Document ZBzG7LqZnKR83kjqGawD002DO

ASME BOILER AND PRESSURE VESSEL CODE AN INTERNATIONALLY RECOGNIZED CODE SECTION IV Rules for Construction of Heating Boilers 1995 EDITION JULY 1, 1995 ASME BOILER AND PRESSURE VESSEL COMMITTEE SUBCOMMITTEE ON HEATING BOILERS THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS United Engineering Center 345 East 47th Street New York, N.Y. 10017 RS-002986 1/17/02 NUECE8 Date of Issue -- July 1, 1995 (Includes all Addenda dated December 1994 and earlier) This code or standard was developed under procedures accredited as meeting the criteria for American National Standards. The Consensus Committee that approved the code or standard was balanced to assure that individuals from competent and concerned interests have had an opportunity to participate. The proposed code or standard was made available for public review and comment which provides an opportunity for additional public input from industry, academia, regulatory agencies, and the public-at-large. ASMH does not "approve," "rate," or "endorse" any item, construction, proprietary device, or activity. ASME does not take any position with respect to the validity of any patent rights asserted in connection with any items mentioned in this document, and does not undertake to insure anyone utilizing a standard against liability for infringement of any applicable Letters Patent, nor assume any such liability. Users of a code or standard are expressly advised that determination of the validity of any such patent rights, and the risk of infringement of such rights, is entirely their own responsibility. Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted as government or industry endorsement of this code or standard. ASME accepts responsibility for only those interpretations issued in accordance with governing ASME procedures and policies which preclude the issuance of interpretations by individual volunteers. ASME collective membership mark NA fLV* PNT' r)1 fUMj /* \ p 7" h r fn_q_prl flLl) I r1 m A KA \ RP The above ASME symbols are registered in the U.S. Patent Office. "ASME" is the trademark of the American Society of Mechanical Engineers. Copyright 1995 by THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS All Rights Reserved The Specifications published and copyrighted by The American Society for Testing and Materials are reproduced with the Society's Permission. No pan of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher. Library of Congress Catalog Card Number: 56-3934 Printed in the United States of America Adopted by the Council of the American Society of Mechanical Engineers, 1914. Revised 1940, 1941, 1943, 1946. 1949. 1952, 1953. 1956. 1959, 1962. 1965. 1968, 1971. 1974, 1977, 1980, 1983, 1986. 1989, 1992, 1995 R8402987 1/17/02 NUECES. A95 A96 A97 1995 ASME BOILER AND PRESSURE VESSEL CODE SECTIONS I Rules for Construction of Power Boilers II Materials Part A -- Ferrous Material Specifications Part B -- Nonferrous Material Specifications Part C -- Specifications for Welding Rods, Electrodes, and Filler Metals Part D -- Properties HI Subsection NCA -- General Requirements forDivision 1 and Division 2 III Division 1 Subsection NB -- Class 1 Components Subsection NC -- Class 2 Components Subsection ND -- Class 3 Components Subsection NE -- Class MC Components Subsection NF -- Supports Subsection NG -- Core Support Structures Subsection NH -- Class 1 Components in Elevated Temperature Service Appendices El Division 2 -- Code forConcrete Reactor Vessels andContainments m Division 3 -- Containment Systems and Transport Packagings for Spent Nuclear Fuel and High Level Radioactive Waste IV Rules for Construction of Heating Boilers V Nondestructive Examination VI Recommended Rules for the Care and Operation of Heating Boilers VU Recommended Guidelines for the Care of Power Boilers VIII Rules for Construction of Pressure Vessels Division 1 Division 2 -- Alternative Rules Division 3 -- Alternative Rules for Construction of High Pressure Vessels IX Welding and Brazing Qualifications X Fiber-Reinforced Plastic Pressure Vessels XI Rules for Inservice Inspection of Nuclear Power Plant Components ADDENDA Colored-sheet Addenda, which include additions and revisions to individual Sections of the Code, are published annually and will be sent automatically to purchasers of the t.pplicable Sections up to the publication of the 1998 Code. The 1995 Code is available only in the loose-leaf format; accordingly, the Addenda will be issued in the loose-leaf, replacement-page format. INTERPRETATIONS ASME issues written replies to inquiries concerning interpretation of technical aspects of the Code. The Interpretations for each individual Section will be published separately and will be included as part of the update service to that Section. They will be issued semiannually (July and December) up to the publication of the 1998 Code. Interpretations of Section in. Divisions 1 and 2, will be included with the update service to Subsection NCA. Interpretations are not part of the Code or the Addenda. CODE CASES The Boiler and Pressure Vessel Committee meets regularly to consider proposed additions and revisions to the Code and to formulate Cases to clarify the intent of existing requirements or provide, when the need is urgent, rules for materials or constructions not covered by existing Code rules. Those Cases which have been adopted will appear in the appropriate 1995 Code Cases book: (1) Boilers and Pressure Vessels and (2) Nuclear Components. Supplements will be sent automatically to the purchasers of the Code Cases books up to the publication of the 1998 Code. RS-002988 1/17/02 NUECES FOREWORD A95 The American Society of Mechanical Engineers set up a committee in 1911 for the purpose of formulating standard rules for the construction of steam boilers and other pressure vessels. This committee is now called the Boiler and Pressure Vessel Committee. The Committee's function is to establish rules of safety governing the design, fabrication, and inspection during construction of boilers and pressure vessels, and to interpret these rules when questions arise regarding their intent In formulating the rules, the Committee considers the needs of users, manufacturers, and inspec tors of pressure vessels. The objective of the rules is to afford reasonably certain protection of life and property and to provide a margin for deterioration in service so as to give a reasonably long, safe period of usefulness. Advancements in design and material and the evidence of experience have been recognized. This Code contains mandatory requirements, specific prohibitions, and nonmandatory guidance for construc tion1 activities. The Code does not address all aspects of these activities and those aspects which are not specifically addressed should not be considered prohib ited. The Code is not a handbook and cannot replace education, experience, and the use of engineering judg ment The phrase engineering judgment refers to techni cal judgments made by knowledgeable designers experi enced in the application of the Code. Engineering judgments must be consistent with Code philosophy and such judgments must never be used to overrule mandatory requirements or specific prohibitions of the Code. The Committee recognizes that tools and techniques used for design and analysis change as technology progresses and expects engineers to use good judgment in the application of these tools. The designer is respon sible for complying with Code rules and demonstrating compliance with Code equations when such equations are mandatory. The Code neither requires nor prohibits the use of computers for the design or analysis of 1 Construction, as used in this Foreword, is an all-inclusive term comprising materials, design, fabrication, examination, inspection, testing, certification, and pressure relief. components constructed to the requirements of the Code. However, designers and engineers using computer programs for design or analysis are cautioned that they are responsible for all technical assumptions inherent in the programs they use and they are solely responsible for the application of these programs to their design. The Code does not fully address tolerances. When dimensions, sizes, or other parameters are not specified with tolerances, the values of these parameters are considered nominal and allowable tolerances or local variances may be considered acceptable when based on engineering judgment and standard practices as determined by the designer. The Boiler and Pressure Vessel Committee deals with the care and inspection of boilers and pressure vessels in service only to the extent of providing suggested rules of good practice as an aid to owners and their inspectors. The rules established by the Committee are not to be interpreted as approving, recommending, or endors ing any proprietary or specific design or as limiting in any way the manufacturer's freedom to choose any method of design or any form of construction that conforms to the Code rules. The Boiler and Pressure Vessel Committee meets regularly to consider revisions of the rules, new rules as dictated by technological development. Code Cases, and requests for interpretations. Only the Boiler and Pressure Vessel Committee has the authority to provide official interpretations of this Code. Requests for revi sions, new rules, Code Cases, or interpretations shall be addressed to the Secretary in writing and shall give full particulars in order to receive consideration and action (see Mandatory Appendix covering preparation of technical inquiries). Proposed revisions to the Code resulting from inquiries will be presented to the Main Committee for appropriate action. The action of the Main Committee becomes effective only after confirma tion by letter ballot of the Committee and approval by ASME. Proposed revisions to the Code approved by the Committee are submitted to the American National Standards Institute and published in Mechanical Engi- RS-002989 1/17/02 NUECE8 A95 neering to invite comments from all interested persons. After the allotted time for public review and final approval by ASME, revisions are published annually in Addenda to the Code. Code Cases may bt used in the construction of components to be stam>ed with the ASME Code symbol beginning with the date of their approval by ASME. After Code revisions are approved by ASME, they may be used beginning with the date of issuance shown on the Addenda. Revisions, except for revisions to material specifications in Section n, Parts A and B, become mandatory 6 months after such date of issuance, except for boilers or pressure vessels contracted for prior to the end of the 6 month period. Revisions to material specifications are originated by the American Society for Testing and Materials (ASTM and other recognized national or international organizations), and are usually adopted by ASME. However, those revisions may or may not have any effect on the suitability of material, produced to earlier editions of specifications, for use in ASME construction. ASME material specifi cations approved for use in each construction Code are listed in the Appendices of Section II, Parts A and B. These Appendices list, for each specification, the latest edition adopted by ASME, and earlier and later editions considered by ASME to be identical for ASME con struction. Manufacturers and users of components are cautioned against making use of revisions and Cases that are less restrictive than former requirements without having assurance that they have been accepted by the proper authorities in the jurisdiction where the component is to be installed. Each state and municipality in the United States and each province in Canada that adopts or accepts one or more Sections of the Boiler and Pressure Vessel Code is invited to appoint a representative to act on the Conference Committee to the Boiler and Pressure Vessel Committee. Since the members of the Conference Com mittee are in active contact with the administration and enforcement of the rules, the requirements for inspection in this Code correspond with those in effect in their respective jurisdictions. The required qualifications for an Authorized Inspector under these rules may be obtained from the administrative authority of any state, municipality, or province which has adopted these rules. The Boiler and Pressure Vessel Committee in the formulation of its rules and in the establishment of maximum design and operating pressures considers materials, construction, methods of fabrication, inspec tion, and safety devices. Permission may be granted to regulatory bodies and organizations publishing safety standards to use a complete Section of the Code by reference. If usage of a Section, such as Section IX, involves exceptions, omissions, or changes in provisions, the intent of the Code might not be attained. Where a state or other regulatory body, in the printing of any Section of the Boiler and Pressure Vessel Code, makes additions or omissions, it is recommended that such changes be clearly indicated. The National Board of Boiler and Pressure Vessel Inspectors is composed of chief inspectors of states and municipalities in the United States and of provinces in Canada that have adopted the Boiler and Pressure Vessel Code. This Board, since its organization in 1919, has functioned to uniformly administer and enforce the rules of the Boiler and Pressure Vessel Code. The cooperation of that organization with the Boiler and Pressure Vessel Committee has been extremely helpful. The Code Committee does not rule on whether a component shall or shall not be constructed to the provisions of the Code. The Scope of each Section has been established to identify the components and parameters considered by the Committee in formulating the Code rules. Laws or regulations issued by municipal ity, state, provincial, federal, or other enforcement or regulatory bodies having jurisdiction at the location of an installation establish the mandatory applicability of the Code rules, in whole or in part, within their jurisdiction. Those laws or regulations may require the use of this Code for vessels or components not consid ered to be within its Scope or may establish additions or deletions in that Scope. Accordingly, inquiries regarding such laws or regulations are to be directed to the issuing enforcement or regulatory body. Questions or issues regarding compliance of a specific component with the Code rules are to be directed to the ASME Certificate Holder (Manufacturer). Inquiries concerning the interpretation of the Code are to be directed to the ASME Boiler and Pressure Vessel Committee. ASME is to be notified should questions arise concerning improper use of an ASME Code symbol. The specifications for materials given in Section II are identical with or similar to those of specifications published by ASTM, AWS, and other recognized na tional or international organizations. When reference is made in an ASME material specification to a nonASME specification for which a companion ASME specification exists, the reference shall be interpreted as applying to the ASME material specification. Not all materials included in the material specifications in Section II have been adopted for Code use. Usage is limited to those materials and grades adopted by at least one of the other Sections of the Code for applica tion under rules of that Section. All materials allowed A9f VI RS-002890 1/17/02 NUECES by these various Sections and used for construction within the scope of their rules shall be furnished in accordance with material specifications contained in Section II or referenced in Appendices A of Section II, Parts A and B except where otherwise provided in Code Cases or in the applicable Section of the Code. Materials covered by these specifications are acceptable for use in items covered by the Code Sections only to the degree indicated in the applicable Section. Materi als for Code use should preferably be ordered, produced, and documented on this basis; Appendix A to Section II, Part A and Appendix A to Section II, Part B list editions of ASME and year dates of ASTM specifics tions that meet ASME requirements and which may be used in Code construction. Material produced to an acceptable specification with requirements different from the requirements of the corresponding specifica tions listed in Appendix A of Part A or Part B may also be used in accordance with the above, provided the material manufacturer or vessel manufacturer certi fies with evidence acceptable to the Authorized Inspector that the corresponding requirements of specific; dons listed in Appendix A of Part A or Part B haw: been met. Material produced to an acceptable material speci fication is not limited as to country of origin. When required by context in this Section, the singular shall be interpreted as the plural, and vice-versa; and the feminine, masculine, or neuter gender shall be treated as such other gender as appropriate. Publication of the SI (Metric) Edition of the ASME Boiler and Pressure Vessel Code was discontinued with the 1986 Edition. Effective October 1, 1986, the SI Edition was withdrawn as an ASME Boiler and Pressure Vessel Code document. vu RS-002991 1/17/OJ NUECES STATEMENT OF POLICY ON THE USE OF CODE SYMBOLS AND CODE AUTHORIZATION IN ADVERTISING ASME has established procedures to authorize quali fied organizations to perform various activities in ac cordance with the requirements of the ASME Boiler and Pressure Vessel Code. It is the aim of the Society to provide recognition of organizations so authorized. An organization holding authorization to perform vari ous activities in accordance with the requirements of the Code may state this capability in its advertising literature. Organizations that are authorized to use Code Sym bols for marking items or constructions which have been constructed^and inspected in compliance with the ASME Boiler and Pressure Vessel Code are issued Certificates of Authorization. It is the aim of the Society to maintain the standing of the Code Symbols for the benefit of the users, the enforcement jurisdictions, and the holders of the symbols who comply with all require ments. Based on these objectives, the following policy has been established on the usage in advertising of facsimiles of the symbols. Certificates of Authorization, and refer ence to Code construction. The American Society of Mechanical Engineers does not "approve," "certify," "rate," or "endorse" any item, construction, or activity and there shall be no statements or implications which might so indicate. An organization holding a Code Symbol and/or a Certificate of Authorization may state in advertising literature that items, constructions, or activities "are built (produced or performed) or activities conducted in accordance with the requirements of the ASME Boiler and Pressure Vessel Code," or "meet the requirements of the ASME Boiler and Pressure Vessel Code." The ASME Symbol shall be used only for stamping and nameplates as specifically provided in the Code. However, facsimiles may be used for the purpose of fostering the use of such construction. Such usage may be by an association or a society, or by a holder of a Code Symbol who may also use the facsimile in advertising to show that clearly specified items will carry the symbol. General usage is permitted only when all of a manufactur er's items are constructed under the rules. STATEMENT OF POLICY ON THE USE OF ASME MARKING TO IDENTIFY MANUFACTURED ITEMS The ASME Boiler and Pressure Vessel Code pro vides rules for the construction of boilers, pressure vessels, and nuclear components. This includes re quirements for materials, design, fabrication, ex amination, inspection, and stamping. Items con structed in accordance with all of the applicable rules of the Code are identified with the official Code Symbol Stamp described in the governing Section of the Code. Markings such as "ASME," "ASME Standard," or any other marking including "ASME" or the various Code Symbols shall not be used on any item which is not constructed in accordance with all of the applicable requirements of the Code. Items shall not be described on ASME Data Report Forms nor on similar forms referring to ASME which tend to imply that all Code requirements have been met when, in fact, they have not been. Data Report Forms covering items not fully complying with ASME requirements should not refer to ASME or they should clearly identify all exceptions to the ASME require ments. RS-002092 1/17/02 NUECES PERSONNEL ASME Boiler and Pressure Vessel Committee Subcommittees, Subgroups, and Working Groups A95 A96 A97 As of July 1, 1997 MAIN COMMITTEE D. A. Canonico, Chair G. G. Karcher, Wee Chair J. S. Brzuszkiewicz, Secretary R. W. Bames F. P. Barton D. L. Berger M. D. Bernstein M. N. Bressler W. J. Carter T. M. Cullen J. R. Farr R. E. Feigel J. C. Feldstein M. Gold O. F. Hedden A. J. Justin D. F. Landers W. M.Lundy J. R. MacKay T. G. McCarty G. C. Millman R. A. Moen C. C. Neely R. F. Reedy B. W. Roberts F. J. Schaaf, Jr. A. Selz K. K. Tam D. E. Tanner HONORS AND AWARDS COMMITTEE J. R. MacKay, Chair A.). Spencer, Wee Chair F. R. Lyons, Secretary F. P. Barton W. J. Carter J. C. Feldstein M. Cold F. E. Cregor E. C. Kistner, Jr. T. P. Pastor R. F. Reedy EXECUTIVE COMMITTEE (MAIN COMMITTEE) C. C. Karcher, Chair D. A. Canonico, Wee Chair J. S. Brzuszkiewicz, Secretary F. P. Barton J. R. Farr J. C. Feldstein M. Cold O. F. Hedden A. J. Justin J. R. MacKay T. C. McCarty T. E. Quaka R. F. Reedy A. J. Spencer HONORARY MEMBERS (MAIN COMMITTEE) R. D. Bonner R. J. Bosnak H. M. Canavan L. J. Chockie J. S. Clarke W. E. Cooper W. D. Doty R. C. Griffin E. J. Hemzy E. C. Kistner, Jr. J. E. Lattan J. LeCoff F. N. Moschini C. E. Rawlins W. E. Somers L. P. Zick, Jr. MARINE CONFERENCE CROUP J. Tiratto, Chair C. F. Banks L W. Douthwaite J. L. Jones C. F. Wright CONFERENCE COMMITTEE D. E. Tanner -- St Tennessee Department of Labor (Chair) R. D. Reetz -- State of North Dakota Chief Boiler Inspector (Vice Chair) A. J. Justin -- National Board of Boiler and Pressure Vessel Inspectors (Secretary) R. J. Aben, Jr. -- Michigan J. S. Adaro -- Los Angeles, California J. Anderson -- South Dakota R. Barkdoll -- Washington F. P. Barton -- Virginia C. Castle -- Nova Scotia, Canada R. R. Cate -- Louisiana L. Chase -- Northwest Territo ries, Canada R. A. Coomes -- Kentucky J. Corcoran -- Connecticut M. H. Diehl, Jr. -- Maryland D. A. Douin -- Illinois D. Eastman -- Newfoundland and Labrador, Canada Clenn Ebeyer -- New Orleans, Louisiana F. Ellis -- New Hampshire E. Everett -- Georgia F. Gardner -- Delaware H. D. Hanrath -- Ontario, Canada W. J. Holmes -- Chicago, Il linois K. Hynes -- Prince Edward Island, Canada D. T. Jagger -- Ohio D. J. Jenkins -- Kansas M. Kotb -- Quebec, Canada J. P. Larson -- Minnesota K. T. Lau -- Alberta, Canada J. Lemire -- California C. A. Lundberg -- Florida W. C. Lundine -- Oregon G. F. Mankel -- Alaska I. W. Mault -- Manitoba, Canada H. T. McEwen -- Mississippi A. W. Meiring -- Indiana T. J. Monroe -- Oklahoma Y. Nagpaul -- Hawaii J. C. Parsed -- Utah J. D. Payton -- Pennsylvania D. K. Peetz -- Missouri D. C. Price -- Yukon Territory, Canada R. S. Pucek -- Milwaukee, Wisconsin T. E. Rennie -- Arizona L. Roussinos -- British Colum bia, Canada E. A. Sedor -- Nebraska M. Shuff -- West Virginia R. Snyder -- New Jersey N. Surtees -- Saskatchewan, Canada M. J. Verhagen -- Madison, Wis consin R. B. West -- Iowa J. M. Whee -- Vermont K. A. White -- Nevada T. F. Wickham -- Rhode Island C. S. Withers -- Colorado xi RS-002993 1/17/02 NUECE8 SUBCOMMITTEE ON POWER BOILERS (SC I) J. R. MacKay, Chair M. D. Bernstein, Vice Chair P. D. Stumpf, Secretary D. L. Berger E. Everett D. N. French F. R. Cerety T. E. Hansen J. S. Hunter W. L. Lowry T. C. McCough P. A. Molvie D. K. Parrish J. T. Pillow R. C. Presnak B. W. Roberts R. D. Schueler, Jr. R. V. Wielgoszinski R. L. Williams L. W. Yoder Subgroup on Piping (SC 1) T. E. Hanson, Chair D. L. Berger M. D. Bernstein P. P. Edwards W. L. Lowry T. C. McCough R. C. Presnak E. Whittle L. W. Yoder P. L. Ziegler Subgroup on Design (SC 1) M. D. Bernstein, Chair R. D. Schueler, Jr., Vice Chair P. A. Molvie, Secretary M. A. Farrugia J. D. Fishburn C. F. Jeerings K. C. Morrison A. Nassif D. R. Palmer N. Surtees R. V. Wielgoszinski Subgroup on Materials (SC I) B. W. Roberts, Chair C. E. Spader, Chair J. S. Hunter, Secretary T. M. Cullen D. N. French J. F. Henry J. P. Libbrecht F. Masuyama J. T. Parsons J. M. Tanzosh Subgroup on General Requirements (SC I) T. C. McCough, Chair M. D. Bernstein, Vice Chair W. L. Lowry, Secretary D. L. Berger E. Everett F. R. Cerety C. F. Jeerings ). M. Lyons R. E. McLaughlin D. K. Parrish J. T. Pillow W. E. Somers R. L. Williams L. W. Yoder Subgroup on Fabrication and Examination (SC I) D. L. Berger, Chair R. W. Boyce D. N. French J. Hainsworth T. E. Hansen M. H. Iken J. M. Lyons R. E. McLaughlin J. T. Pillow M. E. Reese R. D. Schueler, Jr. R. F. Slack, Sr. R. V. Wielgoszinski SUBCOMMITTEE ON MATERIALS (SC II) M. Cold, Chair T. M. Cullen, Vice Chair F. R. Lyons, Secretary A. P. Ahrendt M. N. Bressler R. Dirscherl W. D. Doty W. D. Edsall M. H. Cilkey D. A. Hansen J. J. Heger J. F. Henry C. C. Hsu F. Masuyama E. Michalopoulos R. A. Moen R. K. Nanstad E. C. Nisbett J. T. Parsons D. W. Rahoi B. W. Roberts E. Shapiro C. E. Spaeder, Jr. R. W. Swindeman J. M. Tanzosh B. E. Thurgood E. O. Woolridge A. W. Zeuthen Subgroup on International Material Spedficatio J. T. Parsons, Chair D. C. Agarwal J. Cameron R. Dirscheri W. D. Doty D. M. Fryer M. Cold M. H. Iken W. M.Lundy H. Masahisa T. F. Miskell F. Osweiller A. P. Povilonis R. D. Schueler, Jr. R. R. Seeley E. A. Steen E. Upitis E. O. Woolridge Subgroup on Ferrous Specifications (SC II) A. W. Zeuthen, Chair B. M. Dingman W. D. Edsall T. Graham W. N. Holliday E. A. Jonas D. C. Krouse J. F. Longenecker W. C. Mack A. S. Melilli E. C. Nisbett J. T. Parsons E. J. Rozic, Jr. E. Upitis E. O. Woolridge R. H. Zong Subgroup on Nonferrous Alloys (SC II) D. W. Rahoi, Chair D. C. Agarwal, Secretary W. R. Apblett L. C. Coffee R. Dirscherl M. H. Cilkey B. B. Hood C. C. Hsu M. Katcher E. Shapiro L. E. Shoemaker R. C. Suthedin Xll RS-002994 1/17/02 NUECE8 Subgroup on Strength, Ferrous Alloys (SC II) B. W. Roberts, Chair J. M. Tanzosh, Secretary A. P. Ahrendt W. R. Apblett T. M. Cullen R. J. Diletto M. Cold J. J- Heger C. L. Hoffmann T. Imoto F. Masuyama R. A. Moen 0. W. Rahoi C. E. Spaeder, Jr. R. W. Swindeman B. E. Thurgood Subgroup on Strength of Weldments (SC II & SC IX) C. E. Spaeder, Jr., Chair W. D. Doty D. W. Rahoi B. W. Roberts C. Robino W. J. Sperko ). M. Tanzosh B. E. Thurgood Subgroup on Toughness (SC II) R. K. Nanstad, Chair J. M. Barsom D. A. Hansen A. Selz R. S. Vecchio S. Yukawa R. Zawierucha Subgroup on External Pressure (SC II) R. W. Mikitka, Chair D. J. Green D. S. Griffin E. Michalopoulos D. Nadel C. E. Spaeder, Jr. C. H. Sturgeon SUBCOMMITTEE ON NUCLEAR POWER (SC III) C J. Pieper, Chair R. M. Jessee, Wee Chair C. A. Sanna, Secretary J. P. Allen III Y. Asada R. W. Barnes J. N. Baysden W. H. Borter E. B. Branch M. N. Bressler F. C. Cherny C. D. Cooper P. R. Deubler W. D. Doty F. R. Drahos K. Ennis B. A. Erler H. D. Hanrath K.-H. Hsu R. 1. Jetter D. F. Landers W. C. LaRochelle T. J. Mawson W. N. McLean R. A. Moen D. B. Nickerson R. F. Perrin R. F. Reedy M. W. Smith J. D. Stevenson R. E. Tome K. R. Wichman Special Working Group on Editing and Review (SC 1 R. F. Reedy, Chair W. H. Borter M. N. Bressler B. A. Erler M. W. Smith Subgroup on General Requirements (SC III & SC 3Q J. N. Baysden, Chair A. Appleton J. R. Barbee L. M. Beason B. H. Berg K. Ennis R. E. Kelley C. S. Korin W. C. LaRochelle A. S. Laurenson C. Lizotte - : M. J. Meyer M. R. Minick L. C. Oakes R. F. Perrin U. Potapovs J. C Regado B. B. Scott D. E. Tanner C. M. Tolson D. V. Walsh Subgroup on Materials, Fabrication, and Examination (SC III) R. M. Jessee, Chair G. P. Milley, Secretary C. W. Allison D. Doyle F. R. Drahos C. M. Foster C. B. Georgiev J. E. Harris C. L. Hoffmann R. W. Jackson C. C. Kim R. A. Moen C. J. Pieper R. R. Seeley N. M. Simpson R. C. Soin W. J. Sperko K. B. Stuckey S. Yukawa Subgroup on Design (SC III) R. W. Barnes, Chair E. B. Branch, Wee Chair R. S. Hill, Secretary Y. Asada M. N. Bressler C. W. Bruny J. R. Cole C. D. Cooper P. R. Deubler N. W. Edwards R. E. Cimple -- H. D. Hanrath _ R. W. Haupt T. lida B. Jarman J. T. Land W. N. McLean D. B. Nickerson E. C. Rodabaugh J. R. Santangeio G. C. Slags J. D. Stevenson J. H. Wawrzeniak K. R. Wichman R. Wray Working Group on Dynamic and Extreme Load Conditions (SG-D) (SC III) R. Wray, Chair P. L. Anderson M. K. Au-Yang R. D. Blevins G. J. Bohm D. L. Caldwell P.-Y. Chen A. Hadjian M. Hartzman W. S. LaPay H. Lockert P. R. Olson R. F. Perry J. Wallach Special Working Group on Seismic Piping Rules (SG-D) (SC III) E. B. Branch, Chair ~ T. M. Adams C. A. Antaki 1L. ^ R. D. Hookway J. C. Minichiello M. S. Sills R. A. Wais X1U RS-002985 Special Working Croup on Environmental Effects (SG-D) (SC III) R. S. Hill, Chair Y. Asada W. J. Heilker C. 1. Hoffman R. A. Moen W.2 Novak S. Yukawa Working Croup on Vessels (SC-D) (SC III) C. W. Bruny, Chair T. K. Burr, Sr. C. D. Cooper C. A. Deaver N. W. Edwards H. D. Hanrath W. J. Heilker B. Jarman T. M. Khan O. Maekawa K. A. Manoiy A. Merend C. K. Miller W. Z. Novak E. Pelling H. S. Thornton Working Croup on Piping (SC-D) (SC III) C. C. Slagis, Chair P. Hirschberg, Secretary T. M. Adams C. A. Antaki A. B. Glickstein R. W. Haupt J. C. Hennart R. S. Hill III R. D. Hookway R. B. Jenkins K. A. Manoiy J. C. Minichiello S. E. Moore A. N. Nguyen D. B. Nickerson O. O. Oyamada R. D. Patel E. C. Rodabaugh j. R. Santangelo M. S. Sills E. A. Wais Working Croup on Pumps (SC-D) (SC III) D. B. Nickerson, Chair H. L. Brammer P. Burchett R. E. Comman, Jr. J. C. Dudiak A. A. Fraser M. Higuchi L. P. Kuah J. W. Leavitt R. A. Schussier D. B. Spencer, Jr. H. Tafarrodi G. K. Vaghasia Working Croup on Valves (SG-D) (SC III) W. N. McLean, Chair E. A. Bake I. L. Beta R. R. Brodin R. J. Kiessel W. G. Knecht R. Koester J. J. McCavin S. N. Shields H. R. Sonderegger J. C. Tsacoyeanes R. C. Visalli J. R. Zahorsky Working Group on Supports (SG-D) (SC III) P. R. Deubler, Chair R. C. Arthur U. S. Bandyopadhyay F. J. Birch M. N. Bressler J. R. Cole R. M. Dulin, Jr. J. C. Finneran, Jr. R. W. Haupt J. C. Hennart T. C. LaCroix A. S. Laurenson A. Lee R. J. Masterson A. E. Meligi A. N. Nguyen H. Noreen, Jr. J. R. Stinson Working Group on Core Support Structures (SG-D) (SC III) J. T. Land, Chair R. H. Hansen K. B. Larsen J. F. Mullooly B. L. Silverblatt Working Croup on Administration (SC-D) (SC III) E. B. Branch, Chair R. W. Barnes, Wee Chair R. S. Hill III, Secretary C. W. Bruny C. D. Cooper P. R. Deubler J. T. Land W. N. McLean D. B. Nickerson J. R. Santangelo C. C. Slagis R. Wray Subgroup on Pressure Relief (SC III) F. C. Cherny, Chair R. J. Doelling S. F. Harrison, Jr. E. M. Petrosky D. J. Scallan M. W. Smith A. L. Szeglin B. S. York J. R. Zahorsky Subgroup on Containment Systems for Spent Fuel and HighLevel Waste Transport Packagings (SC III) J. D. Stevenson, Chair H. H. Chung K. Goldmann R. H. Jones W. H. Lake R. W. Lambert H. W. Lee R. D. McGuire R. E. Nickell D. J. Nolan D. T. Raske T. Saegusa R. H. Smith K. B. Sorenson P. Turula N. (Jrabe C. R. Witt S. Yukawa Working Croup on General Requirements (SG-NUPACK) (SC III) K. Goldmann, Chair Working Croup on Material (SG-NUPACK) (SC III) S. Yukawa, Chair Working Croup on Design (SG-NUPACK) (SC III) D. Stevenson, Chair JOINT ACI-ASME COMMITTEE ON CONCRETE COMPONENTS FOR NUCLEAR SERVICE (SC 3Q B. A. Erler, Chair C. A. Sanna, Secretary J. P. Allen III R. M. Attar A. C. Eberhardt J. Gutierrez D. J. Haavik M. F. Hessheimer T. E. Johnson G. R. Murphy S. F. Putman B. B. Scott R. E. Shewmaker J. D. Stevenson A. Y. Wong Subgroup on Materials, Construction, and Examination (SC 30 D. J. Haavik, Chair J. F. Artuso R. M. Attar B. A. Erler J. Cutierrez xiv RS-002906 1(17/02 NUECES Subgroup on Design (SC 30 D. C. Adams A. C Eberhardt T. E. Johnson S. F. Putman R. E. Shewmaker J. D. Stevenson A. Y. Wong SUBCOMMITTEE ON HEATINC BOtCtKS (SC IV) F. P. Barton, Chair P. A. Motvie, Vice Chair B. P. Feder, Secretary R. B. Duggan W. L. Haag Jr. W. M. Hiddleston J. D. Hoh K. M. McTague R. 1. Mullican E. A. Nordstrom J. L. Seigle D. E. Tanner S. V. Voorhees R. H. Weigel R. V. Wielgoszinski J. 1. Woodworth T. L. Bedeaux, Alternate SUBCOMMITTEE ON NONDESTRUCTIVE EXAMINATION ISC VI T. C. McCarty, Chair H. C. Craber, Vice Chair F. S. Fitzgerald, Secretary j. E. Batey A S. Birte B. H. Clark, Jr. W. T. Clayton R. A Coomes N. Y. Faransso O. F. Hedden F. B. Kovacs J. F. Manning W. C McCaughey R. D. McCuire D. A White Subgroup on General Requirements/Personnel Qualifications (SCV) R D. McCuire, Chair J. E. Batey W. T. Clayton N. Y. Faransso H. C Craber G. W. Hembree J. R. Mackey D. A White Subgroup on Surface Examination Methods (SC V) Subgroup on Care and Operation of Heating Boilers (SC IV) J. 1. Woodworth, Chair 8. P. Feder, Secretary K.). Hoey J. D. Hoh F. M. Lucas K. M. McTague P. A. Molvie R. 1. Mullican R. H. Weigel T. F. Wickham T. L. Bedeaux, Alternate Subgroup on Water Heaters (SC IV) W. L Haag, Jr., Chair T. D. Cantt D. M. Hanning W. M. Hiddleston F. M. Lucas K. M. McTague R. 1. Mullican D. Smith D. E. Tanner M. A. Taylor Subgroup on Cast Iron Boilers (SC IV) K. M. McTague, Chair R. B. Duggan R. H. Weigel T. F. Wickham J. 1. Woodworth T. L. Bedeaux, Alternate Subgroup on Welded Boilers (SC IV) P. A. Molvie, Chair T. L. Bedeaux D. H. Mapes E. A. Nordstrom J. L. Seigle R. F. Slack, Sr. R. P. Sullivan D. E. Tanner R. V. Wielgoszinski H. C Graber, Chair S. J. Akrin T. Alexander A. S. Birks B. H. dark R. A Coomes G. W. Hambree Subgroup on Volumetric Methods (SC V) J. E. Batey, Chair S. J. Akrin W. T. Clayton N. Y. Faransso H. C. Graber G. W. Hembree B. Kellerhall F. B. Kovacs ). F. Manning W. C. McCaughey D. A White Working Group on Radiography (SC V) G. W. Hembree, Chair S. J. Akrin T. Alexander J. E. Batey N. Y. Faransso H. C. Graber E. K. Keitzman F. 8. Kovacs Working Group on Ultrasonics (SC V) W. T. Gayton, Chair O. F. Hedden R. A Kellerhalt J. F. Manning R. W. McClung W. C. McCaughey R. Paillaman F. J. Satder M. L. Shakinovsky Working Group on Acoustic Emissions (SC V) D. A. White, Chair B. H. Clark, Jr. P. M. Horrigan J. F. Manning J. R. Mitchell xv RS-402997 1/17/02 NUECEs SUBCOMMITTEE ON PRESSURE VESSEIS (SC VIII) J. R. Farr, Chair T. P. Pastor, Wee Chair A. J. Roby, Secretary A. P. Ahrendt V. Bogosian S. M. Caldwell W. J. Carter S. C Cyr R. Dirscheri R. M. Elliott R. E. Feigel J. C. Feldstein M. J. Houle W. S. Jacobs C. G. Karcher G. B. Komora K. T. Lau R. W. Mikitka U. R. Miller K. Mokhtarian C. C. Neely K. J. Schneider A. Selz J. R. Sims, Jr. A. J. Spencer E. A. Steen K. K. Tam E. L. Thomas, Jr. Special Working Group on Heat Transfer Equipment (SC VIII) U. R. Miller, Chair R. P. Zoldak, Secretary C. F. Andreone D. E. Bolt S. M. Caldwell T. K. Haldas W. C. Jandrasits G. C. Karcher C. B. Komora R. Mahadeen F. Osweiller J. E. Soehrens A. 1. Soler W. A. Treff S. Yokell Special Working Group on High-Pressure Vessels (SC VIII) J. R. Sims, Jr., Chair P. A. Reddington, Secretary L P. Antalffy J. E. Baxter R. C. Biel T. B. Boyd D. J. Burns P. N. Chaku E. L. Danfelt R. E. Feigel D. M. Fryer J. L. Heck, Jr. A. H. Honza V. T. Hwang M. M. James P. Jansson J. A. Kapp D. P. Kendall A. K. Khare S. C. Mordre G. J. Mraz E. H. Perez L. M. Picqueur E. D. Roll W. L. Stewart J. F. Sullivan F. W. Tatar Special Working Group on Toughness (SC VIII) W. S. Jacobs, Chair J. Cameron W. D. Doty D. A. Hansen G. G. Karcher G. B. Komora K. Mokhtarian J. L. Mooney C. C. Neely M. D. Rana J. W. Stokes Subgroup on General Requirements (SC VIII) R. M. Elliott, Chair A. P. Ahrendt V. Bogosian W. J. Carter W. P. Crow C. R. Good D. B. Kadakia J. C. Keenan W. E. Laveck A. S. Mann C. C. Neely A. S. Olivares K. J. Schneider A. J. Spencer P. M. Thomas Subgroup on Materials (SC VIII) R. Dirscheri, Chair D. C. Agarwal A. P. Ahrendt J. Cameron W. D. Doty W. D. Edsall M. Katcher W. M. Lundy E. E. Morgenegg E. G. Nisbett J. T. Parsons D. W. Rahoi K. K. Tam B. K. Thakur W. N. Van Riet Subgroup on Design (SC VIII) K. Mokhtarian, Chair R. E. Knoblock, Secretary M. R. Bauman M. R. Breach S. M. Caldwell N. W. Edwards J. R. Farr J. A. Hayward G. L. Hollinger W. S. Jacobs G. G. Karcher G. B. Komora R. W. Mikitka U. R. Miller T. P. Pastor M. D. Rana A. Selz S. C. Shah J. W. Stokes K. K. Tam E. L. Thomas, Jr. Subgroup on Fabrication and Inspection (SC VIII) E. A. Steen, Chair K. Mokhtarian, Wee Chair W. J. Bees R. W. Boyce S. C. Cyr R. E. Feigel H. E. Cordon M. J. Houle W. S. Jacobs R. J. Johnson A. S. Lester III F. C. Ouyang M. J. Rice W. P. Webb SUBCOMMITTEE ON WELDING (SC IX) J. G. Feldstein, Chair W. J. Sperko, Wee Chair J. Labrador, Secretary R. Barkdoll D. A. Bowers M. L. Carpenter W. D. Doty P. D. Flenner M. J. Houle R. A. Johnson W. M. Lundy R. D. McGuire J. J. Meyer A. H. Miller B. R. Newmark P. P. Norris S. D. Reynolds, Jr. W. K. Scattergood G. W. Spohn III M. J. Stanko K. C. Taber J. M. Tanzosh - R. R. Young Subgroup on Materials (SC IX) M. L. Carpenter, Chair L. P. Connor P. D. Flenner R. M. Jessee A. H. Miller C. E. Sainz C. E. Spaeder, Jr. W. J. Sperko M. J. Stanko K. C. Taber R. R. Young Subgroup on General Requirements (SC IX) B. R. Newmark, Chair R. Barkdoll P. R. Evans P. C. Filean J. Ghergurovich R. M. Jessee D. W. Mann A. S. Olivares C. E. Wainwright R. A. Weiss K. R. Willens xvi RS-002898 1/17/02 NUECES Subgroup on Procedure Qualification (SC IX) J. J. Meyer, Chair R. K. Brown, Jr. R. A. Johnson A. H. Miller P. P. Norris A. S. Olivares F. C. Ouyang S. D. Reynolds, Jr. M. J. Rice W. K. Scattergood L. J. Sene, Jr. W. J. Sperko T. C. Wiesner Special Working Group on Plant Life Extension (SC XI) F. E. Gregor, Chair L. B. Gross, Secretary D. D. Davis D. A. Craham D. L. Harrison M, P. Lintz P. Manbeck H. W. Massie, Jr. D. W. Peltola D. A. Piccione C. M. Regan V. N. Shah R. J. Tamminga Subgroup on Performance Qualification (SC IX) J. J. Meyer, Chair V. A. Bell D. A. Bowers L P. Connor R. A. Coomes P. D. Flenner C. Herrmann M. J. Houle W. M. Lundy R. D. McGuire S. R. Nordman P. P. Norris W. K. Scattergood G. W. Spohn III Subgroup on Brazing (SC IX) A. S. Artayet M. L. Carpenter C. F. Jeerings A. H. Miller C. Robino K. C. Taber Special Working Group on Editing and Review (SC XI) R. W. Swayne, Chair R. L. Beverly L. B. Gross M. P. Lintz J. E. Staffiera C. J. Wirtz Working Group on General Requirements (SC XI) A. T. Roberts 111, Chair R. C. Edl D. A. Graham L. B. Cross C. A. Ireland D. A. Jackson R. K. Mattu L. Sage R. J. Scott R. J. Tamminga SUBCOMMITTEE ON FIBER-REINFORCED PLASTIC PRESSURE VESSELS (SC X) P. J. Conlisk, Chair D. Eisberg, Vice Chair A. J. Roby, Secretary K. M. Agrawal F. L. Brown J. L. Bustillos T. W. Cowley T. J. Fowler S. V. Hoa L. E. Hunt J. C. Murphy A. L Newberry D. J. Painter J. A. Rolston B. F. Shelley P. R. Wilt SUBCOMMITTEE ON NUCUEAR INSERVICE INSPECTION (SC XI) O. F. Hedden, Chair T. J. Mawson, Vice Chair C. L. Fechter, Secretary C. W. Allison W. H. Bamford, Jr. R. L. Beverly J. M. Bloom R. W. Boyce C. D. Cowfer D. D. Davis R. 1. Dyle T. N. Epps III R. E. Gimple F. E. Cregor L. B. Cross K. lida C. A. Ireland R. D. Kerr D. F. Landers T. F. Lentz J. T. Lindberg G. C. Millman C. R. Osman P. C. Riccardella L. Sage F. J. Schaaf, Jr. J. E. Staffiera R. P. Sullivan R. W. Swayne R.). Tamminga J. C. Tobin R. A. Yonekawa S. H. Bush L. J. Chockie J. P. Houstrup Honorary Members (SC XI) L. R. Katz R. R. MacCary Subgroup on Water-Cooled Systems (SC XI) T. F. Lentz, Chair K. Christian, Secretary C. W. Allison W. J. Briggs T. R. Bugelholl D. D. Davis A. F. Deardorff R. L Dyle L. B. Gross T. C. Hinkle S. D. Kulat M. P. Lintz J. E. Staffiera C. W. Tahnk R. J. Tamminga D. Terao S. M. Walker G. Wasilenko R. A. West Working Group on Inspection of Systems and Components (SG-WCS) (SC XI) C. D. Cowfer, Chair R. L. Dyle, Chair S. D. Kulat, Secretary C. L. BeJew T. W. Brombach R. Fougerousse T. C. Hinkle M. R. Hum J. T. Lindberg M. P. Lintz T. K. McLellan C. C. Park C. Pendleton C. M. Ross C. W. Tahnk K. B. Thomas E. Throckmorton R. A. West J. Whitman Special Working Group on Low-Temperature Heavy Water Reactors (SG-WCS) (SC XI) C. D. Cowfer, Chair J. M. Morrison, Secretary W. Awadalla C. A. Ireland K. F. Schmidt P. R. Vormelker S. H. Zaidi XVII R8-002999 1/17/02 NUECES Working Croup on Implementation of Risk-Based Examination (SG-WCS) (SC XI) A. McNeill III, Secretary J. Agold S. A. Ali B. A. Bishop J. W. Connor A. F. Deardorff H. Q. Do R. Fougerousse S. R. Gusselin J. T. Lindberg 1. Mach R. K. Mattu J. Muscara P.). O'Regan F. A. Simonen T. V. Vo R. A. West Working Group on Concrete Containment (SG-WCS) (SC XI) W. J. Briggs, Chair B. Talmadge, Secretary H. C. Ashar K. K. N. Chao M. J. Feriisi H. T. Hill R. D. Hough C. N. Krishnaswamy D. Naus S. C. Petitgout C. G. Ranganath Working Group on Metal Containment (SG-WCS) (SC XI) J. E. Staffiera, Chair W. E. Norris, Secretary W. J. Briggs K. K. N. Chao M. J. Feriisi R. W. Hammelmann S. C. Petitgout C. G. Ranganath C. W. Robin R. T. Zak Subgroup on Gas-Cooled Systems (SC XI) R. H. Hansen, Chair Subgroup on Liquid-Metal-Cooled Systems (SC XI) C. C. McCargar, Chair W. L. Chase S. Hattori R. Hundal W. Kwant J. C. Tobin Working Group on Liquid-Metal Reactor Covers (SC-LMCS) (SC XI) W. L. Chase, Chair S. Hattori R. Hundal W. Kwant Working Group on Operating Plant Criteria (SG-ES) (SC XI) T. J. Griesbach, Chair R. M. Gamble, Secretary W. H. Bamford, Jr. H. Behnke B. A. Bishop W. F. Brady E. Friedman S. R. Gosselin E. M. Hackett P. J. Hijeck M. Kupinski S. D. Leshnoff P. Manbeck J. S. Panesar W. E. Pennell J. H. Phillips S. Ranganath S. T. Rosinski W. L. Server E. A. Siegel F. A. Simonen T. D. Spry K. K. Yoon S. Yukawa Working.Group on Flaw Evaluation (SG-ES) (SC XI) R. C. Cipolla, Chair W. H. Bamford, )r. M. Basol J. M. Bloom E. Friedman T. j. Griesbach F. D. Hayes D. N. Hopkins K. lida Y. Imamura M. Kupinski H. S. Mehta . J. G. Merkle J. S. Panesar R. K. Qashu S. Ranganath D. A. Scarth T. S. Schurman W. L. Server F. A. Simonen K. R. Wichman G. M. Wilkowski K. K. Yoon S. Yukawa A. Zahoor V. A. Zilberstein Working Group on Pipe Flaw Evaluation (SG-ES) (SC I D. A. Scarth, Chair C. M. Wilkowski, Secretary W. H. Bamford, Jr. J. M. Bloom R. C. Cipolla N. G. Cofie S. K. Daftuar G. H. De Boo E. Friedman D. N. Hopkins K. lida H. S. Mehta J. C. Merkle J. S. Panesar D. Quinones K. K. Yoon S. Yukawa A. Zahoor V. A. Zilberstein Sjuuub^girvoup|i ovnii ELTvatluatuiounii Sjutahniudoaridmsi (SC aXIi)/ W. H. Bamford, Jr., Chair M. Kupinski, Secretary J. M. Bloom R. C. Cipolla R. M. Gamble T. J. Griesbach P. J. Hijeck K. lida Y. Imamura J. Journet J. G. Merkle S. Ranganath P. C. Riccardella D. A. Scarth W. L. Server C. A. Tomes W. A. Van Der Sluys K. R. Wichman G. M. Wilkowski K. K. Yoon S. Yukawa Subgroup on Nondestructive Examination (SC XI) R. L. Beverly, Chair N. R. Bentley, Secretary D. C. Adamonis F. L. Becker F. T. Carr C. B. Cheezem W. T. Clayton J. F. Cook C. D. Cowfer F. J. Dodd T. N. Epps III D. O. Henry M. R. Hum S. N. Liu R. D. McGuire M. C. Modes C. R. Osman F. J. Schaaf J. C. Spanner, Jr. C. J. Wirtz xvm ogjOOSOOO NUECES J 3 J s \ Working Croup on Procedure Qualification and Volumetric Examination (SG-NDE) (SC XI) C. D. Cowfer, Chair C. E. Larsen, Secretary D. C Adamonis F, L. Becker N. R. Bendy B. Bevins F. T. Carr C. B. Cheezem W. T. Clayton R. A. Courtney S. R. Doctor F. J. Dodd T. N. Epps III R. A. Kellerhall J. K. McClanahan M. C Modes M. Saporito T. T. Taylor S. M. Walker Working Croup on Personnel Qualification and Surface Visual and Eddy Current Examination (SG-NDE) (SC XI) ). F. Cook, Chair C. J. Wiitz, Secretary B. L. Curtis N. Economos H. B. Garland D. O. Henry H. E. Houserman J.). McArdle III R. D. McCuire S. A. Redner M. F. Sherwin A. L. Smith D. Spake J. C. Spanner, Sr. J. G Spanner, Jr. Working Group on Pressure Testing (SG-NDE) (SC XI) G. P. Alexander T. M. Ansetmi T. B. Basso ). Boughman T. R. Bugetholl R. J. Cimoch C. E. Jenson W. N. Keister D. Lamond F. J. Schaef D. Terao Subgroup on Repairs, Replacements, and Modifications (SC XI) R. E. Gimple, Chair W. C. Holston, Secretary R. W. Boyce M. N. Bressler S. B. Brown A. L. Finney C. E. Hartz R. A. Hermann C. A. Ireland R. D. Kerr D. F. Landers R. S. Lewis M. S. McDonald R. R. Stevenson R. P. Sullivan R. W. Swayne R. E. Tome D. E. Waskey R. A. Yonekawa Working Croup on Welding and Special Repair Processes (SG-RR&M) (SC XI) D. E. Waskey, Chair R. E. Cantrell, Secretary D. A. Delsignore A. L. Finney P. D. Fisher A. J. Giannuzzi R. A. Hermann R. P. Indap R. D. Kerr B. R. Newton P. P. Norris J. E. O'Sullivan J. H. Sodergren K. R. Willens Working Croup on Design Reconciliation (SG-RR&M) (SC XI) W. C. Holston, Chair R. E. Tome, Secretary R. W. Boyce S. B. Brown J. E. Chamley J. Conner T. E. Hiss E. V. Imbro D. N, Irvine, Jr. D. F. Landers R. W. Swayne F. Tehranchi H. J. Thailer Working Croup on Responsibilities and Program Requirements (SC-RR&M) (SC XI) R A. Yonekawa, Chair R. R. Stevenson, Secretary S. 1C Fisher C. M. Foster C. E. Hartz R. S. Lewis M. S. McDonald U. Potapovs S. M. Swilley A. J. Walcutt SUBCOMMITTEE ON TRANSPORT TANKS (SCXII) A. Selz, Chair P. D. Stumpf, Secretary A. N. Antoniou K. Ennis M. Hennemand C. H. Hochman G. C. Karcher P. Laluc M. R. Minick T. P. Pastor M. D. Rana C. M. Serratella G. R. Stoeckinger N. Surtees J. P. Swezy A. P. Var^iese W. L White Subgroup on Design and Materials (SC XII) M. D. Rana, Chair C. R. Stockinger Subgroup on Fabrication and Inspection (SC XII) D. J. Kreft SUBCOMMITTEE ON SAFETY VALVE REQUIREMENTS (SC-SVR) E. C Kistner, Jr., Chair M. D. Bernstein, Vice Chair U. D'Urso, Secretary J. F. Ball J. A. Cox R. D. Danzy R. J. Doelling D. A. Douin R. C. Friend H. I. Gregg S. F. Harrison, Jr. C. F. Laitner H. D. Michael C. A. Neumann I. W. Reynolds M. Robinson D. J. Scallan C. M. Schroepfer A. J. Spencer J. C. Standfast E. A. Steen L. L. Thompson J. A. West T. J. Ferrigan, Alternate Subgroup on General Requirements (SC-SVR) M. D. Bernstein, Chair J. F. Ball V. M. Deluca D. A. Douin H. D. Michael C. A. Neumann J. W. Reynolds J. W. Richardson M. Robinson J. C. Standfast L. L. Thompson RS-003001 1/17/02 NUECES Subgroup on Testing (SC-SVR) S. F. Harrison, Jr., Chair S. Cammeresi J. A. Cox W. F. Hart D. M. Papa D. J. Scallan C. M. Schroepfer Subgroup on Design (SC-SVR) R. C. Friend, Chair J. Cahoon, Jr. R. D. Danzy D. B. DeMichael R. J. Doelling H. I. Cregg S. R. Irvin C. F. Laitner P. R. Sieved A. J. Spencer E. A. Steen T. R. Tarbay J. A. West SUBCOMMITTEE ON DESIGN (SC-D) W. J. Carter, Chair F. S. Fitzgerald, Secretary R. W. Barnes C Becht J. L Hechmer O. F. Hedden R. W. Mikitka K. Mokhtarian W. J. O'Donnell R. D. Schueler, Jr. M. P. Schwartz A. Selz Special Working Group on Bolted Flanged Joints (SC-D) R. W. Mikitka, Chair G. D. Bibel C. Kharshafdjian D. L. Kurle E. Michaiopoulos J. R. Payne R. W. Schneider R.- D. Schueler, Jr. A. Selz Subgroup on Openings (SC-D) P. Schwartz, Chair W. Mikitka, Secretary R. Breach T. Hwang S. C. Lou R. B. Luney K. C. Morrison D. R. Palmer M. D. Rana E. C. Rodabaugh Subgroup J. L. Hechmer, Chair T. P. Pastor, Secretary P. J. Conlisk A. G. Eggers C, L. Hollinger D. P. Jones A. Kalnins Design Analysis (SC-D) W. J. Koves T. H. Liu O. Maekawa A. Merend T. V. Narayanan E. L. Thomas, Jr. Subgroup on Elevated Temperature Design (SC-D) C. Becht IV, Chair J. M. Corum, Secretary C. R. Brinkman R. D. Campbell D. S. Griffin R. I. Jeffer C. Lawton R. K. Mattu W. J. O'Donnell C. C. Schultz, Jr. L. K. Severud D. F. Shaw A. L. Snow B. E. Thurgood Subgroup C. R. Brinkman P. R. Donavin J. A. Hayward J. L. Hechmer D. P. Jones Fatigue Strength (SC-D) C. Kharshafdjian C. Lawton A. Merend H. H. Ziada SUBCOMMITTEE ON BOILER AND PRESSURE VESSEL ACCREDITATION (SC-BPVA) A. J. Spencer, Chair A. J. Justin, Vice Chair K. 1. Baron, Secretary M. B. Doherty D. A. Douin P. D. Edwards R. M. Elliott C. E. Ford J. J. Greene R. C. Howard B. B. Macdonald M. L. Sisk B. C. Turczynski R. V. Wieigoszinski R. L Williams V. A. Bell, Alternate V. Bogosian, Alternate S. C. Cyr, Alternate M. A. DeVries, Alternate J. R. Farr, Alternate R. G. Friend, Alternate W. C. LaRochelle, Alternate A. S. Lester III, Alternate K. M. McTague, Alternate G. P. Milley, Alternate R. E. Muise, Alternate P. G. Scheckermann, Alternate N. Surtees, Alternate SUBCOMMITTEE ON NUCLEAR ACCREDITATION (SC-NA) T. E. Quaka, Chair R. R. Stevenson, Vice Chair S. Griffin, Secretary C. W. Allison M. N. Bressler G. Deily F. R. Drahos J. E. Harris M. Kotb W. C. LaRochelle U. Potapovs H. B. Prasse A. J. Spencer G. M. Tolson L. M. Beason, Alternate R. W. Boyce, Alternate S. Dasgupta, Alternate P. D. Edwards, Alternate J. P. Ellenberger, Alternate R. E. Feigel, Alternate H. D. Hanrath, Alternate K. A. Huber, Alternate A. J. Justin, Alternate N. C. Kist, Alternate R. P. McIntyre, Alternate L. C. Oakes, Alternate R. E. Tilton, Staff Representative 2 US> xx RS-003002 1/17/02 NUECE8 CONTENTS A Detailed Contents Precedes Each Part and Subpart, the Appendices, and the Forms Foreword................................................................................................................................................................. v Statements of Policy ...................................................................................................................... ix Personnel........................................................................................................................................... xi Preamble ........................................................................................................................................... xxiii Part HG Part HF _ Part HC Part HLW General Requirements for All Materials of Construction...................................... Requirements for Boilers Constructed of Wrought Materials............................... Subpart HW --Requirements for Boilers Fabricated by Welding....................... Subpart HB --Requirements for Boilers Fabricated by Brazing........................ Requirements for Boilers Constructed of Cast Iron............................................. Requirements for Potable Water Heaters............................................................... 1 71 89 113 123 139 Appendices ....................................................................................................................................... Guide to Manufacturers'Data Report Forms ................................................................................... SI Units............................................................................................................................................. Index ................................................................................................................................................ 181 219 239 243 xxi R8-003003 1/17/0* NUECES PREAMBLE The rules of this Section of the Code cover minimum construction requirements for the design, fabrication, installation, and inspection of steam heating, hot water heating, hot water supply boilers which are directly fired with oil, gas, electricity, coal, or other solid or liquid fuels, and for operation at or below the pressure and temperature limits set forth in this document. Similar rules for potable water heaters are also included. For Section IV application, the boiler proper or other vessels terminate at: (a) the first circumferential joint for welding end connections; (b) the face of the first flange in bolted flanged connections; or (c) the first threaded joint in that type of connection. The rules are divided into four major Parts: Part HG, applying to all materials of construction except as provided for in Part HLW; Part HF, applying to assemblies fabricated of wrought material, except as provided for in Part HLW; Part HC, applying to cast iron assemblies; and Part HLW, applying to potable water heaters. Part HF is further subdivided into Subpart HW, containing rules for welded construction, and Subpart HB, containing rules for brazed construction. The Parts and Subparts of this Section are divided into Articles. Each Article is given a number and a title, as for example, Part HG, Article 3, Design. Articles are divided into paragraphs which are given a threedigit number, the first of which corresponds to the Article number, thus, under Article 3 of Part HG will be found paragraph HG-307. Paragraphs are further subdivided into subparagraphs. Major subdivisions of paragraphs are designated by three- or four-digit num bers followed by a decimal point and a digit or digits. Where necessary, further subdivisions are represented by letters and then by numbers in parentheses. Minor subdivisions of the paragraphs are also represented by letters. A reference to one of these paragraphs in the text of the Section includes all of the applicable rules in that paragraph. Thus, reference to HG-307 includes all the rules in HG-307.1 through HG-307.4. This Section does not contain rules to cover all possible details of design and construction. Where complete details are not given, it is intended that the manufacturer, subject to the acceptance of the Author ized Inspector, shall provide details of design and construction which will be as safe as otherwise required by these rules. When the strength of any part cannot be computed with a satisfactory assurance of safety, these rules provide procedures for establishing its maximum allow able working pressure. XXlll RS-003004 1/17/02 NUECES PART HG GENERAL REQUIREMENTS FOR ALL MATERIALS OF CONSTRUCTION Article 1 HG-100 HG-101 Scope and Service Restrictions Scope................................................................................................................................ Service Restrictions........................................................................................................ 5 5 Article 2 HG-200 HG-201 - Material Requirements General Material Requirements..................................................................................... Specific Material Requirements...................................................................................... 6 6 Article 3 HG-300 HG-301 HG-305 HG-306 HG-307 HG-309 HG-312 HG-315 HG-320 HG-321 HG-323 HG-325 HG-326 HG-327 HG-328 HG-330 HG-340 HG-341 HG-342 HG-343 HG-345 HG-346 HG-350 HG-360 HG-370 Design Design Pressure............................................................................. Shells Under Internal Pressure........................................................................................ Formed Heads, Pressure on Concave Side................................................................... Formed Heads, Pressure on Convex Side..................................................................... Flat Heads...................................................................................................................... Spherically Dished Covers (Bolted Heads)................................................................... Cylindrical Parts Under External Pressure................................................................... Thickness of Tubes........................................................................................................ Openings in Boilers, General Requirements................................................................. Reinforcement Required for Openings in Shells and Formed Heads......................... Flanged-in Openings in Formed Heads......................................................................... Reinforcement Required for Openings in Flat Heads................................................... Limits of Metal Available for Reinforcement................................... Strength of Reinforcement............................................................................................. Reinforcement for Multiple Openings........................................................................... Inspection and Access Openings.................................................................................... Stayed Surfaces............................................................................................................... Staybolts.......................................................................................................................... Dimensions of Stays...................................................................................................... Dimensions of Diagonal Stays....................................................................................... Staying of Heads........................................................................................................... Tubesheets With Firetubes Used as Stays..................................................................... Ligaments........................................................................................................................ Requirements for Tube Holes and Tube Attachments................................................. External Piping Connections........................................................................................... 7 7 7 8 9 12 14 19 20 21 23 24 24 26 26 27 28 29 31 31 31 35 35 37 38 1 RS-003008 1/17/02 NUECE8 Article 4 HG-400 HG-401 HG-402 HG-403 HG-405 Pressure Relieving Devices Pressure Relieving Valve Requirements.......................................................................... Minimum Requirements for Safety and Safety Relief Valves..................................... Discharge Capacities of Safety and Safety Relief Valves............................................. Heating Surface................................................................................................................ Thermal Elements for Pressure-Temperature ReliefValves.......................................... 39 40 42 44 44 Article 5 HG-500 HG-501 HG-502 HG-503 HG-504 HG-505 HG-506 HG-510 HG-512 HG-515 HG-520 HG-530 HG-531 HG-532 HG-533 HG-540 Tests, Inspection, and Stamping Proof Tests to Establish Design Pressure...................................................................... General............................................................................................................................. Procedure......................................................................................................................... Tests of Parts Subject to Collapse................................................................................. Tests of Duplicate Parts................................................................................................. Test Gages........................................................................................................................ Inspection of Proof Tests................................................................................................ Hydrostatic Tests............................................................................................................ Safety and Safety Relief Valve Accumulation Tests.................................................... Inspection Tests and Certification of Boilers................................................................ Master and Partial Data Reports.................................................................................... - Stamping of Boilers....................................................................................................... Stamping of Parts and Accessories................................................................................. Stamping of Field Assembled Wrought Boilers............................................................. Inspection and Stamping of Field Assembled BoilerPressure Parts.............................. Code Symbol Stamps....................................................................................................... 45 45 46 48 48 48 48 48 49 49 50 51 53 54 54 55 Article 6 HG-600 HG-601 HG-602 HG-603 HG-604 HG-605 HG-606 HG-607 HG-610 HG-611 HG-612 HG-613 HG-614 HG-615 HG-620 HG-621 HG-630 HG-631 HG-632 HG-633 HG-634 HG-640 Instruments, Fittings, and Controls General.............................................................................................................................. For Steam Heating Boilers.............................................................................................. Steam Gages.................................................................................................................... Water Gage Glasses......................................................................................................... Water Column and Water Level Control Pipes............................................................. Pressure Control............................................................................................................... Automatic Low-Water Fuel Cutoff and/or Water Feeding Device.............................. Modular Steam Heating Boilers..................................................................................... For Hot Water Heating or Hot Water Supply Boilers.................................................. Pressure or Altitude Gages.................................................................... ....................... Thermometers.................................................................................................................. Temperature Control......................................................................................................... Low-Water Fuel Cutoff................................................................................................... Modular Hot Water Heating Boilers............................................................................. For All Boilers................................................................................................................. Instruments, Fittings, and Controls Mounted InsideBoiler Jackets................................ Electric Wiring................................................................................................................. Electrical Code Compliance............................................................................................ Type Circuitry to Be Used............................................................................................ Limit Controls.................................................................................................................. Shutdown Switches and Circuit Breakers...................................................................... Controls and Heat Generating Apparatus...................................................................... 58 58 58 58 59 59 59 59 60 60 60 60 60 60 60 60 61 61 61 61 61 61 2 RS-003006 1/17/02 NUECES Article 7 HG-700 HG-701 HG-703 HG-705 HG-707 HG-709 HG-710 HG-715 HG-716 HG-720 HG-725 Installation Requirements Installation Requirements, All Boilers............................................................................ Mounting Safety and Safety Relief Valves................................................................... Piping................................................................................................................................ Feedwater and Makeup Water Connections.................................................................. Oil Heaters........................................................................................................................ Provisions for Thermal Expansion in Hot Water Systems.......................................... Stop Valves...................................................................................................................... Bottom Blowoff and Drain Valves................................................................................. Modular Boilers.............................................................................................................. Setting............................................................................................................................... Methods of Support......................................................................................................... 62 62 62 63 63 63 67 68 68 69 69 Figures HG-307 HG-309 HG-312.1 HG-312.2 HG-312.3 HG-312.6 HG-312.7 HG-320 ~ HG-321 HG-326 HG-340.1 HG-340.2 HG-340.3 HG-343 HG-345.1(a) HG-345.1(b) HG-345.2 HG-350.1 HG-350.2 HG-350.3 HG-350.4 HG-402 HG-530.1 HG-530.2 HG-530.3 Some Acceptable Types of Unstayed Flat Heads and Covers.................................... Spherically Dished Steel Plate Covers With Bolting Flanges...................................... Chart for Determining Wall Thickness of Cylindrical Furnaces When Constructed of Carbon Steel.......................................................................... Chart for Determining Wall Thickness of Cylindrical Furnaces When Constructed of Carbon Steel.......................................................................... Acceptable Type of Ring Reinforced Furnace.............................................................. Connection Between Plain and Conugated Furnace..................................................... Acceptable Type of Semicircular Furnace Reinforcement............................................ Chart Showing Limits of Sizes of Openings With Inherent Compensation in-Cylindrical Shells.................................................................................................. Chart for Determining Values of F............................................................................... Some Representative Configurations Describing the t. Reinforcement Dimension................................................................................................................... Pitch of Staybolts Adjacent to Upper Comers of Fireboxes...................................... Acceptable Proportions for Ends of Through-stays....................................................... Examples of Acceptable Comer Welds for Pressures Not Over 30 psi....................................................................................... Details of Installation of Diagonal Stays..................................................................... Sketch Showing Application of HG-345.1 to the Staying of Boilers......................... Sketch Showing Application of HG-345.1 to the Staying of Boilers.......................... Method of Determining Net Area of Irregular Segment of a Head........................... Example of Tube Spacing With Pitch of Holes Equal in Eveiy Row............................................................................................................. Example of Tube Spacing With Pitch of Holes Unequal in Every Second Row............................................................................................................................. Example of Tube Spacing With Pitch of Holes Varying in Every Second and Third Row........................................................................................................... Example of Tube Spacing With Tube Holes on Diagonal Lines............................... Official Symbol for Stamp to Denote The American Society of Mechanical Engineers' Standard................................................................................................... Official Symbol for Stamp to Denote The American Society of Mechanical Engineers' Standard................................................................................................... Form of Stamping on Completed Boilers or Their Nameplates for Steam and Water Boilers..................................................................................................... Form of Stamping on Completed Boilers or Their Nameplates for Boilers Suitable for Water Only............................................................................................ 11 13 15 16 17 19 20 22 23 25 29 29 29 32 33 34 36 36 36 37 37 42 51 52 52 3 A95 RS-003007 1/17/02 NUECES HG-530.4 HG-530.5 HG-530.6 HG-530.7 HG-703.1(a) HG-703.1(b) HG-703.2 HG-725(a) HG-725(b) Form of Data Cast on Cast Iron Boiler Sections for Steam and Water Boilers.......................................................................................................................... Form of Data Cast on Cast Iron Boiler Sections for Boilers Suitable for Water Only................................................................................................................. Form of Stamping on Completed Cast Iron Boilers or Their Nameplates for Steam and Water Boilers......................................................................................... Form of Stamping on Completed Cast Iron Boilers or Their Nameplates for Boilers Suitable for Water Only............................................................................... Steam Boilers in Battery--Pumped Return--Acceptable Piping Installation.............. Steam Boilers in Battery--Gravity Return--Acceptable Piping Installation............... Hot Water Boilers in Battery--Acceptable Piping Installation ................................... Spacing and Weld Details for Supporting Lugs in Pairs on Horizontal-Return Tubular Boiler............................................................................................................. Welded Bracket Connection for Horizontal-Return Tubular Boiler............................. 53 53 54 54 64 65 66 70 70 Tables HG-321 HG-340 HG-370 HG-400.1 HG-709.1 HG-709.2 HG-715 Values of Spherical Radius Factor K\........................................................................... Allowable Pitch of Stays, in........................................................................................... Minimum Thickness of Material for Threaded Connections to Boilers...................... Minimum Pounds of Steam per Hour per Square Foot of Heating Surface.............. - Expansion Tank Capacities for Gravity Hot Water Systems..................................... Expansion Tank Capacities for Forced Hot Water Systems........................................ Size of Bottom Blowoff Piping, Valves, and Cocks --........................................... 