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ASME BPVC VII 2023

ASME BPVC VII 2023

$377.00

ASME BPVC.VII-2023 Section VII, Recommended Guidelines for the Care of Power Boilers

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ASME 2023 207
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The purpose of these recommended guidelines is to promote safety in the use of power boilers. The term “power boiler” in this Section includes stationary, portable, and traction type boilers, but does not include locomotive and high temperature water boilers, nuclear power plant boilers, heating boilers, pressure vessels, or marine boilers. This Section provides such guidelines to assist those directly responsible for operating, maintaining, and inspecting power boilers. Emphasis has been placed on industrial type boilers because of their extensive use. Guidelines are also provided for operation of auxiliary equipment and appliances that affect the safe and reliable operation of power boilers. Careful application of this Section will help users to comply with applicable regulations within their jurisdictions, while achieving the operational, cost and safety benefits to be gained from the many industry best-practices detailed within these volumes. All changes to this 2013 Edition are incorporated into the appropriate page and each affected area is identified with a designator. Each Section includes a Summary of Changes that lists the material affected by the change, plus the nature of the change. There will no longer be Addenda service for this 2013 Edition or for future Editions. Intended for manufacturers, users, constructors, designers and others concerned with the design, fabrication, assembly, erection, examination, inspection and testing of pressure vessels, plus all potential governing entities.

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PDF Pages PDF Title
5 TABLE OF CONTENTS
10 LIST OF SECTIONS
11 FOREWORD
13 STATEMENT OF POLICY ON THE USE OF THE ASME SINGLE CERTIFICATION MARK AND CODE AUTHORIZATION IN ADVERTISING
STATEMENT OF POLICY ON THE USE OF ASME MARKING TO IDENTIFY MANUFACTURED ITEMS
14 PERSONNEL
36 CORRESPONDENCE WITH THE COMMITTEE
38 ORGANIZATION OF SECTION VII
40 SUMMARY OF CHANGES
41 CROSS-REFERENCING IN THE ASME BPVC
43 SUBSECTION 1 WATERTUBE DRUM-TYPE INDUSTRIAL STEAM BOILERS
ARTICLE 100 FUNDAMENTALS OF WATERTUBE BOILERS
100.1 STEAM GENERATION
100.2 WATERTUBE BOILERS
100.2.1 Watertube Boilers.
100.2.2 Shop-Assembled (Package) Boilers.
100.2.3 Field-Assembled Boilers.
100.3 STEAM DRUMS
44 Figures
Figure 100.2.1-1 Watertube Boiler
Figure 100.2.2-1 Package Boiler
45 Figure 100.3-1 Simple Steam Drum
46 100.4 ECONOMIZERS
Figure 100.3-2 Steam Drum With Internals — Baffle Type
47 Figure 100.3-3 Steam Drum With Internals — Cyclone Separator Type
48 100.5 SUPERHEATERS
100.6 COMBUSTION
Figure 100.4-1 Typical Economizer
49 100.7 BOILER EFFICIENCY AND AIR EMISSIONS
50 ARTICLE 101 BOILER OPERATION
101.1 GENERAL GUIDELINES
101.1.1 Personnel Training.
101.1.2 Preventing Explosions.
51 101.1.3 Maintaining Proper Water Level.
101.1.4 Maintaining Proper Furnace Pressure.
101.1.5 Maintaining Clearance for Expansion.
101.1.6 Reference Sources.
52 101.2 PREPARING FOR OPERATION
101.2.1 Inspection.
101.2.2 Chemical Cleaning.
101.2.3 Safety Checklist for Boiler Examination.
101.2.4 Water-Side Checklist.
53 101.2.5 Fire-Side Checklist.
101.2.6 External Checklist.
54 101.2.7 Pressure Testing.
55 101.3 STARTING UP
101.3.1 General
101.3.2 Establish Water Level
101.3.3 Light-Off
56 101.3.4 Going Online
101.4 ONLINE OPERATION
101.4.1 Operating Data.
101.4.2 Water-Side Operations.
59 101.4.3 Pressure Relief Valves.
101.4.4 Leaks.
101.4.5 Soot Blowing.
60 101.5 OUT-OF-SERVICE OPERATION
101.5.1 General.
101.5.2 Shutdown.
101.5.3 Draining.
101.5.4 Isolation and Preparation.
61 101.5.5 Waterside Cleaning.
101.5.6 Fireside Cleaning.
Figure 101.5.4-1 Typical Valve Lineup Prior to Out-of-Service Operation
62 101.5.7 Storage.
