PROCEDURE NO.

PTD-DSG-116
PAGE OF
1 9
PROCESS TECHNOLOGY PROCEDURES
PREPARED BY
Edited from existi!
do" #$ %.R. B&r'&rt
DATE
A(ri) *+. ,+++
DEPART-ENT. PROCESS TEC/NO0OGY
APPRO1ED BY
%RB
SUB%ECT. AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 2 DES2GN GU2DE
RE12S2ON DATE
114+14+,
RE1.
1

1.0 SCOPE
This design guide
1
outlines the requirements of the American Society of Mechanical
Engineers (ASME) Boiler and Pressure Vessel Code Section !"
2.0 CODES AND STANDARDS
The latest issue of each of the follo#ing codes and standards shall $e considered a %art
of this design guide"
1" ASME Boiler and Pressure Vessel Code
Section ! &ules for Construction of Po#er Boilers
Section V!!! &ules for Construction of Pressure Vessels
'" American (ational Standards !nstitute (A(S!)
B)1"1 Chemical Plant and &efinery Pi%ing
3.0 RESPONSIBILITIES
The %rocess engineer is res%onsi$le for*
1" Setting the design %ressure ma+imum allo#a$le #or,ing %ressure (MA-P) and
tem%erature of Section ! .essels
'" /etermining the num$er si0e and set %ressures of the safety relief .al.es
)" Setting design conditions and configuration of attached %i%ing and certain
instrumentation requirements as outlined in ASME Code Section !
4.0 DEFINITIONS
ASME Code Section ! defines the follo#ing terms*
1" Po#er Boiler is a $oiler in #hich steam or other .a%or is generated at a %ressure of
more than 11 %ounds %er square inch gauge (%sig) for use e+ternal to itself"
'" 2igh3Tem%erature -ater Boiler is a #ater $oiler intended for o%eration at
%ressures in e+cess of 145 %sig and6or tem%eratures in e+cess of '15 degrees
7ahrenheit (7)"
)" 7ired Steam Boiler is a %ressure .essel in #hich steam is generated $y the
a%%lication of heat resulting from the com$ustion of fuel (solid liquid or gaseous)"
1
Re5. + of t'e Desi! G6ide 7&s &d&(ted 7it' miim&) "'&!es from & P&s&de& do"6met3 DSG--P1B3 1+49,
8" Vessels ,no#n as e.a%orators or heat e+changers or .essels in #hich steam is
generated $y the use of heat resulting from the o%eration of a %rocessing system
containing a num$er of %ressure .essels are unfired %ressure .essels"
5.0 DESIGN CONDITIONS OF SECTION I VESSELS
Mechanical design conditions of %ressure and tem%erature indicated in the design criteria
for the %articular 9o$ shall $e used" The ASME Code 9urisdictional limits for %i%ing drum3
ty%e $oilers are dis%layed in 7igure 1"
7igure 1 3 ASME Code :urisdictional ;imits for Pi%ing 3 /rum3Ty%e Boilers
6.0 SAFETY-RELIEF VALVES
ASME Code Section ! requirements for safety3relief .al.es are summari0ed $elo#" All
%ressures are %sig"
6.1 Safet Va!"e# Re$%&'e(
The follo#ing safety .al.es are required*
1" <ne safety .al.e or safety relief .al.e is required if the #ater3heating surface area
is less than 155 square feet"
'" T#o or more safety .al.es or safety relief .al.es are required for areas of 155
square feet or more"
6.2 P'e##%'e Sett&)*# +f Safet Va!"e#
The follo#ing requirements shall a%%ly to %ressure settings of safety .al.es*
1" <ne or more safety .al.es must $e set at or $elo# the MA-P (design %ressure) of
the $oiler"
'" !f additional .al.es are used the highest %ressure setting shall not e+ceed the
MA-P $y more than ) %ercent %sig"
)" The com%lete range of %ressure settings of all the safety .al.es on a $oiler shall
not e+ceed 15 %ercent of the highest %ressure to #hich any .al.e is set" E+am%les
are gi.en $elo#*
PS!=
E+am%le 1
/esign %ressure '55"5
7irst %ressure setting '55"5
2ighest setting allo#ed '54"5
&ange of settings allo#ed '54"5 to 1>1"8
E+am%le '
/esign %ressure '55"5
7irst %ressure setting 1?1"5
2ighest setting allo#ed 1@8"8
&ange of settings allo#ed 1@8"8 to 1?1"5
AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 1 DES2GN GU2DE
PROCEDURE NO.
