. 4. Pi ot s fety v ve sh be provided with re i b e power source nd power s upp y. (1). V ve in the impu se cut-in duct of the pu se s fety v ve sh be m int i ned t fu -open position nd with e d se . (2). S fety v ves to be contro ed by the compressed g s sh be provided with re i b e g s source nd power supp y. (3). The hydr u ic pi ot s fety v ve sh be provided with re i b e hydr u i c tr nsfer system nd power supp y. (4). So enoid pi ot s fety v ve sh be provided with re i b e power supp y. nd rehe te

7-2. rt-up sep r

inst

tio

C use 143 The set pressure of s fety v ves for boi er c sing (boi er she ) r sh be set nd c ibr ted ccording to the specific tions shown in T b e The set pressure of s fety v ves of economizer, rehe ter nd the st tor for once-through boi er sh be 1.1 times the oper ting pressure t the n oc tions. T b e 7-2 Set Pressure of S fety V ve R ted ste m pressure (MP ) Set pressure of s fety v ve 0.8 Oper ting pressure + 0.03MP Oper ting pressure + 0.05 MP 0.8 < p 5.9 1.04 times oper ting pressure 1.06 times oper ting pressure

> 5.9 1.05 times oper ting pressure 1.08 times oper ting pressure Notes: A s fety v ve sh be provided on the boi er nd set ccording to the re tiv e y ow set pressure indic ted in the t b e. As for the boi er with rehe ter, the s fety v ve th t needs to be set ccording to re tive y ow pressure sh be the s fety v ve in the rehe ter so th t it c n be ensured to be opened first.

The oper ting pressures indic ted in the t b e refer to the oper ting pressures t the impu se sent-out point in c se of the pu se s fety v ve nd the oper ting pressures t the inst tion point of s fety v ve in c se of the other types of s fety v ves. C use 144 Gener y the differenti pressure for opening nd c osing s fety v ves sh be 4% ~ 7% of the set pressure nd ess th n 10% s m ximum. When the set pressur e is 0.3MP , the ========================================40 ======================================== 40 m x. differenti pressure for opening nd c osing sh be 0.03 MP . C use 145 The set pressure nd se ting-b ck pressure for the s fety v ves in the new y inst ed boi er nd the s fety v ves fter the m inten nce sh be c ibr ted . The inspection of re i bi ity nd pop-up perform nce test sh be m de to the contro circuit of the pi ot s fety v ves. C use 146 S fety v ves of in-service boi ers sh be t e st subjected to c ibr tio n nd inspection once ye r. The inspection nd testing items sh be the set pressu re, se ting-b ck pressure, tightness, etc. Gener y, the c ibr tion sh be m de under the ope r tion conditions of boi er. In c se it is difficu t to m ke c ibr tion t site or the s fety v ves re rep ired, the c ibr tion of the s fety v ve c n be m de on the c ibr tion bench for s fety v ves. In this c se, on y the djustment of set pressure nd tightness test re m de to the s fety v ves. After the c ibr tion of s fety v ves, the resu ts of set pressure test, se tin g-b ck pressure test, tightness tests, etc., sh be put on the boi er technic fi es. After c ibr tion, s fety v ves sh be ocked up or se ed with e d. It is f orbidden to incre se the set pressure of s fety v ves t r ndom or inv id te the s fety v ves by the me ns of dding weights, moving weights, b ocking the f ps, etc. During oper tion of boi

ers, it is forbidden to bring s fety v ves out of ine. C use 147 In order to prevent the f ps nd se ts of s fety v ves from sticking, the m nu bursting open of s fety v ves sh be m de periodic y. C use 148 Before s fety v ves re de ivered from the m nuf cturers, they sh be tt c hed with n mep te be ring the fo owing items: 1. Mode of s fety v ve; 2. N me of m nuf cturer; 3. Seri No.; 4. M nuf cture time (ye r/month) ; 5. Nomin pressure, MP ; 6. Di meter of f ow p ss ge of v ve, mm; 7. Open ift, mm; 8. Disch rge coefficient; 9. Pressure c ss. The disch rge coefficient of s fety v ves sh be determined by test m de by t he m nuf cturers of s fety v ves. (II). Pressure G uge C use 149 E ch boi er sh not on y be provided with the pressure g uges th t re direc t y connected to the ste m sp ce of boi er c sing (boi er she ), but so provided with the pressure g uges inst ed in the fo owing positions: 1. Before the feed w ter contro v ve; 2. At the out et of dissoci b e economizer; 3. Between the out et of rehe ter nd m in ste m v ve; ========================================41 ======================================== 41 4. At the in et nd out et of rehe ter; 5. In the st rt-up sep r tor of once through boi er; 6. Before the v ve of the prim ry ste m nd w ter system of once through boi er ; 7. At the suction nd disch rge of boi er w ter circu tion pump for the forcedf ow boi er; 8. At the suction nd disch rge of fue oi pump for the oi -burnt boi ers; 9. At the in et of g s source for the g s-burnt boi ers. C use 150 Se ection of pressure g uges sh comp y with the fo owing provisions: 1. For the boi ers with r ted ste m pressure < 2.5MP , the ccur cy of pressur e g uge sh not be ower th n C ss 2.5, nd for the boi ers with r ted ste m pressure > 2 .5MP , the ccur cy of pressure g uge sh not be ower th n C ss 1.5. 2. The pressure g uges sh be se ected for use ccording to the oper ting pres sures. The imit v ue of sc e r nge of pressure g uges sh be 1.5 ~ 3.0 times the oper ting p ressure, nd it wi be better to se ect 2 times the oper ting pressure.

3. The size of the di for the pressure g uge sh ow the boi er oper tors to see c e r y the pressure re dings, nd the di meter of di for the pressure g uge sh not be sm er th n 100mm. C use 151 The se ected pressure g uges sh comp y with the requirements set in the re ev nt st nd rds, nd their c ibr tion nd m inten nce sh comp y with the requirements m de by the st te metering uthorities. Before inst tion of s fety v ve, c ibr t ion sh be m de nd the d te for next c ibr tion sh be indic ted. Red ine to indic te the oper ting pressure sh be m rked on the sc e of pressure g uge. After c ibr tion, the pressure g uge sh be se ed with e d. C use 152 Inst tion of pressure g uge sh comp y with the fo owing requirements: 1. It sh be inst ed in position th t is convenient for observ tion nd pu rging, nd protected from the ffection of high temper ture, freezing nd vibr tion. 2. W ter se ed joint sh be provided for the pressure g uge set up for the st e m sp ce. When the stee tube is used for the w ter se ed joint, the inside di meter of the tu be sh not be sm er th n 10mm. Tee v ve sh be inst ed in the connection pipe between the pressure g uge nd boi er c sing in order to f ci it te purging the pipe ine nd rep cing nd c ibr ting the pressure g uge. The tee v ve for the pressure g uge of ste m sp ce sh be inst ed between t he pressure g uge nd the w ter se ed joint. C use 153 When one of the fo owing conditions occurs to pressure g uge, the pressure g uge sh be stopped to use. 1. For the pressure g uge with stop screw, when there is no pressure, the poin ter f i s to return to the stop screw fter swinging. As for the pressure g uge without sto p screw, when there is no pressure, the devi tion v ue of pointer from the Zero exceeds the permiss ib e error specified for the pressure g uge. 2. The g ss f ce is broken or the sc e is inexp icit; 3. The e d se is d m ged or the v id ted period of c ibr tion is expired; ========================================42 ======================================== 42 4. There is e k ge in g uge or pointer jitters; 5. There re some other defects th t ffect the ccur te indic tion of pressure g uges. (III). W ter Leve G uge C use 154 E ch boi er sh be t e se provided with two w ter eve g uges th t re independent e ch other. Boi ers th t comp y with one of the fo owing conditions c n be provided

