Boilers Basic Components (Att. VIII)

7/23/2019 Boilers Basic Components (Att. VIII)

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ATTACHMENT VIII TO SAIR’s GUIDELINES

SOME EQUIPMENT BASIC CONCEPTS

Boilers Basic Components

CONTENTS PAGE

INTRODUCTION………………………………………………………… 2

STEAM SYSTEM ………………………………………………………… 2

BOILER CHARACTERISTICS ………………………………………….. 3

Major Boiler Componen! …………………………………………………. ""Mi!#ellaneo$! Boiler Componen! ………………………………………..."%

&ABRICATION …………………………………………………………… "'

NONDESTRUCTI(E E)AMINATION…………………………………. 22HYDROSTATIC TESTIN*………………………………………………. 23

BOILER SA&ETY (AL(ES ……………………………………………... 23

STANDARDS AND CODES……………………………………………….2+

*LOSSARY…………………………………………………………………2%



INTRODUCTION

T,i! !e#ion pro-ie! an inro$#ion o ,e !eam /enerain/ e0$ipmen $!e 1 Sa$iAram#o in#l$in/ an o-er-ie4 o5 pi#al plan !eam !!em!. T,e pe! o5 1oiler! an

1oiler #omponen! $!e 1 Sa$i Aram#o are e!#ri1e.

STEAM SYSTEM OVERVIEW

Terminology for the Design n! O"ertions of #oilers

A pi#al !eam !!em !,o4n in &i/$re " pro-ie! ,ermal ener/ in ,e 5orm o5 !eam

o a n$m1er o5 #on!$mer!. T,e 6e elemen! in ,i! !!em are ,e !eam /eneraor! ,e

i!ri1$ion !!em an ,e $!er!. S$ppl o5 1oiler 5ee4aer 7B&89 o ,e !eam

/eneraor an re#o-er o5 #onen!ae 5or re##lin/ are al!o in#l$e in ,e !eam !!em.

" Boiler 2 Deaeraor 3 B&8 :$mp ; Conin$o$! Blo4o4n &a#iliie!

+ Inermien Blo4o4n &a#iliie! % :re!!$re Re$#in/ Saion ' De!$per,eaer

< Di!ri1$ion :ipin/ an (al-e! = Conen!ae Re$rn S!em

S( S!em Sa5e (al-e!

$IGURE % TYPICA& STEAM SYSTEM

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T,e !eam /eneraor #an 1e ei,er a par o5 a pro#e!! $ni $!in/ 4a!e or !$rpl$! ,ea or a

!eparae o55!ie 5a#ili 1$rnin/ 5$el in a 1oiler. T,e 5$el #an 1e /a! oil or #oal. Seam

#an al!o 1e /enerae 1 re#o-er o5 4a!e ,ea 5rom ,e e?,a$! o5 a /a! $r1ine.8a!e or !$rpl$! pro#e!! ,ea #an #ome 5rom 5$rna#e 5l$e /a!e! pro#e!! #ooler! 7,ea

e?#,an/er!9 or ,o pro$# r$no4n. T,e !eam i!ri1$ion ne4or6 #on!i!! o5 pipin/

an -al-e! ,a iner#onne# 1e4een ,e pro$#er! an #on!$mer! o5 !eam. Seam #an 1e pro$#e an #on!$me a -ario$! pre!!$re le-el!. T,e!e i55eren pre!!$re le-el! are

$!$all #onne#e -ia pre!!$re re$#in/ an !eam e!$per,eain/ !aion! !o ,a

!$rpl$!e! o5 !eam a ,i/,er pre!!$re le-el! #an 1e $ili@e a lo4er pre!!$re le-el!.Al,o$/, no !anari@e #ommonl $!e !eam pre!!$re le-el! in Sa$i Aram#o plan!

ran/e 5rom % o %2+ p!i/. Mo! plan! ,a-e a ,i/,>pre!!$re 7H:9 le-el o5 % o %2+

p!i/ pl$! one or m$#, lo4er pre!!$re le-el!. &or e?ample !eam pre!!$re le-el! a

A10ai0 are %2+ an % p!i/ an a Ra! Tan$ra ,e !eam pre!!$re le-el! are % 22+"+ an % p!i/. T,e!e %> o 22+>p!i/ le-el! are re5erre o a! mei$m>pre!!$re 7M:9

le-el!. U!$all ,ere i! al!o a lo4>pre!!$re 7L:9 le-el a "+ p!i/.

T,e !eam !!em 1e/in! 4i, ,e !$ppl o5 reae 4aer o a eaeraor 4,ere i!!ol-e

/a!e! !$#, a! o?/en an #ar1on io?ie are remo-e prior o inro$#ion o5 ,e 4aerino ,e 1oiler. T,e!e /a!e! are $ne!ira1le 1e#a$!e o5 ,eir #orro!i-e aa#6 on meal

!$r5a#e!. T,e 4aer i! eaerae 1 ,eain/ i o i! !a$raion empera$re an ,en!#r$11in/ i 4i, !eam o #arr a4a ,e i!!ol-e /a!e!. T,e eaeraor operain/

pre!!$re i! normall ,e !ame a! ,e L: !eam !!em 7"+ p!i/9. Boiler 5ee4aer p$mp!

are $!e o eli-er B&8 5rom ,e eaeraor o ,e 1oiler !eam r$m. T4o or more p$mp!are pro-ie o en!$re a relia1le !$ppl o5 4aer o ,e 1oiler. 8,ere-er po!!i1le

#onen!e !eam 5rom ,e !eam $!er! i! #olle#e in a #onen!ae !!em an re$rne o

,e eaeraor 5or re##lin/.

#OI&ER C'ARACTERISTICS

Ty"es

T,e ,ree main pe! o5 1oiler! $!e 1 Sa$i Aram#o are 4aer>$1e 5ire$1e an

ele#ri#. 8aer>$1e 1oiler! are ill$!rae in &i/$re! 2 ,ro$/, +. T,e!e are ,e lar/e!an mo! #ommon 1oiler pe!. A 5ire$1e 1oiler i! ill$!rae in &i/$re % an an ele#ri#

1oiler i! ill$!rae in &i/$re '.

