4/23/2019 Applying ASME Boiler Code to Steam Generation Systems - Chemical Engineering

HEAT TRANSFER PDF

APPLYING ASME BOILER CODE TO STEAM GENERATION

SYSTEMS
By Martha Choroszy, David Ballow and Ali Bourji WorleyParsons | January 1, 2013

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The ASME Boiler and Pressure Vessel Code (ASME BPVC), which is administered by ASME (New York, N.Y.; www.asme.org; founded as the American
Society of Mechanical Engineers), is a well-established standard for the design and fabrication of boilers and pressure vessels. ASME code-symbol
stamps show compliance with the requirements of the standard, but code stamping of steam systems in ethylene and other large heaters can be
controversial.

Much of the challenge for those in the chemical process industries (CPI) stems from the fact that the main focus of the code is on power boilers,
rather than on petroleum re nery or petrochemical heaters, so de nitions are sometimes not clear. Furthermore, it can be di cult to de ne which
authority has jurisdiction over steam generation systems in the CPI. Even in the U.S., state boiler codes vary among the states. In other countries,
adherence to ASME standards may or may not be required, thus leaving it up to the owners of the asset to decide. This article provides guidance on
the requirements for stamping within the ASME code and explains how state boiler codes can a ect the requirements.

 Figure 1. Most operators agree that Section 1 of the ASME Boiler and Pressure
Vessel code is the most appropriate standard for steam-generation systems, such
as the more common natural-circulation type (above) and the forced-circulation
type (below)

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STEAM-GENERATION SYSTEMS
When it comes to steam-generation systems, safety is the primary concern for both the owners of the system and for the authorities that have
jurisdiction over them. All parties want safe and reliable equipment designed for the intended purpose. Section 1 of the ASME BPVC contains the
rules for construction of power boilers [1]. Power boilers are de ned as boilers that generate steam at pressures in excess of 15 psig, for external
use. Most designers and owners of steam-generation systems from red heaters agree that ASME Code Section 1 is the appropriate design code for
the steam system.

Steam systems in red heaters typically consist of the following: steam drum; relief valves; boiler-feedwater preheat tubes; steam-generation
tubes; steam superheating tubes; an end-stage or interstage de-superheater; startup vent and silencer; interconnecting piping; inline instruments;
and, for ethylene heaters, a primary transfer line exchanger (TLE) as shown in Figure 1. The steam generation system can be one of two types:
either natural circulation or forced circulation. The natural circulation type is more common. Figure 1 (bottom) shows a typical set-up for a forced-
circulation system.

ASME JURISDICTION
The jurisdictional limits of ASME from Section 1 of the BPVC are shown in Figure 2. The gure, “Code Jurisdictional Limits for Piping — Drum Type
Boilers,” was adapted from ASME 2010 BPVC Section 1, with permission of ASME [2].

The ASME BPVC describes three areas of technical responsibility: the boiler proper, the boiler external piping and joint, and non-boiler external
piping and joint. The boiler proper falls under the administrative jurisdiction and technical responsibility of Section 1 of the ASME BPVC. The boiler
proper and boiler external piping and joint fall under the administrative jurisdiction of ASME BPVC and require mandatory certi cation, along with
code stamping, ASME data forms and authorized inspection.

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FIGURE 2. The ASME BPVC describes three areas of technical responsibility: boiler proper; boiler external piping and
joint; and non-boiler external piping and joint
Technical responsibility for boiler external piping is assigned to the ASME section committee of B31.1. Non-boiler external piping and joint is not
considered to be within the jurisdiction of ASME BPVC section 1, and those components are usually designed according to B31.1 in utility
applications or B31.3 in chemical or re nery plant applications.

Even the application of the “Code Jurisdictional Limits for Piping — Drum Type Boilers” to steam systems in ethylene heaters can be problematic,
because the language of the section is clearly intended for a conventional boiler. Most engineers agree, and several U.S. state boiler codes require
that the steam drum be designed to ASME Section 1. In non-code states, the drum may be designed to Section VIII.