on y with direct-re ding w ter eve g uge. 1. Boi er with r ted ev por ting c p city 0.5t/h; 2. E ectric he ting boi er; 3. Boi er with r ted ev por ting c p city 2t/h nd re i b e w ter eve monitoring nd contro device; 4. Boi er equipped with two sets of remote w ter eve disp y units which re i ndependent e ch other. C use 155 W ter eve g uge sh be inst ed in position th t is convenient for observ tion. When it is inst ed t height bove 6000mm from the oper tion f oor, the remote w ter- eve disp y unit sh be inst ed. The sign s for the w ter eve dis p y unit c n not be t ken from the prim ry instrument. C use 156 For the boi ers with the remote w ter eve disp y unit to monitor w ter eve s, there sh be two re i b e w ter eve disp y units in the contro room, nd m e nwhi e one direct-re ding w ter eve g uge sh be m int ined in norm service in oper t ions. C use 157 W ter eve g uges sh be provided with the fo owing design tions nd protections: 1. W ter eve g uges sh be provided with the rem rk b e design tions for the m ximum nd minimum s fety w ter eve nd norm w ter eve . The ower visib e edge of the eve g uge sh be t e st 50mm higher th n the m ximum f me bound ry nd 25mm ower th n the minimum s fety w ter eve , nd the upper visib e edge of the eve g uge sh be t e st 25mm higher th n the m ximum s fety w ter eve . 2. In order to prevent w ter eve g uge from hurting peop e when it is d m ged, the protective devices (such s protective hood, f st v ve, se f- ocking be d, etc.) sh be provided for the g ss tube w ter eve g uge, however, they sh not hinder the observ tion of ctu eve . 3. W ter eve g uge sh be provided with dr in v ve which sh be piped to s fety point. C use 158 The structure nd setting up of w ter eve g uge sh comp y with the fo owi ng requirements: 1. The g ss p te (tube) nd p te mic c n be purged nd rep ced during the o per tion of boi er. 2. A set of w ter eve g uge consisting of two or more th n two g ss p tes or p te mic s c n ensure continuous indic tion of w ter eve . 3. The inside di meter of ste m nd w ter connection pipes between w ter eve g uge or w ter co umn meter nd boi er c sing (boi er she ) sh not be sm er th n 18mm. Wh en the ength of

========================================43 43

========================================

the connection pipe is gre ter th n 500mm or there is bend, the inside di mete r sh be en rged in order to ensure the sensitivity nd ccur cy of w ter eve g uge. 4. The connection pipe sh be s short s possib e. In c se the connection pip e is not set up in horizont position, the condens te in the ste m connection pipe sh run to the w ter eve g uge by itse f whi e the w ter in the w ter connection pipe sh f ow to the boi er c sing (boi er she ) so s to prevent f se w ter eve from est b ishment. 5. Both the f ow p ss ge di meter of v ves nd the inside di meter of g ss tub e sh not be sm er 8mm. C use 159 V ve sh be inst ed in the ste m nd w ter connection pipes between the w ter eve g uge (or w ter co umn meter) nd boi er c sing (boi er she ), nd it sh be fu y open during the oper tion of boi er.

C use 162 E ch boi er sh be provided with n independent b ow-down pipe, nd the bends in the b ow-down pipe sh be minimized so s to ensure through b ow- d own, nd sh be connected to s fety p ce outdoors or b ow-down exp nsion t nk. When the b o w-down exp nsion t nk under pressure is used, it sh be equipped with s fety v ve.

When b ow-down pipe ine is sh red by sever boi ers, b ow-down sh rried out with two or more th n two boi ers t the s me time.

not be c

0.7MP , two b ow-down v ves sh

be inst

ed in the b ow-down pipe in series.

(IV) B ow-down nd Dr in Devices C use 160 B ow-down v ves sh be inst ed t the owest points of the boi er c sing (boi er she ), the bottom ring of vertic boi er nd the ower he ders for e c h group of w ter w s. Dr in v ves sh be inst ed t the owest points of the he ders of superhe t er or rehe ter nd e ch group of economizer. Boi ers with superhe ters re gener y provided with conti nuous b ow-down device. G te v ves, segment v ves or s nting b ock v ves shou d be used fo r b ow-down v ves. The nomin di meter of the port of b ow-down v ves is 20 ~ 65mm. the nomin d i meter of the port of b ow down v ve on the boi er she of horizont boi er sh not be sm er th n 40mm. C use 161 For the boi ers with ev por ting c p city 1t/h or the r ted ste m pressure

(V) Instruments for Temper ture Me surement C use 164 Instruments for temper ture me surement sh be set up in the fo owing re ev nt oc tions of boi ers. 1. Ste m temper ture t the out et of superhe ter nd t the in et nd out et of rehe ter; 2. Ste m temper ture t the out et of e ch group consisting of sever horizont tube sections for the superhe ter; 3. Ste m temper ture before nd fter the desuperhe ters; 4. W ter temper ture t the out et of iron c st economizer; ========================================44 ======================================== 44

5. F ue g s temper ture t the out et of furn ce of pu verized-co -burnt boi er ; 6. F ue g s temper ture t the in ets of reherter nd superhe ter; 7. The ir temper ture t the ir in et of the ir prehe ter; 8. F ue g s temper ture t the disch rge point of f ue g s; 9. Oi temper ture t the oi in et of the burners of oi -burnt boi er; 10. Temper tures of the ower nd upper w s of the boi er c sing for boi er wi th r ted ste m pressure 9.8MP , 11. Met w temper ture of coi s for the superhe ter nd rehe ter of boi er w ith r ted ste m pressure > 9.8MP ; 12. F ue g s temper ture t the out et of ir prehe ters of oi -burnt boi er. Boi ers with superhe ters sh so be provided with the recording instrument o f superhe ted ste m temper tures. (VI). Protection Devices C use 165 Boi ers with r ted ev por ting c p city 2t/h sh be provided with the high eve nd ow eve rms (the high eve nd ow eve rm sign s sh be distinguished) nd the ow- eve inter ock protection device. Boi ers with r ted ev por ting c p city 6t/h sh so be provided with the ste m over-pressure rm nd inter ock protection device. The ow- eve inter ock protection device sh be b e to be ctu ted t the o west s fety eve . The set v ue of overpressure inter ock protection device sh be ower th n th e ower set v ue of s fety v ve. C use 166 Boi ers using fue s of pu verized co , oi or g s sh be provided with the

C use 163 The b ow-down v ves nd b ow-down pipes of boi ers sh with screw.

not be connected

inter ock devices of the fo owing functions: 1. When there is power f i ure for dr ft f ns, the ir supp ies nd fu e supp ies sh be cut off utom tic y; 2. When there is power f i ure for b owers, the fue supp ies sh be cut off utom tic y; 3. When the pressures of oi nd g s fue s re ower th n the specified v ues, the oi supp y or g s supp y sh be cut off utom tic y. C use 167 Boi ers using fue s of pu verized co , oi or g s sh be provided with re i b e ignition sequence contro nd extinguishing protection devices. During the ignition sequence contro , the tot ir vo ume before ignition sh not be sm er th n three times the tot vo ume from the furn ce to the f ue t the in et of s t ck, nd the venti tion time sh t e st st for 20 seconds in c se of she boi er, for 60 seconds in c se of w ter tube boi er nd gener y st for more th n 3 minutes in c se of the boi ers for e e ctricity gener tion. The unit venti tion ir vo ume sh be gener y m int ined t the tot combu stion ir vo ume t the r ted o d. In c se of the boi ers for e ectricity gener tion, gen er y it sh be m int ined t 25% ~ 30% of the tot combustion ir vo ume t the r ted o d. ========================================45 ======================================== 45 C use 168 Boi ers with rehe ters sh be provided with the protection devices of the fo owing functions: 1. When the ste m temper ture t out et of rehe ter re ches the m ximum permissi b e v ue, the emergency w ter spr y sh be cut-in utom tic y. 2. The corresponding protective me sures sh be t ken ccording to the oper ti on modes of units, utom tic contro conditions nd rehe ter design, to prevent the met w of rehe ter from over-temper ture. C use 169 Once-through boi ers sh be provided with the fo owing protection devices: 1. A rming device for the feed w ter f ow being ower th n the w ter f ow t st rt up under ny conditions; 2. A rming device for the midd e-point temper ture exceeding the specified v u e fter the boi er runs to the entire once through oper tions. 3. Autom tic cut-off device for the fue supp y of boi ers when the feed w ter f i ure time exceeds the specified time. C use 170 Under the oper tion of boi er, it is not owed to t ke the protection device s nd inter ocks out of the service. The power supp y of inter ock protection devices

be c osed by itse f.