23 30 38 39 67 67 68 R8-003008 1/17/02 NUECES ARTICLE 1 SCOPE AND SERVICE RESTRICTIONS A97 ) HG-100 SCOPE (a) The rules of Part HG apply to steam heating boilers, hot water heating boilers, hot water supply boilers, and to appurtenances thereto. They shall be used in conjunction with the specific requirements in Part HF, Boilers of Wrought Materials, and Part HC, Cast Iron Boilers, whichever is applicable. The foreword provides the basis for these rules. Part HG is not intended to apply to jjotable water heaters except as provided for in Part HLW. (b) This Part contains mandatory requirements, spe cific prohibitions, and nonmandatory guidance for mate rials, designs, fabrication, examination, inspection, test ing, certification, and pressure relief. (c) Laws or regulations issued by a municipality, state, provincial, federal, or other enforcement or regula tory body having jurisdiction at the location of an installation, establish the mandatory applicability of these rules, in whole or in part HG-101 SERVICE RESTRICTIONS HG-101.1 Service Restrictions. The rules of this Section are restricted to the following services: (a) steam boilers for operation at pressures not ex ceeding 15 psi; ' : (b) hot water heating boilers and hot water supply boilers for operating at pressures not exceeding 160 psi and/or temperatures not exceeding 250F, at or near the boiler outlet, except that when some of the wrought materials permitted by Part HF are used, a lower temperature is specified. A97 HG-101.2 Services in Excess of Those Covered by This Section. For services exceeding the limits specified in HG-101.1, the rules of Section I shall apply. t 5 RS-003009 1/17/02 NUECES ARTICLE 2 MATERIAL REQUIREMENTS HG-200 GENERAL MATERIAL REQUIREMENTS HG-200.1 Materials Subject to Pressure Stress. Material subject to stress due to pressure shall conform to one of the specifications given in Section II and shall be limited to those that are permitted in HF-200 for boilers of wrought materials and HC-200 for cast iron boilers. HG-200.2 Internal Parts Subject to Deterioration. Materials shall not be used for internal parts which are liable to fail due to deterioration when subjected to saturated steam temperatures at or below the maximum allowable working pressure. HG-200.3 Materials Not Found in Section n. Mate rial not covered by specifications in Section II shall not be used unless authorization to use the material is granted by the Boiler and Pressure Vessel Committee on the basis of data submitted to the Committee in accordance with Appendix A. HG-200.4 Materials Use Not Limited by Speci fication Title. The title or scope paragraph of a material specification in Section II as respects product form or service shall not limit the use of a material, provided the material is suitable for the application and its use is permitted by the rules of this Section. HG-200.5 Materials Use Not Limited by Method of Production. Materials covered by specifications in Section II are not restricted as to the method of production unless so stated in the Specification, and as long as the product complies with the requirements of the Specification. HG-200.6 Materials With Thicknesses Exceeding Specification Limits. Materials having thicknesses out side of the limits given in the title or scope clause of a specification in Section II may be used in construction, provided they comply with the other requirements of the Specification and with all thickness requirements of this Code. HG-200.7 Materials Not Identified by Mill Test Reports. Materials not identified by mill test reports may be used for nonpressure, parts such as baffles, external supports, and insulating rings, the failure of which will not endanger the vessel to which they are attached. The allowable stress value shall not exceed 80% of the maximum allowable stress permitted for similar material in Tables HF-300.1 and HF-300.2. Satisfactory performance of a specimen in such service shall not make the material acceptable for use in pressure parts of a vessel. HG-201 SPECIFIC MATERIAL REQUIREMENTS Specific material requirements for assemblies con structed of wrought materials are given in Part HF, Article 2 and for assemblies constructed of cast iron in Part HC, Article 2. 6 AlA7tO nobce ARTICLE 3 DESIGN HG-300 DESIGN PRESSURE (a) The design pressure is the pressure used in the formulas of this Article, in conjunction with the allow able stress values, design rules, and dimensions specified for determining the minimum required thicknesses for the parts of a boiler. The design pressure for a heating boiler shall be at least 30 psi. (b) The term maximum allowable working pressure refers to gage pressure, or the pressure in excess of the atmospheric pressure in the boiler. The maximum allowable working pressure, as stamped on the boiler per HG-530, must be less than or equal to the design pressure for any of its parts. (c) No boiler shall be operated at a pressure higher than the maximum allowable working pressure except when the safety valves or relief valves are discharging, at which time the maximum allowable working pressure shall not be exceeded by more than the amount specified in HG-400.1 and HG-400.2. A95 HG-300.1 Vacuum Boilers. Rules for factory sealed boilers to be operated only under vacuum conditions are given in Appendix S. HG-301 SHELLS UNDER INTERNAL PRESSURE HG-301.1 General. The required thickness and the design pressure of cylindrical shells, pipe, and headers shall be determined in accordance with the following formulas: where P-- design pressure, psi (but not less than 30 psi) 5= maximum allowable stress value from Tables HF-300.1 and HF-300.2, psi t= required wall thickness, in. R = inside radius of cylinder, in. E= efficiency of longitudinal joint or of ligament between tube holes, whichever is the lesser. For welded joints, use the efficiency specified in HW-702. For seamless shells, use E = 1. HG-301.2 Pipes Used as Tubes. Pipes used as tubes shall be designed in accordance with HG-31S. HG-305 FORMED HEADS, PRESSURE ON CONCAVE SIDE HG-305.1 General. The required thickness at the thinnest point after forming1 of ellipsoidal, torispherical, and hemispherical heads under pressure on the concave side (plus heads) shall be computed by the appropriate formulas in this paragraph. (a) Notation. The symbols used in this paragraph are defined as follows: t= required wall thickness after forming, in. P = design pressure, psi (but not less than 30 psi) D = inside diameter ofthe head skirt; or inside length of the major axis of an ellipsoidal head; or inside diameter of a cone head at the point under con sideration, measured perpendicular to the longi tudinal axis, in. S = maximum allowable stress value as given in Tables HF-300.1 and HF-300.2, psi PR ~ SE- 0.6P SEt P =----------- R + 0.6f 1 In order to insure that a finished head is not less than the minimum thickness required, it is customary to use a thicker plate to take care of possible thinning during the process of forming. The neck of an opening in a head with an integrally flanged oipening will thin out due to the fluing operation. This is permissible provided the neck thickness is not less than the minimum thickness specified in HG-301 or the thickness required for a cylindrical shell having a diameter equal to the maximum diameter of the opening. (See HG-323.) 7 RS-003011 1/17/02 NUECE8 HG-305.1 1995 SECTION IV HG-306.1 L= inside spherical or crown radius, in. E = lowest efficiency of any joint in the head. For welded joints, use the efficiency specified in HW-702. For seamless heads, use = 1, except for hemispherical heads furnished without a skirt, in which case use the efficiency of the head-to-shell joint HG-305.2 Ellipsoidal Heads. The required thickness and the design pressure of a dished head of semiellipsoidal form, in which half the minor axis (inside depth of the head minus the skirt) equals one-fourth of the inside diameter of the head skirt shall be calculated by the following formulas: PD ' ~ 2SE- 0.2P HG-305.5 Formed Heads With Stays. A formed head of a lesser thickness than that required by the rules of this paragraph may be used provided it is stayed as a fiat surface according to the rules of HG340 for stayed flat plates, no allowance being made in such staying for the holding power due to the curvature of the head unless all the following conditions are met: (a) the head is at least two-thirds as thick as required by the rules of this paragraph for an unstayed head; (b) the head is at least 7/g in. thick; (c) the stays are through-stays attached to the head by outside and inside nuts; (d) the design pressure on the head is taken as that calculated for an unstayed formed head plus the pressure calculated for the stays by the formula for stayed surfaces in HG-340 using a value of C = 1.63. or 2SEt - P =----------- D + 0.2/ HG-305.3 Torispherical Heads. The required thick ness and the design pressure of a torispherical head shall be calculated by the following formulas (see HG305.6): 0.885M. ' ~ SE - 0.1 P or SEt P =------------------ 0.885L + 0.1/ HG-305.4 Hemispherical Heads. The required thick ness and the design pressure of a hemispherical head in which P does not exceed 0.665SE shall be calculated by the following formulas: HG-305.6 Inside Crown Radius of Unstayed Heads. The inside crown radius to which an unstayed formed head is dished shall be not greater than the outside diameter of the skirt of the head. The inside knuckle radius of a torispherical head shall be not less than 6% of the outside diameter of the skirt of die head but in no case less than three times the head thickness. HG-305.7 Heads Built Up of Several Shapes. A - head for a cylindrical shell may be built up of several head shapes, the thicknesses of which satisfy the require ments of the appropriate formulas above, provided that adjoining shapes are so formed that they have a common tangent transverse to the joint HG-305.8 Length of Skirts. The required length of skirt on heads concave and convex to pressure shall comply with HW-715. HG-305.9 Permissible Diameter of Flat Spots on Formed Heads. If a torispherical, ellipsoidal, or hemi spherical head is formed with a flattened spot or surface, the diameter of the flat spot shall not exceed that permitted for flat heads as given by the formula in HG-307, using C = 0.20. PL ' ~ 2SE- 0.2P or 2SEt P =---------L + 0.2/ HG-306 FORMED HEADS, PRESSURE ON CONVEX SIDE HG-306.1 Unstayed dished heads with the pressure on the convex side shall have a design pressure equal to 60% of that for heads of the same dimensions having the pressure on the concave side (see HG-503). 8 RS-003012 1/17/02 NUECES HG-307 ARTICLE 3 -- DESIGN HG-307.3 HG-307 FLAT HEADS HG-307.1 General. The minimum thickness of un stayed heads, cover plates, and blind flanges shall conform to the requirements given in this paragraph. These requirements apply to both circular and noncircu lar heads and co .^rs. In addition, flat heads or covers made of cast iron shall be subjected to the proof test provisions of HG-500. Some acceptable types of flat heads and covers are shown in Fig. HG-307. (a) The symbols used in this paragraph and Fig. HG-307 are defined as follows: C = a factor depending upon the method of attach ment of the head, shell, pipe, or header dimen sions, and other items as listed in HG-307.4 below, dimensionless. The factors for welded covers also include a factor of 0.667 that effec tively increases the allowable stress for such construction to 1.55. D = long span of noncircular heads or covers mea sured perpendicular to short span, in. d= diameter^ or short span, measured as indicated in Fig. HG-307, in. He = gasket moment arm, equal to the radial distance from the center line; of the bolts to the line of the gasket reaction, as shown in Fig. HG-307, sketches (j) and (k), in. L-- perimeter of noncircular bolted head measured along the centers of the bolt holes, in. 1= length of flange or flanged heads, measured from the tangent line of knuckle, as indicated in Fig. HG-307, sketches (a) and (c), in. m= the ratio tr/ts, dimensionless P = design pressure, psi r= inside comer radius on the head formed by flanging or forging, in. 5 = maximum allowable stress value, psi, using val ues given in Tables HF-300.1 and HF-300.2 r= minimum required thickness of flat head or cover, in. te = minimum distance from beveled end of drum, pipe, or header, before welding, to outer face of head, as indicated in Fig. HG-307, sketch (i), in. tf-- actual thickness of the flange on a forged head, at the large end, as indicated in Fig. HG-307, sketch (b), in. //, = actual thickness of flat head or cover, in. tr = required thickness of seamless shell, pipe, or header, for pressure, in. /,= actual thickness of shell, pipe, or header, in. tw = thickness through the weld joining the edge of a head to the inside of a drum, pipe, or header, as indicated in Fig. HG-307, sketch (g), in. /] = throat dimension of the closure weld, as indi cated in Fig. HG-307, sketch (r), in. W = total bolt load, lb, as further defined in HG-307.2 Z= a factor for noncircular heads and covers that depends on the ratio of short span to long span, as given in HG-307.2 below, dimensionless HG-307.2 Thickness of Circular, Flat, Unstayed Heads, Covers, and Blind Flanges. The thickness of flat unstayed heads, covers, and blind flanges shall conform to one of the following requirements:2 (a) Circular blind flanges of ferrous materials con forming to ANSI B16.5 shall be acceptable for the diameters and pressure-temperature ratings in Tables 2 to 8 of that Standard when of the types shown in Fig. HG-307, sketches (j) and (k). (b) The minimum required thickness of flat unstayed circular heads, covers, and blind flanges shall be calcu lated by the following formula: t = d V CP/S (1) except when the head, cover, or blind flange is attached by bolts causing an edge moment [Fig. HG-307, sketches (j) and (k)], in which case the thickness shall be calculated by - r = d V CP/S + l.9WHcISd* (2) When using Formula (2), the thickness t shall be calculated for both operating conditions and gasket seating, and the greater of the two values shall be used. For operating conditions, the value of P shall be the design pressure, the value of 5 at design temperature shall be used, and W shall be the sum of the bolt loads required to resist the end pressure load and to maintain tightness of the gasket. For gasket seating, P equals zero, the value of 5 at atmospheric temperature shall be used, and W shall be the average of the required bolt load and the load available from the bolt area actually used. HG-307.3 Thickness of Noncircular, Flat, Unstayed Heads, Covers, and Blind Flanges (a) Flat unstayed heads, covers, or blind flanges may be square, rectangular, elliptical, obround, segmental, 2 The formulas provide safe construction as far as stress is concerned. Greater thicknesses may be necessary if deflection would cause leakage at threaded or gasketed joints. 9 RS-003013 1/17/02 NUECES HG-307J 1995 SECTION IV HG-307.4 or otherwise noncircular. Their required thickness shall be calculated by the following formula: t = d VZCP/S (3) where 2.44 Z = 3.4-------- D (4) with the limitation that Z need not be greater than 2.5. (b) Formula (3) does not apply to noncircular heads, covers, or blind flanges attached by bolts causing a bolt edge moment [Fig. HG-307, sketches (j) and (k)]. For noncircular heads of this type, the required thickness shall be calculated by the following formula: r = d yj ZCP/S + 6WHc/SLd2 (5) When using Formula (5), the thickness t shall be calculated in the same way as specified above for Formula (2). HG-307.4 Values of C for Use in Formulas in HG-307.2 and HG-307.3. For the types of construction shown in Fig. HG-307, the values of C to be used in Formulas (1), (2), (3), and (5) are: > Figure HG-307, sketch (a): C = 0.17 for flanged circular and noncircular heads forged integral with or butt welded to the shell, pipe, or header, with an inside comer radius not less than three times the required head thickness, with no special requirement with regard to length of flange, and where the welding meets all the requirements for circumferential joints given in Part HF, Subpart HW. C = 0.10 for circular heads, when the flange length for heads of the above design is not less than I = (l.l -0.8^) 4dh, (6) When C = 0.10 is used, the taper shall be at least 1:3. Figure HG-307, sketch (b): C = 0.17 for circular and noncircular heads forged integral with or buttwelded to the shell, pipe, or header, where the corner radius on the inside is not less than three times the thickness of the flange and where the welding meets all the requirements for circumferential joints given in Part HF, Subpart HW. Figure HG-307, sketch (c): C = 0.20 for circular flanged plates screwed over the end of the shell, pipe, or header, with inside corner radius not less than 31, in which the design of the threaded joint against failure by shear, tension, or compression, resulting from the end force due to pressure, is based on a factor of safety of at least five, and the threaded parts are at least as strong as the threads for standard piping of the same diameter. Seal welding may be used, if desired. Figure HG-307, sketch (d): C = 0.13 for integral flat circular heads when the dimension d does not exceed 24 in., the ratio of thickness of the head to the dimension d is not less than 0.05 nor greater than 0.25, the head thickness th is not less than the shell thickness ts, the inside comer radius is not less than 0.25r, and the construction is obtained by special tech niques of upsetting and spinning the end of the shell, pipe, or header, such as employed in closing header ends. Figure HG-307, sketches (e), (f), and (g): C = 0.33m but not less than 0.20 for circular plates, welded to the inside of a drum, pipe, or header, and otherwise meeting the requirements for the respective types of fusion welded boiler drums. If a value of m less than 1 is used in calculating r, the shell thickness ts shall be maintained along a distance inwardly from the inside face of the head equal to at least l-fd^. The throat thickness of the fillet welds in sketches (e) and (f) shall be at least 0.7ts. The size of the weld tw in sketch (gj shall be not less than two times the required thickness of a seamless shell nor less than 1.25 times the nominal shell thickness but need not be greater than the head thickness; the weld shall be deposited in a welding groove with the root of the weld at the inner face of the head as shown in the figure. C = 0.33 for noncircular plates, welded to the inside of a dram, pipe, or header, and otherwise meeting the requirements for the respective types of fusion welded boiler drums. The throat thickness , of the fillet welds in sketches (e) and (f) shall be at least 0.7tj. The size of the weld r,,. in sketch (g) shall be not less than two times the required thickness of a seamless shell nor less than 1.25 times the nominal shell thickness but need not be greater than the head thickness; the weld shall be deposited in a welding groove with the root of the weld at the inner face of the head as shown in the figure. Figure HG-307, sketch (h): C = 0.33 for circular plates welded to the end of the shell when r, is at least 1.25rr and the beveled end of the shell is located at a distance no less than 2r nor less than I.25r, from the outer face of the head. The width at the bottom of the welding groove shall be at least equal to the shell thickness but need not be over !/4 in. 10 R8-003014 1/17/02 NUECES C - 0.13 Id) Center of weld ARTICLE 3 -- DESIGN Center of lap Fig. HG-307 r 3tf min. C -0.10 (a) (b) (c) 0.7ff fi*.- 2/, min. nor less than i.25f, but need not be greater than r I y Continuation of shell optional Ctrl Projection beyond weld is optional )r-f- Bevel optional L 45 deg. max. Sketches (e). If), (g) Circular Covers, C 0.33m; Noncircular Covers, C 1 0.33 <e> (f) Min. f, but need not be over 1/4 in. . rt - 2tr but not less than 1.25 f. HC __l C - 0.33m C min. 0.20 (i) C - 0.30 (Use Eq. (2) or (5)1 (i) C - 0.30 [Use Eq. (2) or (5)1 Ik) /////W'V, Retaining ring C= 0.30 (m) m. Threaded ring -I--!--WfHUC - 0.30 In) m C 0.30 (o) (Pi Id) FIG. HG-307 SOME ACCEPTABLE TYPES OF UNSTAYED FLAT HEADS AND COVERS The Above Illustrations Are Diagrammatic Only. Other Designs Which Meet the Requirements of HG-307 Will Be Acceptable. 11 RS-003016 1/17/02 NUECES HG-307.4 1995 SECTION IV HG-309 Figure HG-307, sketch (i): C = 0.33m but not less than 0.20 for circular plates welded to the end of the drum, pipe, or header, when an inside weld with minimum throat thickness of 0.7/, is used, and when the beveled end of the drum, pipe, or header is located at a distance not less than 2/r nor less than 1.251, from the outer face of the head. The width at the bottom of the welding groove shall be at least equal to /,, but need not be over *4 in. Figure HG-307, sketches (j) and (k): C = 0.3 for circular and noncircular heads and covers bolted to the shell, flange, or side plate, as indicated in the figures. Note that Formula (2) or (5) shall be used because of the extra moment applied to the cover by the bolting. When the cover plate is grooved for a peripheral gasket, as shown in sketch (k), the net cover plate thickness under the groove or between the groove and the outer edge of the cover plate shall be not less than dyj\.9WHc/Sd3 for circular heads and covers, nor less than d^6WHc/SLd2 shown, and otherwise meeting the requirements for fusion welded boiler drums. The end of the shell, pipe, or header shall be crimped over at least 30 deg., but not more than 45 deg. The crimping may be done cold only when this operation will not injure the metal. The throat of the weld shall be not less than the thickness of the flat head or the shell, pipe, or header, whichever is greater. Figure HG-307, sketch (s): C = 0.33 for circular beveled plates having a diameter not exceeding 18 in., inserted into a shell, pipe, or header, the end of which is crimped over at least 30 deg., but not more than 45 deg., and when the undercutting for seating leaves at least 809b of the shell thickness. The beveling shall be not less than 75% of the head thickness. The crimping shall be done when the entire circumference of the cylinder is uniformly heated to the proper forging temperature for the material used. For this construction, the ratio tjd shall be not less than the ratio P/S nor less than 0.05. The design pressure for this construction shall not exceed P = S/5d. Figure HG-307 is diagrammatic only. Other designs which meet the requirements of HG-307 will be ac ceptable. for noncircular heads and covers. Figure HG-307, sketches (m), (n), and (o): C = 0.3 for a circular plate inserted into the end of a shell, pipe, or header, and held in place by a positive mechani cal locking arrangement, and when all possible means of failure either by shear, tension, compression, or radial deformation, including flaring, resulting from pressure and differential thermal expansion, are resisted with a factor of safety of at least five. Seal welding may be used, if desired. Figure HG-307, sketch (p): C = 0.25 for circular and noncircular covers bolted with a full-face gasket to shells, flanges, or side plates. Figure HG-307, sketch (q): C = 0.75 for circular plates screwed into the end of a shell, pipe, or header, having an inside diameter d not exceeding 12 in.; or for heads having an integral flange screwed over the end of a shell, pipe, or header, having an inside diameter d not exceeding 12 in.; and when the design of the threaded joint against failure by shear, tension, compres sion, or radial deformation, including flaring, resulting from pressure and differential thermal expansion, is based on a factor of at least five. If a tapered pipe thread is used, the requirements of Table HG-370 shall also be met. Seal welding may be used, if desired. Figure HG-307, sketch (r): C = 0.33 for circular plates having a dimension d not exceeding 18 in. inserted into the shell, pipe, or header, and welded as HG-309 SPHERICALLY DISHED COVERS (BOLTED HEADS) (a) Notation. The symbols used in the formulas of this paragraph are defined as follows: A = outside diameter of flange, in. B= inside diameter of flange, in. C= bolt circle diameter, in. t= minimum required thickness of head plate after forming, in. L= inside spherical or crown radius, in. r= inside knuckle radius, in. P= design pressure, psi S = maximum allowable stress value as given in Tables HF-300.1 and HF-300.2 T = flange thickness, in. M0 = the total moment, in.-lb, determined as in Sec tion VIII, Division 1, Appendix 2, 2-6, except that for heads of the type shown in Fig. HG309, sketch (d), a moment Hrhr (which may add or subtract) shall be included in addition to the moment HDhD where Hr= radial component of the membrane load in the spherical segment, lb, acting at the intersection of the inside of the flange ring with the center line of the dished cover thickness Hr=HD cot ft 12 RS4)03016 1/17/02 NUECES HG-309 ARTICLE 3 -- DESIGN Edge of weld shall not overlap knuckle r Not less than 2f and in no case less than 1/2 in. Knuckle l radius \ - Gasket \ Loose Flange Type (a) - Gasket ' Integral Flange Type Id HG-309.1 FIG. HG-309 SPHERICALLY DISHED STEEL PLATE COVERS WITH BOLTING FLANGES hr= lever arm of force Hr about centroid of flange ring, in. Hd= axial component of the membrane load in the spherical segment, lb, acting at the inside of the flange ring = 0.785&P hD = radial distance from the bolt circle to the inside of the flange ring, in. NOTE: Since Hrh, in some cases will subtract from the total moment, the moment in the flange ring when the internal pressure is zero may be the determining loading for the flange design. HG-3t).l Heads Concave to Pressure. Circular spherically dished heads with bolting flanges, concave to the pressure and conforming to the several types illustrated in Fig. HG-309 shall be designed in accord ance with the following formulas: (a) Heads of the Type Shown in Fig. HG-309, Sketch (a) (1) The thickness of the head t shall be determined by the appropriate formula in HG-305. (2) The head radius L or the knuckle radius r shall not exceed the limitations given in HG-305. (3) The flange shall comply at least with the requirements of Section VIII, Division 1, Appendix 2, Fig. 2-4 and shall be designed in accordance with the provisions of 2-1 through 2-7. (Within the range of ANSI B16.5, the flange facings and drillings should conform to those standards and the thickness specified therein shall be considered as a minimum requirement.) (b) Heads of the Type Shown in Fig. HG-309, Sketch (b). (No joint efficiency factor is required.) (1) Head thickness _ 5PL 6S (2) Flange thickness 77 For ring gasket, lM0tA + BV SB LA -B. For full-face gasket, T = 0.6 P \B{A + B)(C - B) S A-B NOTE: The radial components of the membrane load in the spherical segment are assumed to be resisted by its flange. R8-003017 1/17/02 NUECES HG-309.1 1995 SECTION IV Within the range of ANSI B16.S, the flange facings and drillings should conform to those standards, and the thickness specified herein shall be considered as a minimum requirement. (c) Heads of the Type Shown in Fig. HG-309, Sketch (c). (No joint efficiency factor is required.) (1) Head thickness 5PL 65 (2) Flange thickness for ring gaskets shall be calculated as follows: (a) For heads with round bolting holes, / 1.875Me(C + B) > SBOC - SB) 5 PL 65 (2) Flange `hickness T = F + ^F2 + J where and PB^4L2-B2 F =-------------------- 85(A - B) HG-312.1 where PL i C + B Q 45 VlC-SB. (II) (b) For heads with bolting holes slotted through the edge of the head. I 1.875M,,(C + B) > 5B(3C - 5B) (HI) where PL \ C + B Q 45 L3C - B- (IV) (3) Flange thickness for full face gaskets shall be calculated by the following formula: HG-312 CYLINDRICAL PARTS UNDER EXTERNAL PRESSURE HG-312.1 Plain Type Furnaces. Plain furnaces that are complete cylinders shall conform to the following. (a) The thickness of the furnace wall shall be not less than % in. (b) The design temperature of the furnace shall be taken as 500F. (c) Furnaces shall be rolled to a circle, with a maximum deviation from the true circle of not more than *4 in. (d) The thickness of the furnace wall shall be deter mined by the use of Fig. HG-312.1 or Fig. HG-312.2. The symbols defined below and shown in Fig. HG- 312.1 or Fig. HG-312.2 are used in the formulas of this paragraph: .... t= minimum required wall thickness of furnaces, T,a.Ja>t}J2EzH m The value of Q in Eq. (V) is calculated by Eq. (II) for round bolting holes or by Eq. (IV) for bolting holes slotted through the edge of the head. (4) The required flange thickness shall be T as calculated in (2) or (3) above, but in no case less than the value of t calculated in (1) above. (d) Heads of the Type Shown in Fig. HG-309, Sketch (d). (No joint efficiency factor is required.) (1) Head thickness L= design length of plain furnace taken as the dis tance from center to center of weld attachment, in.; design length of ring reinforced furnace sec tion, taken as the greatest center-to-center dis tance between any two adjacent stiffening rings; or the distance from the center ofthe first stiffen ing ring to the center of the furnace weld attach ment, in. In case a flared-end assembly is used, the distance shall be measured to the point of tangency between the flare and the furnace and the adjacent stiffening ring. D0 = outside diameter of furnace, in. P= design pressure, psi 14 as* J A95 ARTICLE 3 -- DESIGN Factor B - P(D,, / t ) Fig. HG-312.1 50.000 40.000 35.000 30.000 25.000 20.000 IB.000 16,000 14.000 12.000 10,000 9.000 8.000 7.000 6.000 5.000 4.000 3.500 3.000 2.500 2.000 1,800 1,600 1,400 1,200 1,000 900 BOO 700 600 500 400 350 300 250 200 160 160 140 120 too 90 80 70 60 50 FIG. HG-312.1 CHART FOR DETERMINING WALL THICKNESS OF CYLINDRICAL FURNACES WHEN CONSTRUCTED OF CARBON STEEL Specified Yield Strength 24,000 psi to, But Not Including 30,000 psi 15 R8-003019 1/17/02 NUECES Length -F Outtide Diameter LI D- Factor B * P(DQ/ t ) Fig. HG-312.2 1995 SECTION IV o o.ooooi o.oooi oaoi Factor A o.o\ 50.000 40.000 35.000 30.000 25.000 20.000 18,000 16,000 14.000 12.000 10,000 9.000 8.000 7.000 6.000 5.000 4.000 3.500 3.000 2.500 2.000 1,800 1,6 00 1,4 00 1,200 1,000 900 00 700 600 500 400 350 300 250 200 1 80 I 60 I 40 120 00 90 80 70 60 50 o.i A95 FIG. HG-312.2 CHART FOR DETERMINING WALL THICKNESS OF CYLINDRICAL FURNACES WHEN CONSTRUCTED OF CARBON STEEL Specified Yield Strength 30,000 psi to 38,000 psi 16 RS-003020 1/17/02 NUECES HG-312^ ARTICLE 3 -- DESIGN HG-312.4 HG-312.2 Tubes. The wall thickness of ferrous tubes subject to external pressure shall be determined by use of Fig. HG-312.1 or Fig. HG-312.2, as applicable, using the procedure outlined in HG-312.3 and adding to that value a minumum addition? thickness of 0.04 in. as an allowance for rolling anr> structural stability. HG-3123 Procedure for Determining Wall Thick ness of Plain Furnaces and Tubes. The required wall thickness of the furnace and tubes shall be not less than determined by the following procedure: Step 1: Assume a value for t. Determine the ratio L/D0 and D0/t. Step 2: Enter left-hand side of Fig. HG-312.1 or Fig. HG-312.2 at value of L/D0. Step 3: Move horizontally to the line representing D0/t determined in Step 1. (For intermediate D0lt ratios, interpolations shall be made between lines on the chart in Fig. HG-312.1 or Fig. HG-312.2.) Step 4: From this intersection move vertically to the material line of the proper temperature. Step 5: From this intersection move horizontally to the right and read the value of B. Step 6: Compute the allowable working pressure Pa by the following formula B Step 7: Compare P,, with P. If Pa is less than P, a greater value of t must be selected or a smaller value of L or some combination of both to increase Ptt so that it is equal to or greater than P. (An example is included in Appendix C.) HG-312.4 Ring Reinforced Type Furnace. Ring reinforced furnaces as shown in Fig. HG-312.3 may be constructed with completely circular stiffening rings provided: (a) the stiffening ring is rectangular in cross section and is fabricated from one piece of plate, or from plate sections or bars provided full-penetration welds are used in assembling; (b) the stiffening ring after fabrication has a thickness of not less than 5/l6 in. and not more than 13/16 in. and in no case thicker than l'/4 times the furnace wall; (c) the ratio of height of the stiffening ring to its thickness (Hr/Tr) is not over eight nor less than three; (d) the stiffening ring is attached to the furnace by a full penetration weld as shown in Fig. HG-312.3; FIG. HG-3123 ACCEPTABLE TYPE OF RING REINFORCED FURNACE (e) the thickness of the furnace wall is a minimum of V4 in.; (f) the design temperature of the furnace shall be taken as 500F; (g) the boiler design permits replacement of the furnace. A flared or welded OG-ring may be accepted as meeting this requirement. (See Fig. HG-312.3.) (h) the thickness of the furnace wall or tube wall and the design of stiffening rings are determined by the use of Figs. HG-312.1 or HG-312.2. The symbols defined in HG-312.1, and shown in Figs. HG-312.1 or HG-312.2 are used in the design formula. Steps 1 through 7 of HG-312.3 shall apply. (/') the required moment of inertia of a circumferen tial stiffening ring shall not be less than determined by the formula: where Is = required moment of inertia of the stiffening ring about its neutral axis parallel to the axis of the furnace, in.4 As = cross-sectional area of the stiffening ring, sq in. A= factor determined from Figs. HG-312.1 or HG-312.2 P, Dg, and t are as defined in HG-312.1. 17 rS-003021 1/17/02 NUECES HG-312.5 1995 SECTION IV HG-312.7 HG-312.5 Procedure for Determining Moment of Inertia of Stiffening Rings. The moment of inertia for a stiffening ring shall be determined by the following procedure. Step 1: Assuming that the furnace has been designed and D0, L, and t are known, select a rectangular member to be used for a stiffening ring and determine its area A, and its moment of inertia /. Then calculate B by the formula: 4, t+-- L where B = factor on the right-hand side of Fig. HG-312.1 or Fig. HG-312.2 P, D,,, t, As, and L are defined above. Step 2: Enter the right-hand side of Fig. HG-312.1 or Fig. HG-312.2 at the value of B determined in Step 1. Step 3: Follow horizontally to the material line. Step 4: Move down vertically to the bottom of the chart and read the value of A. Step 5: Compute the value of the required moment of inertia /, from the formula given above. Step 6: If the required /, is greater than the moment of inertia 1 for the section selected in Step 1, a new section with a larger moment of inertia must be selected and a new /, determined. If the required /, is smaller than / for the section selected by Step 1, that section should be satisfactory. (An example is included in Appen dix C.) HG-312.6 Corrugated Furnaces. The design pres sure of corrugated furnaces, such as the Leeds suspen sion bulb, Morison, Fox, Purves, or Brown, having plain portions at the ends not exceeding 9 in. in length shall be computed as follows: P = Ct/D where P= design pressure, psi t= thickness, in., not less than 5/16 in. for Leeds, Morison, Fox, and Brown, and not less than ?/16 in. for Purves and other furnaces corrugated by sections not over 18 in. long D= mean diameter, in. C= 17,300, a constant for Leeds furnaces, when corrugations are not more than 8 in. from center to center and not less than 2l/4 in. deep C= 15,600, a constant for Morison furnaces, when corrugations are not more than 8 in. from center to center and the radius of the outer corrugation is not more than one-half of the suspension curve C = 14,000, a constant for Fox furnaces, when corru gations are not more than 8 in. from center to center and not less than 1V2 in. deep C= 14,000, a constant for Purves furnaces, when rib projections are not more than 9 in. from center to center and not less than l3/8 in. deep C = 14,000, a constant for Brown furnaces, when corrugations are not more titan 9 in. from center to center and not less than 1% in. deep (a) In calculating the mean diameter of the Morison furnace, the least inside diameter plus 2 in. may be taken as the mean diameter. (b) The longitudinal and circumferential joints shall be fusion welded of the double-welded butt type. (c) The thickness of a corrugated or ribbed furnace shall be ascertained by actual measurement by the furnace manufacturer, by gaging the thickness of the corrugated portions. If a hole is drilled through the sheet to determine the thickness, the hole shall be not more than 3/g in. When the furnace is installed, this hole shall be located in the bottom of the furnace and closed by'a threaded plug. For the Brown and Purves furnaces, the hole shall be in the center of the second flat from the boiler front; for the Morison, Fox, and other similar types, in the center of the top corrugation, at least as far in as the fourth corrugation from the front end of the furnace. HG-312.7 Combination Type Furnaces. Combina tion type furnaces for external pressure may be con structed by combining a plain circular section and a corrugated section provided: (a) each type of furnace is designed to be selfsupporting, requiring no support from the other furnace at their point of connection; (b) HG-312.1 and HG-312.3 shall be used for calcu lating the design pressure of the plain section; in applying the length in the text, or L in the formulas, the length used shall always be twice the actual length of the plain section; the actual length of plain section is the distance measured from the center line of the head attachment weld to the center line of the full penetration weld joining the two sections. (c) the design pressure of the corrugated section shall be determined from HG-312.6; 18 RS-003022 1117/02 NUECE8 HG-312.7 ARTICLE 3 -- DESIGN HG-315.2 120 deg. arc shall be stayed as a flat plate in accordance with HG-340. FIG. HG-312.6 CONNECTION BETWEEN PLAIN AND CORRUGATED FURNACE (d) the full penetration weld joining a plain selfsupporting section to a corrugated self-supporting sec tion shall be located as shown in Fig. HG-312.6. HG-312.8 Semicircular Furnaces or Crown Sheets Subjected to External Pressure. Unstayed furnaces or crown sheets-where the top portion is semicircular and the unstayed portion does not exceed 120 deg. in arc shall conform to the following. (a) The thickness of the semicircular furnace or crown sheet shall be not less than Vj6 in. (b) The design temperature of the semicircular fur nace or crown sheet shall be taken as 500F. (c) Semicircular portions of the furnace or crown sheet shall be rolled to practically a true circle, with a maximum deviation from the true circle of not more than '4 in. (d) The allowable working pressure of the semicircu lar furnace or crown sheet shall be not more than 70% of Pa as computed from the procedure outlined in HG312.1 and HG-312.3 and using the applicable chart. Fig. HG-312.1 or Fig. HG-312.2. (e) Bar Reinforcement (1) Bar reinforcement, vhen required to reduce the effective furnace length L, shall be computed using the formulas in HG-312.5 and HG-312.4. (2) Bar reinforcement shall be fabricated and in stalled as shown in Fig. HG-312.7. (3) Bar reinforcement, after fabrication, shall have a thickness of not less than Vj6 in. and not more than 13/16 in. and in no case thicker than 1*4 times the wall section of the semicircular portion. (4) The ratio of height of the bar reinforcement to its thickness Hr/Tr shall be not more than eight nor less than three. (f) For unstayed furnaces or crown sheets, where the top portion is semicircular and the unstayed portion exceeds 120 deg. in arc, that portion exceeding the HG-315 THICKNESS OF TUBES HG-315.1 Ferrous Tubes. The minimum thickness of ferrous tubes subject to internal pressure shall be as follows: Outside Diameter D, in. 1 or over but less than 2% 2V2 or over but less (ban 3% 3'/ or over but less than 4 4 or over but less than 5 3 or over but less than 6 Minimum Wall Thickness T, in. 0.095 0.105 0.120 0.135 0.150 NOTE: The minimum wall thickness of steel or wrought iron tubes 6 in. outside diameter and larger shall be calculated by the formula: t = 0.025ID where D = outside diameter of tube, in. 1 = minimum wall thickness, in. For tubes subject to external pressure see HG-312.2. HG-3152 Nonferrous Tubes. The minimum thick ness of nonferrous tubes, whether straight, bent, or coiled, shall be as follows. (a) Installed by Rolling (1) Where the design pressure is over 30 psi, t = D/30 + 0.03 (2) Where the design pressure does not exceed 30 psi. r = D/45 + 0.03 where D = outside diameter of tube, in. t = minimum wall thickness, in. (3) In no case shall a tube installed by rolling be thinner than 0.061 in. (b) Installed by Welding, or Brazing, or With Flared Connections, Assembled With Copper or Copper Alloy Fittings 19 RS-003023 1/17/0* NUECES HG-315.2 1995 SECTION IV HG-320.1 FIG.-HG-312.7 ACCEPTABLE TYPE OF SEMICIRCULAR FURNACE REINFORCEMENT A97 (1) Where the design pressure is over 30 psi: Material Cu Red Brass Admiralty 70-30 Cu-Ni 80-20 Cu-Ni 90-10 Cu-Ni Cu-Si Spec. No. SB-75, SB-111 SB-43, SB-111, SB-395 SB-395 SB-111, SB-395 SB-111, SB-395 SB-111, SB-395 SB-315 Alloy 655 Formula t = D/50 + 0.027 in. X = D/40 + 0.03 in. X = D/45 + 0.03 in. X = D/55 + 0.03 in. X = D/50 + 0.03 in. X = D/65 + 0.03 in. t = D/65 + 0.03 in. A97 (2) Where the design pressure does not exceed 30 psi: HG-320 OPENINGS IN BOILERS, GENERAL REQUIREMENTS3-4 HG-320.1 Shape of Openings.5 Openings in cylindri cal, spherical, or conical portions of boilers or in formed heads shall preferably be circular, elliptical, or obround6 except as otherwise provided in HG-320.2. When the long dimension of an elliptical or obround opening exceeds twice the short dimension, the reinforcement across the short dimension shall be increased as neces sary to provide against excessive distortion due to twisting moment. Material Cu Red Brass Admiralty 70-30 Cu-Ni 80-20 Cu-Ni 90-10 Cu-Ni Cu-Si Spec. No. SB-75, SB-111 SB-43, SB-111, SB-395 SB-395 SB-111, SB-395 SB-111, SB-395 SB-111, SB-395 SB-315 Alloy 655 Formula t = D/70 + 0.03 in. t = D/60 + 0.03 in. X = D/65 + 0.03 in. X = D/75 + 0.03 in. X = D/70 + 0.03 in. X = D/65 + 0.03 in. X = D/65 + 0.03 in. (3) In no case shall the minimum thickness of tubes installed by welding be less than 0.061 in. There is no specified overriding minimum thickness require ment for tubes installed by brazing except that the thickness used must meet the brazing qualification requirements of Section IX, Part QB. 3 The rales governing openings as given in this Code are based on the stress intensification created by the existence of a hole in an otherwise symmetrical section. They are based on experience with vessels designed with a safety factor of five applied to the specified minimum tensile strength of the shell material. External loadings such as those due to thermal expansion or to unsupported weight of connecting piping have not been evaluated. These factors should be given attention in unusual designs or under conditions of cyclic loading. 4 Typical examples of the application of these rales are given in Appendix D. 5 The opening made by a pipe or a circular nozzle, the axis of which is not perpendicular to the boiler wall or head, may be considered an elliptical opening for design purposes. 6 An obround opening is one which is formed by two parallel sides and semicircular ends. 20 RS-003024 1/17/02 NUECE8 HG-320.2 ARTICLE 3 -- DESIGN HG-321.2 HG-320.2 Size of Openings. While openings in cylindrical and spherical shells are not limited as to size provided they are adequately reinforced, the rules given herein for reinforcement are intended to apply to openings not exceeding the following dimensions: (a) for boilers 60 in. in diameter and less: one-half the boiler diameter but not over 20 in.; (b) for boilers over 60 in. in diameter one-third the boiler diameter, but not over 40 in.; (c) larger openings should be given special attention and may be provided with reinforcement in any suitable manner that complies with the intent of the Code rules. It is recommended that the reinforcement provided be distributed close to the opening. (A provision of about two-thirds of the required reinforcement within a dis tance of one-fourth of the nozzle diameter on each side of the finished opening is suggested.) Special consideration should be given to the fabrication details used and the inspection employed on critical openings; reinforcement often may be advantageously obtained by use of a thicker shell plate for a boiler course or inserted locally, around the openings; welds may be ground to concave contour and the inside comers of the opening rounded to a generous radius to reduce stress concentrations. Appropriate proof testing may be advisable in extreme cases of large openings ap proaching full boiler diameter, openings of unusual shape, etc. HG-3203 Strength and Design of Finished Openings (a) All references to dimensions in this and suc ceeding paragraphs apply to the finished construction after adjustment has been made for any material added as corrosion or other allowance. For design purposes, no metal added as corrosion or other allowance may be considered as reinforcement. Reinforcement shall be provided to satisfy the requirements of HG-321 for all openings except as otherwise provided in (b), (c), and (d) below. (b) Openings in a definite pattern, such as tube holes, may be designed in accordance with the rules for ligaments in HG-350 provided the diameter of the largest hole in the group does not exceed that permitted by the chart in Fig. HG-320. The symbols given in Fig. HG-320 are defined as follows: P = design pressure, psi d = maximum allowable diameter of opening, in. D = outer diameter of the shell, in. t= nominal thickness of the shell, in. S= maximum allowable stress value, psi, taken from Table HF-300 K= PD/2St (c) No calculations need be made to determine the availability of reinforcement for single openings in boilers not subject to rapid fluctuations in pressure or temperature and in which the outside diameter of the opening does not exceed one-fourth of the inside diame ter of the boiler, provided the hole cut in the wall of the shell or head does not exceed the following sizes: (1) 2 in. pipe size for welded connections in boiler walls over 3/g in. thick and for all threaded, studded, or expanded connections; (2) 3 in. pipe size for welded connections in boiler walls 3/g in. thick and under. (d) No calculations need be made to demonstrate compliance with HG-321 for single openings not cov ered in HG-320.3(c) when the diameter of the opening in the shell or header does not exceed that permitted in Fig. HG-320. HG-321 REINFORCEMENT REQUIRED FOR OPENINGS IN SHELLS AND FORMED HEADS HG-321.1 General. The rules in this subparagraph apply to all openings other than openings in a definite pattern covered by HG-320.3(b), openings covered by HG-320.3(c) and HG-320.3(d), flanged-in openings in formed heads covered by HG-323, and openings in flat heads covered by HG-325. (a) Reinforcement shall be provided in such amount and distribution that the requirements for area of rein forcement are satisfied for all planes through the center of the opening and normal to the boiler surface. For a circular opening in a cylindrical shell, the plane containing the axis of the shell is the plane of greatest loading due to pressure. HG-321.2 Design for Internal Pressure. The total cross-sectional area of reinforcement A required in any given plane for a boiler under internal pressure shall be not less than A = dtrF where d= the diameter in the given plane of the finished opening, in. F= a correction factor which compensates for the variation in pressure stresses on different planes with respect to the axis of a vessel. A value of 1.00 shall be used for all configurations except 21 RS-00302S 1/17/02 NUECE8 Fig. HG-320 1989 SECTION IV Maximum Diameter o f Opening Id), in. 1 5 10 15 20 Drum Diameter x Thickness, (Dt), in.1 25 Maximum Diameter o f Opening (d), in. A95 Drum Diameter x Thickness, (Dt), in.1 175 200 and over FIG. HG-320 CHART SHOWING LIMITS OF SIZES OF OPENINGS WITH INHERENT COMPENSATION IN CYLINDRICAL SHELLS Maximum Permissible Diameter of Opening Is 8 in. 22 R8-003028 1/17/02 NUECES HG-321.2 ARTICLE 3 -- DESIGN HG-323J that Fig. HG-321 may be used for integrally reinforced openings in cylindrical shells. tr= the required thickness of a seamless shell or head computed by the rules of the Code for the designated pressure, in., except that: (a) when the opening and its reinforce ment are in a torispherical head and are entirely within the spherical portion, tr is the thickness required for a seamless hemispherical head of the same radius as that of the spherical portion; (b) when the opening is in a cone, tr is the thickness required for a seamless cone of diameter D measured where the nozzle axis pierces the inside wall of the cone; (c) when the opening and its reinforce ment are in an ellipsoidal head and are located entirely within a circle the center of which coin cides with the center'of the head and the diame ter of which is equal to 80% of the shell diame ter, tr is the thickness required for a sphere of radius K\D where D is the shell diameter and K\ is given by Table HG-321. Value of r FIG. HG-321 CHART FOR DETERMINING VALUES OF F TABLE HG-321 VALUES OF SPHERICAL RADIUS FACTOR Ki Equivalent Spherical Radius = Ki D; DI2h = axis ratio. Interpolation Permitted for Intermediate Values. D/2h Ki Dl2h 2.0 0.90 3.0 1.36 1.8 0.81 2.8 1.27 1.6 0.73 2.6 1.18 1.4 0.65 2.4 1.08 1.2 0.57 2.2 0.99 1.0 0.50 GENERAL NOTE: D = inside length of major axis, in. d = inside depth of ellipsoidal head measured from the tangent line, in. HG-323 FLANGED-IN OPENINGS IN FORMED HEADS HG-323.1 Reinforcement Requirements. Flanged-in openings in torispherical, ellipsoidal, and hemispherical heads shall be provided with reinforcement in accord ance with HG-321, except for heads which meet the requirements in HG-323.2, HG-323.3, and HG-323.4. HG-323.2 Restrictions on Location. The flangedin opening and its reinforcement shall be entirely within the spherical portion of torispherical heads, and within a circle the center of which coincides with the center of the head and the diameter of which equals 80% of the shell diameter for ellipsoidal and hemispherical heads. The center line of the opening shall not be closer to the above boundary circle than the diameter of the opening. HG-323_3 Minimum Thickness Requirements of Flanged-in Openings (a) For flanged-in openings that do not exceed 6 in. in any dimension and for flanged-in openings of any dimension that are stayed by an attached flue, the thickness of the head shall not be less than that required by HG-305 for a blank head, nor less than that required by HG-305 for torispherical heads. (b) For unstayed flanged-in openings that exceed 6 in. in any inside dimension, the head thickness shall be increased 15% but not less than `/g in. greater than that required by (a) above. 23 R8-003027 1/17/02 NUECE8 HG-323.4 1995 SECTION IV HG-326.4 HG-323.4 Minimum Flange Depth. The minimum depth of flange of a flanged-in opening, when not stayed by an attached flue, shall equal 31 or (f + 3) in., whichever is less, where t is the required head thickness. The depth of flange shall be determined by placing a straightedge across the outside of the opening along the major axis and measuring from the straight edge to the edge of the flanged opening. HG-323.5 Minimum Gasket Bearing Surface. The minimum width of bearing surface for a gasket on a flanged-in manhole opening shall be lV)6 in. HG-325 REINFORCEMENT REQUIRED FOR OPENINGS IN FLAT HEADS HG-325.1 General. The rules in this paragraph apply to all openings other than small openings covered by HG-320.3(c). HG-325.2 Specific Requirements. Flat heads that have an opening With a diameter that does not exceed one-half of the head diameter or shortest span, as defined in HG-307, shall have a total cross-sectional area of reinforcement not less than that given by the formula: A m Q.5dt ............................ . where d = diameter of the finished opening, in. t = minimum required thickness of plate, in. As an alternative, the thickness of flat heads may be increased to provide the necessary opening reinforce ment as follows: (a) in Formula (1) or (3) of HG-307 by using 2C or 0.75 in place of C, whichever is less; (b) in Formula (2) or (5) of HG-307 by doubling the quantity under the square root sign. Except for the types of construction shown in Fig. HG-307, sketches (j) and (k), the value of 2C to be used in the formulas need not exceed 0.75. HG-326 LIMITS OF METAL AVAILABLE FOR REINFORCEMENT HG-326.1 Designation of Limits of Reinforcement The boundaries of the cross-sectional area in any plane normal to the boiler shell and passing through the center of the opening within which area metal must be located in order to have value as reinforcement are designated as the limits of reinforcement for that plane. HG-326.2 Limits of Reinforcement Parallel to Boiler Shell. The limits of reinforcement measured parallel to the boiler shell, shall be at a distance, on each side of the axis of the opening, equal to the greater of the following: (a) the diameter of the finished opening; (b) the radius of the finished opening plus the thick ness of the boiler shell, plus the thickness of the nozzle wall. HG-326.3 Limits of Reinforcement Normal to Boiler Shell. The limits of reinforcement measured normal to the boiler shell, shall conform to the contour of the surface at a distance from each surface equal to the smaller of the following: (a) 2`/2 times the nominal shell thickness; (b) 2l/2 times the nozzle wall thickness, plus the thickness of any added reinforcement exclusive of weld metal on the side of the shell under consideration. HG-326.4 Use of Excess Boiler Shell and Other Thicknesses. Metal which may be included as contribut ing to the area of reinforcement required by HG-321 shall lie within the limits of reinforcement specified in HG-326.2 and HG-326.3 and shall be limited as set forth in (b), (c), (d), and (e) below. (a) Notation. The symbols used in this paragraph are defined as follows: A] = area in excess thickness in the boiler shell avail able for reinforcement sq in. A2 = area in excess thickness in the nozzle wall avail able for reinforcement sq in. E\ = 1 when an opening is in the solid plate or when the opening passes through a circumferential joint in a shell or cone (exclusive of head-toshell joints) E] = the joint efficiency obtained when any part of the opening passes through any other welded joint tt = thickness of attached reinforcing pad or height of the largest 60 deg. right triangle supported by the vessel and nozzle outside diameter projected surfaces and lying completely within the area of integral reinforcement, in. (see Fig. HG-326) t= nominal thickness of the boiler shell, in. tr = required thickness of a seamless shell or head as defined in HG-321, in. tn = nominal thickness of nozzle wall, in. tm = required thickness of a seamless nozzle wall, in. 24 ARTICLE 3 -- DESIGN Fig. HG-326 FIG. HG-326 SOME REPRESENTATIVE CONFIGURATIONS DESCRIBING THE te REINFORCEMENT DIMENSION 25 ^8-003028 1/17/02 NUECES HG-326.4 1995 SECTION IV HG-328.2 d = diameter in the plane under consideration of the finished opening, in. (See HG-321.2 and Fig. HG-326.) F= factor F from HG-321.2 and Fig. HG-321 (b) Metal in the Boiler Shell Over and Above the Thickness Required to Resist Pressure. The area of the boiler shell available as reinforcement which shall be used is the larger of the values of A\ given by the formulas: Ai = (Eit - F`r)d or = 2(E,r - Ftr)(t + tn) (c) Metal over and above the thickness required to resist pressure in that part of a nozzle wall extending outside the boiler shell. The maximum area in the nozzle wall available as reinforcement which shall be used is the smaller of the values of Ai given by the formulas: Ai = (/,, - trn)5t or A2 = (r,, - rr,,)(5r,, + It,) either the boiler shell or any reinforcing pad used as reinforcement shall be credited with an allowable stress value equivalent to the weaker of the materials con nected by the weld. Boiler-to-nozzle or pad-to-nozzle attachment weld metal within the pad may be credited with a stress value equal to that of the boiler shell or pad, respectively. HG-327.2 Strength of Attachment Material (a) On each side of the plane defined in HG-326.1, the strength of the attachment joining the boiler shell and reinforcement or any two parts of the attached reinforcement shall be at least equal to the smaller of: (1) the strength in tension of the cross section of the element of reinforcement being considered; (2) the strength in tension of the area defined in HG-321 less the strength in tension of the reinforcement area which is integral in the boiler shell as permitted by HG-326.4; (3) the strength of the attachment joint shall be considered for its entire length on each side of the plane of the area of reinforcement defined in HG-326.1. For obround openings, consideration shall also be given to the strength of the attachment joint on one side of the plane transverse to the parallel sides of the opening which passes through the center of the semicircular end of the opening. All metal in the nozzle wall extending inside the boiler shell may be included. No allowance shall be taken for the fact that a differential pressure on an inwardly extending nozzle may cause opposing stress to that of the stress in the shell around the opening. (d) Metal added as reinforcement, exclusive of metal attached only by studs, may be included. (e) Weld metal which is fully continuous with the vessel shell may be included. HG-327 STRENGTH OF REINFORCEMENT HG-327.1 Strength of Nozzle and Added Material. Material in the nozzle wall and added material used for reinforcement shall preferably be the same as that of the boiler shell, but if material with a lower allowable stress value is used, the area provided by such material shall be increased in proportion to the inverse ratio of the allowable stress values of the reinforcement and the boiler shell material. No advantage may be taken of the increased strength of reinforcement material having a higher allowable stress value than the material of the boiler shell. Deposited weld metal outside of HG-328 REINFORCEMENT FOR MULTIPLE OPENINGS HG-328.1 When Limits of Reinforcement Overlap. When any two adjacent openings are spaced at less than two times their average diameter so that their limits of reinforcement overlap, the two openings (or similarly for any larger group of openings) shall be provided with reinforcement in accordance with HG321 with a combined reinforcement that has a strength equal to the combined strength of the reinforcement that would be required for the separate openings. No portion of the cross section shall be considered as applying to more than one opening or be evaluated more than once in a combined area. HG-328.2 Combined Reinforcement for Multiple Openings. When more than two adjacent openings are to be provided with a combined reinforcement, the minimum distance between centers of any two of these openings shall preferably be at least \V2 times their average diameter, and the area of reinforcement between them shall be at least equal to 50% of the total required for these two openings. 26 RS-003030 1/17/02 NUECES HG-328.1 ) ARTICLE 3 -- DESIGN portion of the cross section shall be considered as applying to more than one opening or be evaluated more than once in a combined area. HG-32&2 Combined Reinforcement for Multiple Openings. When more than two adjacent openings are to be provided with a combined reinforcement, the minimum distance between centers of any two of these openings shall preferably be at least lV2 times their average diameter, and the area of reinforcement between them shall be at least equal to 50% of the total required for these two openings. HG-32&2 *I 26.1 R8-003031 1/17/02 NUECES Fig. HG-3262 Includes consideration of these areas if 1995 SECTION IV A96 A97 Exvq Without Reinforcing Element A dtf F + 2tnf, R1 - f,i) Area required dlEit-FtJ - 2tn (E,t- FtJ (1 - frt) 2lf + t,,) tEjt-ty-2t,, lEyt-FtJ (1 - frt) Area available in shell; use larger value *2 Slfji " fml ^2* ^lfn " W ^r2*n A, 2fn Area available in nozzle projecting outward; use smaller value Area available in inward nozzle A1 outward nozzle weld (leg)2fr2 A inward nozzle weld (leg)2frj Area available in outward weld Area available in inward weld If Ai + >4 + A3 + A41 + A43 > A If A| + Ai * A3 + + A<3 < A Opening is adequately reinforced Opening is not adequately reinforced so reinforcing elements must be added and/or thickness must be increased With Reinforcing Element Added A same as A above Area required At = same as Ai above Area available m 6(f,, - fm) 1r2t 2(t,,- tm) (2.5t,, + :#] fr2 At = same as A3 above tlk. Ik " ^ (T' - A*i A42 A3 outward nozzle weld (leg)2^ - outer element weld - (leg)2fr4 inward nozzle weld (leg)2fr2 wmi = As - {Dp- d -2tn) f, [Note (1)] Area available in nozzle projecting outward; use smaller area Area available in inward nozzle Area available in outward weld Area available in outer weld Area available in inward weld Area available in element If Ai + A2 + A3 + A41 + A42 + A*3 + A5 > A Opening is adequately reinforced NOTE: (1) This formula is applicable for a rectangular cross-sectional element that falls within the limits of reinforcement. FIG. HG-326.2 NOMENCLATURE AND FORMULAS FOR REINFORCED OPENINGS (This Figure Illustrates a Common Nozzle Configuration and Is Not Intended to Prohibit Other Configurations Permitted by the Code.) 26.2 R8-003032 1/17/02 NUECES HG-328.2 ARTICLE 3 -- DESIGN HG-330.4 (a) Two adjacent openings as considered under HG328.2 shall have a distance between centers not less than V/3 times their average diameter. (b) In lieu of providing reinforcement for individual openings, reinforcement may be provided for any num ber of closely spaced adjacent openings, in any arrange ment, by providing reinforcement for an assumed open ing of a diameter enclosing all such openings. (c) When a group of openings is provided with reinforcement by a thicker section butt welded into the shell or head, the edges of the inserted section shall be tapered as prescribed in HW-701.1. HG-328.3 When Reinforcing Each of a Series of Openings Is Impractical. When there is a series of tube openings in a boiler and it is impractical to reinforce each opening, the construction will be accept able provided the ligaments between openings are calcu lated by the rules given in HG-350. HG-330 INSPECTION AND ACCESS OPENINGS HG-330.1 General Inspection Openings (a) All boilers shall be provided with suitable man hole openings and handhole or washout plug openings to permit inspection and removal of accumulated sediment. (b) Electric boilers of a design employing a remov able cover which will permit access for inspection and cleaning and having an internal gross volume (exclusive of casing and insulation) of not more than 3 cu ft need not be fitted with washout or inspection openings. Electric boilers equipped with immersion type resist ance elements not provided with a manhole shall have an inspection opening or handhole located in the lower portion of the shell or head. The inspection opening shall not be smaller than 3 in. pipe size. In addition, electric boilers designed for steam service shall have an inspection opening or manhole at or near the normal waterline. (c) Furnaces of internally fired boilers shall be pro vided with access doors as required by HG-330.5. HG-330.2 Manholes. A manhole shall be placed in the front head below the tubes of a horizontal-return tubular boiler 60 in. or over in diameter. There shall be a manhole in the upper part of the shell, or in the head of a firetube boiler over 60 in. in diameter, except in a vertical firetube boiler. HG-3303 Size of Manholes and Gasket Surfaces (a) An elliptical manhole opening shall not be less than 11 in. x 15 in. or 10 in. x 16 in. in size. (b) A circular manhole opening shall not be less than 15 in. in diameter. (c) The minimum width of bearing surface for a gasket on a manhole opening shall be n/16 in. (d) No gasket for use on a manhole or handhole of any boiler shall have a thickness greater than '/g in. when compressed. HG-330.4 Handholes and Washout Plugs (a) Boilers of the locomotive or firebox type, except those set in brick or otherwise so constructed as to render such openings inaccessible, shall have one handhole or washout plug near each comer in the lower part of the waterleg and at least one opening near the line of the crown sheet In addition, boilers designed for steam service shall have at least one inspection opening above the top row of tubes. This inspection opening shall be a minimum of NPS 3 or a handhole as specified in (f) below and used solely for inspection purposes. (b) A boiler of the scotch type shall have a handhole or washout plug in the front head below or on each side of the furnace or on each side of the shell near the front head, a handhole or washout plug in the bottom of the shell, an opening to inspect the top of the furnace and an inspection opening above the top row of tubes. This inspection opening shall be a minimum of NPS 3 or a handhole as specified in (f) below and used solely for inspection purposes. Scotch marine boilers (wet-back type) shall also have an opening for inspection of the water space at the rear of the combus tion chamber. (c) Vertical firetube or similar type boilers having gross internal volume (exclusive of casing and insula tion) more than 5 cu ft shall have at least three handholes or washout plugs in the lower part of the waterleg and at least two handholes or washout plugs near the line of the lower tubesheet. Such boilers having gross internal volume not over 5 cu ft shall have at least two washout openings in the lower part of the waterleg and at least one washout opening near the line of the lower tubesheet. In addition, boilers designed for steam service shall have at least one inspection opening above the lowest permissible water level. This inspection opening shall be a minimum of NPS 3 or a handhole as specified in (f) below and used solely for inspection purposes. (d) Washout plugs shall be not smaller than l'/2 in. pipe size for boilers having gross internal volume more than 5 cu ft. Washout plugs shall be not smaller than 1 in. pipe size for boilers having gross internal volume not more than 5 cu ft. (e) Washout openings may be used for return pipe connections and the washout plug placed in a tee so 27 i/i7/oa NUECES HG-330.4 1995 SECTION IV HG-340.5 that the plug is directly opposite and as close as possible to the opening in the boiler. (f) A handhole opening shall not be less than 23/4 in. x 3'/2 in. but it is recommended that, where possible, larger sizes be used. HG-330.5 Access Doors (a) A fire door or other access not less than 11 in. x 15 in. or 10 in. x 16 in. or 15 in. in diameter, shall be provided for the furnace of an internally fired boiler in which the least furnace dimension is 28 in. or over. The minimum size of access door used in a boiler setting shall be 12 in. x 16 in., or equivalent area, the least dimension being 11 in. (b) Fuel Burning Equipment. Fuel burning equipment may be installed in the fire door opening provided the cover plate can be unbolted or unlatched to give fullsize access to the furnace through the fire door opening. C= 3.1 for stays screwed through plates and fitted with single nuts outside of plate, or with inside and outside nuts, omitting washers C= 3.5 for stays with heads not less than ' .3 times the diameter of the stays screwed through plates, or made a taper fit and having the hciJs formed on the stays before installing them and not riv eted over, said heads being made to have a true bearing on the plate C= 4.0 for stays fitted with inside and outside nuts and outside washers where the diameter of washers is not less than 0.4p and thickness not less than t r= radius of firebox comer, in. (b) When two flat stayed surfaces intersect at an angle as shown in Fig. HG-340.1, the pitch from the staybolt nearest to the intersection to the point of tangency of the comer curve with the plate shall be 90r [CS P = V ~P HG-340 STAYED SURFACES HG-340.1 Required Thickness and Design Pressure (a) The required thickness and design pressure for stayed flat plates and those parts which, by these rules, require staying, as flat plates with stays or .staybolts of uniform cross section that are symmetrically spaced, shall be calculated by the following formulas: / = p V P/SC (1) P = i*SC/p2 (2) where t= required thickness of plate, in. P= design pressure, psi 5 = maximum allowable stress value given in Ta bles HF-300.1 and HF-300.2 p = maximum pitch measured between straight lines passing through the centers of the stays in the different rows, which lines may be horizontal, vertical, or inclined, in. C = 2.7 for stays welded to plates or for stays screwed through plates not over"'/l6 in. in thick ness, with ends riveted over C= 2.8 for stays welded to plates or for stays screwed through plates over 7/16 in. in thickness, with ends riveted over where fl is the angle shown in Fig. HG-340.1. (c) When two plates are connected by stays and only one of these plates requires staying, the value of C shall be governed by the thickness of the plate requiring stoying. .. HG-340.2 Proportions of Through-Stays With Washers. Acceptable proportions for the ends of through-stays with washers are indicated in Fig. HG340.2. HG-340.3 Maximum Pitch of Stays. The maximum pitch shall be 8'/2 in. except that for welded-in stays the pitch may be greater provided it does not exceed 15 times the diameter of the stay. HG-340.4 Unsymmetrical Staying. Where the stay ing of shells is unsymmetrical by reason of the construc tion, it is permissible to consider the load carried by each stay as that on the area calculated by taking the distance from the center of the spacing on one side of the stay to the center of the spacing on the other side. HG-340.5 Stay Distance to Corner Joints, Welded Joints, and Flanges (a) In the construction of a heating boiler designed for not over 30 psi and having welded joints, the allowable distance from a comer welded joint to the nearest row of stays may be a full pitch as provided by the formula in HG-340.1. A welded joint in a flat surface shall be between two rows of stays which are not over one pitch apart except that the type of joint 28 R8-003034 1/17/02 NUECE8 HG-340.5 ARTICLE 3 -- DESIGN HG-341.4 li * Max. r-p as calculated by HG-340.5 Min. rm 3 f If the radius "r* In Fig. HG-340.1 exceeds the pitch, the curved plate shall be stayed as a flat plate in accordance with HG-340. FIG. HG-340.3 EXAMPLES OF ACCEPTABLE CORNER WELDS FOR PRESSURES NOT OVER 30 psi FIG. HG-340.1 PITCH OF STAYBOLTS ADJACENT TO UPPER CORNERS OF FIREBOXES Not less than-2'/2 diameters of bolt as measured on the out side of the threaded portion, but must be 0.4 pitch of stays if C- 4.0 Not less than 1/2 t if C - 3.5 or less, and not less than / if C - 4.0 FIG. HG-340.2 ACCEPTABLE PROPORTIONS FOR ENDS OF THROUGH-STAYS shown in Fig. HG-340.3 shall have a row of stays not more than one pitch from the weld. (b) In the construction of heating boilers to be de signed for water pressures above 30 psi, comer joints shall comply with the requirements of HW-701.3. (c) When the edge of a flat stayed plate is flanged, the distance from the center of the outermost stays to the inside of the supporting flange shall not be greater than the pitch of the stays plus the inside radius of the flange. HG-340.6 Allowable Pitch of Stays. The allowable pitch, in inches, for stays as given in Table HG-340 may be used in place of the pitch calculated under HG-340.1 when the allowable stress of the steel is 11,000 psi or greater. HG-341 STAYBOLTS HG-341.1 Threaded Staybolts. The ends of staybolts extending through the plate shall extend beyond the plate not less than two threads when installed, after which they shall be riveted over or upset by an equiva lent process without excessive scoring of the plate, or they may be fitted with threaded nuts through which the staybolt shall extend. The outside ends of solid staybolts 8 in. or less in length, if of uniform diameter throughout their length, shall be drilled with telltale holes at least 3/16 in. in diameter to a depth extending at least l/2 in. beyond the inside of the plate. If such staybolts are reduced in section below their diameter at the root of the thread, die telltale holes shall extend at legist V2 in. beyond the point where the reduction in section commences. Hollow staybolts may be used in place of solid staybolts with drilled ends. Solid staybolts over 8 in. long need not be drilled. Staybolts used in waterlegs of watertube boilers shall be hollow or drilled at both ends, in accordance with the requirements above stated, irrespective of their length. All threaded staybolts not normal to the stayed surface shall have not less than three engaging threads of which at least one shall be a full thread; but if the thickness of the material in the boiler is not sufficient to give one full engaging thread, the plates shall be sufficiently reinforced on the inside by a steel plate welded thereto. Telltale holes are not required in staybolts attached by welding. HG-341.2 Staybolts Upset for Threading. The ends of steel stays upset for threading shall be fully annealed after upsetting. HG-34U Staybolts Fitted With Nuts. The ends of staybolts fitted with nuts shall not be exposed to direct radiant heat from fire. HG-341.4 Welded-In Staybolts. Requirements for welded-in staybolts are given in HW-710. 