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Prepared By: YOUSAF NADIR KHAN Sr. Officer (Inspection) Attock Refinery Ltd. PAKISTAN
CODE INTRODUCTION
ASME
American Society of Mechanical Engineers ASME was founded in 1880 in response to numerous steam boiler pressure vessel failures. First performance test code of Steam Boilers trail was conduct in 1884. First revision of an ASME standard was made in 1900 . ASME has over 140,000 members in 158 countries worldwide . It produces approximately 600 codes and standards covering many technical areas.
ASME
American Society of Mechanical Engineers
ASME Founders
ASME BPVC CODES ASME Section I ASME Section II Part A ASME Section II Part B ASME Section II Part C ASME Section II Part D ASME Section III ASME Section IV ASME Section V ASME Section VIII Div. 1 ASME Section VIII Div. 2 ASME Section VIII Div. 3 ASME Section IX ASME B31.3 ASME B31.1
– Power Boilers – Materials
– Nuclear Codes – Heating Boilers – NDE – Pressure Vessel – Welding & Brazing – Process Piping – Power Piping
ASME BPVC Timeline 1911 – 1915 1923 1924 1925 1941 1963 1968 1971 1997
– – – – – – – – –
ASME set up the B&PV Committee – to formulate std rules for construction of boilers and pressure vessel First Code issued – ASME 1 – Power Boilers Heating Boilers – Section IV Materials – Section II Pressure Vessel – Section VIII Div. 1 Welding & Brazing – Section IX Nuclear Codes – Section III Pressure Vessel – Section VIII Div. 2 NDE – Section V Pressure Vessel – Section VIII Div. 3
ASME and National Board Stamps
S –
Steam boilers
A
Assembly only
–
U – U2 – U3 – PP – R – NB –
Pressure vessels Pressure vessels Pressure vessels Power piping (B31.1) Repair National Board
ASME VIII Div. 1 INSPECTION REQUIREMENTS
ASME Section VIII It provides requirements applicable to the design, fabrication, inspection, testing, and certification of pressure vessels operating at either internal or external pressures. This code was established in 1925 (Sec. VIII, Div.1) ASME Section Div. 1 Operating Pressure: 15 (psi) to 3,000 (psi) ASME Section Div. 2 Operating Pressure: 3,000 (psi) to 10,000 (psi) Its requirements are more rigorous than in Division 1 ASME Section Div. 3 Operating Pressure: above 10,000 (psi) It does not establish maximum pressure limits Its requirements are more rigorous than in Division 1 and 2
ASME Section VIII Div. 1 Forward Introduction: U-1, U-2, U-3, U-4 Subsection A: UG – General Requirements Subsection B: (Methods of Fabrication) UW – Welded pressure vessels UF – Forged pressure vessels UB – Brazed pressure vessels Subsection C: (Classes of Material - Special Constructions) Materials: UCS – Carbon and Low Alloy Steel UNF – Non ferrous Materials UHA – High Alloy Steel (Continued)
ASME Section VIII Div. 1 UCI – Cast Iron UCL – Cladding and Lining UCD – Cast Ductile Iron UHT – Ferritic Steels with Heat Treatment ULW – Layered Constructions ULT – Low Temperature Service UHX – Shell and Tube Heat Exchanger Subsection D: Mandatory and Non mandatory Appendices Index ASME Code Key Words: Shall: mandatory rules May not: prohibition may can: Recommendations/Exemptions from prohibitions shall be: Recommendations
INSPECTION REQUIREMENTS Pressure Vessel
Stamped
1. 2. 3. 4. 5. 6. 7.