(VII). M in V ves nd Others C use 172 Rem rk b e signs sh be provided for v ves in the pipe ines nd d mpers in the f ue nd ir system, indic ting the design tion, number, open nd c ose direction nd f uid f ow direction of v ves nd d mpers. M in contro v ves sh so be pr ovided with indic tions of opening positions. A the oper ting mech nisms of v ves nd d mpers sh be inst ed in the oc tions convenient for oper tions. C use 173 The m in ste m v ve sh be inst ed c ose to the out et of he der of boi e r c sing (boi er she ) or reherter. For the boi er of unit, the m in ste m v v e c n be inst ed t the in et of turbine. In c se of the vertic she boi er, the m in ste m v ve c n be inst ed in the oc tions convenient for oper tion within the boi er house. Two cut-off v ves s h be inst ed in e ch ste m pipe ine connected to the ste m m nifo d between boi er nd ste m. Th e dr inpipe nd v ve to the tmosphere sh be inst ed between the cut-off v ves, nd its d i meter sh not be sm er th n 18mm. C use 174 For the boi ers with r ted ev por ting c p city 220t/h sh be provided with the remote-contro vent v ve to the tmosphere. C use 175 The feed w ter cut-off v ve nd check v ve sh be inst ed in the feed w t er ========================================46 ======================================== 46

pipe ine t the in et of indissoci b e economizer. For the boi er of unit, it is possib e for no feed w ter check v ve to be inst ed in the feed w ter pipe ine. The feed w ter cut -off v ve nd feed w ter check v ve sh be inst ed respective y t the in et of dissoci b e ec onomizer nd in the feed w ter pipe ine to boi er c sing (boi er she ). C use 176 The feed w ter cut-off v ve sh be inst ed between boi er c sing (boi er she ) (or the he der t the in et of economizer) nd feed w ter check v ve, nd it sh

the boi er is in oper tion, the d mper sh

sh be re i b e. C use 171 When m in f ue pipe is sh red inst ed in the f ue br nch for re i b e fixing device so s to ensure th t when m int ined t fu -open position nd sh not

by sever boi ers, the f ue d mpers sh be e ch boi er. The d mper sh be provided with be

be c ose y connected with the feed w ter check v ve. C use 177 Boi ers with ev por ting c p city gre ter th n 4t/h sh be provided with utom tic feed w ter regu tor, nd the m nu -contro feed w ter device sh b e inst ed in the oc tions convenient for the oper tions m de by boi ers oper tors. C use 178 Emergency w ter dr in v ves sh be inst ed between the owest s fety w te r eve nd norm w ter eve of the boi er c sing for the boi ers with r ted e v por ting c p city

3.8MP , nd v ve sh be inst ed in the w ter dr inpipe in order to dr in w ter s soon s there is overf ow. This v ve sh be in c ose position under the oper tion of bo i er. C use 179 Vent v ves sh be inst ed in the oc tions where the ir m y ccumu t ed prob b y such s boi er c sing (boi er she ), superhe ter, rehe ter, economizer , etc. C use 180 Boi ers with different oper ting pressures re respective y provided with independent ste m pipe ine nd feed w ter pipe ine. In c se s me ste m m nifo d is sh red by them, there sh be n utom tic depressurizing device in the ste m pipe ine wi th higher pressure nd s fety device (such s check v ve) to protect the ower pressure side fro m being overpressurized. When the feed w ter differenti pressure does not exceed 20% o f the highest oper ting pressure mong them, it is possib e for the m in feed w ter system to feed the w ter to the boi er. C use 181 The feed w ter system of boi er sh ensure s fety nd re i b e w ter supp y. The boi er house sh be provided with st ndby feed w ter equipment. The rr ng ement nd number nd c p city of st ndby feed w ter equipment sh be determined ccordin g to the design specific tions by the design unit. C use 182 Boi ers with r ted ev por ting c p city 1t/h sh be provided with boi er w ter s mp ing device. When there re requirements for the qu ity of ste m, s te m s mp ing device sh so be provided. The s mp ing device nd s mp ing points sh ens ure the represent tiveness of w ter s mp es nd ste m s mp es. Ch pter 8 Boi er House C use 183 Gener y, boi er sh be inst ed in boi er house which is set up sep r t e y. The boi er room sh not set up direct y in the houses where there is crowd o

f peop e (such s pub ic b throom, c ss room, dining-h , udience h s of cinem nd the tr e, w iting room, ========================================47 ======================================== 47

etc.), or bove, be ow, dj cent to or on both sides of the m in ev cu tion exit . The new y bui t boi er house sh not be dj cent to the residenti houses. C use 184 In c se boi er room is set up in the semi-b sement or on the first f oor of th e mu ti-storey or high-rise bui dings, the fo owing requirements sh be s tisfi ed simu t neous y. 1. The r ted ev por ting c p city of e ch boi er sh not exceed 10t/h nd the r ted ste m pressure sh not exceed 1.6MP . 2. E ch boi er sh be provided with re i b e over-pressure inter ock protect ion nd ow w ter eve inter ock protection. 3. M inten nce nd test sh be m de to the s fety ccessories nd inter ock pr otection devices of e ch boi er periodic y, in order to ensure their sensitivity nd re i bi it y. 4. The ppropri te exp osion proof me sures sh be t ken for the structures in the boi er house. 5. Boi er oper tors who m ke the oper tions independent y sh ho d boi er op er tion permit with n ppropri te c ss nd h ve experience of more th n 5 ye rs in oper ting s me c tegory of boi er continuous y nd never h ve h d ny ccident occurred. 6. There sh be s fety ev cu tion p ss ge. C use 185 Boi er house shou d not set up in the b sement, between f oor or t the top of the high-rise or mu ti-storey bui dings. However, in c se they h ve to be set up in such p ces due to the imit tion of conditions, not on y the requirement set in C use 184 of this Cod e, but so the fo owing requirements sh be comp ies with. Moreover, the consent sh be gi ven by the s fety contro nd supervision regu tory uthorities t municip or prefecture eve or bove this eve . 1. The r ted ev por ting c p city sh not exceed 4t/h nd r ted ste m pressure sh not exceed 1.6MP . 2. Boi ers sh be fired with oi nd g s s fue or he ted e ectric y. 3. The connection of fue supp y sh be m de with rgon rc b ck we ding. Besides, when boi er is inst ed in b sement, the dr ft venti tion me sures sh be t ken. C use 186 Boi er house sh not be owed to be djoined with C ss A nd C ss B p nt

rooms or C ss C fire-h z rd p is djoined with

nt rooms where inf mm b e iquid is used. If it

the other p nt bui dings, it sh be p rtitioned with firew . However, the w ste he t boi er is not imited by this c use. C use 187 The fire-resist nce c ss nd requirements of boi er house bui ding sh comp y with the requirements m de in Code for Fire Protection of Bui ding Design nd Code for Fire Protection of High-rise Civi Bui ding Design . There sh be t e st re e se re in the exterior w s or roof of the boi er house, equ to 10% of the covering re of boi er house (such s g ss windows, sky ight, we k w s, etc.). It is not owed the re e se points to be djoined with the rooms nd p ss ges where there is crowd of peop e. C use 188 Boi er house sh comp y with the fo owing requirements: ========================================48 ======================================== 48

1. The equipment rr ngement in boi er house sh be convenient for oper tion, p ssing through nd m inten nce. 2. Sufficient ight nd good venti tion sh be provided s we s the necess ry temper ture owering nd nti-freeze me sures. 3. The ground surf ce sh be f t without steps nd protected from w ter ccum u tion. 4. There sh be cert in dist nce from some members of o d-be ring girders nd co umns, etc. of boi er house to the boi er or the other me sures sh be t ken to preve nt the d m ges c used by high temper ture. C use 189 There re t e st two exits for e ch tier of boi er house, which sh be set up on e ch side respective y. On y one exit c n be provided for the sing e-tier boi er house with tot widt h of front end of boi er (inc uding the p ss ge between boi ers) not exceeding 12m nd n re not exceeding 200m 2 . The door of boi er house to the outdoors sh be opened outw rd nd sh not b e ocked up or tched during the oper tion of boi er. The entr nce, exit nd p ss ge of boi er house sh be unimpeded. C use 190 There sh be sufficient ighting t the oper tion positions within boi er hou se nd t oc tions of w ter eve g uges, pressure g uges, temper ture meters, f o

Ch pter 9 Oper tion M n gement C use 192 The personne in ch rge of boi er house sh get f mi i r with the s fety know edge of boi er nd c rry out the oper tions ccording to the regu tions n d ru es. C use 193 During boi er oper tions, oper tors sh imp ement systems re ted to the s fety oper tions of boi er, nd m int in we the shift oper tion records nd s hift re ief records. Communic tion devices or sign ing devices sh be inst ed in oper tion room of boi er nd t the m jor ste m-user points. C use 194 The boi er sh be shut down immedi te y s soon s one of the fo owing c ses occurs during the oper tion of boi er: 1. W ter eve of boi er is ower th n the min. visib e edge of the w ter eve g uge. 2. When the feed w ter f ow is incre sing continuous y nd other me sures re t ken, but the w ter eve sti keeps dropping down. 3. W ter eve of boi er surp sses the m x. visib e w ter eve (fu eve ), w ter eve f i s to be visib e fter dr ining w ter. 4. A the feed w ter pumps re in f i ure or there is f i ure in the feed w t er system, nd ========================================49 ======================================== 49 w ter c n not be fed into boi er. 5. A the w ter eve g uges or s fety v ves re inv id ted. 6. A the pressure g uges set up in the ste m sp ces re inv id ted. 7. Boi er e ements get d m ged nd end nger the s fety of oper tion personne . 8. Combustion equipment is d m ged, furn ce w s re co psed or the boi er fr me is burnt red, etc., which wi end nger serious y the s fety oper tion of boi ers. 9. Other bnorm conditions th n wi end nger the s fety oper tion of boi ers. C use 195 In c se of e king of pressure e ements, serious coking of furn ce, over-temper ture of he ted surf ce met nd it is not possib e to restore them to the norm conditions, nd ny other import nt prob ems re found during the oper tion of b oi er, the boi er sh be shut down. C use 196 The

wmeters, etc. Boi er house sh be provided with st nd-by ighting equipment or too s. C use 191 Boi er inst ed in the open sh be provided with oper tion room, nd re i b e me sures s we , to protect it from r inf , wind, freeze nd corrosion.

