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ASME
BS
CE M & P
Material Requirements.
Material Requirements
Material Requirements
Material Requirements
Fabrication ( Heat
Treatment
Requirement)
6.0 Hot and cold forming
6.1 Hot pressing ( includes
hot squeezing, hot sizing, hot
swaging and hot upsetting )
Si
Mn
0.25 max
0.035 max
0.035 max
0.10 min
0.035 max
0.035 max
0.035 max
0.035 max
0.10 min
0.27-0.63
0.93 max
0.29-1.06
0.06-0.18
0.35 max
Tb
0.27 max
Grade
Manufacture
Ta
Tc
Grade A1
Carbon
Mn
P
S
Si
0.27
0.93 max
0.035
0.035
0.10
Grade C
Carbon
Mn
P
S
Si
0.35
0.29-1.06
0.035
0.035
0.10
Product Analysis
Permissible
variation
diameter (see table reg 36)
in
requirements of the
specification, otherwise all
remaining material in the
heat or lot shall be rejected.
Hardness requirements
79 HRB or 143 HB for A1
2. Boost bending
3. Press or squeeze bending
4. Rool bending
TFR = D / ( e * r)
D = Tube OD in mm
( e = Nominal wall thickness)
r = radius of bend measured to
the center line of tube mm
The TFR for other tube bends
of the same material group and
the same bending process shall
fall within 110 % of the first
value calculated for the first
bend. The demonstrated bend
can be subjected to the
Where,
P
=
test pressure.
D
=
Outside diameter of
the tube.
t
=
Nominal
wall
thickness of the tube.
s
=
Stress which shall be
taken as 40% of the minimum
tensile strength at room
temperature.
(ii)
Notwithstanding
anything
contained in clause (i), the hydraulic test for
tubes in Makers' premises may be dispensed
with by the Inspecting Authority provided
that the tubes are subject to non-destructive
testing by an appropriate method like
Special requirements
9.1 Superheaters and
reheaters with alloy tubes,
tubes that have been hot or
cold worked or with welds
the require post weld heat
treatment shall be heat
treated. Horizontal
procedure.
10
Bend
Ratio
R/D <
3.0
R/D
>=3.0
R/D <
=1.3
R/D
>1.3
Heattrea
tment
SR
No
PBHT
No
PBHT
Surface Condition
The ferritic cold drawn steel
tubes shall be free from scale
and suitable for inspection.
11
treatment.
Grade 12x1Mo shall be normalized at
950 980 degree C and tempered at
720-750 degree C for a period of 1 to 3
hours.
Max.
diff in
bore
Up to
80 mm
80-300
Over
300
1.0
Max out
of
alignme
nt of
adjacent
tube
1.0
1.5
2.0
1.5
2.0
12
t = [(PD)/(2S + P )] + 0.005
D+E
Preheating No welding or
tack welding shall be carried
out, when the temperature of
parent metal within 150 mm of
joint is less than 5 C. When the
risk of hydrogen cracking is
high, the preheating temp
should either be maintained or
boosted for a min of 2 hours
after welding to facilitate
hydrogen removal. When
preheat is specified, it should
be continued without any
interruption.
Repair of defects in
material
Defects in material may be
repaired by the boiler
manufacture provided
acceptance by the inspector
is first obtained for the
method and extent of repairs.
Material that cannot be
13
14
15
Carbon
Silicon
0.25% max
0.40% max Manganese
1.40% max Phosphorous
0.05%
Part PW
Carbon or ally steel having a
carbon content of more than
0.35% shall not be used in
welded construction or be
shaped by oxygen cutting or
other thermal cutting
processes.
max
Sulphur
0.05% max When the ladle
analysis is not available, the analysis of
sample tubes selected at random may be
used.
Where the temperature is below
400C either rimming or killed steel may Welding electrodes and filler
be used. If rimming steel is used in the metal shall be selected to
manufacture of electric resistance welded
16
17
18
Welding Processes
The following welding
process may be used for any
section I construction :
shielded metal arc,
submerged arc, gas metal
arc, flux core arc, gas
tungsten arc, plasma arc,
19
rewelding.
Hydrostatic Pressure Tests :The hazard involved in
pressure testing shall be
considered by the manufacture
and adequate precaution shall
be taken.
Water shall be used as the
pressuring agent. The quality
of water used shall be such that
it prevents both corrosion and
any residue of injurious solids.