MATERIALS FABRICATION WELDING NDE PWHT (Supplementary) HYDRO TEST NAME PLATE
Non Stamped
Non Stamped but (T.P.I)
INSPECTION REQUIREMENTS 1- MATERIALS Examination of all materials before fabrication to make certain they have the required thickness, to detect defects [UG-93(d)], to make certain the materials are permitted by this Division (UG-4), and that traceability (UG-77) to the material identification(UG-93) has been maintained. Identification for all material used in the fabrication of the vessel or part (UG-93); E.g. Plate Correct Material (As per Purchase Order/specs) Visual Inspection for cracks specifically for impact tested material Markings original/ transferred Securing Partial Data Reports [UG-120(c)] (If part is ASME stamped) Check MTR according to ASME Section II Part A (Continued)
INSPECTION REQUIREMENTS 1- MATERIALS Documentation of impact tests when such tests are required (UF-5, UCS-66, UHA-51,UHT-6, and ULT-5) Check Impact energy according to UG-84 (For C.S) and Lateral Expansion according to UHA-51 (For S.S and Duplex) Concurrence of the Inspector prior to any base metal repairs (UG-78 and UF-37) Documentation and Review of NDE results e.g. Lamination or Ultrasonic Testing e.t.c (If Required) according to specs. NACE Requirement (If Required)
INSPECTION REQUIREMENTS 2- FABRICATION Heads and Shells Forming according to UG-79 UG-79 (a) Limits are provided on cold working of all carbon and low alloy steels, nonferrous alloys, high alloy steels, and ferritic steels with tensile properties enhanced by heat treatment [UCS-79(d), UHA-44(a), UNF-79(a), and UHT-79(a)(1)]. UG-79 (b) If the plates are to be rolled, the adjoining edges of longitudinal joints of cylindrical vessels shall first be shaped to the proper curvature by preliminary rolling to avoid having objectionable flat spots along the completed joints. (Continued)
INSPECTION REQUIREMENTS 2-1(a) Heads Forming Heads Forming
Bumping
Bumping Cold Hot
Bumping & Spinning
Spinning
INSPECTION REQUIREMENTS 2-1(b) Heads Forming Inspection UG-81(a) The inner surface of an ellipsoidal head shall not deviate outside of the specified shape by more than 1-1⁄4% of Inside Diameter nor inside the specified shape by more than 5⁄8% of Inside Diameter.
According to UG-32 Knuckle Radius = I.D*0.17 Crown Radius = I.D*0.9
INSPECTION REQUIREMENTS 2-1(c) Heads/Shell Forming Inspection UG-80(a)(2) (Design : Internal Pressure)
Heads The difference in diameters shall not exceed 1%. (Ovality) Shell The difference in diameters shall not exceed 1%. (Ovality) Permissible difference in inside diameters given above may be increased by 2% of the inside diameter of the opening. (Ovality) Formula: [(Maximum I.D - Minimum I.D)/ Nominal I.D] x 100% ≤ 1%
INSPECTION REQUIREMENTS 2-1(d) Heads/Shell Forming Inspection UG-80(b)(2) (Design : External Pressure) Shell Must meet requirements for Internal Pressure UG-80(a)(2). Must meet requirements in Figure UG-80.1. Measurement shall be made from a segmental circular template from the out side of shell.
INSPECTION REQUIREMENTS Figure UG-80.1
INSPECTION REQUIREMENTS 2-2(a) Alignment Requirement UW-33(a) Welded joint category UW-3.
UW-3 (b): Circumferential welded joints are butt joints if the angle(α) is equal to or less than 30 deg. (Otherwise will be a corner joint)
(Continued)
INSPECTION REQUIREMENTS 2-2(a) Alignment Requirement UW-33(a) Alignment of sections at edges to be butt welded shall be such that the maximum offset is not greater than as defined in UW-33
The section thickness t is the nominal thickness of the thinner section at the joint. (Continued)
INSPECTION REQUIREMENTS 2-2(b) Taper Transition UW-9(c), UW-33(b) When differ in thickness by more than one-fourth of the thickness (t/4) of the thinner section, or by more than 1⁄8 in. (3 mm), whichever is less. Taper may be machined or welded. Weld metal build up shall be subject to the requirements of UW-42.