8aer>$1e 1oiler! ,a-e no real pre!!$re or !i@e limiaion!. T,e 1a!i# #on5i/$raion i! a

5ire1o? !$rro$ne 1 $1e! 5ille 4i, 4aer. Lo#ae a ,e op o5 ,e 4aer>$1e 1oiler

i! a r$m in 4,i#, !eam i! !eparae 5rom ,e 4aer. 8aer #ir#$lae! 5rom ,e !eam

r$m o4n ,ro$/, ,e 4aer $1e! an 1a#6 o ,e !eam r$m. T,i! $!$all o##$r! 1e#a$!e o5 na$ral #ir#$laion al,o$/, !ome 1oiler! ,a-e 5or#e #ir#$laion !!em!.

T,e !maller>!i@e 4aer>$1e 1oiler! are $!$all !,op a!!em1le an eli-ere o ,e 5ielin a #omplee $ni. T,e!e $ni! are re5erre o a! pa#6a/e 1oiler!. T,e ma?im$m !i@e o5

pa#6a/e 1oiler! epen! lar/el on ran!poraion limi!. Lar/er $ni! #an 1e !,ippe in a

5e4 mo$le! 4,i#, are a!!em1le in ,e 5iel. Man Sa$i Aram#o 1oiler! are pa#6a/e$ni! 4i, ,e lar/e! ,a-in/ a #apa#i o5 a1o$ % l1,r o5 !eam a a e!i/n

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pre!!$re o5 a1o$ << p!i/. Tpi#al pa#6a/e 1oiler! are !,o4n in &i/$re! 2 an 3. Lar/er

!i@e 4aer>$1e 1oiler! are 5iel ere#e. A pi#al 5iel>ere#e 1oiler i! !,o4n in &i/$re

;.

$IGURE ( PAC)AGE WATER*TU#E #OI&ER

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$IGURE + WATER*TU#E #OI&ER

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$IGURE , $IE&D*ERECTED WATER*TU#E #OI&ER

A /a! $r1ine 4a!e ,ea 1oiler i! ill$!rae in &i/$re +. T,e!e 1oiler! are $!$all a

!pe#ial e!i/n. T,e #an 1e e!i/ne a! $n5ire $ni! operain/ on 4a!e ,ea onl or a!

!$pplemenar 5ire $ni! 4i, /a! or li0$i 5$el o in#rea!e !eam pro$#ion. Be#a$!eo5 ,e pe o5 !$pplemenar 5irin/ $!e ,e 1oiler !,o4n in &i/$re + #an al!o 1e re5erre

o a! a $#>5ire 4a!e ,ea 1oiler. Boiler !i@e i! epenen on ,e !i@e o5 ,e /a! $r1ine.

T,e pi#all pro$#e " o ; l1,r o5 !eam a "+ o % p!i/.

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$IGURE - GAS TUR#INE WASTE 'EAT #OI&ER

&ire$1e 1oiler! are /enerall o5 !mall !i@e 7$ner " l1,r an more #ommonl$ner + l1,r9 an lo4 pre!!$re 7$ner 2+ p!i/ an more #ommonl "+ p!i/ or

lo4er9. T,e !eam i! $!$all no !$per,eae. T,e name 5ire$1e #ome! 5rom ,e

arran/emen 4,ere ,o #om1$!ion pro$#! 5lo4 in!ie $1e! ,a are lo#ae in a 4aer>5ille #linri#al !,ell. &ire$1e 1oiler! are le!! e?pen!i-e ,an 4aer>$1e 1oiler! o5 ,e

!ame !i@e an pre!!$re rain/. &ire$1e 1oiler! are $!$all pa#6a/e an !6i mo$ne.

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$IGURE . $IRETU#E #OI&ER

Ele#ri# 1oiler! are o5en $!e 5or !mall !eam loa! a lo#aion! o$!ie o5 main plan!

5or e?ample me#,ani#al !,op! inin/ ,all! an ,o!pial!. Ele#ri# 1oiler! are $!$all-er !mall in !i@e 7/enerall le!! ,an 2+ l1,r9 an lo4 pre!!$re 7le!! ,an " p!i/9.

In a re!i!an#e 1oiler ele#ri# re!i!an#e ,eain/ elemen! are immer!e in a 4aer 1a,

,a i! en#lo!e in an o$er pre!!$re -e!!el. Hea inp$ an !eam o$p$ are re/$lae 1#onrol! 4,i#, !ele# ,e n$m1er o5 ,eain/ elemen! o 1e ener/i@e.

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$IGURE / E&ECTRIC STEAM #OI&ER

&i/$re < li!! ,e major 1oiler! in Sa$i Aram#o plan!.

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$IGURE 0 SAUDI ARAMCO #OI&ERS

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SAUDI ARAMCO #OI&ERS 1CONT2D3

M4or #oiler Com"onents

T,e major #omponen! o5 a pi#al Sa$i Aram#o 1oiler are !,o4n in &i/$re = 4,i#, i!an ill$!raion o5 Ra! Tan$ra H: Boiler No. ". T,e $pper r$m 7!eam r$m9 pro-ie!

!pa#e 5or !eparain/ !eam 5rom 4aer. I al!o pro-ie! li0$i ,ol$p #apa#i 7pi#all

5rom " o % !e#on!9 o allo4 5or a nami# re!pon!e o loa #,an/e! 4i,o$ lo!in/li0$i in ,e 4aer $1e!.

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Seam r$m inernal! 5or ,i! pe 1oiler are !,o4n in &i/$re ". In#l$e are 1a55le! an

!#reen! o a!!i! in !eparain/ ,e !eam an 4aer mi?$re enerin/ 5rom ,e $1e!. O,er

e-i#e! !$#, a! ##lone !eparaor! are al!o $!e in !ome 1oiler! o !eparae ,e !eam.O,er r$m inernal! in#l$e 5ee4aer pipin/ 1lo4o4n pipin/ an #,emi#al inje#ion

pipin/.