63 ARTICLE 102 BOILER AUXILIARIES
102.1 PREPARATION OF AUXILIARIES FOR SERVICE
102.2 FUEL-BURNING EQUIPMENT
102.2.1 General.
102.2.2 Preparation for Operation.
102.2.3 Ignitors.
64 102.2.4 Gas Systems.
Figure 102.2.3-1 Simplified Pilot Gas Piping Arrangement
65 102.2.5 Oil Systems.
66 Figure 102.2.5.2-1 Simplified Fuel Oil Train — Single Burner With Oil Heating
67 Figure 102.2.5.2-2 Simplified Light Fuel Oil Train — Multiple Burner
68 102.2.6 Response to Tube Failure.
102.3 AIR HEATERS
102.3.1 Preparation for Placing in Service.
69 Figure 102.3.1-1 Typical Tubular Air Heater
70 102.3.2 Placing in Service.
102.3.3 Normal Operation.
Figure 102.3.1-2 Typical Regenerative Air Heater
71 102.3.4 Emergency Operation Due to Fire.
102.4 BOILER FEED PUMPS
102.4.1 Preparation for Service.
Figure 102.3.1-3 Details of Regenerative Air Heater, Bisector Type
72 102.4.2 Placing in Service.
102.4.3 Normal Operation.
102.5 AUXILIARY DRIVES
102.5.1 Motor Start-Up and Operation Checks.
73 Figure 102.4.2-1 Typical Centrifugal Boiler Feed Pump, Water Connections
74 Figure 102.5-1 Typical Motor Drive
Figure 102.5-2 Typical Single-Stage Turbine Drive
75 Figure 102.5-3 Typical Turbine Drive Arrangement
76 102.5.2 Mechanical Drive Turbine Start-Up and Operation Checks.
102.6 Draft Fans
102.6.1 Preparation for Service.
102.6.2 Placing in Service.
102.6.3 Normal Operation.
102.6.4 Emergency Operation.
77 102.7 Dampers
Figure 102.6.1-1 Airfoil Blade Centrifugal Fan With Inlet Vane Control
78 Figure 102.7-1 Typical Outlet Fan Dampers (Multilouver)
79 ARTICLE 103 APPURTENANCES
103.1 BOILER PRESSURE RELIEF VALVES
103.1.1 General.
103.1.2 Pressure Relief Valve Maintenance.
80 103.1.3 Pressure Relief Valve Testing.
81 Figure 103.1.2.9-1 Typical Direct Spring-Loaded Safety Valve
82 Figure 103.1.2.9-2 Recommended Direct Spring-Loaded Safety Valve Installation
84 Figure 103.1.3-1 Application of Test Gag
85 Figure 103.1.3-2 Hydraulic Lift Assist Device
86 103.1.4 Pressure Relief Valve Changeover Valve.
Figure 103.1.4-1 Changeover Valve
87 103.2 Pressure Relief Valves for Economizers and Auxiliaries
103.2.1 General.
103.2.2 Examination and Maintenance.
88 103.2.3 Repair and Testing.
103.2.4 Organic Fluid Vaporizers.
103.3 TRANSPORTATION AND INSTALLATION OF PRESSURE RELIEF VALVES
103.4 WATER COLUMNS, GAGE GLASSES, AND LEVEL TRANSMITTERS
89 103.4.1 Proper Blowdown Procedure.
103.4.2 Proper Valve Types.
103.4.3 Proper and Complete Heat Insulation.
103.4.4 Leakage Correction.
Figure 103.4-1 Typical Installation of a Boiler Water-Level Gage
90 Figure 103.4.1-1 Gage Glass and Water Column Blowdown Procedure
91 103.5 BOILER BLOWDOWN
103.6 PRESSURE GAGES
103.6.1
Figure 103.4.2-1 Y‐Type Globe Valve
92 103.6.2
103.6.3
103.6.4
103.6.5
103.7 FEEDWATER REGULATOR VALVE
103.8 SOOT BLOWERS
93 103.9 FUSIBLE PLUGS
94 ARTICLE 104 INSTRUMENTATION, CONTROLS, AND INTERLOCKS
104.1 GENERAL
104.2 INDICATORS AND RECORDERS
104.2.1 Indicating Devices.
104.2.2 Recording Devices.
95 104.2.3 Preparation for and Placing in Service.
104.2.4 Checking and Testing.
104.3 WATER-LEVEL INDICATION
104.4 CONTROLS AND INTERLOCKS
104.4.1 Controls.
96 104.4.2 Interlocks.