fo owing requirements sh be s tisfied when the m inten nce personne enter in the boi er to do work. 1. Before entering the inside of boi er c sing (boi er she ) for work, the met b ocking p te which c n indic te the b ocking position nd h s sufficient strength sh be used to iso te re i b y the pipe ines of ste m, feed w ter, b ow-down, etc., connected to t he other boi ers under oper tion, nd the m nho es in boi er c sing (boi er she ) nd the h ndho es in he ders sh be opened to ow ir to h ve convection of cert in time. 2. Before entering f ue or furn ce ch mber for work, venti tion sh be c rrie d out, nd the f ue g tes connected to the m in f ue pipe or the f ue pipes of ny other boi er under oper tion sh be shut off tight y to prevent toxicity, fire nd exp osion. 3. For the boi ers using oi or g s s their fue , the oi nd g s supp y sh be re i b y b ocked. 4. When working in boi er c sing (boi er she ) nd d mp f ue pipe using mp fo r ighting, the ighting vo t ge sh not be over 24V. Whi e working in re tive y dry f ue, the ppropri te s fety me sures sh be t ken nd ighting vo t ge not higher th n 36V sh be used. It is prohibited to use open f me for ighting. 5. When working in boi er c sing (boi er she ), there sh be some body outsid e the boi er for supervision nd ttend nce. C use 197

The corrosion protection me sures sh be t ken for st nd-by or our-of-service boi ers. C use 198 In order to pro ong the service ife of boi er, economize fue , ensure the qu ity of ste m nd prevent d m ges of boi er p rts or ccidents incurred due to sc e deposit, w ter tr sh nd corrosion, the units using boi ers sh do good job in w ter qu ity m n gement ccording to the stipu tions m de in M n gement Regu tions on Boi er W ter Tre tment . C use 199 The w ter qu ity of boi ers with r ted ste m pressure 2.5MP sh comp y with the specific tions m de in GB1576 W ter Qu ity of Low Pressure Boi er . The w ter qu ity of boi ers with r ted ste m pressure 3.8MP sh comp y with the specific tions m de in GB12145 St nd rd for Ste m nd W ter Qu ity of Therm Power Gener tion Units nd ========================================50 ======================================== 50

 Ste m-driven Equipment . They sh not be put into oper tion without re i b e me sures for w ter tre tment. C use 200 B ow-down system sh be imp emented by the units using boi ers. Periodic b ow-down sh be c rried out t ow o d whi e w ter eve is strict y monit ored. Ch pter 10 Testing nd Inspection C use 201 The testing nd inspection of in-service boi ers sh consist of extern inspection, intern inspection nd hydr u ic test. The units using boi ers sh m ke rr ngement for periodic test nd inspection, nd the s fety supervision institutes t eve s sh supervise nd inspect the imp ement tion of inspection p ns nd the qu ity of testing n d inspection. The units nd inspection personne eng ged in the periodic test nd inspection for boi ers sh be qu ified ppropri te y ccording to Ru es for Confirming Qu ific tion of Boi er nd Pressure Vesse Test nd Inspection Institutions of L bor Dep rtments . C use 202 Gener y, extern inspection sh be m de once every ye r to the in-service

boi ers, nd intern inspection sh be m de once every two ye rs, nd hydr u ic test sh be performed once every six ye rs. When the intern inspection nd extern inspection re c rried out in s me y e r, the intern inspection sh be m de first nd then the extern inspection. The interv s for the intern inspection nd hydr u ic test of boi ers for gene r tion units of the e ectric power systems c n be djusted ppropri te y b sed on the overh u perio d of the power p nt. Fore those boi ers th t the intern inspection c n not m de to, hydr u ic test sh be performed once every three ye rs. C use 203 In ddition to the periodic inspections, the intern inspection sh so b e performed when there is one of the fo owing c ses of boi ers. 1. Before putting the boi er which is removed nd reinst ed, into oper tion; 2. Boi er h s been t ken out of service for more th n one ye r nd needs to be r estored to oper tion; 3. After the m jor pressure component is subjected to n import nt rep ir or reb ui ding nd h s been put into oper tion for one ye r; 4. When there is doubt for the re i bi ity of equipment s fety b sed on the re su ts of st intern inspection nd the boi er oper tion conditions. C use 204 Key points for the intern inspection re s fo ows: 1. P rts with defects found during st inspection;

2. Check the intern nd extern surf ces of pressure components of boi er, n d especi y check whether there is ny cr ck, g p nd corrosion t the openings, we ds, turn -up rims. 3. Check whether there is ny erosion nd corrosion on the w of tubes, especi y, on the ========================================51 ======================================== 51

w of tubes oc ted in oc tions where the f ue g s is t re tive y high ve o city nd the b owing re of soot b owers. 4. Whether there is ny cr ck, bre k nd corrosion on the br ces nd the br ced e ements of boi er. 5. Whether exp nds re tight nd whether there is ny circumferenti cr ck nd c ustic britt eness of exp nded p rts t exp nds. 6. Whether there is ny recess, bend, swe nd overhe ting. 7. Whether there is ny corrosion t the cont ct point between boi er c sing (bo i er she ) nd refr ctory iners. 8. Whether there is overhe ting of pressure components or boi er fr mes due to t he d m ges of brick w or firew . 9. Whether there is ny sc e deposit nd tr sh on the w ter side of pressure co mponents. 10. Whether there is ny corrosion nd cr ck t the connections of w ter in et p ipe nd b ow-down pipe to the boi er c sing (boi er she ) nd whether the connection of b ow-down v ves nd b ow-down pipes re so id. C use 205 The key points for the extern inspection re s fo ows: 1. Whether the v rious kinds of systems for boi er house re comp ete y est b is hed nd the boi er oper tors nd testing personne of w ter qu ity re qu ified with certi fic tes of posts. 2. Whether the s fety p ss ges round boi ers re unimpeded nd there is ny def orm tion nd e k ge in visib e pressure components, pipes nd v ves within the boi er house . 3. Whether the s fety ccessories re sensitive nd re i b e nd the p ss ges of w ter eve g uges, w ter co umns, s fety v ves, pressure g uges, etc., connected to the bo i er body re b ocked. 4. Whether the ctions of high w ter eve nd ow w ter eve rm devices nd ow w ter eve inter ock protection devices re sensitive nd re i b e. 5. The ctions of over-pressure rm nd over-pressure inter ock protection dev ices re sensitive nd re i b e. 6. The ignition sequence nd extinguishing protection devices re sensitive nd re i b e. 7. Whether the oper tion of uxi i ry equipment of boi er is norm .

