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IBR

ASME

BS

CE M & P

Material Requirements.

Material Requirements

Material Requirements

Material Requirements

COLD DRAWN SEAMLESS STEEL


BOILER AND SUPERHEATER TUBES
FOR DESIGN METAL
TEMPERATURES NOT EXCEEDING
454C (850F).

Open hearth, electric


furnace, or basic oxygen
steel shall be used for boiler
pressure parts exposed to the
fire or products of
combustion. When used for
internal pressure, the
material stress and
dimensions shall meet the
appropriate requirements of
PG-27 and part PW and be in
accordance with the
followings.

For ferritic steel, the


phosphorus and sulfer content
shall not exceed 0.05% each in
the laddle analysis.

Fabrication ( Heat
Treatment
Requirement)
6.0 Hot and cold forming
6.1 Hot pressing ( includes
hot squeezing, hot sizing, hot
swaging and hot upsetting )

Material.- The tubes shall be seamless and


made of steel produced by an Open Hearth
or Electric Process or any of the Oxygen
Processes. The Steel shall not contain more
than 0.050 per cent of sulphur or of
phosphorus and the oxygen process steel
shall in addition not contain more than
0.006 per cent of nitrogen.
The
manufacturer shall supply a certificate of Tubes should be of the
analysis when required to do so.
following specifications only.
The tube shall be seamless and
manufactured from steel produced by an
open hearth or electric process or any of the
oxygen processes. The steel shall be fully
killed.
The steel shall conform to the following
limits of chemical composition.

SA- 178 Electric resistant


welded carbon steel and
carbon manganese steel
boiler tubes

SA 210 Seamless medium-

Semi killed steel shall be used


only for plates, and seamless
and welded tubes in carbon
and carbon manganese steels
with an upper limit of the
specified tensile strength
ranges of 640 N/mm2 and with
a thickness not exceeding 100
mm.
Rimming steel shall be used
only for welded tubes in
carbon and carbon manganese
steel with an upper limit of the
specified tensile strength range
of 490 N/mm2 and under
service temperature condition
of 400 C or less.
Carbon and carbon manganese
steel plates for cold forming

Materials shall be hot pressed


at temp as noted and shall be
pressed heat treated after hot
pressing as notes in the
following table. Unless
specifically permitted by the
welding procedure
specification, welds shall not
be in the hot pressed area.
See CE M & P Table 1.
Hot Bending
Material shall be heated
within the temp ranges hoted
below and shall be given a
final heat treatment after
bending as noted in the
following table.

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

shall be supplied in to the


normalized condition.

Manufacture

Ta

Tc

carbon steel boiler and


superheater tubes

For grade Tb and Tc for each reduction of


0.01% below the specified carbon
maximum an increase of 0.06% Mangenese
above the specified maximum will be
permitted upto a maximum of 1.35%.
Heat Treatment :- Hot finished tubes need
not be heat treated, cold drawn tubes shall
be given a sub-critical annealing a full
anneal or a normalising heat treatment after
the final cold finished process.

Electric resistance welded or


induction welded tubes shall
The steel shall be fully
be used in the as welded
killed.
condition only where the
specified upper limit of tensile
Tube shall be made by the
strength does not exceed 540
seamless process and shall be N/mm2
either hot finished or cold
drawn, as specified.
4.2.1 Cutting of Material
Heat treatment

Weld preparation and opening


of the required shapes shall be
Hot finished tube need not be formed by either of the
heat treated. Cold finished
following methods:
tube shall be given sub
critical anneal, a full anneal, 1. Machining, chipping or
or a normalizing heat
grinding: Chipped surface
treatment after the final cold which will not be covered with
drawing process.
weld metal shall be ground
smoothly after chipping.
Surface Condition
2. Thermal cutting and
gouging.
If pickling or short blasting
or both are required, this
4.2.1.2 Any metal damaged
shall be specifically stated in metallurgicaly in the process
the order.
of cutting to size or forming
the edges or end preparation
Chemical composition
shall be removed by

See CE M & P Table 2.


Hot Draw or Hot
Correction
The following procedure
may be applied to elements
after final post weld heat
treatment when necessary to
adjust to dimensional
tolerances.
6.3.1 The hot draw operation
( application of heat to
localized lengths and less
than the full circumference of
tube or pipe ) may be applied
to materials P1 A through
p5F without requiring
subsequent heat treatment,
provided the temp ranges
itemized below are not
exceed. No drawing is
permitted on stainless steel.
6.3.2 Stainless steel may be
hot adjusted to shape using
the following procedure.
Operation may be performed
before or after the final heat
treatment. A torch using
natural gas as fuel shall be

Workmanship and Tolerance:- The tubes


shall be well finished cleaned free from
harmful defects. They shall be reasonably
straight, smooth, cylindrical and subject to
the following tolerances. Finished tubes
shall be reasonably straight and have
smooth ends free of burrs. They shall have a
workmanlike finish. surface imperfections
like any discontinuity or irregularity found
in the tube may be removed by grinding
provided that smooth curved surface is
maintained and the wall thickness is not
decreased to less than that permitted. The
outside diameter at the point of grinding
may be reduced by the amount so removed

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

outside When requested on the


purchase order, a product
analysis shall be made by the
Permissible variation in wall thickness
supplier from one tube or
percentage (see table reg 36)
billet per heat. The chemical
Test specimens (i) Test specimens
composition thus determined
required for the flattening and
shall conform to the
expanding/flaring test shall be taken from
requirements specified.
the ends of finished tubes prior to upsetting
swaging, expanding or any other forming
If original test fails, retest of
operations or being cut to length. They
two additional billets or
shall be smooth on the ends and free from
tubes shall be made. Both
burrs and flaws.
retest for the elements in the
question shall meet the

machining, grinding, chipping


or thermal cutting back to
sound metal.

used. The tip of the torch


shall at no times be closer
than 6 from the tube. A
length of tube 4 minimum
Surfaces that have benn
length, shall be heated for the
thermally cut shall be cut back full circumference to a temp
by machining or grinding so as of 982 to 1093 C. The metal
to remove all burnt metals,
temperature in this zone must
harmful notches, slag and
be 982 C minimum at the
scale, but slight discoloration
time the tube is bent. A temp
of machine thermally cut edges measurement must be taken
on mild steel shall not be
from each location that is
regarded as detrimental.
being heated for adjustment
to shape.
If alloy steels are prepared by
See table 3.
thermal cutting, the surface
shall be dressed back by
6.4 Cold Pressing( Includes
grinding or machining for a
cold swaging, cold upset,
distance of at least 1.5mm,
cold squeezing, cold sizing )
unless it has been shown that
the material has not been
Interstage and fabrication
damaged by the cutting
heat treatment requirements
process.
after cold pressing operation
shall be as noted in the table
After the edges are prepared
4 . When local heat treatment
for welding, they shall be
is used, the entire length of
visually examined for flares,
the swaged area and
cracks, laminations, slag
transition zone shall be
inclusion etc. The edges shall
heated to the required
be examined for thermally cut temperature. If a bend is
material. Any weld repair as a
required in the swaged area,

If desirable and practicable, tensile test may


be carried out on full section of the tubes up
to the capacity of the testing machine. For
large size tubes, the tensile test specimen
shall consist of strip cut longitudinally from
the tube and which is not straightened
within the gauge length and further heat
treated.

requirements of the
specification, otherwise all
remaining material in the
heat or lot shall be rejected.