$IGURE 5 #OI&ER COMPONENTS * RAS TANURA 'P #OI&ER NO6 %7

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$IGURE %7 STEAM DRUM INTERNA&S * RAS TANURA 'P #OI&ER NO6 0

Mo! 4aer>$1e 1oiler! ,a-e a lo4er r$m 7m$ r$m9 5or #olle#in/ !eimen an

imp$riie!. T,i! r$m al!o a#! a! a lo4er ,eaer 5or #onne#ion o5 ,e 4aer $1e!.T,e 4aer #ir#$i 1e4een ,e r$m! #on!i!! o5 o4n#omer! an ri!er!. A o4n#omer i!

a $1e in an $n,eae or le!! ,eae area o5 ,e 1oiler. A ri!er i! a $1e in ,e ,eae or

,oer !e#ion o5 ,e 1oiler. 8aer en! o 5lo4 1 na$ral #ir#$laion 5rom ,e !eam

r$m o ,e m$ r$m -ia ,e o4n#omer! an ,en 1a#6 o ,e !eam r$m -ia ,e

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ri!er!. E-aporaion a6e! pla#e in ,e ri!er! an ,e !eam4aer mi?$re 4ei/,! le!! ,an

,e 4aer in ,e o4n#omer!. In !ome 1oiler! #ir#$laion i! 5or#e 1 p$mpin/.

Mo! 4aer>$1e 1oiler! ,a-e 4all 5loor an roo5 $1e! !$rro$nin/ ,e 5ire1o?. 8aer5lo4! in ,e!e $1e! 5rom ,e m$ r$m o ,e !eam r$m. In aiion o a1!or1in/ ,ea

,e!e $1e! #ool ,e 1oiler en#lo!$re an re$#e ,e amo$n o5 re5ra#or re0$ire. In

&i/$re = ,e 5loor 5ron 4all an roo5 $1e! are !,o4n 5ormin/ a #onin$o$! 5lo4pa,5rom ,e m$ r$m o ,e !eam r$m. A re5ra#or laer i! o5en pla#e on ,e 5loor

$1e! o re$#e ,e ,ea ran!5er o ,e!e $1e!. T,e !ie4all $1e! are #onne#e o

1oom an op ,eaer! 4,i#, in $rn are #onne#e o ,e r$m! 1 !$ppl an relie5$1e!. Aja#en $1e! in ,e!e 4all! are o5en 4ele o #onne#in/ !eel !rip! o 5orm a

#onin$o$! mem1rane 4all 4,i#, i! ill$!rae in &i/$re "". T,i! #on!r$#ion permi! a

pre!!$re>i/, en#lo!$re.

$IGURE %% TYPICA& WATER WA&& CONSTRUCTION

Mo! 4aer>$1e 1oiler! al!o ,a-e !eam !$per,eaer!. 8,en !eam i! !eparae 5rom

4aer in ,e !eam r$m i i! !a$rae a ,e r$m pre!!$re. T,i! !eam i! ro$e ,ro$/,

,e !$per,eaer $1e! o rai!e ,e !eam empera$re a1o-e !a$raion empera$re. T,e

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!$per,eaer i! $!$all lo#ae a ,e e?i o5 ,e 5ire1o? 4,ere ,e 5l$e /a! empera$re i!

,i/, eno$/, 5or e55i#ien ,ea ran!5er. Ho4e-er !#reen $1e! are o5en $!e j$! a,ea o5

,e !$per,eaer o !,iel ,e !$per,eaer 5rom ire# raiaion 5rom ,e ,o #om1$!ion/a!e!. Heaer! are $!e o i!ri1$e ,e !eam o ,e parallel 5lo4pa,! $!e in ,e

!$per,eaer an o #olle# i. A! !,o4n in &i/$re = ,e!e ,eaer! are lo#ae a ,e

1oom o5 ,e !$per,eaer !o ,a ,e enire !$per,eaer #oil i! raina1le 7a Sa$i Aram#ore0$iremen9.

Sa5e -al-e! are $!$all in!alle 1o, on ,e !eam r$m an a ,e 1oiler o$le o proe# 1o, ,e 1oiler an ,e !$per,eaer 5rom o-erpre!!$re.

Boiler! #an 1e e!i/ne o 5ire nearl an 5$el ei,er !oli li0$i or /a! or

#om1inaion! o5 ea#,. Sa$i Aram#o! 1oiler! 5ire /a! an oil 5$el!.

Com1$!ion air i! !$pplie o ,e 1oiler 1 a 5or#e ra5 5an. T,i! air ener! ,e 1oiler

,ro$/, a 4in1o? 4,ere i i! i!ri1$e o ,e 1$rner!. T,e air mi?e! 4i, ,e 5$el in,e 1$rner! an #om1$!ion a6e! pla#e in ,e #om1$!ion @one o5 ,e 1oiler. T,ere are

man pe! an #on5i/$raion! o5 1$rner! epenin/ $pon ,e 5$el! 5ire an ,e !i@e

an e!i/n o5 ,e 1oiler.

Hea i! ran!5erre 5rom ,e 1$rnin/ 5$el an ,o /a!e! o ,e 4aer 4all $1e!

!$rro$nin/ ,e #om1$!ion @one. T,e!e 5l$e /a!e! ,en 5lo4 pa! ,e !$per,eaer $1e!

an ,ro$/, ,e 1oiler 1an6 $1e!. Ba55le! are o5en $!e in ,e 1oiler 1an6 o e5ine ,e5l$e /a! 5lo4> pa,. T,e 5l$e /a!e! ,en e?i ,e 1oiler ,ro$/, a 5l$e /a! $# an !a#6.

To impro-e e55i#ien# man 1oiler! ,a-e e#onomi@er!. T,e!e are ,ea e?#,an/er! ,aran!5er ,ea 5rom ,e 5l$e /a! lea-in/ ,e 1oiler o ,e 1oiler 5ee4aer. T,i! re$#e! ,e

!a#6 empera$re.

Some 1oiler! ma al!o $!e a #om1$!ion air pre,eaer o impro-e e55i#ien#. T,i! i! al!o

a ,ea e?#,an/er an i! $!e o ran!5er ,ea 5rom ,e 5l$e /a! lea-in/ ,e 1oiler o ,e air

,a i! $!e 5or #om1$!ion.

&i/$re "2 i! a !impli5ie 5lo4 plan o5 a 1oiler an i! a$?iliarie!. I !,o4! ,o4 ,e!e

#omponen! an ,o!e e!#ri1e in ,e 5ollo4in/ pa/e! 5i ino ,e o-erall !eam

/eneraion !!em.