PTD-DGS-116
RE1.
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DATE
114+14+,
PAGE OF
, 1,
6.3 O"e','e##%'e L&-&tat&+)#
The highest %ressure allo#ed in a $oiler #hen the safety .al.es are relie.ing shall not $e
more than 4 %ercent a$o.e the highest %ressure to #hich any .al.e is set (%sig) and in no
case shall the %ressure rise to more than 4 %ercent a$o.e the MA-P (design %ressure)"
E+am%les are gi.en $elo#*
PS!=
E+am%le 1
/esign Pressure 155
Ma+imum $oiler %ressure allo#ed 154 (#hen .al.es are relie.ing)
7irst %ressure setting
155
1
(4A ma+imum accumulation)
Second %ressure setting 15) ()A ma+imum accumulation)
E+am%le '
/esign %ressure '55
7irst %ressure setting
1?1
1
(1'A ma+imum accumulation)
Second %ressure setting
1>1
1
(4A ma+imum accumulation)
Ma+imum o.er%ressure 1>1 B4A C 1@4
1?1 B1)A C 1@4
1
Although the ASME Code allo#s 4 %ercent o.er%ressure (4 %ercent
accumulation for safety3relief .al.es set at or $elo# the design %ressure)
the #idely acce%ted standard is to use ) %ercent accumulation for all
safety3relief .al.es on Section ! .essels" Consequently .al.e
manufacturers ha.e $een a$le to standardi0e their ca%acity charts at )
%ercent accumulation"
6.4 Ca,a.&t +f Safet Va!"e#
The required steam relie.ing ca%acity in %ounds %er hour on a high tem%erature #ater
$oiler is determined $y di.iding the ma+imum British thermal units (Btus) %roduced at the
$urners $y 1555"
6.5 S%,e'/eate' Safet Va!"e Re$%&'e-e)t#
The follo#ing requirements shall a%%ly to su%erheater safety .al.es*
1" E.ery attached su%erheater shall ha.e one or more safety .al.es in the steam flo#
%ath $et#een the su%erheater outlet and the first sto%3.al.e"
'" /ischarge ca%acity of the safety .al.es on an attached su%erheater may $e
included in determining the num$er and si0e of safety .al.es for the $oiler
%ro.iding there are no inter.ening .al.es and that the $oiler safety .al.es ha.e at
least ?1 %ercent of the total ca%acity required"
AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 1 DES2GN GU2DE
PROCEDURE NO.
PTD-DGS-116
RE1.
1
DATE
114+14+,
PAGE OF
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)" All inde%endently fired su%erheaters that may $e shut off from the $oiler must ha.e
one or more safety .al.es ha.ing a ca%acity equal to 4 %ounds of steam %er hour
%er square foot of area e+%osed to the hot gases"
AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 1 DES2GN GU2DE
PROCEDURE NO.
PTD-DGS-116
RE1.
1
DATE
114+14+,
PAGE OF
8 1,
0.0 E1TERNAL PIPING RE23IRE4ENTS
E+ternal %i%ing shall $e in accordance #ith ASME Code Section ! $ut the design
fa$rication installation and testing shall $e in accordance #ith A(S!6ASME B)1"1 Po#er
Pi%ing"
0.1 C+(e 5%'&#(&.t&+)a! L&-&t#
7or the latest code and reference num$ers refer to A(S! B)1"1" Dse the code and
reference num$ers in accordance #ith the follo#ing sections"
0.2 Re$%&'e-e)t - Va'&at&+)# f'+- N+'-a! O,e'at&+)
There is no short3term .ariation from normal o%eration %ermitted in $oiler e+ternal %i%ing
inside the .alues required $y ASME Code Section !" The %i%ing system under A(S!