If any test specimen shows flaws or


defective machining it may be discarded
and another specimen substituted.

89 HRB or 179 HB for C

All specimens shall be tested at room


temperature
Number of tests: The test shall be made on
minimum 2 tubes for first 100 tubes and 1
per 100 or part thereof for tubes over 100
numbers.

Hardness requirements
79 HRB or 143 HB for A1

Tension Test- one tension


test shall be made on a
specimen for lots of no more
than 50 tubes. Tension test
shall be made on specimen
from two tubes for lot of
more than 50 tubes.

Flattening Test :- One


flattening test shall be made
Tensile and Hardness tests:-The test
on specimens from each end
specimen shall comply with the following
of one finished tube from
requirements. The hardness test may be
each lot, but not the one used
carried out on the wall cross section or on a for the flaring test. Tears or
flat on the outside surface of the tube
breaks occurring at the 12 or
sample. . (see reg 38 Table)
6 oclock position on grade
C tubing with sizes of 60.3
Flattening Test A ring not less than 50mm mm in outside diameter and
in length cut form one end of each selected smaller shall not be
tube shall be flattened between two parallel considered a basis for

result of thermal cutting shall


be to an approved welding
procedure.

the area shall be heat treated


prior to making bend.

6.5 Cold Bending


Care shall be taken that weld Cold bending is defined as an
preparations are correctly
operation performed at metal
profiled and within specified
temp below 593 C
tolerance.
Tube bending procedure Test
Demonstration bend produce
for test shall be bent to an
angle of atleast 90 degree. This
shall be deemed to represent
the minimum requirements and
for all bend angles. The
departure from circularity
(DFC) shall be measured at the
bend apex and thickness
measurements shall be taken at
30 degree internal from within
bend angle. Test specimen
from within the bend angle is
always preferred.
Procedure Test
Requirements
Any of the following process
can be employed for tube
bending
1.Rotary draw bend

After cold bending, heat


treatment shall be applied as
required in the table below.
See Table 5.
Heat Treatment
8.1 Heat treatment required
after forming or welding
shall be performed
subsequent to the operation
that require heat treatment
except when the shop
planning sequence
established that the
component will be post weld
heat treated as part of the
subsequent assembly.
8.2 Requirements for carbon
and alloy steel ( P1 through
P6C material )

flat surfaces to a distance between the plates rejection.


(H) as calculated by the formula given
below without showing any sign of a crack Flaring Test:- One flaring
of flaw.
test shall be made on
specimen from each end of
the one finished tube from
each lot, but not the one used
for flattening test.
where,
a
=
thickness of tube (9 mm).
D
=
Outside diameter of the tube Hardness test:- Brinell or
Rockwell hardness tests shall
(mm).
be made or specimens from
C
=
a constant as given below.
C
=
0.09 for steel having a two tubes from each lot.
specified minimum tensile strength
Hydrostatic or
from 31 kgf/mm2 upto and
2
Nondestructive Electric
including 35 kgf/mrn .
C
=
0.07 for steel having a Test
specified minimum tensile strength over 35 Each tube shall be subjected
to the hydrostatic, or, instead
kgf/mm2 upto and
2
of this test, a nondestructive
including 42 kgf/mm .
C
=
0.05 for steel having a electric test may be used
specified minimum tensile strength over 42 when specified by the
kgf/mm2 upto and
including
90 purchaser.
2
kgf/mm .
C
=
0.03 for steel having a Forming Operation
specified minimum tensile strength over 50 When inserted in the boiler,
kgf/mm2 upto and
including
62 tubes shall stand expanding
2
and bending without
kgf/mm .
showing cracks or flaws.
40. Flanging and drift expanding tests (a) When properly manipulated,
The tube shall withstand either the flanging super heater tubes shall stand

2. Boost bending
3. Press or squeeze bending
4. Rool bending

Post Bend Heat


treatment(PBHT)
Demonstration bend shall be
subjected to post bend heat
treatment, if required
Tube Forming Ratio
It is calculated for each
material group and process.
2

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

8.2.1 When pipe or tube wall


thickness exceed 0.75 for
P1 A, B, C material and
0.625 wall thickness for
P3A through P5A materials,
and for all thickness of P5D
to P6C, post weld heat
treatments is required. When
a forming or welding
procedures require a post
forming or post weld heat
treatment, the heat treatment
shall be in accordance with
table IX and the following
paragraph of 8.2
8.2.2 Holding time for P nos
1A through 5F shall be 1
hr/in of thickness with
hour minimum for material
thinner than 0.25. Air
cooled or furnace cooled to
427 C.
8.2.3 P6B and P6C material
shall be heated to 774 + 10
C, held for one hour per inch,
with a hour, minimum
holding times, furnace cooled
to 593 C, then air cooled.
8.2.4 When an elements
contain several grade of

test or the drift expanding test, at the option


of the manufacturer.
(b) Flanging tests- A test piece cut
from the end of the tube in a plane
perpendicular to the axis of the tube shall
show no crack or flaw after flanging to the
specified outside diameter as given in the
table below(c) Drifting expanding test- A test
piece cut from the end of a tube in a plane
perpendicular to the axis of the tube shall
show no crack after expanding by a mandrel
having an included angle of 30 or 60 at
the option of the manufacturer to increase
the outside diameter as given in the table
below
( see table Reg 40 amendments).
Additional test before rejection(i) If any one or more tests specified in
these regulations fail , two further tests of
the same kind may be made on two other
tubes of the same batch. If any of these tests
fails , the batch of the tubes represented
may be given a further heat treatment and
entire set of test shall be repeated.
(ii) If the repeat tests are satisfactory the
tubes shall be accepted .If any failure in the