8. Whether the oper tion of w ter tre tment equipment of boi er is norm nd th e indexes of w ter qu ity n ysis comp y with the requirements set in the st nd rds. C use 206 Gener y, hydr u ic test sh be m de once every six ye rs for the boi er, besides, it is so necess ry to c rry out hydr u ic test fter the import nt re p irs or modific tions re m de to the pressure components of boi ers. Intern inspection of boi ers sh be m de prior to the hydr u ic test nd the strength c cu tion sh be m de if necess ry. It is not owed to determine the oper ting pressure of boi er by the me ns of hydr u ic test. C use 207 Pressure of hydr u ic test sh comp y with the specific tions s shown in T b e 10-1. ========================================52 52 T b e 10-1 Hydr u ic Test Pressure Description Oper ting pressure of boi er c sing (boi er she ) p Testing pressure Boi er body < 0.8 MP 1.5 p , but sh not be <0.2MP

========================================

Boi er body 0.8 ~ 1.6 MP p

+ 0.4 MP Boi er body >1.6Mp 1.25 p Superhe ter Any pressure S me s the testing pressure of boi er body Dissoci b e economizer Any pressure 1.25 p + 0.5MP The testing pressure for rehe ters is 1.5 p 1 ( p 1 is the oper ting pressure of rehe ter). The hydr u ic test pressure of the body of once-through boi er is 1.25 times the pre ssure t the out et of f uid nd sh not be sm er th n 1.1 times the pressure t the in et of econo mizer. During hydr u ic test, the di phr gm pressure sh not exceed 90% of the yie d point of component m teri s t the testing temper ture. C use 208 During hydr u ic test of boi er, w ter pressure sh be incre sed or decre se d gr du y. When the w ter pressure is incre sed to the oper ting pressure, incre se of pressure sh be p used for checking whether there is w ter e king or bnorm phenomenon, nd then the pressure is incre sed to the testing pressure. The boi er sh be m int ined t the testing pressure for 20 minutes, nd then the testing pressure sh be decre sed to the oper tin g pressure for m king inspections. During inspections the pressure sh be m int ined const nt. The hydr u ic test sh be performed when the surrounding ir temper ture is b ove 5 o C, nd nti-freeze me sures sh be t ken when the temper ture is be ow 5 o C. W ter used for hydr u ic test sh be m int ined t temper ture bove the dew point so s to prevent t he dewf gener ted on the boi er surf ce. However, the temper ture shou d not be too high in order to c use v poriz tion nd stress due to too high differenti temper ture, nd gener y it shou d be 20 ~ 70 o C. W ter temper ture of hydr u ic test for the pressure components of oy stee s h be higher th n the tr nsform tion temper ture of britt eness of the used stee type. During the hydr u ic test of the pressure components m de of ustenitic stee , t he m ss concentr tion of ch orions in w ter sh be contro ed so th t it wi not exce ed 25mg/ . In c se this requirement f i s to be s tisfied, the w ter ogging sh be removed comp ete y

fter hydr u ic test. C use 209 When boi ers is under hydr u ic test, it sh be considered s ccept b e s the fo owing conditions re in conformity with: 1. There is no w ter be d nd spr y on the met w s nd we ds of pressure com ponents. 2. After the pressure is decre sed to the oper ting pressure, there is no drip f rom exp nds. 3. After hydr u ic test, no residu deform tion is found. C use 210 The Report on Boi er Testing nd Inspection sh be put in to the technic f i es of boi er. ========================================53 ======================================== 53 Ch pter 11 Supp ement ry Provisions

C use 211 When there occurs boi er ccident, the unit h ving the ccident sh report nd h nd e the ccident ccording to the Methods for Reporting Boi er nd Pressure Vesse Accident . C use 212 This Code sh be put into effect from J nu ry 1, 1997. Me nwhi e, the Code for Supervision of Ste m Boi er S fety Techniques (L o-Ren-Guo No. [1987] 4) issued on Febru ry 17, 1987 by the former L bor Ministry sh be inv id ted. ========================================54 54 Appendix I Qu ific tion of We ding Procedure C use 1 The qu ific tion of we ding procedure is to ev u te whether the we ding unit is qu ified to we d we ding joint which comp ies to the requirements of the prod uct specific tions set in this Code nd to verify whether the we ding procedure instructions prep r ed by the we ding unit re suit b e. C use 2 Qu ific tion of we ding procedure is procedure verific tion test m de befo re the st rt of production b sed on the we d bi ity test, which sh be m de fter the prep r tion of ========================================

we ding procedure instructions is comp eted nd before the we ding st rts for pr oducts. As for the we ding procedure ev u tion, the ski ed we ders from the we ding un it (it is not owed to h ve the we ders from the extern unit) re rr nged to work out the we ding procedure specimen ccording to the stipu tions m de in the we ding procedure instruction s, nd then visu inspection, non-destructive ex min tion, mech nics property test, mett ogr phic test, etc., sh be m de to the procedure specimen, me nwhi e, the ctu process p r meters in we d ing nd resu ts of inspections of e ch item sh be recorded in the Report on We ding Procedure Qu ific tion. The specified technic responsib e person of the we ding unit sh m ke ex min tio n nd give pprov to this report. C use 3 The we ding unit sh est b ish we ding procedure instructions for e ch kind of we ding joints on products (to be c ssified ccording to the types of joints, p rent met , we ding m teri , we ding process nd procedure, etc.). In c se ny condition or p r met er is ch nged, the we ding procedure instructions sh be prep red sep r te y. C use 4 The fo owing contents sh be inc uded in the we ding procedure instructions:

1. The number nd d te of we ding procedure instructions; 2. Number of the corresponding Report on We ding Procedure Qu ific tion; 3. We ding process nd utom tion eve ; 4. Types of joints, with or without b ckings nd br nd of b cking m teri s; 5. Schem tics re used to show the beve s, g ps, we ding p ss distribution nd s equence; 6. Stee gr de nd c ssific tion no. of p rent met s; 7. The thickness r nge of p rent met nd deposited met nd the di meter r ng e of tubes; 8. The br nd nd di meter of e ectrodes nd we ding wires, the br nd nd type of we ding f uxes, the type, br nd nd di meter of tungsten e ectrode, the design tion nd composition of protection g ses; 9. We ding position nd the we ding direction for vertic we ding; 10. Minimum temper ture of pre-he ting, pre-he ting modes, m ximum inter-p ss te mper ture, temper ture r nge for post-we ding he t tre tment nd the r nge of temper ture h o ding time. 11. We ding process of e ch p ss of we ding joints, the br nd nd di meter of e ectrodes, we ding wires nd tungsten e ectrodes, the type, po rity nd r ted v ue r nge of we ding current, ========================================55 ======================================== 55 the vo t ge r nge of rc, we ding r te r nge, wire de ivery speed r nge, the dis t nce from the

conductivity nozz e to the workpiece, the size of nozz es nd the ng e of nozz e to the workpiece, the composition nd f ow of protection g s, g s shie d nd t i g s protection, the we ding pp ic tion techniques (with/without swinging, swinging method, root c e ring me thod, with/without h mmering, etc.); 12. We ding equipment nd instrument; 13. Sign ture nd d te of the persons who m de the prep r tions, review nd ppr ov of the instructions. C use 5 The fo owing contents sh be inc uded in the Report on We ding Procedure Qu ific tion: 1. Number nd d te of Report on We ding Procedure Qu ific tion; 2. Number of corresponding We ding Procedure Instructions; 3. We ding method; 4. Types of joints; 5. Stee Gr de, C ssific tion No., thickness, di meter nd Qu ity Certific te No. of p rent met of the procedure specimen nd the number of verific tion report.; 6. Br nd, type, di meter nd Qu ity Certific te No. of we ding m teri s; 7. We ding positions; 8. Pre-he ting temper ture nd inter-p ss temper ture; 9. Post-we ding he t tre tment temper ture nd temper ture ho ding time; 10 .The ctu we ding p r meters nd we ding techniques for e ch p ss of we d. 11. Resu ts of visu inspection nd non-destructive ex min tion of we ded joint s; 12. Number of the reports on tensi e test, bending test, imp ct resist nce test nd mett ogr phic test, the st nd rd of test methods nd the test resu ts, nd the m cro inspection nd test resu ts of the profi es of fi et we ds; 13. Conc usion of the qu ific tion of we ding procedure; 14. N me of we der nd stee st mp number; 15. Sign ture nd d te m de by the testing nd inspection personne nd persons m king review nd pprov of the reports. C use 6 E ch copy of we ding procedure instructions sh be provided with one copy or more th n one cope of the Reports on We ding Procedure Qu ific tion. One copy o f Report on We ding Procedure Qu ific tion c n be re ted to one copy or more th n one copy of We ding Procedure Instructions. Either the We ding Procedure Instructions which h ve subjected to the verific ti ons, c n be used direct y in the production, or b sed on the We ding Procedure Instructions nd the Report on We ding Procedure Qu ific tion to est b ish the we ding procedure c rd for usin g in production. C use 7 The procedure specimens for butt we d re c ssified s p te specimen nd tube specimen. The procedure specimens for fi et we ds re c ssified s p te-top te specimen nd tube-to-p te specimen, see Fig. 1-1. The qu ntity nd size of procedure specime n sh s tisfy the ========================================56 ========================================

 56 requirements for cutting v rious types of specimens. C use 8 In c se the we ding conditions nd p r meters th t ffect properties re the s me, the we ding procedure qu ific tion of butt we ds for p tes is pp ic b e to th e butt we ds for piping whi e the we ding procedure qu ific tion of butt we ds for piping is pp ic b e to the butt we ds for piping. C use 9 Except for the we ding positions which h ve speci requirements for the we ding

p r meters, the we ding procedure qu ific tion for ny we ding position is pp ic b e to the other we ding positions. Gener y, the downh nd we ding position sh be t ken for t he p te specimen nd the horizont rot tion or horizont fixing position sh be t ken for pip e specimen. The bo t type we ding position sh be t ken for p te-to-p te specimen, nd the tube v ertic fixing position sh be t ken for the tube-to- p te specimen. C use 10 We ding procedure qu ific tions re c ssified ccording to the import nt f c tors th t ffect properties nd the effective r nge of c ssific tions is s fo ows:

1. We ding processes (1). E ch of the g s we ding, m nu rc we ding, submerged rc we ding, g s tun gstun rc we ding, met inerti g s we ding, p sm rc we ding, e ectros g we ding nd other we ding process f s into type, nd e ch of v rious combin tion of these processes sh consist of type.

