ASME BPVC VII (2010): Boiler and Pressure Vessel Code, Part VII, Recommended Guidelines for the Care of Power Boilers

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by  American Society of Mechanical Engineers

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2010 ASME Boiler and
Pressure Vessel Code
AN INTERNATIONAL CODE
VII
Recommended Guidelines
for the
-Care of Power Boilers
8
SETTING THE ST'(NDARD

I ELI
IL
ASME Boiler and Pressure Vessel Committee on Power Boilers
11II111111111111111111111111111111111111
X07011
Date of Issuance: July 1, 2011
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Copyright © 2011 by
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CONTENTS
List of Sections ......................................................................... vii
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
Statement of Policy on the Use of the Certification Mark and Code Authorization in
Advertising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xl
Statement of Policy on the Use of ASME Marking to Identify Manufactured Items. . . . . . . . . . . . xi
Submittal of Technical Inquiries to the Boiler and Pressure Vessel
Committee - Mandatory .............................................................. XlI
Personnel .............................................................................. xi v
Introduction ............................................................................ XXVlI
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxviii
List of Changes in Record Number Order ................................................. xxx
Subsection C 1 Fundamentals ............................................................ .
Cl.IOO Steam Generation ......................................................... .
Cl.200 Boiler Types .............................................................. .
Cl.300 Package Boilers ........................................................... . 2
Cl.400 Field-Assembled Boilers ................................................... . 2
Cl.500 Combustion .............................................................. . 2
C1.600 Boiler Efficiency .......................................................... . 4
Figures
C1.2-1 Simple Steam Drum ....................................................... . 2
C1.2-2 Steam Drum With Tubes .................................................. . 2
Cl.2-3a Steam Drum Internals - Baffle Type ....................................... . 3
C1.2-3b Steam Drum Internals - Double-Row Arrangement, Cyclone
Separator Type ......................................................... . 3
Subsection C2 Boiler Operation ......................................................... . 5
C2.IOO General Guidelines ........................................................ . 5
C2.200 Preparing for Operation .................................................... . 6
C2.300 Starting Up ............................................................... . 9
C2.400 On-Line Operation ........................................................ . 11
C2.500 Out-of-Service Operation .................................................. . 15
Subsection C3 Boiler Auxiliaries ........................................................ . 18
C3.100 Preparation of Auxiliaries for Service ....................................... . 18
C3.200 Fuel-Burning Equipment ................................................... . 18
C3.300 Air Heaters ............................................................... . 31
C3.400 Economizers .............................................................. . 34
C3.500 Boiler Feed Pumps ........................................................ . 36
C3.600 Auxiliary Drives .......................................................... . 36
C3.700 Draft Fans .............. , ................................................. . 40
C3.800 Dampers ................................................................. . 40
iii
Figures
C3.2-1 Typical Pilot and Gas Piping Arrangement .................................. . 18
C3.2-2 Typical Fuel Oil Train ..................................................... . 21
C3.2-3 Typical Underfeed Stoker. ................................................. . 23
C3.2-4 Feeder-Distributor for Firing of Coal on a Spreader Stoker .................... . 23
C3.2-5 Spreader Stoker, Continuous Ash Discharge Grate ............................ . 24
C3.2-6 Typical Bowl Mill ........................................................ . 26
C3.2-7 Typical Impact Mill ....................................................... . 27
C3.2-8 Arrangement of Ball-Tube Mill ............................................. . 28
C3.2-9 Burner for Horizontal Firing of Coal ........................................ . 28
C3.3-1 Typical Tubular Air Heater ................................................ . 32
C3.3-2 Typical Regenerative Air Heater ............................................ . 33
C3.3-3 Details of Regenerative Air Preheater, Bisector Type ......................... . 34
C3.4-1 Typical Economizer ....................................................... . 35
C3.5-1 Typical Centrifugal Boiler Feed Pump, Water Connections .................... . 37
C3.6-1 Typical Motor Drive ...................................................... . 38
C3.6-2 Typical Single Stage Turbine Drive ......................................... . 38
C3.6-3 Typical Turbine Drive Arrangement ........................................ . 39
C3.7-1 Airfoil Blade Centrifugal Fan With Inlet Vane Control ....................... . 41
C3.8-1 Typical Outlet Fan Dampers (Multilouver) ................................... . 42
Subsection C4 Appurtenances ........................................................... . 43
C4.100 Safety Valves ............................................................. . 43
C4.200 Safety Relief Valves or Relief Valves ....................................... . 50
C4.300 Pressure Gages ........................................................... . 52
C4.400 Fusible Plugs ............................................................. . 53
C4.500 Feedwater Regulator Valve ................................................. . 53
C4.600 Blowdown ................................................................ . 53