all forgings, welding and


following test.
bending operations necessary
for application without
1.Visual Examination : Outer
developing defects.
surface shall be free from
defects such as cracks,
SA 213 Seamless ferritic
indentation, laps, and scales.
and austenitic alloy-steel
Surface defects may be
boiler, super heater, and
removed by grinding ,the
heat-exchanger tubes
minimum design thickness
shall be ensured.
Materials and Manufacture
2. Transverse Examination :
Tubes shall be made by the
Transverse defects on bens OD
seamless process and shall be by MPI in accordance with
either hot finished or cold
BSEN 1290 or LPI accordance
finished, as specified. Grade with BSEN 571 part 1.
TP347HFG shall be cold
finished.
3. Hardness Test : The
hardness at the extrados of
Grain Size
bend of hot formed bends shall
not be higher than 804V10
The grain size of grades
higher than the hardness of
304H, 316H, 321, 347H,
undeformed material.
348H and 310HCbN, as
determined in accordance
4. Mechanical Test : All hot
with test methods E 112,
formed bends or bends
shall be NO. 7 or finer.
requiring PBHT other than SR
shall be sectioned and
The grain size of cold
subjected to the following
worked Grade TP 321H, as
mechanical test.
determined in accordance

materials, it shall be heated


to the minimum temperature
required by the highest P
number in the assembly, as
required by table IX without
exceeding the maximum
temperature permitted for the
lower P number. All
superheater and reheater
tubing combination shall be
heat treated at 677 C
minimum except as noted in
8.3.3 and 8.3.9
8.2.4.1 For ferritic material
to be welded to stainless steel
tubing, see par 8.2.3
8.2.5 When heat treatment is
not required to heat treat any
weld or formed part within
the limits shown in table IX.
8.2.6 Heat treatment is
required when closely placed
attachments are welded to
pipe or tubing.
8.2.7 After hot forming
P5A,D or F material, cool to
204 C before post forming
heat treatment is initiated.
8.2.8 All P3, all P4 A and P5
A material shall be post weld
heat treated after machining

tests should occur, the entire batch of the


tubes shall be rejected.
Hydraulic Test- (i) Each tube shall be tested
at the Maker's Works on completion of
manufacture and shall withstand a hydraulic
pressure, to one and half times the design
pressure subject to a minimum of 0.70
kgf/mm2 but not greater than pressure
calculated by the following formula

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

with test method E 112 shall


be No 7 or coarser.

Tensile test in accordance with peg finning.


BSEN 10002 part 1.
8.2.9 After spiral finning
Charpy V notch test in
heat treat as follows
Heat Treatment
accordance with BSEN 10045
P1 A,B,C tubing -- None
part1.
P4 G tubing 593-718 C
6.1 All tubes of grades
8.2.10 All bifurcates require
shown in table, except T5c
5. Thickness: It shall confirm
a post weld heat treatment
and T91, and in accordance
to the thinning requirements.
8.2.11 When hot draw
with 6.1.1 shall be reheated
operations are performed,
and furnished in the fullGang bending of tube panels:- they will be within the temp
annealed, isothermal
Demonstration bends produced limit provided in 6.3.1
annealed, or normalized and by the gang bending method
8.2.11.1 The hot draw
tempered condition. If
shall confirm to the
temperature shall be limited
furnished in the normalized
requirements for single tube.
to 788 C for all P5 material.
and tempered condition, the
The gang bending method
If P5 material are heated to
minimum tempering
shall be qualified by a
temp in excess of 788 C
temperature for grade T5, T9, procedure test valid for the
during hot draw, a
T21 and T22 shall be 675 C, specific machine used. The
subsequent heat treatment is
and the minimum tempering panel shall consist of at least 3 required to the requirements
temperature for grades T11,
tubes which have been welded of Table IX.
and T17 shall be 650 C.
together before bending.
6.1.1 Tubing of Grades T2
and T12 either hot-finished
or cold-drawn, may be given
a final heat treatment at 650
C to 730 C instead of heat
treatments specified in 6.1 at
the option of the
manufacture.

Tube bending requirements


Thinning of bend extrodus and
DFC limits shall be
demonstrated by the following
dimensional testing.
1. Measure nondestructively
2% of production run,
including the first bend for
thinning and DFC.

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

ultrasonic or / and Eddy current testing.


HOT FINISHED SEAMLESS
CARBON STEEL BOILER AND
SUPERHEATER TUBES FOR DESIGN
METAL TEMPERATURES NOT
EXCEEDING 454C (850F).

6.1.3 Grades T91 shall be


normalized at 1040 C
minimum and tempered at
730 C minimum as a final
heat treatments.

2. Additionally where R/D <


1.3 a sample test bend is
required before
commencement of production.

6.3 All austenitic tubes shall


be furnished in the heat
treated condition. The heat
treatment procedure, except
for the H grade and S 30815,
shall consist of heating the
material to a minimum
temperature of 1040 C and
quenching in water or rapidly
cooling by other means.

Tube thinning at the bend


extrados : The thickness atany
point after bending shall not be
less than eext where

Material.- The tubes shall be seamless and


made of steel produced by an Open Hearth
or Electric Process or any of the Oxygen
Processes. The chemical composition of the
material of the tubes shall conform to the
following analysis and the steel produced by
the Oxygen process shall in addition not
contain more than 0.006 percent of
nitrogen:6.4 All H, S 30815, S33228
Chemical Composition (ladle analysis).
and S31272 grades shall be
furnished in the solution
treated condition. For these
*Carbon
0.25% max
grades, separate solution heat
Silicon
0.35% max
treatments are required for
Manganese 0.35% min
solution annealing; inPhosphorus 0.050% max
process heat treatments are
Sulphur
0.050% max
not permitted as a substitute
for the separate solution
These provisions cover two quality groups
annealing treatments. If cold
of steels, namely grade 1 and grade 2,
working in involved in
depending on their tensile properties.
processing, the minimum
*A carbon content not exceeding 0.35 per
solution treating temperature
cent may be permitted subject to the

eext = eact X (2 * R/D) + 0.5


( 2 * R/D) + 1.
eext = Required min. wall
thickness at extrados in mm
eact = Nominal thickness of
supplied tube suppliers max
(+Ve) tolerance in mm
R = Radius of tube bend
measured to center line.
D = Nominal OD of the tube
(mm)
The thinning on the extrados of
bends formed in 2 stages, i.e.
hot formed after initial hot or
cold bending shall not exceed
30% of the thickness of the
straight tube local to the bend
as measured during a test

superheater, reheater and


economizerelements that
meet the following
requirements may be
exempted from post weld
heat treatment if, (1) All
tubes are carbon steel
(2)Attachments
welds are exempt from HT
(3) All forming operations
used to fabricate the
assembly are exempt from
post weld HT.

approval of the Inspecting Authority.