Steam superheat tubes, economizer tubes and steam generation tubes are also designed to meet the requirements of ASME Section 1.

STAMP REQUIREMENTS
The ASME BPVC clearly requires all equipment considered to be “boiler proper” and “boiler external piping and joint” to be stamped. Steam
systems for ethylene heaters are typically manufactured by multiple vendors and assembled in the eld by a di erent contractor. The particular
ASME stamp and partial data report produced depends on the type of manufacturer. Table 1 shows a common setup, where multiple vendors
provide the various components of the steam system.

Table 1. Multiple Vendors supply various steam-System components

ASME Code stamp (by Code stamp requirement (by Assembler Stamp (by
  Component name Category
Code vendor) eld assembler) eld assembler)
Stamp ASME partial Stamp ASME partial data Stamp ASME partial
       
type data report type report type data report
Boiler feed water (BFW) feed piping to pre- ASME A P-3A
1 Piping     PP P-4A
heater B31.1
ASME
2 BFW feed piping to de-superheater Piping     PP P-4A
B31.1
ASME
3 BFW pre-heater Equipment S P-4A    
SEC. I
ASME
4 BFW piping to steam drum Piping     PP P-4A
B31.1
ASME
5 Steam drum Equipment S P-4A    
SEC. I
6 Pressure-reducing de-superheating stations Pressure ASME V P-7    

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(PRDs) on steam drums relief valve SEC 1
Vendor ASME
7 Riser and downcomer S P-4A S P-4A
piping SEC. I
Primary transfer-line heat exchanger (TLE), ASME
8 Equipment S P-4A    
steam-side SEC. I
ASME
9 Primary TLE blowdown Piping     PP P-4A
B31.1
Super high-pressure (SHP) piping from ASME
10 Piping     PP P-4A
steam drum B31.1
ASME
11 Upper steam superheater (USSH) Equipment S P-4A    
SEC. I
ASME
12 De-superheater Equipment S P-4A    
SEC. I
Vendor ASME
13 De-superheater piping S P-4A S P-4A
piping SEC. I
ASME
14Lower steam superheater (LSSH) Equipment S P-4A    
SEC. I
ASME
15 SHP export piping Piping     PP P-4A
B31.1
 

MASTER STAMP
If compliance with ASME BPVC Section 1 is required by law, a master stamp is required. For a forced- ow steam-generation unit, the code is clear
— manufacturers of forced- ow systems must provide a master stamp. For eld-assembled boilers, a master stamp is clearly required.

The master stamp must be provided by whoever has responsibility for the entire boiler unit. In cases where the manufacturer is not the assembler,
the manufacturer or engineering contractor may provide partial data reports to the assembler, and the assembler may a x the stamp jointly with
the manufacturer, according to the rules of section PG-106 in ASME BPVC Section 1. In this case, both the engineering contractor and the
authorized inspector must sign the P-3A forms provided by the assembler.

The question that arises for steam-generation units on ethylene heaters is this: When adherence to ASME BPVC Section 1 is voluntary, is a master
stamp required? The answer is no. If compliance is voluntary, the owner of the system may opt to comply with some parts of the code, but not
others.

OWNER REQUIREMENTS
Almost all owner speci cations require that the steam drum, primary transfer line heat exchanger (TLE; steam side), and boiler proper piping are
designed according to ASME BPVC Section 1, and stamped by the supplier. Few owners require a master stamp unless a stamp is required by the
local authority having jurisdiction.

Owner speci cations for steam systems can sometimes be confusing, and at other times do not address the subject at all. Statements such as “the
steam system shall be in accordance with ASME section 1” can be di cult to interpret.