INSPECTION REQUIREMENTS 2-3(a) Nozzles, Manholes and other attachments UG-82 / UG-92 All attachments must be fit with the vessel outside or inside curvatures. Pressure parts, such as saddle type nozzles, manhole rings, and reinforcement around openings, extend over pressure retaining welds, such welds shall be ground flush for the portion of the weld to be covered. UG-82(a) E.g. Nozzle Reinforcement Pad attachment. Non pressure parts, such as lugs, brackets, and support legs and saddles, extend over pressure retaining welds, such welds shall be ground flush as described above, or such parts shall be notched or coped to clear those welds. UG-82(b) E.g. Insulation Ring
INSPECTION REQUIREMENTS 2-3(b) Nozzle and Manhole inspection Technique
(Continued)
INSPECTION REQUIREMENTS 2-3(b) Nozzle and Manhole inspection Technique
INSPECTION REQUIREMENTS 3- WELDING No welding of any kind be done when the temperature of the base metal is lower than −20°C. (UW-30) At temperatures between 0°C and −20°C, the surface of all areas within 75 mm of Welding shall be heated up to 15°C. (UW-30) Cleaning of the surface to be weld shall be as per UW-32(a) Surface shall be clean and free of scale, rust, oil, grease, slag, detrimental oxides, and other deleterious foreign material. UW-32(a) Welding Process shall be used as acceptable in UW-27. No welding to be done until the qualification are in place. (UW-26) GTAW-SMAW-SAW –FCAW-SMAW are most common. (UW-27) WPS/WQT shall qualification shall be as per UW-28 (WPS) & UW-29 (WQT) with provisions of ASME IX.
INSPECTION REQUIREMENTS 3-1(a) Welding Requirements (Safety First) 3-1(a-1) Before Welding Review of weld book. (WPS, PQR, Weld Map/Matrix, WQT) Consumables and MTRs. Welding process and ancillaries (cable, Regulator, Oven, e.t.c). Tack welding material. 3-1(a-2) During Welding Pre-heat values (Heating method, location and control method) In-process distortion control (Sequence or balanced welding) Consumable control (Specification, size, condition, and any special treatments) Welding Procedure requirements. Arc Strikes
INSPECTION REQUIREMENTS 3-1(a-3) After Welding
Carry out visual inspection of the welded joint UG-97. (Profile, Defect e.t.c)
Longitudinal and circumferential Butt Joints, These joints shall also be checked for weld reinforcement height as per UW-35.
Weld size (Leg length) of Nozzles and other parts shall be checked as per UW-16, Drawing or Specs.
(Continued)
INSPECTION REQUIREMENTS 3-1(a-3) After Welding In case of any rejection during visual inspection repair or build up shall be made as per UW-38 and UW-42. After the completion of welding it is important for welder or operator to punch his identification number, stamp or symbol at interval of 1m along the weld for traceability and to satisfy UW-37 equipments. (Punching Thickness limitation: 6mm for ferrous and 13mm for non ferrous) Welding Symbols
INSPECTION REQUIREMENTS 4- NDE (Non Destructive Examination) Part UW and ASME Sec. V When required acceptance criteria: UW- 51 (Full RT) & UW-52 (Spot RT) [also see UW-14] RT Types RT-1 (Full): RT-3 : (Spot)
RT-2 :
RT-4 : (Spot)
INSPECTION REQUIREMENTS 5- PWHT (Post Weld Heat Treatment) UW-2, UW-40, UCS-56 When required (as per UW-2, UW-40 and specs) PWHT must be performed according to UCS-56 and Table-UCS-56. Review PWHT specification for specified thickness and material and verify PWHT graph as per UCS-56(c)(2), UCS-56(d)(1), UCS-56(d)(2), UCS-56(d)(3), UCS-56(d)(5), UCS-56(d)(2) and Table no. UCS-56. Also follow WPS.
