1、POWER BOILERSA GuIdE tO SEctIOn I Of thE ASME BOILER And PRESSuRE VESSEL cOdESecond EditionbyJohn R. MacKayandJames t. Pillowfounding Authors:Martin d. BernsteinandLloyd W. Yoder 2011, ASME, 3 Park Avenue, New York, NY 10016, USA (www.asme.org)First edition, 1998Second edition, 2011All rights reserv
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8、al Sales at infocentralasme.orgLibrary of Congress Cataloging-in-Publication DataMackay, John R.Power boilers : a guide to Section I of the ASME boiler and pressure vessel code / by John R. MacKay and James T. Pillow ; founding authors: Martin D. Bernstein and Lloyd W. Yoder.2nd ed.p. cm.First editi
9、on, 1998 by Martin D. Bernstein and Lloyd W. Yoder.Includes index.ISBN 978-0-7918-5967-41. Steam-boilersStandardsUnited States. 2. Pressure vessels StandardsUnited States. I. Pillow, James T. II. Title.TJ288.B47 2011621.183021873dc222011009378Cover Illustration: Courtesy of Cleaver-BrooksDedication
10、to The First EditionThe authors dedicate this book to their distinguished colleague on Subcommittee I, the late Walter Harding of Combustion Engineering. From the 1950s until his retirement in the 1980s, Walter Harding served with distinction on the ASME Boiler and Pressure Vessel Committee in many
11、capacities, including Chairman of the Main Committee. An engineer of the greatest integrity, Harding was an inspiring role model for younger committee members, extremely knowledgeable, ever helpful, cheerful, and the possessor of a fine sense of humor. We were fortunate to have had the privilege of
12、serving with him.The authors of the Second Edition dedicate this book to their esteemed colleague on Section I, the late Martin D. Bernstein. Martin (Marty to most of his good friends) served with passion and dedication from the early 1970s un-til his untimely passing in 2002, at which time he was V
13、ice-chairman of the Committee. In addition to his duties on Section I, Marty was an active member of the ASME Committee on Safety Valve Requirements, serving as Vice- Chairman from 1990 and Chairman in 2000. We were fortunate to know Marty and to have had the pleasure of his company during the frequ
14、ent Boiler Code weeks over the years.Dedication to The Second EditioniiiTable of ContentsList of Figures . ixList of Tables . xiiForeword . xiiiIntroduction xvAcknowledgment xixchapter 1Scope of Section I, Organization and, Serice Limits . 1Scope . 1The Organization of Section I . 4The Parts of Sect
15、ion I . 5Interpretations . 10Pressure Range of Section I Boilers . 11Fired Versus Unfired Boilers 11The Use of Section VIII Vessels in a Section I Boiler . 12Standards Referenced by Section I . 14chapter 2how and Where Section I is Enforced and Effectie dates . 17United States and Canada . 17Interna
16、tional Acceptance 19Uniform Boiler and Pressure Vessel Laws Society 19National Board Inspection Code . 20Effective Dates of the Code and Code Revisions . 20chapter 3Materials . 25How Material is Ordered 25Using Section II 25Finding and Using Design Stresses in Section II, Part D . 28Marking of Mater
17、ials 29Use of Non-Asme Material Specifications and Material Not Fully Identified . 30Special Concerns 31Material Requirements for Boiler External Piping . 33Electric Resistance Welded (ERW) Materials 33Nonpressure Part Materials . 34Material Test Reports . 34Strength of Materials After Fabrication 3
18、5Cold Forming of Austenitic Materials 36Cold Forming of Creep Strength-Enhanced Ferritic Steels 38Does New Material Get Old? . 39Use of Materials in Inventory . 41Code Guidance on the Use of Old Materials 41 chapter 4Boiler design . 43Design Life . 43Design Allowable Stresses . 44Design Methods 44De
19、sign Loads 45Distinction Between Boiler Proper Piping and Boiler External Piping 50Some Design Differences: Section I Versus B31.1 51Bend Design 52Openings and Compensation 54Ligament Design . 61Interpretations on Openings, Compensation, and Ligaments . 65Nozzle Attachment Rules . 66Dished Heads 70F
20、lat Heads . 76Interpretations on Heads . 76Stayed Surfaces . 78Supports and Attachment Lugs . 82Loading on Structural Attachments 82Design of Pressure Relief Valve Nozzles . 84Thermocouple Installations 85chapter 5Piping design 89Introduction . 89Shock Service for Feedwater and Blowoff Piping . 89Pu