29 RS-003035 1/17/02 NUECE8 Table HG-340 TABLE HG-340 ALLOWABLE PITCH OF STAYS, in.2 A95 1995 SECTION IV 0 IH XVs t O CD K MN HH 000 ^c^r^sr N O' N m N rt H rt 0 <0 -S ^_'C s? w* XT' *h r> mmvm rrt rrt rrt rrt 0 0 rv n h' v* t m n n rrt rrt rrt rrt 0 s < N* h' #>' IV CM CM rt rrt rt rt rt CM rt rt O rt rt rt rt >nh\\\\\S rt rt O O rt rt rt rt 00^ <o'o2C-S` rt rt O' O' N N H CO <o ^ NHHH v in' o n in v NHHH n5n?n v* IV IV nn h' n n n n rrt rrt rrt rrt rt rt O O rt rt rt rt N 0 -v v* . . On''s rt O' O' O' a> (N N rrt rrt rrt rrt rrt 0 sr* 2 STiS* 0 ^ rt rt rt O' 00 rr HN r< r* O' O' CO 00 5 2 IN S' 0 <0 0 <o v HHHH 0 <0 *o oo Tn ^ % rrt rt rt rt <0 rS* N N rt rt rrt rrt rrt rrt 0 -S' s" s M IV XV rrt rrt rrt O rrt rrt rrt rrt "o S' -S'-S' rt O' O' O' VS vN Vs O' O' O' CO 0 O' 00 00 00 0 0 0 O-i XV* XsVTs* >'f*ri*v CO CO 00 N II 0 (N 0 ^ Nr*-^ 00 0 00 HV' XT' pH N K\ H rt O Oh sT N S N mv ri' rt H H H rrt rrt rrt O' O' 00 00 CO 0D N N h c 0 N* ^ S- >~>vs ^ ^5* r*> irt'' XV* <0 rt\ N H o oS .ac g rt rrt rt rrt rrt rrt O' 0s CO CO CO N 00 ^ V* s in^* r*. js. ,o i2 o CM S <> xSV xNV- 00 =C>~,,'CSC <0 S' U1 m H O rt rrt rrt rt O' O' O' CO CO N N N 00 -?rsc='r_S' r- o so -o o. & 0 -S' <0 rv * XV in h o o rrt rrt rrt O' csi sr 0 CM rt (O' H H O' O' V ar 0 nT1 J iv* vT <0 -- XT' vf v- H O > nN rrt rrt O' 00 (N rrt 0 rrt O' 00 h 00 O' *C0 0 T* 0 CO CO h* N 00 a^^rr r- r-* r > 0 0 wfrt N 0 O O 0 ,^^,2?'2C N N O O.i <o o m 0 Tn O O 0 <o m m m V h' V ' <o >o n in mmmm 0 ^ V N* r4 XV* IV XVs in in m in 00 2C2C mmv v X ** II ^ oO 3 gO ~II ^ II 0 -0 0 rtS* \N S-^ -- x' in'* pO' <0 N *0 IN ov^!? 0 oo h> <o <io ^ 0 s'" <o <o c m 0 VHH 0 -- V IV r> in in in in 0 -S_S1^2C mmc 0 00 irn- ' usV" vT1 nn xsvT** fTV V <0 vNp>l*> m s >o -0 <0 vT1 s9> m V0H X0 0 ^S' 5^ mv v v 0 .. 8 o x<u 2 *2S b.* *T 3 /) s- 0. & C o> 41 Q oooo n it m >o moo N N CO O' o o o in O rt CM CM rt rrt rt rt oooo tn fl' in iO rrt rt rrt rt jj <M II *5. zC 30 os-00303 1I1TIW NUECES HG-342 ARTICLE 3 -- DESIGN HG-345.1 HG-342 DIMENSIONS OF STAYS HG-342.1 Required Area of Stays. The required area of a stay at its minimum cross section (usually at the root of the thread) and exclusive of any allowance for corrosion shall be obtained by dividing the load on the stay computed in accordance with HG-342.2, HG-342.3, and HG-342.4 by the allowable stress value for the material. HG-342.2 Load Carried by Stays. The area sup ported by a stay shall be computed on the basis of the full pitch dimensions with a deduction for the area occupied by the stay. The load carried by a stay is the product of the area supported by the stay and the design pressure. HG-342.3 Stays Longer Than 120 Diameters. Stays exceeding 120 diameters in length shall be supported at intervals not exceeding 120 diameters or the crosssectional area of the stay shall be increased by not less than 15% of die required area of the stays calculated in HG-342.1. HG-342.4 Stays Fabricated by Welding. Stays made of parts jointed by welding shall be computed for strength using a joint efficiency of 60% for the weld. Welded stays shall be used only where it is impractical to use stays of one-piece construction. HG-342^ Minimum Cross-Sectional Area. No fer rous screwed stay, or ferrous stay welded in by the fusion process of welding shall have a cross-sectional area less than 0.44 sq in. Copper-Nickel Plate Thickness, in. Not exceeding '/% Over '/(, but not over 3/lt Over 3/|6 Min. Staybolt Diameter, in. V, 7/l6 '/2 HG-343 DIMENSIONS OF DIAGONAL STAYS HG-343.1 Required Area of Diagonal Stays. To determine the required area of a diagonal stay, multiply the area of the direct stay, required to support the surface, by the slant or diagonal length of the stay; divide this product by the length of a line (drawn perpendicular to the surface supported) to the center of the palm of the diagonal stay, as follows: aL A =-- l where A = sectional area of diagonal stay, sq in. a = sectional area of direct stay, sq in. L= length of diagonal stay as indicated in Fig. HG343, in. / = length of line, drawn perpendicular to boiler head or surface supported, to center of palm of diagonal stay, as indicated in Fig. HG-343, in. Example: Given diameter of direct stay = 1 in., a = 0.7854 sq in., L=60 in., /=48 in.; substituting and solving: 0.7854 x 60 A =----------------= 0.98 sectional area, sq in. 48 HG-342.6 Minimum Diameter of Nonferrous Stays (a) For nonferrous staybolted construction using un threaded copper staybolts and copper plates, the mini mum diameter of the staybolts shall be as follows: Copper Plate Thickness, in. Not exceeding '/j Over '/j, but not over 3/,6 Over 3/|6 Min. Staybolt Diameter, in. '/j \ 34 (b) For nonferrous staybolted construction using un threaded copper-nickel staybolts and copper-nickel plates, the minimum diameter of staybolts shall be as follows: Diameter = 1.11 in. (Use l'/g in.) HG-343.2 Diagonal Stays for Segments of Tubesheets. For staying segments of tubesheets such as in horizontal firetube boilers, where L is not more than 1.15 times / for any stay, the stays may be calculated as direct stays using 90% of the allowable stress values calculated in HG-342.1. HG-345 STAYING OF HEADS HG-345.1 General (a) Those portions of heads which require staying shall be stayed as fiat plates under the provisions of these rules. 31 RS-003037 1/17/02 NUECES HG-345.1 1995 SECTION IV HG-345.1 NOTES: 1. Determine area of diagonal stays per HG-343.1 2. Determine weld details and weld size for stay-to-tubesheet and stay-to-shell per HW-710 3. Determine diagonal stay pitch per HG-340.1 4. Max. r8t Min. r 3 f t" nominal thickness of tubesheet FIG. HG-343 DETAILS OF INSTALLATION OF DIAGONAL STAYS (b) For unflanged heads in boilers designed for not over 30 psi pressure, with the heads attached with single fillet welds in accordance with HW-701.3(a), staying is not required if the greatest distance measured along a radial line from the inner surface of the shell to a fully supported line or point does not exceed 1.25/j. For unflanged heads in boilers designed for over 30 psi with heads attached in accordance with HW701.3(b), or for flanged heads of any pressure, staying is not required if the greatest distance measured as above does not exceed 15p. The value of p shall be obtained by applying the equation of HG-340 with a C value of 2.7 or 2.8 depending on the plate thickness. (c) For purposes of applying the above paragraph a fully supported point is <i stay rod or tube passed through the head and welded, having sufficient area to meet the requirements of HG-342, and having an area of weld in shear at least 1.25 times the required area of the staying member. A fully supported line is a flanged or welded comer joint or is a line tangent to a row of tubes or stays not over one pitch apart between edges and extending to within one pitch of the shell or the diametrically opposite side of the shell. (d) For unflanged heads, the maximum distance be tween the inner surface of the shell and the centers of stays shall not be more than the allowable pitch as determined by HG-340, using the value of C given for the thickness of plate and the type of stay used. (e) For a flanged head welded to the shell, the maximum distance between the inner surface of the supporting flange and lines parallel to the surface of the shell passing through the centers of the stays shall be p as determined by the formula in HG-340, plus the inside radius of the supporting flange, using the value of C given for the thickness of plate and the type of stay used. (f) The maximum distance between the edges of the tube holes and the center'of the first row of stays shall be p as determined by the formula in HG-340, using the value of C given for the thickness of plate and the type of stay used. (g) When a portion of the head in a horizontal firetube boiler is provided with a manhole opening, the flange of which is formed from the solid plate and turned inward to a depth of not less than three times the required thickness of the head, measured from the outside or, when an unflanged manhole ring meeting the requirements of HG-321 is provided in a flat stayed head of a firetube boiler, the area to be stayed may be reduced by 100 sq in. provided both the following requirements are met [see Figs. HG-345.1 (a) and HG345.1 (b)]. 32 RS-003038 1/17/02 NUECES /I 3 ARTICLE 3 -- DESIGN U Fig. HG-345.1(a) CO DC CO LOi. o > H< (/) lii o m cn o o z o <o CL cl < o 5 o X CO Ho-- UJ CO 'ffl LO <c3no o 33 RS-003039 1/17/02 NUECES Fig. HG-345.1(b) U 1995 SECTION IV o c<0 co uL X A to Eo JJ .tOo $ o coa3. -- co ss E6 !i EO) 1! ffol gpft- (0 o =1 PO .I-230bOI) -0ux0o)) o *- c <>A *3.E 00 Q Ld QOO o 2o > < 00 o m coni Ll. o 2 O <o Q. o_ < o 5 o 00 o 00 S' in cni <3 O I oo 5 : UJ o 5 2 "D -J -- C<C 2. UJ 2ui c O i- CM CO osg Nueces HG-345.1 ARTICLE 3 -- DESIGN HG-350.1 (1) The distance between the manhole opening and the inner surface of the supporting flange does not exceed one-half the maximum allowable pitch for an unflanged manhole or one-half the maximum allowable pitch plus the inside radius of the supporting flange for a flanged-in manhole in a flanged head. (2) The distance between the centers of the first row of stays, or the edges of the tube holes, and the manhole opening does not exceed one-half the maximum allowable pitch as determined by HG-340. HG-346 TUBESHEETS WITH FIRETUBES USED AS STAYS HG-346.1 Required Thickness, Maximum Pitch, and Design Pressure, The required thickness, maximum pitch, and design pressure for tubesheets with firetubes used as stays shall be calculated using the following formulas: HG-345.2 Flanged Heads (a) The area of a segment of a flanged head to be stayed shall be the area enclosed by lines drawn 2 in. from the tubes and a distance of 3 in. from the shell, as shown in Fig. HG-345.2. (b) The net area to be stayed in a segment of a flanged head may be determined by the following formula: 4(H-d- 2? j 2(R - d) 0.608 3 V H-d-l where A = area to be stayed, sq in. H= distance from tubes to shell, in. R = radius of boiler head, in. d= 3 in. (See Fig. HG-345.2.) HG-345.3 Unflanged Heads (a) The area of a segment of an unflanged head to be stayed shall be the area enclosed by the shell and a line drawn 2 in. from the tubes. (b) The net area to be stayed in a segment of an unflanged head may be determined by the following formula: 4(h - if r^R~ 0.608 3 y (H - 2) where: t= required thickness of plate, in. p = maximum pitch measured between the centers of tubes in different rows, which lines may be horizontal, vertical, or inclined, in. C = 2.7 for firetubes welded to plates not over ' *7/16 in. in thickness '' C = 2.8 for firetubes welded to plates over 7/16 in. in thickness 5 = maximum allowable stress value given in Ta bles HF-300.1 and HF-300.2 P= design pressure, psi D = outside diameter of the tube, in. HG-346.2 Maximum Pitch of Firetubes Used as Stays. The pitch of firetubes used as stays shall not exceed 15 times the diameter of the tube. HG-3463 Dimensions and Welding of Firetubes Used as Stays (a) The dimensions of firetubes used as stays shall meet the requirements of HG-312.2 and HG-342. (b) Firetubes welded to the tubesheet and used as stays shall meet the requirements of HW-713. HG-350 LIGAMENTS HG-350.1 General. The rules in this paragraph apply to groups of openings which form a definite pattern in cylindrical pressure parts and to openings spaced not more than two diameters center to center. 35 ^8-003041 1/17/02 NUECES HG-350.1 1995 SECTION IV HG-350.4 5'/. 554 554 5% 554 554 554 __ Vvsvr TT] `in` \) LIJ L iiV v L) L ) N-4 NV Longitudinal Line FIG. HG-345.2 METHOD OF DETERMINING NET AREA OF IRREGULAR SEGMENT OF A HEAD FIG. HG-350.1 EXAMPLE OF TUBE SPACING WITH PITCH OF HOLES EQUAL IN EVERY ROW (a) The symbols defined below are used in the formulas of this paragraph: p = longitudinal pitch of adjacent openings, in. p' = diagonal pitch of adjacent openings, in. p" = transverse pitch of adjacent openings, in. /?] = pitch between corresponding openings in a se ries of symmetrical groups of openings, in. d= diameter of openings, in. n = number of openings in length px E = efficiency of ligament (b) The efficiency of ligaments between openings is defined as the ratio of the average strength of the material between adjacent openings to the average strength of the plate away from the openings. Where a series of openings has more than one efficiency, the lowest value shall govern. (c) The pitch shall be measured on the fiat plate before rolling. HG-350.2 Openings Parallel to Shell Axis. The ligament efficiency shall be determined as follows. (a) For equal pitch of openings in every row (see Fig. HG-350.1), the efficiency is given by the formula: P (b) For unequal pitch in symmetrical groups of open ings (as in Figs. HG-350.2 and HG-350.3), the efficiency is given by the formula: Px-nd E= Pi (2) (c) For openings which do not fall into symmetrical groups, the efficiency shall be the value calculated as follows for the group of openings which gives the lowest efficiency: VV St Sinr w--9 -554 6% t>'/4 D7 D4 rLJ[),nL 0 LI) L ) L ) L J r Vi:f\/Lj -LC\p)t r^ L K. <------- 12 in. r n D/ IT vL / N. Longitudinal Line FIG. HG-350.2 EXAMPLE OF TUBE SPACING WITH PITCH OF HOLES UNEQUAL IN EVERY SECOND ROW (1) the efficiency given by Formula (2) above using pi equal to the inside diameter of the shell or 60 in., whichever is less; (2) 1.25 times the efficiency given by Formula (2) above using pt equal to the inside radius of the shell or 30 in., whichever is less. HG-350.3 Openings Transverse to Shell Axis. The ligament efficiency of openings spaced at right angles to the axis of the shell is equal to two times the efficiency of similarly spaced holes parallel to the shell axis as calculated in accordance with the rules in HG350.2. HG-350.4 Holes Along a Diagonal. The ligament efficiency shall be determined as follows. (a) The efficiency of openings which are equally spaced along diagonal lines (see Fig. HG-350.4) is given by the formula: p'-d p'F (3) where F is a factor from Fig. HG-321 for the angle which the diagonal makes with a plane through the longitudinal axis of the boiler. 36 RS-003042 1/17/W NUECES HG-350.4 ARTICLE 3 -- DESIGN c 554 DVY 6% VY .5% VY 6% 6* V) YVJVw^ 554 6% 1,554 5-5-4 vVY VY VN in. VYkY^ r k ) ) (\Ak/d Y r^ ^ r kj J>1 V ^ V (\ N J rK VY (\ ^ ^) rKikj c\\j -2954 In Longitudinal Line FIG. HG-3503 EXAMPLE OF TUBE SPACING WITH PITCH OF HOLES VARYING IN EVERY SECOND AND THIRD ROW HG-360.2 FIG. HG-350.4 EXAMPLE OF TUBE SPACING WITH TUBE HOLES ON DIAGONAL LINES (b) The ligament efficiency of openings which are unequally spaced along diagonal lines shall be deter mined as in HG-350.1(c) except that Formula (3) shall be used in place of Formula (2). HG-360 REQUIREMENTS FOR TUBE HOLES AND TUBE ATTACHMENTS HG-360.1 Tube Holes and Ends (a) Tube holes shall be drilled full size from the solid plate, or they may be punched '/2 in- smaller in diameter than full size when the plate thickness exceeds 3/g in. and Vg in. smaller in diameter than full size when the plate thickness is 3/g in. or less, and then drilled, reamed, or finished full size with rotating cutters. Tube holes may be counterbored where the metal is thicker than that required to get a proper bearing by expanding, so as to form narrow seats into which the tube ends can properly expand, provided there is space available to permit a proper amount of flare of the tube end. (b) The sharp edges of tube holes shall be taken off on both sides of the plate with a file or other tool. HG-360.2 Requirements for Tube Attachment Ends of firetubes may be expanded, expanded and flared, expanded and beaded, expanded and welded, or welded. Firetubes attached by expanding and welding or welding shall comply with HW-713. Firetubes attached by expanding and flaring or expanding shall comply with the following: (a) If the firetube ends are in contact with primary furnace gases, the tubes shall extend beyond the tubesheet a distance not less than the tube thickness or */g in., whichever is greater, but not more than V4 in. or the tube thickness, whichever is greater. (b) If the firetube ends are not in contact with primary furnace gases, the tubes shall extend beyond the tubesheet a distance not less than the tube thickness or !/g in., whichever is greater, but not more than 3/g in. or the tube thickness, whichever is greater. (c) Watertubes may be attached by expanding, ex panding and flaring, expanding and beading, expanding and welding, or welding. Where attached by other than expanding and beading, the tubes shall extend beyond the tubesheet a distance not less than `/4 in. nor more than V2 in. Watertubes not exceeding 2 in. O.D. with welded tapered ferrules, when not expanded, expanded and flared, expanded and beaded, expanded and welded, or welded, may be attached mechanically. When such method of attachment is used, the tapered ferrule shall completely penetrate the head or drum and be mechani cally clamped to the header or drum with bolting of no less than 3/g in. diameter, and the tubing shall not be used to support the pressure vessel. (d) Where firetubes or watertubes are attached by welding, the tube holes may be drilled, flame cut, or A97 A97 A97 37 RS-003043 1/17/02 NUECES HG-360.2 1995 SECTION IV HG-370.2 punched. The tube holes may be punched full size provided the thickness of the tubesheet does not exceed s/l6 in. The diameter of the tube hole in any case shall not be more than V32 in. greater than the outside diameter of the tube. Where tubes are attached by fillet welding from one side only to a tubesheet exceeding 5/16 in. thickness, the tubes shall be expanded before being welded. Tubes may be attached by welding as provided in HW-713. (e) Watertubes in hot water boilers may be installed into headers with the use of O-ring seals in lieu of expanding, welding, or brazing, provided the following conditions are met. (]) The watertube shall not exceed 2 in. outside diameter, nor 12 ft in length. (2) The tube hole diameter shall be not more than V32 in- larger than the outside diameter of the tube. (3) The tube hole shall be recessed to accommodate the O-ring. (4) The cross section of the O-ring shall have a diameter not less than '/8 in. nor greater than V4 in. (5) The outside diameter of the O-ring shall not be less than the outside diameter of the recessed groove. (6) The inside, diameter of the O-ring shall be at least V32 in. smaller than the outside diameter of the tube. (7) The O-ring material shall be ASTM D 2000 M3GE 705 A19 silicon. (8) The O-ring shall be located or shielded from the combustion chamber in such a manner that the temperature of the O-ring shall not exceed 450F. (9) The headers shall be held together by stay rods adequately designed to carry the end loading and prevent the headers from spreading apart. The design stress of the stay rods shall not exceed that permitted in the appropriate stress table in Section IV. (10) Means shall be provided to prevent the tubes from losing contact with the O-ring seal due to tube movement without loosening the stay rods. (11) If the tube length exceeds 6 ft, the tubes shall be supported at their midlength. TABLE HG-370 MINIMUM THICKNESS OF MATERIAL FOR THREADED CONNECTIONS TO BOILERS Size of Pipe Connection, in. Under \ V< to 1, ind. I1/* to 2V2, ind. 3 to 3Vi, ind. 4 to 5, ind. 6 to 8, ind. 9 to 12, ind. Minimum Thickness of Material Required, in. v 54* 74* v, Ve 1 I1/, HG-370 EXTERNAL PIPING CONNECTIONS HG-370.1 Threaded Connections. Pipe connections, if threaded, shall be tapped into material having a minimum thickness as specified in Table HG-370, except that when a curved surface is to be tapped the minimum thickness shall be sufficient to permit at least four full threads to be engaged. HG-370.2 Flanged Connections (a) It is recommended that dimensional requirements of bolted flange connections to external piping conform to ANSI B16.5, Steel Pipe Flanges and Flanged Fittings. Such flanges may be used for pressure-temperature ratings in accordance with the Standard. (b) Steel flanges which do not conform to ANSI B16.5 shall be designed in accordance with the rules in Appendix II of Section VUI, Division 1, for the design pressure and temperature conditions. The outside diameter , and bolting shall conform to a standard ap proved by ANSI. 38 RS-003044 1/17/02 NUECES ARTICLE 4 PRESSURE RELIEVING DEVICES HG-400 PRESSURE RELIEVING VALVE REQUIREMENTS A96 A96 HG-400.1 Safety Valve Requirements for Steam Boilers (a) Each steam boiler shall have one or more offi cially rated safety valves that are identified with the V or HV Symbol of the spring pop type adjusted and sealed to discharge at a pressure not to exceed IS psi. (b) No safety valve for a steam boiler shall be smaller than NPS l/2. No safety valve shall be larger than NPS 4'/2- The inlet opening shall have an inside diameter equal to, or greater than, the seat diameter. (c) The minimum relieving capacity of valve or valves shall be governed by the capacity marking on the boiler called for in HG-530. (d) The minimum valve capacity in pounds per hour shall be the greater of that determined by dividing the maximum Btu output at the boiler nozzle obtained by the firing of any fuel for which the unit is installed by 1000, or shall be determined on the basis of the pounds of steam generated per hour per square foot of boiler heating surface as given in Table HG-400.1. For cast iron boilers constructed to the requirements of Part HC, the minimum valve capacity shall be determined by the maximum output method. In many cases a greater relieving capacity of valves will have to be provided than the minimum specified by these rules. In every case, the requirement of HG-400.1(e) shall be met. (e) The safety valve capacity for each steam boiler shall be such that with the fuel burning equipment installed, and operated at maximum capacity, the pres sure cannot rise more than 5 psi above the maximum allowable working pressure. (f) When operating conditions are changed, or addi tional boiler heating surface is installed, the valve capacity shall be increased, if necessary, to meet the new conditions and be in accordance with HG-400.1(e). The additional valves required, on account of changed TABLE HG-400.1 MINIMUM POUNDS OF STEAM PER HOUR PER SQUARE FOOT OF HEATING SURFACE Boiler Heating Surface Firetube Boilers Watertube Boilers Hand fired Stoker fired Oil, gas, or pulverized fuel fired Waterwall heating surface: Hand fired Stoker fired Oil, gas, or pulverized fuel fired 56 78 8 10 88 10 12 14 16 GENERAL NOTES: (a) When a boiler is fired only by a gas having a heat value not in - excess of 200 Btu/cu ft, the minimum safety valves or safety relief valve relieving capacity may be based on the values given for hand fired boilers above. (b) The minimum safety valve or safety relief valve relieving capacity ' for electric boilers shall be 3^ Ib/hr/Vw input (c) For heating surface determination, see HG-403. conditions, may be installed on the outlet piping pro vided there is no intervening valve. HG-400.2 Safety Relief Valve Requirements for Hot Water Boilers (a) Each hot water heating or supply boiler shall have at least one officially rated safety relief valve, of the automatic reseating type, identified with the V or HV Symbol, and set to relieve at or below the maximum allowable working pressure of the boiler. (b) Hot water heating or supply boilers limited to a water temperature not in excess of 210F may have, in lieu of the valve(s) specified in (a) above, one or more officially rated temperature and pressure safety relief valves of the automatic reseating type identified with the HV symbol, and set to relieve at or below the maximum allowable working pressure of the boiler. (c) When more than one safety relief valve is used on either hot water heating or hot water supply boilers. A96 A97 rS-003048 1/17/02 NUECES HG-400J 1995 SECTION IV HG-401.1 the additional valves shall be officially rated and may have a set pressure within a range not to exceed 6 psi above the maximum allowable working pressure of the boiler up to and including 60 psi, and 5% for those having a maximum allowable working pressure ex ceeding 60 psi. (d) No safety relief valve shall be smaller than NPS 3/4 nor larger than NPS 4V2 except that boilers having a heat input not greater than 15,000 Btu/hr may be equipped with a rated safety relief valve of NPS */2. (e) The required steam relieving capacity, in pounds per hour, of the pressure relieving device or devices on a boiler shall be the greater of that determined by dividing the maximum output in Btu at the boiler nozzle obtained by the firing of any fuel for which the unit is installed by 1000, or shall be determined on the basis of pounds of steam generated per hour, per square foot of boiler heating surface as given in Table HG-400.1. For cast iron boilers constructed to the requirements of Part HC, the minimum valve capac ity shall be determined by the maximum output method. In many cases a greater relieving capacity of valves will have to be provided than the minimum specified by these rules. In every case, the requirements of HG400.2(g) shall be met (f) When operating conditions are changed, or addi tional boiler heating surface is installed, the valve capacity shall be increased, if necessary, to meet the new conditions and shall be in accordance with HG400.2(g). The additional valves required, on account of changed conditions, may be installed on the outlet piping provided there is no intervening valve. (g) Safety relief valve capacity for each boiler with a single safety relief valve shall be such that with the fuel burning equipment installed and operated at maximum capacity, the pressure cannot rise more than 10% above the maximum allowable working pressure. When more than one safety relief valve is used, the overpressure shall be limited to 10% above the set pressure of the highest set valve allowed by HG400.2(a). A97 HG-400.3 Safety and Safety Relief Valves for Tanks and Heat Exchangers (a) Steam to Hot Water Supply. When a hot water supply is heated indirectly by steam in a coil or pipe within the service limitations set forth in HG-101, the pressure of the steam used shall not exceed the safe working pressure of the hot water tank, and a safety relief valve at least NPS 1, set to relieve at or below the maximum allowable working pressure of the tank, shall be applied on the tank. (b) High Temperature Water to Water Heat Ex changer. 1 When high temperature water is circulated through the coils or tubes of a heat exchanger to warm water for space heating or hot water supply, within the service limitations set forth in HG-101, the heat exchanger shall be equipped with one or more officially rated safety relief valves that are identified with the V or HV Symbol, set to relieve at or below the maximum allowable working pressure of the heat exchanger, and of sufficient rated capacity to prevent the heat exchanger pressure from rising more than 10% above the maximum allowable working pressure of the vessel. (c) High Temperature Water to Steam Heat Ex changer.' When high temperature water is circulated through the coils or tubes of a heat exchanger to generate low pressure steam, within the service limitations set forth in HG-101, the heat exchanger shall be equipped with one or more officially rated safety valves that are identified with the V or HV Symbol, set to relieve at a pressure not to exceed 15 psi, and of sufficient rated capacity to prevent the heat exchanger pressure from rising more than 5 psi above the maximum allowable working pressure of the vessel. For heat exchangers requiring steam pressures greater than 15 psi, refer to Section I or Section Vm, Division 1. HG-401 MINIMUM REQUIREMENTS FOR SAFETY AND SAFETY RELIEF VALVES HG-401.1 Mechanical Requirements (a) The inlet opening shall have an inside diameter approximately equal to, or greater than, the seat diame ter. In no case shall the maximum opening through any part of the valve be less than '/4 in. in diameter or its equivalent area. (b) Safety .relief valves officially rated as to capacity shall have pop action when tested by steam. (c) O-rings or other packing devices when used on the stems of safety relief valves shall be so arranged as not to affect their operation or capacity. (d) The design shall incorporate guiding arrangements necessary to insure consistent operation and tightness. Excessive lengths of guiding surfaces should be avoided. Bottom guided designs are not permitted on safety relief valves. (e) Safety valves shall have a controlled blowdown of 2 psi to 4 psi and this blowdown need not be adjustable. A96 A96 A96 A96 A96 `Suggested installation practices for the secondary side of heat exchangers. 40 rs-403046 1117/02 NUECES HG-401.1 ARTICLE 4 -- PRESSURE RELIEVING DEVICES HG-40U (c) O-rings or other packing devices when used on the stems of hot water safety relief valves shall be so arranged as not to affect their operation or capacity. (d) The design shall incorporate guiding arrangements necessary to insure consistent operation and tightness. Excessive lengths of guiding surfaces should be avoided. (e) Steam valves shall have a controlled blowdown of 2 psi to 4 psi and this blowdown need not be adjustable. (f) The spring shall be designed so that the full lift spring compression shall be no greater than 80% of the nominal solid deflection. The permanent set of the spring (defined as the difference between the free height and height measured 10 min after the spring has been compressed solid three additional times after presetting at room temperature) shall not exceed 0.5% of the free height. (g) There shall be a lifting device and a mechanical connection between the lifting device and the disk capable of lifting the disk from the seat a distance of at least '/16 in. with no pressure on the boiler. (h) A body drain below seat level shall be provided by the Manufacturer for all safety valves and safety relief valves, except that the body drain may be omitted when the valve seat is above the bottom of the inside diameter of the discharge piping. For valves exceeding NPS 2V2 the drain hole or holes shall be tapped not less than NPS For valves NPS 2V2 or smaller, the drain hole shall not be less than '/4 in. in diameter. Body drain connections shall not be plugged during or after field installation. In hot water relief valves of the diaphragm type, the space above the diaphragm shall be vented to prevent a buildup of pressure above the diaphragm. Hot water relief valves of the diaphragm type shall be so designed that failure or deterioration of the diaphragm material will not impair the ability of the valve to relieve at the rated capacity. (i) In the design of the body of the valve consider ation shall be given to minimizing the effects of water deposits. (j) Valves shall be provided with wrenching surfaces to allow for normal installation without damaging op erating parts. (k) The set pressure tolerances, plus or minus, of steam safety valves shall not exceed 2 psi, and for safety relief valves shall not exceed 3 psi for pressures up to and including 60 psig and 5% for pressures above 60 psig. HG-401.2 Material Selection (a) Cast iron seats and disks are not permitted. (b) Adjacent sliding surfaces such as guides and disks shall both be of corrosion resistant material. (c) Springs of corrosion resistant material or having a corrosion resistant coating are required. (d) Material for seats and disks should be such as to provide a reasonable degree of resistance to steam cutting. (e) Material for valve bodies and bonnets or their corresponding metallic pressure containing parts shall be listed in Section II, except that in cases where a manufacturer desires to make use of materials other than those listed in Section n, he shall establish and maintain specifications requiring equivalent control of chemical and physical properties and quality. HG-4013 Manufacture and Inspection (a) A Manufacturer shall demonstrate to the satisfac tion of an ASME designee that his manufacturing, production, and testing facilities and quality control procedures will insure close agreement between the performance of random production samples and the performance of those valves submitted for capacity certification. (b) Manufacturing, inspection, and test operations including capacity are subject to inspections at any time by an ASME designee. (c) A Manufacturer may be granted permission to apply the HV Code Symbol to production pressure relief valves capacity certified in accordance with HG402.3 provided the following tests are successfully completed. This permission shall expire on the fifth anniversary of the date it is initially granted. The permission may be extended for 5 year periods if the following tests are successfully repeated within the 6 month period before expiration. (!) Two sample production pressure relief valves of a size and capacity within the capability of an ASME accepted laboratory shall be selected by an ASME designee. (2) Operational and capacity tests shall be con ducted in the presense of an ASME designee at an ASME accepted laboratory. The valve Manufacturer shall be notified of the time of the test and may have representatives present to witness the test. (3) Should the valve fail to relieve at or above its certified capacity or should it fail to meet performance requirements of this Section, the test shall be repeated at the rate of two replacement valves, selected in accordance with HG-401.3(c)(l), for each valve that failed. (4) Failure of any of the replacement valves to meet the capacity or the performance requirements of this Section shall be cause for revocation within 60 days of the authorization to use the Code Symbol on that particular type of valve. During this period, the 41 RS-003047 1/17/02 NUECES HG-401J 1995 SECTION IV HG-402.3 Manufacturer shall demonstrate the cause of such defi ciency and the action taken to guard against future occurence, and the requirements of HG-401.3(c) above shall apply. HG-401.4 Manufacturer's Testing (a) Every steam valve shall be tested to demonstrate its popping point, blowdown, and tightness. Every hot water valve shall be tested to demonstrate its opening point and tightness. Steam valves shall be tested on steam or air and hot water valves on water, steam, or air. When the blowdown is nonadjustable, the blowdown test may be performed on a sampling basis. (b) A Manufacturer shall have a well-established program for the application, calibration, and mainte nance of test gages. (c) Testing time on steam valves shall be sufficient, depending on size and design, to insure that test results are repeatable and representative of field performance. (d) Test fixtures and test drums shall be of adequate size and capacity jo assure representative pop action and accuracy of blowdown adjustment. (e) A tightness test shall be conducted at maximum expected operating pressure, but not at a pressure exceeding the reseating pressure of the valve. HG-401.5 Design Requirements. At the time of the submission of valves for capacity certification, or testing in accordance with this Section, the ASME Designee has the authority to review the design for conformity with the requirements of this Section, and to reject or require modification of designs which do not conform, prior to capacity testing. HG-402 DISCHARGE CAPACITIES OF SAFETY AND SAFETY RELIEF VALVES HG-402.1 Valve Markings. Each safety or safety relief valve shall be plainly marked with the required data by the Manufacturer in such a way that the markings will not be obliterated in service. The markings shall be stamped, etched, impressed, or cast on the valve or on a nameplate which shall be securely fastened to the valve. The markings shall include the following: (a) the name or an acceptable abbreviation of the Manufacturer; (b) Manufacturer's design or type number; (c) NPS size _______ in. (the nominal pipe size of the valve inlet); (d) set pressure _______ psi ; (e) capacity _______ lb/hr, or capacity _______ Btu/hr in accordance with HG-402.3; FIG. HG-402 OFFICIAL SYMBOL FOR STAMP TO DENOTE THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS' STANDARD if) year built or, alternatively, a coding may be marked on the valves such that the valve Manufacturer can identify the year the valve was assembled and tested; .. - (g) ASME Symbol as shown in Fig. HG-402. HG-402.2 Authorization to Use ASME Stamp. Each safety valve to which the Code Symbol (Fig. HG-402) is to be applied shall be produced by a Manufacturer and/or Assembler who is in possession of a valid Certificate of Authorization. (See HG-540.) HG-402.3 Determination of Capacity to Be Stamped on Valves. The Manufacturer of the valves that are. to be stamped with the Code symbol shall submit valves for testing to a place where adequate equipment and personnel are available to conduct pres sure and relieving-capacity tests which shall be made in the presence of and certified by an authorized observer. The place, personnel, and authorized observer shall be approved by the Boiler and Pressure Vessel Committee. The valves shall be tested in one of the following three methods. (a) Coefficient Method. Tests shall be made to deter mine the lift, popping, and blowdown pressures, and the capacity of-at least three valves each of three representative sizes (a total of nine valves). Each valve of a given size shall be set at a different pressure. However, safety valves for steam boilers shall have all nine valves set at 15 psig. A coefficient shall be established for each test as follows: Actual steam flow Kd = ------------------------------ = Coefficient of Theoretical steam flow discharge The average coefficient of the tests required shall be taken as the coefficient K of the design, and the stamped capacity for all sizes and pressures of the design shall not exceed the value determined from the following formulas: 42 RS-003048 1/17/02 NUECES HG-402-3 ARTICLE 4 -- PRESSURE RELIEVING DEVICES HG-402.6 For 45 deg. seat, W = (51.45 irDLP x 0.707AT) 0.90 Maximum slope = average slope x 1.05 For flat seat, W = (51.45 ttDLPK) 0.90 For nozzle, W = (51.45 APK) 0.90 where W= weight of steam/hr, lb D = seat diameter, in. L= lift, in. P-- absolute pressure, psi (accumulated) Kd= coefficient of discharge for a single test K= average coefficient of discharge A = nozzle-throat area, sq in. NOTE: The maximum and minimum coefficient determined by the tests of a valve design shall not vary more than 5% from the average. If one or more tests ate outside the acceptable limits, one valve of the Manufacturer's choice shall be replaced with another valve of the same size and pressure setting or by a modification of the original valve. Following this test a new average coefficient shall be calculated, excluding the replaced valve test If one or more tests are now outside the acceptable limits, as determined by the new average coefficient, a valve of the Manufacturer's choice must be replaced by two valves of the same size and pressure as the rejected valve. A new average coefficient, including the replacement valves, shall be calculated. If any valve, excluding the two replaced valves, now falls outside the acceptable limits, the tests shall be considered unsatisfactory. (b) Slope Method. If a Manufacturer wishes to apply the Code Symbol to a design of pressure relief valves, four valves of each combination of pipe and orifice size shall be tested. These four valves shall be set at pressures that cover the approximate range of pressures for which the valve will be used, or that cover the range available at the certified test facility that shall conduct the tests. The capacities shall be based on these four tests as follows. (1) The slope (dW/dP) of the actual measured relieving capacity versus the flow pressure for each test point shall be calculated and averaged: Slope -- dW/dP = measured capacity/absolute flow pressure (psia) All values derived from the testing must fall within plus or minus 5% of the average value: Minimum slope = average slope x 0.95 If the slope values derived from the test do not fall between the minimum and maximum slope values, the authorized observer shall require that additional valves be tested at the rate of two for each value beyond the maximum and minimum values with a limit of four additional valves. (2) The relieving capacity to be stamped on the valve shall not exceed 90% of the average slope times the absolute flow pressure: W average slope [(stamped set pressure x 1.10) + 14.7] 0.90 (c) Three-Valve Method. If a Manufacturer wishes to apply the Code Symbol to steam safety valves or safety relief valves of one or more sizes of a design set at one pressure, he shall submit three valves of each size of each design set at one pressure for testing and the stamped capacity of each size shall not exceed 90% of the average capacity of the three valves tested. NOTE: The discharge capacity as determined by the test of each valve tested shall not vary by mote than 5% of the average capacity of the three valves tested. If one of the three valve tests falls outside of the limits, it may be replaced by two valves and a new average calculated based on all four valves, excluding the replaced valve. HG-402.4 Pressures at Which Capacity Tests Shall Be Conducted. Safety valves for steam boilers shall be tested for capacity at 5 psi over the set pressure for which the valve is set to operate. Capacity certifica tion tests of safety relief valves for hot water heating and hot water supply boilers shall be conducted at 110% of the pressure for which the valve is set to operate. . HG-402.5 Opening Tests of Pressure-Temperature Relief Valves. For the purpose of determining the set (opening) pressure, the test medium shall be room temperature water. The actual set pressure is defined as the pressure at the valve inlet when the flow rate through the valve is 40 cc/min. Capacity tests shall be conducted with steam (see HG-402.7) at a pressure 10% above the actual water set pressure. For production capacity check tests, the rated capacity shall be based on the actual water set pressure. HG-402.6 Capacity Tests of Pressure-Tempera ture Relief Valves. For the purpose of determining the capacity of pressure-temperature relief valves, dummy elements of the same size and shape as the regularly applied thermal element shall be substituted and the 43 RS-003049 1/17/02 NUECES HG-402.6 1995 SECTION IV HG-405 A95 relieving capacity shall be based on the pressure element only. Valves selected to meet the requirements of production testing, HG-401.3, shall have their tempera ture elements deactivated by the Manufacturer prior to or at the time of capacity testing. HG-402.7 Fluid Medium for Capacity Tests. The tests shall be made with dry saturated steam. For test purposes the limits of 98% minimum quality and 20F maximum superheat shall apply. Correction from within these limits may be made to the dry saturated condition. The relieving capacity shall be measured by condensing the steam or with a calibrated steam flowmeter. (a) To determine the discharge capacity of safety relief valves in terms of Btu, the relieving capacity in pounds for steam per hour W is multiplied by 1000. HG-402.8 Where and by Whom Capacity Tests Shall Be Conducted (a) Tests shall be conducted at a place where the testing facilities, methods, procedures, and person super vising the tests (Authorized Observer) meet the applica ble requirements of ASME PTC 25-1994. The tests shall be made under the supervision of and certified by an Authorized Observer. The testing facilities, methods, procedures, and qualifications of the Authorized Ob server shall be subject to the acceptance of ASME on recommendation of an ASME Designee. Acceptance of the testing facility is subject to review within each 5 year period. (b) Capacity test data reports for each valve model, type, and size, signed by the Manufacturer and the Authorized Observer witnessing the tests, shall be sub mitted to the ASME Designee for review and ac ceptance.2 - NOTE: When changes are made in the design, capacity certification tests shall be repeated. HG-402.9 Test Record Data Sheet A data sheet for each valve shall be filled out and signed by the authorized observer witnessing the test. Such data sheet 2 Valve capacities are published in "Pressure Relief Device Certifica tions.'' This publication may be obtained Grom The National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus. Ohio, 43229. will be the manufacturer's authority to build and stamp valves of corresponding design and construction. When changes are made in the design of a safety or safety relief valve in such a manner as to affect the flow path, lift, or performance characteristics of the valve, new tests in accordance with this Section shall be performed. NOTE: See HG-S12 for safety and safety relief valve accumulation test requirements. See HG-701 for safety and safety relief valve installation requirements. HG-403 HEATING SURFACE The heating surface shall be computed as follows. (a) Heating surface, as part of a circulating system in contact on one side with water or wet steam being heated and on the other side with gas or refractory being cooled, shall be measured on the side receiving heat. (b) Boiler heating surface and other equivalent sur face outside the furnace shall be measured circumferen tially plus any extended surface. (c) Waterwall heating surface and other equivalent surface within the furnace shall be measured as the projected tube area (diameter x length) plus any ex tended surface on the furnace side. In computing the heating surface for this purpose, only the tubes, fire boxes, shells, tubesheets, and the projected area of headers need be considered, except that for vertical firetube steam boilers, only that portion of the tube surface up to the middle of the gage glass is to be computed. HG-405 THERMAL ELEMENTS FOR PRESSURE-TEMPERATURE RELIEF VALVES The thermal elements for pressure-temperature relief valves shall be so designed and constructed that they will not fail in any manner which could obstruct flow passages or reduce capacities of the valves when the elements are subjected to steam temperatures. NOTE: Since the temperature elements are designed for temperatures up to only 250F, they will fail when subjected to steam pressures with corresponding saturation temperatures in excess of 250*F. 44 RS-003060 1/17/02 NUECES ARTICLE 5 TESTS, INSPECTION, AND STAMPING HG-500 PROOF TESTS TO ESTABLISH DESIGN PRESSURE HG-501 GENERAL (a) The design pressure for pressure parts of boilers for which the strength cannot be computed with a satisfactory assurance of accuracy shall be established in accordance with the requirements of this paragraph, using one of the test procedures applicable to the type of loading and to the material used in its construction. (b) The tests in these paragraphs may be used only for the purpose of establishing the design pressure of those elements or component parts for which the thick ness cannot be determined by means of the design rules given in the Code. The design pressure of all other elements or component parts shall not be greater than that determined by means of the applicable de sign rules. HG-501.1 Types of Tests. Provision is made for two types of tests for determining the internal design pressure: (a) tests based on yielding of the part to be tested; these tests are limited to materials with a ratio of minimum specified yield to minimum specified ultimate strength of 0.625 or less. If a proof tested part shows no evidence of permanent yielding per HG-502.1 and HG-502.2, it may be Code stamped. (b) tests based on bursting of the part The part proof tested under the burst test provisions shall not be Code stamped. HG-501.2 Retests. A retest shall be allowed on a duplicate pressure part if errors or irregularities are obvious in the test results. HG-501.3 Precautions. Safety of testing personnel should be given serious consideration when conducting proof tests, and particular care should be taken during the conducting of bursting tests per HG-502.3. HG-501.4 Pressure Application (a) Previously Applied. The pressure parts for which the design pressure is to be established shall not pre viously have been subjected to a pressure greater than l'/2 times the desired or anticipated design pressure. (b) Application. In the procedures given in HG-502.1 for the strain measurement test and HG-502.2 for the displacement measurement test, the hydrostatic pressure in the pressure part shall be increased gradually until approximately one-half the anticipated design pressure is reached. Thereafter, the test pressure shall be in creased in steps of approximately one-tenth or less of the anticipated design pressure until the pressure required by the test procedure is reached. The pressure shall be held stationary at the end of each increment for a sufficient time to allow the observations required by the test procedure to be made and shall be released to zero to permit determination of any permanent strain or displacement after any pressure increment that indicates an increase in strain or displacement over the previous equal pressure increment. HG-501.5 Critical Areas. As a check that the mea surements are being taken on the most critical areas, the Inspector may require a lime wash or other brittle coating to be applied on all areas of probable high stress concentrations in the test procedures given in HG-502.1 and HG-502.2. The surfaces shall be suitably clean before the coating is applied in order to obtain satisfactory adhesion. The technique shall be suited to the coating material. NOTH: Strains should be measured as they apply to membrane stresses. In regard to bending stresses it is recognized that high localized and secondary stresses may exist in pressure parts designed and fabricated in accordance with these rules. Insofar as practical, design rules for details have been written to hold such stresses at a safe level consistent with experience. HG-501.6 Yield Strength and Tensile Strength. For proof tests based on yielding, HG-502.1 and HG502.2, the yield strength (or yield point for those materials which exhibit that type of yield behavior 45 RS-003061 1/17102 NUECES HG-501.6 1995 SECTION IV HG-502.2 indicated by a "sharp-kneed" portion of the stressstrain diagram) of the material in the part tested, shall be determined in accordance with the method prescribed :n the applicable material specification and as described in ASTM E 8, Tension Testing of Metallic Materials. For proof tests based on bursting, HG-502.3, the tensile strength instead of the yield strength of the material in the part tested shall be similarly determined. (a) Yield or tensile strength so determined shall be the average from three or four specimens cut from the part tested after the test is completed. The specimens shall be cut from a location where the stress during the test has not exceeded the yield strength. The speci mens shall not be oxygen cut because this might affect the strength of the material. If yield or tensile strength is not determined by test specimens from the pressure part tested, alternative methods are given in HG-502.1, HG-502.2, and HG-502.3 for evaluation of proof test results to establish the design pressure. (b) When excess stock from the same piece of wrought material is available the test specimens may be cut from this excess stock. The specimens shall not be removed by flame cutting or any other method involving sufficient heat to affect the properties of the specimen. HG-502 PROCEDURE HG-502.1 Strain Measurement Test (a) Subject to limitations of HG-501.1(a), this proce dure may be used for pressure parts under internal pressure, constructed of any material permitted to be used under the rules of Section IV. Strains shall be measured in the direction of the maximum stress at the most highly stressed parts (see HG-501.5) by means of strain gages of any type capable of indicating strains to 0.00005 in./in. (0.005%). Pressure shall be applied as provided in HG-501.4(b). (b) After each increment of pressure has been applied, readings of the strain gages and the hydrostatic pressure shall be taken and recorded. The pressure shall be released and any permanent strain at each gage shall be determined after any pressure increment that indicates an increase in strain for this increment over the previous equal pressure increment. Only one application of each increment of pressure is required. (c) Two curves of strain against test pressure shall be plotted for each gage line as the test progresses, one showing the strain under pressure and one showing the permanent strain when the pressure is removed. The test may be discontinued when the test pressure reaches the value H which will, by the formula, justify the desired working pressure, but shall not exceed the pressure at which the plotted points for the most highly strained gage line reaches the value given below for the material used: (1) 0.2% permanent strain for carbon, low alloy, and high alloy steels; (2) 0.5% strain under pressure for copper-base alloys. (d) The design pressure P, psi, for parts tested under this paragraph shall be computed by one of the following formulas: (1) if the average yield strength is determined by HG-501.6, (2) if the actual average yield strength is not determined by test specimens, P = 0.4H where H= hydrostatic test pressure, psi, at which the test i was stopped in accordance with HG-502.1(c) Tj= specified minimum yield strength Ya= actual average yield strength from test spec imens HG-502.2 Displacement Measurement Test (a) Subject to the limitations of HG-501.1(a), this procedure may be used only for pressure parts under internal pressure, constructed of materials having a definitely determinable yield point. Displacement shall be measured at the most highly stressed parts (see HG501.5) by means of measuring devices of any type capable of measuring to 0.001 in. This displacement may be measured between two diametrically opposed reference points in a symmetrical structure, or between a reference point and a fixed base point. Pressure shall be applied as provided in HG-501.4(b). (b) After each increment of pressure has been applied, readings of the displacement and the hydrostatic pressure shall be taken and recorded. The pressure shall be released and any permanent displacement shall be deter mined after any pressure increment that indicates an increase in measured displacement for this increment over the previous equal pressure increment. Only one application of each increment is required. Care must be taken to insure that the readings represent only displacements of the parts on which measurements are being made and do not include any slip of the measuring 46 RS-0030S2 1/17/02 NUECES HG-502.2 ARTICLE 5 -- TESTS, INSPECTION, AND STAMPING HG-502.4 devices or any movement of the fixed base points or of the pressure part as a whole. (c) Two curves of displacement against test pressure shall be plotted for each reference point as the test progresses, one showing the displacement under pres sure, and one showing the permanent displacement when the pressure is removed. The application of pressure shall be stopped when it is evident that the curve through the points representing displacement un der pressure has deviated from a straight line. (d) The pressure coincident with the proportional limit of the material shall be determined by noting the pressure at which the curve representing displacement under pressure deviates from a straight line. The pressure at the proportional limit may be checked from the curve of permanent displacement by locating the point where the permanent displacement begins to increase regularly with further increases in pressure. Permanent deformation at the beginning of the curve that results from the equalization of stresses and irregularities in the material may be disregarded. The design pressure P, psi, at test temperature for parts tested under this paragraph shall be computed by one of the following formulas. (1) If the average yield strength is determined by HG-501.6, r, P = 0.5H -- y. (2) In order to eliminate the necessity of cutting tensile specimens and determining the actual yield strength of the material under test, one of the following formulas may be used to determine the design pressure: (a) for carbon steel, meeting an acceptable Code specification, with a specified minimum tensile strength of not over 70,000 psi. (b) for any acceptable material listed in Sec tion IV, P = 0.4W (2b) where H= hydrostatic test pressure coincident with the proportional limit of the weakest element of the component part tested, psi y, = specified minimum yield strength, psi y,,= actual average yield strength from test speci mens, psi S = specified minimum tens; strength, psi (e) When Formula (2a) or (2b) is used, the material in the pressure part shall have had no appreciable cold working or other treatment that would tend to raise the yield strength above the normal. HG-502J Bursting Tests (a) This procedure may be used for pressure parts under internal pressure when constructed of any material permitted to be used under the rules of Section IV. The design pressure of any component part proof tested by this method shall be established by a hydrostatic test to failure by rupture of a full-size sample of such pressure part. As an alternative, the hydrostatic test may be stopped when the test pressure reaches a value that will, by the formula in (b) below, justify the design pressure. (b) The design pressure P, psi, for parts tested under this paragraph shall be computed by the following formula: BS P = -- x---------- 5 Sa or Sm where B= bursting test pressure, psi S= specified minimum tensile strength, psi Sa= average actual tensile strength of test speci mens, psi Sn = maximum tensile strength of range of speci fication, psi HG-502.4 Brittle Coating Test Procedure (a) Subject to the limitations of HG-501.1(a), this procedure .may be used only for boiler and boiler parts under internal pressure, constructed of materials having a definitely determinable yield point The component parts that require proof testing shall be coated with a lime wash or other brittle coating in accordance with HG-501.5. Pressure shall be applied in accordance with HG-501.4. The parts being proof tested shall be examined between pressure increments for signs of yielding as evidenced by flaking of the brittle coating, or by the appearance of strain lines. The application of pressure shall be stopped at the first sign of yielding, or if desired, at some lower pressure. (b) The design pressure P, psi, for parts tested under this paragraph shall be computed by one of the following formulas: (1) if the average yield strength is determined in accordance with HG-501.6, 47 RS403083 1/17/02 NUECES HG-502.4 1995 SECTION IV HG-510 Y, P = 0.5H -- Ya (2) to eliminate the necessity of cutting tensile specimens and determining the actual yield strength of the material under test, one of the following formulas may be used to determine the design pressure: (a) for carbon steel meeting an acceptable Code specification, with a specified minimum tensile strength of not over 70,000 psi, P = 0.5H (2a) (b) for any acceptable material listed in Sec tion IV, P = 0.4H (2b) where H= hydrostatic test pressure at which the test was stopped, psi Ys= specified minimum yield strength, psi Y,, = actual average yield strength from test speci mens, psi S = specified minimum tensile strength, psi (c) When Formula (2a) or (2b) is used, the material in the pressure part shall have had no appreciable cold working or other treatment that would tend to raise the yield strength above the normal. HG-505 TEST GAGES (a) An indicating gage shall be connected directly to the pressure part. If the indicating gage is not readily visible to the operator controlling the pressure applied, an additional indicating gage shall be provided where it will be visible to the operator throughout the duration of the test. For large pressure parts, it is recommended that a recording gage be used in addition to indicating gages. (b) Dial indicating pressure gages used in testing shall be graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1V2 nor more than 4 times that pressure. Digital reading pressure gages having a wider range of pressure may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages. (c) All gages used in proof testing shall be cali brated against a standard deadweight tester or a cali brated master gage before the proof test is begun. Gages shall be recalibrated at any time that there is reason to believe they are in error. HG-506 INSPECTION OF PROOF TESTS Tests to establish the design pressure of pressure parts shall be witnessed and accepted by an Authorized Inspector. HG-503 TESTS OF PARTS SUBJECT TO COLLAPSE Parts of the boiler normally subject to collapse for which specified rules are not provided in this Section shall withstand without excessive deformation a hydro static test of not less than three times the desired design pressure. HG-504 TESTS OF DUPLICATE PARTS When the design pressure of a pressure part has been established by a proof test, duplicate parts of the same materials, design, and construction need not be proof tested but shall be given the standard hydrostatic test at l!/2 times the maximum allowable working pressure. The dimensions and minimum thickness of the structure to be tested should not vary materially from those actually used. A geometrically similar part may be qualified by a series of tests covering the complete size range of the pressure part. HG-510 HYDROSTATIC TESTS A95 Cast iron boilers shall be tested in accordance with HC-410. All other boilers shall be subjected to a hydrostatic test pressure which falls between the follow ing limits. (a) The lower limit shall be the greater of 60 psi or l'/2 times the maximum allowable working pressure to be stamped on the boiler. (b) The upper limit shall be the greater of 60 psi or ll/2 times the design pressure. Close visual inspection is not required during this stage. The hydrostatic test pressure may then be reduced to the maximum allowable working pressure to be stamped on the boiler and maintained at this pressure while close visual inspection for leakage is made of all joints and connections. In making hydrostatic pres sure tests, the pressure shall be under such control that the test pressure established shall not be exceeded by more than 10 psi. 48 09-003064 1)17/02 NUECES HG-512 ARTICLE 5 -- TESTS, INSPECTION, AND STAMPING HG-515.3 HG-512 SAFETY AND SAFETY RELIEF VALVE ACCUMULATION TESTS If the safety valve or safety relief valve capacity cannot be computed or if it is desirable to prove the computations, it may be checked in any one of the following ways and, if found insufficient, additional capacity shall be provided: (a) by making an accumulation test, that is, by shutting off all discharge outlets from the boiler and forcing the fires to the maximum, the safety valve equipment shall be sufficient to prevent an excess pressure beyond that specified in HG-400.1(f) and HG- 400.2(0; (b) by measuring the maximum amount of fuel that can be burned, and computing the corresponding evapo rative capacity upon the basis the heating value of the fuel. (See B-100, B-101, and B-102.) HG-515 INSPECTION TESTS AND CERTIFICATION OF BOILERS HG-515.1 General. The inspection and testing of boilers to be marked with the Code H Symbol shall conform to the general requirements for inspection and testing in the following paragraphs and, in addition, to the specific requirements for inspection and tests given in Parts HF and HC. HG-515.2 Manufacturer's Responsibility. The Manufacturer has the responsibility of providing the Inspector with all specified information and of assuring that the quality control, the detailed examination, and the tests required by this Section are performed at the stages of construction necessary to permit them to be meaningful (see F-202.5). These responsibilities shall include, but not be limited to, providing or making available for review the following: (a) the Certificate of Authorization from the ASME Boiler and Pressure Vessel Committee authorizing the Manufacturer to fabricate the type of boiler being constructed (see HG-540); (b) the drawings and design calculations for the boiler or part (see Part HG, Article 3; Part HF, Article 3; Subpart HW, Article 7; Subpart HB, Article 1300; and Part HC, Article 3); (c) identification for all materials used in the fabrica tion of the boiler or part (see Part HG, Article 2; Subpart HW, Article 5; Subpart HB, Article 1100; and Part HC, Article 2); (d) any Partial Data Reports when required (see HG-531); (e) access for the Inspector to those parts of the plant concerned with the supply or fabrication of materials for the boiler; keeping the Inspector informed of the prog ress of the work so that the required inspections can be performed in the proper sequence (see HW-900, HB-1500, and F-202.5); (f) evidence of examination of all material before and during fabrication to make certain it has the required thickness, has no unacceptable defects, is one of the acceptable materials permitted by this Section, and that traceability to the material identification has been maintained (see HG-201, HC-502.5, F-202.4, and HF-210); (g) concurrence of the Inspector for correction of nonconformities in accordance with the Quality Control System (see F-202.6); . (h) evidence of qualification of the welding and/or brazing procedures before they are used in fabrication (see HW-610, HB-1001, HB-1202, and F-202.7); (i) evidence of qualification of all welders, welding operators, or brazers before the welders, welding opera tors, or brazers are used in production work, except that performance qualification by radiography, in confor mance with Section IX, QW-304 for welders or QW305 for welding operators, may be performed within the first 3 ft of the first production weld (see HW401, HW-610, HB-1001, HB-1202, and F-202.7); (j) records of examination of parts prior to joining to make certain that they have been properly fitted for welding or brazing and that the surfaces to be joined have been cleaned and the alignment tolerances are maintained (see Subpart HW, Article 8; Subpart HB, Article 14; and F-202.7); (k) records of examination of parts as fabrication progresses for material marking, that surface defects are not evident, and that dimensional geometries are maintained (see HG-515.1; HF-210; Subpart HW, Arti cle 8; HC-200f HC-502'.5f and HC-502.6); (l) subjecting the boiler to the required hydrostatic test (see HG-510); (m) affixing the required stamping and/or nameplate to the boiler and making certain it is affixed to the proper boiler (see HG-530); (n) preparing the required Manufacturer's Data Re port and having it certified by the Inspector (see HG520) for boilers and boiler parts constructed of wrought materials, and having it certified by the test engineer if constructed of cast material (see HC-403); (o) providing for retention of Manufacturer's Data Reports [see HG-520.1(b), HC-403, and HC-502.10]. HG-515.3 Inspection by Authorized Inspector (a) Except as otherwise permitted by Part HC, the inspection required by this Section shall be by an 49 RS-003065 1/17/02 NUECES HG-515J 1995 SECTION IV HG-520.I Inspector employed by a state or municipality of the United States, a Canadian province, or an Inspector regularly employed by an insurance company authorized to write boiler and pressure vessel insurance. These Inspectors shall have been qualified by written examina tion under the rules of any state of the United States or province of Canada which has adopted the Code. (b) The Inspector shall make all inspections specifi cally required of him plus such other inspections as he believes are necessary to enable him to certify that all boilers and boiler parts constructed of wrought material which he authorizes to be stamped with the Code Symbol have been designed and constructed in accordance with the requirements of this Code Section. The required inspections and verifications shall include, but not be limited to, the following: (1) checking to see that the Manufacturer has a valid Certificate of Authorization (see HG-540) and is working to the quality control system accepted by the Society (see HG-540.1); (2) checking to see that the design calculations, drawings, specifications, procedures, records, and test results are available (see HG-300, HG-200, HG-500, HF-200, and HW-700); (3) checking to see that material used in the con struction of the boiler and parts complies with the requirements (see HG-200, HF-200, and HB-1100); (4) checking to see that all welding procedures have been qualified (see HW-910); (5) checking to see that all welders and welding operators have been qualified (see HW-911); (6) checking to see that all brazing procedures have been qualified (see HB-1501); (7) checking to see that all brazer and brazer operators have been qualified (see HB-1502); (8) checking to see that the proper joint factor is used for brazed joints that can only be inspected from one side (blind joint) (see HB-1503); (9) checking to see that material imperfections repaired by welding were acceptably repaired (see HW830 and HB-1402); (10) visual inspection of boiler parts to confirm that the material identification numbers have been properly transferred (see HF-210); (11) witnessing of proof tests conducted to establish the maximum allowable working pressure of boilers (see HG-500); (12) inspecting each boiler and water heater during construction and after completion (see HG-515.3); (13) performing internal and external inspections and witnessing hydrostatic tests (see HG-510); (14) verifying that stamping and/or nameplate is proper and that it has been stamped and/or attached to the proper boiler (see HG-530 through HG-533); (15) signing the certificate of inspection on the Manufacturer's Data Report when the boiler or part is complete and in compliance with all the provisions of this Section (see HG-532.3, HG-533.6, and HG-520.2). HG-515.4 Duty of Authorized Inspector (a) Each boiler shall be inspected during construction and after completion and, at the option of the Authorized Inspector, at such other stages of the work as he may designate. For specific requirements, see the applicable parts of this Section. Each Manufacturer or assembler is required to arrange for the services of Authorized Inspectors (see HG-515.2) to perform such inspections on all of this work within the scope of this Section, whether performed in the shop or in the field. (b) When multiple, duplicate boiler fabrication makes it impracticable for the Inspector to personally perform each of his required duties, the Manufacturer, in collabo ration with the Inspector, shall prepare an inspection and quality control procedure setting forth in complete detail the method by which the requirements of this Section shall be maintained (see HG-515 for summaries of the responsibilities of .the Manufacturer and the duties of the Inspector). This procedure shall be included in the Manufacturer's written Quality Control System (see HG-540). This procedure shall be submitted to, and shall have received the acceptance of, the inspection agency. It shall then be submitted by the inspection agency for written acceptance by the legal jurisdiction concerned and by an ASME Designee. The inspection procedure shall be used in the plant of the named Manufacturer by the inspection agency submitting it, and shall be carried out by an Inspector in the employ of that inspection tigency. Any changes in this inspection and Quality Contri'l Procedure which affect the require ments of this Section are subject to review and accept ance by the parties required for a joint review. The joint reviews required by HG-540 shall include an ASME Designee. The Data Report for a multiple dupli cate boiler shall include under "Remarks," the statement "Constructed under the provisions of HG-515.4(b)." HG-S20 MASTER AND PARTIAL DATA REPORTS HG-520.1 Manufacturer's Master Data Report Each manufacturer of heating boilers of wrought materi als to which the Code H Symbol is to be applied shall compile a Manufacturer's Data Report for each boiler he produces, except that an individual Manufacturer's 50 rS-OOSOM HG-520.1 ARTICLE 5 -- TESTS, INSPECTION, AND STAMPING HG-530.1 inspected, and stamped in a continuous 8 hr period. Form H-2 or H-3 shall be used. (a) The boiler Manufacturer shall have the responsi bility of furnishing a copy of the completed Manufactur er's Data Report at the place of installation to the inspection agency, the purchaser, and the state, munici pal, or provincial authority. (b) The Manufacturer shall either keep a copy of the Manufacturer's Data Report on file for at least 5 years, or the boiler may be registered and the original Data Report filed with the National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio 43229. HG-520.2 Partial Data Reports (a) Manufacturer's Partial Data Reports for those parts of a boiler requiring inspection under this Code, which are furnished by other than the shop of the manufacturer responsible for the completed boiler, shall be executed by the parts manufacturer and shall be forwarded in duplicate to the manufacturer of the finished boiler. (b) Partial Data Reports (Form H-4) shall be com pleted for all parts that require inspection under this Code which are fabricated by a manufacturer other than the manufacturer of the completed boiler. These Partial Data Reports, together with his own inspection, shall be the final Authorized Inspector's authority to witness the application of the Code Symbol to the completed boiler. HG-530 STAMPING OF BOILERS A96 HG-530.1 Stamping Requirements for Boilers Other Than Those Constructed Primarily of Cast Iron (See HG-530.2) (a) All boilers to which the Code Symbol is to be applied shall be built according to the rules of this Section by a manufacturer who is in possession of a Code Symbol Stamp and a valid Certificate of Authori zation. Each boiler shall be stamped with the Code Symbol shown in Fig. HG-530.1 and with the follow ing data: (1) the boiler manufacturer's name, preceded by the words "Certified by;" (2) maximum allowable working pressure; (3) safety or safety relief valve capacity (mini mum), lb/hr or MBH,6 as determined according to HG400.1(d) and HG400.2(d); (4) heating surface, sq ft, as determined according to HG-403 (or kilowatt power input for electric boilers); (5) manufacturer's serial number. A96 `Thousands of Btu per hr. FIG. HG-530.1 OFFICIAL SYMBOL FOR STAMP TO DENOTE THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS' STANDARD (6) year built; (7) maximum water temperature. A95 NOTE: The year built may be incorporated into the serial number as a prefix consisting of the last two digits of the year. (b) Items (1) through (7) listed in (a) above, with the markings arranged substantially as shown in Fig. HG-530.2 or Fig. HG-530.3, shall be stamped with letters at least s/l6 in. high and in some conspicuous place on the boiler proper or on a nameplate at least %4 in. thick permanently fastened to the boiler proper. The location of the stamping shall be as follows: (1) Horizontal Tubular Flue Type Boilers: on the front head above the central rows of tubes or flues. (2) Locomotive Firebox, Compact, or Vertical Firetube Type Boilers: over or near the fire door or handhole or washout plug opening on the front end or side. (3) Watertube Type Boilers: on a head of the top outlet drum. Waterwalls and headers shall carry identifying markings. (4) Split-Section and Section Firebox Type Wrought Boilers: over or near the fire door or handhole or washout plug opening on the front end or side. Each section shall carry identifying markings. (5) Scotch Type Boilers: on either side of the shell near the normal water level line adjacent to the front tubesheet. (c) On any of the above type boilers where there is not sufficient space in the places designated and on other types and new designs of boilers, the nameplate shall be located in a conspicuous place. (d) The stamping or nameplate on the boiler proper shall not be covered with insulating or other material unless: (1) the required markings are duplicated and stamped directly on the boiler casing in some conspicu ous place using letters and numerals at least s/16 in. high; (2) an opening with a removable cover is provided in the jacket or other form of casing so that, when A95 51 R8-003047 1/17/02 NUECES HG-530.1 1995 SECTION TV FORM OF STAMPING ON COMPLETED BOILERS OR THEIR NAMEPLATES (Not Applicable for Boilers Constructed Primary of Cast Iron) HG-530.2 ---- r'TjS |1 1t lI 1J TT Certified by (Name of Manufacturer) 23MAWP, Steam 15 psi 3MAWP, Water___ psi 3Maximum Water Temp____ *F 'Heating surface sq ft Minimum relief valve capacity__ Ib/hr or MBH ---- ('/TjK >I 1f V. 1 \/ Certified by (Name of Manufacturer) MAWP, Water____ psi Maxim um Water Temp--------*F 'Heating surface____ sq ft Minimum relief valve capacity__ Ib/hr or MBH Manufacturer's serial no. _ 3Year built NOTES: Acceptable abbreviations to any of the stamp wording may be used. (1) Kilowatt power input for electric boilers. (2) May be omitted when year built is prefix to serial number (see HG-530.1). (3) For steam only boilers, MAWP Water and Maximum Water Temperature markings are optional. A95 FIG. HG-530.2 STEAM AND WATER BOILERS A97 FIG. HG-5303 BOILERS SUITABLE FOR WATER ONLY A95 removed, the stamping or nameplate on the boiler proper can be viewed; (3) the required data are duplicated by stamping or marking with letters at least % in. high on a nonferrous nameplate at least 3 in. x 4 in. size and permanently attaching the nameplate to the casing in some conspicuous place by mechanical means or by an adhesive system meeting the requirements of Appen dix J. (e) The Code Symbol may be preapplied to a name plate. The nameplate may be attached to the boiler after the final fabrication and examination sequence but before the hydrostatic test, provided the procedure for sequence of stamping is described in the manufactur er's accepted quality control system. The Code Symbol and manufacturer's serial number shall be stamped on nameplates but the other data may be stamped, etched, cast, or impressed thereon. if) The ASME Code Symbol Stamp(s) shall not be used by an organization to which it was not issued. HG-530.2 Marking Requirements for Cast Iron Boilers (a) All boiler parts or sections to which the Code Symbol is to be applied shall be built according to the rules of this Section by a manufacturer1 who is in 'The foundry which casts the boiler parts or sections and which may shop assemble. possession of a Code'Symbol Stamp and a valid Certificate of Authorization. Each boiler section, includ ing end and intermediate cored sections, shall be cast with the Code Symbol shown in Fig. HG-530.1 and with the following data cast in letters or numerals at least 3/16 in. high; (1) the boiler or parts manufacturer's1 name or acceptable abbreviation, preceded by the words "Certi fied by:" (or "Cert, by" on cast iron boiler sections only where space for marking is limited; the abbreviation "Cert, by" shall not be used on nameplates); (2) maximum allowable working pressure2 (3) pattern number, (4) casting date; (5) 3 the shop assembler's4 name or acceptable ab breviation (if different from manufacturer). Arrangement of data cast on sections shall be substan tially as shown in Fig. HG-530.4 or Fig. HG-530.5. Other data may be cast on the sections. The marking "ASME" or "ASME standard" shall not be used. (b) When the boiler size and number of sections have been decided, the completed boiler shall be marked 2 May be stamped. 