INSPECTION REQUIREMENTS 6- HYDRO TESTING (UG-99) Vessel shall be tested after completion of all fabrication and examinations. UG-99 (a)(1), UG-99 (a)(2). Cosmetic and Grinding on the base metal is allowed after this test. UG-99 (a)(2). Testing pressure : 1.3 x (MAWP) x (Lowest Stress Ratio) UG-99 (a)(2)(b). The hydrostatic test pressure at the top of the vessel shall be the minimum of the test pressures. Any nonhazardous liquid at any temperature may be used for the hydrostatic test if below its boiling point. UG-99(h) Combustible liquids having a flash point less than 43°C, Such as petroleum distillates, may be used only for near atmospheric temperature tests. UG-99(h) (Continued)
INSPECTION REQUIREMENTS 6- HYDRO TESTING (UG-99) Metal temperature during hydrostatic test. UG-99(h) 17°C minimum above the MDMT and 48°C maximum Liquid relief valve set to 1-1⁄ 3 times the test pressure is recommended for the pressure test system. (Caution) Vent shall be provided at the heights point to purge air. UG-99(i) The maximum allowable working pressure may be assumed to be the same as the design pressure when calculations are not made to determine the maximum allowable working pressure. (Foot Note 34 of Ed.2013) Pressure chambers of combination units that have been designed to operate independently shall be hydrostatically tested as separate vessels. UG-99(e)(i) Vessels may be tested after painting (Internal/External) except for those in lethal service, Other lines may be painted after leak test. UG-99(k)
INSPECTION REQUIREMENTS 6-1 PNEUMATIC TEST (UG-100) This test may be used in lieu of hydro test. UG-100(a) (1) That are so designed and/or supported that they cannot safely be filled with water. UG-100(a)(1) (2) Not readily dried, that are to be used in services where traces of the testing liquid cannot be tolerated. UG-100(a)(2) Testing pressure : 1.1 x (MAWP) x (Lowest Stress Ratio) UG-100 (b) Metal Temperature 17°C minimum above the MDMT . UG-100 (c) The pressure in the vessel shall be gradually increased to not more than one-half of the test pressure. Thereafter, the test pressure shall be increased in steps of approximately one-tenth of the test pressure until the required test pressure has been reached. UG-100 (d)
6-2 CLOSE INSPECTION HYDRO TEST Maintains this test pressure for 10 minutes before inspection. Then, if test is above maximum allowable working pressure (MAWP), reduces to MAWP while making a full thorough inspection for leaks. PNEUMATIC TEST Reduces the pressure to the maximum operating pressure before proceeding with the inspection; holds the pressure for a sufficient period of time to permit inspection of the system.
INSPECTION REQUIREMENTS 6-3 TEST GAGES (UG-102) An indicating gage shall be connected directly to the vessel at top of the vessel. UG-102 (a) Range shall be less than 1-1⁄2 nor more than 4 times that pressure. UG-102 (b) Degree of accuracy in digital gage is more than dial gage. UG-102 (b) All gages shall be calibrated against a standard deadweight tester or a calibrated master gage. UG-102 (b) Gages shall be recalibrated at any time that there is reason to believe that they are in error. (Practice: 6 months) UG-102 (c)
INSPECTION REQUIREMENTS 7- NAME PLATE Vessel Marking. UG-116 Certification and Authorized inspection mark. UG-117 Marking Method. UG-118
INSPECTION REQUIREMENTS 8- DATA REPORT (MDR/PDR) UG-120, Non Mandatory Appendix W Form U 1 Form U1-A Form U1-B Form U1-P Form U2 Form U-2A Form U 3 Form U-3A Form U4 Form U5
(Exchangers) (Pressure vessel, Single Chamber) (Graphite Pressure Vessel) (Plate Type Heat Exchanger) (Pressure Vessel Part Fabricated by Another Manufacturer) (Pressure Vessel Part Fabricated by Another Manufacturer
(Supplementary Sheet for Vessels) (Supplementary Sheet for Tube and Shell Type Exchangers)
INSPECTION REQUIREMENTS 8- DATA REPORT (MDR/PDR)
.