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$IGURE %( TYPICA& STEAM GENERATION SYSTEM

Mis8ellneo9s #oiler Com"onentsSome 1oiler! re0$ire aemperaor! o4n!ream o5 ,e !eam !$per,eaer o #onrol ,e

1oiler !eam o$le empera$re a -ario$! loa!. T,e !$per,eaer i! e!i/ne o pro-ie a!pe#i5i# !eam empera$re a e!i/n #oniion!. A o,er #oniion! ,i! empera$re

ma 1e e?#eee an i! #onrolle 1 !prain/ ,i/,>0$ali 4aer ino ,e o$le !eam o

#ool or aemperae i.

Oil>5ire 1oiler! $!$all re0$ire !oo1lo4er! o perioi#all #lean ,e 1oiler $1e!. Soo>

1lo4er! ire# a 1la! o5 !eam a $1e! in ,e irie! par o5 ,e 1oiler o 1la!

#om1$!ion pro$#! o55 ,e $1e !$r5a#e!. T,i! #lean! ,e $1e! an in#rea!e! ,earan!5er.

Boiler! ,a-e 1lo4o4n #onne#ion! in 1o, ,e !eam an m$ r$m! o remo-e#on#enrae !eimen an imp$riie! ,a re!$l 5rom e-aporaion o5 ,e 1oiler 4aer.

Blo4o4n 5rom ,e !eam r$m i! $!$all #onin$o$! an ,e amo$n i! !e o #onrol

imp$ri le-el! 1elo4 !pe#i5ie ma?im$m!. T,e 1lo4o4n rae ma 1e in#rea!e ore#rea!e o##a!ionall epenin/ $pon 1oiler 4aer anal!i!. Blo4o4n 5rom ,e m$

r$m i! $!$all inermien 1a!e on e?perien#e. M$ r$m 1lo4o4n primaril

remo-e! !eimen.

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$A#RICATION

T,i! !e#ion pro-ie! in5ormaion on ,e major !ep! in-ol-e in ,e 5a1ri#aion ana!!em1l o5 1oiler #omponen! in#l$in/ in!pe#ion an e!in/.

T,e 5a1ri#aion an e!in/ o5 4aer>$1e 1oiler! are #o-ere 1 Sa$i Aram#o Maerial!S!em Spe#i5i#aion 32>SAMSS>2". T,i! !pe#i5i#aion re0$ire! ,a ,e 1oiler 1e 1$il

in a##oran#e 4i, ,e ASME Boiler an :re!!$re (e!!el Coe >Se#ion I :o4er Boiler!.

T,e 4elin/ o5 pre!!$re par! i! #o-ere e?en!i-el in ,e Coe. Mo! 4el! m$! 1e

in!pe#e 1 raio/rap, o 5in an 5la4! ,a nee o 1e repaire in ,e 4el. T,e

#omplee 1oiler m$! 1e ,ro!ai#all e!e o emon!rae ,a i! #on!r$#ion i!

!o$n. T,e e!in/ !,o$l al!o 5in mar/inal e5e#! 4,i#, 4o$l 1e apparen 4,en!$1je#e o ,e ma?im$m allo4a1le 4or6in/ pre!!$re.

T,i! !e#ion i! inene o a!!i! ,e SAIR in $ner!anin/ ,e re0$iremen! 5or

5a1ri#aion an e!in/ o5 pre!!$re par! 5or Sa$i Aram#o 1oiler! in a##oran#e 4i, ,eCoe. T,e Coe #onain! man !pe#i5i# eaile re0$iremen!

&a1ri#aion in#l$e! all a#i-iie! $!e 1 ,e man$5a#$rer o #on-er maerial! ino

#omplee 1oiler!. A 4ie ran/e o5 man$5a#$rin/ pro#e!!e! i! $!e in#l$in/ 4elin/

1enin/ 5ormin/ rollin/ #$in/ rillin/ an ma#,inin/. T,e Coe pro-ie! onl alimie n$m1er o5 /eneral r$le! #o-erin/ mo! a!pe#! o5 1oiler 5a1ri#aion. T,i! permi!

,e man$5a#$rer 1roa lai$e in !ele#in/ ,e mo! appropriae man$5a#$rin/

pro#e!!e!. T4o area! are #o-ere in ,i! !e#ion !pe#i5i#all 4elin/ an $1e

#onne#ion!.

Wel!ing

Boiler #omponen! are /enerall a!!em1le 1 4elin/. Mo! o5 ,i! 4elin/ i! one in,e man$5a#$rer! !,op. T,e 1oiler i! $!$all eli-ere o ,e 5iel in #omplee $ni! or in

lar/e mo$le! 5or 5inal a!!em1l. 8elin/ i! #o-ere e?en!i-el in :ar :8 o5 ,e Coe

in#l$in/ maerial! e!i/n ,ea reamen an e?aminaion o5 4ele join!.All 4elin/ o5 pre!!$re par! m$! 1e one 1 0$ali5ie 4eler! 5ollo4in/ e!a1li!,e

eaile pro#e$re!. T,e re0$iremen! 5or e!a1li!,in/ !ai!5a#or pro#e$re! an 5or

eerminin/ ,a ea#, 4eler #an ma6e !ai!5a#or 4el! a##orin/ o ,e!e pro#e$re!

are #onaine in Se#ion I) o5 ,e Coe.T,e /eneral e!i/n re0$iremen! 5or lon/i$inal #ir#$m5erenial an o,er pe! o5

4ele join! are #o-ere in :ar. :8>=. Do$1le>4ele 1$>pe join! are pre5erre.

Sin/le>4ele 1$>pe join! ma al!o 1e $!e i5 ,e e!i/n o5 ,e!e join! permi!#omplee join peneraion. A !in/le 4ele join ma re0$ire #on!iera1l more 4elin/

,an a o$1le>4ele join !o i i! no normall $!e 4,ere i i! po!!i1le o ma6e a

o$1le>4ele join. :ar. :8>=.; re0$ire! ,a 1enin/ !re!!e! no 1e applie ire#l o4ele join!. Tpi#al 4ele join! are !,o4n in &i/$re "3.

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$IGURE %+ Ty"i8l Wel!e! :oints

Post*Wel! 'et Tretment

Mo! 4el! on 1oiler pre!!$re par! re0$ire po!>4el ,ea reamen. T,i! re$#e!

!re!!e! in ,e 4el an ,e ajoinin/ 1a!e maerial! ,a e-elop $rin/ ,e 4elin/ pro#e!!. :o!>4el ,ea reamen i! al!o o5en re5erre o a! !re!! relie-in/. T,e

manaor re0$iremen! 5or po!>4el ,ea reamen are li!e in :ar. :8>3=.