3 Optional. 4The shop which assembles sections into boilers and which is in possession of a Code Symbol Stamp and valid Certificate of Authorization. 52 RS-003058 1/17/02 NUECES HG-530.2 ARTICLE 5 -- TESTS, INSPECTION, AND STAMPING HG-531 FORM OF DATA CAST ON CAST IRON BOILER SECTIONS fm 1111 Certified by Neme of Menufecturer for MAWP, Steam 15 psi MAWP, Water_____ psi (2) (3) (Pattern number) (4) (Casting date) / Certified by r Hi 11 I I 1 1 Name of Manufacturer 51 for *Jr MAWP, Water_____ psi (2) 13) (Pattern number) (4) (Casting date) NOTE: (1) through (5) refer to HG-530.2(aH1HaX5); (5) is optional. A9S FIG. HG-530.4 STEAM AND WATER BOILERS FIG. HG-530.5 BOILERS SUITABLE FOR WATER ONLY A95 A95 with the Code Symbol shown in Fig. HG-530.1 and with the following data: (1) the shop assembler's name preceded by the words "Certified by;" (2) maximum allowable working pressure; (3) safety or safety relief valve capacity (mini mum), lb/hr or MBH, as determined according to HG400.1(e) and HG-400.2(d); (4) maximum water temperature. (c) The markings for the completed boiler shall be arranged substantially as shown in Fig. HG-530.6 or Fig. HG-530.7. (d) The provisions of (b) above shall be met utilizing one of the following methods: (1) stamping the required markings on a nonferrous nameplate at least 3 in. x 4 in. in size and %4 in. thick using letters and numerals at least '/8 in. high and permanently attaching the nameplate to the boiler proper in some conspicuous place. The nameplate shall not be covered with insulating or other material except that when a jacket or other form of casing is applied to a boiler, an opening with a removable cover shall be provided, for viewing the required stamping. (2) stamping the required markings directly into the boiler casing in some conspicuous place using letters and numerals at least 5/n in. high; (3) stamping or marking the required data on a nonferrous or nonmetallic nameplate at least 3 in. x 4 in. in size using letters and numerals at least % in. high and permanently attaching the nameplate to the casing in some conspicuous place by mechanical means or by an adhesive system. The nameplate and the adhesive system shall meet the requirements of Appen dix 3. Other data may be stamped on the casing or the nameplate provided the required markings are distinct and separate from the other data. The marking "ASME" or "ASME standard" shall not be used. (4) when nameplates are shipped detached, the space for attachment shall bear the statement: "This installation is not complete unless the nameplate is attached here." (5) the Code Symbol may be preapplied to a nameplate. (6) the ASME Code Symbol Stamp(s) shall not be used by an organization to which it was not issued. A95 A95 A95 HG-531 STAMPING OF PARTS AND ACCESSORIES (a) Parts of boilers for which Partial Data Reports are required by HG-520.2 shall be marked with the following: (1) the official Code Symbol shown in Fig. HG530.1 above the word "Part;" 53 R8-003089 1/17/02 NUECE8 HG-531 1995 SECTION IV HG-533.2 FORM OF STAMPING ON COMPLETED CAST IRON BOILERS OR THEIR NAMEPLATES n_n fill Certified by (Name of Shop Assembler) MAWP. Steam 15 psi MAWP, Water____ psi Maximum Water Temp.____ *F Minimum relief valve capacity__ Ib/hr or MBH --Certified by /ljS 1 I I1 (Name of Shop Assembler) MAWP. Water____ psi Maximum Water Temp.____ *F Minimum relief valve capacity__ Ib/hr or MBH A95 FIG. HG-530.6-STEAM AND WATER BOILERS FIG. HG-530.7 BOILERS SUITABLE FOR WATER ONLY A95 (2) the part manufacturer's name; (3) the part manufacturer's serial number. (b) No part or accessory of a boiler may be marked with the Code Symbol shown in Fig. HG-530.1 unless so specified in the Code. The markings "ASME" or "ASME standard" shall not be used. HG-532.3 Application of Stamping and Signing Data Sheets. Proper stamping as required by HG-530.2 shall be applied at the shop arid the data sheets shall be signed by the same or different Inspectors who shall indicate the portions of the inspections made at the shop and in the field. HG-532 STAMPING OF FIELD ASSEMBLED WROUGHT BOILERS HG-532.1 Responsibility of Manufacturer of Boiler Unit When a boiler manufactured of wrought material is furnished by one manufacturer and is not assembled and subjected to hydrostatic test prior to shipment, the manufacturer of the boiler unit shall compile a Manufacturer's Data Report Form H-2 or H-3 recording all items of the complete boiler unit. HG-532.2 Execution of Manufacturer's Data Re port The Manufacturer's Data Report shall be properly executed by the manufacturer and the Authorized In spector, who shall sign the certificate of shop inspection certifying that each enumerated item which has been inspected at the shop conforms to the requirements of the ASME Code. The manufacturer in signing each Data Report shall state under his signature the expiration date on the Certificate of Authorization to use the Symbol. HG-533 INSPECTION AND STAMPING OF FIELD ASSEMBLED BOILER PRESSURE PARTS HG-533.1 Authorized Assemblers and Welders. The assembly of any parts or subassemblies of the unit that requires welding shall be made by one possessing a heating boiler stamp. The welding of any parts or subassemblies during field assembly shall be done by persons who meet the requirements of HW-610. HG-533.2 Execution of Data Report SheeL When the assembly is made by anyone other than the manufac turer of the boiler unit, the Data Report sheet properly executed in accordance with HG-532 shall be forwarded to the assembler who shall be responsible for the proper handling of the Data Report and who shall fill in such items as are not filled in at the shop, and sign the Data Sheet as the "assembler" or "assembling organization" instead of "manufacturer." He shall also append, above his signature, the statement: "We certify that the field assembly of all parts conform with the requirements of the ASME Boiler and Pressure Vessel Code." 54 R8403060 1/17/02 NUECES HG-533J ARTICLE 5 -- TESTS, INSPECTION, AND STAMPING HG-540.2 HG-5333 Field Inspection by Authorized Inspec tor. The field inspection shall be made by an Authorized Inspector (as defined in HG-31S.3) and the Inspector shall make such inspections as he believes are needed to enable him to certify that the boiler has been constructed in accordance with the Code. Properly executed Manufacturer's Data Reports, together with the Inspector's own inspection, shall constitute his authority to sign the certificate of field inspection. HG-533.4 Application of Assembler's Stamp. The Assembler's H Stamp, together with the assembler's name or an acceptable abbreviation, shall be applied in the field on the boiler near the stamping called for in HG-530.2, when the assembly is accepted by the Authorized Inspector. HG-533.5 Application for H Symbol Applicants for an H Symbol to be used only in the field assembly of heating boilers shall so state on the application form, and the Certificate of Authorization issued to such applicants shall show that the authorization to use the H Symbol is limited to the field assembly of welded boilers constructed to Section IV (see HG-540). HG-533.6 Certificate of Field Inspection. The cer tificate of field inspection on the Data Report shall be executed by the Authorized Inspector. The assembler or assembling organization shall have the responsibility for forwarding and filing of Manufacturer's Data Reports as required by HG-520.1(a) and HG-520.1(b). A97 HG-533.7 Mechanical Field Assembly. For a boiler manufactured of wrought materials that has not been completed in the Manufacturer's shop, field assembly involving no welding does not need to be performed by a Company possessing a heating boiler stamp. However, when a boiler is not assembled by a stamp holder, the Manufacturer assuming responsibility for the completed boiler is responsible for providing for field inspection by an Authorized Inspector employed by the Manufacturer's Authorized Inspection Agency, and signature of the Certificate of Field Assembly Compliance by a representative of the Manufacturer, after the required hydrostatic test has been completed. Application of an assembler H stamp in accordance with HG-533.4 is not required. HG-540 CODE SYMBOL STAMPS HG-540.1 Authorization. A Certificate of Authoriza tion to use the Code Symbols H, HLW, and/or HV will be granted by the Society pursuant to the provisions of the following paragraphs. Stamps for applying the Code Symbol shall be obtained from the Society. HG-540.2 Application for Certificate of Authori zation (a) Any organization desiring a Certificate of Authori zation shall apply to the Boiler and Pressure Vessel Committee of the Society, on forms issued by the Society,35 s* pecifying the Stamp desired and the scope of Code activities to be performed. When an organization intends to build Code items in plants in more than one geographical area, either separate applications for each plant or a single application listing the addresses of all such plants may be submitted. Each application shall identify the Authorized Inspection Agency provid ing Code inspection at each plant A separate Certificate of Authorization will be prepared and a separate fee charged by the Society for each plant. Each applicant must agree that each Certificate of Authorization and each Code Symbol Stamp are at all times the property of the Society, that they will be used according to the rules and regulations of this Section of the Code, and that they will be promptly returned to the Society upon demand, or when the applicant discontinues the Code activities covered by his Certificate, or when the Certificate of Authorization .has expired and no new Certificate has been issued. The holder of a Code Symbol Stamp shall not allow any other organization to use it. (b) Issuance of Authorization. Authorization to use Code Symbol Stamps may be granted or withheld by the Society in its absolute discretion. If authorization is granted, and the proper administrative fee paid, a Certificate of Authorization evidencing permission to use any such Symbol, expiring on the triennial anniver sary date thereafter, will be forwarded to the applicant. Each such certificate will identify the Code Symbol to be used,'and the type of shop and/or field operations for which authorization is granted (see Appendix K). The Certificate will be signed by the Chairman of the Boiler and Pressure Vessel Committee and the Director of Accreditation. (c) Six months prior to the date of expiration of any such Certificate, the applicant must apply for a renewal of such authorization and the issuance of a new Certificate. The Society reserves the absolute right to cancel or refuse to renew such authorization, re turning, pro rata, fees paid for the unexpired term. The Certificate of Authorization for the use of the H, HLW, and/or HV Code Symbol Stamp is valid for 3 The application forms and related information and instructions may be obtained by writing to the Secretary, ASME Boiler and Pressure Vessel Committee, 345 East 47th Street, New York, N.Y. 10017. 55 "Eff NUECES HG-544U 1995 SECTION IV HG-540.6 3 years; the H (cast iron) Certificate of Authorization for the H (cast iron) Code Symbol Stamp is valid for one year. HG-5403 Inspection Agreement As a condition of obtaining and maintaining a Certificate of Authoriza tion to use the H or HLW Code Symbol Stamps, the Manufacturer (except for cast iron heating boilers) must have in force at all times an inspection contract or agreement with an Authorized Inspection Agency as defined in HG-515.3 to provide inspection services. This inspection agreement is a written agreement between the Manufacturer and the Inspection Agency which specifies the terms and conditions under which the inspection services are to be furnished and which states the mutual responsibilities of the Manufacturer and the Authorized Inspectors. A Certificate Holder shall notify the Society whenever his agreement with an Authorized Inspection Agency is cancelled or changed to another Authorized Inspection Agency. 'Neither Manufacturers nor Assem blers of pressure relief valves are required to have an inspection agreement with an Authorized Inspection Agency. A Certificate of Authorization may be granted to a Manufacturer or Assembler of safety valves to use the safety valve Symbol Stamp providing such stamp is applied only to safety valves that have been capacity certified in accordance with the requirements of this Section. HG-540.4 Quality Control System. Any Manufac turer or Assembler holding or applying for a Certificate of Authorization to use the H, HLW, or HV Stamp shall have, and demonstrate, a quality control system to establish that all Code requirements, including material, design, fabrication, examination (by the Manufacturer), inspection of boilers, vessels, parts (by the Authorized Inspector), pressure testing, and certification will be met. The quality control system shall be in accordance with the requirements of Appendix F, except for Cast Iron Boiler Certificate Holders. It must be in accordance with the requirements of Article 5 of Part HC. A97 HG-540.5 Evaluation for Authorization and Reau thorization. Before issuance or triennial renewal of a Certificate of Authorization for use of the H or HLW Stamp, the Manufacturer's facilities and organization are subject to a joint review by his Inspection Agency and an individual certified as an ASME designee who is selected by the concerned legal jurisdiction, except that for H (cast iron) the review shall be yearly by an ASME designee selected by ASME. A written description or checklist of the quality control system that identifies what documents and what procedures the Manufacturer will use to produce a Code item shall be available for review. The purpose of the review is to evaluate the appli cant's quality control system and its implementation. The applicant shall demonstrate sufficient administrative and fabrication functions of the system to show that he has the knowledge and ability to produce the Code items covered by his quality control system. Fabrication functions may be demonstrated using current work, a mock-up, or a combination of the two. A written report to the Society shall be made jointly by the ASME designee and the Inspection Agency employed by the Manufacturer to do his Code inspec tion. This report is then reviewed by the Subcommittee on Boiler and Pressure Vessel Accreditation, which will either issue a Certificate of Authorization or notify the applicant of deficiencies revealed by the review. In such a case, the applicant will be given an opportunity to explain or correct these deficiencies. Certificates of Authorization will be endorsed to indicate the scope of activity authorized. Authorization may include field operations if the review team deter mines that these operations are adequately described in the quality control manual, and this determination is accepted by the Society. Before issuance or renewal of a Certificate of Authori zation for use of the H (cast iron) Stamp to produce cast iron boilers, each Manufacturer (the foundry who casts the boiler parts or sections and who may shop assemble) or Assember is subject to review by an ASME designee. A written description or checklist of the quality control system in accordance with the requirements of Part HC shall be available for review. The ASME designee shall make a written report to the Society, where the Subcommittee on Boiler and Pressure Vessel Accreditation will act on it as described above. HG-540.6 Authorization of Changes. The Manufacturer may at any time make changes in the quality control system concerning the methods of achieving results, subject to acceptance by the Authorized Inspec tor. For Manufacturers of multiple duplicate pressure vessels,6 acceptance of these changes by the jurisdiction (if applicable) and an ASME designee is also required. For Manufacturers and Assemblers of HV stamped safety and safety relief valves, such acceptance shall be by the ASME designee. For those areas where there is no jurisdiction, that function shall be performed by an ASME designee A97 6 See HG-5I5.4 for additional requirements applicable to multiple, duplicate pressure vessel fabrication. 56 R8-003062 1/17/02 NUECES HG-540.6 ARTICLE 5 -- TESTS, INSPECTION, AND STAMPING selected by ASME. Where a jurisdiction does not review a Manufacturer's facility, that function shall be performed by an ASME designee who is selected by the concerned legal jurisdiction. Where the jurisdiction is the Manufacturer's Inspection Agency, the joint review and joint report shall be made by the jurisdiction and an ASME designee selected by ASME. HG-540.7 Code Construction Before Receipt of Certificate of Authorization. When used to demon strate his quality control system, a Manufacturer may start fabricating Code items before receipt of a Certifi cate of Authorization to use a Code Symbol Stamp under the following conditions. (a) The fabrication is done with the participation of the Authorized Inspector and is subject to his acceptance. (b) The activity is in conformance with the appli cant's quality control system. HG-540.7 56.1 RS-003083 1/17/02 NUECES HG-540.7 ARTICLE 5 -- TESTS, INSPECTION, AND STAMPING (c) The item is stamped with the appropriate Code Symbol and certified once the applicant receives his Certificate of Authorization from the Society. HG-540.8 Regulations on Use of Code Symbol Stamps. The Boiler and Pressure Vessel Committee may at any time make such regulations concerning the issuance and use of Code Symbol Stamps as it deems appropriate, and all such regulations shall become bind ing upon the holders of any valid Certificates of Authori zation. HG-540.8 57 RS-003064 1/17/02 NUECES ARTICLE 6 INSTRUMENTS, FITTINGS, AND CONTROLS HG-600 GENERAL All instruments, fittings, and controls described in this Article shall be installed prior to operation. HG-601 FOR STEAM HEATING BOILERS HG-602 STEAM GAGES A97 (a) Each steam boiler shall have a steam gage or a compound steam gage connected to its steam space or to its water column or to its steam connection. The gage or piping to the gage shall contain a siphon or equivalent device that will develop and maintain a water seal that will prevent steam from entering the gage tube. The piping shall be so arranged that the gage cannot be shut off from the boiler except by a cock placed in the pipe at the gage and provided with a tee- or lever-handle arranged to be parallel to the pipe in which it is located when the cock is open. The gage connection boiler tapping, external siphon, or piping to the boiler shall not be less than NPS '/4. Where steel or wrought iron pipe or tubing is used, the boiler connection and external siphon shall be not less than NPS V2. Ferrous and nonferrous tubing having inside diameters at least equal to that of standard pipe sizes listed above may be substituted for pipe. (b) The scale on the dial of a steam boiler gage shall be graduated to not less than 30 psi nor more than 60 psi. The travel of the pointer from 0 psi to 30 psi pressure shall be at least 3 in. HG-603 WATER GAGE GLASSES (a) Each steam boiler shall have one or more water gage glasses attached to the water column or boiler by means of valved fittings not less than NPS V2, with the lower fitting provided with a drain valve of a type having an unrestricted drain opening not less than % in. in diameter to facilitate cleaning. Gage glass replacement shall be possible under pressure. Water glass fittings may be attached directly to a boiler. Boilers having an internal vertical height of less than 10 in. may be equipped with a water level indicator of the Glass Bull's-Eye type provided the indicator is of sufficient size to show the water at both normal operating and low-water cutoff levels. (b) The lowest visible part of the water gage glass shall be at least 1 in. above the lowest permissible water level recommended by the boiler Manufacturer. With the boiler operating at this lowest permissible water level, there shall be no danger of overheating any part of the boiler. Each boiler shall be provided at the time of the manufacture with a permanent marker indicating the lowest permissible water level. The marker shall be stamped, etched, or cast in metal; or it shall be a metallic plate attached by rivets, screws, or welding; or it shall consist of material with documented tests showing its suitability as a permanent marking for the application. This marker shall be visible at all times. Where the boiler is shipped with a jacket, this marker may be located pn the jacket. NOTE: Transparent material other than glass may be used for the water gage provided that the material will remain transparent and has proved suitable for the pressure, temperature, and corrosive conditions expected in service. (c) In electric boilers of the submerged electrode type, the water gage glass shall be so located to indicate the water levels both at startup and under maximum steam load conditions as established by the manufac turer. (d) In electric boilers of the resistance element type, the lowest visible part of the water gage shall be located at least 1 in. above the lowest permissible water level specified by the Manufacturer. Each electric boiler of this type shall also be equipped with an automatic low-water cutoff on each boiler pressure vessel so located as to automatically cut off the power supply 58 R8-003086 1/17/02 NUECES HG-603 ARTICLE 6 -- INSTRUMENTS, FITTINGS, AND CONTROLS HG-607 to the heating elements before the surface of the water falls below the visible part of the glass. (e) Tubular water glasses on electric boilers having a normal water content not exceeding 100 gal shall be equipped with a protective shield. HG-604 WATER COLUMN AND WATER LEVEL CONTROL PIPES (a) The minimum size of ferrous or nonferrous pipes connecting a water column to a steam boiler shall be 1 in. No outlet connections, except for damper regulator, feedwater regulator, steam gages, or apparatus which does not permit the escape of any steam or water except for manually operated blowdowns, shall be attached to a water column or the piping connecting a water column to a boiler (see HG-705 for introduction of feedwater into a boiler). If the water column, gage glass, low-water fuel cutoff, or other water level control device is connected to the boiler by pipe and fittings, no shutoff valves of any type shall be placed in such pipe, and a cross or equivalent fitting to which a drain valve and piping may be attached shall be placed in the water piping connection at every right angle turn to facilitate cleaning. The water column drain pipe and valve shall be not less than NPS 3/4. (b) The steam connections to the water column of a horizontal firetube wrought boiler shall be taken from the top of the shell or the upper part of the head, and the water connection shall be taken from a point not above the center line of the shell. For a cast iron boiler, the steam connection to the water column shall be taken from the top of an end section or the top of the steam header, and the water connection shall be made on an end section not less than 6 in. below the bottom connection to the water gage glass. HG-605 PRESSURE CONTROL Each automatically fired steam boiler shall be pro tected from overpressure by two pressure-operated con trols. (a) Each individual automatically fired steam boiler shall have a safety limit control that will cut off the fuel supply to prevent steam pressure from exceeding the 15 psi maximum allowable working pressure of the boiler. Each control shall be constructed to prevent a pressure setting above 15 psi. (b) Each individual steam boiler or each system of commonly connected steam boilers shall have a control that will cut off the fuel supply when the pressure reaches an operating limit, which shall be less than the maximum allowable pressure. (c) Shutoff valves of any type shall not be placed in the steam pressure connection between the boiler and the con trols described in (a) and (b) above. These controls shall be protected with a siphon or equivalent means of main taining a water seal that will prevent steam from entering the control. The control connection boilertapping, external siphon, or piping to the boiler shall not be less than NPS V4, but where steel or wrought iron pipe or tubing is used, they shall not be less than NPS x/i. The minimum size of an external siphon shall be NPS V^orVg in. O.D. nonfer rous tubing. A97 HG-606 AUTOMATIC LOW-WATER FUEL CUTOFF AND/OR WATER FEEDING DEVICE (a) Each automatically fired steam or vapor-system boiler shall have an automatic low-water fuel cutoff so located as to automatically cut off the fuel supply when the surface of the water falls to the lowest visible part of the water gage glass. If a water feeding device is installed, it shall be so constructed that the water inlet valve cannot feed water into the boiler through the float chamber and so located as to supply requisite feedwater. * ' * >-- (b) Such a fuel cutoff or water feeding device may be attached directly to a boiler. A fuel cutoff or water feeding device may also be installed in the tapped openings available for attaching a water glass direct to a boiler, provided the connections are made to the boiler with nonferrous tees or Y's not less than NPS '/2 between the boiler and the water glass so that the water glass is attached directly and as close as possible to the boiler; the run of the tee or Y shall take the water glass fittings, and the side outlet or branch of the tee or Y shall take the fuei cutoff or water feeding device. The ends of all nipples shall be reamed to full- size diameter. (c) Fuel cutoffs and water feeding devices embodying a separate chamber shall have a vertical drain pipe and a blowoff valve not less than NPS 3/4, located at the lowest point in the water equalizing pipe connections so that the chamber and the equalizing pipe can be flushed and the device tested. HG-607 MODULAR STEAM HEATING BOILERS (a) Each module of a modular steam heating boiler shall be equipped with; 59 Rs-oojo$e 1/17/02 NUECE8 HG-607 1995 SECTION IV HG-621 (!) steam gage, see HG-602 (2) water gage glass, see I'G-603 (3) pressure control, see HG-605(a) (4) low water cutoff, see HG-606 (b) The assembled modular steam boiler shall also be equipped with pressure control, see HG-605(b). HG-610 FOR HOT WATER HEATING OR HOT WATER SUPPLY BOILERS HG-611 PRESSURE OR ALTITUDE GAGES A97 (a) Each hot water heating or hot water supply boiler shall have a pressure or altitude gage connected to it or to its flow connection in such a manner that it cannot be shut offfrom the boiler except by a cock withtee orleverhandle, placed on the pipe near the gage. The handle of the cock shall be parallel to the pipe in which it is located when the cock is open. (b) The scale on the dial of the pressure or altitude gage shall be graduated approximately to not less than ll/2 nor more than 3'/2 times the pressure at which the safety relief valve is set (c) Piping or tubing for pressure- or altitude-gage connections shall be of nonferrous metal when smaller than NPS 1. A95 HG-612 THERMOMETERS Each hot water heating or hot water supply boiler shall have a thermometer so located and connected that it shall be easily readable. The thermometer shall be so located that it shall at all times indicate the tempera ture of the water in the boiler at or near the outlet HG-613 TEMPERATURE CONTROL Each automatically fired hot water heating or hot water supply boiler shall be protected from over-temper ature by two temperature-operated controls. (a) Each individual automatically fired hot water heating or hot water supply boiler shall have a safety limit control that will cut off the fuel supply to prevent water temperature from exceeding the maximum allow able temperature of 250F at the boiler outlet. This water temperature safety control shall be constructed to prevent a temperature setting above 250F. (b) Each individual hot water heating or hot water supply boiler or each system of commonly connected boilers without intervening valves shall have a control that will cut off the fuel supply when the water temperature reaches an operating limit, which shall be less than the maximum allowable temperature. HG-614 LOW-WATER FUEL CUTOFF (a) Each automatically fired hot water boiler with heat input greater than 400,000 Btu/hr shall have an automatic low-water fuel cutoff which has been designed for hot water service, and it shall be so located as to automatically cut off the fuel supply when the surface of the water falls to the level established in (b) below (see Fig. HG-703.2). (b) As there is no normal waterline to be maintained in a hot water boiler, any location of the low-water fuel cutoff above the lowest safe permissible water level established by the boiler manufacturer is satisfactory. (c) A coil-type boiler or a watertube boiler with heat input greater than 400,000 Btu/hrrequiring forcedcircula tion to prevent overheating of the coils or tubes shall have a flow-sensing device installed in lieu ofthe low-waterfuel cutoffrequired in (a) above to automatically cut offthe fuel supply when the circulating flow is interrupted. (d) A means shall be provided for testing the operation of the external low-water fuel cutoff without resorting to draining the entire system. Such means shall not render the device inoperable except as described as follows. If the means temporarily isolates the device from the boiler dur ing this testing, it shall automatically return to its normal position. The connection may be so arranged that the de vice cannot be shut off from the boiler except by a cock placed at the device and provided with a tee or lever-handle arranged to be parallel to the pipe in which it is located when the cock is open. A96 A97 HG-615 MODULAR HOT WATER HEATING BOILERS (a) Each module of a modular hot water heating boiler shall be equipped with: (1) pressure/altitude gage, see HG-611 (2) thermometer, see HG-612 (3) temperature control, see HG-613(a) (b) The assembled modular hot water heating boiler shall also be equipped with: (1) temperature control, see HG-613(b) (2) low water fuel cutoff, see HG-614 HG-620 FOR ALL BOILERS HG-621 INSTRUMENTS, FITTINGS, AND CONTROLS MOUNTED INSIDE BOILER JACKETS Any or all instruments, fittings, and controls required by these rules may be installed inside of boiler jackets provided the water gage on a steam boiler is accessible without the use of tools and provided the water gage and pressure gage on a steam boiler or the thermometer and pressure gage on a water boiler are visible through an opening or openings at all times. 60 RS-003087 1/17/02 NUECES HG-630 ARTICLE 6 -- INSTRUMENTS, FITTINGS, AND CONTROLS HG-640 HG-630 ELECTRIC WIRING HG-631 ELECTRICAL CODE COMPLIANCE All field wiring for controls, heat generating appa ratus, and other appurtenances necessary for the opera tion of the boiler or boilers should be installed in accordance with the provisions of the National Electric Code and/or should comply with the applicable local electrical codes. All boilers supplied with factory mounted and wired controls, heat generating apparatus, and other appurtenances necessary for the operation of the boilers should be installed in accordance with the provisions of the nationally recognized standards such as listed in footnote 2 of HG-640. HG-632 TYPE CIRCUITRY TO BE USED Whether field or factory wired, the control circuitry shall be positively grounded and shall operate at 150 V or less. One of the two following systems may be employed to provide the control circuit (a) Two-Wire Nominal 120 V System With Separate Equipment Ground Conductor (1) This system shall consist of the line, neutral, and equipment ground conductors. The control panel frame and associated control circuitry metallic enclo sures shall be electrically continuous and be bonded to the equipment ground conductor. (2) The equipment ground conductor and the neu tral conductor shall be bonded together at their origin in the electrical system as required by the NEC.1 (3) The line side of the control circuit shall be provided with a time delay fuse sized as small as practicable. (b) Two-Wire Nominal 120 V System Obtained By Using An Isolation Transformer (1) The two-wire control circuit shall be obtained from the secondary side of an isolation transformer. One wire from the secondary of this transformer shall be electrically continuous and shall be bonded to a convenient cold water pipe. All metallic enclosures of control components shall be securely bonded to this ground control circuit wire. The primary side of the isolation transformer will normally be a two-wire source with a potential of 230 V or 208 V or 440 V. (2) Both sides of the two-wire primary circuit shall be fused. The hot leg on the load side of the isolation transformer shall be fused as small as practica ble and in no case fused above the rating of the isolation transformer. 1See Appendix H. HG-633 LIMIT CONTROLS Limit controls shall be wired on the hot or line side of the control circuit. HG-634 SHUTDOWN SWITCHES AND CIRCUIT BREAKERS A manually operated remote heating plant shutdown switch or circuit breaker should be located just outside the boiler room door and marked for easy identification. Consideration should also be given to the type and location of the switch to safeguard against tampering. If the boiler room door is on the building exterior the switch should be located just inside the door. If there is more than one door to the boiler room, there should be a switch located at each door. (a) For atmospheric-gas burners, and oil burners where a fan is on a common shaft with the oil pump, the complete burner and controls should be shut off. (b) For power burners with detached auxiliaries, only the fuel input supply to the firebox need be shut off. HG-640 CONTROLS AND HEAT GENERATING APPARATUS (a) Oil and gas-fired and electrically heated boilers should be equipped with suitable primary (flame safe guard) safety controls, safety limit switches, and burners or electric elements as required by a nationally recog nized standard.2 (b) The symbol of the certifying organization3 which has investigated such equipment as having complied with a nationally recognized standard shall be affixed to the equipment and shall be considered as evidence that the unit was manufactured in accordance with that standard. 2 Examples of these nationally recognized standards are: American National Standards Z21.13, Gas Fired Low Pressure Steam and Hot Water Boiler. American National Standards Z21.17, Domestic Gas Conversion Burners. Underwriters' Laboratories, Inc., UL 296, Standards for Safety, Oil Burners. Underwriters' Laboratories, Inc., UL 573, Electric Space Heating Equipment. Underwriters' Laboratories, Inc., UL 726, Standards for Safety, Oil Fired Boiler Assemblies. Underwriters' Laboratories, Inc., UL 795, Standards for Safety Commercial -- Industrial Gas-Heating Equipment. 3 A certifying organization is one that provides uniform testing, examination, and listing procedures under established, nationally recognized standards and that is acceptable to the authorities having jurisdiction. 61 RS-003088 1/17/02 NUECES ARTICLE 7 INSTALLATION REQUIREMENTS HG-700 INSTALLATION REQUIREMENTS, ALL BOILERS HG-701 MOUNTING SAFETY AND SAFETY RELIEF VALVES HG-701.1 Permissible Mounting. Safety valves and safety relief valves shall be located in the top or side1 of the boiler. They shall be connected directly to a tapped or flanged opening in the boiler, to a fitting connected to the boiler by a short nipple, to a Y-base, or to a valveless header connecting steam or water outlets on the same boiler. Coil or header type boilers shall have the safety valve or safety relief valve located on the steam or hot water outlet end. Safety valves and safety relief valves shall be installed with their spindles vertical. The opening or connection between the boiler and any safety valve or safety relief valve shall have at least the area of the valve inlet. HG-701.2 Requirements for Common Connections for Two or More Valves (a) When a boiler is fitted with two or more safety valves on one connection, this connection shall have a cross-sectional area not less than the combined areas of inlet connections of all the safety valves with which it connects. (b) When a Y-base is used, the inlet area shall be not less than the combined outlet areas. When the size of the boiler requires a safety valve or safety relief valve larger than 4'/2 in. in diameter, two or more valves having the required combined capacity shall be used. When two or more valves are used on a boiler, they may be single, directly attached, or mounted on a Y-base. 'The top or side of the boiler shall mean the highest practicable part of the boiler proper but in no case shall the safety valve be located below the normal operating level and in no case shall the safety relief valve be located below the water level. HG-701.3 Threaded Connections. A threaded con nection may be used for attaching a valve. HG-701.4 Prohibited Mountings. Safety and safety relief valves shall not be connected to an internal pipe in the boiler. HG-701.5 Use of Shutoff Valves Prohibited. No shutoff of any description shall be placed between the safety or safety relief valve and the boiler, or on discharge pipes between such valves and the atmosphere. HG-701.6 Safety and Safety Relief Valve Discharge Piping fa) A discharge pipe shall be used. Its internal crosssectional area shall be not less than the full area of the valve outlet or of the total of the valve outlets discharging thereinto and shall be as short and straight as possible and so arranged as to avoid undue stress on the valve or valves. A union may be installed in the discharge piping close to the valve outlet. When an elbow is placed on a safety or safety relief valve discharge pipe, it shall be located close to the valve outlet downstream of the union. (b) The discharge from safety or safety relief valves shall be so arranged mat there will be no danger of scalding attendants. The safety or safety relief valve discharge shall be piped away from the boiler to the point of discharge, and there shall be provisions made for properly draining the piping. The size and arrange ment of discharge piping shall be independent of other discharge piping and shall be such that any pressure that may exist or develop will not reduce the relieving capacity of the relieving devices below that required to protect the boiler. HG-703 PIPING HG-703.1 Provisions for Expansion and Contrac tion. Provisions shall be made for the expansion and contraction of steam and hot water mains connected 62 RS-003069 1/17/02 NUECES HG-703.1 ARTICLE 7 -- INSTALLATION REQUIREMENTS HG-709.2 to boilers by providing substantial anchorage at suitable points and by providing swing joints when boilers are installed in batteries, so there will be no undue strain transmitted to the boilers. See Figs. HG-703.1(a), HG703.1 (b), and HG-703.2 for typical schematic arrange ments of piping incorporating strain absorbing joints for steam and hot water heating boilers. A95 HG-703.2 Return Pipe Connections (a) The return pipe connections of each boiler supply ing a gravity return steam heating system shall be so arranged as to form a loop substantially as shown in Fig. HG-703.1 so that the water in each boiler cannot be forced out below the safe water level. (b) For hand-fired boilers with a normal grate line, the recommended pipe sizes detailed as "A" in Fig. HG-703.1 are NPS lV2 for 4 sq ft or less firebox area at the normal grate line, NPS l}/2 for areas more than 4 sq ft up to 14.9 sq ft, and NPS 4 for 15 sq ft or more. (c) For automatically fired boilers which do not have a normal grate line, the recommended pipe sizes detailed as "A" in Fig. HG-703.1 are NPS 11/2 for boilers with minimum safety valve relieving capacity 250 lb/hr or less, NPS 2V2 for boilers, with minimum safety valve relieving capacity from 251 lb/hr to 2000 lb/hr, inclu sive, and NPS 4 for boilers with more than 2000 lb/hr minimum safety valve relieving capacity. (d) Provision shall be made for cleaning the interior of the return piping at or close to the boiler. Washout openings may be used for return pipe connections and the washout plug placed in a tee or a cross so that the plug is directly opposite and as close as possible to the opening in the boiler. HG-705 FEEDWATER AND MAKEUP WATER CONNECTIONS (a) Steam Boilers. Feedwater or water treatment shall be introduced into a boiler through the return piping system. Alternatively, feedwater or water treatment may be introduced through an independent connection. The water flow from the independent connection shall not discharge directly against parts of the boiler exposed to direct radiant heat from the fire. Feedwater or water treatment shall not be introduced through openings or connections provided for inspection or cleaning, safety valve, water column, water gage glass, or pressure gage. The feedwater pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or between the check valve and the return pipe system. (b) Hot Water Boilers. Makeup water may be intro duced into a boiler through the piping system or through an independent connection. The water flow from the independent connection shall not discharge directly against parts of the boiler exposed to direct radiant heat from the fire. Makeup water shall not be introduced through openings or connections provided exclusively for inspection or cleaning, safety relief valve, pressure gage, or temperature gage. The makeup water pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or between the check valve and the piping system. HG-707 OIL HEATERS (a) A heater for oil or other liquid harmful to boiler operation shall not be installed directly in the steam or water space within a boiler. (b) Where an external type heater for such service is used, means shall be provided to prevent the introduc tion into the boiler of oil or other liquid harmful to boiler operation. HG-709 PROVISIONS FOR THERMAL EXPANSION IN HOT WATER SYSTEMS All hot water heating systems incorporating hot water tanks or fluid relief columns shall be so installed as to prevent freezing under normal operating conditions. HG-709.1 Heating Systems With Open Expansion Tank. An indoor overflow from the upper portion of the expansion tank shall be provided in addition to an open vent, the indoor overflow to be carried within the building to a suitable plumbing fixture or the basement. A95 HG-709.2 Closed Heating Systems. An expansion tank shall be installed that will be consistent with the volume and capacity of the system. If the system is designed for a working pressure of 30 psi or less, the tank shall be suitably designed for a minimum hydro static test pressure of 75 psi. Expansion tanks for systems designed to operate above 30 psi shall be constructed in accordance with Section VIII, Division 1. Provisions shall be made for draining the tank without emptying the system, except for prepressurized tanks. The minimum capacity of the closed type expansion tank may be determined from Tables HG-709.1 and A95 63 R8-003070 1/17/02 NUECE8 Fig. HG-703.1(a) 1995 SECTION IV 64 c\ o p< <hco o Q. ol CO <ha-. LlI oo < a: OC Q 'SSi UJ a. > DC UJ t= < CO 2 o Co/c) aa> T3 o C CO E oE < UJ zc rco-n CJ3 RS-003071 1117/02 NUECES RS-003072 1/17/02 NUECES FIG. HG-703.1(b) STEAM BOILERS IN BATTERY -- GRAVITY RETURN --ACCEPTABLE PIPING INSTALLATION Fig. HG-703.2 1995 SECTION IV GENERAL NOTES: (1) Recommended control. See HG-614. Acceptable shutoff valves or cocks in the connecting piping may be installed for convenience of control testing and/or service. (2) The common return header stop valves may be located on either side of the check valves. A97 FIG. HG-703.2 HOT WATER BOILERS IN BATTERY -- ACCEPTABLE PIPING INSTALLATION 66 RS-003073 1/17/02 NUECES HG-709.2 ARTICLE 7 -- INSTALLATION REQUIREMENTS HG-710.4 TABLE HG-709.1 EXPANSION TANK CAPACITIES FOR GRAVITY HOT WATER SYSTEMS Based on two-pipe system with average operating water temperature 170F, using cast iron column radiation with heat emission rate 150 Btu/hr sq ft equivalent direction radiation Installed Equivalent Direct Radiation, sq ft [Note (I)] Tank Capacity, gal Up to 350 Up to 450 Up to 650 Up to 900 Up to 1100 Up to 1400 Up to 1600 Up to 1800 Up to 2000 Up to 2400 18 21 24 30 35 40 2-30 2-30 2-35 2-40 NOTE: (1) For systems with more than 2400 sq ft of Installed equivalent direct water radiation, the required capacity of the cushion tank shall be increased on the basis of 1 gal tank capacity/33 sq ft of additional equivalent direct radiation. TABLE HG-709.2 EXPANSION TANK CAPACITIES FOR FORCED HOT WATER SYSTEMS1 Based on average operating water temperature 195F, fill pressure 12 psig, and maximum operating pressure 30 psig Tank Capacities, gal System Volume, gal Prepressurized Diaphragm Type Nonpressurized Type 100 9 15 200 17 30 300 25 45 400 33 60 500 42 75 1000 83 150 ' 2000 165 300 NOTE: (1) System volume includes volume of water In boiler, radiation, and piping, not including the expansion tank. Expansion tank capacities are based on an acceptance factor of 0.4027 for prepressurized types and 0.222 for nonprepressurized types. A procedure for estimating system volume and determining expansion tank sizes for other design conditions may be found in Chapter 13 of the 1987 Systems and Applications Volume of the ASHRAE Handbook. HG-709.2 or from the following formula where the necessary information is available: V, = [(0.0004IT - 0.0466)V, ]/[(PJPf) - (Pa/P,,)} A97 where V, = minimum volume of tanks, gal V, = volume of system, not including tanks, gal T = average operating temperature, F Pa = atmospheric pressure, psia Pf = fill pressure, psia P0 = maximum operating pressure, psia A95 HG-7093 Hot Water Supply Systems. If a system is equipped with a check valve or pressure reducing valve in the cold water inlet line, consideration should be given to the installation of an airtight expansion tank or other suitable air cushion. Otherwise, due to the thermal expansion of the water, the safety relief valve may lift periodically. If an expansion tank is provided, it shall be constructed in accordance with Section VUI, Division 1. Except for prepressurized tanks, which should be installed on the cold water side, provisions shall be made for draining the tank without emptying the system. See Fig. HLW-809.1 for a typical acceptable installation. HG-710 STOP VALVES HG-710.1 For Single Steam Boilers. When a stop valve is used in the supply pipe connection of a single steam boiler, there shall be one used in the return pipe connection. HG-710.2 For Single Hot Water Heating Boilers (a) Stop valves shall be located at an accessible point in the supply and return pipe connections as near the boiler nozzle as is convenient and practicable, of a single hot water heating boiler installation to permit draining the boiler without emptying the system. (b) When the boiler is located above the system and can be drained without draining the system, stop valves may be eliminated. HG-710.3 For Multiple Boiler Installations. A stop valve shall be used in each supply and return pipe connection of two or more boilers connected to a common system. See Figs. HG-703.1 and HG-703.2. HG-710.4 Type of Stop Valve(s) (a) All valves or cocks shall conform with the appli cable portions of HF-203 and may be ferrous or nonferrous. (b) The minimum pressure rating of all valves or cocks shall be at least equal to the pressure stamped upon the boiler, and the temperature rating of such 67 RS-003074 1/17/02 NUECE8 HG-710.4 1995 SECTION IV HG-716 valves or cocks, including all internal components, shall be not less than 250F. (c) Valves or cocks shall be flanged, threaded or have ends suitable for welding or brazing. (d) All valves or cocks with stems or spindles shall have adjustable pressure type packing glands and, in addition, all plug type cocks shall be equipped with a guard or gland. The plug or other operating mechanism shall be distinctly marked in line with the passage to indicate whether it is opened or closed. (e) All valves or cocks shall have tight closure when under boiler hydrostatic test pressure. HG-710.5 Identification of Stop Valves by Tags. When stop valves are used, they shall be properly designated substantially as follows by tags of metal or other durable material fastened to them: Supply Valve - Number () Do Not Close Without Also Closing Return Valve Number ( ) Return Valve - Number () Do Not Close Without Also Closing Supply Valve Number () ... , HG-715 BOTTOM BLOWOFF AND DRAIN VALVES (a) Bottom Blowoff Valve. Each steam boiler shall have a bottom blowoff connection fitted with a valve or cock connected to the lowest water space practicable with a minimum size as shown in Table HG-715. The discharge piping shall be full size to the point of discharge. (b) Boilers having a capacity of 25 gal or less are exempt from the above requirements, except that they must have a 3/4 in. NPS minimum drain valve. (c) Drain Valve. Each steam or hot water boiler shall have one or more drain connections, fitted with valves or cocks connecting to the lowest water con taining spaces. The minimum size of the drain piping, valves, and cocks shall be 3/4 in. The discharge piping shall be full size to the point of discharge. When the blowoff connection is located at the lowest water containing space, a separate drain connection is not required. (d) Minimum Pressure Rating. The minimum pres sure rating of valves and cocks used for blowoff or drain purposes shall be at least equal to the pressure stamped on the boiler but in no case less than 30 psi. TABLE HG-715 SIZE OF BOTTOM BLOWOFF PIPING, VALVES, AND COCKS Minimum Required Safety Valve Capacity, lb of steam/hr [Note (1)3 Blowoff Piping, Valves, and Cocks Size, in. (min.) Up to 500 501 to 1250 1251 to 2500 2501 to 6000 6001 and larger % 1 1% XV4 2 NOTE: (1) To determine the discharge capacity of safety relief valves in terms of Btu, the relieving capacity in lb of steam/hr is multiplied by 1000. The temperature rating of such valves and cocks shall not be less than 250F. HG-716 MODULAR BOILERS (a) Individual Modules (1) The individual modules shall comply with all the requirements of Part HG, except as specified in HG-607, HG-615, and this paragraph. The individual modules shall be limited to a maximum input of 400,000 Btuh (gas), 3 gal/hr (oil), or 115 kW (electricity). (2) Each module of a steam heating boiler shall be equipped with: (a) safety valve, see HG-701 (b) blowoff valve, see HG-715(a) (c) drain valve, see HG-715(c) (3) Each module of, a modular hot water heating boiler shall be equipped with: (a) safety relief valve, see HG-701 (b) drain valve, see HG-715(c) (b) Assembled Modular Boilers (1) The individual modules shall be manifolded together at the job-site without any intervening valves. The header or manifold piping is field piping and is exempt from Article 2, Part HG, HF, HB, or HC. (2) The assembled modular steam heating boiler shall also be equipped with: (a) feedwater connection, see HG-705(a) (b) return pipe connection, see HG-703.2 (3) The assembled modular hot water heating boiler shall also be equipped with: (a) makeup water connection, see HG-705(b) (b) provision for thermal expansion, see HG-709 (c) stop valves, see HG-710.2 68 NS-003076 1/17/02 NUECES HG-720 ARTICLE 7 -- INSTALLATION REQUIREMENTS HG-725.7 HG-720 SETTING Boilers of wrought materials of the wet-bottom type having an external width of over 36 in. shall have not less than 12 in. between the bottom of the boiler and the floorline, with access for inspection. When the width is 36 in. or less, the distance between the bottom of the boiler and the floorline shall be not less than 6 in., except that, when any part of the wet bottom is not farther from an outer edge than 12 in., this distance shall be not less than 4 in. HG-72S METHODS OF SUPPORT HG-725.1 Loadings (a) The design and attachment of lugs, hangers, saddles, and other supports shall take into account the stresses due to hydrostatic head in determining the minimum thicknesses required. Additional stresses im posed by effects other than working pressure or static head which increase the average stress by more than 10% of the allowable working stress shall also be taken into account. These effects include the weight of the component and its contents, and the method of support. (b) In applying the requirements of (a) above, local ized stresses due to concentrated support loads, tempera ture changes, and restraint against dilation of the boiler due to pressure shall be provided for. Lugs, hangers, brackets, saddles, and pads shall conform satisfactorily to the shape of the shell or surface to which they are attached or are in contact. HG-725.2 Boilers Over 72 in. in Diameter. A horizontal-return tubular boiler over 72 in. in diameter shall be supported from steel hangers by the outsidesuspension type of setting, independent of the furnace wall. The hangers shall be so designed that the load is properly distributed. HG-725.3 -Boilers Over 54 in. Up to 72 in. in Diameter. A horizontal-return tubular boiler over 54 in. and up to and including 72 in. in diameter shall be supported by the outside-suspension type of setting, or at four points by not less than eight steel brackets set in pairs, the brackets of each pair to be spaced not over 2 in. apart and the load to be equalized between them. [See Fig. HG-725(a).] HG-725.4 Boilers Up to 54 in. in Diameter. A horizontal-return tubular boiler up to and Including 54 in. in diameter shall be supported by the outsidesuspension type of setting, or by not less than two steel brackets on each side. HG-725.5 Supporting Members. If the boiler is supported by structural steel work, the steel supporting members shall be so located or insulated that the heat from the furnace can not impair their strength. HG-725.6 Lugs or Hangers. Lugs, hangers, or brack ets made of materials in accordance with the Code requirements may be attached by fusion welding pro vided they are attached by fillet welds along the entire periphery or contact edges. Figure HG-725(b) illustrates an acceptable design of hanger bracket with the addi tional requirement that the center pin be located at the vertical center line over the center of the welded contact surface. The bracket plates shall be spaced at least 2l/2 in. apart, but this dimension shall be increased if necessary to permit access for the welding operation. The stresses computed by dividing the total load on each lug, hanger, or bracket, by the minimum crosssectional area of the weld shall not exceed 2800 psi. Where it is impractical to attach lugs, hangers, or brackets by welding, studs with not less than 10 threads/in. (approx. 4 threads/cm) may be used. In computing the shearing stresses, the root area at the bottom of the thread shall be used. The shearing and crushing stresses on studs shall not exceed 8% of the strength given in Table HF-300.1 for bolting materials. HG-725.7 Settings. Boilers of wrought materials of the wet-bottom type having an external width of over 36 in. shall be supported so as to have a minimum clearance of 12 in., between the bottom of the boiler and the floor, to facilitate inspection. When the width is 36 in. or less, the clearance between the bottom of the boiler and the floorline shall be not less than 6 in., except when any part of the wet bottom is not farther from the outer edge than 12 in. This clearance shall be not less than 4 in. Boiler insulation, saddles, or other supports shall be arranged so that inspection openings are readily accessible. 69 RS-003076 1/17/02 NUECES Figs. HG-725(a), HG-725(b) 1995 SECTION IV FIG. HG-725(a) SPACING AND WELD DETAILS FOR SUPPORTING LUGS IN PAIRS ON HORIZONTAL-RETURN TUBULAR BOILER FIG. HG-725(b) WELDED BRACKET CONNECTION FOR HORIZONTAL-RETURN TUBULAR BOILER RS-003077 1/17/02 70 NUECES PART HF REQUIREMENTS FOR BOILERS CONSTRUCTED OF WROUGHT MATERIALS A Detailed Contents Precedes Each Subpart Article 1 HF-100 General Scope........................................................................................................................ 73 Article 2 HF-200 HF-201 HF-202 HF-203 HF-204 HF-205 HF-206 HF-210 Material Requirements General Material Requirements................................................................................ Plate.......................................................................................................................... Rods, Bars, and Shapes........................................................................................... Prefabricated or Preformed Pressure Parts............................................................... Pipe and Tubes........................................................................................................ Material Not Fully Identified.................................................................................... Recertification of Material Produced to a Specification Not Permitted by This Section......................................................................................................... Maintaining Material Identification........................................................................... 74 74 74 74 75 76 77 77 Article 3 HF-300 HF-301 HF-302 Design Stresses and Minimum Thicknesses Maximum Allowable Stress Values..................................................................................... Minimum Thicknesses.............................................................................................. Basis for Establishing Stress Values in TablesHF-300.1 and HF-300.2..................... 78 78 78 Tables HF-300.1 HF-300.2 HF-301.1 HF-301.2 Maximum Allowable Stress Values for Ferrous Materials, ksi................................ Maximum Allowable Stress Values for Nonferrous Materials, ksi.......................... Minimum Allowable Thickness of Ferrous Shell Plates............................................ Minimum Allowable Thickness of Nonferrous Shell Plates........................................ 80 85 88 88 Subpart HW Requirements for Boilers Fabricated by Welding............................................... 89 Subpart HB Requirements for Boilers Fabricated by Brazing................................................. 113 71 RS-003078 1/17/02 NUECE8 ARTICLE 1 GENERAL HF-100 SCOPE The rules in Part HF are applicable to heating boilers that are constructed primarily of wrought materials, and shall be used in conjunction with general requirements of Part HG of this Section. 73 RS-003079 1/17/02 NUECES ARTICLE 2 MATERIAL REQUIREMENTS HF-200 GENERAL MATERIAL REQUIREMENTS Materials subject to stress due to pressure shall conform to one of the specifications given in Section II and shall be limited to those listed in Tables HF300.1 and HF-300.2. HF-201 PLATE A97 (a) Plate used in the construction of pressure con taining parts shall conform to one of the specifications given in Section II for which allowable stress values are given in Tables HF-300.1 and HF-300.2 except as otherwise provided in HF-203 and HF-205. (b) Stainless Type 304, 304L, 316, or 316L plates of SA-240 for which allowable stress values are given in Table HF-300.1 may be used in the construction of hot water heating boilers provided the following are met (1) The water temperature shall not exceed 210F. (2) The material shall be fully annealed. (c) For pressure retaining plate material, a material test report is required to verify that the chemical and mechanical properties are within the permissible range listed in Section II. HF-202 RODS, BARS, AND SHAPES (a) Rods, bars, and shapes may be used in boiler construction for pressure parts such as flange rings, stiffening rings, braces, frames for reinforced openings, stays and staybolts, and similar parts. Rods, bars, and shapes shall conform to one of the specifications in Section II and shall be limited to those listed in Tables HF-300.1 and HF-300.2 except as otherwise provided in HF-203 and HF-205. (b) Rods, bars, and shapes conforming to Section II that are of structural quality may be used for parts not directly subjected to pressure, and materials not identi fied by certification may be used for nonpressure parts such as skirts, baffles, and supports, provided it is demonstrated that the material is of weldable quality. HF-203 PREFABRICATED OR PREFORMED PRESSURE PARTS Prefabricated or preformed pressure parts for boilers which are subject to allowable working stresses due to internal or external pressure in the boilers and which are furnished by other than the shop of the manufacturer responsible for the completed boilers shall conform to all applicable requirements of the Code as related to a completed boiler, including inspection in the shop of the parts manufacturer and the furnishing of Partial Data Reports except as permitted in HF-203.1, HF203.2, and HF-203.3. HF-203.1 Cast, Forged, Rolled, or Die Formed Standard Pressure Parts (a) Pressure parts such as pipe fittings, valves, flanges, nozzles, welding necks, welding caps, manhole frames and covers, and casings of pumps that are part of a boiler circulating system that are wholly formed by casting, forging, or die forming shall not require inspection, mill test reports or Partial Data Reports; however, they shall be made of materials permitted under Section II or in a Code-accepted standard (such as ANSI) covering the particular type of pressure part Such parts shall be marked with the name or trademark of the manufacturer and such other markings as are required by the several standards. Such markings shall be considered as the manufacturer's certification that the product complies with the material specifications and standards indicated and is suitable for service at the rating indicated. The intent of the paragraph will have been met if, in lieu of the detailed marking on the part itself, the parts described herein have been marked in any permanent or temporary manner that will serve to identify the part with the manufacturer's written listing of the particular items and such listings are available for examination by the Inspector. (b) Parts of small size falling within this category for which it is difficult or impossible to obtain identified material or which may be stocked and for which 74 RS-003080 1/17/02 NUECES HF-203.1 ARTICLE 2 -- MATERIAL REQUIREMENTS HF-204.2 mill test reports or certificates cannot be economically obtained and are not customarily furnished, and which do not appreciably affect the safety of the vessel, may be used for relatively unimportant parts or parts stressed to not more than 50% of the stress value permitted by the Code provided they are suitable for the purpose intended and are accepted by the Inspector [see HF203.1 (a)]. The manufacturer of the completed vessel shall satisfy himself that the part is suitable for the design conditions specified for the completed vessel. HF-203.2 Cast, Forged, Rolled, or Die Formed Nonstandard Pressure Parts. Pressure parts such as shells, heads, removable cover plates, and pipe coils which are attached to other wrought parts and which are wholly formed by casting, forging, rolling, or die forming may be supplied basically as materials. All such parts shall be made of materials permitted under Section II and the manufacturer of the part shall furnish mill test reports or other acceptable evidence to that effect. Such parts shall be marked with the name or trademark of the manufacturer and with such other markings as will serve to identify the particular parts with accompanying material identification. The manu facturer of the completed boiler shall satisfy himself that the part is suitable for the design conditions specified for the completed boiler. HF-2033 Welded Standard Pressure Parts for Use Other Than the Shed of a Boiler1 (a) Pressure parts such as pipe fittings, nozzles, welding necks, welding caps, valves, and flanges that are fabricated by one of the welding processes recognized by the Code shall not require inspection, mill test reports, or Partial Data Reports provided: (1) all such parts are made of materials permitted under Section II or in a Code-accepted standard; (2) if arc or gas welded, the welding complies with the rules of this Section. (b) Such parts shall be marked with the name or trademark of the manufacturer and with such other markings as will serve to identify the materials of which the parts are made. Such markings shall be considered as the manufacturer's certification that the product complies with HF-203.3(a)(l). A statement by the parts manufacturer that all welding complies with Code requirements shall be accepted as evidence that the product complies with HF-203.3(a)(2). 