- 066 ] 1.

P te specimen 2. Tube specimen 3. Tube-to-p te specimen 4. Tube-to-tube specimen

Fig. I-1 We ding Procedure Specimens (2). A we d of product c n be m de with we ding process or procedure nd c n so be combin tion of sever we ding process or procedures. For the we d m de with c ombin tion of ========================================57 ======================================== 57 sever we ding processes or procedures, qu ific tion c n be m de to e ch we di ng process or procedure respective y ccording to the thickness r nge of deposited met or th e thickness r nge of p rent met . It is so possib e to m ke qu ific tion with the combin tion o f we ding processes nd procedures. After the qu ific tion m de to the combined we ding processes o r procedures, one nd sever types of we ding processes or procedures c n be omitted for the we d s of products, however, the thickness of deposited met of e ch we ding process or procedure r em ined for qu ific tion sh be within the respective y qu ified effective r nge.

2. Stee gr de of p rent met (1). For the c ssific tions of stee gr de, refer to T b e I - 1 . T b e I-1 P rent Met Stee Gr de C ssific tion C ssific tion No. Type Stee Gr de No. (St nd rd Numbering) 1 Non- oy stee Q235-A, Q235-B, Q235-C, Q235-D (GB3274) 10 [GB8163, GB3087, YB(T)33], 15 [GB699,GB710, GB711], 20[GB699, GB710,GB711, GB8163, GB3087, YB(T)33] 20G [GB5310, YB(T)32], 20R [GB6654, YB(T)40], 20g [GB713, YB(T)41], 25 (GB699), etc. 22g [GB713, YB(T)41], 25 (GB699), etc. 2 A oy stee (specified yie d point v ue 392MP ) 12Mng [GB713, YB(T)41], 16Mng [GB713, YB(T)41],

16Mng [GB6654, YB(T)40], etc. 3 He t-resist nt oy stee 12CrMo [GB3077, YB(T)32], 12CrMoG (GB5310) 15CrMo [GB3077, YB(T)32], 15CrMoG (GB5310) 12Cr1MoV [GB3077, YB(T)32], 12Cr1MoVG (GB5310), etc. 4 He t-resist nt oy stee 12Cr2MoWVTiB [GB5310, YB(T)32], 12Cr3MoVSiTiB [GB5310, YB(T)32], etc. (2). As for the stee gr de th t is not isted in the N tion St nd rds nd the Industri St nd rds, if the chemic compositions, mech nics properties nd we ding perfor m nces re simi r with some stee gr de in the T b e, it c n be inc uded in the ppropri t e type, nd if they re not, it c n be c ssified ddition y. For the stee gr de th t is not isted i n the N tion St nd rds nd the Industri St nd rds, the we ding procedure qu ific tion sh be m de respective y. (3). The we ding procedure qu ific tion for the foreign stee m teri s sh b e m de on the b sis of e ch stee gr de. However, when the fo owing conditions re s tisfied t the s me time, the we ding procedure qu ific tion c n be omitted. ========================================58 ======================================== 58

(A). The stee of this gr de h s been subjected to the we d bi ity test (we ding cr ck testing, mech nics property test of we ding joints, nd the corrosion resisting test if necess ry); (B). The stee of this gr de is equiv ent with cert in stee gr de isted in T b e I -1 in terms of chemic compositions nd mech nics properties whi e the cert in stee gr de h s re dy been subjected to the we ding procedure qu ific tion. (4). The different stee we ds consisting of two types of p rent met s sh st i be qu ified for the we ding procedures even if the we ding procedure qu ific tion h s been m de respective y for both different met s. However, the we ding procedure qu ific tion with C ssif ic tion No. 2 for the s me type of p rent met s is pp ic b e to the we ded joints th t is m de u p of p rent met with this c ssific tion No nd the p rent met with C ssific tion No. 1. 3. Thickness of p rent met nd thickness of deposited met (1). For the effective r nge of qu ified p rent met thickness th t correspond s to the thickness t (herein fter to be referred to s the s me) of the butt we d procedure specimen th t h s re dy

been subjected to the we ding procedure qu ific tion, refer to T b e I-2. T b e I-2 Effective R nge for Qu ific tion of P rent Met (in mm) Thickness of p rent met of procedure specimen ( t ) Effective r nge of thickness for qu ific tion of p rent met

t < 8 1.5 2 t nd > 12 t t 1.5 t

8 0.75

(herein fter to be referred to s the s me) of e ch we ding process or e ch we d ing procedure th t h s re dy been subjected to the we ding procedure qu ific tion , refer to T b e I-3.

t w < 8 2 t w , nd 12 t w

T b e I 3 Effective R nge of Thickness for Qu ific tion of Deposited Met in mm) Deposited met thickness of procedure specimen t w Effective r nge of thickness for qu ific tion of deposited met Upper imit 1.5

(2). For the effective r nge of thickness for qu ific tion of deposited met orresponding to the thickness t w

Lower imit v ue Upper 1.5

imit v ue

 8 1.5 t w (3). When g s-we ding procedure is used, the effective r nge of thickness for qu ific tion of p rent met is the thickness of the procedure specimen. (4). When the mu ti-p ss we ding of m nu rc we ding, submerged re we ding, g s tungstun rc we ding nd met inerti g s we ding (except for short circuit tr nsition) re used, the upper imit sh be 1.3 t (or 1.3 t w ) in c se the upper imit of the effective r nge of thickness for qu ific tion of deposited met exceeds 200mm. ========================================59 ======================================== 59 (5). As for sing e-p ss we ding or mu ti-p ss we ding, if the thickness of ny p ss of we ding is gre ter th n 13mm, the upper imit of effective r nge of thickness for qu ific tion of p rent met is 1.1 t . (6). As for the met inerti g s we ding with short circuit tr nsition, the upp er imit of effective r nge of thickness for qu ific tion of p rent met is 1.1 t . (7). If the combined we ding processes or combined we ding procedures re used f or the we ding of procedure specimen, it is not owed to determine the upper imit of the effective r nge of thickness of p rent met for qu ific tion of procedure specimen by simp y s um up the upper imit of effective r nge of deposited met thickness for qu ific tion of e ch we ding process or we ding procedure. (8). The effective r nge of p rent met thickness for the qu ific tion of the procedure specimens with s me thickness sh so be v id for the we ds of p rent met s with different thickness, but it is v id on y the thickness of p rent met on both sides of t he we d does not exceed this effective r nge. (9). In c se the procedure specimen h s been subjected to the post-we ding he t tre tment t temper ture exceeding the critic temper ture, the upper imit of effective r n ge of p rent met thickness for qu ific tion is 1.1 t

 60 Shie ding g s sh be c ssified ccording to the composition of g ses. In c se two or more th n two types of g ses re mixed, it sh be c ssified ccording to the compo sitions nd proportions. The b ck shie ding g ses sh be divided s to be pp ied or not to b e pp ied. 8. B ckings B ckings sh be divided into two types, i.e. used nd not used. In c se it is used , it sh be c ssified ccording to the stee gr de (see T b e I 1). 9. Prehe ting Prehe ting sh be divided into two c ses, i.e. "imp ement tion" nd "no imp em ent tion". In c se prehe ting is imp emented, the c ssific tion for prehe ting sh be m de ccording to the ower imits of prehe ting temper tures.

except for the g s we ding. (10). The effective r nge of p rent met thickness nd deposited met thicknes s for the qu ific tion of fi et we d for the procedure specimen sh be s s me s th t shown in T b e I-2 nd T b e I-3, nd the thickness of specimen sh be c cu ted ccording to th e fo owing requirements. (A). The thickness of p te-to-p te fi et we d specimen sh be the thickness of webs s shown in Fig. I-4. (B). The thickness of tube-to-p te fi et we d specimen sh be the thickness of the tube w . 4. E ectrodes E ectrodes sh be c ssified ccording to the types of e ectrodes. The type nu mbers with the digits being the s me except the third digit sh be considered s the s me type, nd it is not owed to be substituted e ch other between different types. 5. We ding wires We ding wires sh be c ssified ccording the types. E ch type sh be c te gory, nd sh be c ssified ccording to the sh pes such s the wire, be t, fo ding, etc. Afte r the we ding process qu ific tion of we ding wires with high nd extr in their type n mes re m de, the we ding wires of the s me chemic compositions except for su phur nd phosphorous, with high nd extr indic ted in their type n mes, c n be exempted from m king the qu ific tion s. 6. F uxes sh be c ssified ccording to types, nd e ch type sh be one c t egory. It is not owed to be substituted e ch other. When the mixed f uxes re used, they sh be c ssified ccording to the mix proportions. 7. Shie ding g s ========================================60 ========================================