Tempera$re! re0$ire 5or !re!! relie-in/ are in ,e ran/e o5 "">";& an m$! 1e,el $p o !e-eral ,o$r! epenin/ on ,e ,i#6ne!! o5 ,e 4el an ,e pe o5 maerial!$!e. An enire #omponen !$#, a! a r$m or ,eaer #an 1e !re!! relie-e a! a #omplee

$ni in ,e man$5a#$rer! !re!! relie-in/ 5$rna#e. Alernai-el ini-i$al 4el! or

/ro$p! o5 4el! #an 1e !re!! relie-e $!in/ pora1le ,eain/ elemen! ,a are pla#earo$n ,e 4el!.

T9;e Conne8tions

T,e major 5iel 4or6 on 1oiler pre!!$re par! #on!i!! o5 #onne#in/ $1e! an pipe! o

r$m! ,eaer! or o,er $1e! an pipe!. T,e!e #onne#ion! are ne#e!!ar in ere#in/

ne4 1oiler! an 5or repla#in/ $1e! or !e#ion! o5 $1e! a5er ,e 1oiler ,a! 1een in

!er-i#e. Mo! $1e! are #onne#e o ,e !eam an m$ r$m! 1 e?panin/ ,em ino,ole! in ,e r$m 4all. O,er #onne#ion! are mae 1 4elin/.

E<"n!e! T9;e Conne8tions

T$1e! are $!$all aa#,e o ,e r$m 1 e?panin/ 7or rollin/9 ,e en o5 ea#, $1e

ino a ,ole in ,e r$m 4all. A /roo-e i! $!$all #$ in ,e !ie o5 ,i! ,ole. A !pe#ial ool

7#alle an e?paner9 i! $!e o pre!!$re e?pan ,e $1e in ,i! ,ole lea-in/ ,e $1e 1earin/ i/,l a/ain! ,e r$m 4all. A pi#al e?pane $1e #onne#ion i! ill$!rae in

> "= >



&i/$re "; 4,i#, i! 1a!e on S,e/$m Boiler &>"". :ar. :8T ""." re0$ire! ,a ,e

$1e e?en "; o 3; in. ,ro$/, ,e r$m 4all. Al!o ,e $1e en m$! 1e 5lare o an

o$!ie iameer o5 a lea! "< in. /reaer ,an ,e $1e ,ole. E?pane $1e #onne#ion!are /enerall !$ia1le 5or pre!!$re! $p o a1o$ "2 p!i 4,i#, #o-er! all Sa$i Aram#o

1oiler!. In !ome #a!e! 4,ere ,e $1e! are !$1je# o $n$!$al loain/ or empera$re

#oniion! lea6! ma e-elop in e?pane $1e #onne#ion!. In ,e!e #a!e! a !eal 4el#an 1e $!e o en!$re i/, #onne#ion!. T,e ma?im$m !i@e !eal 4el i! 3< in. an !re!!

relie-in/ i! no re0$ire. T$1e! !,all 1e re>e?pane a5er !eal 4elin/ a! re0$ire per

:ar. :8T "">".

In #a!e! 4,ere e?pane $1e #onne#ion! are no po!!i1le $1e! are 4ele o !$1! or

no@@le! alrea 4ele o ,e r$m or ,eaer. T,i! permi! ,e 4el! on ,e r$m o 1e

!re!! relie-e 1e5ore ,e $1e! are #onne#e.

$IGURE %, Ty"i8l e<"n!e! ;oiler t9;e

Tpi#al $1e #onne#ion! are !,o4n in &i/$re "+. T,e!e #onne#ion! are a6en 5rom &i/.

:8>"%." 4,i#, ill$!rae! 2= pe! o5 a##epa1le 5$!ion 4ele #onne#ion!. O,er pe!

> 2 >



o5 #onne#ion! 4,i#, mee all ,e Coe re0$iremen! 4o$l al!o 1e a##epa1le. F:ar. :8>

"+ #onain! pro#e$re! 5or #al#$lain/ ,e re0$ire !ren/, o5 ,e!e 4el!.G

Re5er o ,e appropriae #onne#ion! 5rom &i/$re :8>"%>".

T,i#6ne!! o5 -e!!el !,ell or ,ea in.

n T,i#6ne!! o5 no@@le 4all in.

4 Dimen!ion o5 aa#,men 4el mea!$re a! !,o4n in.# No le!! ,an ,e !maller o5 "; in. or .' min.

> 2" >



$IGURE %- Ty"i8l T9;e Conne8tions to Dr9ms n! 'e!ers

Wel!e! Conne8tions

T,e mo! #ommon 4ele #onne#ion! mae in ,e 5iel #on!i! o5 #ir#$m5erenial 1$>

4ele join! in $1e! pipe! an ,eaer!. Be#a$!e o5 ,eir !mall !i@e !re!! relie-in/an raio/rap, are no re0$ire 5or man #ir#$m5erenial $1e 4el!. &or e?ample

raio/rap, i! no re0$ire on #ir#$m5erenial 4el! ,a o no e?#ee ,e 5ollo4in/

imen!ion! 7:ar. :8>;"."9

• All #omponen! ;.+>in. o$!ie iameer or .+>in. 4all ,i#6ne!!. T,i! !,o$l

#o-er all 1oiler an !$per,eaer $1e!.

• Componen! no e?po!e o 5l$e /a! empera$re! e?#eein/ <+&

> Seam !er-i#e "%>in. nominal pipe !i@e ".%2+>in. 4all ,i#6ne!!.> 8aer !er-i#e ">in. nominal pipe !i@e "."2+>in. 4all ,i#6ne!!.

:o!>4el ,ea reamen i! /enerall no re0$ire 5or #ir#$m5erenial 4el! in $1e! 4i,

a ma?im$m !pe#i5ie #,romi$m #onen o5 3.J. T,i! !,o$l #o-er mo! #on-enional 1oiler an !$per,eaer $1e maerial!.