C4.700 Soot Blowers ............................................................. . 53
Figures
C4.1-1 Safety Valve Nameplate ................................................... . 43
C4.1-2 Typical Safety Valve ...................................................... . 45
C4.1-3 Recommended Safety Valve Installation ..................................... . 46
C4.1-4 Application of Test Gag ................................................... . 48
C4.1-5 Hydraulic Lift Assist Device ............................................... . 49
C4.2-1 Test Apparatus for Seat Tightness ........................................... . 51
Table
C4.2-1 Leakage Rates for Safety Relief Valves for Set Procedures to
1,000 psig (7 MPa) ..................................................... . 51
Subsection CS Instrumentation, Controls, and Interlocks ................................. . 55
C5.100 General .................................................................. . 55
C5.200 Indicators and Recorders ................................................... . 55
C5.300 Controls and Interlocks .................................................... . 56
Subsection C6 Inspection ............................................................... . 58
C6.100 Scope .................................................................... . 58
C6.200 Inspection Frequency ...................................................... . 58
C6.300 Preparation for Inspection .................................................. . 59
C6.400 Inspection of Internal Surfaces and Parts .................................... . 59
IV
C6.500 Inspection of Extemal Surfaces and Parts .................................... . 64
C6.600 Care and Maintenance ..................................................... . 65
C6.700 Repairs ............................ " .................................... . 66
C6.800 Hydrostatic Test. .......................................................... . 66
C6.900 Boilers - General ........................................................ . 66
C6.l000 Authorized Inspector ...................................................... . 67
Figures
C6.1-1 Typical Boiler Water Level Gage Installation ................................ . 58
C6.3-1 Typical Valve Lineup Prior to Inspection .................................... . 60
C6.4-1 Typical Stays ............................................................. . 62
C6.4-2 Typical Forms of Fusible Plugs ............................................. . 63
Subsection C7 Repairs, Alterations, and Maintenance .................................... . 68
C7.100 Repairs and Alterations .................................................... . 68
C7.200 Maintenance .............................................................. . 68
C7.300 Boiler Maintenance Programs .............................................. . 69
C7.400 Steam Boilers ............................................................. . 70
Subsection C8 Control of Internal Chemical Conditions .................................. . 76
C8.100 General ................................................. , ................ . 76
C8.200 Intemal Cleaning of Boilers ................................................ . 76
C8.300 Laying Up of Boilers ...................................................... . 77
C8.400 Deposits ................................................................. . 78
C8.500 Internal Corrosion ......................................................... . 80
C8.600 Corrosion Cracking of Boiler Steel ......................................... . 84
C8.700 Steam Contamination ...................................................... . 85
C8.800 Sampling, Testing, Controlling, and Reporting of Analyses of Water ........... . 87
C8.900 Fire-Side Conditions ....................................................... . 87
Figures
C8.4-1 Scale Causing Overheating and Tube Failure ................................ . 79
C8.4-2 Deposit Effect on Boiler Tube Versus Tube Temperature ..................... . 79
C8.5-1 Oxygen Corrosion in an Economizer Tube ................................... . 81
C8.5-2 Caustic Gouge-Type Attack on Boiler Tube ................................. . 81
C8.5-3 Chelate Attack Caused by Excessive Feed of Chemical ....................... . 82
C8.5-4 CO Carbonic Acid Attack on Condensate Pipe .............................. . 83
2
C8.5-5 Oxygen Attack on Condensate Pipe ......................................... . 83
C8.6-1 H+ Damage on Boiler Tube ................................................ . 86
Tables
C8.8-1 Methods for Sampling of Water and Steam .................................. . 87
C8.8-2 Methods of Analysis for the Control of Water for Boilers ..................... . 88
C8.8-3 Useful Tests for the Control of Water for Boilers ............................. . 89
Subsection C9 Preventing Boiler Failures ................................................ . 91
C9.100 General .................................................................. . 91
C9.200 Overpressure ............................................................. . 91
C9.300 Weakening of Structure .................................................... . 93
C9.400 Operation of Combustion Equipment ........................................ . 96
v
C9.500 Furnace Explosions 97
C9.600 Furnace Implosions 97
Mandatory Appendices
I Submittal of Technical Inquiries to the Boiler and Pressure
Vessel Committee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
II Standard Units for Use in Equations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 100
Nonmandatory Appendices
A Procedures for Care and Maintenance of Package Boilers . . . . . . . . . . . . . . . . . . . . .. 101
B Watertube Boilers - Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 102
C Watertube Boilers - Operating Checks Relating to Maintenance. . . . . . . . . . . . . .. 109
D Firetube Boilers - Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. III
E Firetube Boilers - Operating Checks Relating to Maintenance. . . . . . . . . . . . . . . .. 112
F Guidance for the Use of U.S. Customary and SI Units in the
ASME Boiler and Pressure Vessel Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 113
Glossary ............................................................................... 116
vi