The effective r nge of prehe ting temper ture for qu ific tion is th t the decr e se in qu ified prehe ting temper ture is not over 50oC. 10. Post-we ding he t tre tment Post-we ding he t tre tment sh be divided into two c ses, i.e. "imp ement tio n" nd "no imp ement tion". In c se the post-we ding he t tre tment is imp emented, it sh be c ssified ccording to the he t tre tment types such s norm izing, norm izing + temperi ng, stress re ief, etc. The he t tre tment of stress re ief sh be c ssified b sed on the combin tion of the ower imits of he t tre tment temper ture with the temper ture-ho ding time of unit thickness. C use 11 Qu ific tion items for the but we ding procedure specimen re the visu inspection, non-destructive ex min tion, mech nics property test nd met ogr p hic test. For the testing items nd number of specimens of mech nics property test, see T b e I 4. When it is required to m ke met ogr phic test for the product we ds, specimen for met ogr phic test sh be cut from procedure specimen. C use 12 For the dimensions of tensi e test specimens nd bend test specimens, see Appendix II. Dimensions of the imp ct test specimens sh comp y with the stipu tions of V-notch m de in N tion St nd rd - GB/T229 Met Ch rpy-type Test . T b e I - 4 Items nd Number of Specimens for Mech nics Property Test Thickness of procedure specimen t (mm) Items nd number of specimens (piece) Tensi e F ce-bend B ck-ben d Side-bend Imp ct We ding joint Fu we ding joint 1.5 t < 10 2 / 2 2 / / 10

t < 20 2 / 2 2 Note Note t 20 2 Note / / 4 Note Notes: When the outside di meter of tube is 76mm, fu -size procedure specimen c n be used s specimen for tensi e test to substitute two tensi e test specimens of the sp it tube. ========================================61 ======================================== 61 When the p rent met thickness of ongitudin joint of boi er c sing (boi er she ) is > 20mm nd 70mm, tensi e test specimen of fu -we d met sh be t ken. When the p ren t met thickness is > 70mm, two tensi e test specimens sh be t ken. It is possib e to substitute two f ce-bend specimens nd two b ck-bend specimen s with four tr nsverse side-bend specimens. As for joints of different types of stee s, it is possib e to substitute the tr nsverse f ce-bend nd b ck-bend specimens with the ongitudin f ce-bend nd b ck-bend specimens.

When qu ifying the we ds m de by the combined we ding processes or we ding pro cedures, the tensi e f ce of bend specimen sh inc ude the deposited met s of e ch typ e of we ding process nd e ch we ding procedure. When the imp ct-toughness test is required for the product we ds, 3 specimens s h be t ken by cutting respective y from the we ds nd he t inf uence zone of the proc edure specimens. The notches sh be cut out on the side f ce of we ding joints on the specimen.

In c se of the joints of different types of stee s, 3 specimens sh be t ken by cutting from the we ds nd he t inf uence zone respective y on e ch side of the procedure specimens for performing the imp ct-toughness test. C use 13 For the cutting oc tions of specimens for the p te procedure specimen of butt we d, see Fig. I-2. For the cutting oc tions of specimens for the tube procedur e specimen of butt we d, see Fig. I-3. 1. Above 50 2. Disc rded 3. Tensi e test specimen 4. B ck-bend specimen 5. F ce-bend specimen 6.

Sp re 8. B ck-bend specimen 9. F ce-bend specimen 10. Tensi e test specimen 11. Imp ct test specimen 12. Disc rded 13. Disc rded 14. Side-bend specimen 15. Tensi e test specimen 16.

Met 7.

ogr phic test specimen

Side-bend specimen 17.

Sp re 19. Side-bend specimen 20. Tensi e test specimen 21. Side-bend specimen 22. Imp ct test specimen 23. Disc rded 24. ( )When the side-bend specimen is not t ken 25. (b) When the side-bend specimen is t ken 26. Disc rded 27.

Tensi e specimen 29.

Tensi e test specimen 33.

Imp ct test specimen 35. Disc rded 36.

Longitudin 34.

Longitudin 32.

Met 31.

ogr phic test specimen f ce-bend specimen

Longitudin 30.

Longitudin 28.

f ce-bend specimen

b ck-bend specimen

b ck-bend specimen

Met 18.

ogr phic test specimen

Above 30 37. (c) When the ongitudin bend specimen is t ken ========================================62 ======================================== 62

Fig. I-2 Cutting oc tions of specimens from butt we d p te specimen ========================================63 ======================================== 63 [ 073 ] 1.

(b) When no imp ct test specimen is required 3. (c) When the imp ct test is required 1 Tensi e test specimen; 2 F ce-bend specimen; 3 F ce-bend specimen 4 Side-bend specimen; 5 Imp ct test specimen; 6

5. (12)

These

re o'c ock m rks, nd st nd for the positioning m rks for the we ding t horizont fixing or s nting y fixing positions.

Met

ogr phic test specimen;

( ) When the tensi e test specimen is 2.

comp ete tube

Fig. I-3 Cutting oc tions of specimens from butt we d tube specimen ========================================64 ======================================== 64 C use 14 The testing method nd ccept b e st nd rd for e ch qu ific tion item of the b ut we d procedure specimens sh be s s me s for the product we ds, nd sh co mp y with the re ev nt stipu tions m de in Ch pter 5 of this Code. E ch tensi e test specimen nd bend specimen sh meet the ccept b e st nd rd, nd no rithmetic ver ge v ue sh be t k en. C use 15 In c se the combined we ding specimen p us butt we ding specimen (the beve type nd dimension of the tter re not defined) re used for the qu ific tion of the fi et we d joint which is required to be we ded with comp ete penetr tion, the testing items fo r the qu ific tion of we ding procedure sh inc ude mech nics property ( it is possib e to use eithe r the butt we ding specimen for testing or the we ding process qu ific tion for the butt we ding, the import nt f ctors of which re s s me s th t for the fi et we ding, for the qu ific tion), the visu inspection nd section inspection of fi et we ding procedure specimen. Five sections sh b e t ken from p te-to-p te specimen, see Fig. I-4. Four sections sh be t ken from tube-to -p te specimen, see Fig. I-5. In c se the butt we ding specimen, the beve type nd dimensions of w hich re s s me s the we d joints, is used for m king qu ific tion, the testing nd inspection it ems of the we ding procedure qu ific tion sh be the visu inspection, non-destructive ex min t ion nd mech nics property test. C use 16 The testing method nd ccept b e st nd rd for the visu inspection of the fi et we ding procedure specimen sh be s s me s for the product we ds, nd sh comp y with the re ev nt stipu tions m de in Ch pter 5 of this Code. It is not owed to h ve defects such s cr ck, in dequ te me t, incomp ete penetr tion, etc., t the roots of e ch we d on e ch section inspection specimen. C use 17 The qu ific tion resu ts of different type stee we ding procedure specimens s h s tisfy the requirements of product design. C use 18 If necess ry, the chemic composition n ysis of deposited met sh be m d e to the we ding procedure specimen, nd the h rdness distribution sh be determ ined for the we ded

joints. C use 19 When the types of import nt f ctors of product we ds re different from th t of the qu ified we ding procedure specimens (the types sh be b sed on the stipu ti ons of C use 10) or the ch nges in the import nt f ctors of product we ds re beyond the effective imits specified in C use 10, the we ding procedure qu ific tion sh be re-m de. C use 20 As for the product we ds th t re required to m ke the imp ct-toughness test, if there is one of the fo owing c ses, the we ding procedure qu ific tion sh b e m de g in. ========================================65 ======================================== 65

[ 075 ] 1. Web 2.

Wing p te 3.

Inspection f ce of m crospecimen

1 Disc rded p rt 2

Height of we d eg is not sm 4.

er th n the thickness v ue of web.