1 Arc and gas welded pipe for use as the shell of a boiler shall be subject to the same requirements as a shell fabricated from plate, including inspection at the point of manufacture and Partial Data Reports. HF-204 PIPE AND TUBES Pipe and tubes of seamless or welded construction shall conform to one of the specifications given in Section n for which allowable stress values are given in Tables HF-300.1 and HF-300.2 except as otherwise provided in HF-203 and HF-205 when used in the construction of pressure containing parts. HF-204.1 Integrally Finned Tubes. Integrally finned tubes may be made from tubes that conform in every respect with one of the specifications given in Section II except that the pressure test is not required for nonferrous tubes. These tubes may be used under the following conditions. (a) The tubes after finning shall have a temper or condition which conforms to one of those provided in the governing specifications. (b) The maximum allowable stress value for the finned tube shall be that given in Tables HF-300.1 and HF-300.2 for the tube before finning, except as permitted in (c) below. (c) The maximum allowable stress value for a temper or condition that has a higher stress value than that of the tube before finning may be used provided that qualifying tensile tests demonstrate that such a temper or condition is obtained. The stress values used shall not exceed those shown in Tables HF-300.1 and HF300.2 for the temper or condition involved. The qualify ing tensile tests shall be made on specimens of finned tube from which the fins have been removed by ma chining. (d) The maximum allowable internal or external de sign pressure of the tube shall be based on either the minimum wall thickness of the finned section or of the unfinned section, whichever is smaller. (e) In addition to the tests required by the governing specifications (except for pressure tests for nonferrous tubes), each tube after finning shall withstand without evidence of leakage an internal pneumitic test of not less than 250 psi for 5 sec. The test method used shall permit easy visual detection of any leakage, such as immersion of the tube under water or a pressure differen tial method.2 HF-204.2 Stainless Tubes. Tubes of SA-249 and SA-213 for which allowable stress values are given in Table HF-300.1 may be used in the construction of hot water heating boilers provided the following condi tions are met. 2 The pressure differential method is described in Materials and Research Standards, Vol. 1, No. 7, July 1961, published by ASTM. RS-003081 1/17102 NUECES HF-204.2 1995 SECTION IV HF-205J A97 (a) The total internal water volume of watertube boilers with Grade 304, 3041,316, or 316L tubes shall be limited to not over 578 cr in. (2'/2 gal)- The diameter of these tubes shall be limited to l1/^ in. O.D. (b) The total internal water volume of firetube boilers with Grade 304, 304L, 316, or 316L tubes shall be limited to not over 80 gal. The diameter of these tubes shall be limited to a maximum of 4 in. O.D. (c) All tubes subject to internal pressure shall have a minimum thickness of 0.039 in. Any tubes subject to external pressure shall have a minimum thickness of 0.039 in. for outside diameters up to and including 5/g in., 0.062 in. for outside diameters over % in. up to and including 11/2 in., and 0.078 in. for outside diameters over l'/2 in. up to and including 4 in. (d) The water temperature shall not exceed 210F. (e) The material shall be fully annealed. (f) Nonpressure part attachments that have essentially no load carrying function, such as extended heating surfaces, shall be joined to pressure parts by any welding process performed in accordance with a Weld ing Procedure Specification (in compliance with Section IX as far as applicable), except that for automatic welding processes, procedure and performance qualifi cation testing is not required. (g) Heat input during welding of fins of the tubes shall be kept low to reduce heat effect on the water side surfaces of the tubes. (h) Type 304, 304L, 316, or 316L tubes, fittings, or headers, joined by welding, shall use the GTAW or GMAW process. (i) Welding or brazing shall be qualified in accord ance with Section IX. HF-205.2 Acceptance by Testing (a) Plate. The chemical check analyses and mechani cal tests of plates shall be made as required in the permitted specification with the following modifications. The carbon and manganese contents shall be determined in all check analyses. The Inspector shall decide whether these contents are acceptable when the permitted speci fication does not specify carbon and manganese limits. When the direction of rolling is not definitely known, two tension specimens shall be taken at right angles to each other from a comer of each plate, and two bend specimens shall be taken from the middle of adjacent sides of each plate. One tension specimen and both bend specimens shall meet the permitted specification requirements. . (b) Tubes and Pipe. Each length of tube or pipe shall be subjected to a chemical check analysis and sufficient mechanical tests to satisfy the Inspector that all the material is identified with a given heat or heat treatment lot and that the material complies with the chemical and mechanical requirements of the permitted specification. Material specified as suitable for welding, cold bending, close coiling, and similar operations shall be given sufficient check tests to satisfy the Inspector that it is suitable for the fabrication procedure to be used. (c) Rods, Bars, and Shapes. Each length of rods shall be subjected to a chemical check analysis and sufficient mechanical tests to satisfy the Inspector that all the material is identified with a given heat or heat treatment lot, and that the material complies with the chemical and mechanical requirements of the permitted specification. Material specified as suitable for welding, cold bending, and similar operations shall be given check tests to satisfy the Inspector that it is suitable for the fabrication procedure to be used. HF-205 MATERIAL NOT FULLY IDENTIFIED Material that has lost its identity with a permitted specification may be accepted provided that it satisfies the conditions given in either HF-205.1 or HF-205.2. HF-205.1 Acceptance by Authentic Test Record and Marking. Each piece shall be shown to have chemical requirements and mechanical properties within the permissible range of the permitted specification in Section II by an authentic test record and by marking identifying it with that record. When the permitted specification requires other tests or more restrictive tests than those of the specification covered by the authentic test record, the material shall be subjected to sufficient additional tests to satisfy the Inspector that it complies with the permitted specification. HF-2053 Marking and Report on Tests of Nonidentified Material. When the identity of the material with the permitted specification has been established in accordance with HF-205.1 or HF-205.2, each piece of material (except as alternatively provided in the specification for tubes, pipe, rods, bars, or shapes) shall be marked to the satisfaction of the Inspector by the boiler manufacturer or the testing agency, with a mark ing giving the permitted specification number and grade or type and a serial S-number identifying the particular lot of material. A suitable report, clearly marked as being a "Report on Tests of Nonidentified Material," shall be furnished, properly filled out and certified by the boiler manufacturer or testing agency, and this report, when accepted by the Inspector, shall constitute authority to use the material. 76 R8-003082 1/17/02 NUECES HF-206 ARTICLE 2 -- MATERIAL REQUIREMENTS HF-210 HF-206 RECERTIFICATION OF MATERIAL PRODUCED TO A SPECIFICATION NOT PERMITTED BY THIS SECTION A particular production lot of material may be recerti fied to a permitted specification by the boiler or part manufacturer under the following conditions. (a) The specification to which the material was pro duced, processed, and purchased must be available for comparison to the permitted specification. (b) A test report from the material manufacturer must be available. (c) The material must have marking, acceptable to the Inspector, for identification to the test report. (d) The test report must show that all chemical and mechanical properties of the lot comply with the requirements of the permitted specification. (e) When conformance of the lot to the permitted specification has been established, it may be accepted and marked, as required by the permitted specification, by the boiler or part manufacturer. HF-210 MAINTAINING MATERIAL IDENTIFICATION (a) Material for pressure parts shall carry identifica tion markings as required by the applicable material specification. If the original identification markings are cut out or the material is divided into two or more parts, the marking shall either be accurately transferred prior to cutting or a coded method of identification shall be used to assure identification of each piece of material during subsequent fabrication. (b) Materials may be identified by any method suit able to the Inspector, provided the method used does not result in sharp discontinuities and identifies the material until the boiler is completed. 77 RS403083 1/17/02 NUECES ARTICLE 3 DESIGN STRESSES AND MINIMUM THICKNESSES HF-300 MAXIMUM ALLOWABLE STRESS VALUES Tables HF-300.1 and HF-300.2 give the maximum allowable stress values indicated for ferrous and nonferrous materials, respectively, conforming to the specifi cations listed therein. HF-301 MINIMUM THICKNESSES1 A95 A95 A95 HF-301.1 Ferrous Plates (a) Except as permitted in (c) below and for cylindri cal shells in Table HF-301.1, the minimum thickness of any ferrous plate, or pipe used in lieu of plate, under any pressure shall be V4 in. (b) The minimum thicknesses of ferrous shell and other ferrous plates, heads, and tubesheets for various shell diameters of boilers shall be as shown in Table HF-301.1. All sheets, except those having tubes installed by rolling, or those calculated as cylindrical parts under external pressure (HG-312.1 to HG-312.6), may be classified as shell plates. (c) Plate thickness less than that permitted by HF301.1(a) and HF-301.1(b) may be used when all of the following requirements are met. (1) The operating service shall be limited to closed hot water heating systems at a maximum pressure of 30 psi. (2) The internal water volume shall be limited to not over 6 cu ft. (3) All pressure parts shall be limited to a maxi mum diameter of 30 in OD. (4) The boiler shall be limited to a maximum thermal input of 400,000 Btu/hr. 'These minimum thicknesses for pressure shall not be less than required by design formulas in Part HG, Article 3, nor less than those thicknesses established by proof testing in Pan HG, Article 5. (5) No plate shall be less than 3/32 in. (actual thickness), but if less than 3/16 in. (actual thickness), the plate shall not be exposed to the primary products of combustion. HF-301.2 Nonferrous Plates (a) The minimum thickness of any nonferrous plate under pressure shall be Vt in. for copper, admiralty, and red brass, and 3/32 in. for copper-nickel. (b) The minimum thicknesses of nonferrous shells and other copper or copper-alloy plates, heads, and tubesheets for various shell diameters of boilers shall be as shown in Table HF-301.2. All sheets, except those having tubes installed by rolling, may be classified as shell plates. (c) The minimum thickness of any nonferrous tubes heet with tubes installed by rolling shall be 5/n in. HF-302 BASIS FOR ESTABLISHING STRESS VALUES IN TABLES HF-300.1 AND HF-300.2 (a) In the determination of allowable stress values for pressure parts, the Committee is guided by successful experience in service, insofar as evidence of satisfactory performance is available. Such evidence is considered equivalent to test data where operating conditions are known with reasonable certainty. In the evaluation of new materials, it is necessary to be guided to a certain extent by the comparison of test information with similar data on successful applications of similar materials. (b) At any temperature below the creep range, the allowable stresses are established at no higher than the lowest of the following: (]) V5 of the specified minimum tensile strength at room temperature; (2) Vs of the tensile strength at temperature; R&-C93084 1/17/02 NUECES HF-302 ARTICLE 3 -- STRESSES AND THICKNESSES (3) 2/3 of the specified minimum yield strength at room temperature; (4) % of the yield strength at temperature. (c) For bolting materials, the basis for setting stresses is the same as for all other materials with the exception that (1) and (2) above are; (1) % of the specified minimum tensile strength at room temperature; and (2) l/4 of the tensile strength at temperature. The following limitation also applies to bolting mate rials: at temperatures below the creep range, the stresses for materials whose strength has been enhanced by heat treatment or by strain hardening shall not exceed the lesser of 20% of the specified minimum tensile strength at room temperature or 25% of the specified minimum yield strength at room temperature unless these values are lower than the annealed values, in which case the annealed values shall be used. HF-302 V 79 RS-0030SS 1/17702 NUECES Table HF-300.1 1995 SECTION IV A97 TABLE HF-300.1 MAXIMUM ALLOWABLE STRESS VALUES FOR FERROUS MATERIALS, ksi (Multiply by 1000 to Obtain psi) Spec. No. Grade Plate Steels Carbon Steels SA-36 SA-285 SA-285 SA-285 A B C SA-455 SA-455 SA-455 SA-515 SA-515 SA-515 60 _ 65 70 SA-516 SA-516 SA-516 SA-516 55 60 65 70 Nominal Composition P-No. Group No. Spec. Min. Tensile Strength, ksi Note(s) Max. Allow. Stress Value, ksi C-Mn-Si C C C C-Mn C-Mn C-Mn C-Si C-SI C-Si Q-Si C-Mn-Si C-Mn-Si C-Mn-SI 11 11 11 11 12 12 12 11 11 12 11 11 11 12 58.0 45.0 50.0 55.0 75.0 73.0 70.0 60.0 65.0 70.0 55.0 60.0 65.0 70.0 (7X20) (8) (9) (10) 11.6 9.0 10.0 11.0 15.0 14.6 14.0 12.0 13.0 14.0 11.0 12.0 13.0 14.0 Sheet Steels Carbon Steels SA-414 SA-414 SA-414 SA-414 SA-414 SA-414 SA-414 A B C D E F G SA-620 C C C C-Mn C-Mn C-Mn C-Mn C 11 11 11 11 11 12 12 1 45.0 50.0 55.0 60.0 65.0 70.0 75.0 40.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 8.0 Pipe and Tubes Seamless Carbon Steel SA-53 SA-53 A B SA-106 SA-106 SA-106 A B C SA-192 SA-210 A-l C C-Mn C-Si C-Si C-Si C-Si C-Si 11 11 11 11 12 11 11 48.0 60.0 48.0 60.0 70.0 (47.0) 60.0 9.6 12.0 9.6 12.0 14.0 (1) 9.4 12.0 80 RS-003086 1/17/03 NUECE8 ARTICLE 3 -- STRESSES AND THICKNESSES Table HF-300.1 A97 TABLE HF-300.1 (CONT'D) MAXIMUM ALLOWABLE STRESS VALUES FOR FERROUS MATERIALS, ksi (Multiply by 1000 to Obtain psi) Spec. No. Grade Nominal Composition P-No. Group No. Spec. Min. Tensile Strength, ksi Note(s) Max. Allow. Stress Value, ksi Pipe and Tubes (Cant'd) Electric Resistance Welded Carbon Steel SA-53 SA-53 SA-135 SA-135 SA-178 SA-178 SA-226 A B A B A C C C-Mn C C-Mn C C C-Si 11 11 11 11 11 11 11 48.0 60.0 48.0 60.0 (47.0) 60.0 (47.0) (2) (2) (2) (2) (1)(2) (2) (1X2) 8.2 10.2 8.2 10.2 8.0 10.2 8.0 Butt Welded SA-53 Steel C 11 48.0 (4) 5.8 Forgings Carbon Steels SA-105 SA-181 SA-181 SA-266 SA-266 SA-266 Class 60 Class 70 1 2 3 C-Si C-Si C-Si C-Si C-Si C-Si 12 11 12 11 12 12 70.0 60.0 70.0 60.0 70.0 75.0 14.0 12.0 14.0 12.0 14.0 15.0 Castings Carbon Steels SA-216 SA-216 WCA WCB C-Si C-Si 11 12 60.0 70.0 (5) 9.6 (5) 11.2 Bolting Carbon Steels SA-307 SA-193 SA-193 SA-311 B B5 B7 1018, Class A SA-311 1035, Class A SA-311 1045, Class A SA-311 SA-311 1045, Class B 1050, Class A SA-320 SA-320 SA-325 SA-354 SA-354 L7 L43 1 BC BD c 5Cr-V2Mo lCr-0.2Mo lCr-0.2Mo l3/,Ni-3/,,Cr-V,Mo C C C 60.0 100.0 100.0 125.0 125.0 (6) (6) (6) (21) (21a) (21b) (21) (21a) (21b) (21) (21a) (21b) (21) (2la) (21) (21a) (21b) (6) (6) (6) (6) (6) 15.0 25.0 25.0 14.0 13.0 17.0 16.0 19.0 18.0 23.0 20.0 19.0 25.0 25.0 7.0 25.0 25.0 81 RS-003087 1/17/03 NUECE8 Table HF-300.1 1995 SECTION IV A97 TABLE HF-300.1 (CONT'D) MAXIMUM ALLOWABLE STRESS VALUES FOR FERROUS MATERIALS, ksi (Multiply by 1000 to Obtain psi) Spec. No. Grade . Nominal Composition P-No. Group No. Spec Min. Tensile Strength, ksi Note(s) Max. Allow. Stress Value, ksl Bars and Stays Carbon Steels SA-36 SA-675 SA-675 SA-675 SA-675 SA-675 SA-675 45 50 55 60 65 70 C-Mn-Si C C C C C C 11 11 11 11 11 11 12 58.0 45.0 50.0 55.0 60.0 65.0 70.0 (7) 11.6 9.0 10.0 11.0 12.0 13.0 14.0 Plate Alloy Steel SA-240 SA-240 SA-240 SA-240 SA-240 SA-240 304 304L 316 316L 439 S44400 18Cr-8NI lSCr-SNi 16Cr-12Ni-2Mo 16Cr-12Ni-2Mo 18Cr-Ti 18Cr-2Mo 81 a1 81 81 72 72 75.0 (16X17) 15.0 70.0 (16X17) 14.0 75.0 (14X16X17) 15.0 70.0 (14X16X17) 14.0 65.0 (11X12X13X14) 13.0 60.0 (11X14X19) 12.0 Tube Alloy Steel SA-213 SA-213 SA-213 TP304 TP304L TP316 SA-213 TP316L SA-249 SA-249 SA-249 SA-249 TP304 TP304L TP316 TP316L SA-268 SA-268 S44400 TP439 Smls. 18Cr-8Ni Smls. 18Cr-8Ni Smls. 16Cr-12Ni- 2Mo Smls. 16Cr-12Ni- 2Mo Wld. 18Cr-8Ni Wld. 18Cr-8Ni Wld. 16Cr-12Ni-2Mo Wld. 16Cr-12Ni-2Mo 18Cr-2Mo 18Cr-Ti 8 8 8 8 8 8 8 8 7 7 1 1 1 1 1 1 1 1 2 2 75.0 70.0 75.0 70.0 75.0 70.0 75.0 70.0 60.0 60.0 (15X16X17) (15X16X17) (14X15X16X17) (14X15X16X17) (2X15X16X17) (2X15X16X17) (2X14X15X16X17) (2X14X15X16X17) (11X14X19) (11X12X13X14) 15.0 14.0 15.0 14.0 12.8 11.9 12.8 11.9 12.0 12.0 RS-OOSOtt L 1/17/02 82 NUECES ARTICLE 3 -- STRESSES AND THICKNESSES Table HF-300.1 A97 TABLE HF-300.1 (CONT'D) MAXIMUM ALLOWABLE STRESS VALUES FOR FERROUS MATERIALS, ksi (Multiply by 1000 to Obtain psi) Spec. No. Grade Nominal Composition P-No. Group No. Spec. Min. Tensile Strength, ksi Note(s) Max. Allow. Stress Value, ksi Pipe Alloy Steel SA-312 SA-312 SA-312 TP304 TP304L TP316 SA-312 TP316L SA-312 SA-312 SA-312 SA-312 TP304 TP304L TP316 TP316L Smls. 18Cr-8Ni Smls. 18Cr-8NI Smls. 16Cr-12Ni- 2Mo Smls. 16Cr-12Ni- 2Mo Wld. 18Cr-8Ni Wld. 18Cr-8Ni Wld. 16Cr-12Ni-2Mo Wld. 16Cr-12Ni-2Mo 8 8 8 8 8 8 8 8 1 1 1 1 1 1 1 1 75.0 (16X17) 15.0 70.0 (16X17) 14.0 75.0 (14X16X17) 15.0 70.0 (14X16X17) 14.0 75.0 (2X16X17) 12.8 70.0 (2X16X17) 11.9 75.0 (2X14X16X17) 12.8 70.0 (2X14X16X17) 11.9 Bar Alloy Steel SA-479 SA-479 S44400 439 18Cr-2Mo 18Cr-Ti 72 72 60.0 (11X14X19) 12.0 70.0 (11X12X13X14) 14.0 Forgings Alloy Steel SA-182 SA-182 SA-182 SA-182 F304 F304L F316 F316L 18Cr-8Ni 18Cr-8Ni 16Cr-12Ni-2Mo 16Cr-12Ni-2Mo 81 81 81 81 75.0 (16X17X22) 15.0 70.0 (16X17X22) 14.0 75.0 (14X16X17X22) 15.0 70.0 (14X16X17X22) 14.0 Castings Alloy Steel SA-351 SA-351 CF8C CF3M NOTES: See next page. 18Cr-10Ni-Cb 16Cr-12Ni-2Mo 81 81 70.0 (5X17X18) 11.2 70.0 (5X14X17X18) 11.2 RS-003089 83 1/17/02 NUECES Table HF-300.1 1995 SECTION IV NOTES: (1) Tensile value in parentheses is expected minimum. (2) The stress value includes a joint factor of< .85. (3) The stress value includes a joint factor of 0.80. (4) The stress value includes a joint factor of C 60. (5) The stress value includes a casting quality factor of 0.80. Increased casting quality factors as a result of material examination beyond the requirements of the material specifications shall not be permitted. (6) The stress value Is established from a consideration of strength only and will be satisfactory for average service. For bolted joints, where freedom from leakage over a long period of time without retightening is required, lower stress values may be necessary as determined from the relative flexibility of the flange and bolts, and corresponding relaxation properties. (7) These allowable stress values apply also to structural shapes. (8) For thicknesses up to \ in., inclusive. (9) For thicknesses over J/8 In. to 0.580 in., inclusive. (10) For thicknesses over 0.580 to 0.750 in., inclusive. (11) The maximum thickness of material covered by this Table is 3/g in. (12) The service temperature shall not exceed 200F. (13) Filler metal shall be Type 430 with a nominal titanium content of approximately 1.25%. The 300 series of chromium-nickel-iron filler metals shall not be used in welding vessels conforming to the requirements of Section IV. (14) The welding processes employed in fabrication shall be limited to the gas tungsten arc welding process and the gas metal arc welding process. Shielding gas for the gas shielded metal arc process shall be argon or helium. Oxygen up to 2% may be added to the argon. (15) Tubing material shall be fully annealed. (16) Limitations of HF-204.2 also apply. (17) The water temperature shall not exceed 210F. (18) The minimum thickness for header material is 0.10 in. (19) Filler metal shall be Type 430 with a nominal molybdenum content of approximately 2%. The 300 series of chromium-nickel-iron filler metals shall not be used In welding vessels conforming to the requirements of Section IV. (20) See Appendix 4 for Canadian Standards Association structural steels specification for plates and bars not exceeding V, in. for use at the same maximum allowable stress value as SA-36. A97 (21) For tie-rods and draw bolts on cast-iron sectional boilers subject to system pressure. Welding is not permitted. (a) To 7/a in. diam. incl. (b) Over 7/B in. to l1/, in. incl. (c) To 3 in. incl. A97 (22) These allowable stresses apply only to material 5 in. and under in thickness. 84 A97 Spec. No. ARTICLE 3 -- STRESSES AND THICKNESSES Table HF-300J! TABLE HF-300.2 MAXIMUM ALLOWABLE STRESS VALUES FOR NONFERROUS MATERIALS, ksi (Multiply by 1000 to Obtain psi) Copper or Copper Alloy No. Form Condition P-No. Spec. Min. Tensile Stress, ksi Spec. Min. Yield Stress, ksi Note(s) Max. Allow. Stress Value, ksi Copper SB-42 SB-42 SB-42 Copper Copper Copper Pipe Pipe Pipe SB-75 SB-75 SB-75 SB-111 SB-111 Copper Copper Copper Copper Copper SB-152 Copper SB-283 SB-395 C37700 Copper Copper-Silicon SB-96 C66500 SB-98 SB-98 SB-98 SB-98 C65500 C65500 C65100 C65100 SB-315 C65500 Red Brass SB-43 C23000 SB-111 C23000 SB-395 C23000 Smls. Tubes Smls. Tubes Smls. Tubes Smls. Condenser Tubes Smls. Condenser Tubes Plate, Sheet, Strip, & Bar Forging Brass Smls. Tubes Plate & Sheet Rods Rods Rods Rods Pipe & Tube Smls. Pipe Smls. Condenser Tubes Smls. Condenser Tubes Annealed/061 Hard Drawn/H80 -- Va In. to 2 in. NPS, incl. Light Drawn/H55 -- 2l/2 in. to 12 in. NPS, incl. Annealed/050/060 Light Drawn/H55 Hard Drawn/H80 Light Drawn/H55 Hard Drawn/H80 Annealed As Forged/MlO/Mll Light 0rawn/H55 Annealed/061 Soft Anneal/060 Quarter Hard/HOl Soft Anneal/060 Half Hard/H02 Annealed/030/061 Annealed/061 Annealed/061 Annealed/O 61 31 30.0 9.0 31 45.0 40.0 31 36.0 30.0 31 30.0 9.0 31 36.0 30.0 31 45.0 40.0 31 36.0 30.0 31 45.0 40.0 31 30.0 10.0 31 36.0 30.0 33 50.0 18.0 33 52.0 15.0 33 55.0 24.0 33 40.0 12.0 33 - a 55.0 : 20.0 33 50.0 15.0 32 40.0 12.0 32 40.0 12.0 32 40.0 12.0 (2) (1X2) (1X2) (2) (1X2) (1X2) (2) (2) (2) (8X9) (1X2) 6.0 9.0 7.2 6.0 7.2 9.0 7.2 9.0 6.0 5.8 7.2 (5) 10.0 (5) 10.1 (5) 10.0 (5) 8.0 (5) 11.0 (5) 10.0 8.0 8.0 8.0 R8-0030S1 1/17/02 NUECE8 Table HF-300J 1995 SECTION IV A97 TABLE HF-300.2 (CONT'D) MAXIMUM ALLOWABLE STRESS VALUES FOR NONFERROUS MATERIALS, ksi (Multiply by 1000 to Obtain psi) Spec No. Copper or Copper Alloy No. Form Condition P-No. Spec. Min. Tensile Stress, ksi Spec Min. Yield Stress, ksi Note(s) Max. Allow. Stress Value, ksi Admiralty SB-395 C44300 SB-395 C44400 SB-395 C44500 SB-171 SB-171 SB-171 C44300 C44400T C44500 Smls. Condenser Tubes Smls. Condenser Tubes Smls. Condenser Tubes Tube Plates, & 4 in. Tube Plates, S 4 in. Tube Plates, 4 in. Naval Brass SB-171 C46400 Tube Plates, S3 in. Copper-Nickel SB-111 C70600 SB-111 C71000 SB-111 C71500 SB-171 SB-171 SB-395 SB-395 SB-395 C70600 C71500 C70600 C71000 C71500 SB-466 SB-466 SB-466 C70600 C71000 C71500 Smls. Condenser Tubes Smls. Condenser Tubes Smls. Condenser Tubes Plates, S 5 in. Plates, S 2*/2 in. Smls. Condenser Tubes Smls. Condenser Tubes Smls. Condenser Tubes Pipe & Tube Pipe 4 Tube Pipe & Tube Nickel-Copper SB-164 N04400 SB-164 N04400 Bar Rounds Annealed/061 Annealed/061 Annealed/061 Annealed Annealed/061 Annealed/061 Annealed/061 Annealed/061 Annealed/061 Annealed/061 Annealed Annealed Annealed Hot or Cold Worked, Annealed Hot Worked (As Worked or Stress Relieved) 86 32 32 32 32 32 32 32 34 34 34 34 34 34 34 34 34 34 34 42 42 45.0 45.0 45.0 45.0 45.0 45.0 50.0 40.0 45.0 52.0 40.0 50.0 40.0 45.0 52.0 38.0 45.0 50.0 70.0 80.0 15.0 15.0 15.0 15.0 15.0 15.0 20.0 15.0 16.0 18.0 15.0 20.0 15.0 16.0 18.0 13.0 16.0 18.0 25.0 40.0 9.0 9.0 9.0 9.0 9.0 9.0 10.0 8.0 9.0 10.4 8.0 10.0 8.0 9.0 10.4 7.6 9.0 10.0 (7) 14.0 (7) 16.0 R8-003092 1117/02 NUECES A97 Spec No. ARTICLE 3 -- STRESSES AND THICKNESSES Table HF-300J TABLE HF-300.2 (CONT'D) MAXIMUM ALLOWABLE STRESS VALUES FOR NONFERROUS MATERIALS, ksi (Multiply by 1000 to Obtain psi) Copper or Copper Alloy No. Form Condition P-No. Spec Min. Tensile Stress, ksi Spec Min. Yield Stress, ksi Note(s) Max. Allow. Stress Value, ksi Nickel-Copper (Cont'd) SB-165 N04400 SB-165 N04400 SB-165 N04400 Smls. Pipe and Tube, 5 in. O.D. max. Smls. Pipe and Tube, Over 5 in. O.D. Smls. Pipe and Tube, All Sizes Annealed Annealed Stress Relieved 42 70.0 28.0 42 70.0 25.0 42 85.0 55.0 (7) 14.0 (7) 14.0 (7) 17.0 Integrally Finned Tubes SB-359 ... (6) Castings, Bronze and Brass SB-61 SB-62 SB-584 C92200 C83600 C84400 Steam Metal Bronze 85-5-5-5 Compo sition Brass 81-3-7-9 Compo sition Brass 34.0 16.0 (3X4) 5.4 30.0 14.0 (3X4) 4.8 29.0 13.0 (3X4) 4.6 NOTES: (1) When nonferrous materials conforming to specifications given in Section II are used In welded or brazed construction, the maximum allowable working stresses shall not exceed the values given herein for the material in the annealed condition. (2) When material is to be welded, the phosphorous deoxided types should be specified. A97 (3) The stress value includes a casting quality factor of 0.80. Increased casting quality factors as a result of material examination beyond the requirement of the material specification shall not be permitted. This is not intended to apply to valves and fittings made to recognized standards. A97 (4) In the absence of evidence that the casting is of high quality throughout, values not in excess of 80% of those given in the Table shall be used. This is not intended to apply to valves and fittings made to recognized standards. A97 (5) Copper-silicon alloys are not always suitable when exposed to certain median and high temperatures, particularly steam above 212F. Therefore, this material is limited to the construction of hot water boilers to be operated at a temperature not to exceed 200F. A97 (6) Use in accordance with HF-204 and HF-204.1. A97 (7) To be used for HLW connections only. A97 (8) For use in HG-307.2(b) Eq. (2), the maximum allowable stress at room temperature (100F, max.) shall be 10.0 (through lV2 in. thickness) and 9.2 (over ll/2 in. thickness). A97 (9) No welding or brazing permitted. 87 RS-003093 1/17/02 NUECES Tables HF-301.1, HF-301.2 1995 SECTION IV TABLE HF-301.1 MINIMUM ALLOWABLE THICKNESS OF FERROUS SHELL PLATES Minimum Ferrous Material Thickness Allowable Under Rules, in. Diameter or Width of Shell, Tubesheet, or Head, in. Tubesheet or Head With Rolled Tubes Shell Plate 42 or under Over 42 to 60 Over 60 to 78 Over 78 A y*1 V. 5A* 7A y. % 7A NOTE: (1) Shell plate in. thickness Is permissible for cylindrical shells 24 in. in diameter or less, and for a maximum allowable working pressure not over 30 psi. TABLE HF-301.2 MINIMUM ALLOWABLE THICKNESS OF NONFERROUS SHELL PLATES Diameter or Width of Shell, Tubesheet, or Head, in. [Note (1)] Minimum Nonferrous Material Thickness Allowable Under Rules, in. Tubesheet or Head Shell Plate Copper Admiralty & Red Brass Copper-Nickel Alloy Copper Admiralty & Red Brass Copper-Nickel Alloy 24 or under Over 24 to 36 Over 36 to 42 Over 42 to 60 Over 60 to 78 Over 78 `A.* ' *A** y.r: - Vs 2 Vi2 JA*2 Vi y. 5A* y* y JA4 y. % 5A* 5A. 7A 7A v. y. y* lA 7A 7A NOTES: (1) For the purpose of applying Tables HF-301.1 and HF-301.2 to a noncylindrical boiler, the equivalent shell diameter shall be taken as the width of the unsupported portion of any plate, measured before stays are installed. (2) See HF-301.2(c). 88 NUECES PART HF -- SUBPART HW REQUIREMENTS FOR BOILERS FABRICATED BY WELDING Article 4 HW-400 HW-401 Article 5 HW-500 ~ HW-501 HW-502 Article 6 HW-600 HW-610 HW-611 HW-612 HW-613 Article 7 HW-700 HW-701 HW-702 HW-703 HW-710 HW-711 HW-712 HW-713 HW-715 HW-720 HW-730 HW-731 HW-740 HW-745 Article 8 HW-800 HW-80I General Requirements Scope................................................................................................................................................... Responsibility of Manufacturer or Contractor........................................................................ 91 91 Material Requirements Permissible Materials...................................................................................................................... Materials of Different Specifications........................................................................................ Materials for Small Parts............................................................................................................. 92 92 92 Welding Processes and Qualifications Welding Processes.......................................................................................................................... Welding Qualifications.................................................................................................................... No Production Work Without Qualifications.......................................................................... Interchange of Qualifying Tests Among Manufacturers Prohibited.................................. Maintenance of Records of Qualifications and Identifying Marks.................................... 93 93 93 93 93 Design of Weldments Design of Welded Joints................................................................................................................ General Requirements.................................................................................................................... Joint Efficiencies.............................................................................................................................. Minimum Thickness of Welded Parts....................................................................................... Welded Stays..................................................................................................................................... Heads or Tubesheets Attached by Welding............................................................................ Furnace Attachments...................................................................................................................... Tubes Attached by Welding......................................................................................................... Head-to-Shell Attachments........................................................................................................... Openings in Welds.......................................................................................................................... Welded Connections........................................................................................................................ Minimum Requirements for Attachment Welds...................................................................... Resistance Welding- in Carbon Steel for Other Than Butt Welded Joints..................... Resistance Welding of Hydraulically Formed Panels........................................................... 94 94 95 95 95 97 98 98 98 99 99 100 103 105 Fabrication Requirements Forming Plates................................................................................................................................. Base Metal Preparation.................................................................................................................. 109 109 89 RS-003096 1/17/02 NUECES HW-810 HW-812 HW-813 HW-820 HW-830 HW-840 Assembly............................................................................................................................................ Alignment Tolerance....................................................................................................................... Distortion............................................................................................................................................ Specific Welding Requirements.................................................................................................... Repair of Weld Defects................................................................................................................ Posthydrotest Welding of Nonpressure Parts to Pressure Parts........................................ 109 109 110 110 Ill Ill Article 9 HW-900 HW-910 HW-911 Inspection Inspection During Fabrication...................................................................................................... Check of Welding Procedure Qualifications............................................................................ Check of Welder and Welding Operator Performance Qualifications............................. 112 112 112 Figures HW-701.1 Butt Welding of Plates of Unequal Thickness................................... ................................. HW-701.3 Some Forms of Attachments of Pressure Parts to Flat Plates to Form a Comer Joint (Tee Joint).......................................................................................................................... HW-710.4(a) Some Acceptable Types of Diagonal Stays for Installation byWelding........................ HW-710.4(b) - Unacceptable Types of Diagonal Stays for Installation by Welding............................... HW-715.1 Heads Attached to Shells............................................................................................................... HW-731 Some Acceptable Types of Welds for Fittings, Nozzles and Other Connections to Shells, Drums, and Headers..................................................................................................... HW-740 Three-Ply Joint Assemblies.......................................................................................................... HW-745 Two-Ply Joint Assemblies............................................................................................................... 94 96 97 97 99 101 104 107 Table HW-713 . Firetube Extension Through Tubesheets for Welded Construction.................................... 98.1 A96 A97 90 R8-003096 1/17/02 NUECES ARTICLE 4 GENERAL REQUIREMENTS HW-400 SCOPE The requirements of this Subpart HW are applicable to boilers and parts thereof that are fabricated by welding. HW-401 RESPONSIBILITY OF MANUFACTURER OR CONTRACTOR Each manufacturer or contractor is responsible for the welding done by his organization and shall establish the procedures and conduct the tests required in Section IX to qualify the welding procedures he uses in the construction of the weldments built under Section IV and the performance tests of welders and welding operators who apply these procedures. RS-003097 1/17/02 NUECE8 ARTICLE 5 MATERIAL REQUIREMENTS HW-500 PERMISSIBLE MATERIALS Materials used in welded construction of pressure parts shall conform to one of the specifications given in Section II and shall be limited to those for which allowable stress values are given in Tables HF-300.1 and HF-300.2 and for which weld group P-Numbers are assigned in Section IX. (a) Carbon or alloy 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. (b) Stud material for arc stud welding and resistance stud welding of carbon steel shall be low carbon steel of an acceptable material in this Section and with a carbon maximum of 0.27% and with a minimum tensile strength of 60,000 psi. See further limits in HW-730.4 and HW-820.3. (c) Materials joined by the inertia and continuous drive friction welding processes shall be limited to materials assigned P-Numbers in Section IX and shall not include rimmed or semikilled steel. HW-501 MATERIALS OF DIFFERENT SPECIFICATIONS Two materials of different specifications may be joined by welding provided the requirements of QW251.2 of Section IX are met. HW-502 MATERIALS FOR SMALL PARTS Small parts used in welded construction under the provisions of HF-203.1 shall be of good weldable quality. 92 RS-003098 1/17/02 NUECES ARTICLE 6 WELDING PROCESSES AND QUALIFICATIONS HW-600 WELDING PROCESSES The welding processes that may be used under this Part are restricted to the following: fa) arc or gas welding processes are restricted to shielded metal arc, submerged arc, gas metal arc, gas tungsten arc, plasma arc, atomic hydrogen metal arc, and oxyfuel gas welding; fb) pressure welding processes are restricted to flash, induction, resistance, pressure thermit, pressure gas, and inertia and continuous drive friction welding; (c) definitions are given-in Section IX which include variations of these processes. 304 for welders or QW-305 for welding operators, may be performed within the first 3 ft of the first production weld. HW-612 INTERCHANGE OF QUALIFYING TESTS AMONG MANUFACTURERS PROHIBITED The performance qualification tests for welders and welding operators conducted by one manufacturer or contractor shall not qualify a welder or welding operator to do work for any other manufacturer or contractor. HW-610 WELDING QUALIFICATIONS Unless specified otherwise for a particular process, the procedures, the welders, and the welding operators used in welding pressure parts and in joining nonpres sure parts (attachments) to pressure parts shall be qualified in accordance with Section IX. HW-611 NO PRODUCTION WORK WITHOUT QUALIFICATIONS No production work shall be undertaken until the procedures, the welders, and the welding operators have been qualified, except that performance qualification by radiography, in conformance with Section IX, QW- HW-613 MAINTENANCE OF RECORDS OF QUALIFICATIONS AND IDENTIFYING MARKS The Manufacturer or contractor shall maintain a record of the welding procedures and welders and welding operators employed by him showing the date and results of test and the identification mark assigned to each welder. These records shall be certified to by the Manufacturer or contractor and be accessible to the Inspector. The welder or welding operator shall stamp his identification mark on or adjacent to all welded joints made by him at intervals of not greater than 3 ft, or the Manufacturer shall keep a record of the welded joints on a vessel and the welders and welding operators used in making the joints. 93 R8-003099 1/17/02 NUECES ARTICLE 7 DESIGN OF WELDMENTS HW-700 DESIGN OF WELDED JOINTS HW-701 GENERAL REQUIREMENTS All welds, fillet or full penetration, shall be made to a qualified welding procedure by qualified welders for each welding process employed (manual, semiautomatic, automatic), in accordance with the applicable provisions of Section IX to assure satisfactory penetration and fusion into the base metal to the root of the weld. All members, prior to being welded, shall be properly fitted, aligned, and retained in position in accordance with the procedure specification for the welding procedure to be used. HW-701.1 Butt Joints. Longitudinal, circumferential, and other joints uniting plates of a drum, shell, or other pressure parts, except as provided in HW-701.1, HW-701.2, HW-701.3, HW-710, HW-711, and HW712, shall be butt joints. A butt joint shall be doublewelded butt or may have filler metal added from one side only, provided the weld penetration is complete and there is reinforcement on both sides of the joint. There shall be no valley either on the edge or in the center of the joint and the weld shall be so built up that the weld metal shall present a gradual increase in thickness from the surface of the plate to the center of the weld. At no point shall the plate on one side of the joint be offset with the plate on the other side of joint in excess of the alignment tolerance in HW812 except as provided in HW-715(a)(2). (a) A tapered transition section having a length not less than three times the offset between the adjoining surfaces as shown in Fig. HW-701.1, shall be provided at joints between materials that differ in thickness by more than one-fourth of the thickness of the thinner material or by more than % in. The transition section may be formed by any process that will provide a uniform taper. The weld may be partly or entirely in the tapered section or adjacent to it as indicated in Fig. HW-701.1. The transition requirement also applies (a) (b) Preferred Mathod Parmissibla (Cantar linas (Circumfarantial coineida) joints only) (c) Not Parmissibla FIG. HW-701.1 BUTT WELDING OF PLATES OF UNEQUAL THICKNESS when there is a reduction in thickness within a cylindri cal shell course and to tapers within formed heads. In longitudinal shell joints, the middle lines of the adjoining thicknesses shall be in alignment within the fabricating tolerances specified in HW-812. (b) Where fusion welded steel plate boilers are made up of two or more courses, the welded longitudinal joints of adjacent courses shall be not less than 6 in. apart, HW-701.2 Lap Joints (a) Boilers designed for not more than 30 psi and having inside diameters not exceeding 24 in. I.D. may have longitudinal or circumferential joints uniting plates of a shell made with lap joints, provided the joint is not in direct contact with the products of combustion. 94 RS-003100 1/17/02 NUECES HW-701.2 ARTICLE 7 -- DESIGN OF WELDMENTS HW-7I0.4 (b) For boilers over 30 psi or 24 in. I.D., lap joints may be used only where stayed plates are joined, where a cylindrical shell and a stayed wrapper are joined, or as permii'ed in HW-711. (c) Except as permitted in HW-711, lap joints shall be full fillet welded inside and outside and the throats of the fillet welds shall be not less than 0.7 times the thickness of the thinner plate. The surface overlap shall be not less than 4 times the thickness of the thinner plate. HW-701.3 Corner or Tee Joints (a) Boilers designed for not more than 30 psi may have the comer or tee joints made with single full fillet welds. The throat of the fillet weld shall be not less than 0.7 times the thickness of the thinner plate joined [see Fig. HW-701.3, sketches (a), (b), and (c)]. (b) Hot water boilers designed to these rules for pressures in excess of 30 psi shall have comer or tee joints made only with full penetration welds [see Fig. HW-701.3, sketches (d) and (e)] or double full fillet welds [see Fig. HW-701.3, sketch (f)]. HW-702 JOINT EFFICIENCIES The following joint efficiencies are to be used in the formulas of this Section (i.e., HG-301 and HG305) for joints completed by an arc or gas welding process. (a) E = 85% for full penetration butt joints as attained by double welding or by other means which will obtain the same quality of deposited weld metal on the inside and outside weld surfaces, to provide complete joint penetration and assurance that the weld grooves are completely filled (HW-701.1). Welds which use metal backing strips which remain in place are excluded. (b) E = 80% for full penetration single-welded butt joints with backing strips other than those included in (a) above. (c) E = 60% for single-welded butt joints without use of backing strips. (d) E = 65% for double full fillet lap joints meeting the requirements of HW-701.2(b). (e) E = 49% for double full fillet lap joints meeting the requirements of HW-701.2(a). HW-702.1 Joint Efficiencies for External Pressure Design. Joint efficiency E factors are not required to be used when the boiler part is designed for external pressure only. HW-703 MINIMUM THICKNESS OF WELDED PARTS The minimum thicknesses specified in HF-301 and Tables HF-301.1 and HF-301.2 apply if greater than the thicknesses calculated utilizing the above listed joint efficiency factors with formulas of this Section. HW-710 WELDED STAYS HW-710.1 Insertion of Stays. Except as provided in HW-710.4 and HW-710.5, the stays are to be inserted through holes having a maximum gap around the periph ery of the stay of Vl6 in. The size of the weld in shear, measured parallel to that portion of the stay in or extended through the plate, shall be not less than 5/i6 times the required diameter of the stay and in no case less than '/4 in. For a stay with other than circular cross section, the minimum size of the weld shall be that calculated for a circular stay of the same crosssectional area. To provide for the above specified welding, the plate may be countersunk by machining or pressing, or the stay may protrude through the plates, or a combination of those methods may be used. The end of the stay shall not be ..covered by weld metal and shall not be below the surface of the plate. HW-710.2 Projection of Stays Exposed to Products of Combustion. The ends of stays inserted through plates shall not project more than \ in. beyond surfaces exposed to the products of combustion. HW-7103 Fit-Up and Welding of Stays. The fitup and welding shall be such that excessive weld deposits do not project beyond the surface of the plate at the root of the weld. HW-710.4 Welding of Diagonal Stays. Diagonal stays shall be attached to the inner surface of the shell, but not to a head or tubesheet, by fillet welds only provided the following [see Figs. HW-710.4(a) and HW-710.4(b)]: (a) Fillet welds shall be not less than \ in. size and shall continue the full length of each side of the portion of the stay in contact with the shell. The product of the aggregate length of these fillet welds times their throat shall be not less than 1.25 times the required cross-sectional area of the stay. A fillet weld across the end of the stay is optional but shall not be credited in calculating the required area of fillet welds. (b) The longitudinal center line of the stay (projected if necessary) shall intersect the surface of the plate to 95 RS-003101 1/17/02 NUECE8 Fig. HW-701.3 1995 SECTION IV (f) ts nominal shell thickness th nominal head thickness tm " lesser of ts or th GENERAL NOTE: (a), (b), and <c) permissible for boilers designed for pressures up to 30 psi,- Id), (e), or (f) required for boilers designed for pressures over 30 psi; (g) not permissible. FIG. HW-701.3 SOME FORMS OF ATTACHMENTS OF PRESSURE PARTS TO FLAT PLATES TO FORM A CORNER JOINT (TEE JOINT) RS-003102 96 1/17/02 NUECE8 HW-710.4 ARTICLE 7 -- DESIGN OF WELDMENTS HW-7I1.1 GENERAL NOTE: A round bar or a round bar with a forged palm FIG. HW-710.4(a) SOME ACCEPTABLE TYPES OF DIAGONAL STAYS FOR INSTALLATION BY WELDING FIG. HW-710.4(b) UNACCEPTABLE TYPES OF DIAGONAL STAYS FOR INSTALLATION BY WELDING which the stay is attached within the outer boundaries of the attaching welds (also projected if necessary). (c) Diagonal stays shall, for boilers designed for not more than 30 psi pressure, comply with the requirements of HW-710.1, HW-710.2, and HW-710.3 and shall, for boilers designed for pressures in excess of 30 psi, comply with the requirements of HW-710.5. HW-710.5 For Pressures in Excess of 30 psi. The stays shall be inserted into holes countersunk in the sheet except as provided in HW-710.4, and shall be attached by full penetration welds. HW-711 HEADS OR TUBESHEETS ATTACHED BY WELDING HW-711.1 Flanged Heads or Tubesheets. Boilers may be constructed by attaching an outwardly or in wardly flanged head or tubesheet to the shell by fillet welding provided: (a) the head or tubesheet is supported by tubes, or braces, or both; (b) the joint attaching an outwardly flanged head or tubesheet is wholly within the shell and forms no part thereof; RS-003103 1/17/02 NUECE8 HW-711.1 1995 SECTION IV HW-715 (c) inwardly flanged heads or tubesheets are full fillet welded inside and outside; (d) the throats of the full fillet welds are not less than 0.7 times the thickness of the head or tubesheet; (e) on inwardly flanged heads or tubesheets, the minimum length of the straight flange shall conform with the requirements of HW-701.2; (f) the shell at the weld is not in contact with primary furnace gases; (g) these constructions shall not be used on the rear head of a horizontal-return tubular boiler, and inwardly flanged heads or tubesheets shall not be used on a boiler with an extended shell. HW-711.2 Unflanged Heads or Tubesheets. Boilers may be constructed by attaching unflanged heads or tubesheets to the shell by welding, provided: (a) the head or tubesheet is supported by tubes or braces, or both, as required by HG-340, or its thickness is calculated using the appropriate formula from HG-307; (b) the welding for boilers designed for not more than 30 psi meets the minimum requirements for HW701.3(a); (c) the weld for boilers designed for pressure in excess of 30 psi is a full penetration weld applied from either or both sides as shown in Fig. HW-701.3, sketch (d) or (e), or a double full fillet weld as shown in Fig. HW-701.3, sketch (f); (d) the shell or wrapper sheet, where exposed to primary furnace gases and not water cooled, shall not extend beyond the outside face of the head or tubesheet for a distance greater than the thickness of the head or tubesheet; (e) this construction shall not be used on the rear head of a horizontal-return tubular boiler. HW-712 FURNACE ATTACHMENTS HW-712.1 For Pressures Not More Than 30 psi. A furnace or crown sheet in a boiler designed to these rules for pressures not more than 30 psi may be attached to a head or tubesheet with a full fillet weld, provided: (a) the furnace shall not extend beyond the outside face of the head or tubesheet for a distance greater than the thickness of the head or tubesheet, unless protected by refractory material; the furnace shall be trimmed to remove any excess material before welding; (b) the throat of the full fillet weld is not less than 0.7 times the thickness of the head or tubesheet; (c) the joint attaching a cylindrical furnace to a head or tubesheet is wholly outside the cylindrical portion of the furnace. HW-712.2 For Pressures in Excess of 30 psi. A furnace or crown sheet in a hot water boiler designed to these rules for pressures in excess of 30 psi shall be attached to a head or tubesheet, as shown in Fig. HW-701.3, by a full penetration weld, with the furnace or crown sheet extending at least through the full thickness of the head or tubesheet, but when exposed to primary gases, furnace or crown sheet projections shall not extend beyond the face of the plate by more than 3/g in., unless protected by refractory material. HW-713 TUBES ATTACHED BY WELDING (a) The edge of the plate at the tubesheet hole may be beveled or recessed. The depth of any bevel or recess shall not be less than the tube thickness or '/8 in., whichever is greater, nor more than one-third of the tubesheet thickness. Where the plate is beveled or recessed, the projection of the tubes beyond the tube sheet shall not exceed a distance equal to the tube thickness, but shall extend at least through the tubesheet. (b) The maximum and minimum distance the firetube shall extend through the tubesheet shall be in accordance with Table HW-713. (c) The minimum size of the weld for firetubes used as stays shall be that calculated in accordance with HW-710.1 for a solid circular stay having the same cross-sectional area as the firetube. (d) The above projections do not apply to watertubes; the maximum projection for watertubes is '/2 >n- For attachment of watertubes by welding, see HW-731. A97 A97 HW-715 HEAD-TO-SHELL ATTACHMENTS Ellipsoidal, torispherical, hemispherical, and other types of formed heads, concave or convex to the pressure shall have the following requirements as to skirt length. (a)(1) An ellipsoidal or torispherical head which is attached to a shell by a butt joint need not be provided with a skirt when the nominal head thickness does not exceed ll/4 times the nominal shell thickness. When the nominal head thickness exceeds 1 *4 times the nominal shell thickness, a skirt shall be provided having a length not less than three times the nominal head thickness or ll/2 in., whichever is smaller. When a skirt is used it shall meet the requirements for shell thickness in HG-301. (2) Flanged heads concave to pressure may be attached to shells using a butt weld with one plate offset as shown in Fig. HW-715.1 provided the welded joint is not in contact with primary furnace gases. The 98 R8-003104 1/17/02 NUECES ARTICLE 7 -- DESIGN OF WELDMENTS Table HW-713 TABLE HW-713 FIRETUBE EXTENSION THROUGH TUBESHEETS FOR WELDED CONSTRUCTION A97 Tubesheet beveled or recessed Tubesheet not beveled or recessed NOTE: (1) See HG-360.2. Tubes Exposed to Primary Furnace Gases [Note (1)] min. = the tube shall extend at least through the tubesheet max. = ttutx Tubes Not Exposed to Primary Furnace Gases [Note (1)] min. = the tube shall extend at least through the tubesheet max. = greater of fox* or \ in. min. = greater of , or Vj in. max. = greater of tM or V4 in. min. = greater of tu or l/s In. max. = greater of or \ In. RS-00310S 98.1 1/17/02 NUECES HW-715 ARTICLE 7 -- DESIGN OF WELDMENTS HW-730.1 2th min., but not less than 1/2 in. for ellipsoidal heads 2th min. + 1/2 in.--for other heads 2ff min. Tangent line. f. ' 3th min., but need not exceed 1-1/2 in. 3th min. + 1/2 in., but not less than 1 in. <j- 3th m*n- * W in., but not less than 1 in. 'h Taper optional nr 3ts min. 2t. min. (a) Single Fillet Weld Bevel optional -f, 2-1/2 rmax. If min. A desired Avoid sharp break Depth of offset " ts Pressure on this side 1-1/2 t min.. f or f- 1/2 in. max. (b) Butt Weld With One Plate Edge Offset Details (c), (d), and (e) are Not Permissible FIG. HW-715.1 HEADS ATTACHED TO SHELLS A95 offset shall be smooth and symmetrical and shall not be machined or otherwise reduced in thickness. There shall be a uniform force fit with the mating section at the root of the weld. (b) Ellipsoidal or torispherical heads, concave or convex to the pressure, shall have a skirt length not less than that shown in Fig. HW-715.1 provided the welded joint is not in contact with primary furnace gases. Heads that are fitted inside or over a shell shall have a driving fit before welding. (c) Formed heads of full hemispherical shape, con cave to pressure, need not have an integral skirt, but where a skirt is provided for butt welded attachment, the thickness of the skirt shall be at least that required for a seamless cylindrical shell of the same diameter. (d) Flanged ellipsoidal or torispherical heads convex to pressure may be attached to the shell with a full fillet weld with throat no less than 0.7 times the head thickness. The shell at the weld shall not be in contact with primary furnace gases. HW-720 OPENINGS IN WELDS Any type of opening that meets the requirements for reinforcement given in HG-321 may be located in a butt welded joint. HW-730 WELDED CONNECTIONS HW-730.1 Strength of Attachment Welds (a) Nozzles, other connections, and their reinforce ment may be attached to a boiler by arc or gas welding. Sufficient welding shall be provided on either side of the line through the center of the opening parallel to the longitudinal axis of the shell to develop the strength of the shell as prescribed in HG-327 through shear or tension in the weld, whichever is applicable. The strength of groove welds shall be based on the area subjected to shear or to tension. The strength of fillet welds shall be based on the area subjected to shear, computed on the minimum leg dimension. The inside periphery of fillet weld shall be used in computing its length. (b) Weld strength calculations for pressure loadings are not required for the following: (1) nozzle connections made per Fig. HW-731, sketches (a), (b), (c), (g), (h), (o-l), (s-1), (u-1), (v--1), and (w-1); (2) nozzle connections for openings that are ex empt from reinforcement requirements by HG-320.3(c) or HG-320.3(d); and (3) openings designed in accordance with the rules for ligaments in para. HG-350. A97 99 RS-003106 1/17/02 NUECE8 HW-730J 1995 SECTION IV HW-730.2 Stress Values for Weld Metal. The allowable stress values for groove and fillet welds and for shear in nozzle necks in percentages of stress values for the vessel material are as follows: Nozzle-wall shear Groove-weld tension Groove-weld shear Fillet-weld shear 70% 74% 60% 49% NOTE: These values are obtained by combining the following factors: 87`/2% for combined end and side loading, 80% for shear strength, and the applicable joint efficiency factors. HW-730.2 RS-003107 1/17/02 NUECE8 99.1 HW-730J 1995 SECTION IV HW-73I.4 HW-730.3 Telltale Holes in Reinforcement Plates and Saddles. Separate reinforcement plates and saddles used to reinforce the material around openings and that are attached to the outside of a boiler shall be provided with at least one telltale hole [maximum size: !/4 in. pipe tap] that may be tapped for a preliminary compressed-air and soapsuds test for tightness of welds that seal off the inside of the boiler. These telltale holes may be left open when the boiler is in service. If the holes are plugged, the plugging material used shall not be capable of sustaining pressure between the plate and the boiler wall. HW-730.4 Stud Welds. Arc stud welding and resist ance stud welding, as defined in E-101, where the boiler pressure exerts a tensile load on the studs, may be used only for the attachments of bolted unstayed flat heads, cover plates and blind flanges, handholes and manholes, with the further limitations as follows. (a) Studs attached by stud welding shall not be in direct contact with products of combustion or flue gases. (b) Where the pressure exerts a tensile load on the studs, a full face gasket must be used on flat heads, cover plates and blind flanges attached by stud welding. (c) The minimum size stud used shall be not less than '/4 in. nominal diameter, and the maximum size shall not exceed 7/8 in. nominal diameter. (d) The type of stud shall be limited to round exter nally threaded studs. (e) Base metal shall be of ferrous material speci fication as permitted by this Section, and the base metal must be thick enough to prevent bum through. See HW-500(b) for stud material. (J) The maximum spacing of studs shall not exceed 12 times the nominal diameter of the stud. (g) The maximum allowable stress for the stud shall be 7800 psi based on the smallest cross-sectional area (i.e., the root of the thread). HW-731 MINIMUM REQUIREMENTS FOR ATTACHMENT WELDS HW-731.1 General. The location and minimum size of attachment welds for nozzles and other connections shall conform to the requirements in this paragraph. (a) Notation. The symbols used in this paragraph and in Fig. HW-731 are defined as follows: t--nominal thickness of boiler shell or head, in. t,, = nominal thickness of nozzle wall, in. tw = dimension of partial penetration attachment welds (fillet, single-bevel, or single-J), mea sured as shown in Fig. HW-731, in. fc = not less than the smaller of `/4 in. or 0.7 fmin. (inside comer welds may be further limited by a lesser length of projection of nozzle wall beyond the inside face of the boiler wall) rm,n = the smaller of 3/4 in. or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld, in. fi, t2 = not less than the smaller of '/4 in. or 0.7 fmin and t, + t2 not less than l'/4 HW-731.2 Necks Abutting the Boiler Shell (a) Nozzles abutting the boiler shell shall be attached by a full penetration groove weld. Backing strips shall be used with welds deposited from only one side when the shell thickness is over 3/g in. or when complete joint penetration cannot be verified by visual inspection [for example, see Fig. HW-731, sketch (y)]. (b) Nozzles or tubes recessed into thick boiler shells or headers may be welded from only one side by cutting a welding groove in the boiler shell to a depth of not less than tn on the longitudinal axis of the opening. It is recommended that a recess at least l/16 in. deep be provided at the bottom of the groove in which to center the nozzle. The dimension tw of the attachment weld shall be not less than t,, or less than '/4 in. [for example, see Fig. HW-731, sketches (y) and (z)]. HW-7313 Inserted Nozzles Without Added Rein forcement Elements (a) Nozzles inserted into or through a hole cut in the boiler shell and without additional reinforcement elements shall be attached by a full penetration groove weld or by two partial penetration welds, one on each face of the boiler shell. Permissible types of welds are shown in Fig. HW-731, sketches (c) through (h). (b) Backing strips shall be used with full penetration welds deposited from one side only when the shell thickness is over 3/g in. or when complete joint penetra tion cannot be verified by visual inspection. The two partial penetration welds may be any desired combina tion of fillet, single-bevel, and single-J welds. The dimension tw of each weld shall be not less than the smaller of `/4 in. or 0.7 and their sum shall be not less than l'/4 /min (see Fig. HW-731). HW-731.4 Inserted Nozzles With Added Reinforce ment Inserted type nozzles having added reinforcement in the form of one or more separate reinforcement plates shall be attached by welds at the nozzle neck periphery and at the outer edge of each reinforcement plate. The weld at the outer edge of each reinforcement plate shall be a fillet weld with a minimum throat 100 RS403108 1/17/02 NUECE8 ARTICLE 7 -- DESIGN OF WELDMENTS Fig. HW-731 ' the smaller of V* in. or 0.7f min. fw 0.7 f min. (k) FIG. HW-731 SOME ACCEPTABLE TYPES OF WELDED NOZZLES AND OTHER CONNECTIONS TO SHELLS, DRUMS, AND HEADERS US-003109 1/17102 NUECES A95 Fig. HW-731 1995 SECTION IV <u-1l Either method of attachment it satisfactory fl / 1/4 in. 3 in. NPS max. V 7/1 lU-3/8 in. 3/32 in. min. leg , (not less thanf t2\ fa \ / the thickness of schedule 160 pipe) t,1 + fn* - 1-1/4 f min. ' f^ or fj not less tlhan the smaller of 1 /4 m. or 0.7f min. (u-2) <v-1l (v-21 lw-1) (w-21 (w-31 (w-4) For nozzles or tubes recessed into thick boiler shells or headers (see HW-731 2 (b)] when used for other than square, round or oval headers, corners shall be rounded off. -- Nozzle or tube connections ----- [see HW-731.2(b) and HW-731.8] FIG. HW-731 SOME ACCEPTABLE TYPES OF WELDED NOZZLES AND OTHER CONNECTIONS TO SHELLS, DRUMS, AND HEADERS (CONT'D) R8-003110 1/17/02 102 NUECES ( o HW-731.4 ARTICLE 7 -- DESIGN OF WELDMENTS HW-740 dimension of Vi/min. The welds attaching the nozzle to the boiler shell and to the reinforcement shall consist of one of the following combinations: (a) a single-bevel or single-J weld in the shell plate, and a single-bevel or single-J weld in each reinforcement plate. The dimension tw of each weld shall be not less than 0.7 rmin [see Fig. HW-731, sketch (n)]. (b) a full penetration groove weld in the shell plate, and a fillet, single-bevel, or single-J weld with a weld dimension tw not less than 0.7 tmin in each reinforcement plate [see Fig. HW-731, sketch (m)]; (c) a full penetration groove weld in each reinforce ment plate, and a fillet, single-bevel, or single-J weld with a weld dimension tw not less than 0.7 fmin in the shell plate [see Fig. HW-731, sketch (1)]. HW-731.5 Nozzles With Integral Reinforcement Nozzles and other connections having integral reinforce ment in the form of extended necks or saddle type pads shall be attached by a full penetration weld or by means of a fillet weld along the outer edge and a fillet, single-bevel, or single-J weld along the inner edge. The throat dimension of the outer weld shall be not less than '/^min- The dimension tw of the inner weld shall be not less than 0.7 fmin [see Fig. HW-731, sketch (k)]. ......... HW-731.6 Fittings With Internal Threads. The attachment of internally threaded fittings shall meet the following requirements. (a) Except as provided for in HW-731.7, internally threaded fittings shall be attached by a full penetration groove weld or by two fillet or partial penetration welds, one on each face of the boiler wall. The minimum weld dimensions shall be as shown in Fig. HW-731, sketches (u) through (x). (b) Flange-type fittings not exceeding NPS 3 as shown in Fig. HW-731, sketch (w-4), may be attached without additional reinforcement other than that in the fitting and its attachments, provided all of the following conditions are met. (1) The boiler wall thickness shall not exceed \ in. (2) The minimum fillet leg shall be Vyi in. (3) The opening in the boiler wall shall not exceed the outside diameter of the nominal pipe plus 34 in. HW-731.7 Fittings and Nozzles Not Exceeding NPS 3 (a) Internally threaded fittings, nozzles, or equivalent bolting pads may be attached to vessels having a wall thickness not greater than \ in. by a fillet weld deposited from the outside only, having the minimum dimensions shown in Fig. HW-731, sketches (o) through (t). (b) Fittings shown in Fig. HW-731, sketches (u-2), (v-2), (w-2), and (x), may be attached by welds that are exempt from size requirements other than those specified in HW-730.1. (c) Internally threaded fittings may be attached by a groove and fillet weld from the outside only as shown in Fig. HW-731, sketch (w-3). The groove weld tw shall not be less than the thickness of Schedule 160 pipe (ANSI B36.10-1979). (d) Internally threaded fittings and nozzles not ex ceeding NPS 11 /2 as shown in Fig. HW-731, sketches (t-1) and (t-2) may be attached to vessels by a fillet weld deposited from the outside only provided the following conditions are met: (1) The boiler wall thickness shall not exceed \ in. (2) The fillet weld shall be a minimum of 0.7r instead of l1/4rmin shown in Fig. HW-731, sketches (t-1) and (t-2), but in no case less than 3/32 in. leg. HW-731.8 Watertube Attachments. Watertubes not exceeding 3l/2 in. O.D. may be attached to tubesheets with fillet welds deposited from the outside only, having a minimum weld dimension as shown in Fig. HW731, sketch (z) [see HG-360.2(c)]. HW-740 RESISTANCE WELDING IN CARBON STEEL FOR OTHER THAN BUTT WELDED JOINTS Resistance spot and seam welding may be used in the construction of embossed or dimpled assemblies under the following limitations and additional require ments. (a) Materials used in the resistance welded parts are SA-285 and SA-414 with the further limitation that the carbon content is 0.15 maximum on heat analysis. (b) Embossed or dimpled assemblies consist of either two embossed plates welded together, or two dimpled plates welded together, or an embossed or dimpled plate welded to a flat plate as in Fig. HW-745 sketch (a). A third, intermediate plate, frame, or series of spacers, as illustrated in Fig. HW-740, sketch (a) or (c), may be used to form a three-ply assembly. (c) The allowable working pressure for resistance welded embossed or dimpled assemblies shall be the lowest pressure established by the following: (1) a proof test in accordance with the requirements of HG-500; (2) the computed value of the plain plate, if used in resistance spot welded construction. The plain plate. 