21、mp Discharge Head 90Unusually High Piping Design Pressure . 91Short-Term Overstress in Boiler External Piping . 92Hydrostatic Test of Boiler External Piping 96Allowable Stress When Pressure Relief Valves Are Discharging 97Feedwater Piping 98Main Steam Piping . 99Blowoff and Blowdown Piping 102Design
22、 Conditions for Blowoff and Blowdown Piping 104Drains 104Design Conditions for Drain Piping . 107Pipe Connections to the Boiler . 107Addition of Small Connections to Boiler Piping 108chapter 6fabrication 109Fabrication 109Tube Attachment by Expanding . 109Welding Some History 111Welding Rules 112Qua
23、lification of Welding Procedures 113i Table of ContentsQualification of Welder Performance . 113Expiration and Renewal of Welding Qualifications . 114Transfer of Procedures and Welders to Another Organization 116Welding Documentation . 118Welding Nonductile Materials 119Welding Variables 119P-Number
24、s, S-Numbers, F-Numbers, and A-Numbers 120Weldability . 122Design of Welded Joints . 123Bending Stress on Welds 123Acceptance Criteria for Welds 124Tube-to Header Attachment Using Partial Penetration Welds . 125Alignment Tolerance 126Backing Rings . 126Preheating . 126Postweld Heat Treatment 127Test
25、 Plates . 130Interpretations on Welding . 131Volumetric Examination of Welds . 134chapter 7nondestructie Examination and hydrostatic testing 139Nondestructive Examination 139Qualification And Certification Of NDE Personnel . 139Hydrostatic Testing . 140Welding After Hydrostatic Test 144Interpretatio
26、ns On Hydrostatic Testing 144 chapter 8third Party Inspection 151chapter 9certification by data Reports and Stamping 155Certification and Its Significance 155Manufacturers Data Report and Certificate of Conformance Forms 156The Section I Manufacturers Data Report And Certificate Of Conformance Forms
27、 156Completing the Manufacturers Data Report Forms 159Distribution of the Data Report Forms . 159Interpretations on Use of Manufacturers Data Report Forms . 160Code Symbol Stamps and How They Are Obtained 161What the Code Symbol Stamps Cover . 162Reapplication of an ASME Code Symbol Stamp . 164Inter
28、pretations on Code Symbol Stamping . 165chapter 10Quality control System . 173chapter 11Standard Pressure Parts, Vales, and Vale Ratings . 175Standard Pressure Parts . 175Table of Contents iiValve and Valve Ratings 176chapter 12Pressure-Relief Vale Requirements 179Introduction . 179Overpressure Prot
29、ection 180Selection of Pressure-Relieving Devices 188Design of Pressure-Relief Valves . 191Establishing and Certifying Relieving Capacities 192Qualification of Pressure-relief Valve Manufacturers 195Installation Guidelines 195Pressure-Relief Valves in Service 196chapter 13feedwater Supply and Water
30、Leel Indication 199Importance of Feedwater 199Rules for Feedwater Supply 199Tower Mounted Solar Fired Boilers . 202Forced-Flow Steam Generators 202Low Water Level Fuel Cutoffs . 203Water Level Indication . 203Water Columns . 206chapter 14creep and fatigue damage during Boiler Life 209Introduction .
31、209Creep . 209Fatigue 212Boiler Life Extension 214chapter 15determination of Allowable Stresses 217General Philosophy . 217Establishing Allowable Stresses . 218Penalties on Allowable Stresses . 218Design Stresses: Past, Present, and Future . 219Appendix 1 of Section II, Part D 220chapter 16Rules coe
32、ring Boilers in Serice 223Introduction . 223Jurisdictional Requirements 224National Board Inspection Code . 224References . 231Appendix IEolution of the ASME Boiler and Pressure Vessel code . 233iii Table of ContentsAppendix IIOrganization and Operation of the Boiler and Pressure Vessel Standards co
33、mmittees 237Organization and Responsibility . 237A Balance of Interests . 239The Code Sections and Their Related Standards Committee . 240The Service Committee 240The Certification Committees . 242Committee Operations 242How the Committee Does Its Work 242Code Inquiries and Interpretations 242Public
34、ation of Interpretations of the Code 244Additions and Revisions to the Code 245Code Cases 246Voting at the Standards Committee (BPV I) 247Due Process 248Appendix IIIOeriew of code Sections II to XII and Piping codes B31.1 and B31.3 . 249Appendix IVdesign Exercises . 261Design Exercise No. 1, Design
35、of a Header .261 Design Exercise No. 1A, Alternative Design of Header (A-317) 262Design Exercise No. 2, Design of a Head 262Design Exercise No. 3, Choice of Feedwater Stop Valve 263Design Exercise No. 4, Design of a Tube For Lug Loading 264Design Exercise No. 5, Design of an Opening . 266Pg-27 Cylin