U1-A
U1
U4
INSPECTION REQUIREMENTS 9- TOLERANCE SHEET INSPECTION REQUIREMENTS
Page 1-2
Page 2-2
SUMMARY
SUMMARY Verifying that the Manufacturer has a valid Certificate of Authorization UG-117(a) and is working to a Quality Control System UG-117(e). Verifying that the applicable design calculations are available [U-2(b), U-2(c), mandatory Appendix 10-5, and 10-15(d)]. Verifying that materials used in the construction of the vessel comply with the requirements of UG-4 through UG-14 and UG-76, UG-77, UG-78 and UG-93. Verifying that all welding procedures have been qualified with the requirements of UW-27, UW-28, UW-47 and ASME Section IX. Verifying that all welders, welding operators, have been qualified with the requirements of UW-29, UW-48 and ASME Section IX. Verifying that the heat treatments, including PWHT, have been performed according to UG-85, UW-10, UW-40, UW-49, and UF-52. (Continued)
SUMMARY Verifying that material imperfections repaired by welding were acceptably repaired by meeting the requirements of UG-78, UW52(d)(2)(c), UF-37, and UF-47(c). Verifying that weld defects were acceptably repaired and acceptable in UW-51(c) and UW-52(c). Verifying that required nondestructive examinations have been performed and that the results are acceptable to UW-50, UW-51, UW-52 Verifying that required impact test and Lateral Expansion have been performed and that the results are acceptable UG-84, UG-93 and UHA-51. Making a visual inspection of vessel to confirm that the material identification numbers have been properly transferred as required in UG-77 and UG-94. (Continued)
SUMMARY Making a visual inspection of the vessel to confirm that there are no material or dimensional defects as defined UG-95, UG-96, and UG-97. Performing internal and external inspections and witnessing the hydrostatic or pneumatic tests (UG-80, UG-96, UG-97) Verifying that required PWHT has been performed and that the graph is acceptable to the requirements of UCS-56. Hydro or Pneumatic test performed as per UG-99, UG-100 and UG-102. Verifying that the required marking is provided (UG-115) and that any nameplate has been attached to the proper vessel. Signing the Certificate of Inspection on the Manufacturer’s Data Report when the vessel, to the best of his knowledge and belief, is in compliance with all the provisions of this Division.
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The International Boiler and Pressure Vessel Code establishes rules of safety governing the design, fabrication, and inspection of boilers and pressure vessels, and nuclear power plant components during construction
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ASME accepts responsibility for only those interpretations of this document issued in accordance with the estab- lished ASME procedures and policies, which precludes the issuance of interpretations by individuals. The endnotes in this document (if any) are part of this American National Standard. Session 3: asme section iii, component design and construction, including application to the areva epr philippe malouines regulations and codes advisor.
The ASME - American Society of Mechanical Engineers - International Boiler and Pressure Vessel Code (BPVC) is made of 11 sections and contains over 15 divisions and subsections.
Code Sections
I. Power Boilers
II. Materials
III. Rules for Construction of Nuclear Facility Components
IV. Heating Boilers
V. Nondestructive Examination
VI. Recommended Rules for the Care and Operation of Heating Boilers
VII. Recommended Guidelines for the Care of Power Boilers
VIII. Pressure Vessels
IX. Welding and Brazing Qualifications
X. Fiber-Reinforced Plastic Pressure Vessels
XI. Rules for In-service Inspection of Nuclear Power Plant Components
XII. Rules for Construction and Continued Service of Transport Tanks
I. Power Boilers
This Section provides requirements for all methods of construction of power, electric, and miniature boilers; high temperature water boilers used in stationary service; and power boilers used in locomotive, portable, and traction service. Requirements for: Boilers Fabricated by Welding; Boilers Fabricated by Riveting (by reference only); Watertube Boilers; Firetube Boilers; Feedwater Heaters; Miniature Boilers; Electric Boilers; Organic Fluid Vaporizer Generators.
This section provides requirements for all methods of construction of power, electric, and miniature boilers; high temperature water boilers used in stationary service; and power boilers used in locomotive, portable, and traction service. The rules are applicable to boilers in which
- steam or other vapor is generated at a pressures exceeding 15 psig,
- and high temperature water boilers intended for operation at pressures exceeding 160 psig and or temperatures exceeding 250 degree F.
Superheaters, economizers, and other pressure parts connected directly to the boiler without intervening valves are considered as part of the scope of Section 1.