103 RS-duJIll 1/17/02 NUECES HW-740 1995 SECTION IV HW-740 Edg* Mam SP' * warn (a) Two Outer Embossed or Dimpled Plates Welded to Inner Flat Plate Three-Ply Assembly (b) TWo Outer Embossed Plates Welded to Inner Edge Frame and Spacers Filler at required for tension-test As required I *| 1 in.to 1-i/s in. 1 in.to 1-l/a in. T <c> Spot-weld Tension Specimen for Three-Ply Joint m (d) Seam-Weld Specimen for Tension and Macrosection for Three-Ply Joint FIG. HW-740 THREE-PLY JOINT ASSEMBLIES if used, shall meet the requirements for braced and stayed surfaces in KJ-340. (3) the computed value of the plain plate if used in resistance seam welded construction. The plain plate, if used, shall meet the requirements of HG-307.3(a), formulas (3) and (4), with z = 2.5 max., c = 0.2. (d) In lieu of the Procedure and Performance Qualifi cation requirements of Section IX, the following require ments shall be met for resistance spot welded and resistance seam welded pressure vessels. (1) Proof Test. A pressure proof test to destruction shall be conducted on a finished vessel or representative panel. The test shall be conducted as specified in HG502.3. If a representative panel is used, it shall be rectangular in shape and at least 5 pitches in each direction, but not less than 24 in. in either direction. (2) Workmanship Samples (a) Three single spot welded specimens, and/or one seam welded specimen, as shown in Fig. HW-745 for two-ply joints, and in Fig. HW-740 for three-ply joints, shall be made immediately before and after the welding of the proof test vessel. These test specimens shall be representative of the manufacturing practice employed in the fabrication of the proof test vessel. When a difference in the amount of magnetic material in the throat of the machine or the part geometry precludes the welding of satisfactory test specimens at the same machine settings as those used for the proof test vessel, sufficient material shall be placed in the throat of the welding machine to compensate for the difference in size of the proof test panel and the small test specimens. (b) The spot welded specimens shall be sub jected to tensile loading for ultimate strength and visu ally inspected for nugget size, electrode indentation, and evidence of defects. The seam weld specimens shall be similarly tested for ultimate strength and prepared for macrographic examination to reveal nugget size, spac ing, penetration, soundness, and surface conditions. (c) In addition, a typical spot weld sample and seam welded sample shall be cut from the proof test vessel after failure. A portion of each sample shall be sectioned for macroetch examination. (d) All pertinent information obtained from the foregoing tests shall be recorded. These samples and data constitute workmanship samples which shall be available for comparison with quality control specimens that may be made during production. (e) With every change in production run of material or gage, the machine setting control will be verified by test samples. (3) Machine Settings and Controls. The resistance welding machine settings and process control parameters 104 R8-003112 1/17/02 NUECES HW-740 ARTICLE 7 -- DESIGN OF WELDMENTS HW-745 used in the making of the proof test vessel and the workmanship samples shall be recorded. Except for minor variations and adjustments as may be permitted at the discretion of the Authorized Inspector, the applicable settings shall be used in the fabrication of all vessels in a given production run. (4) Pressure Tests and Inspection. All production vessels shall be pressure tested to a pressure not less than 1.5 times the allowable working pressure. These tests and inspection during fabrication shall be in accord ance with HG-510. (5) Records. Records shall be kept of all data obtained from tests of the proof test vessel, the work manship samples, the welding machine settings, the welding procedure, and process control parameters. Records shall be kept of all preheat, postheat, and heattreatment procedures and of inspection procedures. (6) If spot and seam welding machines other than those used for the initial proof test vessel and workman ship samples are to be used in production, each addi tional machine and welding procedure shall be qualified in full accordance with (d). The performance of the additional proof test vessels shall substantiate the allow able working pressure previously established for the specific boiler design. (7) Lap joints only, between two thicknesses of metal sheet, may be resistance spot or seam welded. The use of projection welding (including resistance stud welding) is excluded. (8) The range of thickness of sheet materials which may be resistance spot or seam welded under this case shall be: (a) two-ply joints [see Fig. HW-745, sketch (a)]: (1) the minimum thickness t, or t2 shall be 0.045 in; (2) the maximum thickness t\ or t2 shall be '/4 in. nominal. (b) three-ply joints [see Fig. HW-740, sketches (a) and (b)]: (1) the two outer layers t\ and t2 shall be equal in thickness; (2) the inner layer /3 shall be at least as thick as t, or t2; (3) the minimum thickness of f|, t2, and f3 shall be 0.045 in.; (4) the maximum thickness of ^ and r2 shall be 0.126 in.; (5) the maximum thickness of f3 shall be 0.188 in.; (6) the total thickness of the three layers tx + t2 + t2 shall be 0.135 in. min., 0.378 in. max. HW-745 RESISTANCE WELDING OF HYDRAULICALLY FORMED PANELS Resistance spot and seam welding may be used in the construction of embossed or dimpled assemblies under the following limitations and additional require ments. (a) Materials used in the resistance welded parts of such vessels are: carbon steel SA-285, SA-620, and SA-414, or any proven combination, with the further limitation that the carbon content is 0.15% maximum. (b) Construction consists of employing resistance spot welding or resistance seam welding to join two sheets together [see Fig. HW-740, sketch (a)]. Subsequent to the joining and sealing operation, the assembly is subjected to a hydraulic or pneumatic pressure to achieve a dimpled formation. Construction may consist of two sheets of equal thickness that results in the formation of a dimpled surface on both sides of an assembly or two sheets of different thicknesses that results in the formation of a dimpled surface on only one side of a pressure assembly. Any number of such assemblies may be joined together, by fusion welding, to make a boiler or boiler parts. (c) The allowable working pressure for the construc tion shall be the lowest pressure established by the following: (1) a proof test in accordance with the bursting test procedures in HG-502 and HG-503 need not be followed, provided that when performing the proof test, the application of pressure is continuous until burst or until the proof test is stopped. In using the formulas for calculating the maximum allowable working pressure, a value of 0.80 shall be used for E, the weld joint efficiency factor. All provisions of HG-501 and HG- 504 shall apply. , ;; (2) the computed value of the plain plate, if used in resistance spot welded construction. The plain plate, if used, shall meet the requirements for braced and stayed surfaces in HG-340. (3) the computed value of the plain plate, if used in resistance seam welded construction. The plain plate, if used, shall meet the requirements of HG-307.3 formu las (3) and (4), with z = 2.5 max., c = 0.2, and E = 1.0. (d) The following design limitations apply. (I) A change in any of the variables will require requalification of the design proof test of (c): (a) an increase in the spot or row pitch exceeding `/is in.; (b) a change in the specification, type, or grade of material or material thickness for either sheet or both sheets; 105 R8-003113 1/17/02 NUECE8 HW-745 1995 SECTION IV HW-745 (c) a change in the electrode size or material. (2) A duplicate test panel of that used to establish the maximum allowable working pressure shall be inflated to a pressure at least 5% greater than the maximum forming pressure to be used in production. The rate of pressurization shall be the same as that used in the burst test. The panel shall be sectioned to show at least six spot welds [see Fig. HW-745, sketches (d-1) and (d-2)]. The weld cross sections shall be subjected to macroetch examinations and shall show no cracks. The maximum pillow heights measured, as shown in Fig. HW-745, sketch (e), of panels made in production shall not exceed 95% of the maximum pillow height of this duplicate test panel. The maximum forming pressure shall not exceed 80% of the burst pressure. (e) In lieu of the Procedure Qualification require ments of Section IX, the following requirements shall be met for resistance spot welded and resistance seam welded panels. (1) Proof Test. A pressure proof test to destruction as set forth in (c)(1) above shall be conducted on a finished boiler or representative panel. This test may be a separate test or part of the test in (c)(1) above. If a representative panel is used, it shall.be rectangular in shape and at least 5 pitches in each direction, but not less than 24 in. in either direction. (a) A typical spot weld sample and seam welded sample shall be cut from the proof test panel after failure. A portion of each sample shall be sectioned for macroetch examination. (2) Workmanship Samples (a) Three single spot welded specimens, and/or one seam welded specimen as shown in Fig. HW-745, sketches (b) and (c), shall be made immediately before and after the welding of the proof test panel. These test specimens shall be representative of the manufacturing practice employed in the fabrication of the proof test panel. When a difference in the amount of magnetic material in the throat of the welding machine or the part geometry precludes the welding of satisfactory test specimens at the same machine settings as those used for the proof test panel, sufficient material shall be placed in the throat of the welding machine to compen sate for the difference in size of the proof test panel and the small test specimens. (b) The spot welded specimens shall be sub jected to tensile loading for ultimate strength and visu ally inspected for nugget size, electrode indentation, and evidence of defects. The seam weld specimens shall be similarly tested for ultimate strength and prepared for macrographic examination to reveal nugget size, spac ing, penetration, soundness, and surface condition. (c) All pertinent information obtained from the foregoing tests shall be recorded. These samples and data constitute workmanship samples which shall be available for comparison with quality control specimens that may be made during production. (d) With every change of material gage, the machine setting control shall be verified by test samples. (e) At the beginning of each production run, which is a group of panels or assemblies all produced during a 24 hr period using the same welding process, material, and material thickness, either a tension test or a peel test as shown in Fig. HW-745, sketch (0, shall be performed. The acceptance criterion for these tests shall be that the parent metal adjacent to the weld must fail before the weld itself fails. (3) Machine Settings and Controls. The resistance welding machine settings and process control parameters used in the making of the proof test panel and the workmanship samples shall be recorded. Except for minor variations and adjustments as may be permitted at the discretion of the Inspector, the applicable settings shall be used in the fabrication of all panels in a given production run. (4) Pressure Tests and Inspection. All production boilers shall be pressure tested to a pressure not less than 1.5 times the allowable working pressure. These tests and inspection during fabrication shall be in accord ance with HG-510, except that provisions of HG-510(b) may be exceeded because the application of pressure during formation of the pillows will exceed the design and test pressure by more than the allowed 10 psi. (5) Records. Records shall be kept of all data obtained from tests of the proof test boiler or panel, duplicate test panel, the workmanship samples, the welding machine settings, and the welding procedure and process control parameters. Records shall be kept of all preheat, postheat, and heat-treatment procedures and of inspection procedures. (f) If spot and seam welding machines other than those used for the initial proof test panel, duplicate test panel, and workmanship samples are to be used in production, each additional machine and welding procedure shall be qualified in accordance with (e)(2)(a) and (b) above. (g) Lap joints only, between two thicknesses of metal sheet, may be resistance spot or seam welded. The use of projection welding (including resistance stud welding) is excluded. (h) The range of thickness of sheet materials which may be resistance spot or seam welded shall be: (/) two-ply joints [see Fig. HW-745, sketch (a)]: (a) the minimum thickness t{ or r2 shall be 0.045 in.; 106 R8-003114 1/17/02 NUECES ARTICLE 7 -- DESIGN OF WELDMENTS Fig. HW-745 Spot or seem welds Edge *#am W------------------------As required ----------------- TWo Embossed or Dimpled Plates Embossed or Dimpled Plata to net Plate (a) i i* i i 1 in. < O < 1V4 in. (b) Single-Spot-Weld Tension Specimen, Two-Ply Joint ta| 0 U 1 in. < O < 1% in. Ic) Seam-Weld Specimen for Tension and Macrosection, Two-Ply Joint (d-2) Step 1: Grip specimen in vise or other suitable device. Step 2: Bend specimen (this step may not be required ii the gripped portion of the specimen is greatly thicker than the other portion). Step 3: Peel pieces apart with suitable tool until they are separated. (f) Peel Test FIG. HW-745 TWO-PLY JOINT ASSEMBLIES 107 RS-003116 1/17/02 NUECE8 HW-745 1995 SECTION IV (b) the maximum thickness tt or t2 shall be V4 in. nominal. (i) If arc welding, gas welding, or brazing are used for the attachment of nozzles, tubes, and fittings, for repair or for the closing of peripheral seams, the qualification of welding or brazing procedure and weld ing or brazing performance shall be conducted in accord ance with the requirements of Section DC. Filler metals, if used, shall conform to the requirements of Section IX. (j) For construction having sheets formed within dies where the dies control the shape of the pillow and restrain the spot welds so that the bending in the sheet is outside the heat affected zone, the welding may be done before or after forming. The requirements and limitations in (d)(2) above do not apply to this method of construction. HW-745 RS-003116 108 1/17/02 NUECE8 ARTICLE 8 FABRICATION REQUIREMENTS HW-800 FORMING PLATES The ends of plates which form the longitudinal joints of boiler shells shall be formed by pressure, not sledging, to the proper curvature. HW-801 BASE METAL PREPARATION (a) The preparation of joints prior to welding may involve any of the conventional methods in use such as machining, thermal cutting, chipping, grinding, or combinations of these. (b) Where thermal cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration. (c) The method of base metal preparation used shall leave the welding groove with reasonably smooth sur faces and free from deep notches, striations, or irregular ities. The surfaces for welding shall be free of all scale, rust, oil, grease, or other foreign materials. (d) Cast surfaces to be welded shall be machined, chipped, or ground where necessary to remove foundry scale and to expose sound metal. HW-810 ASSEMBLY (a) Parts that are being welded shall be fitted, aligned, and retained in position during the welding operation within the tolerance specified in HW-812. (b) Bars, jacks, clamps, tack welds, or other appro priate means may be used to hold the edges of the parts to be welded in alignment. (c) Tack welds used to secure alignment shall either be removed completely when they have served their purpose, or their stopping and starting ends shall be properly prepared by grinding or other suitable means so that they may be satisfactorily incorporated into the final weld. Tack welds, whether removed or left in place, shall be made using a fillet weld or butt weld procedure qualified in accordance with Section IX. Tack welds to be left in place shall be made by welders qualified in accordance with Section IX and shall be examined visually for defects, and if found defective shall be removed. It is not necessary that a subcontractor performing such tack welds for the vessel manufacturer be a holder of an ASME Certificate of Authorization. If the tack welds are permanently left in place, the final vessel manufacturer shall maintain the controls to assure that the necessary welding procedure and performance quali fications are met in order to satisfy Code requirements. (d) When joining two parts by the inertia and continu ous drive friction welding processes, one of the two parts must be held in a fixed position and the other part rotated. The two faces to be joined must be essentially symmetrical with respect to the axis of rotation. Some of the basic types of applicable joints are solid round to solid round, tube to tube, solid round to tube, solid round to plate, and tube to plate. HW-812 ALIGNMENT TOLERANCE (a) The edges of plates at butt joints shall not be offset from each other at any point in excess of the amount in the following table, where t is the plate thickness. Direction of Joints in Plate Thickness, Cylindrical Vessels in. Longitudinal Circumferential Up to Vi, incl. Over Vi to 34, incl. Over V4 '4' Vs in. in. '4/ V4t 3/|6 in. (b) Butt joints in heads and butt joints between cylindrical shells and hemispherical heads shall meet the requirements in (a) above for longitudinal joints in cylindrical shells. 109 RS-003117 1/17/02 NUECES HW-813 1995 SECTION IV HW-820.7 HW-813 DISTORTION (a) The cylinder or barrel of a drum or shell shall be circular at any section within a limit of 1% of the mean diameter, based on the differences between the maximum and minimum mean diameters at any section, and if necessary to meet this requirement shall be reheated, rerolled, or reformed. To determine the differ ence in diameters, measurements may be made on the inside or the outside. For vessels with longitudinal lap joints, the permissible difference in inside diameters may be increased by the nominal plate thickness. (b) Cylindrical furnaces and other cylindrical parts subjected to external pressure shall be rolled to a circle with a maximum permissible deviation from the true circle of not more than '/4 in. HW-820 SPECIFIC WELDING REQUIREMENTS HW-820.1 Finished Longitudinal and Circumfer ential Joints (a) Butt welded joints shall have complete penetration and full fusion. The surface of the weld may be left as-welded provided the weld is free of coarse ripples, grooves, overlaps, abrupt ridges, or valleys. A reduction in thickness due to the welding process is acceptable provided all of the following conditions are met. (1) The reduction in thickness shall not reduce the material of the adjoining surfaces below the minimum required thickness at any point. (2) The reduction in thickness shall not exceed V32 in. or 10% of the nominal thickness of the adjoining surface, whichever is less.1 HW-820.2 Fillet Welds. In making fillet welds, the weld metal shall be deposited in such a way that adequate penetration into the base metal at the root of the weld is secured. The reduction of the thickness of the base metal due to ihe welding process at the edges of the fillet weld shall meet the same requirements as for butt welds [see HW-820.1]. HW-820.3 Double-Welded Butt Joints. Before applying weld metal on the second side to be welded, the root of double-welded butt joints shall be prepared by suitable methods such as chipping, grinding, or thermal gouging, so as to secure sound metal at the base of weld metal deposited on the face side, except ' It is not the intent of this paragraph to require measurement of reductions in thickness due to the welding process. If a disagreement between the Manufacturer and the Inspector exists as to the acceptabil ity of any reduction in thickness, the depth shall be verified by actual measurement. for those processes of welding by which proper fusion and penetration are otherwise obtained and by which the root of the weld remains free from impurities. HW-820.4 Stud Welding. In the case where arc stud welding and resistance stud welding is used to attach load canying studs, a production stud weld test of the procedure and welding operator shall be per formed on five studs, welded and tested in accordance with either the bend or torque stud weld testing described in Section IX as follows: (a) prior to start of daily operation if used continu ously on units of similar construction; (b) prior to the start of application to a given unit when not used continuously; (c) after adjustment or servicing is done on welding equipment. HW-820.5 Procedure and Performance Qual ification Tests and Material Requirements for Stud Welding. Procedure and performance qualification tests for stud welds shall be made in accordance with Section IX. Further requirements for stud welding are as follows. (a) Metallic coatings (such as cadmium plating) if used shall not be within x/% in. from the weld end of the stud. ' (b) The base metal must be above 50F during the welding process. HW-820.6 Stud Welding. In the case where stud welding and resistance stud welding are used for joining nonpressure bearing attachments, which have essentially no load carrying function (such as extended heat transfer surfaces, insulation attachment pins, etc), to pressure parts by any automatic welding process performed in accordance with a Welding Procedure Specification (in compliance with Section IX as far as applicable), procedure and performance qualification testing is not required. In the case where stud welding is used to attach nonload-carrying studs, a production stud weld test, appropriate to the end use application requirements, shall be specified by the Manufacturer or assembler and carried out on a separate test plate or tube: (a) prior to start of daily operation if used continu ously on units of similar construction; (b) prior to the start of application to a given unit when not used continuously; (c) after adjustment or servicing is done on welding equipment. HW-820.7 The welded joint between two members joined by the inertia and continuous drive friction welding processes shall be a full penetration weld. Visual examination of the as-welded flash roll of each 110 RS-009118 1/17/02 NUECES HW-820.7 ARTICLE 8 -- FABRICATION REQUIREMENTS HW-840 weld shall be made as an in-process check. The weld upset shall meet the specified amount within 10%. The flash shall be removed to sound metal. HW-820.8 Welding (Brazing) by Non-Certificate Holders (a) Welders, including brazers, and welding and braz ing operators not in the employ of the manufacturer (Certificate of Authorization Holders) may be used to fabricate boilers or parts thereof constructed in accord ance with the Section, provided all of the following conditions are met. (1) All Code construction shall be the responsibil ity of the Manufacturer. (2) All welding shall be performed in accordance with the Manufacturer's welding procedure specifica tions which have been qualified by the Manufacturer in accordance with the requirements of Section IX and this Section. (3) All welders shall be qualified by the Manufac turer in accordance with the requirements of Section IX and this Section. (4) The Manufacturer's quality control system shall include as a minimum: (a) a requirement for complete and exclusive administrative and technical supervision of all welders by the Manufacturer; (b) evidence of the Manufacturer's authority to assign and remove welders at his discretion without involvement of any other organization; (c) a requirement for Assignment of Welder Identification symbols; (d) evidence that this program has been accepted by the Manufacturer's Authorized Inspection Agency which provides the inspection service. (5) The Manufacturer shall be responsible for Code compliance of the completed boiler or part, including Code symbol stamping and providing Data Report Forms properly executed and countersigned by the Inspector, HW-830 REPAIR OF WELD DEFECTS Visible defects, such as cracks, pinholes and incom plete fusion, and defects detected by leakage tests shall be removed by mechanical means or by thermal grooving processes, after which the joint shall be re welded and reexamined. HW-840 POSTHYDROTEST WELDING OF NONPRESSURE PARTS TO PRESSURE PARTS Nonpressure parts may be welded to pressure parts after the hydrostatic test has been performed in accord ance with the requirements as set forth in HG-510 provided the following criteria are met. (a) The welding is done in accordance with this Subpart (see HW-820). (b) The welding is limited to P-No.l materials. (c) The attachment is done by stud welding or with fillet welds where the throat of the weld is not to exceed the lesser of 1.5 times the thickness of the pressure part or % in. (d) The completed weld is inspected by the Author ized Inspector. (e) The Manufacturer's Data Report Form shall be signed only after completion of the welding. (f) Welding is not permitted on brazed joints. Ill R8-003119 1/17/0* NUECES ARTICLE 9 INSPECTION HW-900 INSPECTION DURING FABRICATION The manufacturer shall submit the boiler or other pressure part for inspection at such stages of the work as may be designated by the Inspector. HW-910 CHECK OF WELDING PROCEDURE QUALIFICATIONS (a) It is the duty of the Inspector to assure himself that the welding procedures employed in construction have been qualified under the provisions of Section IX. The manufacturer shall submit evidence to the Inspector that those requirements have been met. (b) The Inspector has the right at any time to call for and witness the test welding and testing, although it is not mandatory that he witness the test welding and the testing unless he so desires. HW-911 CHECK OF WELDER AND WELDING OPERATOR PERFORMANCE QUALIFICATIONS (a) It is the duty of the Inspector to assure himself that all welding is done by welders or welding operators qualified under the provisions of Section IX. The manu facturer shall make available to the Inspector a certified copy of the record of performance qualification tests of each welder and welding operator as evidence that these requirements have been met (b) The Inspector has the right at any time to call for and witness the test welding and testing, although it is not mandatory that he witness the test welding and the testing unless he so desires. 112 RS-0031M 1/17/02 NUECES PART HF -- SUBPART HB REQUIREMENTS FOR BOILERS FABRICATED BY BRAZING Article 10 HB-1115 HB-1001 Article 11 HB-1100 HB-1101 HB-1102 HB-1103 Article 12 HB-1200 HB-1201 HB-1202 Article 13 HB-1300 HB-1301 HB-1302 HB-1303 HB-1304 HB-1305 HB-1306 HB-1307 Article 14 HB-1400 HB-1401 HB-1402 Article 15 HB-1500 HB-1501 HB-1502 General Requirements Scope................................................................................................................................ Responsibility of Manufacturer or Contractor.............................................................. 115 115 Material Requirements General.............................................................................................. Combinations of Dissimilar Materials........................................................................... Brazing Filler Metals....................................................................................................... Fluxes and Atmospheres................................................................................................. 116 116 116 116 Brazing Processes, Procedures, and Qualifications Brazing Processes............................................................................................................ Joint Brazing Procedures................................................................................................. Brazing Qualifications and Records............................................................................... 117 117 117 Design Strength of Brazed Joints................................................................................................ Brazed Joint Efficiency Factors...................................................................................... Minimum Thickness........................................................................................................ Permissible Service Temperature..................................................................................... Application of Brazing Filler Metal............................................................................... Joint Clearance...................................................................................... ;...................... Openings........................................................................................................................... Brazed Connections........................................................................................................ 118 118 118 118 118 119 119 119 Fabrication Requirements Cleaning of Surfaces to Be Brazed............................................................................... Postbrazing Operations..................................................................................................... Repair of Defective Brazing.......................................................................................... 120 120 120 Inspection and Stamping Inspection......................................................................................................................... Inspection of Brazing Procedure..................................................................................... Certification of Brazer and Brazing Operator................................................................. 121 121 121 113 RS403121 1/17/02 NUECE8 HB-1503 HB-1510 Table HB-1305 Visual Examination............................................................................................. 121 Stamping............................................................................................................. 121 Recommended Joint Clearances at Brazing Temperature........................................ 119 R8403122 114 1/17/02 NUECES ARTICLE 10 GENERAL REQUIREMENTS HB-1000 SCOPE The requirements of this Subpart HB are applicable to boilers and parts thereof that are fabricated by brazing. HB-1001 RESPONSIBILITY OF MANUFACTURER OR CONTRACTOR Each manufacturer or contractor is responsible for the brazing done by his organization and shall establish the procedures and conduct the tests required in Section IX to qualify the brazing procedures he uses in the construction of the brazed assemblies built under Section IV and the performance tests of brazers and brazing operators to determine their ability to apply the proce dure properly. RS-003123 1/17/02 NUECES ARTICLE 11 MATERIAL REQUIREMENTS HB-1100 GENERAL Materials used in the construction of boilers and parts thereof by brazing shall conform to the specifications in Section II, and shall be limited to those materials for which allowable stress values have been assigned in Table HF-300.2. The materials being brazed shall be of proved brazing quality with the brazing filler metal employed. Satisfactory qualification of the brazing pro cedure under Section IX is considered proof of accept able material for brazed construction. HB-1102 BRAZING FILLER METALS The selection of the brazing filler metal for a specific application shall depend upon its suitability for the base metals being joined. Satisfactory qualification of the brazing procedure under Section IX is considered proof of the suitability of the filler metal. Brazing used with brazing filler metals other than those listed in Section II, Part C, SFA-5.8 shall be separately qualified for both procedure and performance qualification in accordance with Section IX. HB-1101 COMBINATIONS OF DISSIMILAR MATERIALS Combinations of dissimilar metals may be joined by brazing provided they meet the qualification require ments of Section IX. HB-1103 FLUXES AND ATMOSPHERES Suitable fluxes or atmospheres or combinations of fluxes and atmospheres shall be used to prevent oxida tion of the brazing filler metal and the surfaces to be joined. Satisfactory qualification of the brazing proce dure under Section IX is considered proof of the suitability of the flux and/or atmosphere. R8-003124 116 1/17/02 NUECE8 ARTICLE 12 BRAZING PROCESSES, PROCEDURES, AND QUALIFICATIONS HB-1200 BRAZING PROCESSES Specific brazing processes which are permitted for use under this Section are classified by method of heating and are torch brazing, furnace brazing, induction brazing, electrical resistance brazing, and dip brazing -- salt and flux bath. HB-1201 JOINT BRAZING PROCEDURES A joint brazing procedure shall be developed for each different type of joint of a brazed assembly. A recommended form for recording the brazing procedure is shown in QB-480 of Section IX. If more than one joint occurs in a brazed assembly, the brazing sequence shall be specified on the drawing or in instructions accompanying the drawing. If welding and brazing are to be done on the same assembly, the welding shall precede the brazing unless it is determined that the heat of welding will not adversely affect the braze previously made, and the weld will not be adversely contaminated by the brazing metal. HB-1202 BRAZING QUALIFICATIONS AND RECORDS HB-1202.1 Qualification of Brazing Procedures (a) Each brazing procedure employed in the fabrica tion of boilers shall be qualified in accordance with Section IX. Only qualified procedure specifications shall be followed in construction. Each manufacturer shall conduct the required tests to qualify all brazing proce dures to be used by his organization. (b) The nominal thickness of base material used with lap joints tested using the test fixture shown in QB463.7 of Section IX shall not exceed V2 in. There is no thickness limitation when specimens are tested with out the test fixture shown in QB-463.7. HB-1202.2 Qualification of Brazers and Brazing Operators. All brazers assigned to manual brazing shall have passed the tests prescribed for brazers in Section IX. All brazing operators assigned to brazing by automatic means or by furnace, induction, resistance, or dip brazing shall pass the tests as prescribed in Section IX. Such tests shall be conducted by the manufacturer or contractor. HB-12023 No Production Work Without Qual ifications. No production work shall be undertaken until both the brazing procedure and the brazers or brazing operators have been qualified. HB-1202.4 Maintenance of Records of Qual ifications and Identifying Marks (a) The manufacturer shall maintain a record of the brazers and brazing operators employed by him showing the date and results of qualifying tests and the identifying mark assigned to each. These records shall be certified to by the manufacturer and shall be accessible to the Inspector. (b) Each brazer and brazing operator so qualified shall be assigned an identifying number, letter, or symbol by the manufacturer which shall be used to identify the work of that brazer or brazing operator. 117 RS-003126 1/17/02 NUECES ARTICLE 13 DESIGN HB-1300 STRENGTH OF BRAZED JOINTS (a) It is the responsibility of the designer to determine from suitable tests or from past experience that the specific brazing filler metal selected can produce a joint which will have adequate strength over the operating temperature range. The strength of the brazed joint shall not be less than the strength of the base metal, or the weaker of the two base metals in the case of dissimilar metal joints. (b) For any type of joint, the strength of the brazed section shall exceed that of the base metal portion of the test specimen in the qualification tension tests provided for in QB-150 of Section IX. Lap joints shall have a sufficient overlap to provide a higher strength in the brazed joint than in the base metal. HB-1301 BRAZED JOINT EFFICIENCY FACTORS (a) The joint efficiency factor to be used in design of boilers with brazed joints shall be 0.80 for joints in which visual examination assures that the brazing filler metal has penetrated the entire joint. (b) The joint efficiency factor to be used in the design of boilers shall be 0.50 for joints in which visual examination will not provide proof that the brazing filler metal has penetrated the entire joint. HB-1302 MINIMUM THICKNESS The minimum thickness of nonferrous and other copper or copper-alloy plates, heads, and tubesheets shall be as specified in HF-301. HB-1303 PERMISSIBLE SERVICE TEMPERATURE Satisfactory qualification of the brazing procedure in accordance with Section IX, Part QB is considered satisfactory proof of the adequacy of the base materials, the brazing filler metal, the flux and/or atmosphere, and other variables of the procedure for service not exceeding 250F. HB-1304 APPLICATION OF BRAZING FILLER METAL The design shall provide for the application of the brazing filler metal as part of the design of the joint. 'Where practicable, the brazing filler metal shall be applied in such a manner that it will flow into the joint or be distributed across the joint and produce visible evidence that it has penetrated the joint. (a) Manual Application. The manual application of the brazing filler metal by face-feeding to a joint should be from one side only. Visual observation of the other side of the joint will then show if the required penetra tion of the joint by the filler metal has been obtained. If the side opposite to the filler metal application cannot be visually examined, as is the case with socket-type joints in pipe and tubing (blind joint), a joint efficiency factor of 0.50 shall be used in design of this joint. (b) Preplaced Brazing Filler Metal. The brazing filler metal may be preplaced in the form of slugs, powder, rings, strip, cladding, spraying, or other means. After brazing, the brazing filler metal should be visible on both sides of the joint. If the brazing filler metal is preplaced within a blind joint in such a manner that it penetrates the major portion of the joint during brazing and appears at the visible side of the joint, a joint efficiency factor of 0.80 may be used in the design of the joint. If the brazing filler metal is preplaced on the outside or near the outside of a blind joint, and the other side cannot be inspected to ascertain complete penetration, then a joint efficiency factor of 0.50 shall be used in the design of the joint. 118 RS403126 1/17/02 NUECES HB-1305 ARTICLE 13 -- DESIGN HB-1307 TABLE HB-1305 RECOMMENDED JOINT CLEARANCES AT BRAZING TEMPERATURE Brazing Filler Metal Clearance, in. B Al Si Group B CuP Group B Ag Group B Cu Zn Group B Cu Group 0.006-0.010 for laps < V* in. 0.010-0.025 for laps > % in. 0.001-0.005 0.002-0.005 0.002-0.005 0.000-0.002 HB-1305 JOINT CLEARANCE (a) The joint clearance shall be kept sufficiently small so that the filler metal will be distributed by capillary attraction. Since the strength of a brazed joint tends to decrease as the joint clearance used is increased, the clearances for the assembly of joints in boilers shall be within the tolerances set up by the joint design and as used for the corresponding qualification specimens made in accordance with Section IX. (b) If greater tolerances are to be used in production, the joint must be requalified for those greater tolerances. The control of tolerances required may be obtained by using rivets, spot welding, crimping, or other means which will not interfere with the quality of the braze. If such means are employed in production, they must also be employed in qualification of procedure, brazer, and operator. NOTE: For guidance, see Table HB-1305 which gives recommended joint clearances at brazing temperature for various types of brazing filler metal. Brazing alloys will exhibit maximum unit strength if clearances are maintained within these limits. HB-1306 OPENINGS (a) Openings for nozzles and other connections shall be far enough away from any main brazed joint so that the joint and the opening reinforcement plates do not interfere with one another. (b) Openings for pipe connections in boilers having brazed joints may be made by inserting pipe couplings, not exceeding NPS 3, or similar devices in the shell or heads and securing them by welding, provided the welding is performed by welders who have been quali fied under the provisions of Section IX for the welding position and type of joint used. Such attachments shall conform to the rules for welded connections. HB-1307 BRAZED CONNECTIONS (a) Connections, such as saddle type fittings and fittings inserted into openings formed by outward flang ing of the vessel wall, in sizes not exceeding NPS 3, may be attached to boilers by lap joints of brazed construction. Sufficient brazing shall be provided on either side of the line through the center of the opening parallel to the longitudinal axis of the shell to develop the strength of the reinforcement through shear in the brazing. (b) For nozzle fittings having a bolting flange and an integral flange for brazing, the thickness of the flange attached to the boiler shall not be less than the thickness of the neck of the fitting. 119 *8-003127 1/17/02 NUECES ARTICLE 14 FABRICATION REQUIREMENTS HB-1400 CLEANING OF SURFACES TO BE BRAZED The surfaces to be brazed shall be clean and free from grease, paint, oxides, scale, and foreign matter of any kind. Any chemical or mechanical cleaning method may be used that will provide a surface suitable for brazing. HB-1401 POSTBRAZING OPERATIONS Brazed joints shall be thoroughly cleaned of flux residue by any suitable means after brazing and prior to inspection.1 Other postbrazing operations such as ' Flux residues can be extremely corrosive as well as interfere with visual inspection. thermal treatments shall be performed in accordance with the qualified procedure. HB-1402 REPAIR OF DEFECTIVE BRAZING Brazed joints which have been found to be defective may be rebrazed, where feasible, after thorough clean ing, and by employing the same brazing procedure used for the original braze. If a different brazing procedure is employed, i.e., torch repair of furnace brazed parts, a repair brazing procedure shall be estab lished and qualified. When a repair brazing procedure is established it shall provide control of the application of brazing filler metal to meet the conditions set forth in HB-1301(a). Where these requirements cannot be met, the limitations of HB-1301(b) will apply. 120 R8-003128 1/17/02 NUECE8 ARTICLE 15 INSPECTION AND STAMPING HB-1500 INSPECTION HB-1501 INSPECTION OF BRAZING PROCEDURE The Inspector shall examine the procedure for each type of joint being produced and shall determine that the procedure has been qualified in accordance with the requirements-of Section IX and shall satisfy himself that fabrication of the joint is in accordance with the procedure. Where there is evidence of consistent poor quality, the Inspector shall have the right at any time to call for and witness tests of the brazing procedure. HB-1502 CERTIFICATION OF BRAZER AND BRAZING OPERATOR (a) The manufacturer shall certify that the brazing on a vessel or part thereof has been done by brazers or brazing operators who are qualified under the require ments of Section IX, and the Inspector shall assure himself that only qualified brazers or brazing operators have been used. (b) The manufacturer shall make available to the Inspector a certified copy of the record of the qualifica tion tests of each brazer and brazing operator. The Inspector shall have the right at any time to call for and witness tests of the ability of a brazer or brazing operator. HB-1503 VISUAL EXAMINATION (a) Where possible, both sides of each brazed joint shall be visually examined after fiux residue removal. Where it is not possible to inspect one side of a brazed joint (blind joint), the Inspector shall check the design to determine that the proper joint factor has been employed, unless he can assure himself that the brazing filler metal has been preplaced in such a manner that it satisfied HB-1304. (b) There shall be evidence that the brazing filler metal has penetrated the joint. In a butt braze there shall be no concavity. The braze may be repaired or rebrazed. (c) The presence of a crack in the brazing filler metal shall be cause for rejection. Dye penetrant inspec tion may be used if desired. The braze may be repaired or rebrazed. (d) The presence of a crack in the base metal adjacent to a braze shall be cause for rejection even if the crack is filled with brazing alloy. Such cracking shall not be repaired. (e) Visible pinholes or open defects in the braze shall be cause for rejection. The joint may be rebrazed. (/) Rough fillets, particularly those with a convex appearance, are cause for rejection. Such joints may be repaired or rebrazed. HB-1510 STAMPING Boilers shall be stamped according to the require ments of HG-530 or the stamping may be placed on a nonferrous plate, irremovably attached to a visible part of the boiler. 121 RS-003129 1/17/02 NUECES PART HC REQUIREMENTS FOR BOILERS CONSTRUCTED OF CAST IRON Article 1 HC-100 Genera] Scope........................................................................... i................................................. 125 Article 2 HC-200 HC-201 HC-202 HC-203 HC-204 HC-205 HC-206 HC-207 HC-208 HC-209 HC-210 HC-211 HC-212 HC-213 HC-214 HC-215 - Material Requirements General Material Requirements...................................................................................... Manufacture..................................................................................................................... Chemical Composition.................................................................................................... Tensile Strength Classification....................................................................................... Tension Test................................................................................................................... Test Bars........................................................................................................................ Selection of Test Bar Size............................................................................................. Molding and Pouring Test Bars.................................................................................... Tensile Strength Test Procedure.................................................................................... Transverse Test............................................................................................................... Transverse Test Procedure............................................................................................. Number of Tests............................................................................................................. Retests.............................................................................................................................. Workmanship, Finish, and Repair.................................................................................. Examinations and Tests................................................................................................... Test Records................................................................................................................... 126 126 126 126 126 126 126 127 127 127 128 129 129 130 130 130 Article 3 HC-300 HC-301 HC-310 HC-311 HC-315 HC-320 HC-325 HC-330 Design Maximum Allowable Stress Values.............................................................................. Basis for Establishing Stress Values in Table HC-300 ................................................ Heads................................................................................................................................ Spherically Shaped Covers............................................................................................. Openings and Reinforcements....................................................................................... Comers and Fillets.......................................................................................................... Washout Openings.......................................................................................................... Assembly Method............................................................................................................ 131 131 131 131 133 134 134 134 Article 4 HC-400 HC-401 HC-402 HC-403 Tests Tests to Establish Design Pressure................................................................................ General............................................................................................................................ Bursting Test Procedure................................................................................................. Witnessing, Recording, and Certifying Tests................................................................ 135 135 135 136 123 RS-003130 1/17/02 NUECES HC-404 HC-410 Article 5 HC-501 HC-502 HC-510 Figures HC-205.1 HC-206.1 HC-311 Tables HC-210 HC-213 HC-300 _ Rating of Production Boilers Based on Tests............................................................... Hydrostatic Test.............................................................................................................. 136 136 Quality Control and Inspection General............................................................................................................................. Outline of Features to Be Included in the Written Description of the Quality Control System................................................................................. Examination..................................................................................................................... 137 137 138 Dimensions of Tensile Test Specimen.............................................................. Cast Test Bars................................................................................................................. Spherically Shaped Covers With Bolting Flanges......................................................... 127 128 132 Correction Factors for Transverse Test Bars................................................................ Pipe Plug Size for Minimum Wall Thickness............................................................... Maximum Allowable Stress Values in Tension for Cast Iron, ksi............................. 129 130 131 *8-003131 124 1/17/02 NUECES ARTICLE 1 GENERAL HC-100 SCOPE The rules in Part HC are applicable to heating boilers that are constructed primarily of cast iron, and shall be used in conjunction with general requirements of Part HG of this Section. RS403132 1/17/02 NUECES ARTICLE 2 MATERIAL REQUIREMENTS C HC-200 GENERAL MATERIAL REQUIREMENTS All materials used for heating boilers that are con structed primarily of cast iron shall meet the require ments of this Article for gray iron castings. HC-204 TENSION TEST The tension test shall be considered the primary test for qualification under this Article. The results of the tension or transverse tests shall determine compliance for the various classes given in HC-203. (See HC-212, Retests.) HC-201 MANUFACTURE The melting procedure shall be optional with the Manufacturer. HC-202 CHEMICAL COMPOSITION Drillings taken from test ingots, broken test speci mens, or from castings, shall conform to the following as to chemical composition. (a) The manganese shall be controlled as required to meet Mn > (1.7 x S) + 0.2, where Mn is percent manganese and S is percent sulfur. (b) The phosphorous content shall not exceed 1.00%. HC-205 TEST BARS Test bars shall be cast separately from the castings (see HC-207). The sizes of cast test bars shall be as determined in HC-206. Tension specimens shall be machined from those castings to the dimensions shown in Fig. HC-205.1. Tension test specimens "cast to size" shall not be used. The test bar castings shown in Fig. HC-206.1 may be used for optional transverse tests, when that test is specified. HC-203 TENSILE STRENGTH CLASSIFICATION Castings shall be known and listed by classes ac cording to the minimum requirements as to tensile strengths of test bars, specified as follows: Class No. 20 25 30 35 40 Tensile Strength Min., psi 20,000 25,000 30,000 35,000 40,000 HC-206 SELECTION OF TEST BAR SIZE The dimensions of the test bars as shown in Fig. HC-206.1 shall be determined by the thickness of the controlling section of the casting as follows (the body or shell of the casting shall be the controlling section): Thickness of Controlling Section of Casting, in. 0.5 and under 0.51 to 1.00 over 1.00 Test Bar A B C 126 r8-003,'33 1/17/02 NUECES HC-207 ARTICLE 2 -- MATERIAL REQUIREMENTS HC-209 Dimensions Tension Test Specimen A Tension Test Specimen B Tension Test Specimen C G -- Length of parallel, min., in. D--Diameter, in. R--Radius of fillet, min., in. A--Length of reduced section, min., in. L--Overall length, min., in. C--Diameter of end section, in., approximately E--Length of shoulder, min., in. F--Diameter of shoulder, in. B--Length of end section 0.50 0.500 0.010 1 IVi 3% y* % % i '/m Note (1) 0.75 0.750 0.015 1 I'/i 4 v/. '7,. = '/. Note (1) 1.25 1.25 0.025 2 27. 67. 1% 71. 17,. V,, Note (1) NOTE: (1) Optional to fit holders on testing machine. If threaded, root diameter shall not be less than dimension F. FIG. HC-205.1 DIMENSIONS OF TENSILE TEST SPECIMEN HC-207 MOLDING AND POURING TEST BARS Test bars shall be made under the same sand condi tions as the castings. The bars shall be poured from the same ladles of iron used to pour the castings. The test bars shall receive the same thermal treatment as the castings. Thermal treatment involving a liquid quench from above the critical range is not permitted for castings covered in this Article. HC-208 TENSILE STRENGTH TEST PROCEDURE Tension test specimens (Fig. HC-205.1) shall fit the holders of the testing machine in such a way that the load shall be axial. The use of self-aligning shackles is recommended.1 After reaching a stress equivalent to 15,000 psi, the speed of the moving head of the testing machine shall not exceed 0.125 in./min. HC-209 TRANSVERSE TEST (a) Except for the tensile tests required in HC-402.2, the Manufacturer may waive the tension test and the transverse test may be used. When used, the minimum breaking load, lb, prescribed as follows, shall apply (see HC-212 Retests): 1 The use of ball and socket holders in the tensile strength test is recommended. Tests made under conditions where eccentric loadings may occur will give erroneous results. 127 RS-0031U 1/17/02 NUECES HC-209 1995 SECTION IV HC-210 Twt Bar Diamatar . in. Dimantioni Lanflth1 b in. Diatanoa Batwaan Support* in Tranwaria Tast, in. A 0.875 B 1.20 C 2.00 15 21 27 12 18 24 NOTES: (1) If only tensile tests are specified, dimension b may be reduced to the minimum length shown in Fig. HC-205.1. (2) Test bars shall be plain, cylindrical shapes as shown. Where bars are cast on end, allowance for draft may be made. However, the diameter at the center of the length must correspond _ to the normal diameter, within the following permissible variations: Permissible Variations. Test Bar A Test Bar B Test Bar C 0.05 0.10 0.10 FIG. HC-206.1 CAST TEST BARS2 Class No. 20 25 30 35 40 Test Bar A 0.875 in. Diam., 12 in. Supports, lb 900 1025 1150 1275 1400 Test Bar B 1.20 in. Diam., 18 in. Supports, lb 1800 2000 2200 2400 2600 Test Bar C 2.00 in. Diam., 24 in. Supports, lb 6000 6800 7600 8300 9100 (b) Where the transverse test has been made as prescribed in (a) above and the transverse or flexure test bar fails to meet the load requirements, the Manufac turer shall have the right to have a tension test specimen machined from a broken end of the transverse test bar tested. In the event that this tension test specimen conforms to the requirements of the class specified, as prescribed in HC-203, the class requirements shall be considered as having been met, irrespective of the transverse breaking load. HC-210 TRANSVERSE TEST PROCEDURE (a) The transverse test shall be made on the bar as cast, or as skin machined (provided in the latter case that the diameter is not reduced below the minimum sizes given in Table HC-210) with central loading between supports. Corrections shall be made for sizes of round bars as shown in Table HC-210. In case of slightly elliptical bars (maximum and minimum diame ters both within the tolerances given in Table HC210), loading shall be on the minimum diameter, and the correction factor shall be obtained as follows: Square the depth of the bar measured at the point of application of the original load, multiply by the width, and divide the product by the cube of the diameter of the standard or nominal size bar. A bar whose diameters (maximum and minimum) vary by more than 0.025 in. for the 0.875 in. diameter nominal size, or by more than 0.050 in. for the 1.2 in. and 2.0 in. diameter nominal sizes, respectively, shall be considered a slightly elliptical bar. (b) In all cases, controlling dimensions shall be the diameter of the bar at fracture. 128 R8-00313S 1/17/02 NUECE8 HC-210 ARTICLE 2 -- MATERIAL REQUIREMENTS HC-212 TABLE HC-210 CORRECTION FACTORS FOR TRANSVERSE TEST BARS In Order to Correct to the Standard Diameter, the Breaking Load and Deflection Obtained in Testing the Bar Shall Be Divided by the Respective Correction Factors. Test Bar A 0.B75 in. in Diameter Test Bar 8 1.20 in. in Diameter Test Bar C 2.000 in. in Diameter Diameter of Test Bars, in. Correction Factor Load Deflection Diameter of Test Bars, in. Correction Factor Load Deflection Diameter of Test Bars, in. Correction Factor Load Deflection 0.825 0.830 0.835 0.840 0.845 0.850 0.855 0.860 0.865 0.870 0.875 0.880 0.885 0.890 0.895 0.900 0.905 0.910 0.915 0.920 0.925 0.838 0.853 0.869 0.885 0.900 0.916 1.061 1.054 1.048 1.042 1.036 1.029 0.933 0.949 0.966 0.983 1.000 1.023 1.017 1.012 1.006 1.000 1.017 1.034 1.051 1.069 1.087 0.994 0.989 0.983 0.978 0.972 1.106 1.125 1.143 1.162 1.181 0.967 0.962 0.956 0.951 0.946 1.10 0.770 1.091 l.ll 0.791 1.081 1.12 0.813 1.071 1.13 0.835 1.062 1.14 0.857 1.053 1.15 0.880 1.043 1.16 0.903 1.034 1.17 0.927 1.026 1.18 0.951 1.017 1.19 0.975 1.009 1.20 1.000 1.000 1.21 1.025 0.992 1.22 1.051 0.984 1.23 1.077 0.976 1.24 1.105 0.968 1.25 1.130 0.960 1.26 1.158 0.952 1.27 1.185 0.945 1.28 1.214 0.938 1.29 1.242 0.930 1.30 1.271 0.923 1.90 0.857 1.053 1.91 0.871 1.047 1.92 0.885 1.042 1.93 0.899 1.037 1.94 0.913 1.032 i.95 0.927 1.026 1.96 0.941 1.021 1.97 0.955 1.015 1.98 0.970 1.010 1.99 0.985 1.005 2.00 1.000 1.000 2.01 1.015 0.995 2.02 1.030 0.990 2.03 1.046 0.985 2.04 1.061 0.980 2.05 1.076 0.976 2.06 1.092 0.972 2.07 1.109 0.967 2.08 1.125 0.962 2.09 1.141 0.957 2.10 1.158 0.952 (c) The rate of application of the load shall be such that fracture is produced in not less than 15 sec for the 0.875 in. diameter bar, 20 sec for the 1.2 in. diameter bar, and 40 sec for the 2.0 in. diameter bar. HC-211 NUMBER OF TESTS (a) For purposes of this requirement, a melting period shall not exceed 8 hr. (b) For tensile or transverse tests for each class of iron, two or more test bars shall be cast from each melt, one during the first half of the melting period, and the other during the last half of the melting period. For chemical composition test samples, see HC-202. (c) One chemical composition test and either one tensile or one transverse test shall be made on each melt (or mixture if two or more mixtures of a different class of iron are made in a given melt) for each controlling section (see HC-206) in the castings made from each melt (or mixture).2 HC-212 RETESTS (a) If any test specimen shows defective machining or obvious lack of continuity of metal, it shall be discarded and replaced by another specimen. (b) In case of the failure of a test bar to meet the specified strength within 90% of its value, a retest may 2 Example: If Class 20, Test Bar A, castings alone are being made, one test shall be made on each melt on Test Bar A. If Class 20, controlling sections A and B castings (that is, light and medium sections) are made from the same melt (or mixture), then Test Bars A and B shall be made and tested. In all cases, test bars corresponding to the different tensile classes (Nos. 20, 30, and 40) and controlling sections (A, B, and C) must be made and tested to correspond to the classes of iron specified for the castings, and the controlling sections thereof. 129 RS-003136 1117/02 NUECES HC-212 1995 SECTION IV HC-215 be made. If the retest fails, the casting shall be rejected, except as provided for in (c) below. (c) As provided for in HC-209(b) when the transverse test bars fail to meet the specification requirements, tension test specimens may be machined from the broken ends of the transverse test bar. If the tension specimens meet the requirements of the specified class, the castings shall be accepted. TABLE HC-213 PIPE PLUG SIZE FOR MINIMUM WALL THICKNESS Pipe Plug, IPS Minimum Wall Thickness for 4 Thread Engagement, in. v. 0.15 V* 0.22 y. 0.22 % 0.285 % 0.285 i 0.35 HC-213 WORKMANSHIP, FINISH, AND REPAIR (a) The surface of the casting shall conform substan tially to the dimensions on drawings or to the dimensions predicated by the pattern, and be free from injurious defects. The surface of the casting shall be free from bumt-on sand and shall be reasonably smooth. Risers, fins, and projections used to facilitate the making of the casting shall be removed. In other respects, they shall conform to whatever requirements may be specially agreed upon between the Manufacturer and Purchaser. (b) Seepage about chaplets, and minor leakage de fects, may be repaired by peening or by plugging as directed below. Provided the surrounding metal is sound, a minor leak may be plugged with a solid cast iron tapered thread pipe plug. The maximum size of the pipe plug shall be 1 in. IPS and there shall be no less than four full standard pipe threads in the section metal. (See Table HC-213.) HC-214 EXAMINATIONS AND TESTS The Manufacturer shall be responsible for all exami nations and tests. When requested by a Purchaser, the Manufacturer shall agree to permit a representative of the Purchaser to have entry, at the time while work under the contract of the Purchaser is being performed, to all parts of the Manufacturer's works which concern the castings manufactured to the requirements of this Article. All examinations and tests shall be made at the place of the manufacture prior to shipment, unless otherwise specified and shall be so conducted as not to interfere unnecessarily with the operation of the works. HC-215 TEST RECORDS The Manufacturer shall record and retain all test results required by this Article for a period of at least 1 year. The test results shall be readily identifiable with the casting represented by the test results. 130 rs-oomst 1/17/02 NUECES ARTICLE 3 DESIGN HC-300 MAXIMUM ALLOWABLE STRESS VALUES (a) Table HC-300 gives the maximum allowable stress values in tension for castings conforming to the class iron listed therein. (b) The maximum allowable stress value in bending shall be lV2 times that permitted in tension and the maximum allowable stress value in compression shall be two times that permitted in tension. (cj Stress values in Table HC-300 shall be used in calculations employing the available formulas in Part HG when applicable to the geometry of the boiler or boiler parts. Where the design pressure cannot be calculated under the available formulas, then the design pressure of the part in question shall be established in accordance with the provisions of HC-400. HC-301 BASIS FOR ESTABLISHING STRESS VALUES IN TABLE HC300 In the determination of allowable stress values for pressure parts, the Committee is guided by successful experience in service, insofar as evidence of satisfactory performance is available. Such evidence is considered equivalent to test data where operating conditions are known with reasonable certainty. In the evaluation of new materials, it is necessary to be guided to a certain extent by the comparison of test information with similar data on successful applications of similar materials. At any temperature below the creep range, the allow able stresses are established at no higher than the lowest of the following: (1) '/5 of the specified minimum tensile strength at room temperature; (2) % of the tensile strength at temperature. TABLE HC-300 MAXIMUM ALLOWABLE STRESS VALUES IN TENSION FOR CAST IRON, ksi (Multiply by 1000 to Obtain psi) Spec. No. [Note (1)] Class Minimum Tensile Strength, ksi Maximum Allowable Design Stress Values in Tension, ksi 20 20.0 25 25.0 30 30.0 35 35.0 40 40.0 4.0 5.0 6.0 7.0 8.0 NOTE: (1) Cast iron specifications shall comply with Article 2 of Part HC. HC-310 HEADS HC-310.1 Heads With Pressure on Concave Side. Heads with pressure on the concave side (plus heads) shall be designed in accordance with formulas in HG305 using the maximum allowable stress value in tension from Table HC-300. Bolted flanges when cast integral with concave heads shall have dimensions that conform to ANSI B16.1, Cast Iron Pipe Flanges and Flanged Fittings, Class' 125 and Class 250, and may be used as part of a pressure vessel for pressures not exceeding the ANSI ratings at temperatures not exceeding 450F. HC-310.2 Heads With Pressure on Convex Side. The thickness of heads with pressure on the convex side (minus heads) shall not be less than the thickness required in HC-310.1 for plus heads under the same pressure, nor less than 0.01 times the inside diameter of the head skirt. HC-311 SPHERICALLY SHAPED COVERS Circular cast iron spherically shaped covers with bolting flanges, similar to Fig. HC-311, sketches (a). 131 R8-003138 1/17/02 NUECES HC-311 1995 SECTION IV Use radius in HC-3H.1 FIG. HC-311 SPHERICALLY SHAPED COVERS WITH BOLTING FLANGES (b), and (c), shall be designed in accordance with the following, and shall also be subjected to the proof test provisions of HC-400. (a) Notations. The symbols used in the formulas of this paragraph are defined as follows: A = outside diameter of flange, in. B= inside diameter of flange, in. C = bolt circle diameter, in. t = minimum required thickness of head plate after forming, in. L= inside spherical or crown radius, in. r= inside knuckle radius, in. P = design pressure for existing vessels, psi S = maximum allowable stress value as given in Table HC-300, psi T = flange thickness, in. M0 = the total moment, in.-lb, determined as in Sec tion VIII, Division 1, Appendix 2, 2-6, except that for heads of the type shown in Fig. HC311, sketch (c), a moment Hrhr (which may add or subtract) shall be included in addition to the moment HDhD where Hr = radial component of the membrane load in the spherical segment, lb, acting at the intersection of the inside of the flange ring with the center line of the dished cover thickness = Hd cot A hr= lever arm of force Hr about centroid of flange ring, in. H0 = axial component of the membrane load in the spherical segment, lb, acting at the inside of the flange ring = 0.785B2P /id= radial distance from the bolt circle to the inside of the flange ring, in. y3) = angle formed by the tangent to the center line of the dished cover thickness at its point of intersection with the flange ring, and a line per pendicular to the axis of the dished cover = arc sin [BI(2L -- r] NOTE: Since i, in some cases will subtract from the total moment, the moment in the flange ring when the internal pressure is zero may be the determining loading for the flange design. HC-311.1 Heads Concave to Pressure. Circular spherically dished heads with bolting flanges, concave to the pressure and conforming to the several types illustrated in Fig. HC-311, shall be designed in accord ance with the following formulas: 132 R8-003139 1/17/02 NUECES HC-311.1 ARTICLE 3 -- DESIGN HC-315 (a) Heads of the Type Shown in Fig. HC-31I, Sketch (a) (J) Head thickness 5 PL ~6S T= Q+ 1.875Ma(C + B) SB(3C - B) C+B 3C-B. (HI) (IV) (2) Range thickness T: For ring gasket, M0 A + B' T = SB La - B. For full-faced gasket, JT = 0.6 P rB(A + B)(C - B) S A-B NOTE: The radial components of the membrane load in the spherical segment are assumed to be resisted by its flange. Within the range of ANSI B16.1-1975, the flange facings and drillings should conform to those standards and the thickness specified therein shall be considered as a minimum requirement. (b) Heads of the Type Shown in Fig. HC-3I1, Sketch (b) (1) Head thickness (3) Range thickness for full face gaskets shall be calculated by the following formula: T= Q+ 3BQ(C - B) Q2 + L (V) The value of Q in Eq. (V) is calculated by Eq. (II) for round bolting holes or by Eq. (IV) for bolting holes slotted through the edge of the head. (4) The required flange thickness shall be T as calculated in (2) or (3) above, but in no case less than the value of t calculated in (1). (c) Heads of the Type Shown in Fig. HC-311, Sketch (c) (1) Head thickness 5 PL ~6S (2) Range thickness T = F + V F1 + J where 5 PL 6S (2) Range thickness for ring gaskets shall be calculated as follows: (a) For heads with round bolting holes, and PByj 4L2 - B2 F = ------------------- 8S (A - B) / 1.875A/,,(C + B) t = Q+ /------------------- V 55(7C - SB) (I) PL r C + B 1 Q 45 L7C- 55J (II) (b) For heads with bolting holes slotted through the edge of the head. HC-315 OPENINGS AND REINFORCEMENTS (a) The dimensional requirements in HG-320 through HG-328 are applicable to cast iron and shall be used in the design of openings and reinforcements in boilers and boiler parts. 133 RS-003140 1/17)02 NUECES HC-315 1995 SECTION IV HC-330 (b) Cast iron flanges, nozzles, and opening reinforce ments which enter into the design calculations of the completed boiler or boiler part, shall be cast integrally with the boiler or boiler part. HC-320 CORNERS AND FILLETS A liberal radius shall be provided at projecting edges and reentrant comers in accordance with good foundry practice. Abrupt changes in surface contour and in wall thickness at junctures shall be avoided. Fillets and transition sections between adjacent main pressure con tainment walls or integral attachments thereto, such as nozzles, lugs, supports, flanges, and bosses, shall have radii or the equivalent not less than one times the thickness of the thinner of the sections being joined. HC-325 WASHOUT OPENINGS All cast iron steam and hot water boilers shall be provided with washout openings to permit the removal of any sediment that may accumulate therein. Washout plugs shall not be smaller than NPS l'/2 for boilers having gross internal volume more than 5 cu ft. Washout plugs shall not be smaller than 1 in. for boilers having gross internal volume not more than 5 cu ft. Washout openings may be used for return pipe connections and the washout plug placed in a tee so that the plug is directly opposite and as close as possible to the opening in the boiler. HC-330 ASSEMBLY METHOD Cast iron boilers may be assembled using internal connections, such as electrochemically compatible me tallic push nipples or grommet seals, or external connec tions such as cast iron headers or threaded pipe headers. The completed boiler shall satisfactorily pass the hydro static test prescribed in HC-410. 134 RS-003141 1/17/02 NUECES ARTICLE 4 TESTS HC-400 TESTS TO ESTABLISH DESIGN PRESSURE HC-401 GENERAL (a) The design pressure for a boiler or boiler parts, for which the strength cannot be computed with a satisfactory assurance of accuracy, shall be established in accordance with the requirement of this paragraph using the following test procedure. (b) Safety of testing personnel should be given seri ous consideration when conducting the bursting tests in HC-402. HC-401.1 Purpose for Which Tests May Be Used. The tests in these paragraphs may be used for the purpose of establishing the design pressure of those parts or component parts for which the thickness cannot be determined by means of design rules given in this Section. Design changes shall also require a retest. The maximum allowable working pressure of all other elements or component parts shall not be greater than that determined by means of the applicable design rules. HC-401.2 Frequency of Tests. The tests performed in HC-401.1 shall be repeated within every 5 year period. This testing period may be extended when parts are intermittently produced, in which case the tests shall be performed at the time of or before the first production run after the 5 year period. All requirements of HC-403 shall be met. HC-402 BURSTING TEST PROCEDURE (a) The design pressure of any component part tested by this method shall be established by a hydrostatic test to failure by rupture of a full-size sample of such pressure part. (b) The design pressure of any component part deter mined by this method shall be based on hydrostatically testing three representative boilers or boiler parts to destruction. The lowest value of Pg obtained shall be used in determining the value of PR in the following formula: Specified minimum tensile strength1 Average tensile strength of associ ated test bar (see HC-402.2) where PR = design pressure, psi PB = destruction test pressure, psi NOTE: Due to the geometry of parts of cast iron boilers, failure under hydrostatic tests is principally in bending. When an analysis of the test indicates failure occurred in bending, PR may be multiplied by 1.5. HC-402.1 Test Gages (a) An indicating gage shall be connected directly to the vessel. If the indicating gage is not readily visible to the operator controlling the pressure applied, an additional indicating gage shall be provided where it will be visible to the operator throughout the duration of the test. For large vessels, it is recommended that a recording gage be used in addition to indicating gages. (b) Dial indicating pressure gages used in testing shall be graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than l'/2 nor more than 4 times that pressure. Digital reading pressure gages having a wider range of pressure may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages. (c) All gages shall be calibrated against a standard deadweight tester or a calibrated master gage. Gages 'The specified tensile strength is the tensile strength for the class of iron set forth in Table HC-300. 