36、drical Components Under Internal Pressure (Reproduced from ASME Section I) 269PG-29 Dished Heads (Reproduced from Section I) . 273Appendix VIllustrations of Various types of Boilers . 283Index of Interpretations Referenced in text, their Major Subjects and Abstracts . 295 Index 303Table of Contents
37、ixList of Figureschapter 2Fig. 2.1 Map of States and Provinces with Boiler and Pressure Vessel Laws (Courtesy of the National Board Synopsis of Boiler and Pressure Vessel Laws, Rules and Regulations) . 18chapter 4Fig. PG-33.1 Nominclature and Formulas for Reinforced Openings(Reproduced From ASME Sec
38、tion I) 56Fig. PG-52.1 Diagram for Determining the Efficiency of Longitudinal and Diagonal Ligaments Between Openings in Cylindrical Shells (Reproduced From ASME Section I) 63Fig. PW-15 Examples of Weld Strength Calculations (Reproduced From ASME Section I) . 68Fig. PW-16.1 Some Acceptable Types of
39、Welded Nozzles and Other Connections to Shells, Drums, and Headers (Reproduced From ASME Section I) . 71-74Fig. PG-31 Some Acceptable Types of Unstayed Flat Heads and Covers (Reproduced From ASME Section I) 77chapter 5Fig. PG-58.3.1(a) Code Jurisdictional Limits for Piping Drum-Type Boilers (Reprodu
40、ced From ASME Section I) 92Fig. PG-58.3.1(b) Code Jurisdictional Limits for Piping Isolable Economizers Located in Feedwater Piping and Isolable Superheaters in Main Steam Piping (Reproduced From ASME Section I) 93Fig. PG-58.3.1(c) Code Jurisdictional Limits for Piping Reheaters and Nonintegral Sepa
41、rately Fired Superheaters (Reproduced From ASME Section I) . 94Fig. PG-58.3.2 Code Jurisdictional Limits for Piping An Example of Forced-Flow Steam Generators with No Fixed Steam Or Waterline (Reproduced From ASME Section I) 99Fig. PG-58.3.3 Code Jurisdictional Limits for Piping An Example of Steam
42、Separator Type Forced-Flow Steam Generators with No Fixed Steam or Waterline (Reproduced From ASME Section I) 100chapter 6Fig. 6.1 Dudgeons Roller Expander, Circa 1880 110Fig. 6.2 Prosser Tube Expander, Circa 1880 110xchapter 14Fig. 14.1 Strain in Constant Stress Creep Test . 210Fig. 14.2 Progressio
43、n of Microstructural Damage During Componenet Life (Reproduced From Neubauer and Wedel (1983) 211Fig. 14.3 2 Cr-1Mo 100 Percent of the Minimum Stress-to-Rupture (Reproduced From ASME Section III) . 211Appendix IIFig. A.II.1 Organization of ASME (Condensed) 238Fig. A.II.2 Portion of ASME Organization
44、 Encompassing BPV Committee on Power Boilers (I) . 239Appendix IVFig. A-71 Lug Load on Tube (Reproduced From ASME I) . 264Fig. PW-15 Examples of Weld Strength Calculations Sketch (C) (Reproduced From ASME Section I) . 266Appendix VFig. A.V.1 Supercritical Once-Through Coal Firing Steam Generator (Co
45、urtesy of Foster Wheeler Energy Corporation) 283Fig. A.V.2 Coal Firing Central Station Steam Generator (Courtesy of Foster Wheeler Energy Corporation) 284Fig. A.V.3 Circulating Fluidized Bed Boiler (Courtesy of Foster Wheeler Energy Corporation) . 285Fig. A.V.4 Kraft Process Black Liquor Recovery Bo
46、iler(Courtesy of the Babcock project managers; architect engineers; engineers from boiler manufacturers, boiler operators, and insurance and inspection agencies; and others involved with power boilers and the ASME Code governing their construction.The introduction in the brochure for that 2-day prof
47、essional development course on Section I explained that Section I contains the rules for the construction of power boilers, but that those rules are accompanied by very little explanation. Thus, the course was intended to provide a basic understanding of those rules, their intent, and how they are a
48、pplied, interpreted, and revised. This book is a greatly expanded version of those course notes, with broader and more detailed coverage on various topics of interest to those involved with power boilers.Author John MacKay was asked to take on the task of updating this book. He recruited Jim Pillow,
49、 friend and BPV I colleague, to assist with the effort. John and Jim accepted the challenge as a way to honor the accomplish-ments of Martin and Lloyd and to carry on their work. Both Martin and Lloyd spent their careers working for major boiler manufacturers and decades serving in various capacities on the ASME Boiler and Pressure Vessel Committees. Likewise, John and Jim have spent their careers involved in the design, manufacture, and installa-tion of power boilers and continue their decades of