II. Materials
- Part A-Ferrous Material Specifications
- Part B-Nonferrous Material Specifications
- Part C-Specifications for Welding Rods, Electrodes, and Filler Metals
- Part D-Properties
III. Rules for Construction of Nuclear Facility Components
- Subsection NCA - General Requirements for Divisions 1 and 2
DIVISION 1
- Subsection NB- Class 1 Components
- Subsection NC- Class 2 Components
- Subsection ND- Class 3 Components
- Subsection NE- Class MC Components
- Subsection NF - Supports
- Subsection NG - Core Support Structures
- Subsection NH - Class 1 Components in Elevated Temperature Service
DIVISION 2
- Code for Concrete Containments
DIVISION 3
- Containments for Transportation and Storage
IV. Heating Boilers
This Subsection provides requirements for design, fabrication, installation and inspection of steam generating boilers, and hot water boilers intended for low pressure service that are directly fired by oil, gas, electricity, or coal. It contains appendices which cover approval of new material, methods of checking safety valve and safety relief valve capacity, examples of methods of checking safety valve and safety relief valve capacity, examples of methods of calculation and computation, definitions relating to boiler design and welding, and quality control systems.
V. Nondestructive Examination
Requirements and methods for nondestructive examination which are referenced and required by other code Sections. It also includes manufacturer's examination responsibilities, duties of authorized inspectors and requirements for qualification of personnel, inspection and examination. Examination methods are intended to detect surface and internal discontinuities in materials, welds, and fabricated parts and components. A glossary of related terms is included.
VI. Recommended Rules for the Care and Operation of Heating Boilers
General descriptions, terminology and operation guidelines applicable to steel and cast iron boilers limited to the operating ranges of Section IV Heating Boilers. It includes guidelines for associated controls and automatic fuel burning equipment. Illustrations show typical examples of available equipment. Also included is a glossary of terms commonly associated with boilers, controls, and fuel burning equipment.
VII. Recommended Guidelines for the Care of Power Boilers
Guidelines to promote safety in the use of stationary, portable, and traction type heating boilers. The section provides guidelines to assist operators of power boilers in maintaining their plants as safely as possible. Emphasis has been placed on industrial-type boilers because of their extensive use. Contains Fuels for Routine Operation; Operating and Maintaining Boiler Appliances; Inspection; Prevention of Direct Causes of Boiler Failure; Design of Installation; Operation of Boiler Auxiliaries; Control of Internal Chemical Conditions
VIII. Pressure Vessels
Division 1 - Provides requirements applicable to the design, fabrication, inspection, testing, and certification of pressure vessels operating at either internal or external pressures exceeding 15 psig.
Division 2 - Alternative Rules, provides requirements applicable to the design, fabrication, inspection, testing, and certification of pressure vessels operating at either internal or external pressures exceeding 15 psig.
Division 3 - Alternative Rules for Construction of High Pressure Vessels, provides requirements applicable to the design, fabrication, inspection, testing, and certification of pressure vessels operating at either internal or external pressures generally above 10,000 psi.
IX. Welding and Brazing Qualifications
Rules relating to the qualification of welding and brazing procedures as required by other Code Sections for component manufacture. Covers rules relating to the qualification and re-qualification of welders, brazers, and welding and brazing operators in order that they may perform welding or brazing as required by other Code Sections in the manufacture of components. General Welding Requirements; Welding Procedure Qualifications; Welding Performance Qualifications; Welding Data; Welding Forms; General Brazing Requirements; Brazing Procedure Qualifications; Brazing Performance Qualifications; Brazing Data; Brazing Forms.
X. Fiber-Reinforced Plastic Pressure Vessels
Asme Standards Free Pdf
Requirements for construction of an FRP pressure vessel in conformance with a manufacturer's design report. It includes production, processing, fabrication, inspection and testing methods required for the vessel.
XI. Rules for In-service Inspection of Nuclear Power Plant Components
Rules for the examination, in-service testing and inspection, and repair and replacement of components and systems in light-water cooled and liquid-metal cooled nuclear power plants.
XII. Rules for Construction and Continued Service of Transport Tanks
Requirements for construction and continued service of pressure vessels for the transportation of dangerous goods via highway, rail, air or water at pressures from full vacuum to 3,000 psig and volumes greater than 120 gallons.
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