B)1"1 9urisdiction ho#e.er shall $e considered safe for occasional o%eration for short
%eriods at higher than the design %ressure and6or tem%erature according to the follo#ing
conditions*
1" D% to 11 %ercent increase a$o.e the allo#a$le stress (S) .alue during 15 %ercent
of the o%erating %eriod
'" D% to '5 %ercent of the S .alue during 1 %ercent of o%erating %eriod
)" Stresses resulting from hydrostatic head shall $e ta,en into account
0.3 Stea- P&,&)*
The follo#ing requirements shall a%%ly to steam %i%ing*
1" Steam %i%ing connected to the $oiler drum or to the su%erheater outlet header shall
e+tend u% to and include the first sto% .al.e in each connection e+ce%t as required
$y A(S! B)1"1" !n the case of a single $oiler and %rime mo.er installation the sto%
.al.e required may $e omitted %ro.ided the %rime mo.er throttle .al.e is equi%%ed
#ith an indicator to sho# #hether the .al.e is o%en or closed and designed to
#ithstand the required hydrostatic %ressure test of the $oiler (A(S! B)1"1)"
'" -hen t#o or more $oilers are connected to a common steam header the
connection from each $oiler ha.ing a manhole o%ening shall $e fitted #ith t#o sto%3
.al.es ha.ing an am%le free3$lo# drain $et#een them" The e+ternal %i%ing is u% to
and including the second sto% .al.e and the free3$lo# drain .al.e (A(S! B)1"1)"
)" /esign %ressure of steam %i%ing u% to the first sto% .al.e shall not $e less than the
lo#est set %ressure of any safety6relief .al.e (A(S! B)1"1)" Static head should $e
considered"
8" /esign %ressure of the steam %i%ing $et#een the first and second sto% .al.e
(#here required) shall not $e less than the e+%ected o%erating %ressure or >1
%ercent of the lo#est set %ressure at #hich any drum safety .al.e is set #hiche.er
is greater (A(S! B)1"1)"
AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 1 DES2GN GU2DE
PROCEDURE NO.
PTD-DGS-116
RE1.
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DATE
114+14+,
PAGE OF
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1" Minimum design %ressure shall not $e less than 155 %sig for any condition of
ser.ice or material (A(S! B)1"1)"
4" /esign tem%erature shall not $e less than the saturated steam tem%erature at the
design %ressure (A(S! B)1"1)"
0.4 Fee(6ate' P&,&)*
The follo#ing requirements shall a%%ly to feed#ater %i%ing*
1" 7eed#ater %i%ing for all $oilers e+ce%t high3tem%erature #ater $oilers and forced3
flo# steam generators shall e+tend through the required sto% .al.e and u% to and
including the chec, .al.e e+ce%t as required $y A(S! B)1"1" <n a single $oiler3
tur$ine unit installation the $oiler feed shutoff .al.e may $e located u%stream from
the $oiler feed chec, .al.e (A(S! B)1"1)"
'" -hen t#o or more $oilers are fed from a common source the %i%ing shall $e u% to
and including a glo$e or regulating .al.e located $et#een the chec, .al.e and the
source of su%%ly (A(S! B)1"1)"
)" /esign %ressure of the feed#ater %i%ing from the $oiler u% to and including the
required sto% and chec, .al.e shall e+ceed the MA-P of the $oiler $y either '1
%ercent or ''1 %ounds %er square inch (%si) #hiche.er is the lesser (A(S! B)1"1)"
8" /esign %ressure of the feed#ater %i%ing $et#een the required chec, .al.e and any
regulating .al.e including any $y%ass %i%ing shall not $e less than the %ressure
required to feed the $oiler (A(S! B)1"1)"
1" Minimum design %ressure shall not $e less than 155 %sig for any condition of
ser.ice or material and shall ne.er $e less than the %ressure required to feed the
$oiler (A(S! B)1"1)"
4" /esign tem%erature of the feed#ater %i%ing shall not $e less than the saturated
steam tem%erature at the MA-P of the $oiler (A(S! B)1"1)" !f a $oiler has an
alternati.e feed arrangement each must $e equi%%ed as required $y ASME Code
Section !"