135 os-00 Huece* HC-402.1 1995 SECTION IV HC-410J shall be recalibrated at any time that there is reason to believe that they are in error. HC-402.2 Associated Test Bars. A separately cast test bar shall be produced, machined, and tested in accordance with the requirements of the tensile bar test procedure in Article 2 of Part HC for each of the three boilers or boiler sections to be tested to destruction [see HC-402(b)]. Each test bar shall be from the same ladle of iron from which is cast the boiler or boiler section to be subjected to bursting. The arithmetical average tensile strength, psi, of the three bars shall be determined and shall equal or exceed the minimum tensile strength, specified in Table HC-300, of the class of iron selected by the Manufacturer for use in the formula in HC-402(b) for determining the design pres sure. In no case shall the actual tensile strength of any of the three test bars, used to determine this arithmetical average tensile strength, be more than 10% under the minimum tensile strength listed in Table HC-300 for the class of iron selected by the Manufacturer. The tensile strengths obtained from the associated test bars shall be recorded on the Manufacturer's Master Data Report for Boilers Constructed From Cast Iron (Form H-5). HC-403 WITNESSING, RECORDING, AND CERTIFYING TESTS Tests to establish the design pressure of a boiler or boiler parts shall be witnessed by the Manufacturer's personnel designated to be responsible for the examina tion. These bursting tests shall be recorded on the Manufacturer's Master Data Report for Boilers Con structed From Cast Iron as shown in Form H-5 and the completed form shall be certified by the designated responsible engineering head of the Manufacturer and his signature notarized. These forms shall be kept on file by the Manufacturer as a matter of record. HC-404 RATING OF PRODUCTION BOILERS BASED ON TESTS All boilers or boiler parts of the same material, design, and construction, whose design pressures are based on a test to destruction of a sample boiler or boiler part in accordance with HC-402, shall be considered to have design pressures equal to the maximum allowable working pressure thus determined and shall be subjected to a hydrostatic test pressure in conformity with rules of HC-410. HC-410 HYDROSTATIC TEST All completed boilers or boiler parts shall satisfacto rily pass the hydrostatic test prescribed in this paragraph. HC-410.1 Steam Boilers. All steam boilers shall have each individual section or boiler part subjected to a hydrostatic test pressure of not less than 60 psig at the shop where made. The assembled boiler shall be subjected to a hydrostatic test of not less than 45 psig. HC-410.2 Hot Water Boilers. All hot water heating or hot water supply boilers marked for working pressures not over 30 psi shall Have each individual section or boiler part subjected to a hydrostatic test of not less than 60 psi at the shop where made. Hot water heating and hot water supply boilers marked for working pres sures over 30 psi shall have each individual section or boiler part subjected to a hydrostatic test of 2'/2 times the maximum allowable working pressure at the shop where made. The assembled boiler shall be sub jected to a hydrostatic test pressure not less than l'/2 times the maximum allowable working pressure. HC-410.3 Required Test Pressure. In making hy drostatic pressure tests, the pressure shall be under such control that in no case shall the required test pressure be exceeded by more than 10 psi. 136 R8-003343 111710* NUECES ARTICLE 5 QUALITY CONTROL AND INSPECTION HC-501 GENERAL HC-501.1 Quality Control System. Each Manufac turer1 or shop assembler shall have and maintain a quality control system which will establish that all Code requirements, including material, design, testing, fabrication, examination, and inspection (by the Manu facturer and shop assembler), shall be met. Providing that Code requirements are suitably identi fied, the system may include provisions for satisfying any requirements by the Manufacturer or shop assembler or user which exceed minimum Code requirements and may also include provision for quality control of nonCode work. In such systems, the Manufacturer or shop assembler may make changes in parts of the system which do not affect the Code requirements. The system that the Manufacturer or shop assembler uses to meet the requirements of this Section must be one suitable for his own circumstances. The necessary scope and detail of the system shall depend upon the complexity of the work performed and upon the size and complexity of the organization. A written description of the system the Manufacturer or shop assembler will use to produce a Code item shall be available for review. Depending upon the circumstances, the description may be brief or voluminous. The written description may contain information of a proprietary nature relating to the Manufacturer's or shop assembler's processes. Therefore, the Code does not require any distribution of this information, except to the ASME Designee, as covered by HC-502.11.4. It is intended that information learned about the quality control system in connection with evaluation will be treated as confidential. 1 In Article 5, the Manufacturer referred to is the foundry who casts the boiler part or section and who may shop assemble it. HC-502 OUTLINE OF FEATURES TO BE INCLUDED IN THE WRITTEN DESCRIPTION OF THE QUALITY CONTROL SYSTEM The following is a guide to some of the features which should be covered in the written description of the quality control system. HC-502.1 Product or Work Description. The qual ity control system shall contain a brief description of the products the Manufacturer wishes to fabricate under the Code or the work the shop assembler wishes to accomplish under the Code. HC-502.2 Authority and Responsibility. The au thority and responsibility of those in charge of the quality control system shall be clearly established. Persons performing quality control functions shall have sufficient and well-defined responsibility, the authority, and the organizational freedom to identify quality con trol problems and to initiate, recommend, and provide solutions. HC-502.3 Organization. An organization chart showing the relationship between management and engi neering, purchasing, manufacturing, inspection, and quality control is required to reflect the actual organiza tion. The purpose of this chart is to identify and associate the various organizational groups with the particular function for which they are responsible. The Code does not intend to encroach on the Manufacturer's or shop assembler's right to establish and, from time to time, alter whatever form of organization the Manu facturer or shop assembler considers appropriate for his Code work. HC-502.4 Drawings, Design Calculations, Test Re sults, and Specification Control. The Manufacturer's or shop assembler's quality control system shall provide procedures which will insure that the latest applicable drawings, design calculations, test results, specifications, and instructions required by the Code, as well as 137 RS-003144 1/17/02 NUECES HC-502.4 1995 SECTION IV HC-510 authorized changes, are used for manufacture, assembly, examination, inspection, and testing. HC-502.5 Material Control. The Manufacturer or shop assembler shall include a system that requires verification that the material meets the requirements of Article 2 of Part HC. The system shall assure that only the intended material is used in Code construction. HC-502.6 Examination Program. The Manufactur er's or shop assembler's quality control system shall describe the bursting test procedure and the fabrication operations, sufficiently to determine at which stages specific examinations are to be performed. HC-502.7 Correction of Nonconformities. There shall be a system for correction of nonconformities. A nonconformity is any condition which does not comply with the applicable rules of this Section. Nonconformi ties must be corrected or eliminated before the com pleted component can be considered to comply with this Section. HC-502.8 Calibration of Measurement and Test Equipment. The Manufacturer or shop assembler shall have a system for calibration of all equipment used for examination, measuring, and testing to fulfill the requirements of this Section. HC-502.9 Sample Forms. The forms used in the quality control system and any detailed procedures for their use shall be available for review. The written description shall make necessary references to these forms. The forms exhibited shall be marked "Sample" and completed in a manner typical of actual production and test procedures. HC-502.10 Retention of Records. The Manufacturer or shop assembler shall have a system for retaining the Manufacturer's Data Forms for a minimum of 15 years. HC-502.11 ASME Designee HC-502.11.1 The written description of the quality control system shall include reference to the ASME Designee. HC-502.11.2 The Manufacturer or shop assembler shall make available to the ASME Designee a controlled copy of the written description of the quality control system. HC-502.11.3 The Manufacturer's or shop assem bler's quality control system shall provide for the ASME Designee to have access to all drawings, calculations, specifications, procedures, process sheets, repair proce dures, records, test results, and any other documents as necessary for the ASME Designee to perform his review in accordance with this Section. The Manufac turer or shop assembler may provide such access either to his own files of such documents or by providing copies to the ASME Designee. HC-510 EXAMINATION Examination of each boiler or boiler part shall be in compliance with Article 2 of Part HC. Hydrostatic tests shall be conducted as required in HC-410 by the Manufacturer or shop assembler, and there shall be a means of identifying acceptable boiler sections or parts. 138 RS-00*H* 1/17/0* RUECE8 PART HLW REQUIREMENTS FOR POTABLE-WATER HEATERS Introduction ........................................................................................................................................ 143 Article 1 HLW-100 HLW-101 _ HLW-102 General Scope................................................................................................................................ Service Restriction and Exception.................................................................................. Permissible Stamping...................................................................................................... 145 145 145 Article 2 HLW-200 HLW-201 HLW-202 HLW-203 HLW-204 Material Requirements Lining.............................................................................................................................. Primary Pressure Parts Material................................................................................... Acceptance of Unidentified or Small Quantities of Material...................................... Miscellaneous Pressure Parts Material........................................................................... Flanges and Pipe Fittings ............................................................................................. 146 146 147 147 148 Article 3 HLW-300 HLW-301 HLW-302 HLW-303 HLW-305 HLW-306 HLW-307 HLW-308 HLW-309 Design Design.............................................................................................................................. Minimum Thicknesses .................................................................................................. Shells Under Internal Pressure ...................................................................................... Basis for Establishing Stress Values inTables HLW-300 and HLW-301.................... Blank Unstayed Dished Heads, Pressure onConcave Side........................................... Blank Unstayed Dished Heads, Pressure onConvex'Side........................................... Tubes................................................................................................................................ Openings.......................................................................................................................... Tubes Attached by Rolling............................................................................................. 149 149 149 149 154 154 155 155 155 Article 4 HLW-400 HLW-401 HLW-402 HLW-411 HLW-413 HLW-415 HLW-420 HLW-430 HLW-431 Design of Weldments Design of Welded Joints................................................................................................ General Requirements.................................................................................................... Joint Efficiencies............................................................................................................. Heads or Tubesheets Attached by Welding.................................................................. Tubes Attached by Welding........................................................................................... Head-to-Shell Attachments............................................................................................. Openings in Welds.......................................................................................................... Welded Connections........................................................................................................ Minimum Requirements for AttachmentWelds.............................................................. 156 156 156 157 157 158 158 158 162 139 RS-003148 1117/02 NUECES HLW-432 HLW-440 HLW-450 HLW-451 HLW-452 HLW-453 HLW-454 HLW-460 Article 5 HLW-500 HLW-501 HLW-502 HLW-503 HLW-504 HLW-505 Article 6 HLW-600 HLW-601 HLW-602 Article 7 HLW-700 HLW-701 HLW-702 HLW-703 HLW-704 Article 8 HLW-800 HLW-801 HLW-805 HLW-809 HLW-810 HLW-820 Figures HLW-401.1 HLW-401.2 HLW-411 HLW-413 HLW-415 HLW-431.1 HLW-431.5 Brazed Connections for Copper Lined Vessels............................................................. Welding Processes.......................................................................................................... Welding Qualifications..................................................................................................... Production Work Qualifications...................................................................................... Interchange of Qualifying Tests Among Manufacturers Prohibited............................. Maintenance of Records of Qualifications and Identifying Marks............................... Posthydrotest Welding of Nonpressure Parts to Pressure Parts.................................. Specific Welding Requirements...................................................................................... 166 166 166 166 166 166 168 168 Tests Tests to Establish Maximum Allowable Working Pressure and Production Line Tests............................................................................................................................ General............................................................................................................................. Proof Test....................................................................................................................... Tests of Parts Subject to Collapse................................................................................. Witnessing, Recording, and Certifying Tests................................................................ Hydrostatic Test.............................................................................................................. 170 170 170 171 171 171 Inspection andStamping Inspection and Certification of Water Heaters.............................................................. Manufacturer's Data and Partial Data Reports.............................................................. Stamping of Water Heaters............................................................................................ 172 173 173 Controls Controls............................................................................................................................. Temperature Control......................................................................................................... Limit Controls.................................................................................................................. Controls and Heat Generating Apparatus...................................................................... Electrical Wiring.............................................................................................................. 175 175 175 175 175 Installation Requirements Safety Relief Valves....................................................................................................... Mounting Safety Relief Valves....................................................................................... Water Supply.................................................................................................................... Provisions for Thermal Expansion in Hot Water Systems.......................................... Bottom Drain Valve......................................................................................................... Thermometer.................................................................................................................... 176 176 177 177 179 179 Butt Welding of Plates of Unequal Thickness............................................................... Typical Comer Joints....................................................................................................... Typical Water Heater Welded Joints............................................................................. Tubes Attached by Welding............................................................................................ Heads Attached to Shells................................................................................................ Some Acceptable Types of Welded Nozzles and Other Connections to Shells and Head............................................................................................................................ Some Acceptable Types of Welded Nozzles and Other Connections to Shells and Head............................................................................................................................ 156 157 158 160 161 163 164 140 RS403147 1/17/02 NUECES HLW-432.I HLW-602.1 HLW-602.2 HLW-809.1 HLW-809.2 Tables HLW-300 HLW-301 HLW-809.1 Some Acceptable Types of Brazed Fittings, Nozzles, and Other Connections to Copper-Lined Shellsand Heads................................................................................ Official Symbol to Denote the American Society of Mechanical Engineers' Standard............................................................................... Form of Stamping on Completed Water Heaters......................................................... A Typical Acceptable Piping Installation for Storage Water Heaters inBattery-- A Typical Acceptable Piping Installation for Flow Through Water Heater With Provisions for PipingExpansion................................................................................ 167 173 173 178 179 Maximum Allowable Stress Values in Tension for Lined Materials, ksi................. Maximum Allowable Stress Values for Materials in Tension for Unlined Water Heaters, ksi................................................................................................................ Expansion Tank Capacities for a Water Heater............................................................. 150 152 177 141 R8-003148 1/17/02 NUECE8 INTRODUCTION A97 A97 The following is a brief introduction to Part HLW. It is general in nature, and should not be considered as a substitute for actual review of appropriate articles of the document. However, this will give the user a better understanding of the purpose, requirements, and intent of Part HLW. Part HLW applies to water heaters in commercial or industrial sizes providing corrosion resistance for supplying potable hot water for commercial purposes at pressures not exceeding 160 psig and temperatures not exceeding 210F. Part HLW does not apply to residential size water heaters, which are excluded by provisions of HLW-101. Differences in applicable criteria for water heaters versus hot water heating boilers are as follows. (a) In a water heater, the temperature of the water is limited to a maximum of 210F. (b) A water heater is provided with a corrosion resistant lining or constructed with corrosion resistant materials. (c) A water heater is intended to supply potable hot water with all makeup from a potable water supply system. Vessels built under the rules of Part HLW may be used for storage of potable water. The following is a brief outline of the contents of each Article of Part HLW. A97 Article 1 -- General The scope of Part HLW is given, and the service restriction and exemption are stated. Article 2 -- Materials The material requirements for the linings permitted are specified as well as the lining thickness requirements. The material requirements specified for the lining mate rials were, in general, taken from existing standards by abstracting those requirements which were considered to be those essential for the applications covered by these rules. Article 3 -- Design The design criteria for water heaters is given in Article 3. The pressure is specified as a maximum allowable working pressure of 160 psi with a minimum of 100 psi. The maximum water temperature permitted is 210F. The maximum allowable working pressure of the water heater shall be established in accordance with the proof test provision of HLW-500. As an alternative, stress values in Table HLW-300 may be used in calculations employing the available formulas when applicable to the geometry of the lined water heater or parts. Article 4 -- Weldments The provisions for weldment joint design are similar to those given elsewhere in this Section and in Section Vm, Division 1. In addition, some acceptable joint designs are provided which have been commonly used in the construction of water heaters and have provided satisfactory service performance. Article 5 -- Tests Proof test procedure is delineated for establishing the maximum allowable working pressure of a water heater or parts, and this test is required to be witnessed and accepted by the Authorized Inspector. The Manufac turer's Master Data Proof Test Report for Lined Water Heaters shall be certified by the designated responsible engineering head of the Manufacturer and the forms shall be kept on file by the Manufacturer as a matter of record. RS-003149 1/17/02 NUECES Introduction 1995 SECTION IV Article 6 -- Inspection and Stamping Inspection and stamping requirements for water heat ers are given. An "HLW" Code Symbol Stamp is provided for water heaters made in accordance with Part HLW of Section IV. Article 7 -- Controls Each water heater is required to have an operating control and a separate high-limit temperature-actuated control which shuts off the fuel supply in case of operating control failure. Water heaters should be equipped with suitable primary safety controls, safety limit switches, burners, or electric elements as appro priate and as required by a nationally recognized stan dard. Examples of these nationally recognized standards are listed. Article 8 -- Installation Some acceptable piping installations are shown. Pro visions for the installation of safety relief valves and other valves are given. Introduction RS-003160 144 1/17/02 NUECES ARTICLE 1 GENERAL HLW-100 SCOPE \97 A97 A97 a95 A97 A97 A97 A97 (a) The rules in Part HLW apply to water heaters and water storage tanks with corrosion resistance for supplying potable hot water. The foreword provides the basis for these rules. Part HLW is not intended to apply to hot water heating boilers. (b) This Part contains mandatory requirements, spe cific prohibitions, and nonmandatory guidance for mate rials, designs, fabrication, examination, inspection, test ing, certification, and pressure relief. (c) Laws or regulations issued by a municipality, state, provincial, federal, or other enforcement or regula tory body having jurisdiction at the location of an installation, establish the mandatory applicability of these rules, in whole or in part ............... (d) Linings for lined water heaters are limited to those listed in HLW-200. (e) The materials used in the construction of unlined corrosion resistant water heaters are limited to those listed in Table HLW-301. (f) Water heaters and tanks built under the rules of Part HLW may be provided with cathodic protection. (g) Water heaters used for deionized water fabricated of stainless steel listed in Table HLW-301 may be built to Part HLW provided: (1) all welding meets the requirements of Sec tion IX; (2) the maximum thickness shall be l/2 in. HLW-101. SERVICE RESTRICTION AND EXCEPTION HLW-10I.1 Service Restriction. The rules of Part HLW are restricted to potable water heaters and water storage tanks for operation at pressures not exceeding 160 psi and water temperatures not in excess of 210F. A97 HLW-101J Exception. Based on the Committee's consideration, water heaters are exempted when none of the following limitations is exceeded: (a) heat input of 200,000 Btu/hr; (b) water temperature of 210F; (c) nominal water-containing capacity of 120 gal, except that they shall be equipped with safety devices in accordance with the requirements of HLW-800. A97 HLW-102 PERMISSIBLE STAMPING Any water heater or storage tank that meets all of the requirements of Part HLW, including those for inspection, may be stamped with the Code HLW Symbol even though exempted from such stamping. 145 RS-003161 1/17/02 NUECES ARTICLE 2 MATERIAL REQUIREMENTS HLW-200 LINING A96 (a) Glass Lined. Glass lining shall be of an analysis in tended for use in hot water service and the minimum aver age thickness shall be 0.005 in. The walls, ends, and other parts that are ofsteel and are glass lined shall be ofa quality that is suitable for glass lining by the manufacturer's glass lining process. Glass lining may be applied to parts before assembly. The surfaces of the water heater vessel that are exposed to hot water shall have a coating with a minimum number of discontinuities, and the discontinuities shall av erage not more than '/8 sq in./sq ft of internal surface ex cluding edges and fittings. Thinning at comers may not extend over '/4 in. from the edge. (b) Galvanized. The galvanized coating shall be based uponatleast 1 oz ofzinc/sqftofsurface based upon mathe matical calculations corresponding to a coating thickness of 0.0017 in. The weight of the zinc coating shall be deter mined by weighing the waterheaterbefore galvanizing and again after the coating is applied. The zinc used for coating shall conform to ASTM B 6, Specification forZinc (Slab Zinc) and shall be at leastequal to the grade designated as "Prime Western."The aluminum content of the bath during actual galvanizing operations shall not exceed 0.01%. The galvanizer shall not damage the material by overpickling or by the use of excessively high temperature in pickling or galvanizing. (c) Cement Lined For cement-lined water heaters, the cement shall be applied to provide a minimum thickness of 3/16 in. The lining shall be properly cured, adhere firmly to, and completely cover the interior of the vessel. The joints at the top ofthe waterheater shallbe sealed to prevent corrosion in back ofthe lining. The water absorption of the lining material shall not be more than 17% ofthe dry weight of the test specimen. The calcium oxide content shall not exceed 35%. The silicon content shall notbe less than 25%. (d) Copper-Lined The material used for lining may be any copper of weldable or brazeable quality with a mini mum thickness of 0.005 in. Lining attachments to steel backing by welding or brazing shall be in accordance with Section IX. (e) Fluorocarbon Polymer-Lined. Fluorocarbon poly mer linings shall be of an analysis intended for use in pota ble hot water service, and the minimum thickness shall be 0.003 in. The lining shall be cured at a temperature and for a length of time suitable to assure continuity of lining and elimination of solvents. The water absorption rate of the cured lining shall be less than 2% by the method specified in ASTM D 570 shown in Appendix I. Surfaces to be fluo rocarbon polymer-lined must be cleaned to remove all scale, oxidation, oil, etc., prior to application of the lining. Interior surfaces may be coated with electroless nickel prior to lining. Flue tubes may be covered with a minimum thickness of 0.006 in. of sheet copper prior to the applica tion of the fluorocarbon polymer lining. (J) Amine or Polyamine Epoxy-Lined (1) Amine or polyamine epoxy linings shall be of an analysis intended for use in potable hot water service, and the minimum thickness shall be 0.003 in. The lining shall be cured at a temperature and for a length of time suitable to assure continuity of lining and elimination of solvents. The water absorption rate of the cured lining shall be less than 2% by the method specified in ASTM D 570 shown in Appendix I. Surfaces to be epoxy lined must be cleaned to remove all scale, oxidation, oil, etc., prior to application of the lining. (2) The use of amine or polyamine epoxy linings shall be limited to electric water heaters with immersion type elements, storage tanks, and those surfaces of fired water heaters that are not directly heated by the products of combustion. (g) Thermally Sprayed Metallic Linings. The material used for linings shall be any copper or copper alloy of sprayable quality. Prior to coating, the interior surfaces of the vessel or vessel parts shall be cleaned by grit blasting. The minimum lining thickness shall be 0.005 in. The pro cess shall be controlled to ensure that the temperature of the surface being coated does not exceed 650F. (h) Polymeric, Flexible Linings. Materials used shall be listed by National Sanitation Foundation International (NSFI) as meeting the requirements ofthe Standard ANSI/ NSF14-1900 for potable water service at a minimum tem perature of210F. The waterabsorption rate ofthe material shall be less than 10% by the 2 hr boiling water immersion test specified in SD-570 shown in Appendix I. No reground material shall be used. The minimum thickness ofthe lining shall be 0.020 inch. The interior surfaces of the vessel shall be free of projec tions or discontinuities which exceed one-half the thick- ( A95 A96 146 R8-0091M 1/17/02 NUECES HLW-201 ARTICLE 2 -- MATERIAL REQUIREMENTS HLW-203 HLW-300, HLW-301, and HF-300.2. For plate material, a certificate of compliance or a material test report is required to verify that the chemical and mechanical properties are within the permissible range listed in Section II. Material in all other product forms shall be accepted as complying with its Section II specifica tion when marked as required by (c) below. Material test reports shall be furnished by the mill of origin, except that any material that has lost its identification with a Section II specification, or that is ordered in small quantities, may be accepted, provided that it satisfies the provisions of HLW-202. (hi If a welded assembly is furnished as a part to the Manufacturer of the completed water heater vessel, a Manufacturer's Partial Data Report Form HLW-7 shall be provided by the parts Manufacturer. The parts Manufacturer shall comply with all applicable require ments of Part HLW, including inspection by an Author ized Inspector. (cj The material in (a) above shall have the identifi cation marking required by the appropriate Section II specification. During subsequent steps in fabrication, a painted color identification or some other method acceptable to the Authorized Inspector shall be used for identification. The method used shall remain distin guishable, or be reapplied until the part(s) are affixed in their proper location on the water heater vessel, and until the material is part of a uniquely identifiable subassembly. HLW-202 ACCEPTANCE OF UNIDENTIFIED OR SMALL QUANTITIES OF MATERIAL If the identification of materials required by HLW201 (a) is unavailable, each piece of plate material, or each length of other material, shall be shown to meet the chemical requirements and mechanical properties ofthe Section II specification designated for the part for which the material is to be used. The material shall be subjected to all required tests of the Section II specification. The manufacturer of the completed vessel shall verify that the material complies with the desig nated specification. Testing shall be as in HLW-202.1 and HLW-202.2. HLW-202.1 Plate. The chemical check analysis and physical tests shall be made as required in the designated specification, with the following modification: when the direction of rolling is not definitely known, two tension specimens shall be taken at right angles to each other from a comer of each plate, and two bend specimens shall be taken from the middle of adjacent sides of each plate. One tension specimen and both bend speci mens shall meet the specification requirements. HLW-202.2 Tubes, Pipe, Rods, Bars, and Shapes. Each length of tube, pipe, rod, bar, or shape shall be subjected to a chemical check analysis and physical tests to show that all the material is identified with a given heat or heat treatment lot, and that the material complies with the chemical and physical requirements of the designated specification. HLW-202J Marking and Test Report When the identity of material with a designated specification has been established in accordance with HLW-202.1 or HLW-202.2, each piece of material (except as alterna tively provided in the material specification for tubes, pipes, rods, bars, or shapes) shall be marked or identified by the manufacturer or the testing agency by any method acceptable to the Authorized Inspector, giving the designated specification number and grade or type, and a serial S-number identifying the particular lot of material. A suitable test report shall be furnished, properly filled out and certified by the manufacturer or testing agency. This report when accepted by the Authorized Inspector shall constitute authority to use the material. HLW-203 MISCELLANEOUS PRESSURE PARTS MATERIAL (a) Parts such as flanges, welding caps, welding necks, manhole frames, or manhole covers that are formed by casting, forging, rolling, or die forming, shall be constructed from materials permitted under Part HLW, or by an appropriate ANSI or manufacturer's standard to which the parts are made. Such parts shall be marked with the name or trademark of the manufacturer. Such markings shall be considered as the manufacturer's certification that the product com plies with the material specification and is suitable for service at the rating indicated. A certificate of compli ance or a material test report is not required. (b) Carbon steel or cast iron pressure parts of small size, such as nozzles, internally threaded fittings, hand hole frames, or handhole covers, for which it is difficult or impossible to obtain identified material, or that may be stocked and for which material test reports or certificates cannot be readily obtained, may be con structed from Section II materials other than those listed in Tables HLW-300, HLW-301, and HF-300.2, provided they are suitable for the application. These parts may be identified in any permanent or temporary manner that is acceptable to the Authorized Inspector A97 RS-0031S3 1/17/02 NUECES HLW-203 1995 SECTION IV HLW-204 and that will serve to identify the part with the manufac turer's written listing. The manufacturer who certifies the completed vessel shall satisfy himself that such parts are suitable for the welding, fabrication, service, and test conditions of its design. The use of such parts shall be subject to the acceptance of the Authorized Inspector. HLW-204 FLANGES AND PIPE FITTINGS The following standards covering flanges and pipe fittings are acceptable for use under Part HLW in accordance with the requirements of HLW-203. Pres sure-temperature ratings shall be per the appropriate standard: (a) ANSI B16.5, Flanges and Flanged Fittings (b) ANSI B16.9, Factory-Made Wrought Steel Butt welding Fittings (c) ANSI B16.ll, Forged Steel Fittings, SocketWelding and Threaded (d) ANSI B16.15, Cast Bronze Threaded Fittings (e) ANSI B 16.24, Bronze Pipe Flanges and Flanged Fittings (f) ANSI B 16.28, Wrought Steel Buttwelding Short Radius Elbows and Returns (g) ANSI B16.42, Ductile Iron Pipe Flanges and Flanged Fittings 148 r8jOOS* NUECES ARTICLE 3 DESIGN HLW-300 DESIGN (a) Water heaters are limited to a maximum allowable working pressure of 160 psi and the maximum water temperature shall be 210F. The maximum allowable working pressure for water heaters shall be not less than 100 psi. (b) Water heaters may be fired with oil, gas, or electricity. Water heaters shall be designed using the rules in this Part. (c) The temperature used in design shall not be less than the mean metal temperature (through the thickness) expected under operating conditions for the part consid ered. If necessary, the metal temperature shall be deter mined by computation using accepted heat transfer procedures or by measurements from equipment in service under equivalent operating conditions. Pressure parts subject to direct radiation and/or the products of combustion shall be designed to prevent flame im pingement. (d) Tables HLW-300 and HLW-301 give the maxi mum allowable stress values in tension for materials conforming to the tensile strengths listed therein when the design is based on the formulas given in this Article. (e) The maximum allowable stress value in bending shall be l'/j times that permitted in tension and the maximum allowable stress value in compression shall be two times that permitted in tension. (f) The maximum allowable working pressure of the water heater shall be established in accordance with the proof test provision of HLW-500. As an alternative, stress values in Tables HLW-300 and HLW-301 may be used in calculations employing the available formulas when applicable to the geometry of the water heater or parts. HLW-301 MINIMUM THICKNESSES The minimum thickness of sheet or plate material used for heads or shells in any lined or unlined water heater vessel shall not be less than x/% in. HLW-302 SHELLS UNDER INTERNAL PRESSURE When the provisions of HLW-501 to HLW-504 are not used, the thickness and the maximum allowable working pressure of cylindrical shells, pipe, and headers shall be determined in accordance with the following formulas: PR 1 ~ SE- 0.6P SEt P =--------- R + 0.6r where P-- maximum allowable working pressure, psi (but not less than 100 psi) S-- maximum allowable stress value from Tables HLW-300, HLW-301, HF-300.1, and HF300.2, psi / = required wall thickness, exclusive of liner, in. R = inside radius of cylinder, in. E= efficiency of longitudinal joint or ligament be tween tube holes, whichever is less. For welded joints, use the efficiency specified in HLW-402. For seamless shells, use E = 1. HLW-303 BASIS FOR ESTABLISHING STRESS VALUES IN TABLES HLW-300 AND HLW-301 In the determination of allowable stress values for pressure parts, the Committee is guided by successful experience in service, insofar as evidence of satisfactory performance is available. Such evidence is considered equivalent to test data where operating conditions are known with reasonable certainty. In the evaluation of new materials, it is necessary to be guided to a certain 149 RS-003166 1/17/02 NUECE8 Table HLW-300 1995 SECTION IV A97 TABLE HLW-300 MAXIMUM ALLOWABLE STRESS VALUES IN TENSION FOR LINED MATERIALS, ksi Spec. No. Grade Nominal Composition P-No. Group No. Spec. Min. Tensile Strength, ksi Note(s) Max. Allowable Design Stress, ksi Plate SA-285 A B C SA-455 SA-455 SA-455 SA-285 Modified to Chem. AISI C-1012 AISI C-1015 AISI C-1023 SA-414 Sheet A B C D E F G SA-414 Sheet Modified to Chem. AISI C-1012 AISI C-1015 AISI C-1023 C C c C-Mn C-Mn C-Mn 0.10C to 0.15C 0.13C to 0.18C 0.20C to 0.25C C C C C-Mn C-Mn C-Mn C-Mn 0.10C to 0.15C 0.13C to 0.18C 0.20C to 0.25C Bars and Forging SA-36 SA-105 SA-181 Class 60 C-Mn-SI Forging C-Si Forging C-Si 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 1 1 1 1 2 1 45 50 55 75 (5) 73 (6) 70 (7) (3) 45 50 55 45 50 55 60 65 70 75 '!'. i; v (3) 45 50 55 58 (1) 70 60 11.3 12.5 13.8 18.8 18.3 17.5 11.3 12.5 13.8 11.3 12.5 13.8 15.0 16.3 17.5 18.8 11.3 12.5 13.8 14.5 17.5 15.0 Pipe SA-53 SA-53 SA-106 SA-106 SA-106 SA-53 SA-53 SA-135 SA-135 SA-178 SA-178 A Smls. C 11 B Smls. C-Mn 11 A Smls. C-Si 1 1 B Smls. C-Si 11 C Smls. C-Si 12 A ERW C 11 B ERW C-Mn 11 A ERW C 11 B ERW C-Mn 11 A ERW C 11 C ERW C 11 48 12.0 60 15.0 48 12.0 60 15.0 70 17.5 48 (2) 10.2 60 (2) 12.8 48 (2) 10.2 60 (2) 12.8 47 (2X4) 10.0 60 (2) 12.8 150 R84031SS 1/17/02 NUECES A97 Spec No. ARTICLE 3 -- DESIGN Table HLW-300 TABLE HLW-300 (CONT'D) MAXIMUM ALLOWABLE STRESS VALUES IN TENSION FOR LINED MATERIALS, ksi Grade Nominal Composition P-No. Group No. Spec. Min. Tensile Strength, ksi Note(s) Max. Allowable Design Stress, ksi Plate SA-515 SA-516 60 C-Si 65 C-Si 70 C-Si 55 C-Si 60 C-Mn-Si 65 C-Mn-Si 70 C-Mn-Si 1i 1i 12 11 11 11 12 60 65 70 55 60 65 70 Bars SA-675 45 50 _ 55 60 65 70 C C C C C C 11 a1 i1 i1 i1 i2 45 50 55 60 65 70 GENERAL NOTE: Nonferrous material, if utilized for connections, etc., shall be in accordance with Table HF-300.2. NOTES: (1) These allowable stress values apply also to structural shapes. (2) The stress value includes a joint factor of 0.85. (3) For use only as shell plates, heads, tubesheets, or other surfaces to be glass lined. (4) Tensile value in parentheses is expected minimum. (5) For thickness up to J/j in., ind. (6) For thickness over \ in. to 0.580 in., Incl. (7) For thickness over 0.580 in. to 0.750 in., incl. 15.0 16.3 17.5 13.8 15.0 16.3 17.5 11.3 12.5 13.8 15.0 16.3 17.5 151 RS-003167 1/17/02 NUECES Table HLW-301 1995 SECTION fV A97 TABLE HLW-301 MAXIMUM ALLOWABLE STRESS VALUES FOR MATERIALS IN TENSION FOR UNLINED WATER HEATERS, ksi Spec. No. Grade Nominal Composition P-No. Group No. Spec. Min. Tensile Strength, ksi Note(s) Max. Allowable Design Stress, ksi (See HLW-303) -------------------------------Standard Alternative Plate Alloy Steel SA-240 304 304L 3X6 316L 439 S44400 18Cr-8Ni 18Cr-8Ni 16Cr-12Ni-2Mo 16Cr-12Ni-2Mo 18Cr-Ti 18Cr-2Mo 8 8 8 8 7 7 Tube Alloy Steel SA-213 TP304 TP304L TP316 TP316L Smls. 18Cr-8NI Smls. 18Cr-8Ni Smls. 16Cr-12NI-2Mo Smls. 16Cr-12Ni-2Mo SA-249 TP304 TP304L TP316 TP316L Wld. 18Cr-8Ni Wld. 18Cr-8Ni Wld. 16Cr-X2Ni-2Mo Wld. 16Cr-12Ni-2Mo SA-268 TP439 S44400 S44400 Smls. 18Cr-Ti Smls. 18Cr-2Mo Wld. 18Cr-2Mo 8 8 8 8 8 8 8 8 7 7 7 Bar Alloy Steel SA-479 304 304L 316 3X6L 439 S44400 18Cr-8Ni 18Cr-8Ni 16Cr-12Ni-2Mo X6Cr-12Ni-2Mo 18Cr-Ti 18Cr-2Mo 8 8 8 8 7 7 Pipe Alloy Steel SA-312 TP304 TP304 TP304L TP304L TP316 TP316 TP316L TP316L Smls. 18Cr-8Ni Wld. 18Cr-8Ni Smls. 18Cr-8Ni Wld. X8Cr-8Ni Smls. 16Cr-12Ni-2Mo Wld. 16Cr-12Ni-2Mo Smls. 16Cr-12Ni-2Mo Wld. 16Cr-12Ni-2Mo 8 8 8 8 8 8 8 8 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 75 70 75 70 65 60 75 70 75 70 75 70 75 " 70 60 60 60 75 70 75 70 70 60 75 75 70 70 75 75 70 70 (2X3X6) (2X3X6) (2X3X6) (2X3X6) (1X3X4X5) {1X2X4X5) 16.7 14.3 17.7 14.1 16.3 15.0 17.8(7) 16.5(7) 18.8(7) 16.7(7) (2X3X6) (2X3X6) (2X3X6) (2X3X6) 16.7 14.3 17.7 14.1 (2X3X6X8) (2) (3X6X8) (2X3X6X8) (2X3X6X8) . 14.2 11.9 15.0 12.0 (1X3X4X5) (1X2X4X5) (1)(2)(4)(5)(6) 15.0 15.0 12.8 17.8(7) 16.5(7) 18.8(7) 16.7(7) 15.1(7) 14.0(7) 16.0(7) 14.2(7) (2X3X6) (2X3X6) (2X3X6) (2X3X6) (1X3X4X5) (1X2X4X5) 16.7 14.3 17.7 14.1 16.6 15.0 17.8(7) 16.5(7) 18.8(7) 16.7(7) (2X3X6) (2X3X6X8) (2X3X6) (2X3X6X8) (2X3X6) (2X3X6X8) (2X3X6) (2X3X6X8) 16.7 14.2 14.3 12.2 17.7 15.0 14.1 12.0 17.8(7) 15.1(7) 16.5(7) 14.0(7) 18.8(7) 16.0(7) 16.7(7) 14.2(7) 152 RS-003168 1/17/02 NUECE8 ARTICLE 3 -- DESIGN Table HLW-301 A97 TABLE HLW-301 (CONT'D) MAXIMUM ALLOWABLE STRESS VALUES FOR MATERIALS IN TENSION FOR UNLINED WATER HEATERS, ksi Spec. No. Grade Nominal Composition P-No. Group No. Spec. Min. Tensile Strength, ksi Note(s) Max. Allowable Design Stress, ksi (See HLW-303) ---------------------------Standard Alternative Forgings Alloy Steel SA-182 F304 F304L F316 F316L 18Cr-8Ni 18Cr-8Ni 16Cr-12Ni-2Mo 16Cr-12Ni-2Mo 81 81 81 81 75 70 75 70 (2X3X6) (2X3X6) (2X3X6) (2X3X6) 16.7 14.3 17.7 14.1 17.8(7) 16.5(7) 18.8(7) 16.7(7) NOTES: (1) The maximum is 3/B in. (2) The maximum thickness is l/2 in. (3) The service temperature shall not exceed 210F. (4) Filler metal shall be Type 430 with a nominal molybdenum content of approximately 2%. The 300 series of chromium-nickel-iron filler metals shall not be used in welding vessels conforming to the requirements of Section IV. (5) The welding processes employed in fabrication shall be limited to the gas tungsten arc welding process and the gas metal arc welding process. Shielding gas for~the gas shielded metal arc process shall be argon or helium. Oxygen up to 2% may be added to the argon. (6) Water heaters using this material are to be operated only on deionized water having a minimum specific resistivity of 1.0 Mft/cm. (7) Due to the relatively low yield strength of the austenitic stainless steel materials, these higher stress values were established at temperatures at which the short time tensile properties govern to permit the use of these alloys where slightly greater deformation is acceptable. These higher stress values exceed two-thirds but do not exceed 90% of the yield strength at temperature. Use of these stress values may result in dimensional changes due to permanent strain. These stress values are not recommended for flanges of gasketed joints or other applications where slight amounts of distortion can cause leakage or malfunction. (8) The stress value includes a joint factor of 0.85. 153 RS-003109 1/17/02 NUECE8 HLW-303 1995 SECTION IV HLW-306.1 extent by the comparison of test information with similar data on successful applications of similar materials. At any temperature below the creep range, the allow able stresses are established at no higher than the lowest of the following: (!) *4 of the specified minimum tensile strength at room temperature; (2) % of the tensile strength at temperature; (3) 2/3 of the specified minimum yield strength at room temperature; (4) V3 of the yield strength at temperature. In Table HLW-301 for austenitic stainless steel mate rials, two sets of allowable stress values are provided. The higher values should be used only where slightly greater deformation is not in itself objectionable. The higher alternative allowable stresses are identified by a note. These stresses exceed two-thirds for austenitic stainless steel materials but do not exceed 90% of the minimum yield at temperature. These higher stresses are not recommended for the design of flanges and other strain sensitive applications. HLW-305 BLANK UNSTAYED DISHED HEADS, PRESSURE ON CONCAVE SIDE HLW-305.1 General. When the provisions of HLW501 to HLW-504 are not used, the required thickness at the thinnest point after forming of ellipsoidal and torispherical heads under pressure on the concave side (plus heads) shall be computed by the appropriate formulas in this paragraph. (a) Notations. The notations used in this paragraph are defined as follows: t= required wall thickness, exclusive of liner, in. P = maximum allowable working pressure, psi (but not less than 100 psi) D = inside diameter of the head skirt; or inside length of the major axis of an ellipsoidal head; or inside diameter of a cone head at the point under con sideration, measured perpendicular to the longi tudinal axis, in. S= maximum allowable stress value from Tables HLW-300, HF-300.1, and HF-300.2, psi L = inside spherical or crown radius, in. E = lowest efficiency of any joint in the head; use the efficiency specified in HLW-402. For seamless heads, use E -- 1. HLW-305.2 Ellipsoidal Heads. When the provisions of HLW-501 to HLW-504 are not used, the required thickness and the maximum allowable working pressure of a dished head of semiellipsoidal form, in which half the minor axis (inside depth of the head minus the skirt) equals one-fourth of the inside diameter of the head skirt, shall be calculated by the following formulas: PD ~ 2SE - 0.2P ISEt P =----------- D + 0.2/ HLW-3053 Torispherical Heads. When the pro visions of HLW-501 to HLW-504 are not used, the required thickness and the maximum allowable working pressure of a torispherical head shall be calculated by the following formulas: 0.885PL ~ SE - 0.1P P =-----------------0.885L + 0.1/ HLW-305.4 Inside Crown Radius of Unstayed Heads. The inside crown radius to which an unstayed formed head is dished shall be not greater than the outside diameter of the skirt of the head. The inside knuckle radius of a torispherical head shall be not less than 6% of the outside diameter of the skirt of the head but in no case less than three times the head thickness. HLW-305.5 Hemispherical Heads. Because of the complexity of joint design, hemispherical heads are not permitted. HLW-306 BLANK UNSTAYED DISHED HEADS, PRESSURE ON CONVEX SIDE HLW-306.1 When the provisions of HLW-501 to HLW-504 are not used, unstayed dished heads with the pressure on the convex side shall have a maximum allowable working pressure equal to 60% of that for heads of the same dimension with the pressure on the concave side. 154 RS-003160 1/17/02 NUECES HLW-306.2 ARTICLE 3 -- DESIGN HLW-309 HLW-306.2 Hemispherical Heads. Because of the complexity of joint design, hemispherical heads are not permitted. thickness of nonferrous tubes shall be in accordance with HG-315.2. HLW-307 TUBES HLW-307.1 Ferrous Tubes. When the provisions of HLW-501 to HLW-504 are not used, the thickness of seamless or welded tubes 1 in. diameter and over, and including 24 in. diameter, shall be determined by one of the following formulas: (a) where the length of the tube is not greater than 40 in., PD t =---------+ 0.065 15.000 HLW-308 OPENINGS HLW-308.1 Single openings in water heaters do not require reinforcement under the following conditions. Welded connections attached in accordance with the applicable rules and not larger than: (a) NPS 3 in shells or heads % in. or less; NPS 2 in shells or heads over 3/8 in.; (b) threaded, studded, or expanded connections in which the hole cut in the shell or head is not greater than NPS 2. HLW-308.2 When the provisions of HLW-501 to HLW-504 are not used, all other openings shall be reinforced in accordance with HG-321 of this Section. (b) where the length of the tube is greater than 40 in., PD t =------ -- + 0.065 14.000 where P = maximum allowable working pressure, psi D = outside diameter of tube, in. t= required wall thickness, exclusive of liner, in. HLW-307.2 Nonferrous Tubes. When the provisions of HLW-501 to HLW-504 are not used, the minimum HLW-309 TUBES ATTACHED BY ROLLING (a) The tube hole in the head or tubesheet shall be formed either: (1) to the full size diameter by a method which will not produce irregularities that would interfere with proper rolling and sealing, or (2) to a lesser diameter, then enlarged to full diameter by a secondary drilling, cutting, or reaming operation to remove such irregularities. The sharp edges of tube holes shall be taken off both sides with a file or other tool. (b) The minimum thickness of any tubesheet with tubes installed by rolling shall be 3/16 in. 155 R8-003181 1/17/02 NUECES ARTICLE 4 DESIGN OF WELDMENTS HLW-400 DESIGN OF WELDED JOINTS HLW-401 GENERAL REQUIREMENTS All welds, fillet or full penetration, shall be made to a qualified welding procedure by qualified welders for each welding process employed (manual, semiautomatic, automatic), in accordance with the applicable provisions of Section IX to insure satisfactory penetration and fusion into the base metal to the root of the weld. All members, prior to being welded, shall be properly fitted, aligned, and retained in position in accordance with the Procedure Specification for the welding procedure to be used. HLW-401.1 Butt Joints. Longitudinal or circumfer ential joints uniting plates of a drum, shell, or other pressure parts shall be butt joints. A butt joint shall be double welded butt or may have filler metal added from one side only, provided the weld penetration is complete. (a) If there are two or more courses, the welded longitudinal joints of adjacent courses shall be not less than 6 in. apart. (b) If the plates are of unequal thickness, at no point shall the plate on one side of the joint be offset with the plate on the other side of the joint in excess of one-fourth of the thickness of the thickest plate. The weld may be partly or entirely in the tapered section or adjacent to it as indicated in Fig. HLW-401.1. HLW-401.2 Corner or Tee Joints. Unflanged heads or tubesheets of water heaters may be constructed by attaching unflanged heads or tubesheets to the shell by welding, provided: (a) comer or tee joints shall be as shown in Fig. HLW-401.2, sketches (a), (b), (c), or (d). (b) the head or tubesheet is supported by tubes. (c) the welded joint for Fig. HLW 401.2, sketches (a), (b), and (c) is wholly within the shell and forms no part thereof. The throat of the fillet weld shall be not less than 0.7 times the thickness of the thinner plate. (a) Preferred Method (Center lines coincide) (b) Permissible (Circumferential joints only) (c) Not Permissible FIG. HLW-401.1 BUTT WELDING OF PLATES OF UNEQUAL THICKNESS (d) for Fig. HLW-401.2, sketches (b) and (d) the weld shall have full penetration. HLW-402 JOINT EFFICIENCIES The following joint efficiencies E are to be used in the formulas of this Section (i.e., HLW-302 and HLW305) for joints completed by an arc or gas welding process. (a) E = 85% for full penetration butt joints as attained by double welding or by other means, which will obtain the same quality of deposited weld metal on the inside and outside weld surfaces, to provide complete joint penetration and assurance that the weld grooves are completely filled (HLW-401.1). Welds 156 R8-003162 1/17/02 NUECE8 HLW-402 Not less than 1.25(5 but need not be greater than th 2tt min. (a) Required (b) Rquir*d (c) Required ts - nominal shell thickness th = nominal head thickness FIG. HLW-401.2 TYPICAL CORNER JOINTS (e) Not Permisaible which use metal backing strips which remain in place are excluded. (b) E = 80% for full, penetration single-welded butt joints with backing strips other than those included in (a) above. HLW-402.1 Joint Efficiencies for External Pres sure Design. Joint efficiency E factors are not required to be used when the part is designed for external pressure only. HLW-411 HEADS OR TUBESHEETS ATTACHED BY WELDING Typical water heater welded joints are shown in Fig. HLW-411. HLW-411.1 Flanged heads or tubesheets of water heaters attached by butt welding shall be in accordance with Fig. HLW-415, sketch (d) or (e). HLW-411.2 Flanged heads or tubesheets of water heaters may be constructed by attaching an outwardly or inwardly flanged head or tubesheet to the shell by fillet welding, provided: (a) inwardly flanged head or tubesheets are full fillet welded [see Fig. HLW-415, sketch (a)]; (bj the joint attaching an outwardly flanged head or tubesheet shall be in accordance with Fig. HLW-415, sketch (b) or (c). -- HLW-413 TUBES ATTACHED BY WELDING (a) The edge of the plate at the tubesheet hole may be beveled or recessed to a depth at least equal to the thickness of the tubes. Where the plate is beveled or recessed, the projection of the tubes beyond the tube sheet shall not exceed a distance equal to the tube thickness. The depth of any bevel or recess shall not be less than the tube thickness or '/g in., whichever is greater, nor more than one-third of the tubesheet thickness. (b) Where no bevel or recess is employed, tubes shall extend beyond the tubesheet not less than 1.5 times the tube thickness, nor more than 3 times the tube thickness, or `/4 in., whichever is greater [see Fig. HLW-413, sketch (d)]. (c) When openings are flanged for tubes as shown in Fig. HLW-413, sketch (a), (b), or (e), flanges shall extend parallel to the tube for a minimum distance equal to the tube thickness. 157 a ii - 884)03163 1/17/02 NUECES HLW-413 1995 SECTION IV HLW-430.1 (a) Unstayed, Ranged, and Dished Heads lb) Ranged and Dished Heads With Rue Tube A97 FIG. HLW-411 TYPICAL WATER HEATER WELDED JOINTS (d) Where exposed to gases of greater than 850F, head flanges shall conform to the limitations of Fig. HLW-413. (e) When the temperature of the gases is normally 850F or less, the length of flange or tube may extend beyond the limits of Fig. HLW-413. HLW-415 HEAD-TO-SHELL ATTACHMENTS Ellipsoidal, torispherical, and other types of formed heads, concave or convex to the pressure shall have the following requirements as to skirt length. (a) An ellipsoidal or torispherical head which is attached to a shell by a butt joint as shown in Fig. HLW-415, sketch (e), need not be provided with a skirt when the nominal head thickness does not exceed 1 */4 times the nominal shell thickness. When the nominal head thickness exceeds lV4 times the nominal shell thickness, a skirt shall be provided having a length not less than 3 times the nominal head thickness or \V2 in., whichever is smaller. When a skirt is used, it shall meet the requirements for shell thickness in HLW-301. (b) Ellipsoidal or torispherical heads, concave or convex to pressure, that are to be fitted inside or over a shell (lap joint) shall have a skirt of at least 3 times the nominal head thickness, but in no case less than 1 in. (c) Shells and heads may be attached to shells or heads using a butt weld with one plate edge offset as shown in Fig. HLW-415(d). The weld may be deposited on the inside of the vessel only when the weld is accessible for inspection after the vessel is completed. A97 HLW-420 OPENINGS IN WELDS Any type of opening that meets the requirements for reinforcement given in HG-321 may be located in a butt welded joint. HLW-430 WELDED CONNECTIONS HLW-430.1 Strength of Attachment Welds. Noz zles, other connections, and their reinforcement may be attached to a water heater by arc or gas welding. Sufficient welding shall be provided on either side of the line through the center of the opening parallel to the longitudinal axis of the shell to develop the strength of the shell as prescribed in HG-327 through shear or tension in the weld, whichever is applicable. The 158 RS-0031M 1117/02 NUECES (c) Unflangad and flangad flat haada with muttipia haadt FIG. HLW-411 TYPICAL WATER HEATER WELDED JOINTS (CONT'D) 159 R8-003186 1/17/02 NUECES Fig. HLW-413 1995 SECTION IV A97 May not exceed 3(^+1,) [see HLW-413(c)] tt May not exceed y3 + (c) 1.5 tf min. but may not exceed 3tf or 1/4 in., whichever is greater ff = nominal tube thickness f/, = nominal head thickness FIG. HLW-413 TUBES ATTACHED BY WELDING 160 PS-003166 1/17/02 NUECES ARTICLE 4 -- DESIGN OF WELDMENTS Fig. HLW-415 Bevel i J A97 (a), (b) and (e) Single Fillet Lap Wald Id) Butt Weld With One Plate Edge Offset Whan th it equal to or Ian than 1.26ft Details If), (g), and (h) are not permissible. When th exceeds 1.25rf |e) Butt Weld t, * Nominal shell thickness th " Nominal head thicknen FIG. HLW-415 HEADS ATTACHED TO SHELLS 161 R8-003167 1/17/02 NUECES HLW-430.1 1995 SECTION IV HLW-431.5 strength of groove welds shall be based on the area subjected to shear or to tension. The strength of fillet welds shall be based on the area subjected to shear, computed on the minimum leg dimension. The inside periphery of a fillet weld shall be used in computing its length. HLW-430.2 Stress Values for Weld Metal. The allowable stress values for groove and fillet welds and for shear in nozzle necks in percentages of stress values for the vessel material are as follows: Nozzle wall Groove welded tension Groove weld shear Fillet weld shear 70% 74% 60% 49% NOTE: These values are obtained by combining the following factors: il'/i'b for combined end and side loading, 80% for shear strength, and the applicable joint efficiency factors. HLW-431 MINIMUM REQUIREMENTS FOR ATTACHMENT WELDS HLW-431.1 General. The location and minimum size of attachment welds for nozzles and other connec tions shall conform to the requirements in this paragraph. (a) Notations. The notations used in'this paragraph and in Fig. HLW-431.1 are defined as follows: r = nominal thickness of shell or head, in. t,, = nominal thickness of nozzle wall, in. te = thickness of reinforcement element, in. tw = dimension of partial-penetration attachment welds (fillet, single-bevel, or single-J), mea sured as shown in Fig. HLW-431.1, in. tc = the smaller of V4 in. or 0.7 tn (inside comer welds may be further limited by a lesser length of projection of the nozzle wall be yond the inside face of the water heater wall) ^min.= the smaller of V4 in. or the thickness of either of the parts joined by a fillet, single bevel, or single-J weld, in. t!, t2 = not less than '/3 rmj,,. or V4 in. and + t2 not less than 1V4 t mjn. HLW-431.2 Inserted Nozzles Without Added Rein forcement Elements (a) Nozzles inserted into or through a hole cut in the shell and without additional reinforcement elements shall be attached by a full-penetration groove weld or by two partial penetration welds, one on each face of the shell. Permissible types of welds are shown in Fig. HLW-431.1, sketches (a) through (h). (b) Backing strips shall be used with full penetration welds deposited from one side only when the shell thickness is over 3/g in. or when complete joint penetra tion cannot be verified by visual inspection. The two partial penetration welds may be any desired combina tion of fillet, single-bevel, and single-J welds. The dimension tw of each weld shall be not less than *4 in. or 0.7/ and their sum shall be not less than 1*4 fmin (see Fig. HLW-431.1). HLW-431.3 Inserted Nozzles With Added Rein forcement Inserted-type nozzles having added rein forcement in the form of one or more separate reinforce ment plates shall be attached by welds at the nozzle neck periphery and at the outer edge of each reinforce ment plate. The weld at the outer edge of each reinforce ment plate shall be a fillet weld with a minimum throat dimension of l/2 /min- HLW-431.4 Nozzles With Integral Reinforcement Nozzles and other connections having integral reinforce ment in the form of extended necks or saddle-type pads shall be attached by a full-penetration weld or by means of a fillet weld along the outer edge and a fillet single-bevel, or single-J weld along the inner edge. The throat dimension of the outer weld shall be not less than V2 tnin- The dimension tw of the inner weld shall be not less than 0.7 fmin [see Fig. HLW431.1, sketch (h)]. HLW-431.5 Fittings With Internal Threads and Studded Pads. The attachment of internally threaded fittings and studded pads shall meet the following requirements. (a) Except as provided for in (b) below, internally threaded fittings shall be attached by a full-penetration groove weld or by two fillet or partial penetration welds, one on each face of the water heater wall. The minimum weld dimensions shall be as shown in Fig. HLW-431.5, sketches (u), (v), (w), and (x). (b) Internally threaded fittings or equivalent bolting pads not exceeding NPS 4 may be attached by a fillet weld deposited from the outside only, having the minimum dimensions shown in Fig. HLW-431.5, sketches (a) through (1). Fittings or studded pads which are not subject to a bending load and which will be plugged, such as those for thermostats, anode rods, drain valves, cleanouts, and heating elements, may be attached to water heater vessels having a thickness not greater than 3/8 in. by a fillet weld deposited from the outside only having the minimum dimensions shown in Fig. HLW-431.5, sketch (y). The maximum size opening in the water heater vessel shall be 53/8 in. in 162 RS-003168 1/17/02 NUECES ARTICLE h -- be removed after welding smaller of 1/4 in. or 0.7 r min. FIG. HLW-431.1 SOME ACCEPTABLE TYPES OF WELDING NOZZLES AND OTHER CONNECTIONS TO SHELLS AND HEAD 163 RS-003169 1/17/02 NUECES Fig. HLW-431.5 1995 SECTION IV (z) FIG. HLW-431.5 SOME ACCEPTABLE TYPES OF WELDED NOZZLES AND OTHER CONNECTIONS TO SHELLS AND HEAD 164 RS-003170 1/17/M NUECES HLW-431.5 ARTlLLt any direction but not greater than one-half the vessel diameter. (c) Flange-type fittings not exceeding NPS 2 as shown in Fig. HLW-431.5, sketch (z) may be attached without additional reinforcement other than that in the fitting and its attachments, provided all of the following conditions are met: (1) the water heater wall thickness shall not exceed % in.; (2) the minimum fillet leg shall be Vyi in.; (3) the opening in the water heater wall shall not exceed the outside diameter of the nominal pipe plus 34 in. HLW-431.6 Internally Threaded Fittings Attached by Resistance Welding. Resistance welding may be used for the attachment of fittings under the following limitations and requirements. (a) The welding process utilized shall be limited to projection welding. (b) Materials used in resistance welded parts shall be limited to a maximum carbon content of 0.15%. (c) The thickness t shall not exceed S/I6 in., and the fitting shall not exceed NPS 2. (d) The maximum allowable working pressure for a vessel with fittings attached by resistance welding shall be established by a proof test in accordance with HLW-500. (e) In lieu of the Procedure and Performance Qualifi cation requirements of Section IX, the following require ments shall be met. (1) Workmanship Samples (a) Three welded specimens of each combination of fitting size and base metal thickness employed shall be made immediately before and after the welding of the fittings for the proof test vessel. These test specimens shall be representative of the manufacturing practice employed in the attachment of the fittings to the proof test vessel. Sufficient base metal shall overlap the fitting to allow securement for the tensile test. (b) These welded specimens shall be subjected to tensile loading. Each specimen shall pass the tensile test by shearing the fitting or the base metal. Separation at the weld interface shall constitute failure. Any failure shall require a repeat of the workmanship sample test as herein required. (c) All pertinent information obtained from the foregoing tests shall be recorded. These samples and data constitute workmanship samples which shall be available for comparison with quality control specimens that are made during production. (2) Machine Settings and Controls (a) The resistance welding m*.*.,____ process control parameters used in the attachment of the fittings to the proof test vessel and the workmanship samples shall be recorded. Except for minor variations and adjustments as permitted in the above parameters, the applicable settings shall be used in the fabrication of all vessels in a given production run. (b) The machine settings and control shall be verified by a test sample prior to the start of daily operations, after any service or adjustment is done on the welding equipment, and with every change in material or nominal thickness. (3) Records. Records shall be kept of all data obtained from tests of the proof test vessel, the work manship samples, the welding machine settings, the welding procedure, and process control parameters. (4) If resistance welding machines other than those used for the initial proof test vessel and workmanship samples are to be used in production, each additional machine and welding procedure shall be qualified in full accordance with (e)(1), (e)(2), and (e)(3) above. HLW-431.7 Stud Welds. Arc stud welding and resistance stud welding, as defined in E-101, where the pressure exerts a tensile load on the studs, may be used only for the attachments of bolted unstayed flat heads, cover plates and blind flanges, handholes and manholes, with the further limitations as follows. (a) Studs attached by stud welding shall not be in direct contact with products of combustion or flue gases. (b) Where the pressure exerts a tensile load on the studs, a full face gasket must be used on flat heads, cover plates, and blind flanges attached by stud welding. (c) The minimum size stud used shall be not less than `/4 in. nominal diameter and the maximum size shall not exceed 7/8 in. nominal diameter. (dj The type of stud shall be limited to round exter nally threaded studs. (e) Base metal shall be of ferrous material speci fication as permitted by this Section, and the base metal must be thick enough to prevent bum through. (/) Stud material for arc stud welding and resistance stud welding of carbon steel shall be low carbon steel of an acceptable material in this Section and with a carbon maximum of 0.27% and with a minimum tensile strength of 60,000 psi. (g) The maximum spacing of studs shall not exceed 12 times the nominal diameter of the stud. (h) The maximum allowable stress for the stud shall be 7800 psi based on the smallest cross-sectional area (i.e., the root of the thread). 