The temp of the water used for
the pressure tests shall be
selected by the manufacture
taking in to account the risk of
brittle fracture of the pressure
parts and shall not exceed 50
C. The component being tested
and its connections shall be
vented or evacuated. All temp
tubes, connections and
blanking devices should be
designed to withstand the test
pressure. The full test pressure
shall be maintained for 30 min
for completed boiler and large
component and for a sufficient
length of time for smaller
20
component.
Fabrication
Base metal Preparation
The preparation of the joints
prior to welding may involve
any of the conventional
methods in use such as
machining, thermal cutting,
chipping, grinding, or
combination of these.
Where the thermal cutting is
used, the effect on the
mechanical and metallurgicsl
properties of the base metal
shall be taken into
consideration.
The method of base metal
preparation used shall leave
the welding groove with
reasonably smooth surfaces
and free from deep notches,
striations, or irregularities.
The surface for welding shall
be free of all scale, rust, oil,
greese, or other foreign
materials.
21
(2)
Assembly
Bars, jacks, clamps, tack
welds, or other appropriate
means may be used to hold
the edges of the parts to be
welded in alignment.
22
Alignment Tolerances
When tubes or pipes are
welded together, the
alignment shall be such that
(iii) Tubes 102mm(4 inch) bore and the inside surfaces provide
under- Sample welds simulating the for complete weld
production welds shall be provided for penetration.
mechanical testing either at a rate of 2 per
cent or after each 150 welding hours with a Alignment of sections at
minimum of one sample weld per welder.
edges to be butt welded shall
be such that the maximum
Alternatively, 5 per cent of the offset is not greater than the
welds made by each welder selected at applicable amount as listed
random, with a minimum of one weld per in the table
welder, shall be subjected to non-destructive Section Direction of joints
examination by radiographic or other Thicks
approved method. This rate may be reduced In
Longitu Circumf
to 2 per cent by arrangement with the Inches
dinal
erential
Inspecting Authority after initial satisfactory Up to t
t
results have been produced.
to 3/4 1/8 int
t
to 1.5 1/8 in
3/16 in.
In the event of any non-destructive 1.5 to
1/8 in
1/8 t
test not meeting the requirements, defects in 2.0
the welds represented by that test shall be Over 2
Lesser
Lesser
rectified and the Inspecting Authority may
of 1/16 of 1/8 t
call for an increase in the number of nont or 3/8 or in.
destructive tests until such time as a
in.
satisfactory standard is achieved.
23
Expanding.
Strength welding.
Mechanical bolted bail joint.
Fillet Welds
In making fillet welds, the
weld metal shall be deposited
in such a way as to secure
adequate penetration into the
base metal at the root of the
weld. Fillet weld contours
shall confirm to the
requirements in section 9 and
the surface of such welds
shall be free from coarse
ripples or grooves, and shall
merge smoothly with the
surfaces joined.
PREHEATING
Preheat for welding or
thermal cutting may be
applied by any method which
does not harm the base
material or any weld metal
already applied, or which
does not introduce into the
welding area foreign material
which is harmful to the weld.
When materials of two
different P numbers groups
are joined by welding, the
24
holes.
25
where,
T = minimum thickness of tubes, that is,
nominal thickness less the permissible
negative tolerance in mm (inch),
C = 0.75 mm for working pressure up to
and including 70 kg/cm2 (1000 lbs/sq. inch)
or C=0 for working pressure exceeding 70
kg/cm2 (1000 lbs/sq. Inch.),
W.P. = Working pressure of boiler in kg/cm2
(lbs / sq. inch)
D = External diameter of tube in mm (inch)
f = Permissible stress for the material at the
working metal temperature in kg/cm2 (lbs/
sq. inch.) to be determined on the basis
given below:
26
121 C or 250 F
P No. 9B, Group No. 1.
149 C or 300 F
P No. 10A, Group No. 1
79 C or 175 F
P No. 10E, Group No. 5
300 F with interpass
maintained between 350 F
and 450 F.
Whichever is lower
where,
T.S = Minimum tensile strength of the
material at room temperature,
27
by mechanical means or by
thermal grooving processes,
after which the joint shall be
rewelded and reexamined.
Surface of the weld shall be
sufficiently free from coarse
ripples, grooves, overlaps,
abrupt ridges and valley to
avoid stress raisers.
