Steam Boiler: Code Standard

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ASME Boiler and Pressure Vessel Code

ASME Boiler and Pressure Vessel Code (ASME BPV Code) is a code that is published by the American Society of Mechanical Engineers which is used as standard for design, repair and maintenance, inspect, manufacture, and construct boiler and pressure vessel. ASME code is first published in 1914, since 1954 it had been renewed in every 3 years and also ASME will issue addenda every year. The latest edition now is ASME Boiler and Pressure Vessel Code 2010 edition. This code had been accepted internationally.

ASME Boiler and Pressure Vessel Code (ASME BPV Code) consists of 12 sections. Each section consists of parts, divisions, and subsections. The cost to buy complete ASME BPV code is approximately $6500 more. The following below are sections of ASME Boiler and Pressure Vessel Code:

a) ASME BPV Code Section 12 - Rules for the Construction & Continued Service of Transport Tanks

b) ASME BPV Code Section 11 - Rules for In-service Inspection of Nuclear Power Plant Components

c) ASME BPV Code Section 10 - Fiber-Reinforced Plastic Pressure Vessels

d) ASME BPV Code Section 9 - Welding and Brazing Qualifications

e) ASME BPV Code Section 8 - Pressure Vessels. This code consist 3 divisions as follow:

- ASME BPV Code Section 8 Division 1

- ASME BPV Code Section 8 Division 2 - Alternative Rules

- ASME BPV Code Section 8 Division 3 - Alternative Rules for Construction of High Pressure Vessels

f) ASME BPV Code Section 7 - Recommended Guidelines for the Care of Power Boilers

g) ASME BPV Code Section 6 - Recommended Rules for the Care and Operation of Heating Boilers

h) ASME BPV Code Section 5 - Nondestructive testing

i) ASME BPV Code Section 4 - Rules for Construction of Heating Boilers

j) ASME BPV Code Section 3 - Rules for Construction of Nuclear Power Plant Components

- ASME BPV Code Section 3 - Subsection NCA — General Requirements for Division 1 and Division 2

- ASME BPV Code Section 3 - Division 1 consists of:

* ASME BPV Code Section 3 - Division 1 Subsection NB — Class 1 Components

* ASME BPV Code Section 3 - Division 1 Subsection NC — Class 2 Components

* ASME BPV Code Section 3 - Division 1 Subsection ND — Class 3 Components

* ASME BPV Code Section 3 - Division 1 Subsection NE — Class MC Components

* ASME BPV Code Section 3 - Division 1 Subsection NF — Supports

* ASME BPV Code Section 3 - Division 1 Subsection NG — Core Support Structures

* ASME BPV Code Section 3 - Division 1 Subsection NH — Class 1 Components in Elevated Temperature Service

* ASME BPV Code Section 3 - Division 1 Appendices

- ASME BPV Code Section 3 Division 2 — Code for Concrete Containments

- ASME BPV Code Section 3 Division 3 — Containments for Transportation and Storage of Spent Nuclear Fuel and High Level Radioactive Material and Waste

k) ASME BPV Code Section 2 – Materials

- ASME BPV Code Section 2 Part A — Ferrous Material Specifications

- ASME BPV Code Section 2 Part B — Nonferrous Material Specifications

- ASME BPV Code Section 2 Part C — Specifications for Welding Rods, Electrodes, and Filler Metals

- ASME BPV Code Section 2 Part D — Properties (Customary)

- ASME BPV Code Section 2 Part D — Properties (Metric)

l) ASME BPV Code Section 1 - Rules for Construction of Power Boilers

Requirement ASME for Design Calculation

Design calculation of steam boiler should be performed carefully. Engineers who have responsibility to design steam boiler shall have good understanding about requirement ASME BPV Section I not only for materials, but also for design calculation.

Design calculation ideally should follow ASME Code. The following below is summary of requirement ASME for design calculation:

- General Design, see ASME BPV Section I sub chapter PG 16
- Maximum Allowable Working Pressure, see ASME BPV Section I sub chapter PG 21
- Loading on Steam Boiler, see ASME BPV Section I sub chapter PG 22
- Stress Value for Calculation Formula, see ASME BPV Section I sub chapter PG 23 and ASME BPV Section II Part D
- Calculation Formula for Tube Up To 5 in Outside Diameter, see ASME BPV Section I sub chapter PG 27.2.1
- Calculation Formula for Piping, Drums and Headers, see ASME BPV Section I sub chapter PG 27.2.2
- Thickness Greater Than One-Half the Inside Radius of Component, see ASME BPV Section I sub chapter PG 27.2.3
- Welded Access or Inspection Openings under External Pressure, see ASME BPV Section I sub chapter PG 28
- Dished Head Design and Calculation, see ASME BPV Section I sub chapter PG 29
- Design Stayed Dished Head, see ASME BPV Section I sub chapter PG 30
- Design Unstayed Flat Heads and Covers, see ASME BPV Section I sub chapter PG 31
- Design Calculation for Opening in Shells, Headers, and Heads, see ASME BPV Section I sub chapter PG 32.1
- Design Shape of Opening, see ASME BPV Section I sub chapter PG 32.2
- Design Size of Opening, see ASME BPV Section I sub chapter PG 32.3
- Design Compensation Required for Opening in Shells and Formed Heads, see ASME BPV Section I sub chapter PG 33
- Design Flanged in Openings in Formed Heads, see ASME BPV Section I sub chapter PG 34
- Design Compensation Required for Opening in Flat Heads, see ASME BPV Section I sub chapter PG 35
- Design Limit of Metal Available for Compensation, see ASME BPV Section I sub chapter PG 36
- Design Strength of Compensation, see ASME BPV Section I sub chapter PG 37
- Design Compensation for Multiple Openings, see ASME BPV Section I sub chapter PG 38
- Minimum Thickness and Maximum Working pressure for Stayed Flat Plates, see ASME BPV Section I sub chapter PG 46.1
- Design Calculation of Ligaments, see ASME BPV Section I sub chapter PG 52 and PG 53
- Boiler External Piping and Boiler Proper Connection, see ASME BPV Section I sub chapter PG 58
- Nondestructive Examination Requirements, see ASME BPV Section I sub chapter PW 11
- Heat Treatment Process, see ASME BPV Section I sub chapter PW 38 and PW 39

Code and Calculation Required in Performance Assessment

Performance of power plant generally and steam boiler specifically should be assessed to evaluate them, so they can perform perfectly and give highest efficiency. Performance of all of equipments should be monitored and maintained to give reliable, economical and safety operation. Beside that, performance assessment of steam boiler is used to detect when boiler running with poor efficiency and extend the life of steam boiler.

Code and calculation of performance assessment are taken based on American Society of Mechanical Engineer (ASME) Power Test Code for each equipment. The performance assessments include:

Efficiency of Steam Boiler Based on ASME 4.1

Performance Calculation of Feedwater Heater

Performance Calculation of Steam Turbine Based on ASME PTC 6

The calculations include efficiency, heat rate and steam flow of steam turbine.

Calculation of Turbine Cycle Based on ASME 6.1

Performance Calculation of Condenser Based on ASME PTC 12.1-1983

The calculations include transmittance of thermal, pressure, fouling resistance, cleanliness factor, and cooling process of condenser.

Performance Calculation of Overall Plant

The calculations include heat rate, thermal efficiency and output power either gross or net of overall plant.

Performance Calculation of Cooling Tower

The calculations include range, approach, and cold water temperature of cooling tower.

Performance Calculation of Gas Turbine Based on ASME PTC 22

The calculations include heat rate, fuel consumption, output power and thermal efficiency of gas turbine.

Performance Calculation of Heat Recovery Steam Generator Based on ASME PTC 4.4-1981

The calculation include efficiency, fuel consumption, pinch point and overall effectiveness of HRSG

Rules Regarding the Use of Material on Steam Boiler

All of materials used for construction of the steam boiler for best design should refer to ASME Code (American Society of Mechanical Engineers) because ASME Code takes high care to ensure the quality of the material. All of specification materials with classification of temperature design of material, allowable pressure, corrosion, manufacturing tolerance, erosion, wear and tear can be seen in ASME Boiler and Pressure Vessel (ASME BPV) Code Section II Parts A, B, C, and D. While for design and do calculation steam boiler refers to ASME BPV Section I.

ASME BPV Section II consists of four separate books:

1. ASME BPV Section II Part A: Ferrous Material Specifications

This code provides ferrous material specification that is safe for use on pressurized equipment.

2. ASME BPV Section II Part B: Nonferrous Material Specifications

This code provides nonferrous material specification that is safe for use on pressurized equipment.

3. ASME BPV Section II Part C: Specification for Welding Rod, Electrodes, and Filler Metals

This code provides filler metal procurement guidelines, specification for carbon, stainless and low alloy steel electrodes for shielded metal arc welding, specification for carbon and low alloy steel rods for oxyfuel gas welding, welding shielding gases, and so on.

4. ASME Section II Part D: Properties

This code provides properties of material such as stress tables, physical properties tables, chats and tables for determining shell thickness of components under external pressure.