NOTE Where the material is used for
designed temperature above 399C (750F),
the steel shall be of non-segregated or fully
killed type.
Heat Treatment:- Hot finished pipes need
not be heat treated. Cold drawn pipes shall
be given a sub-critical anneal, a full anneal,
or a normalising heat treatment after the
final cold finishing process
Workmanship and tolerance: The pipes
shall be well finished, cleaned free from
harmful defects. They shall be reasonably
straight, smooth, cylindrical and subject to
the following tolerance. Pipes manufacturer
shall explore a sufficient number of visual
inspections to provide reasonable assurance
that they have been properly evaluated.
(i) Permissible variations in outside
diameter:
Hot finished and cold
finished seamless pipes ( see amend table
43)
Permissible variation in wall thickness:

for grades TP321H, TP347H


and TP348H shall be 1100 C,
and for grade TP304H, and
TP316H, 1040 C. If the
grade H is hot rolled, the
minimum solution treatment
for grades TP321H, and
TP347H, and TP348H shall
be 1050 C, and for grade
TP304H, and TP316H 1040
C.
Chemical Composition
See Attach Table 1. ASME

procedure.

DFC of Tube bends:2(Dmax Dmin) * 100


DFC = (Dmax + Dmin)
Where DFC = Departure from
circularity
Dmax = Maximum OD
measured at the tube bend apex
( mm )
Dmin = Minimum OD
measured at the same cross
section as Dmax (mm)
Heat Treatment of Tube
bends

Product Analysis:An analysis of either one


billet or one tube shall be
made from each heat. The
chemical composition thus
determined shall confirm to
the requirements specified.
For Grade T91 the carbon

The heat treatment of hot or


cold formed shall be as
follows:
(a). All hot formed tube bends
or cold formed tube bends
requiring heat treatment after
bending including bends hot
formed after cold bending shall

The minimum wall thickness at any point


shall not be more than 12.5% under the
nominal wall thickness specified.
Permissible variation in exact length:
Seamless Hot finished and cold finished
pipes can be ordered in specified length or
in random length. If ordered in specified
length, the tolerances for all sizes shall be
+6.0mm/-0.0mm.
SEAMLESS FERRITIC AND AUSTENITIC
ALLOY STEEL BOILER, SUPERHEATER AND
HEAT EXCHANGER TUBES

The design metal temperature shall not


exceed the following limits: (click here to
view the Table Reg 47 )
Diameter.- The external diameter of the
tubes measured at any point shall be within
the following tolerances of the diameter
specified see table reg 48 amendments)
The steel shall conform to the limits of
chemical compositions given in Table 1
and 2.
(click here to view the Reg 48 Table (1))

content may very for the


product analysis by 0.01%
and +0.02% from the
specified range as per table
1.
Hardness Requirements
For T91 hardness should not
exceed 250 HB or 25 HRC
Tension Test
One tension test shall be
made on a specimen for lots
of not more than 50 tubes.
Tension tests shall be made
on specimen from two tubes
for lots of more than 50
tubes.
Flattening Test One
flattening test shall be made
on specimen from each end
of one finished tube, not the
one used for the flaring test,
from each lot.
Flaring Test:- One flaring
test shall be made on
specimen from each end of
the one finished tube from
each lot, but not the one used
for flattening test.

10

be heat treated as follows.


When bends in steel 762 are
normalized and tempered, the
complete manipulated tube
shall be heat treated. The heat
treatment is not necessary in
the following cases.
1.Hot formed tube bends in
steel 320, 360, 440, 243 and
620 need not receive a PBHT
if the bending operation was
completed within the
normalizing range.
2. PBHT may be waived by the
approval of inspecting
authority.
PBHT applicable to cold
formed tubes as follow
Steels
629590,91
762
only
All
other
steels

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

Hardness test:- Brinell or


Rockwell hardness tests shall
be made or specimens from
*The grain size of cold worked grade TP two tubes from each lot.
Hydrostatic or
321H shall be No.7 or coarser.
Nondestructive Electric
Heat treatment :- (i) All tubes of grades in Test
Each tube shall be subjected
Table-1, (click here to view the Table (1))
to the hydrostatic, or, instead
except T 91, 12X1M0 and X20CrMoV121
of this test, a nondestructive
shall be reheated and furnished in full
electric test may be used
annealed, isothermal annealed or
when specified by the
normalized and tempered condition. If
purchaser
furnished in the normalized and tempered
condition, the minimum tempering
temperature for Grades T1 and T11 shall be Forming Operation
When inserted in the boiler,
650 degree C and the minimum tempering
tubes shall stand expanding
temperature for Grades T5, T9 and T22
and bending without
shall 675 Degree C.
showing cracks or flaws.
When properly manipulated,
Tubing of Grades T1,T2 and T12 either
super heater tubes shall stand
hot finished or cold drawn, may be
all forgings, welding and
given a final heat treatment at 650
bending operations necessary
degree C to 730 degree C, instead of
for application without
heat treatments specified in sub-clause
developing defects.
(i) above at the option of the
manufacture.
(click here to view the Reg 48 Table (2))

Grade T91 shall be normalised at 1040


degree C minimum and tempered at 730
degree C minimum as a final heat

Surface Condition
The ferritic cold drawn steel
tubes shall be free from scale
and suitable for inspection.

11

Repair of Tube bends :


Areas of the tube bend which
have been ground to remove
defects shall be examined by
surface flaw detection method
to ensure complete removal of
defects. Repair to the tube
surface by welding is not
permitted.
Site welding of Panel Tube
The site weld which joins the
fin edges of adjacent panel
sections of tube walls should
be a continuous longitudinal
weld between two fin edges.
Any site welding directly to
the tube surface should be
limited to the small area of
make up fin local to the tube
butt welds between panel ends.
Fabrication Tolerance
Linear alignment of butt
welded tubes. The welding of
tube joints shall include
matching, if necessary of the
tube ends at each joint.

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.

A slight amount of oxidation


is not considered scale.
Ferritic hot rolled steel tubes
shall be free of loose scale
and suitable for inspection.

Austenitic steel tubes shall


be pickled free from scale.
Grade X20CrMoV121 shall be normalized
at 1020- 1070 degree C and tempered at 730 When bright annealing is
used, pickling is not
780 degree C for a period of 1 hour
necessary.
minimum.
All austenitic tubes (Table 2 ) shall be
furnished in the heat treat condition. The
heat treatment procedure, except for the H
grades shall consists of heating the material
to a minimum temperature of 1040 degree C
and quenching in water or rapidly cooling
by other means.
All H grades shall be furnished in the
solution treated condition. If cold working
is involved in processing, the minimum
solution treating temperatures for grades
TP321H and TP347H shall be 1100 degree
C and for grades TP304H and TP316H shall
be 1040 degree C. If the P grade is hot
rolled, the minimum solution treatment for
grades TP 321 H and TP 347 H shall be
1050 degree C for grades TP 304H and TP

SA- 226 Electric Resistance


welded carbon steel boiler
and superheater tubes for
High Pressure service.
SA 250 Electric Resistance
welded carbonMolybdenum Alloy steel
boiler and superheater
tubes.
SA 268 Seamless and
welded ferritic stainless
steel tubings for general
services.