NONDESTRUCTIVE E=AMINATION

None!r$#i-e e?aminaion 7NDE9 i! $!e o i!#o-er 5la4! in maerial or 4el!. NDE

,$! a!!$re! !o$n #on!r$#ion o5 1oiler pre!!$re par!. NDE re0$iremen! are e!#ri1e

in Se#ion ( o5 ,e Coe. T,e 5ollo4in/ me,o! are $!e o e?amine ,e 1oiler

• Raio/rap,i# e?aminaion.

• Ulra!oni# e?aminaion.

• Ma/nei# pari#le e?aminaion.

• Li0$i peneran e?aminaion.• (i!$al e?aminaion.

E?#ep 5or #erain #a!e! ,e Coe re0$ire! ,a all lon/i$inal an #ir#$m5erenial 4el!

1e raio/rap,i#all e?amine. Raio/rap,i# in!pe#ion i! no re0$ire 5or man o5 ,e

5ollo4in/ pe! o5 4el!

• Small>!i@e #ir#$m5erenial 1$ 4el! in $1e! an pipe a! e!#ri1e a1o-e.

• Aa#,men 4el! !imilar o ,e pe! !,o4n in &i/$re "+ 7:ar. :8>"%."9 e?#ep

5or in!er>pe no@@le!. T,i! pe o5 4el i! e!!eniall a 1$ 4el an a #lear

raio/rap,i# pi#$re o5 ,e 4el #an 1e o1aine.

8,en i i! no po!!i1le o raio/rap, a 4el $e o ,e !,ape o5 ,e par or 4el ,e

Coe re0$ire! ,a ,e 4el 1e $lra!oni#all e?amine 7:ar. :8>"".29. Ma/nei# pari#lein!pe#ion an li0$i e peneran in!pe#ion! are al!o $!e o lo#ae !mall !$r5a#e

#ra#6!. 8el! are al!o -i!$all in!pe#e.

T,e 5ollo4in/ 4el e5e#! m$! 1e repaire

• An pe o5 #ra#6.

• Kone! o5 in#omplee 5$!ion or peneraion.

> 22 >



• E?#e!!i-e !la/ in#l$!ion! in ,e 4el.

De5e#! in 4ele join! are repaire 1 re4elin/. Small e5e#! in ,e 1a!e maerial!are al!o repaire 1 4elin/. In aiion o ,e in!pe#ion pro#e!!e! li!e a1o-e e5e#!

al!o ma 1e 5o$n 1 lea6a/e e!!. De5e#! m$! 5ir! 1e remo-e $!$all 1 me#,ani#al

mean! !$#, a! /rinin/. T,e join #an ,en 1e re4ele an re>e?amine.

'YDROSTATIC TESTING

A5er ,e 1oiler ,a! 1een ere#e i i! !$1je#e o ,ro!ai# pre!!$re e!! o #on5irm

,a i ,a! 1een properl #on!r$#e. T,i! e! al!o en!$re! ,a ,ere are no mar/inal

e5e#! ,a 4o$l 1e#ome apparen a ,e ma?im$m allo4a1le 4or6in/ pre!!$re.

Re0$iremen! are li!e in :ar. :*>==.

T4o e! #oniion! are re0$ire

• A !ren/, e! a a pre!!$re e0$al o ".+ ime! ,e ma?im$m allo4a1le 4or6in/

pre!!$re o5 ,e 1oiler. :re!!$re i! /ra$all in#rea!e $nil ,i! e! pre!!$re i!rea#,e. T,e pre!!$re m$! 1e #onrolle !o ,a ,e e! pre!!$re i! ne-er

e?#eee 1 more ,an %J.

• A #are5$l -i!$al e?aminaion 5or lea6! a ,e ma?im$m allo4a1le 4or6in/

pre!!$re. An lea6! ,a are 5o$n $rin/ ,i! e! m$! 1e repaire an ,e 1oiler

m$! 1e re>e!e. T,e ma?im$m meal empera$re! !,o$l no e?#ee "2&

$rin/ ,i! e?aminaion.

D$rin/ ,e!e e!! ,e 1oiler i! #ompleel 5ille 4i, 4aer. To ,e e?en po!!i1le all air

in ,e 1oiler i! i!pla#e. T,i! ma6e! i ea!ier o rea#, e! pre!!$re! an re$#e! ,e

poenial 5or#e! ,a 4o$l 1e relea!e in ,e e-en o5 a r$p$re. &or #omplee pa#6a/e

$ni! ,e ,ro!ai# e! i! #on$#e in ,e man$5a#$rer! !,op. A !e#on e! ma 1ere0$ire in ,e 5iel a5er ,e 1oiler i! in!alle. &or 1oiler! ,a are !,ippe in mo$le!

5or 5iel a!!em1l or ere#ion ea#, #omplee !e#ion i! ,ro!ai#all e!e in ,e!,op. A e! o5 ,e enire 1oiler i! #on$#e in ,e 5iel a5er ere#ion i! #omplee.

Con!ieraion m$! 1e /i-en o ,e empera$re o5 ,e 4aer $!e $rin/ ,e!e e!!.

8aer empera$re !,o$l no 1e le!! ,an am1ien empera$re an ne-er le!! ,an '&.T,i! minimi@e! ,e po!!i1ili o5 #aa!rop,i# 1rile 5ra#$re o5 ,ea- 4alle par! $rin/

,e e!. I al!o pre-en! an #on5$!ion 1e4een lea6! an #onen!aion on #ol o$er

!$r5a#e! o5 ,e 1oiler. T,e ma?im$m allo4a1le empera$re $rin/ a e! i! "2&.

SA$ETY VA&VES

Sa5e -al-e! are re0$ire on 1oiler! o pre-en o-erpre!!$rin/ 4,i#, 4o$l re!$l ino-er!re!!in/ o5 ,e pre!!$re par!. T,e !a5e -al-e i! a !a5e e-i#e o5 la! re!or. Ionl a#! 4,en o,er #onrol !!em! 5ail o #onrol pre!!$re in ,e 1oiler. Sa5e -al-e!

are ire# !prin/>loae pop$p>pe -al-e!. T,e are enirel !el5>#onaine an re0$ire

no o$!ie 5or#e! or !i/nal! o ma6e ,em 4or6. A pi#al !a5e -al-e i! ill$!rae in&i/$re "%.