M crospecimen (Equ y divided for cutting) Fig. I-4 Schem tic of M crospecimen Cut from P te-to-p te Specimen 1. The we ding procedure specimen using k i e ectrodes h ve been qu ified wh i e it is ch nged to use cid e ectrodes. 2. The we ding position which h s been qu ified is ch nged to the upw rd vertic we ding position. 3. M x. inter-p ss temper ture is more th n 50 o C higher th n the qu ified inter-p ss temper ture. 4. Type nd po rity of current is ch nged. 5. The ine energy of we ding exceeds the qu ified r nge. 6. In c se sw ying we ding is used, the sw ying mp itude, frequency nd the tim e for st ying t both ends re ch nged. ========================================66 ======================================== 66

[ 076 ] 1.

- Inspection f ce of m crospecimen 3.

- Inspection f ce of m crospecimen

Fig. I-5 Schem tic of M crospecimen Cut from Tube-to-p te Specimen 7. Mu ti-p ss we ding on e ch side is ch nged to sing e-p ss we ding on e ch sid e. 8. Sing e wire we ding is ch nged to mu ti-wire we ding or mu ti-wire we ding is

- Height of we d eg is not sm 4.

er th n the thickness v ue of tube w

- Height of we d eg is not sm 2.

er th n the thickness v ue of tube w

ch nged to sing e wire we ding. As for the product we ds th t re required to m ke imp ct-toughness test, if the ir import nt f ctors re s s me s th t of cert in we ding procedure which h s been qu if ied nd no bove-mentioned c se re occurred, we ding procedure specimen c n be m de ddi tion y b sed on the qu ific tion of the qu ified procedure, to m ke imp ct-toughness test f or supp ement ry qu ific tion. ========================================67 ======================================== 67 Appendix II Specimens for We ding Joint Tensi e Test

nd Bend Test

C use 1 For the dimensions of we ding joint tensi e test specimen, refer to Fig. II-1. When the thickness of p te is gre ter th n 30mm, it is possib e to m ke one or few s pecimens for tensi e test, nd gener y, the thickness of e ch specimen sh be 30mm, nd these spe cimens sh consist of the fu thickness of the we ding joints. For the prep r tion of specimens, s ee Fig. II-2.

[ 07 7 ] 1.

Bro dness 25 2. R dius 25 3. Thickness of p te

Fig. II-1 Tensi e Test Specimen of We ding Joint 4.

Thickness of p te 5.

nd we d

Min.

Fig.II-2 S mp ing Loc tion of We ding Joint Tensi e Test Specimen on Thick P t e Irregu rities on the surf ce of p rent met nd we ding joint of tensi e test specimen sh be removed by the mech nic me ns. C use 2 For the dimensions of the tensi e test specimen of fu we d met , refer to Fi g. II-3. Di meter d o sh t ke the m ximum v ue permissib e within the cross section of we d, but it sh not be gre ter th n 20mm. When the thickness of p te is gre ter th n 70mm, refe r to Fig. II-4 for the s mp ing oc tion of tensi e test specimen of fu we d met . ========================================68 ======================================== 68

C use 3 Refer to Fig. II-5 for the s mp ing oc tions of specimens for mech nics proper ty test specimen nd the met ogr phic test. For the horizont y fixed or s ntin g y fixed tubes, their inspection specimens of butt we ding joints sh be m rked with the o'c ock m r ks. The specimens for mechnics property test nd met ogr phic test sh be t ken by cutting fro m the oc tions s shown in Fig. II-5. As for the vertic y fixed tubes, it is possib e for the s mp ing oc tions not to

Fig. II-4 S mp ing Loc tions of We d Met

Thickness of p te

nd we d

on Thick P te

Fig. II-3 Tensi e Test Specimen of Fu

We d Met

be imited by the o'c ock m rks. C use 4 The dimensions of we ding joint tensi e test specimens s mp ed from the sp it

( ) when the tensi e test (b) When the imp ct (c) When the imp ct specimen is comp ete tube test is not required test is required ========================================69 ======================================== 69 1 Ten ile te t pecimen; 2 Face bend pecimen; 3 Back bend pecimen; 4 Impact te t pecimen; 5 Metallographic te t pecimen; The e are o'clock mark and the po itioning mark for welding at horizontally f ixed or lantingly fixed po ition . Fig. II 5 Sampling Location of Specimen on Tube ========================================70 ======================================== 70

tube re s fo ows: 1. When the outside di meter of tube is gre ter th n 76mm, 20mm sh or B , refer to Fig. II-6. 2. When the outside di meter of tube is 76mm, 12mm sh be t ken for B , refer to Fig. II-6.

be t ken f

the thickne of pecimen i < 6mm; B

Full length of pecimen, mm; D

Clau e 5 For the type of face bend and back bend pecimen for the teel plate weld joi nt , refer to Fig. II 7. In thi figure, broadne of pecimen B i 30mm and length of pecimen L D + 2.5 t 1 + 100mm (where: D

Minimum quantity for pecimen preparation for obtaining a parallel he broadne of contraction ection B . Fig. II 6 Ten ile Te t Specimen of Tube Weld Joint

urface at t

The length to be determined ba ed on the te ter, and it hould not be le 100mm; L

Contraction B = (12 0.3)mm or B = (20 0.3)mm; L 1

ection,

to be taken ba ed on the thickne

Max. broadne

on the urface of weld , mm;

of pecimen, and 6mm

hall be taken when

than

diameter of bend axi , mm; t 1 thickne after fabrication of pecimen, mm). When the thickne of plate i 20mm, t 1 i the thickne of plate. When the thickne of plate i greater than 20mm, t 1 i 20mm. When it i allowed by the thickne of plate, the tran ver e face bend and back bend pecimen hall be taken by cutting in a ame thickne direction, refer to Fig. II 8. The portion of weld higher than the urface of p arent metal on the pecimen hall be removed mechanically. The ten ile face of pecimen hall be re gular and the original urface of parent metal at lea t on one ide of the two ide of weld hall be remained. The corner angle of ten ile face of pecimen hall be rectified into the round corn er with a radiu 2mm. ========================================71 71

========================================

1.

(c) Longitudinal face bend pecimen 3. (b) Tran ver e back bend pecimen 4. (d) Longitudinal back bend pecimen

For the type of tran ver e ide bend ample In thi figure, pecimen broadne

Fig. II 7 Face bend and Back bend

(a) Tran ver e face bend 2.

pecimen

pecimen

of weld joint, refer to Fig. II 9.

B i the procedure pecimen thickne t , and in ca e t 38mm, it can be divided into everal pecimen at an equal broadne , and the broadne pecimen hall be 20 ~ 38mm. Specimen length L = D + 105mm (where: D

the diameter of bend axi , mm). The pecimen thickne t 1 = 10mm. The irregularitie on the urface of parent metal and weld of pecimen hall be removed by the mechanical mean . The corner angle of ten ile face of pecimen hall be rectified into the round corner with a radiu 2mm

1.

Fig. II 8 Sampling Location of Bend Te t Specimen on Thick Plate

========================================72 72

========================================

Fig. II 9 Side bend pecimen ========================================73 73

========================================

Broadne

direction of plate pecimen

Thickne 2.

of plate pecimen

for each

the pecimen thickne , mm; D Out ide diameter of tube, mm), and 10mm B 38mm. Specimen length L D + 2.5 t 1 + 100mm (where: D Diameter of bend axi , mm; t 1 the pecimen thickne , mm). When the thickne of tube wall i greater than 20mm, t 1 = 20mm. The portion of weld above the urface of parent metal hall be removed by mechanical mean . For the ten ile face of peci men, the original urface of parent metal at lea t on one ide of the two ide of weld hall be r emained. The corner angle of ten ile face of pecimen hall be rectified into the round corner with a radiu 2mm.

Clau e 6 The edge of the bend te t pecimen of tube welding joint llel, refer to Fig. II 10. Specimen broadne B = t 1 + D /20 (where: t 1

hall be cut in para

Fig. II 10 Sampling by Cutting for Bend Te t Specimen for Butt Welding Joint o f Tube ========================================74 ======================================== 74

(a) When the ide bend pecimen i not taken (b) When the ide bend pecimen i taken

Di carded

Ten ile te t

pecimen Back

(c) When the longitudinal bend

pecimen i taken

 bend

pecimen Face bend

pecimen Metallographic

te t pecimen Spare

Back bend

pecimen Face bend

pecimen Ten ile te t

pecimen Impact te t

pecimen Di carded

Di carded

Side

 bend

pecimen Ten ile te t

pecimen Side bend

pecimen Metallographic

te t pecimen Spare

Side bend

pecimen Ten ile te t

pecimen Side bend

pecimen Impact te t

pecimen Di carded

Di carded

Longitudinal face

bend pecimen Ten ile

pecimen Longitudinal back

bend pecimen Metallographic

te t pecimen Longitudinal face

bend pecimen Ten ile te t

pecimen Longitudinal back

bend pecimen