Matching of the bores shall be


effected by selection, drifting
( hot or cold ), machining,
swaging or by use of a suitable
expander. Any machine
counter boring required shall
not reduce the thickness of the
tube wall to below the design
thickness. All hot drifts ends
shall be heat treated. The bores
of the ends of the adjacent
tubes should preferably match
exactly. Permissible level for
bore difference and bore
misalignment are given below.
Dia. Of
Tube
bore

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

Angular alignment of butt


weld tubes: Any centerline
angular misalignment should

12

Formulas for calculation of


tube thickness.

not exceed 3 degree. i.e. 5 mm


In 100 mm.

Workmanship and tolerance:- The tubes


shall be well finished, cleaned free from
harmful defects. They shall be reasonably
straight, smooth, cylindrical and subject to
the following tolerances. Finished tubes
shall be reasonably straight and have
smooth ends free of burrs. They shall have
a workmanlike finish. Surface imperfections
like any discontinuity or irregularity found
in the tube may be removed by grinding,
provided that a smooth curved surface is
maintained, and the tube may be removed
by grinding, provided that a smooth curved
surface is maintained, and the wall
thickness is not decreased to less than that
permitted. The outside diameter at the point
of grinding may be reduced by the amount
so removed.

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.

Permissible variation in outside diameter.


(click here to view the Figure reg 48 i)

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

316H shall be 1040 degree C.

Permissible variation in Wall thickness.


(click here to view the Figure reg 48 ii )
(iii) Permissible variation in length for
extact length tubes. (click here to view the

where t = min. required


thickness, in.
P = max. allowable working
pressure, psi
D = Outside diameter of
cylinder, in.
S = Max allowable stress
value at the design
temperature of the metal.
E = Thickness factor for
expanded tube ends.

13

Assembly of component for


Welding
The parts to be welded are
securely held in position by
mechanical means ( welded
bridge piece or tack welding )
to ensure proper alignment and
root gap. Correction of
irregularities in fit up shall not
be carried out by hammering.
The preheat requirements shall
be maintained during tack
welding. Filler material used

Figure reg 48 iii)

Seamless Chromium-Molybdenum Steel


Boiler and Super heater Tubes for design
metal temperatures not exceeding 577C
(1070 F
Material- The tubes shall be manufactured
from steel produced by the Open Hearth or
Electric Process or any of the Oxygen
Process and shall conform to the following
limits of chemical composition

The steel maker shall prove to the


satisfaction of the Inspecting Authority that
the
Carbon
0.15% max
Silicon
0.10% to 0.50%
Manganes 0.30% to 0.70%
e
Phosphoru 0.04% max
s
Sulphur
0.04% max
Chromiu
1.90 to 2.6%
m
Moly
0.87 to 1.2%

satisfactorily repaired shall


be rejected.
Hydrostatic Test
After a boiler has been
completed, it shall be
subjected to pressure tests
using water at no less than
ambient temperature, but in
no case less than 22 C. The
tests shall be made in two
stages in this sequence:
Hydrostatic pressure tests
shall be applied by raising
the pressure gradually to 1.5
times the max. allowable
working pressure as shown
on the data report to be
stamped on the boiler. The
pressure shall be under
proper control at all times so
that the required test pressure
is never exceeded by more
than 6%. Close visual
inspection is not required
during his stage.

should be of a type and class


appropriate to particular weld.
The extremities of this tack
weld shall be ground or
chipped to facilitate proper
fusion, when they are
incorporated in the root run.
All cracked tack welds shall be
removed. All welded bridge
pieces shall be removed. The
weld area ground flush and
examined by a surface flaw
detection method appropriate
to the material before SR.

Post Weld Heat Treatment


It shall be carried out
according to the following
requirements or heat treatment
condition be agreement
between manufacturer and the
inspecting authority or can be
waived by agreement between
purchaser, manufacturer and
inspecting authority by
providing satisfactory past
experience, where absence of
PWHT did not adversely affect
The hydrostatic test pressure the behavior. The controlling
may then be reduced to the
thickness to be weld in
maximum allowable working determining the requirements

14

quality of the steel is of the required high


temperature creep strength
Heat-treatment- The tubes shall be fully
annealed or normalized and tempered, at a
temperature approved by the Inspecting
Authority.
Workmanship and tolerance- The tubes
shall be well finished, clean and free from
harmful defects.They shall be reasonable
straight, smooth cylindrical and subject to
the following tolerances before bending:Diameter - The external diameter of the
tubes measured at any point shall be within
the following tolerances if the diameter
specified:- (Click here to view the Table reg
56a)
Thickness- The thickness of the tubes shall
be within the following tolerances:- (Click
here to view the Table reg 56a)
Thickness- The thickness of the tubes shall
be within the following tolerances:- (Click
here to view the Table 56a)
Length- The tubes shall be not less than the
nominal length, but may exceed it by the

pressure, as shown on the


data report, to be stamped on
the boiler and maintained at
this pressure while the boiler
is carefully examined. The
metal temperature shall not
exceed 48 C during the close
examination.

for PWHT time shall be as


follows.
1. Butt Welds :- The thickness
of thinner pare at the welded
joint.
2. Fillet weld :- Specified
throat thickness of branch at
joint.
When the component to be
At no time during the
post weld heat treatment
hydrostatic test shall any part contains welds with different
of the boiler be subjected to a individual controlling
stress grater than 90% of its
thickness, the governing
yield strength ( 0.2% offset)
thickness is selected as greater
at test temperature
of the individual controlling
thickness.
Test Gages
An indicating gage, visible to Furnace PWHT of
the operator controlling the
components
pressure applied, shall be
1.The temperature of the
connected to the pressure
furnace at the time the
parts. Hydrostatic head on
component is placed should
the gage shall be considered not exceed
depending on the location of (a)for ferritic steel 400 C for
the gage.
component of less than 60mm
thickness and not of complex
Dial pressure gages used in
shape, or 300 C for component
testing shall preferably have of 60 mm thickness or over
dials graduated over their
complex shape.
entire range of about double (b) For austenitic steels 300 C
the intended maximum test
(c) The rate of heating for

15

pressure, but in no case shall


the range be less than 1.5
times that pressure. The
spacing between graduations
shall be such that the
E ELECTRIC-RESISTANCE-WELDED
STEEL BOILER AND SUPERHEATER inspector and the operator
controlling the test shall be
TUBES FOR
able to determine when the
DESIGN METAL TEMPERATURES

required test pressure has


NOT EXCEEDING 454(850 F
been applied. Digital
pressure gages having a
Regulation 58 Material.- (a) Tubes shall
be manufactured from steel produced by an wider range of pressure
readings may be used
Open hearth, or electric process or any of
provided the readings give
the oxygen processes.
the same or greater degree of
Chemical composition. (1) The ladle accuracy as obtained with
analysis shall conform to the following dial pressure gages.
requirements:amount given below: (Click here to view
the Table 56a)