> 23 >



$IGURE %. Ty"i8l Sfety Vl>e

Sa5e -al-e! are re0$ire 5or ,e 1oiler an ,e !$per,eaer. Separae !a5e relie5 -al-e!

are al!o re0$ire on ,e e#onomi@er i5 i #an 1e i!olae 5rom ,e 1oiler. Sa5e relie5-al-e! are !imilar o !a5e -al-e! e?#ep ,a ,e are $!e in li0$i !er-i#e.

#oiler Sfety Vl>es

A lea! 4o !a5e -al-e! are re0$ire on almo! e-er 1oiler. T,e!e -al-e! are lo#ae

on ,e !eam r$m.

> 2; >



Boiler !a5e -al-e! m$! 1e #apa1le o5 relie-in/ all ,e !eam ,e 1oiler #an /enerae

4i,o$ ,e pre!!$re in ,e 1oiler ri!in/ more ,an %J a1o-e ,e ma?im$m allo4a1le

4or6in/ pre!!$re 7MA8:9. I5 ,e -al-e! are !e a pre!!$re! 1elo4 ,e MA8: ,ema?im$m allo4a1le pre!!$re in#rea!e i! %J a1o-e ,e ,i/,e! pre!!$re a 4,i#, an

-al-e i! !e. T,e 5ollo4in/ r$le! e!a1li!, ,e pre!!$re! a 4,i#, ,e!e !a5e -al-e! are o

operae• T,e pre!!$re !ein/ o5 ,e 5ir! -al-e i! a or 1elo4 ,e MA8:.

• T,e ma?im$m !e poin 5or o,er !a5e -al-e! i! 3J a1o-e ,e MA8:.

• T,e ma?im$m ran/e o5 !e poin! i! "J o5 ,e ,i/,e! !e poin.

S9"erheter Sfety Vl>es

A lea! one !a5e -al-e i! re0$ire o proe# ,e !$per,eaer. I i! lo#ae 1e4een ,e

!$per,eaer o$le an ,e 5ir! !op -al-e o4n!ream o5 ,e 1oiler. S$per,eaer !a5e-al-e! !,o$l 1e !e o open 5ir!. T,i! en!$re! a #onin$o$! 5lo4 o5 !eam ,ro$/, ,e

!$per,eaer e-en 4,en ,e !a5e -al-e! are 1lo4in/. T,e pre!!$re rop ,ro$/, ,e

!$per,eaer m$! 1e #on!iere in eerminin/ ,e !a5e -al-e !e poin!.

Sfety Vl>e C"8ity

T,e oal re0$ire #apa#i 5or all ,e !a5e -al-e! i! ,e /reaer o5 ,e 1oiler! ma?im$m

rae #apa#i or a #apa#i 5a#or 4,i#, i! e0$al o ,e 1oiler! ,ea ran!5er !$r5a#e areaime! ,e 5ollo4in/ 5a#or!

• 8aer$1e 1oiler! "% l1 !eam,r>52 o5 ,ea ran!5er !$r5a#e.

• &ire$1e 1oiler! "; l1 !eam,r>52 o5 ,ea ran!5er !$r5a#e.

• &or ele#ri# 1oiler! $!e a #apa#i 5a#or o5 3.+ l1 !eam,r>68 inp$.

T,e #apa#i o5 ,e !$per,eaer !a5e -al-e! ma #onri1$e o ,e 1oiler! oal !a5e-al-e #apa#i. T,e #apa#i o5 ,e 1oiler !a5e -al-e! lo#ae on ,e !eam r$m m$!

1e a lea! '+J o5 ,e oal re0$ire 1oiler !a5e -al-e #apa#i.

Sfety Vl>e O"ertion

Sa5e -al-e! are re0$ire o aain 5$ll li5 7an 5$ll #apa#i9 a a ma?im$m pre!!$re o5

3J a1o-e ,eir !e pre!!$re. A5er openin/ ,e -al-e! are re0$ire o #lo!e a a pre!!$re

no le!! ,an =%J o5 ,eir lo4e! !e pre!!$re!. &or !a5e -al-e! operain/ 1e4een 3an " p!i/ ,e poppin/ oleran#e i! pl$! or min$! " p!i.

T,e Coe al!o re0$ire! ,a no -al-e! 1e in!alle 1e4een ,e !a5e -al-e an ,e 1oileror 1e4een ,e !a5e -al-e an i! i!#,ar/e o amo!p,ere. Di!#,ar/e pipin/ !,o$l 1e

a! !,or an !rai/, a! po!!i1le o a-oi a 1a#6 pre!!$re on ,e -al-e. T,e pipin/ !,o$l

al!o 1e arran/e o a-oi $n$e !re!! on ,e -al-e. T,e i!#,ar/e !,o$l 1e lo#ae

a4a 5rom an pla5orm! or 4al64a!.

STANDARDS AND CODES

+(*SAMSS*7(% Mn9f8t9re of In!9stril #oilers

> 2+ >



Se-eral !anar! an #oe! are $!e o #o-er ,e minim$m re0$iremen! o5 ne4

e0$ipmen p$r#,a!e 1 Sa$i Aram#o.

T,i! Spe#i5i#aion o/e,er 4i, ,e p$r#,a!e orer re5eren#e SAMSS! an

!pe#i5i#aion !,ee! an ,e en/ineerin/ o#$men! re0$ire pre!#ri1e ,e minim$m

#o-er! ,e minim$m manaor re0$iremen! 5or ,e man$5a#$re o5 ne4 in$!rial pe

4aer$1e an 5ire$1e 1oiler! ,a are 5$ele 1 ei,er oil /a! or 1o,.

T,i! !pe#i5i#aion in#l$e! re0$iremen! 5or ,e ,ermal !i@in/ me#,ani#al e!i/n !,op

5a1ri#aion 5iel 5a1ri#aion in!allaion an e!in/ o5 in$!rial 4aer$1e an 5ire$1e

1oiler pe!.

T,e re0$iremen! in ,i! !pe#i5i#aion are in aiion o an !$pplemen ,e re0$iremen!o5 ,e Boiler an :re!!$re (e!!el Coe ASME SEC I.

ASME #oiler n! Press9re Vessel Co!e * Se8tion I? Po@er #oilers

T,i! #oe #o-er! ,e e!i/n 5a1ri#aion an e!in/ o5 1oiler pre!!$re par!.

G&OSSARY

Attem"ertor

A 1oiler a##e!!or 5or re$#in/ an #onrollin/ ,e !eam o$le empera$re 5rom ,e

1oiler.