STATE BOILER CODE REQUIREMENTS

In the U.S., the individual states regulate boilers. There is no “federal” boiler code that applies to all states and territories. Not all 50 states have
boiler codes. Most states that do have boiler codes require compliance with ASME BPVC Section 1. Some states go further and require National
Board Registration and inspection. A sampling of three state boiler-code laws follows. While the language contained in the codes for both
Mississippi and Texas are clear, the language of other states is not.

Mississippi State Boiler Code — commonly known as Title 15, Section III, part 76 — clearly de nes any vessel that generates steam at over 15 psig
as a power boiler [3]. It goes on to say that “Boilers and un red pressure vessels to be installed for operation in Mississippi shall be designed,
constructed, inspected, stamped and installed in accordance with the applicable ASME Boiler and Pressure Vessel Code, and these rules and
regulations.”

Texas State Boiler Code, commonly known as 16 TAC 65, requires that any heating boiler, nuclear boiler, power boiler, un red steam boiler or
process steam generator that is installed in Texas must be inspected, installed and stamped in conformity with the applicable section of the ASME

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BPVC. Such boilers must be registered with the National Board of Boiler and Pressure Vessel Inspectors. Exceptions include reinstalled boilers, as
well as those exempted by the Health and Safety Code, §755.022 [4].

New Jersey Boiler Code is commonly called NJAC 12 subchapter 4. In New Jersey, the term “boiler” means a closed vessel in which water is heated,
steam is generated, steam is superheated, or any combination thereof, under pressure or vacuum, for external use by the direct application of heat
[5]. The term “boiler”shall include red or waste-heat units for heating or vaporizing liquids other than water where these units are separate from
processing systems and are complete within themselves. New Jersey requires compliance with ASME BPVC Section 1 and National Board rules.

CONCLUDING REMARKS
While safety remains of the utmost concern, economics, more than engineering, play a great role in de ning the boundaries where the ASME code
may apply. Unless a more speci c code is developed for ethylene units, the debate about boundaries will continue among owners, engineering
contractors, technology providers and other stakeholders. In general, more stringent requirements of ASME are applied for ethylene plants in the
U.S., compared to other places in the world.

Edited by Scott Jenkins

REFERENCES
1. ASME Section 1, Boiler and Pressure Vessel Code, ASME, July 1, 2010.

2. Reprinted from ASME 2010 BPVC, Section 1, by permission of The ASME (American Society of Mechanical Engineers.) All rights
reserved.

3. Mississippi Department of Health, Title 15, Part III – O ce of Health Protection, 76 – Boiler and Pressure Vessel Safety, July 1, 1975.

4. Texas Boiler Administrative Rules – 16 Texas Administrative Code, January 1, 2008.

5. New Jersey Administrative Code (N.J.A.C.) — Boilers, Pressure Vessels & Refrigeration,October 6, 2008.

AUTHORS

Martha Choroszy is a chief process engineer at WorleyParsons (6330 West Loop South, Bellaire, Tex. 77401; Phone: 713-407-5000; Email:
[email protected]). She received a B.S.Ch.E. degree from the Massachusetts Institute of Technology and an MBA from Tulane
University. She is a licensed professional engineer in Texas and a member of AIChE and NFPA. She is the author of numerous publications, a
recipient of Tulane’s Allen Vorholt award and has served as a Blue Ribbon Panel Member to de ne the National Agenda for the U.S. Core
Combustion Research Program.

David Ballow is a principal process engineer at WorleyParsons in Houston (Email: [email protected]) and is a professional
engineer. He received a B.S.Ch.E. degree from Louisiana Tech University and is a member of AIChE. 

Ali Bourji is a senior technical director at WorleyParsons in Houston (Email: [email protected]). Bourji received his B.S. and M.S.
degrees in chemical engineering from the University of Houston, and a doctorate degree from Lamar University. He is a professional engineer and a
member of AIChE and AFPM. Dr. Bourji is the author of numerous publications and serves on the Chemical Engineering PhD Advisory Council at
Lamar University.

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