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

ferritic steel shall not exceed


the following
(i)220/hr for thickness < 25
mm
(ii)5500 C/hr divided by the
thickness (mm) for thickness
exceeding 25mm up to and
including 100 mm.
(iii) 55 C/hr for t > 100 mm
(4)The rate of heating from
300 C for austenitic steel shall
not exceed
(i)
220 C/Hr for t< 25mm,
(ii)
200 C/Hr for t> 25mm
(d) During heating and holding
period, the furnace atmosphere
shall be so controlled as to
avoid excessive oxidation of
the surface of the component.
There shall be no direct
impingement of flame on the
component.
(e) Component in ferritic steels
shall be cooled in the furnace
temp, not exceeding 400 C.
Below 400 C it may be cooled
in air.

tubes, the strip shall be rolled in single


widths and shall not be slit longitudinally
except to trim the edges. The steel used for
design temperature above 400C but not
exceeding 454C shall be of the fully killed
type. The question of high temperature
creep strength of the material shall be the
subject of agreement between the
manufacturer and Inspecting Authority.

provide deposited weld metal


of chemical composition and
mechanical properties
compatible with the material
to be joined and the service
condition anticipated.
Rimmed and semi killed
steel shall not be joined by
the inertia and continuous
drive friction welding
processes.

For pressure retaining welds


in 2.25Cr-1Mo materials,
Manufacture - The tube shall be made by
other than circumferential
electric resistance welding and heat treated
as per the table given below. In case of cold butt welds less than or equal
to 3.5 in. in outside diameter,
finished tubes the heat treatment shall be
when design metal
done after the final cold finishing process.
temperature exceed 850 F,
(Click here to view the table reg 58)
the weld metal shall have a
The tube shall be well finished and free carbon content greater than
from harmful defects. The external weld 0.05%.
(flash) shall be removed completely i.e.
flushed with outside surface. The internal Welding grooves
weld upset shall be trimmed throughout the The dimension and shape of
length of the tube so that the maximum the edges to be joined by butt
welds shall be such that to
height shall not exceed 0.25 mm.
permit complete fusion and
complete joint penetration
Thickness - The thickness of each tube

17

(f) component in austenitic


steels shall be rapidly cooled
from the solution treated temp.
Additional Requirements for
PWHT of joints between
dissimilar ferritic steels
PWHT is possible provided
T1-T2 >| 30 for carbon and
carbon manganese steels and
20 C for all other steels.
Where T1 = lowest soaking
temp acceptable for the steel
requiring the higher PWHT
temp given in table
T2 = Highest soaking temp
acceptable for steel requiring
lower PWHT temp range.
The PWHT temp for butt
welds shall be with in higher
range given in Table
appropriate to two steels being
welded. Where a major
component of steels for which
PWHT is given in table is
welded to minor component of
a steel for which PWHT is

excluding the weld shall conform to the


permissible variation given below: (Click
here to view the table reg 58)

Joints Between Materials


Of Unequal thickness.

A tapered transition section


having a length not less than
The minimum thickness in the weld area
three times the offset
shall not be less than that permitted in the
between the adjoining
body of the tubes.
surfaces shall be provided at
the joints between material
(e) Diameter - The outside diameter of
that differ in thickness by
each tube measured at any position shall
more than one forth of the
conform to the specified diameter within the thickness of the thinner
limits of plus 0.75% and minus 0.75% with material or by more than 1/8
a minimum of 0.30 mm over and under.
in. The transition section
may be formed by any
(f) Length- Unless otherwise specified
process that will provide a
tube shall be supplied as random length.
uniform taper. The weld may
Where the length is specified as exact
be partly or entirely into the
length or cut length, the permissible
tapered section or adjacent to
variation shall be + 6mm -0 mm for length
it.
up to and including 6 meters. For every 3
meter increase in length above 6 meters, the Circumferential Welds in
positive tolerance shall be increased by 1.5
Tube and Pipe
mm with a maximum of 12 mm.
When components of
different diameter or
thickness are welded
COLD DRAWN-RESISTANCEtogether, the transition shall
WELDED STEEL BOILER AND
not exceed a slope of 30 deg.
SUPERHEATER TUBES FOR DESIGN From the smaller to the
METAL TEMPERATURE NOT
larger diameter. The

18

given, the weld shall be heat


treated within a temp range
given for the minor component
for a time appropriate to the
thickness of the major
component.
Repairs of weld
An approval welding
procedure shall be employed.
The nature and extent of such
repair should be reported to
inspecting authority.
Details of weld repair shall be
made available to NDE
personel responsible for
examination.
Defects should be cut out by an
appropriate method. Where
welds are partially removed,
the portion cut out shall be
sufficiently deep and long to
remove the defect. At the end
of the cavity, there shall be a
gradual taper from the base of
the cut to the surface of the
weld metal. The width and
profile of the cut shall be such
as to give adequate access for

EXCEEDING 454C (850F)

transition may be formed by


any process that will provide
a uniform taper.

Material.- Material, tube grade and


Radiographic Examination
chemical composition for these tubes shall
be in accordance with the appropriate clause All longitudinal and
circumferential butt welded
of Regulation 58.
joints shall be
Manufacture.- Tube shall be manufactured radiographically examined
throughout their entire length
as prescribed in Regulation 58(b)and
in accordance with article 2
subsequently cold drawn.
of section V.
Tolerances.- Tolerance on thickness and
When it is impractical to use
outside diameter shall be as follows
a combination of
radiography parameters such
Thickness:- + 7.5% - 7.5%
that a geometric unsharpness
OD :- + 0.5% -0.5%
(With a minimum of 0.10mm over and of 0.07 in. will not be
exceeded, ultrasonic
under).
Tolerance on length shall be in accordance examination of the weld and
the heat affected zone shall
with Regulation 58(f).
be used lieu of radiography.