104.4.3 Safety Controls.
97 104.4.4 Preparation for and Placing in Service.
104.4.5 Checking and Testing.
98 ARTICLE 105 EXAMINATIONS
105.1 SCOPE
105.2 INSPECTION AND EXAMINATION FREQUENCY
99 105.3 PREPARATION FOR INSPECTION OR EXAMINATION
105.3.1 General.
105.3.2 External Surfaces and Parts.
105.4 EXAMINATION OF INTERNAL SURFACES OF BOILERS AND APPURTENANCES
105.4.1 All Boilers.
100 Figure 105.4.1.2-1 Typical Forms of Fusible Plugs
101 105.4.2 Watertube Boilers.
105.5 EXAMINATION OF EXTERNAL SURFACES OF BOILERS, APPURTENANCES, AND AUXILIARIES
105.5.1 General.
102 105.5.2 Piping.
105.5.3 Pressure Relief Valves.
105.5.4 Other Boiler-Related Items.
105.6 CARE AND MAINTENANCE
105.6.1 Housekeeping.
105.6.2 Certificates and Licenses.
105.6.3 Record Keeping and Logs.
103 105.7 REPAIRS
105.8 PRESSURE TESTS
105.9 GENERAL LISTING OF EXAMINATIONS
105.9.1 All Examinations.
104 105.9.2 Internal Examinations.
105.10 INSPECTOR
105.11 POM OUTAGE EXAMINATIONS AND OPERATIONAL WALKDOWNS
105 ARTICLE 106 REPAIRS, ALTERATIONS, AND MAINTENANCE
106.1 REPAIRS AND ALTERATIONS
106.2 MAINTENANCE
106.2.1 General.
106.2.2 Information to Assist in Maintenance.
106.2.3 Maintenance Checks.
106 106.2.4 Operating Checks Relating to Maintenance.
106.3 BOILER MAINTENANCE PROGRAMS
106.3.1 Examination and Overhaul Procedures.
106.3.2 Maintenance and Overhaul Scheduling.
106.3.3 Equipment Histories and Spare Parts Inventories.
106.3.4 Personnel Training.
106.3.5 Equipment Improvement.
107 106.4 MAINTENANCE CHECKS FOR STEAM BOILERS
106.4.1 Watertube Boilers.
111 106.5 CHECKLISTS TO ASSIST IN MAINTENANCE
112 SUBSECTION 2 PERTAINING TO ALL STEAM BOILERS
ARTICLE 200 PROTECTING HEAT TRANSFER SURFACES
200.1 GENERAL
200.2 INTERNAL CLEANING OF BOILERS
113 200.3 LAYING UP OF BOILERS
200.3.1 Water Side.
200.3.2 Dry Storage.
200.3.3 Wet Storage.
114 200.3.4 Fire Side.
200.4 DEPOSITS
200.4.1 Scale.
115 Figure 200.4.1-1 Scale Causing Overheating and Tube Failure
Figure 200.4.1-2 Deposit Effect on Boiler Tube Versus Tube Temperature
116 200.4.2 Sludge.
200.4.3 Internal Deposit Monitoring.
200.5 INTERNAL CORROSION
200.5.1 General.
200.5.2 Oxygen Corrosion.
200.5.3 Caustic Corrosion.
117 Figure 200.5.2-1 Oxygen Corrosion in an Economizer Tube
Figure 200.5.3-1 Caustic Gouge-Type Attack on Boiler Tube
118 200.5.4 Chelate Corrosion.
200.5.5 Acid Corrosion.
200.5.6 Auxiliary Equipment Corrosion.
Figure 200.5.4-1 Chelate Attack Caused by Excessive Feed of Chemical
119 Figure 200.5.6-1 CO2 Carbonic Acid Attack on Condensate Pipe
120 200.5.7 Examinations.
Figure 200.5.6-2 Oxygen Attack on Condensate Pipe
121 200.6 CORROSION CRACKING OF BOILER STEEL
200.6.1
200.6.2
200.6.3
200.6.4
200.6.5
200.6.6
200.6.7
122 200.7 STEAM CONTAMINATION
200.7.1 General.
Figure 200.6.6-1 H+ Damage on Boiler Tube
123 200.7.2 Control of Steam Contamination.
200.8 SAMPLING, TESTING, CONTROLLING, AND REPORTING OF ANALYSES OF WATER
200.8.1 Sampling.
124 200.8.2 Testing.