?" 7or $oilers #ith a #ater3heating surface more than 155 square feet the smallest
feed %i%ing and connection shall ha.e a %i%e si0e of )68 inch"
0.5 B!+6+ff P&,&)*
Blo#off %i%ing is a %i%e connection %ro.ided #ith .al.es located in the e+ternal %i%ing
through #hich the #ater in the $oiler may $e $lo#n out under %ressure e+ce%ting drains
such as are used on #ater columns gauge glasses or %i%ing to feed#ater regulators etc"
The follo#ing requirements shall a%%ly to $lo#off %i%ing*
AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 1 DES2GN GU2DE
PROCEDURE NO.
PTD-DGS-116
RE1.
1
DATE
114+14+,
PAGE OF
6 1,
1" -hen the allo#a$le #or,ing %ressure e+ceeds 155 %si the $lo#off %i%ing for all
$oilers e+ce%t forced3flo# steam generators #ith no fi+ed steam and #ater line
high3tem%erature #ater $oilers and those used for traction and6or %orta$le
%ur%oses shall e+tend through and including the second .al.e (A(S! B)1"1)" The
$lo#off %i%ing for all traction and6or %orta$le $oilers and for forced circulation and
electric $oilers #ith a normal #ater content not e+ceeding 155 gallons is required to
e+tend through only one .al.e #hich is used to determine the o%erating condition
of such equi%ment (ASME Code Section !)"
'" Continuous $lo#do#n %i%ing is not considered as $lo#off %i%ing $y the ASME
Code" 2o#e.er continuous $lo#do#n %i%ing through the first shutoff .al.e must
ha.e a design %ressure rating at least equal to the lo#est set %ressure of any
safety .al.e at the corres%onding saturated3steam tem%erature (A(S! B)1"1)"
)" Surface $lo#off shall not e+ceed a '316'3inch %i%e si0e (ASME Code Section !)"
8" Each $oiler shall ha.e a $ottom $lo#off %i%e fitted #ith a .al.e or coc, in direct
connection #ith the lo#est #ater s%ace %ractica$le (ASME Code Section !)"
1" Minimum si0e of %i%e and fittings for $oilers #ith greater than 155 square feet of
heating surface shall $e 1 inch (ASME Code Section !)"
4" /esign %ressure shall e+ceed the MA-P of the $oiler $y either '1 %ercent or ''1
%sig #hiche.er is less (A(S! B)1"1)"
?" Minimum design %ressure is 155 %sig in any case (A(S! B)1"1)"
>" /esign tem%erature shall not $e less than the tem%erature of saturated steam at
the MA-P of the $oiler (A(S! B)1"1)"
a" Minimum %i%e thic,ness is Schedule >5 (A(S! B)1"1)"
$" 7or design %ressures o.er '55 %sig the .al.es shall $e steel #ith a rating of
)55 %ounds (A(S! B)1"1)"
0.6 4&#.e!!a)e+%# P&,&)*
Miscellaneous %i%ing shall include the %i%ing for such items as drains .ents surface3
$lo#off steam and #ater %i%ing for #ater columns gauge glasses and %ressure gauges
and the recirculation return line for a high3tem%erature #ater $oiler" -hen a drain is not
intended for $lo#off %ur%oses #ith the $oiler under %ressure a single .al.e is acce%ta$leE
other#ise t#o .al.es in series are required (A(S! B)1"1)"
0.0 D'a&)#
The follo#ing requirements shall a%%ly to drains*
1" Am%le drains shall $e %ro.ided #here required to %ermit com%lete drainage of all
%i%ing su%erheaters #ater#alls #ater screens integral economi0ers high3
tem%erature #ater $oilers and all other $oiler com%onents in #hich #ater may
collect (A(S! B)1"1)"
AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 1 DES2GN GU2DE
PROCEDURE NO.
PTD-DGS-116
RE1.