Heat Treatment.- After final cold finishing


the tubes shall be heat treated as follows:
(click here to view the Table 63a)
The ends which are subjected to cold

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

working operation shall be suitably


normalized or sub-critically annealed as
above.
*Temperature range 880 Deg.C to 940
Deg.C
#Temperature range 660 Deg.C to 720
Deg.C.
CONSTRUCTION AND
WORKMENSHIP
BOILER AND SUPERHEATER TUBES
SUBJECT TO INTERNAL PRESSURE
Steel Tubes- (a) All tubes which are subject
to internal pressure of water or steam shall
be cold drawn or hot finished seamless or
electric resistance welded in accordance
with Regulations 36 to 63. Except as
provided for in clause (b) below they shall
be without joint
Tubes having an external diameter not
exceeding 5 inches may be jointed and such
joints may be flash welded, machine forge
welded arc or gas welded. Tubes above 5"
diameter may also be welded provided they
are located outside the furnace. Such welds
must conform to the requirements of
Chapter VIII.

atomic hydrogen arc,


oxyhydrogen, oxyacetylene,
laser beam, electron beam,
flash, induction, resistance,
pressure thermit, pressure
gas, and inertia and
continuous drive friction
welding.
Arc stud welding and
resistant stud welding may
be used for non pressurebearing attachments having a
load or non-load-carrying
function. Stud size shall be
limited to
1 in. diameter maximum.
Welding Qualification and
Weld Records
The welding procedure
Specifications, the welders
and the welding operators
used in welding pressure
parts and in joining loadcarrying nonpressure parts,
such as all permanent or
temporary clips and lugs, to
pressure parts shall be
qualified in accordance with
section 9.

20

component.

Flash welding shall be undertaken on a


welding machine of a type approved by the
Inspecting Officer. The external fin caused
by welding shall be removed subject to a
maximum height of 5 % percent of the tube
outside diameter . The internal fin shall also
be removed subject to a maximum height of
20 per cent of the wall thickness of the tube.
Arc welded but joints shall be made by the
metallic shielded arc process and post weld
heat treated effectively except in the
following cases:
for alloy steel(i) in case of 0.5 Molybdenum Steels if
thickness does not exceed 13 mm and
outside diameter does not exceed 127mm
in case of 1 chromium Molybdenum steel
if thickness does not exceed 13 mm and
outside diameter does not exceed 127 mm
and preheated to 125C.
in case of 2 Chromium 1 Molybdenum
steel, post weld heat treatment is not
necessary under the following conditions:
(1)

a maximum specified Chromium


content of 3.0%

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)

a maximum nominal outside


diameter of 102 mm,
(3)
a maximum thickness of 8 mm,
(4)
a maximum specified carbon content
of 0.15%,
(5)
a maximum preheat temperature of
150C.

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.

For carbon steel:(i) a maximum carbon percentage of 0.30.


(ii) a maximum thickness of 9 mm.

Tack welds used to secure


alignment shall either be
removed completely when
they have served their
When gas welding is implied the technique
purpose or their stopping and
followed shall be approved by an Inspecting starting ends shall be
Officer.
properly prepared by
grinding or other suitable
The technique employed in all field welding means so that they may be
of tubes shall be subject to the approval of satisfactorily incorporated
the chief Inspector of
into the final weld. Tack
Boilers.
welds shall be made by buut
weld or fillet weld.
All butt welds of tubes shall be tested as
required hereunder:When joining two parts by
the inertia and continuous
(i) Components greater than 178 mm (7 drive friction welding
inch) bore- All welds shall be non- proceses, one of the two
destructively tested by radiographic or other parts must be held ina fixed
approved methods.
position and the other part
rotated. The two faces to be
(ii) Tubes greater than 102 mm (4 inch) joined must be essentially
bore and upto and including 178 mm symmetrical with respect to

22

(7.inch) bore- 10 per cent of the welds by


each welder, selected at random with a
minimum of 2 welds per welder, shall be
subjected to non-destructive examination by
radiographic or other approved method.

the axis of rotation.

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

Attachment of Steel Tubes- (a) Tubes shall


be connected to the tube plates by one of the
following methods.
(1)
(2)
(3)

Expanding.
Strength welding.
Mechanical bolted bail joint.

Drift or roller expanded tubes shall


project through the neck or bearing part in
the holes by at least a quarter of an inch and
shall be secured from drawing out by being
bell mouthed to the extent of 1 /32'' for each
inch in diameter plus 2/32''.
Tubes may be seal welded into fittings or
headers for both boilers and super heaters
after they have been expanded and flared
provided the material in the fittings or
headers does not contain carbon in excess of
0.35 per cent.
In the case of drifted or roller expanded
tubes, the tube holes in the tube plates of
drums, pockets, or headers shall be formed
in such a way that the tubes can be
effectively tightened in them. Where the
tube ends are not normal to the tube plate,
there shall be a neck or belt of parallel
seating of at least in. depth measured in a
plane normal to the axis of the tube at the

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.

preheat used will be that of


the material with the higher
Where tubes are strength welded direct to
preheat specified on the
the tube plates, the technique followed shall welding procedure
be approved by the Inspecting Authority and specification.
all welds shall be suitably heat treated. In
the case of plates below 22 mm thickness,
Minimum temperature for
the requirement of stress relieving by heat
preheating
treatment after welding of the tubes may be
waived provided the weld satisfies the
P No. 1, Group No. 1,2,3
requirements of the maximum hardness and
also the requirements concerning the impact 79 C ( 175 F) for material
values of the weld metal. The welding
which has both a specified
procedure adopted and the weld sequence
maximum carbon content in
selected shall also be subject to the approval excess of 0.30% and a
of the Inspecting Authority. This provision
thickness at the joint in
is applicable to only shop welding of tubes
excess of 1 in.; 10 C for all
at the Manufacturers' Works.
other materials in this
grouping.
Tubes spacers, supporting clips and lugs
may be welded to the tubes. Flash welding
P No. 3, Group No. 1,2,3
of studs for supporting refractories, etc., is
79 C ( 175 F) for material
also permissible.
which has both a specified
The tubes shall be so arranged that they are minimum tensile strength in
accessible for cleaning internally and
excess of 70000 psi or a
externally
thickness at the joint in
excess of 5/8 in.; 10 C for all
The Working Pressure of the tubes
other materials in this
shall be determined by the following
grouping.
formula :P No. 4, Group No. 1,2.

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:

121 C ( 250 F) for material


which has both a specified
minimum tensile strength in
excess of 60000 psi or a
thickness at the joint in
excess of 1/2 in.; 10 C for all
other materials in this
grouping.
P No. 5A, B, C
204 C ( 400 F) for material
which has both a specified
minimum tensile strength in
excess of 60000 psi or has
both a specified minimum
chromium content above 6.0
% and a thickness at the joint
in excess of in.; 149 C
( 300 F ) for all other
materials in this groupings.
P No. 6, Group No. 1,2,3
204 C or 400 F

The working metal temperature shall be


taken as-

P No. 7, Group No. 1,2.


None

For integral economiser tubes, the


maximum water temperature for which the
part of the element is designed plus 11C
(20F).

P No. 8, Group No. 1,2.


None
P No. 9A, Group No. 1.

26

For furnace and boiler tubes, the saturation,


temperature corresponding to the working
pressure plus 28C (50F).
For conviction superheater tubes, the
examination steam temperature for which
the part of the element is designed plus
39C (70F).
For radiant superheater tubes, the design
maximum steam temperature plus 50C
(90F).