#ln8e

Aj$!in/ ,e operaion o5 ,e !eam !!em o minimi@e ,e amo$n o5 pre!!$re

re$#ion 1e4een ,e -ario$! !eam pre!!$re le-el!.

Blo4o4n

8aer remo-e 5rom ,e 1oiler o #onrol ,e le-el o5 i!!ol-e imp$riie! in ,e 1oiler4aer.

#oiler Effi8ien8y

T,e raio o5 ,e ,ea a1!or1e 1 ,e 4aer an !eam 4i,in ,e 1oiler o ,e ,ea in ,e5$el 5ire. T,e 5$el 5ire ma 1e e?pre!!e in erm! o5 i! ,i/,er ,eain/ -al$e 7HH(9 or

lo4er ,eain/ -al$e 7LH(9.

Ctions

:o!ii-el #,ar/e ion! in ,e 4aer 5or e?ample #al#i$m ma/ne!i$m an !oi$m.

Boiler &ee4aer 7B&89Treae 4aer ,a ,a! 1een ,eae eaerae an o!e 4i, #,emi#al! o remo-e

re!i$al o?/en.

#9rner

A me#,ani#al e-i#e $!e o inro$#e air an 5$el ino ,e 1oiler a ,e proper #oniion!

o e!a1li!, an mainain i/niion an #om1$!ion.

> 2% >



E8onomier

A e-i#e 5or ran!5errin/ ,ea 5rom ,e 5l$e /a! o ,e B&8 1e5ore ,e B&8 ener! ,e

1oiler r$m.

$l9e Gs

*a!eo$! pro$#! 5rom ,e #om1$!ion o5 5$el.

$9elBAir Rtio

T,e raio o5 ,e po$n! o5 air per po$n o5 5$el re0$ire 1 ,e 1oiler.

'igher 'eting Vl9e 1''V3

T,e amo$n o5 ,ea relea!e $rin/ #omplee #om1$!ion o5 5$el 4i, ,e !oi#,iomeri#

amo$n o5 r air in#l$in/ ,e ,ea o5 #onen!aion o5 4aer 5orme 1 1$rnin/,ro/en.

&ine Tr8ing

Small !eam line! ele#ri#al ,eaer! or o,er ,eain/ meia aa#,e o a pipeline omainain empera$re.

&o@er 'eting Vl9e 1&'V3

T,e amo$n o5 ,ea relea!e $rin/ #omplee #om1$!ion o5 5$el 4i, ,e !oi#,iomeri#

amo$n o5 r are e?#l$in/ ,e ,ea o5 #onen!aion o5 4aer 5orme 1 1$rnin/,ro/en.

M<im9m Contin9o9s Rting 1MCR3

T,e e!i/n o$p$ #apa#i o5 ,e 1oiler in on! per ,o$r.

M9! Dr9m Or &o@er Dr9m

A #linri#al -e!!el near ,e 1oom o5 ,e 1oiler 4,i#, a#! a! a #olle#ion ani!ri1$ion ,eaer. Soli! an !eimen en o a##$m$lae in ,i! r$m an are remo-e

1 inermien 1lo4o4n.

Offsite

All e0$ipmen an 5a#iliie! ,a are no #la!!i5ie a! on!ie 5a#iliie!. O55!ie 5a#iliie!

in#l$e an6a/e an iner#onne#in/ line! pro$# loain/ 1lenin/ an $ili !!em!

an !a5e !!em!.

Onsite

E0$ipmen or 5a#iliie! ,a are par o5 ,e plan pro#e!!e!.

P8ge! or Sho"*Assem;le! #oilers

A 1oiler 4,i#, i! a!!em1le in ,e -enor! !,op ino one or more lar/e pie#e! an ,en!,ippe o ,e !ie 5or 5inal a!!em1l.

Soot #lo@er

> 2' >



A me#,ani#al e-i#e ,a $ili@e! !eam o #lean 1oiler $1e! 1 remo-in/ pari#le! o5

$n1$rne #ar1on or a!,.

Stem Dr9m

A #linri#al -e!!el near ,e op o5 ,e 1oiler ,a a#! a! a i!ri1$ion an #olle#ion

,eaer an a relea!e poin 5or !eam. T,e r$m al!o ,o$!e! !eparaion e0$ipmen o r,e !eam.

Stem T9r;ine

Seam $r1ine! are $!e o ri-e me#,ani#al e0$ipmen !$#, a! p$mp! or #ompre!!or!

an ele#ri#al /eneraor!. T$r1ine! ma 1e 5$ll #onen!in/ non#onen!in/ or e?ra#ion>

#onen!in/ pe!. In a 5$ll #onen!in/ $r1ine all ,e !eam enerin/ ,e $r1ine i!

#onen!e a5er i e?pan! ,ro$/, ,e $r1ine. A non#onen!in/ $r1ine $!$all e?,a$!!,e !eam o i!ri1$ion pipin/ a a lo4er pre!!$re ,an ,e inle pre!!$re. An e?ra#ion>

#onen!in/ $ni e?,a$!! par o5 ,e inle !eam a an inermeiae pre!!$re le-el an

#onen!e! ,e remainin/ !eam.

S9"erheter

A ,ea ran!5er !$r5a#e o4n!ream o5 ,e !eam r$m e!i/ne o rai!e ,e !eamempera$re a1o-e ,e !a$raion empera$re. T,e !$per,eaer i! arran/e 4i,in ,e

1oiler o a1!or1 ,ea 1 raiaion #on-e#ion or 1o,.

'P

An a11re-iaion 5or ,i/, pre!!$re $!e in re5eren#e o !eam !!em pre!!$re le-el!

a1o-e a1o$ 2+ p!i/.

&P

An a11re-iaion 5or lo4 pre!!$re $!e in re5eren#e o !eam !!em pre!!$re le-el! le!!

,an a1o$ % p!i/.

MP

An a11re-iaion 5or mei$m pre!!$re $!e in re5eren#e o !eam !!em pre!!$re le-el! o5 a1o$ % o 2+ p!i/.

Vessel P9rging

Remo-in/ -apor! 5rom a -e!!el 1 i!pla#in/ 4i, !eam or iner /a!.

Boilers Basic Components (Att. VIII)

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Transcript of Boilers Basic Components (Att. VIII)