Undercut shall not exceed
0.8mm or 10% of the wall
thickness, whichever is less
and shall not encroach on the
required section thickness.
The surface of the finished
weld shall be suitable to
permit proper interpretation
of radiographic and other ND
techniques.
The total repair depth shall
not exceed 10% of the base
material thickness. The total
depth of a weld repair shall
be taken as the sum of the
depths of repair made from
both side of a weld at a given
location. The total area of
such repairs shall not exceed
28
100 in2.
Weld Test
For Stud Welding
Where stud welding is used
to attach load carrying studs,
a production stud weld test
of the procedure and welding
operator shall be performed
on a separate test plate or
tube prior to the start of
production welding on the
first work piece. This weld
test shall consist of five
studs, welded and subjected
to either the band or torque
stud welding testing.
For Flash butt welding
The tube butt welds are made
using the flash welding
process. Production testing
shall be performed in
accordance with section IX
as follows.
29
(in mm).
Bend thickness below the minimum value
required under (a) shall be permitted in
cases where the manufacturer can
demonstrate by bursting tests carried out on
at least three bends that the strength of the
bend is not less than that of the straight
tube.
Where the amount of thinning at any
location around the bend extrados on cold
formed bends exceeds 25 % of the actual
thickness of the tube on the straight, the
bends shall be suitably heat treated. The
actual thickness of the same plans as the
line of the extrados at each end of the bend.
Departure from circularity in tube bends:
The departure from circularity at the bend
apex shall not exceed 10 % for bends
performed in single bending operation and
15 % for bends which are hot pressed after
the primary, bending operation.
30
(Dmax-Dmin / D ) X 100
where
Dmax is the maximum outside diameter
measured in the tube bend apex (mm),
Dmin is the minimum outside diameter
measured at the same cross-section as Dmax
(mm),
31
S.R / 1.6 or SC
Whichever is lower"
where,
T.S = Minimum tensile strength of the
material at room temperature,
Et = Yield point (0.2% proof stress) at
working metal temperature 't',
Sr = the average stress to produce rupture
in 100,000 hours and in no case more than
1.33 times the lowest stress to produce
rupture at the working metal temperature,
Sc = the average stress, to produce an
elongation of 1% (creep) in 100,000 hours,
at the working metal temperature.
Note: In case Sc values are not available in
Material Standard and such materials are
known to have been used in boilers in India
or abroad, then for such materials the
allowable stress may be taken as the lower
of
Et / 1.5 or SR / 1.5.
In no case, however, shall the thickness of
and evaluate.
Cracks, lack of fusion, or
incomplete penetration are
unacceptable regardless of
length.
Other imperfection are
unacceptable if the indication
exceeds the reference level
and their length exceeds the
following:
in. for t up to in.
1/3 t for t from in. to 2.25
in.
in. for t over 2.25 in.
where t is the thickness of
the weld.
Bend Test
PW-53.9.1 The bend test
specimen shall be transverse
to the welded joint of the full
thickness of the plate and
shall be of rectangular cross
section with a width 1.5
times the thickness of the
specimen. When the capacity
of the available testing
amachine does not permit
32
33
elongation required in PW
53.8.1 is attained, the
specimen shall be considered
to have failed and the
D max. = maximum
specimen shall be stopped.
external diameter of the tube as
Cracks at the corner of the
gauged at the bend,
specimen shall not be
D min.
= minimum
considered as a failure. The
external diameter of the tube as
appearance of small
gauged at the bend,
imperfection in the convex
D = nominal external diameter of the
surface shall not be
tube,
considered as a failure if the
R
=
Radius of the bend on the
greatest dimension does not
Central line of the bend.
exceed 1/16 in.
Flash Welding
Tests for Initial Qualification of a welder- When joining two parts by
the inertia and continuous
(A)
Theoretical Examination - A welder drive friction welding
shall be required to answer questions on the precesses, one of the two
following subjects, orally or otherwise
parts must be held in a fixed
position and the other parts
1. Electric Welderrotated. The two faces to be
joined must be essentially
(i) Weld preparation
symmetrical with respect to
the axis of rotation.
(ii) Elementary knowledge of the working
of welding equipment.
circularity,
34
35
36
(iii)
Vertical Fixed- One test of groove
welded joint with the axis of the pipe in a
vertical position and the seam welded
circumferentially in a horizontal position.
37
38