1
DATE
114+14+,
PAGE OF
: 1,
'" /rain or $lo#off .al.es shall $e %ro.ided as necessary"
)" /rain lines including %i%e fittings and .al.es shall com%ly #ith the requirements
for steam %i%ing or #ater %i%ing according to the ser.ice"
8" Each su%erheater shall $e equi%%ed #ith at least one drain located to effecti.ely
%ro.ide for the %ro%er o%eration of the a%%aratus"
1" Each high3tem%erature #ater $oiler shall ha.e a $ottom drain connection #ith a 13
inch minimum %i%e si0e fitted #ith a .al.e or coc, in direct connection #ith the
lo#est #ater s%ace %ractica$le"
4" -hen the .al.e or .al.es for #ater#alls #ater screens and integral economi0ers
in A(S! B)1"1 are not intended for $lo#off %ur%oses $ut are intended for use only
as a drain .al.e #hen the $oiler is not under %ressure a single shutoff .al.e is
acce%ta$le %ro.ided it is a ty%e that can $e loc,ed in the closed %osition or
%ro.ided a $lan, is inserted in a suita$le flanged and $olted connection located on
the do#nstream side of the .al.e" -hen such a single .al.e is used it need not $e
designed s%ecifically for $lo#off ser.ice $ut shall $e adequate for the %ressure and
tem%erature conditions at #hich the $oiler o%erates"
0.7 I)#t'%-e)tat&+)
?">"1 -ater ;e.el !ndicators (A(S! B)1"1)
The follo#ing requirements shall a%%ly to #ater le.el indicators*
1" Each $oiler e+ce%t forced3flo# steam generators #ith no fi+ed steam and #ater
line and high3tem%erature #ater $oilers of the forced3circulation ty%e that ha.e no
steam and #ater line shall ha.e at least one #ater gauge glass"
'" Boilers o%erated at %ressures o.er 855 %sig e+ce%t electric $oilers of the electrode
ty%e shall $e %ro.ided #ith t#o #ater gauge glasses #hich may $e connected to a
single #ater column or connected directly to the drum"
)" T#o inde%endent remote le.el indicators may $e used instead of one of the t#o
required gauge glasses for $oiler drum #ater le.el indication in the case of %o#er
$oilers #ith all drum safety .al.es set at or a$o.e @55 %si" -hen $oth remote le.el
indicators are in relia$le o%eration the gauge glass may $e shut off $ut shall $e
maintained in a ser.icea$le condition"
8" -hen the direct reading of gauge glass #ater le.el is not readily .isi$le for the
o%erator in the #or,ing area t#o de%enda$le indirect indications shall $e %ro.ided
either $y transmission of the gauge glass image or $y remote le.el indicators"
?">"' Pressure =auges (A(S! B)1"1)
AS-E BO20ER AND PRESSURE 1ESSE0 CODE3
SECT2ON 1 DES2GN GU2DE
PROCEDURE NO.
PTD-DGS-116
RE1.
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DATE
114+14+,
PAGE OF
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The follo#ing requirements shall a%%ly to %ressure gauges*
1" Each $oiler shall ha.e a %ressure gauge located so that it is easily reada$le" The
%ressure gauge shall $e installed so that it shall indicate the %ressure in the $oiler
at all times"
'" Each steam $oiler shall ha.e the %ressure gauge connected to the steam s%ace or
to the #ater column or its steam connection"
)" A .al.e or coc, shall $e %laced in the gauge connection ad9acent to the gauge" An
additional .al.e or coc, may $e located near the $oiler %ro.iding it is loc,ed or
sealed in the o%en %osition" (o other shutoff .al.es shall $e located $et#een the
gauge and the $oiler"
8" The %i%e connection shall $e of am%le si0e and shall $e arranged so that it may $e
cleared $y $lo#ing out"
1" Steam $oilers shall ha.e a gauge or connection that contains a si%hon or
equi.alent de.ice #hich #ill de.elo% and maintain a #ater seal that #ill %re.ent
steam from entering the gauge tu$e"
4" Pressure gauge connections shall $e suita$le for the MA-P and tem%erature $ut
if the tem%erature e+ceeds 854 degrees 7 $rass or co%%er %i%e or tu$ing shall not
$e used"
?" !f connections to the $oiler e+ce%t the si%hon are used they shall not $e less than
1683inch standard %i%e si0eE ho#e.er #here steel or #rought iron %i%e or tu$ing is
used it shall not $e less than 16'3inch inside diameter"
>" Minimum si0e of a si%hon if used shall $e 1683inch inside diameter"
@" The dial of the %ressure gauge shall $e graduated to a%%ro+imately dou$le the
%ressure at #hich the safety .al.e is set $ut in no case shall it $e less than 1316'
times this %ressure (ASME Code Section !)"