Power Boiler

Design,
Inspection,
and Repair
ASME Code Simplified

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

McGraw-Hill
New York

Chicago San Francisco Lisbon London Madrid

Mexico City Milan New Delhi San Juan Seoul
Singapore Sydney Toronto

Contents

ice
xvii
>duction
xix

ipter 1. Boiler Fundamentals

1.1
1.2

1.3

1.4

1.5
1.6
1.7
1.8

1.9

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

2. Materials
2.1

Production
2.1.1 Steel making process
2.1.2 Ferrous metals and alloys

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Contents

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

Chapter 3. Boiler Design

3.1
3.2

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

Contents

3.8.3
3.8.4

Design calculations
Design Process

vii

100
101

Chapter 4. Boiler Piping

103

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127

t
->'
1
*"
*"
%^
*'*
*'
|

4.1 Pipe Classifications

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

ipter 5. Safety and Safety Relief Valves

129

5.1 Working Principle

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

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viii

Contents

Chapter 6. Fabrication
6.1

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

Chapter 7. Watertube Boilers

7.1
7.2

7.3
7.4
7.5
7.6

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

Chapter 8. Firetube Boilers

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

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Contents

ix

:
f
l+
r
i'-'

8.4.4 Combustion chamber tubesheet

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

258
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265
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285

Npter 9. Feedwater Heaters

289

f
I*
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^
I
Sv
**
^

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298
298

9.1
9.2

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

ttapter 10. Miniature Boilers

It

301

f 10.1
m 10.2
s

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

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304
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305
305
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305
305
305
306
306
306
307

M p t e r i i . Electric Boilers

309

Ci1.1 Working Principle

309
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313
314
314
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315
315

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

Contents

11.4

Inspection and Stamping

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

Chapter 12. Organic Fluid Vaporizers

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

Chapter 13. Shop Inspection

13.1

13.2

13.3

13.4
13.5

13.6
13.7
13.8

Boiler Fabrication Shop

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

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Contents

xi

ipter 14. Stamping and Data Reports

349

14.1 Stamp Holders

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

350
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359
360
362
362

ipter 15. Auxiliaries and Appurtenances

365

15.1 Boiler Auxiliaries

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

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386

pter16. FuelI Systems

387

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

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xii

Contents

16.4
16.5
16.6
16.7

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

Chapter 17. Boiler Controls

17.1

Basic Boiler Controls

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

pter 18. Boiler Installation

18.1
18.2
18.3

18.4
18.5
18.6
18.7
18.8

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

Chapter 19. Boiler Operation

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

Contents

19.8
19.9
19.10
19.11

Boiler Shutdown
Periodic Tests
Boiler Room Emergency
Operation Logsheet

^Chapter 20. In-service Inspection

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

tapter 21. Boiler Maintenance

xiii

450
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460
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463
463
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465
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475
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475
477

21.1 Maintenance Personnel

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

477
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493

ipter 22. Boiler Repairs

495

22.1 Repair Organizations

22.2 Repairs
22.2.1 Routine repairs
22.2.2 Major repairs

495
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496
497

xiv

Contents

22.3
22.4

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

Chapter 23. Water Treatment

23.1

498
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506
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508
509
510
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512

515

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

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523
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532
533
533
534

23.6

535

Conclusion

Appendix A. Maximum Stress Values for Ferrous Materials

537

Appendix B. Maximum Stress Values for Nonferrous Materials

545

Appendix C. Dimensions of Plates

549

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

I
Ifcppendix F. Tube Thickness

xv

551
555
557

)pendix G. Charts for Components under

External Pressure

559

mdix H. MAWP for Watertubes

563

mdix I. Manufacturers' Data Report for Watertube Boilers

565

mdix J. Manufacturers' Data Report for Firetube Boilers

569

mdix K. Manufacturers' Data Report for Miniature Boilers

573

mdix L. Manufacturers' Data Report for Electric Boilers

577

spendix M. Manufacturers' Data Report for Organic

Fluid Vaporizer

581

mdix N. Manufacturers' Data Report for Pressure Piping

585

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

589

mdix P. First Inspection Report

593

mdix Q. Suggested Format for Welding Procedure

Specifications (WPS)

597

idix R. Unit Conversions

Bibliography
Index
611

607

601