200.9 Fire-Side Conditions
200.9.1 General.
Tables
Table 200.8.1-1 Methods for Sampling of Water and Steam
Table 200.8.2-1 Methods of Analysis for the Control of Water for Boilers
125 Table 200.8.2-2Useful Tests for the Control of Water for Boilers
126 200.9.2 Soot.
200.9.3 Slag.
200.9.4 Corrosion.
128 ARTICLE 201 PREVENTING BOILER FAILURES
201.1 GENERAL
201.2 OVERPRESSURE
201.2.1 Indicators — Steam Pressure Gages.
201.2.2 Pressure Relief Valves.
201.2.3 Relief Equipment — Fusible Plugs.
201.3 HIGH OR LOW WATER LEVEL
201.3.1 Indicators — Gage Glasses.
129 201.3.2 Indicators — Automatic High- and Low-Water-Level Alarms.
201.3.3 Automatic Trip.
130 201.4 WEAKENING OF STRUCTURE
201.4.1 Boiler Start-Up.
131 201.4.2 Control of Water Level.
201.4.3 Erosion.
201.4.4 Internal Corrosion.
201.4.5 External Corrosion.
132 201.4.6 Boiler Shutdown.
201.4.7 Boiler Out of Service.
133 201.4.8 Failure of Supports.
201.4.9 Mechanical Damage.
201.5 OPERATION OF COMBUSTION EQUIPMENT
134 201.6 FURNACE EXPLOSIONS
201.7 FURNACE IMPLOSIONS
136 ARTICLE 202 DOCUMENTS, RECORDS, AND REFERENCES
202.1 CODE DOCUMENTATION
202.2 REFERENCED DOCUMENTS
137 202.3 RECORD DRAWINGS AND DOCUMENTATION
202.4 REFERENCES
202.4.1 Published Documents Referenced in This Code.
138 202.4.2 Other Documents Relating to Boilers.
139 SUBSECTION 3 OTHER BOILER TYPES
ARTICLE 300 FIRETUBE BOILERS
300.1 GENERAL
300.2 OUT-OF-SERVICE OPERATION
300.2.1 Isolation.
300.2.2 Water-Side Cleaning.
300.3 INTERNAL EXAMINATIONS
300.3.1 Stays and Braces.
140 Figure 300.3.1-1 Typical Stays
142 300.3.2 Tube Defects.
300.3.3 Ligaments Between Tube Holes.
300.3.4 Manholes and Other Openings.
300.3.5 Fire Surfaces.
300.4 EXTERNAL EXAMINATION
300.5 MAINTENANCE
300.5.1 General.
300.5.2 Maintenance Checks.
143 300.5.3 Operating Checks Relating to Maintenance.
300.5.4 Checklist to Assist in Maintenance.
144 ARTICLE 301 ELECTRIC STEAM BOILERS
301.1 TYPES AND FEATURES
301.2 RESISTANCE-ELEMENT ELECTRIC BOILERS
145 Figure 301.2-1 Typical Electric Steam Boiler With Resistance Elements
146 301.2.1 Water Quality and Treatment for Resistance-Element Electric Boilers.
147 Figure 301.2-2 Typical Electric Steam Boiler With Electronic Water-Level Controls
148 Figure 301.2-3 Typical Large Industrial 300-kW Electric Steam Boiler With Resistance Elements Mounted Horizontally
149 301.2.2 General Care and Maintenance of Resistance-Element Electric Boilers.
301.3 ELECTRODE STEAM BOILERS
301.3.1 Basic Electrode Steam Boilers.
301.3.2 Commonly Used Electrode Steam Boiler Designs.
150 Figure 301.3.1-1 Electrode Steam Boiler
151 301.3.3 Jet-Spray Electrode Steam Boiler Designs.
301.3.4 Water Quality and Treatment for Electrode Steam Boilers.
152 Figure 301.3.3-1 Basic Electrode Steam Boiler With Jet Spray and Mechanical Control Shield
153 301.3.5 Electrical System Requirements for Electrode Steam Boilers.