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.

Permissible working stress for tubes: -For


temperature at or below 454C

T.S / 2.7 or Et/1.5.

Requirements for Post


welded Heat Treatments

Whichever is lower

See Attach Table 2.

For temperature above 454C

Repair Of Weld Defects

SR / 1.5 or SC . whichever is lower

Imperfections such as crack,


pinholes, and incomplete
fusion detected visually or by
leakage tests or by the
examinations described in
PW-11 and found to be
rejectable, shall be removed

where,
T.S = Minimum tensile strength of the
material at room temperature,

27

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
General : Tubes that are hot or cold bent for
parts of boilers, includingeconomizers,
furnace walls, superheaters and reheaters,
shall comply with thisclause and suitably
heat treated.
Buttwelds shall not be permitted within
bends.
Thinning anddeparture from circularity

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

limits shall be demonstrated by one of the


followingmethods :
a) relevant and satifactory service
experience;
b) a procedure test;
c) By measurement of 2% of the bends,
including the first bend of each shift.
Themethod selected shall be at the option of
the manufacturer.
Thinning on Tube bends: Thinning on tube
bends shall comply with the following:
a) At any location around the bend extrados,
the reduction in thickness (inpercent) below
the calculated minimum permissible design
thicknessof thestraight tube, except where
permitted by (b), shall not exceed :
100 / ((4R/D) + 2)
where

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.

R is the mean radius of the bend to the


centre-line of the tube (in mm).
1. One sample test at the start
D is the ordered outside diameter of the tube of Production
2. One sample shall be tested

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.

The departure from circularity (in percent)


shall be calculated from:

at the beginning, mid point


and end of each work shift.
3. When production shift are
consecutive, a test at the end
of the shift may serve as the
test for the beginning of next
shift.\
4. When a welding operator
is replaced during
production.
5. If any machine setting are
changed.
Acceptance standard for
Radiographic Examination
Indications shown on the
radiographs of welds and
characterized as
imperfections are
unacceptable under the
following conditions, and
shall be repaired as provided
in PW-40 and the repair
radiographed to PW-51
Any indication characterized
as a crack, or zone of
incomplete fusion or
penetration.

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),

Any other elongated


indication on the radiograph
which has a length greater
than
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.

D is the ordered outside diameter of the tube Any group of aligned


(in mm).
indications that have an
aggregate length greater than
(d)For radiant superheater tubes, the design
t in a length of 12t, except
maximum steam temperature plus 50C
when the distance between
(90F)
the successive imperfection
exceeds 6L where L is the
Permissible Working Stress for tubes:length of the longest
imperfections in the group.
For temperature at or below 454C (850F)

T.S / 3.5 or Et / 1.6


Whichever is lower
For temperature above 454 C (850
F---------

Acceptance standard for


Ultrasonic Examination
Imperfaction that cause an
indication greater than 20%
of the reference level shall be
investigated to the extent that
the ultrasonic examination
personnel can determine
their shape, identity, location,

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

tubes as supplied be less than those given in


the table below (subject to tolerances
specified in Regulations 36(d), 43(d), 48(c),
53(c), 56A(IV) and 58(d). (Click here to view
the Table 338)
In the case of coiled tubes for boilers of the
forced flow of forced circulation type, the
minimum thickness of tubes as supplied
may, however, be as follows: (Click here to
view the Table 338)
(c) Where tubes are bent, care shall be taken
to ensure that the total strain at the bend is
not more than that at the straight part of the
tube.
The deviation from circularity in percentage
at any cross-section of a bend shall be
calculated by the following formula:
C = (Dmax Dmin / D) X 100
This deviation shall not exceed
20 * D / R
where,
C

The percentage deviation of

testing a specimen of the full


thickness of the welded
plate, the specimen may be
cut with a thin saw into as
many portion of the
thickness as necessary, each
of which shall be tested and
shall meet the requirements.
The inside and the outside
surface of the weld shall be
machined to a plane surface
flush with the surface of the
specimen. The edges of this
surfaces shall be rounded to
a radius not over 10% of the
thickness of the test
specimen. The specimen
shall be bent cold under free
bending conditions until the
least elongation measured
within or across
approximately the entire
weld on the outside fibres of
the bend test specimen is
30%, or 700000/U + 20%,
whichever is less.
PW 53.9.2 When a crack is
observed in the convex
surfaces of the specimen
between the edges before the

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,

(iii) Properties of material to be weldedcold and hot working, thermal conductivity,


fusion point, oxidation (for welders engaged

34

in alloy steel welding).

(iv) Elementary knowledge of electrotechnical principles,-kinds of current,


striking arc voltage, welding-arc voltage.
(v) Welding defects and their preventioninfluence of length of electric arc, effects of
excessive or too low amperage, slag
inclusions, porosity finishing the surface of
welding bead.
Electrodes for different types of welds and
steels and joints in different positions.

2. Gas WelderWeld preparation.


Working of
welding equipment.
Elementary knowledge of properties of
materials to be welded -cold and hot
working, thermal conductivity, fusion

35

point, oxidation (for welders engaged in


alloy steel welding).
Elementary knowledge of fuel gas and
flame adjustments for favorable welding
condition.
Kinds of welds, welding defects and their
prevention, welding technique (right-ward
and left-ward), welding with two torches on
vertical surface, excess of gas or oxidation,
preheating of base material and subsequent
heat treatment.
Filler metals.
2.Test Welds for Initial Qualification
(Electric or Gas):(b) For Pipe WeldingOne test on groove weld joint for each of
the following welding positions
(i) Horizontal Rolled - Pipe with its axis
horizontal and rolled during welding so that
the weld metal is deposited from above with
the axis of the weld horizontal.

36

(ii) Horizontal Turned- Pipe with its axis


horizontal the upper half welded first, the
pipe then being turned through 180 degree
and the other half then welded.

(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

(iv) Horizontal Fixed- One test of groove


welded joint with the axis of the pipe in a
horizontal position and the seam welded
without rotating the pipe.
Qualification in positions (ii) or (iii) shall
qualify also for position (i) qualification
'in position (iv) shall qualify for position
(i) or (ii).
(2) One Weld of a branch to a pipe.
The size of pipe to be welded shall be
not less than 127 mm. (5 inches) in
external diameter and 10 mm. (3/8 inch)
thick, and a branch pipe shall not be less
than 89 mm. (3-1/2 inches) outside
diameter and 6 mm. (1/4 inch) thick.
(c) Tube Welding- A butt welded Joint of
two pieces boiler tubes with the axis in
a vertical position, and tubes of same
size fixed in adjoining positions. This
test shall be in addition to the test for
pipe welding under clause (b).

38

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