301.3.6 Maintenance Requirements for Electrode System Boilers.
154 Figure 301.3.3-2 Electrode Steam Boiler With Jet Spray and Variable-Speed Pump Control
156 ARTICLE 302 UTILITY BOILERS
302.1 START-UP
302.1.1 Establish Water Level.
302.1.2 Direct Spring-Loaded Pressure Relief Valves.
157 SUBSECTION 4 COAL-FIRED AND OTHER SOLID-FUEL-FIRED BOILERS
ARTICLE 400 STOKER-FIRED BOILERS
400.1 GENERAL
158 Figure 400.1-1 Typical Underfeed Stoker
Figure 400.1-2 Feeder–Distributor for Firing of Coal on a Spreader Stoker
159 400.2 PREPARATION FOR SERVICE
400.3 STOKER FIRING
Figure 400.1-3 Spreader Stoker, Continuous Ash Discharge Grate
160 400.4 SHUTTING DOWN
400.5 HIGH WATER LEVEL IN STOKER-FIRED BOILERS
400.6 BOILER TUBE FAILURE ON STOKER-FIRED UNITS
161 ARTICLE 401 PULVERIZED-COAL-FIRED BOILERS
401.1 GENERAL
401.2 PREPARATION FOR SERVICE
401.3 MAINTAINING PROPER FURNACE PRESSURE
401.4 PULVERIZED-COAL FIRING
162 Figure 401.2-1 Typical Bowl Mill
163 Figure 401.2-2 Typical Attrition Mill
164 Figure 401.2-3 Arrangement of Ball-Tube Mill
Figure 401.4-1 Burner for Horizontal Firing of Coal
165 401.5 SHUTTING DOWN
401.6 FIRE IN NONOPERATING PULVERIZERS
166 401.7 FIRE IN OPERATING PULVERIZERS
167 401.8 FIRE IN PULVERIZED-FUEL SYSTEMS
401.9 INSTRUMENTATION, CONTROLS, AND INTERLOCKS FOR PULVERIZED-FUEL OPERATION
401.10 CYCLONE FURNACES
168 ARTICLE 402 ASH REMOVAL
402.1 GENERAL
402.2 BOTTOM ASH — WET REMOVAL
402.3 BOTTOM ASH — DRY REMOVAL
169 402.4 FLY ASH REMOVAL
170 402.5 FIRE-SIDE CLEANING
171 ARTICLE 403 MAINTENANCE
403.1 MAINTENANCE CHECKS — STOKERS
403.1.1 Underfeed Stoker.
403.1.2 Spreader Stoker.
403.1.3 Dump Grates.
403.1.4 Traveling Grates.
172 403.2 MAINTENANCE CHECKS — PULVERIZED-COAL FIRING
403.2.1 Feeder.
403.2.2 Pulverizer.
403.2.3 Exhauster.
403.2.4 Burner.
403.3 MAINTENANCE CHECKS — ASH REMOVAL SYSTEM
403.3.1
403.3.2
173 SUBSECTION 5 GLOSSARY
186 Table I-100-1 Standard Units for Use in Equations
MANDATORY APPENDIX I STANDARD UNITS FOR USE IN EQUATIONS
187 NONMANDATORY APPENDIX A CHECKLISTS FOR MAINTENANCE EXAMINATIONS
ARTICLE A-100 PROCEDURES FOR CARE AND MAINTENANCE OF PACKAGE BOILERS
A-100.1 CLEANING OF PARTS AND STRAINERS
A-100.2 CARE OF MOTORS AND ELECTRICAL EQUIPMENT
A-100.3 DRYING OF PARTS AFTER WATER IMMERSION
188 A-100.4 PERMANENT OR SEASONAL SHUTDOWN
189 ARTICLE A-101 MAINTENANCE CHECKS FOR GAS-, OIL-, AND SOLID-FUEL-FIRED WATERTUBE BOILERS
190 Forms
Form A-101-1 Watertube Boilers — Maintenance Checks
198 Form A-102-1 Watertube Boilers — Operating Checks Relating to Maintenance
ARTICLE A-102 OPERATING CHECKS RELATING TO MAINTENANCE FOR GAS-, OIL-, OR SOLID-FUEL-FIRED WATERTUBE BOILERS
200 Form A-103-1 Firetube Boilers — Maintenance Checks
ARTICLE A-103 MAINTENANCE CHECKS FOR FIRETUBE BOILERS
201 Form A-104-1 Firetube Boilers — Operating Checks Relating to Maintenance
ARTICLE A-104 OPERATING CHECKS RELATING TO MAINTENANCE FOR FIRETUBE BOILERS
202 NONMANDATORY APPENDIX B GUIDANCE FOR THE USE OF U.S. CUSTOMARY AND SI UNITS IN THE ASME BOILER AND PRESSURE VESSEL CODE
B-100 USE OF UNITS IN EQUATIONS
B-200 GUIDELINES USED TO DEVELOP SI EQUIVALENTS
206 B-300 SOFT CONVERSION FACTORS

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