165 RS-003171 1/17/02 NUECES HLW-431.8 1995 SECTION IV HLW-453 HLW-431.8 Friction Welding. Materials joined by the inertia and continuous drive friction welding pro cesses shall be limited to material assigned P-Numbers in Section IX and shall not include rimmed or semikilled steel. HLW-432 BRAZED CONNECTIONS FOR COPPER LINED VESSELS Brazing shall meet the applicable requirements of Subpart HB, Articles 10 through 15, inclusive. Some acceptable brazed connections are as shown in Fig. HLW-432.1. HLW-440 WELDING PROCESSES The welding processes that may be used under this Part are restricted to the following. (a) Arc or gas welding processes are restricted to shielded metal arc, submerged arc, gas metal arc, gas tungsten arc, plasma arc, atomic hydrogen metal arc, oxyhydrogen, and oxyacetylene. (b) Pressure welding processes are restricted to flash, induction, resistance, pressure thermit, pressure gas, and inertia and continuous drive friction welding. (c) Definitions are given in Section IX which include variations of these processes. HLW-450 WELDING QUALIFICATIONS Unless otherwise specified in this Part the procedures, the welders, and the welding operators used in welding pressure parts and in joining nonpressure parts (attach ments) to pressure parts shall be qualified in accordance with Section IX. HLW-451 PRODUCTION WORK QUALIFICATIONS (a) No production work shall be undertaken until the procedures, the welders, and the welding operators have been qualified, except that performance qual ification by radiography, in conformance with Section IX, QW-304 for welders or QW-305 for welding opera tors, may be performed within the first 3 ft of the first production weld. (b) Welders, including brazers, and welding and braz ing operators not in the employ of the manufacturer (Certificate of Authorization Holders) may be used to fabricate water heaters or parts thereof constructed in accordance with the Section, provided all of the follow ing conditions are met. (1) All Code construction shall be the responsibil ity of the Manufacturer. (2) All welding shall be performed in accordance with the Manufacturer's welding procedure specifica tions which have been qualified by the Manufacturer in accordance with the requirements of Section IX and this Section. (3) All welders shall be qualified by the Manufac turer in accordance with the requirements of Section IX and this Section. (4) The Manufacturer's quality control system shall include as a minimum: (a) a requirement for complete and exclusive administrative and technical supervision of all welders by the Manufacturer; (b) evidence of the Manufacturer's authority to assign and remove welders at his discretion without involvement of any other organization; (c) a requirement for Assignment of Welder Identification symbols; (d) evidence that this program has been accepted by the Manufacturer's Authorized Inspection Agency which provides the inspection service. (5) The Manufacturer shall be responsible for Code compliance of the completed vessel or part, including Code symbol stamping and providing Data Report Forms properly executed and countersigned by the Inspector. HLW-452 INTERCHANGE OF QUALIFYING TESTS AMONG MANUFACTURERS PROHIBITED The performance qualification tests for welders and welding operators conducted by one manufacturer or contractor shall not qualify a welder or welding operator to do work for any other manufacturer or contractor. HLW-453 MAINTENANCE OF RECORDS OF QUALIFICATIONS AND IDENTIFYING MARKS The Manufacturer or contractor shall maintain a record of the welding procedures and welders and welding operators employed by him showing the date and results of test and the identification mark assigned to each welder. These records shall be certified to by the Manufacturer or contractor and be accessible to the Inspector. The welder or welding operator shall stamp his identification mark on or adjacent to all 166 rS-00317* ARTICLE 4 -- DESIGN OF WELDMENTS Fig. HLW-432.1 Swage flange on tank exterior ac* c O (a) lb) FIG. HLW-432.1 SOME ACCEPTABLE TYPES OF BRAZED FITTINGS, NOZZLES, AND OTHER CONNECTIONS TO COPPER-LINED SHELLS AND HEADS 167 HS-003!75 I/17'O* nuecb* HLW-453 1995 SECTION IV HLW-460.7 welded joints made by him at intervals of not greater than 3 ft, or the Manufacturer shall keep a record of the welded joints on a water heater vessel and the welders and welding operators used in making the joints. HLW-454 POSTHYDROTEST WELDING OF NONPRESSURE PARTS TO PRESSURE PARTS Nonpressure parts may be welded to pressure parts after the hydrostatic test has been performed as set forth in HLW-505, provided the following criteria are met: (a) The welding is limited to P-No. 1 materials. (b) The attachment is done by stud welding, or by fillet welding where the throat of the weld does not exceed the lesser of 1.5 times the thickness of the pressure part or l/4 in. (c) The completed weld is inspected by the Author ized Inspector. (d) The Manufacturer's Data Report Form shall be signed only after the completion of the welding. HLW-460 SPECIFIC WELDING REQUIREMENTS HLW-460.1 Finished Longitudinal and Circumfer ential Joints (a) Butt welded joints shall have complete penetration and full fusion. The surface of the weld may be left as-welded provided the weld is free of coarse ripples, grooves, overlaps, abrupt ridges, or valleys. A reduction in thickness due to the welding process is acceptable provided all of the following conditions are met. (1) The reduction in thickness shall not reduce the material of the adjoining surfaces below the minimum required th.ckness at any point. (2) Thv: reduction in thickness shall not exceed V32 in. or 10% of the nominal thickness of the adjoining surface, whichever is less.1 HLW-460.2 Fillet Welds. In making fillet welds, the weld metal shall be deposited in such a way that adequate penetration into the base metal at the root of the weld is secured. The reduction of the thickness of the base metal due to the welding process at the edges 1 It is not the intent of this paragraph to require measurement of reductions in thickness due to the welding process. If a disagreement between the Manufacturer and the Inspector exists as to the acceptabil ity of any reduction in thickness, the depth shall be verified by actual measurement. of the fillet weld shall meet the same requirements as for butt welds [see HLW-460.1]. HLW-460.3 Double-Welded Butt Joints. Before applying weld metal on the second side to be welded, the root of double-welded butt joints shall be prepared by suitable methods such as chipping, grinding, or thermal gouging, so as to secure sound metal at the base of weld metal deposited on the face side, except for those processes of welding by which proper fusion and penetration are otherwise obtained and by which the root of the weld remains free from impurities. HLW-460.4 Repair of Weld Defects. Visible defects, such as cracks, pinholes, and incomplete fusion, and defects detected by leakage tests shall be removed by mechanical means or by thermal grooving processes, after which the joint shall be rewelded and reexamined. HLW-460.5 Stud Welding. In the case where arc stud welding and resistance stud welding is used to attach load canying studs, a production stud weld test of the procedure and welding operator shall be per formed on five studs, welded and tested in accordance with either the bend or torque stud weld testing described in Section IX as follows: (a) prior to start of daily operation if used continu ously on units of similar construction; (b) prior to the start of application to a given unit when not used continuously; (c) after adjustment or servicing is done on welding equipment. HLW-460.6 Procedure and Performance Qualifi cation Tests and Material Requirements for Stud Welding. Procedure and performance qualification tests for stud welds shall be made in accordance with Section IX. Further requirements for stud welding are as follows. (a) Metallic coatings (such as cadmium plating) if used shall not be within l/2 in. from the weld end of the stud. (b) The base metal must be above 50F during the welding process. HLW-460.7 Stud Welding. In the case where stud welding and resistance stud welding are used for joining nonpressure bearing attachments, which have essentially no load carrying function (such as extended heat transfer surfaces, insulation attachment pins, etc), to pressure parts by any automatic welding process performed in accordance with a Welding Procedure Specification (in compliance with Section IX as far as applicable), procedure and performance qualification testing is not required. 168 rSj00* Nuecs8 HLW-460.7 ARTICLE 4 -- DESIGN OF WELDMENTS HLW-460.9 In the case where stud welding is used to attach nonload-carrying studs, a production stud weld test, appropriate to the end use application requirements, shall be specified bv the Manufacturer or assembler and carried out on a separate test plate or tube: (a) prior to start of daily operation if used continu ously on units of similar construction; (b) prior to the start of application to a given unit when not used continuously; (c) after adjustment or servicing is done on welding equipment. HLW-460.8 Tack Welds. Tack welds used to secure alignment shall either be removed completely when they have served their purpose, or their stopping and starting ends shall be properly prepared by grinding or other suitable means so that they may be satisfactorily incorporated into the final weld. Tack welds, whether removed or left in place, shall be made using a fillet weld or butt weld procedure qualified in accordance with Section IX. Tack welds to be left in place shall be made by welders qualified in accordance with Section IX and shall be examined visually for defects, and if found defective, shall be removed. It is not necessary that a subcontractor performing such tack welds for the vessel manufacturer be a holder of an ASME Certificate of Authorization. If the tack welds are permanently left in place, the final vessel manufacturer shall maintain the controls to assure that the necessary welding procedure and performance quali fications are met in order to satisfy Code requirements. HLW-460.9 Friction Welding (a) When joining two parts by the inertia and continu ous drive friction welding processes, one of the two parts must be held in a fixed position and the other part rotated. The two faces to be joined must be essentially symmetrical with respect to the axis of rotation. Some of the basic types of applicable joints are solid round to solid round, tube to tube, solid round to tube, solid round to plate, and tube to plate. (b) The welded joint between two members joined by the inertia and continuous drive friction welding processes shall be a full penetration weld. Visual exami nation of the as-welded flash roll of each weld shall be made as an in-process check. The weld upset shall meet the specified amount within 10%. The flash shall be removed to sound metal. 169 R8-003176 1/17/03 NUECES ARTICLE 5 TESTS HLW-500 TESTS TO ESTABLISH MAXIMUM ALLOWABLE WORKING PRESSURE AND PRODUCTION LINE TESTS HLW-501 GENERAL The required thickness for pressure parts and the maximum allowable working pressure for water heaters that are not based- upon the formulas of Article 3 shall be established by a proof test. The proof test shall consist of the application of hydrostatic pressure to a full size sample of a water heater vessel. Material in excess of the material thicknesses or of higher strengths than specified for parts of proof test vessel(s) shall be acceptable for production of such parts. The maximum allowable working pressure for a series of water heaters may be established by a proof test on one vessel from the series, or two vessels from the series if the ligament spacing differs. Vessels with the smallest and largest ligament spacing on the heads shall be tested. Vessels in the series shall have: (a) heads of the same geometry and thickness; (b) cylindrical shell and tube(s), if used, that differ only by length; and (c) openings of the same size and type as those present on the vessel proof tested. Optional openings in the shell may be added in accordance with the provisions of HLW-308. Optional openings in the heads may be added in accordance with the provisions of HLW-308 if such head openings are located entirely within a circle, the center of which coincides with the center of the head and the diameter of which is equal to 80% of the head diameter. cleaned. A brittle coating shall be applied. The technique shall be suited to the coating material. (b) The hydrostatic pressure shall be increased gradu ally until approximately one-half the anticipated maxi mum allowable working pressure is reached. Thereafter, the test pressure shall be increased in steps of approxi mately V|o or less of the anticipated maximum allowable working pressure. The pressure shall be held stationary at the end of each increment for a sufficient time to allow the observations required by the testprocedure to be made, and shall be released to zero to permit determination of any permanent strain or displacement after any pressure increment that indicates an increase in strain or displacement over the previous equal pressure increment as evidenced by flaking of the brittle coating, or by the appearance of strain lines. The application of pressure shall be stopped when the intended test pressure has been reached, or at the first sign of yielding. (c) The yield strength shall be the average of three specimens cut from the part tested after the test is completed. The specimens shall be cut from a location where the stress during the test has not exceeded the yield strength. When excess stock from the same piece of wrought material is available the test specimens may be cut from this excess stock. The specimens shall not be removed by flame cutting or any other method involving sufficient heat to affect the properties of the specimen. (d) The maximum allowable working pressure P in psi for the water heater tested under this paragraph shall be computed by one of the following formulas: (I) if the average yield strength is determined in accordance with HLW-502.1(c) above, HLW-502 PROOF TEST HLW-502.1 Test Procedure (a) The outer surface of the vessel shall be suitably (2) to eliminate the necessity of cutting tensile specimens and determining the actual yield strength of 170 R8-003176 1/17/02 NUECE8 HLW-502.1 ARTICLE 5 -- TESTS HLW-505.2 the material under test, or when the test has been stopped before any yielding, one of the following formulas may be used to determine the maximum allowable working pressure: (a) for carbon steel meeting an acceptable Code Specification, with a specified minimum tensile strength of not over 70,000 psi. (b) for any acceptable material listed in Sec tion IV, shall be recalibrated at any time that there is reason to believe that they are in error. HLW-503 TESTS OF PARTS SUBJECT TO COLLAPSE HLW-503.1 Parts of water heaters subject to collapse which have not been proof tested in accordance with HLW-502 and for which specified rules are not provided in this Section shall withstand, without excessive defor mation, a hydrostatic test of not less than three times the desired maximum allowable working pressure. P = 0.4H where H-- hydrostatic test pressure at which the test was stopped, psi T, = specified minimum yield strength, psi Ya = actual average yield strength from test speci mens, psi, as outlined in HLW-502.1(c) S= specified minimum tensile strength, psi When either of the formulas in (a) and (b) above is used, the material in the pressure part shall have no appreciable cold working or other treatment that would tend to raise the yield strength above the normal. NOTE: Due to the geometry of parts commonly used in lined water heaters, yielding due to bending often occurs at pressures which are unusually low compared to burst strength. When an analysis of the test indicates yielding occurred in bending, P may be multiplied by 1.5. HLW-502.2 Test Gages (a) An indicating gage shall be connected directly to the water heater vessel. If the indicating gage is not readily visible to the operator controlling the pressure applied, an additional indicating gage shall be provided where it will be visible to the operator throughout the duration of the test. For large water heater vessels, it is recommended that a recording gage be used in addition to indicating gages. (b) Dial indicating pressure gages used in testing shall be graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1nor more than 4 times that pressure. Digital reading pressure gages having a wider range of pressure may be used provided the readings give the same, or greater, degree of accuracy as obtained with dial pressure gages. (c) All gages shall be calibrated against a standard deadweight tester or a calibrated master gage. Gages HLW-504 WITNESSING, RECORDING, AND CERTIFYING TESTS Tests to establish the maximum allowable working pressure of complete vessels or parts shall be witnessed by the manufacturer's personnel designated to be respon sible for the examination. These tests shall also be witnessed and accepted by the Authorized Inspector. These proof tests shall be recorded on Form HLW-8, Manufacturer's Master Data Proof Test Report for Water Heaters or Storage Tanks. The completed form shall be certified by the designated responsible engineering head , of the manufacturer. These forms shall be kept on file by the manufacturer as a matter of record. HLW-505 HYDROSTATIC TEST HLW-505.1 All water heater vessels shall be sub jected to a hydrostatic test of l'/2 times the maximum allowable working pressure with the exception that the test pressure for glass-lined, and fluorocarbon polymerlined, or amine or polyamine epoxy-lined water heater vessels shall be at least equal to, but not exceed within the tolerances of test pressure in HLW-505.2, the maximum allowable working pressure to be marked on the water heater vessel. Water heater vessels which are to be galvanized or cement-lined may be pressure tested either before or after galvanizing or cement lining. HLW-505.2 While under the hydrostatic test pressure an inspection for leakage shall be made of all joints and connections. In making hydrostatic pressure tests the pressure shall be under such control that in no case shall the required test pressure be exceeded by more than 10 psi. 171 RS-003177 1/17/02 NUECES ARTICLE 6 INSPECTION AND STAMPING HLW-600 INSPECTION AND CERTIFICATION OF WATER HEATERS HLW-600.1 Inspection by Authorized Inspector. The inspection required by this Section shall be by an Inspector employed by a State or Municipality of the United States, a Canadian Province, or an Inspector regularly employed by an insurance company authorized to write boiler and pressure vessel insurance. These Inspectors shall have been qualified by written examina tion under the rules of any State of the United States or Province of Canada which has adopted the Code. HLW-600.2 Manufacturer's Responsibility (a) The manufacturer who completes any water heater vessel to be marked with the Code HLW Symbol has the responsibility of complying with all requirements of this Section, and through proper certification of assuring that any work done by others also complies with the requirements of this Section. (b) The manufacturer has the responsibility of provid ing the Authorized Inspector with all specified informa tion and assurance that the quality control system is in compliance with that outlined in Appendix F. These responsibilities shall include, but are not limited to, providing or making available for review the following: (1) a valid Certificate of Authorization for use of the HLW Symbol from the ASME Boiler and Pressure Vessel Committee (see HLW-602); (2) the design calculations perArticle 3 or the certified proof test results per Article 5 and associated drawings (see HLW-300 and HLW-500); (3) identification of materials to show compliance with Articles 2 and 3 and compliance with the provisions of Section IX (see HLW-200 and HLW-300); (4) evidence of qualification of welding and/or brazing procedures (see HLW-432 and HLW-450); (5) records of qualifications of each welder, weld ing operator, or brazer as evidence of compliance with the provisions of Section IX (see HLW-432 and HLW-450); (6) any Manufacturer's Partial Data Reports when required by HLW-601.2; (7) evidence of examination of materials before fabrication to make certain it has the required thickness, has no unacceptable indications, and is one of the acceptable materials permitted by this Section and that traceability to the material identification has been main tained [see HLW-201(c) and F-202.4]; (8) the manufacturer shall submit the water heater vessel or other pressure part for inspection at such stages of the work as may be designated by the Inspector. , HLW-600.3 Authorized Inspector's Duty (a) The Authorized Inspector shall make such inspec tions as he believes are needed to enable him to certify that the water heater vessels have been constructed in accordance with the rules of this Section. He shall assure himself that the manufacturer is complying with all of the requirements of this Section. (b) It is the duty of the Inspector to assure himself that the welding procedures employed in construction are qualified under the provisions of Section IX. The manufacturer shall submit evidence to the Inspector that those requirements have been met. (c) It is the duty of the Inspector to assure himself that all welding is done by welders or welding operators qualified under the provisions of Section IX. The manu facturer shall make available to the Inspector a certified copy of the record of performance qualification tests of each welder and welding operator as evidence that these requirements have been met. The Inspector has the right at any time to call for and witness the test welding and testing although it is not mandatory that he witness the test welding and the testing unless he so desires. (d) The provisions of HG-515.4(b) apply to the fabri cation of multiple duplicate water heaters and stor age tanks. 172 RS-003178 1/17/02 NUECES HLW-601 MANUFACTURER'S DATA AND PARTIAL DATA REPORTS HLW-601.1 Manufacturer's Data Report (a) Each manufacturer shall complete a Manufactur er's Data Report for each vessel he produces. Form HLW-6 may be used. Individual manufacturer's data reports, if used, will satisfy the requirements for the Manufacturers' Data Report The report may cover a single vessel or may include the serial numbers in uninterrupted sequence of identical water heater vessels completed, inspected, and stamped in a continuous 8 hr period. (b) The manufacturer shall have the responsibility of furnishing a copy of the completed Manufacturer's Data Report at the place of installation to the inspection agency, the purchaser, and the state, municipal, or provincial authority. The manufacturer shall either keep a copy of the Manufacturers' Data Report on file for at least 5 years, or the water heater vessel may be registered and the original Data Report filed with the National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio 43229. HLW-601.2 Partial Data Reports (a) Manufacturer's Partial Data Reports for those parts of a water heater vessel requiring inspection under this Code, which are furnished by other than the shop of the manufacturer responsible for the completed heater, shall be executed by the parts manufacturer and shall be forwarded in duplicate, to the manufacturer of the finished water heater. (b) Partial Data Reports (Form HLW-7) shall be completed for all parts that require inspection under this Code which are fabricated by a manufacturer other than the manufacturer of the completed water heater regardless of whether individual Manufacturer's Data Reports are compiled for the completed units. These Partial Data Reports, together with his own inspection, shall be the final Inspector's authority to witness the application of a Code Symbol to the completed water heater. HLW-602 STAMPING OF WATER HEATERS HLW-602.1 Stamping Requirements for Water Heaters. All water heaters to which the Code Symbol is to be applied shall be built according to the rules of this Section by a manufacturer who is in possession of a Code Symbol Stamp and a valid Certificate of Authorization per procedure of HG-540. Each water heater vessel shall be marked or stamped with the Code Symbol shown in Fig. HLW-602.1 and the form FIG. HLW-602.1 OFFICIAL SYMBOL TO DENOTE THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS' STANDARD Certified by (Name of manufacturer) Maximum Allowable W. Ppsi Maximum Allowable Input Manufacturer's Serial No. Year Built ____________ - Btu/hr _ kW FIG. HLW-602.2 FORM OF STAMPING ON COMPLETED WATER HEATERS of stamping shown in Fig. HLW-602.2 with the follow ing data: (a) the manufacturer's name, preceded by the words "Certified by" (b) maximum allowable working pressure; (c) maximum allowable input in Btu/hr; electric heaters may use KW or BTU/hr. (expressed at the rate of 3500 BTU/hr. per KW) or both. In lieu of the input markings storage tanks shall be marked "Storage Only" (d) manufacturer's serial number (this may be a serial number or a combination model and serial number); (e) year built (the year built may be incorporated into the serial number). HLW-602.2 Stamping a Proof Tested Vessel. A completed vessel or one tested prior to lining may have the required Code Symbol and marking applied, provided: (a) the proof test was stopped before any visible yielding; 173 R8-003179 HLW-602.2 1995 SECTION IV HLW-602.4 (b) all welding was qualified as required by HLW-451; (c) the MAWP is calculated by the method of HLW502.1(d)(2); (d) the interior of a lined vessel must be inspected to verify that it was not damaged; and (e) the completed vessel is subjected to the hydro static test provisions of HLW-505. HLW-6023 When the Code Symbol and marking required by HLW-602.1, items (7) through (5), is applied directly to the water heater vessel, it shall be stamped with letters and figures at least 5/]g in. high or on a stamping plate at least 3/M in. thick permanently fastened to the water heater vessel. Stamping plates bearing the stamping and marking required in HLW602.1 may be used in lieu of stamping these data directly on the water heater vessel if the stamping plates are permanently attached to the water heater vessel. In this case the required data on the stamping plate shall be in characters not less than '/g in. high. If the required marking or stamping is to be covered by insular" jn, jacket, or other form of casing, one of the following shall be provided: (a) an opening with a removal cover for viewing the marking or stamping; (b) a nameplate, located in a conspicuous place on the jacket, duplicating the required Code Symbol and data. This plate shall be at least 3 in. x 4 in. in size marked with letters and numerals at least l/g in. high and of either metallic material attached by mechanical means or of any material attached by an adhesive system meeting the requirements of Appendix J. HLW-602.4 Water heaters fabricated of austenitic stainless steel material listed in Table HLW-301 shall have a precautionary statement warning that the water heaters are to be operated only on deionized water having a minimum specific resistivity of 1.0 Mfl/cm clearly marked and located on the water heater so that it will be readily visible. 174 R84)03180 1/17/02 NUECES ARTICLE 7 CONTROLS HLW-700 CONTROLS HLW-701 TEMPERATURE CONTROL HLW-701.1 Each individual automatically fired water heater, in addition to the operating control used for normal water heater operation shall have a separate high limit temperature actuated combustion control that will automatically cut off the fuel supply. The tempera ture range of the high limit temperature actuated control shall not allow a setting over 210F. (a) On gas-fired water heaters, the high limit tempera ture control when actuated shall shut off the fuel supply with a shutoff means other than the operating control valve. Separate valves may have a common body. (b) On electrically heated water heaters, the high limit temperature control when actuated shall cut off all power to the operating controls. (c) On oil-fired water heaters, the high limit tempera ture control when actuated shall cut off all current flow to the burner mechanism. (d) On indirect water heating systems, the high limit temperature control when activated shall cut off the source of heat. switches, and burners, or electric elements as required by a nationally recognized standard.1 (b) The symbol of the certifying organization12 3which has investigated such equipment as having complied with a nationally recognized standard shall be affixed to the equipment and shall be considered as evidence that the controls and heat generating apparatus were manufactured in accordance with that standard. HLW-704 ELECTRICAL WIRING HLW-704.1 Electrical Code Compliance. All field wiring for controls, heat generating apparatus, and other appurtenances necessary for the operation of the water heater should be installed in accordance with the provi sions of the National Electrical Code and/or should comply with the applicable local electrical codes. All water heaters supplied with factory mounted and wired controls, heat generating apparatus, and other appurte nances necessary for the operation of the water heaters should be installed in accordance with the provisions of the nationally recognized standards such as listed in footnote 1 of HLW-703. HLW-702 LIMIT CONTROLS Limit controls used with electric circuits should break the hot or line sides of the control circuit. HLW-703 CONTROLS AND HEAT GENERATING APPARATUS (a) All water heaters should be equipped with suitable primary (flame safeguard) safety controls, safety limit 1 Examples of these nationally recognized standards that are currently effective: ANSI C95.3, Standard for Safety Oil-Fired Water Heaters (UL 732). ANSI Z 21.10.3, American National Standards for Gas Water Heaters, Volume III, Circulating Tank, Instantaneous and Large Automatic Storage Type Water Heaters. Underwriters' Laboratories Inc. UL 795, Standards for Safety, Commercial-Industrial Gas-Heating Equipment. Underwriters' Laboratories Inc. UL 1453, Standard for Safety, Electric Booster and Commercial Storage Tank Water Heaters. 3A certifying organization is one that provides uniform testing, examination, and listing procedures under established, nationally recognized standards and that is acceptable to the authorities having jurisdiction. 175 R8-003181 1/17/02 NUECES ARTICLE 8 INSTALLATION REQUIREMENTS HLW-800 SAFETY RELIEF VALVES HLW-800.1 Safety Relief Valve Requirements for Water Heaters (a) Each water heater shall have at least one officially rated safety relief valve or at least one officially rated pressure temperature relief valve. The valve(s) shall be marked with the ASME Code Symbol V or HV to evidence compliance with the construction and rating requirements of the ASME Boiler and Pressure Vessel Code. No safety relief valve shall be smaller than NPS 3/4. (b) The pressure setting shall be less than or equal to the maximum allowable working pressure of the water heater. However, if any of the other components in the hot water supply system (such as valves, pumps, expansion or storage tanks, or piping) have a lesser working pressure rating than the water heater, the pressure setting for the relief valve(s) shall be based upon the component with the lowest maximum allow able working pressure rating. If more than one safety relief valve is used, the additional valve(s) may be set within a range not to exceed 10% over the set pressure of the first valve. (c) The required relieving capacity in Btu/hr of the safety relief valve shall not be less than the maximum allowable input unless the water heater is marked with the rated burner input capacity of the water heater on the casing in a readily visible location, in which case the rated burner input capacity may be used as a basis for sizing the safety relief valves. The relieving capacity for electric water heaters shall be 3500 Btu/hr per kW of input. In every case, the following requirements shall be met. Safety relief valve capacity for each water heater shall be such that with the fuel burning equipment installed and operated at maximum capacity the pressure cannot rise more than 10% of maximum allowable working pressures. (d) If operating conditions are changed or additional heater heating surface is installed, the safety relief valve capacity shall be increased, if necessary, to meet the new conditions and shall be in accordance with the above provisions. In no case shall the increased input capacity exceed the maximum allowable input capacity. The additional valves required, on account of changed conditions, may be installed on the outlet piping pro vided there is no intervening valve. HLW-801 MOUNTING SAFETY RELIEF VALVES HLW-801.1 Installation. Safety relief valves shall be installed by either the installer or the manufacturer before a water heater is placed in operation. HLW-801.2 Permissible Mountings. Safety relief valves shall be connected to the top of water heaters or directly to a tapped or flanged opening in the water heater, to a fitting connected to the water heater by a short nipple, to a Y-base, or to a valveless header connecting water outlets on the same heater. Safety relief valves shall be installed with their spindles upright and vertical with no horizontal connecting pipe, except that, when the safety relief valve is mounted directly on the water heater vessel with no more than 4 in. maximum interconnecting piping, the valve may be installed in the horizontal position with the outlet pointed down. The center line of the safety relief valve connection shall be no lower than 4 in. from the top of the shell. No piping or fitting used to mount the safety relief valve shall be of a nominal pipe size less than that of the valve inlet. HLW-801.3 Requirements for Common Connec tion for Two or More Valves (a) When a water heater is fitted with two or more safety relief valves on one connection, this connection shall have a cross-sectional area not less than the combined areas of inlet connections of all the safety relief valves with which it connects. (b) When a Y-base is used, the inlet area shall be not less than the combined outlet areas. When the size 176 RS-003182 1/17/02 NUECES than 4'/2 in. diameter, two or more valves having tne required combined capacity shall be used. When two or more valves are used on a water heater, they may be single, directly attached, or mounted on a Y-base. HLW-801.4 Threaded Connections. A threaded connection may be used for attaching a valve. HLW-801.5 Prohibited Mountings. Safety relief valves shall rot be connected to an internal pipe in the water heater or a cold water feed line connected to the water heater. HLW-801.6 Use of Shutoff Valves Prohibited. No shutoff of any description shall be placed between the safety relief valve and the water heater, or on discharge pipes between such valves and the atmosphere. HLW-801.7 Safety Relief Valve Discharge Piping (a) When a discharge pipe is used, its internal crosssectional area shall be not less than the full area of the valve outlet or of the total of the valve outlets discharging thereinto, and shall be as short and straight as possible and so arranged as to avoid undue stress on the valve or valves. When an elbow is placed on a safety relief discharge pipe, it shall be located close to the valve outlet. - (b) The discharge from safety relief valves shall be so arranged that there will be no danger of scalding attendants. When the safety relief valve discharge is piped away from the water heater to the point of discharge, there shall be provisions for properly draining the piping and valve body. The size and arrangement of discharge piping shall be such that any pressure that may exist or develop will not reduce the relieving capacity of the relieving devices below that required to protect the water heater. HLW-805 WATER SUPPLY HLW-805.1 Connections. Water supply shall be introduced into a water heater through an independent water supply connection. Feedwater shall not be intro duced through openings or connections provided for cleaning, safety relief valves, drain, pressure gage, or temperature gage. HLW-805.2 Pressure. If the water supply pressure to a water heater exceeds 75% of the set pressure of the safety relief valve, a pressure reducing valve is required. HLW-805.3 Stop Valves. Stop valves should be placed in the supply and discharge pipe connections FOR A WATER HEATER1 Tank Capacities, gal System Volume, gal Prepressurized Diaphragm Type Nonprepressurize Type 50 100 200 300 400 500 1000 2000 1 2 3 4 5 6 12 24 3 6 12 18 24 30 60 120 NOTE: (1) Capacities in this Table are given as a guide to reduc eliminate relief valve weeping under conditions of partial v system demands or occasional water draw during recovery. System volume includes water heater capacity plus all p capacity for a recirculation system or water heater capacity for a nonrecirculation system. The capacities are based upon a water temperature rise 40*F to 180*F, 60 psi fill pressure, maximum operating pre of 1Z5 psi, 20% water recovery, and an acceptance fact 0.465 for prepressurized types and 0.09156 for nonprepn ized types. A procedure for estimating system volume ar determining expansion tank sizes for other design cone may be found in Chapter 13 of the 1987 System: Applications Volume fo the ASHRAE Handbook. of a water heater installation to permit draining water heater without emptying the system. HLW-809 PROVISIONS FOR THERMAL EXPANSION IN HOT WATER SYSTEMS HLW-809.1 Expansion Tank. If a syste: equipped with a check valve or pressure reducing in the cold water inlet line, consideration shou given to the installation of an airtight expansion or other suitable air cushion. Otherwise, due t thermal expansion of the water, the safety relief may lift periodically. If an expansion tank is pro it shall be constructed in accordance with Section Division 1. See Fig. HLW-809.1 for a typical acce installation. Except for prepressurized diaphragn tanks, which should be installed on the cold wate provisions shall be made for draining the tank w emptying the system. HLW-809.2 Piping. Provisions shall be ma the expansion and contraction of hot water connected to water heaters by providing sub: anchorage at suitable points and by providing 177 RS403183 1/17/02 NUECES Fig. HLW-809.1 1995 SECTION IV Water Hum With Top Relief Opening Water Heater With Side Relief Opening GENERAL NOTE: Thermometer requirements are in HLW-820. NOTE: *- (1) Recirculation system may be gravity or pump actuated. FIG. HLW-809.1 A TYPICAL ACCEPTABLE PIPING INSTALLATION FOR STORAGE WATER HEATERS IN BATTERY 178 RS-003184 1/17/02 NUECES HLW-809.2 n ARTICLE 8 -- INSTALLATION REQUIREMENTS HLW-820 u GENERAL NOTE: Thermometer requirements are in HLW-820. FIG. HLW-809.2 A TYPICAL ACCEPTABLE PIPING INSTALLATION FOR FLOW THROUGH WATER HEATER WITH PROVISIONS FOR PIPING EXPANSION joints when water heaters are installed in batteries, so that there will be no undue strain transmitted to the water heaters. See Figs. HLW-809.1 and HLW-809.2 for typical schematic arrangements of piping incorporating strain absorbing joints. the lowest water space practicable. The minimum size bottom drain valve shall be % in. (b) Any discharge piping connected to the bottom drain connection shall be full size to the point of discharge. HLW-810 BOTTOM DRAIN VALVE (a) Each water heater shall have a bottom drain pipe connection fitted with a valve or cock connected with HLW-820 THERMOMETER Each installed water heater shall have a thermometer so located and connected that it shall be easily readable. The thermometer shall be so located that it shall at all times indicate the temperature of the water in the hot water heater at or near the outlet A95 .) 179 R8-00J186 1/17/02 NUECE8 APPENDICES Mandatory Appendix 1 1-100 1-200 1-300 Preparation of Technical Inquiries to the Boiler and Pressure Vessel Committee Introduction...................................................................................................................... Inquiry Format................................................................................................................ Submittal........................................................................................................................... 185 185 185 Appendix 2 2-100 2-200 Codes, Standards, and Specifications Referenced in Text Reference Standards........................................................................................................ Organizations................................................................................................................... 186 186 Table 2-100 Codes, Standards, andSpecificationsReferenced in Text................................................ 187 Appendix 3 3-100 3-101 - Adhesive Attachment of Nameplates to Casing Scope................................................................................................................................ Nameplate Application ProcedureQualification............................................................. 188 188 Appendix 4 4-100 4-101 4-102 4-103 4-104 4-200 Alternative Specification for Plates and Bars in Lieu of SA-36 for Flat Plates and Bars Introduction.................................................................................................................... Specification.................................................................................................................... Marking............................................................................................................................ Manufacture.................................................................................................................... General Requirements.................................................................................................... Maximum Allowable Stress.......................................................................................... 189 189 189 189 190 190 Tables 4-100 4-101 Chemical Composition HeatAnalysis, Plates and Bars................................................ Mechanical Properties Plates andBars.......................................................................... 189 189 Appendix 5 5-100 5-200 5-300 5-400 Vacuum Boilers Scope............................................................................................................................... Maximum Pressure and Temperature............................................................................ Design Parameters......................................................................................................... Welding........................................................................................................................... 191 191 191 191 181 R8v-0ir0/30128B NUECES 5-500 5-600 5-700 Alternative to Hydrotest................................................................................................. Instruments, Fittings, and Controls................................................................................ Inspection Openings........................................................................................................ 192 192 192 Nonmandatory Appendix A A-100 A-101 A-102 A-103 A-104 A-105 A-106 A-107 Approval of New Materials Under the ASME Boiler and Pressure Vessel Code Code Policy..................................................................................................................... Application....................................................................................................................... Mechanical Properties.................................................................................................... Other Properties............................................................................................................. Weldability...................................................................................................................... Physical Changes............................................................................................................ Requests for Additional Data......................................................................................... Code Case....................................................................................................................... 193 193 193 194 194 194 194 194 Appendix B B-100 B-101 B-102 _ Method of Checking Safety Valve and Safety Relief Valve Capacity by Measuring Maximum Amount of Fuel That Can Be Burned Procedure........................................................................................................................ Examples........................................................................................................................ Heats of Combustion of Fuels....................................................................................... 196 196 196 Appendix C C-100 C-10I Examples of Method of Calculating a Welded Ring Reinforced Furnace For a Steam or Hot Water Boiler................................................................................ For a Hot Water Boiler................................................................................................. 198 199 Appendix D D-100 D-101 Examples of Methods of Computation of Openings in Boiler Shells Pad Reinforced Opening................................................................................................. Nozzle Reinforced Opening........................................................................................... 201 202 Figures D-100 D-101 Computation of Typical Pad Reinforcement.................................................................. Computation of a Typical Nozzle Fitting..................................................................... 201 202 Appendix E E-100 E-101 Terminology Terms Relating to Design............................................................................................... Terms Relating to Welding........................................................................................... 204 205 Appendix F F-100 F-202 Quality Control System General............................................................................................................................. Outline of Features to Be Included in the Written Description of the Quality Control System........................................................................................................... 209 209 Appendix H List of Abbreviations and Addresses......................................................................... 211 182 RS-003187 1/17/02 NUECES Appendix I Appendix K Appendix L Specification for Test Method for Water Absorption of Mastics........................ 212 Guide to Information Appearing on Certificate of Authorization........................ 216 Guide to Manufacturer's Data Report Forms....................................................... 219 183 RS-003188 1/17/02 NUECE8 APPENDIX 1 -- MANDATORY PREPARATION OF TECHNICAL INQUIRIES TO THE BOILER AND PRESSURE VESSEL COMMITTEE 1-100 INTRODUCTION The ASME Boiler and Pressure Vessel Committee meets regularly to consider written requests for interpre tations and revisions to the Code rules, and to develop new rules as dictated by technological development. The Committee's activities in this regard are limited strictly to interpretations of the rules or to the consider ation of revisions to the present rules on the basis of new data or technology. As a matter of published policy, ASME does not approve, certify, rate, or endorse any item, construction, proprietary device, or activity, and, accordingly, inquiries requiring such consideration will be returned. Moreover, ASME does not act as a consultant on specific engineering problems or on the general application or understanding of the Code rules. If, based on the inquiry information submitted, it is the opinion of the Committee that the inquirer should seek assistance, the inquiry will be returned with the recommendation that such assistance be obtained. All inquiries that do not provide the information needed for the Committee's full understanding will be returned. (b) Background. State the purpose of the inquiry, which would be either to obtain an interpretation of Code rules, or to propose consideration of a revision to the present rules. Provide concisely the information needed for the Committee's understanding of the in quiry, being sure to include reference to the applicable Code Section, Division, Edition, addenda, paragraphs, figures, and tables. If sketches are provided, they shall be limited to the scope of the inquiry. (c) Inquiry Structure. Prepare statements in a con densed and precise question format, omitting superfluous background information, and, where appropriate, com posed in such a way that "yes" or "no" (perhaps with provisos) would be an acceptable reply. This inquiry statement should be technically and editorially correct. (d) Proposed Reply. State what it is believed that the Code requires. If in the inquirer's opinion a revision to the Code is needed, recommended wording shall be provided. 1-200 INQUIRY FORMAT Inquiries shall be limited strictly to interpretations of the rules or to the consideration of revisions to the present rules on the basis of new data or technology. Inquiries shall be submitted in the following format. (a) Scope. Involve a single rule or closely related rules. An inquiry letter concerning unrelated subjects will be returned. 1-300 SUBMITTAL Inquiries shall preferably be submitted in typewritten form; however, legible handwritten inquiries will also be considered. They shall include the name and mailing address of the inquirer, and be mailed to the following address: Secretary ASME Boiler and Pressure Vessel Committee 345 East 47th Street New York, N.Y. 10017 185 R8-003188 1/17/02 NUECES APPENDIX 2 -- MANDATORY CODES, STANDARDS, AND SPECIFICATIONS REFERENCED IN TEXT 2-100 REFERENCE STANDARDS Specific editions of standards incorporated in this Code are shown in Table 2-100. It is not practical to refer to a specific edition of each standard throughout the Code text, so edition references are centralized here. Table 2-100 will be revised at intervals and reissued as needed. UL CGA 2-200 ORGANIZATIONS Listed below are abbreviations and addresses of specific organizations referred to in this Code. ANSI American National Standards Institute 11 West 42nd Street, 13th Floor New York, NY 10036 ASHRAE American Society of Heating, Refrigerating and Air Conditioning Engineers 1791 Tullie Circle NE Atlanta, GA 30329 NEC AGA Underwriters' Laboratories, Inc. 333 Pfingston Road Northbrook, IL 60062 Canadian Gas Association 55 Scarsdale Road Don Mills, Ontario, Canada M3B 2R3 National Electric Code NFPA 70 National Fire Protection Association International Batterymarch Park Quincy, MA 02269 American Gas Association 1515 Wilson Blvd. Arlington, VA 22209 American Gas Association Laboratories 8501 East Pleasant Valley Road Cleveland, OH 44131 186 RS-0031M 1/17/02 NUECES APPENDIX A Table 2-100 TABLE 2-100 CODES, STANDARDS, AND SPECIFICATIONS REFERENCED IN TEXT B16.1-1989 B16.5-1981 B16.9-1986 B16.11-1980 B16.15-1985 B16.24-1991 B 16.28-1986 B 16.42-1987 American National Standards Cast Iron Pipe Flanges and Flanged Fittings Steel Pipe Flanges and Flanged Fittings Factory-Made Wrought Steel Buttwelding Fittings Forged Steel Fittings, Socket Welding and Threaded Cast Bronze Threaded Fittings Cast Copper Alloy Pipe Flanges and Flanged Fittings Wrought Steel Buttwelding Short Radius Elbows and Returns Ductile Iron Pipe Flanges and Hanged Fittings PTC 25-1994 ASME Performance Test Code Pressure Relief Devices UL 969-1982 Underwriters Laboratory Standards For Safety Marking and Labeling Systems GENERAL NOTE: The issue date, shown immediately following the hyphen after the number of the standard, is the effective date of issue (edition) of the standard. ') 187 R3403191 1/17/02 NUECES APPENDIX 3 -- MANDATORY ADHESIVE ATTACHMENT OF NAMEPLATES TO CASING 3-100 SCOPE The rules in Appendix 3 cover minimum requirements for nameplates and for the use of adhesive systems for the attachment of nameplates to casing, limited to: fa) the use of pressure-sensitive acrylic adhesives preapplied by the nameplate manufacturer and protected with a moisture stable release liner, (b) use of the preapplied adhesive within 2 years of its application; (c) use of an application procedure qualified as out lined in 3-101. 3-101 NAMEPLATE APPLICATION PROCEDURE QUALIFICATION (a) Each nameplate manufacturer's construction shall be qualified in accordance with ANSI/UL 969, Marking and Labeling Systems, for a surface temperature rating greater than that achieved on the surface of the casing in the area where the nameplate is applied during operation. The exposure conditions shall be for high humidity or occasional exposure to water. In addition if the boiler or water heater is designed and marked for outdoor installation, indoor-outdoor qualification shall be obtained with a cold box temperature of -40F. (b) Each lot or package of nameplates shall be marked with the adhesive application date. (c) The manufacturer's quality control system shall define that written procedures, acceptable to the Author ized Inspector (or ASME Designee for cast iron boilers), for the application of adhesive backed nameplates shall be prepared and qualified. The application procedure qualification shall include the following essential vari ables: (1) each nameplate manufacturer's material and construction, including thickness range, UL File No., and rated substrate temperature(s) and finish; (2) the maximum temperature achieved on the surface of the casing in the area at which the nameplate is applied; (3) cleaning requirements for the casing surface; (4) application temperature range and pressure technique. 188 RS-003192 1/17/02 NUECES APPENDIX 4 -- MANDATORY ALTERNATIVE SPECIFICATION FOR PLATES AND BARS IN LIEU OF SA-36 FOR FLAT PLATES AND BARS 4-100 INTRODUCTION Structural quality steels, Canadian Standard Associa tion Specification CSA G40.21-1976, Grades 38W and 44W, Plates and Bars, not exceeding \ in. may be used in lieu of"SA-36 in the construction of Section IV hot water boiler components. 4-101 SPECIFICATION 4-101.1 This specification covers structural quality steel plates, shapes, and bars for general construction and engineering purposes. 4-101.2 A number of strength levels are available under this specification and are designated by the minimum yield strength in ksi. The purchser must specify the grade and, if applicable, the category. 4-101-3 The types of steel covered by this specifica tion are the following: (a) Type W -- Weldable Steels. Steels of this type meet specified strength requirements and are suitable for general welded construction where notch toughness at low temperatures is not a design requirement. 4-101.4 See Table 4-100 for chemical composition and Table 4-101 for mechanical properties. 4-102 MARKING The material shall be marked with the CSA designa tion and grade, and heat number. A mill test report shall be supplied satisfying the requirements of the CSA G40.21-1976 specification and shall be in U.S. customary units. TABLE 4-100 CHEMICAL COMPOSITION HEAT ANALYSIS, PLATES AND BARS Element Carbon, max. Manganese Phosphorus, max. Sulfur, max. Silicon, max. Composition Limit, % 0.22 0.50--1.50 0.04 0.05 0.40 TABLE 4-101 MECHANICAL PROPERTIES PLATES AND BARS Tensile strength min., psi max., psi Yield strength min., psi for Grade 38W min., psi for Grade 44W Elongation in 2 in., min.,% Elongation in 8 in., min.,% 60,000 90,000 38,000 44,000 23 20 4-103 MANUFACTURE 4-103.1 The steel shall be made by any of the following processes: (a) basic open hearth; (b) basic electric furnace; or (c) basic oxygen furnace. 4-103.2 When specified by the purchaser, plates provided from coils shall not be supplied under this specification. 189 1117(0* NUECES 4-104 1995 SECTION TV 4-104 GENERAL REQUIREMENTS 4-104.1 The steel shall meet the requirements of ASME SA-6. 4-200 MAXIMUM ALLOWABLE STRESS (a) The maximum allowable stress for this C-MnSi material shall be the same as that allowable for SA36 of Table HF-300.1, Maximum Allowable Stress Value of 11.6 ksi. (b) The material shall be considered to be P-No. 1, Group 1. 4-200 190 flsjooai* APPENDIX 5 -- MANDATORY VACUUM BOILERS 5-100 SCOPE Section IV Rules permit a boiler to operate with internal pressure or with a vacuum. Rules in this Appendix cover the minimum requirements for the design, fabrication, and inspection of a boiler for vacuum operation only. Exemptions from certain Section IV requirements are provided. All other requirements of Section IV shall be met. 5-200 MAXIMUM PRESSURE AND TEMPERATURE (a) Maximum Allowable Working Pressure. The boiler shall be designed for 15 psi vacuum (0 psi). This value shall be used in all calculations, in lieu of the requirements of HG-300(a). (b) Maximum temperature shall not exceed 210F. 5-300 DESIGN PARAMETERS (a) The thickness of cylindrical shells under external pressure shall be calculated in accordance with HG-312, except that, when boilers are designed for noncorrosive service at a maximum pressure difference between outside and inside of 15 psi, the thickness shall be not less than Vs in. (b) Rectangular boilers under external pressure shall have thicknesses calculated in accordance with Appen dix 13-8 and 13-9 of Section VIII, Division 1. For noncorrosive service only, the thickness shall be not less than Vs in. (c) Stays in compression shall meet the requirements of the following: l/r < 50 where: / = length r = radius of gyration (d) The furnace thickness shall be calculated in ac cordance with HG-301, using 15 psi design pressure. For noncorrosive service only, the thickness shall be not less than Vg in. (e) Head thickness shall be calculated in accordance with HG-305, HG-306, or HG-307, using 15 psi design pressure, except that, when boilers are designed for noncorrosive service at a maximum pressure difference between outside and inside of 15 psi, the thickness shall be not less than */g in. (f) Tube thickness shall be calculated in accordance with HG-315. (g) As an alternative to the calculations in items (a) through (f), the vessel may be: (1) designed and constructed to Code requirements for an internal pressure of 30 psig using the proof test requirements of HG-501 or HG-502. However, no external pressure rating may be shown with the Code stamping unless Code requirements for external pressure are met (see HG-503). (2) designed and constructed as a vacuum vessel for an external pressure of 15 psia using the proof test requirements of HG-503. 5-400 WELDING (a) Joint Efficiency. No factor has to be used for parts designed for external pressure (X = 1). For the furnace joint, efficiencies shall be in accordance with HW-702. (b) Comer or tee joints shall be in accordance with HW-701.3. (c) Attachment welds shall be in accordance with HW-731. (d) Welding Qualifications shall be in accordance with ASME Section IX. 191 ^8-003*05 . 1/17/02 Nueces 5-500 1995 SECTION IV 5-700 5-500 ALTERNATIVE TO HYDROTEST A helium leak test, conducted at the maximum vacuum to which the boiler will be exposed, may be used in lieu of the hydrostatic test requirements specified in HG-510. This test shall be witnessed by the authorized inspector. The test shall be conducted in accordance with Section V, Article 10, Appendix IV or V. Maximum acceptable leakage rate shall be: Appendix IV -- Detector Probe Appendix V -- Tracer Probe Appendix V -- Hood 1 x KT4 std cm3/sec 1 x 10-5 std cm3/sec 1 x 10-6 std cm3/sec 5-600 INSTRUMENTS, FITTINGS, AND CONTROLS Vacuum boilers_shall be provided with instruments, fittings, and controls in accordance with Articles 6 and 7 of Part HG, but they are exempt from the following requirements if pressure and temperature controls are provided as described in (a),' (b), and (c) below: HG-603 Gauge Glass HG-604 HG-605 HG-606 HG-703.2 HG-705 HG-715 Water Column Pressure Control (second control only) Low Water Cut-Off Return Pipe Connection Feedwater Connection Blowoff and Drain Valves These exemptions are applicable only when the fol lowing devices are installed: (a) Pressure Control. A pressure control which inter rupts the burner operation in response to boiler pressure, and is set at 2.5 psig vacuum (12.2 psia). (b) Temperature Control. Two temperature controls responsive to boiler temperature which can interrupt burner operation, one shall operate at a temperature below 210F, and the other shall prevent the temperature from exceeding 210F with no automatic recycle. The use of a fusible plug to perform the second of these two functions is permissible. (c) Safety Valve. A safety valve without a test lever, set at 7.1 psig (22 psia) maximum pressure and sized in accordance with HG-400. 5-700 INSPECTION OPENINGS Heat exchanger coil openings may be used to satisfy the requirements for inspection and access. 192 R8-003196 1/17/02 NUECES APPENDIX A APPROVAL OF NEW MATERIALS UNDER THE ASME BOILER AND PRESSURE VESSEL CODE A-100 CODE POLICY (a) It is the policy of the ASME Boiler and Pressure Vessel Committee to adopt for inclusion in Section n. Parts A and B, only such specifications as have been adopted by the American Society for Testing and Materials, and in Section n, Part C, only such specifica tions as have been adopted by the American Welding Society. (b) It is expected that requests for Code approval will normally be for materials for which there is an ASTM or AWS specificatibn. For materials made to a recognized national or international specification other than those of ASTM or AWS, the inquirer shall notify the standards-developing organization that a request has been made to ASME for adoption of their specification under the ASME Code. For other materials, a request shall be made to ASTM or AWS to develop a specifica tion that can be presented to the Code Committee. (c) It is the policy of the ASME Boiler and Pressure Vessel Committee to consider requests to adopt new materials only from boiler, pressure vessel, or nuclear power plant component Manufacturers or end users. Further, such requests should be for materials for which there is a reasonable expectation of use in a boiler, pressure vessel, or nuclear power plant component constructed to the rules of one of the Sections of this Code. A-101 APPLICATION (a) The inquirer shall identify to the Committee the Section or Sections and Divisions of the Code in which the new material is to be incorporated, the temperature range of application, whether cyclic service is to be considered, and whether external pressure service is to be considered. The inquirer shall identify all product forms, size ranges, and specifications for which incorpo ration is desired. (b) The inquirer shall state whether or not the material is covered by patents, whether or not it is licensed, and if licensed, any limitations on its manufacture. A-102 MECHANICAL PROPERTIES (a) Together with the specification for the material, the inquirer shall furnish the Committee with adequate data on which to base design values for inclusion in the applicable tables. The data shall include values of ultimate tensile strength, yield strength, reduction of area, and elongation, at 100F (or 50C) intervals, from room temperature to 100F (or 50C) above the maximum intended use temperature, unless the maximum intended use temperature does not exceed 100F. If adoption is desired at temperatures at which time-dependent behavior may be expected to control design values, data on these time-independent properties shall be provided to a temperature 100F (50C) above the temperature at which time-dependent behavior be comes significant. Any heat treatment that is required to produce the tensile properties should be fully described. (b) If coverage is desired at temperatures at which time-dependent behavior may be expected, creep rate and creep rupture strength data of base metal and appropriate weld metals and weldments shall also be provided, at 100F (or 50C) intervals to 100F (or 50C) above the maximum intended use temperature. (c) If adoption at temperatures below room tempera ture is requested, and if it is desired to take design advantage of increased strength at lower temperatures, data on the time-independent properties shall be pro vided at 100F (or 50C) intervals to and including the lowest intended use temperature. (d) Notch toughness data shall be provided for materi als for which Code toughness rules would be expected 193 RS-003197 1/17/02 NUECES A-102 1995 SECTION IV A-107 to apply. The data shall include test results for the intended lowest service metal temperature and for the range of material thicknesses desired. For welded con struction, the notch toughness data shall include the results of Code toughness tests for weld metal and heat-affected zone for weldments made by the intended welding processes. (e) If the material is to be used in components that operate under external pressure, stress-strain curves (tension or compression) shall be furnished, at 100F (or 50C) intervals over the range of design temperatures desired. External pressure charts are based on the early portion (up to 1% strain) of the stress-strain curve. The stress-strain curve (not load versus extension) shall be determined using a Class B-2 or better accuracy extensometer as defined in ASTM E 83. Numerical data, when available, should be submitted. The data should include the original cross-sectional area of the test specimen and stress-strain curves with units marked on them. (f) If the material is to be used in cyclic service and the construction Code in which adoption is desired requires explicit consideration of cyclic behavior, fatigue data shall also be furnished over the range of design temperatures desired. (g) In general, for all mechanical properties, data shall be provided from at least three heats of material meeting all of the requirements of a specification for at least one product form for which adoption is desired, for each test at each test temperature. When adoption for both cast and wrought product forms is desired, data from at least three heats each of a wrought and of a cast product form shall be submitted. It is desired that the data represent all product forms for which adoption is desired. For product forms for which the properties may be size dependent, data from products of different sizes, including the largest size for which adoption is desired, shall be provided. (h) Test methods employed shall be those referenced in or by the material specifications, or shall be appro priate ASTM test methods or recommended practices for the properties tested. (i) Information describing service experience in the temperature range contemplated will be useful to the Committee. A-103 OTHER PROPERTIES The inquirer shall furnish to the Committee adequate data necessary to establish values for coefficient of thermal expansion, thermal conductivity and diffusivity, Young's modulus, shear modulus, and Poisson's ratio, when the construction Code in which adoption is desired requires explicit consideration of these properties. Data shall be provided over the range of temperatures for which the material is to be used. A-104 WELDABILITY The inquirer shall furnish complete data on the weldability of material intended for welding, including data on procedure qualification tests made in accordance with the requirements of Section IX. Welding tests shall be made over the full range of thickness in which the material is to be used. Pertinent information, such as postweld heat treatment required, susceptibility to air hardening, effect of welding procedure and heataffected zone and weld metal notch toughness, and the amount of experience in welding the material shall be given. A-105 PHYSICAL CHANGES For new materials, it is important to know the structural stability characteristics and the degree of retention of properties with exposure at temperature. The influence of fabrication practices, such as forming, welding; and ' thermal treatment, on the mechanical properties, ductility, and microstnicture of the material are important, particularly where degradation in proper ties may occur. Where particular temperature ranges of exposure or heat treatment, cooling rates, combina tions of mechanical working and thermal treatments, fabrication practices, exposure to particular environ ments, etc., cause significant changes in the mechanical properties, microstructure, resistance to brittle fracture, etc., it is of prime importance to call attention to those conditions that should be avoided in service or in manufacture of parts or vessels from the material. A-106 REQUESTS FOR ADDITIONAL DATA The Committee may request additional data, including data on properties or material behavior not explicitly treated in the construction Code in which adoption is desired. A-107 CODE CASE The Code Committee will consider the issuance of a Code Case, to be effective for a period of 3 years, 194 R8-003198 1/17/02 NUECES A-107 APPENDIX A permitting the use of a new material, provided that the following conditions are met: (a) the inquirer provides evidence that a request for coverage of the material in a specification has been made to ASTM; (b) the material is commercially available and can be purchased within the proposed specification require ments; (c) the inquirer shows that there will be a reasonable demand for the material by industiy and that there exists an urgency for approval by means of a Code Case; (d) the requests for approval of the material shall clearly describe it in ASTM specification form, including such items as scope, process, manufacture, conditions for delivery, heat treatment, chemical and tensile re quirements, forming properties, testing specifications and requirements, workmanship, finish, marking, inspec tion, and rejection; (e) all other requirements identified previously under Code Policy and Application apply; and (f) the inquirer shall furnish the Code Committee with all the data specified in this Appendix. A-107 195 RS-003199 1/17/02 NUECES i APPENDIX B METHOD OF CHECKING SAFETY VALVE AND SAFETY RELIEF VALVE CAPACITY BY MEASURING MAXIMUM AMOUNT OF FUEL THAT CAN BE BURNED B-100 PROCEDURE The maximum quantity of fuel C that can be burned per hour at the time of maximum forcing is determined by a test: The maximum number of heat units per hour, or CH, is then determined, using the values of H given in B-102. The weight of steam generated per hour is found by the formula: CxHx 0.75 IV = ---------------- 1000 where W= weight of steam generated/hr, lb C = total weight or volume of fuel bumed/hr at time of maximum forcing, lb or cu ft H = heat of combustion of fuel, Btu/lb or Btu/cu ft (see B-102) The sum of the safety valve capacities marked on the valves shall be equal to or greater than W. B-101 EXAMPLES Example ]. A boiler at the time of maximum forcing uses 2150 lb of Illinois coal/hr of 12,100 Btu/lb. of 6400 Btu/lb are burned under a boiler at the maximum rate of 2000 lb /hr. C x H = 2000 x 6400 = 12,800,000 W = (C x H x 0.75) -h 1000 = 9600 Example 3. An oil-fired boiler at maximum forcing uses 1000 lb of crude oil (Texas)/hr. C x H = 1000 x 18,500 = 18,500,000 IV = (C x H x 0.75) + 1000 = 13,875 Example 4. A boiler fired with natural gas consumes 3000 cu ft/hr. C x H - 3000 x 960 = 2,880,000 W = (C x H x 0.75) * 1000 = 2160 C x H = 2150 x 12,100 = 26,015,000 W = (C x H x 0.75) -i- 1000 = 19.511 Example 2. Wood shavings of heat of combustion B-102 HEATS OF COMBUSTION OF FUELS For the purpose of checking the safety valve capacity as described in B-100, the following values of heats of combustion of various fuels may be used: 196 RS-003200 1/17/02 NUECE8 B-102 APPENDIX B H = Btu/lb Semibituminous coal ..................................... 14,500 Anthracite ...................................................... 13,700 Screenings .................................................. 12,500 Coke ......................................................... 13,500 Wood, hard or soft, kiln dried....................... 7,700 Wood, hard or soft, air dried........................ 6,200 Wood shavings ................................................ 6,400 H = Btu/lb Peat, air dried, 25% moisture.......................... 7,500 Lignite ....................................................... 10,000 Kerosene .................................................... 20,000 Petroleum, crude oil, Pennsylvania ............... 20,700 Petroleum, crude oil, Texas .......................... 18,500 H = Btu/cu ft Natural gas ........................................................... 960 Blast-furnace gas ................................................ 100 Producer gas .................................................... 150 Water gas, uncarbureted ....................................... 290 B-102 197 RS-003201 1/17/02 NUECES APPENDIX C EXAMPLES OF METHOD OF CALCULATING A WELDED RING REINFORCED FURNACE C-100 FOR A STEAM OR HOT WATER BOILER (a) Design Data [HG-300(a)]. 30 psi pressure (250F); 36 in. (D0) O.D.; 15 in. (L) center-to-center distance of reinforcing rings. Use formulas from HG-312 where t = wall thickness of furnace, in. L-- center-to-center distance between two adjacent stiffening rings, in. . D0 = outside diameter of furnace, in. P = design pressure, psi (30 psi min.) (per HG-300) Tr= thickness of stiffening ring, in. Hr = height of stiffening ring, in. (b) Selection of t and L (First Trial). Assume t = `/4 in. and L = 15 in. L/D0 = 15/36 = 0.417, D0lt = 36/0.25 = 144 Temperature: 500F [see HG-312.3(f)] Factor B = 12,000 (from Fig. HG-312.2) B 12,000 Pa --------- = -------- = 83 psi D0/t 144 (c) Selection of Tr and Hr (First Trial) [HG312.3(b)], Assume T, = 5/i6 in. and Hr = 1.5 in. 0.3125 x 1.53 / = ------------------ = 0.0879 in.4 12 As = 0.3125 x 1.5 = 0.469 sq in. (d) Determination of Is (First Trial) PD0 30 x 36 Factor B =------- = --------------- = 3840 As 0.469 t + -- 0.25 +------- L 15 From Fig. HG-312.2, Factor A = 0.00029 ,/ 0.469\ 36J x 15 (0.25 + -jj-j 0.00028 14 = 0.109 in.4 Since /, is greater than l (0.0879 in.4), the assumed reinforcing ring is not acceptable. (A ring with a greater I must be selected or L must be reduced.) (e) Selection of Tr and Hr (Second Trial). Assume Tr = 0.3125 in., Hr = 2.5 in., and L = 1.5 in. Hr 2.5 8.0-------------- = Tr 0.3125 0.3125 x 2.53 / = ------------------ = 0.407 in.4 12 198 RS-003202 1117/02 NUECES C-100 A, = 0.3125 x 2.5 = 0.781 sq in. APPENDIX C (d) Determination of I, (First Trial) (f) Determination of /, (Second Trial) 30 x 36 Factors = -------------------- = 2692 0.781 0.3125 +------- 15 From Fig. HG-312.2, Factor A = 0.00022 PDo Factor B = A, t+-- L 100x30 0.843 0.500 + lo- = 5681 From Fig. HG-312.2, ,/ 0.78 h 362 x 15 |0.3125 + -jj-J 0.00022 Factor A = 0.00042 C-101 = 0.111 in.4 Since I (0.407 in.4) is greater than /,, the assumed reinforcing ring is acceptable. C-101 FOR A HOT WATER BOILER (a) Design Data. 100 psi working pressure (250F); 30 in. (D0) O.D.; 30 in. (L) center-to-center distance of reinforcing rings. Use formulas from HG-312 and same notation as in C-100(a). (b) Selection of t and L (First Trial). Assume t = Vi in. and L = 30 in. L/D0 = 30/30 = 1 and D0/t = 30/0.500 = 60 Temperature: 500F [see HG-312.3(f)] Factor B = 12,300 (from Fig. HG-312.2) Since /, is greater than I (0.356 in.4), the assumed reinforcing ring is not acceptable. (A ring with a greater / must be selected or L must be reduced.) (e) Selection of L (Second Trial). Assume L = 22 in., Tr = 3/g in., and H = 2.25 in. B 12,300 Pa Djt -------- = 205 psi 60 (c) Selection of Tr and Hr (First Trial). Assume Tr = V8 in. and Hr = 2.25 in. 0.375 x 2.253 / = ----------------- = 0.356 in.4 12 As = 0.375 x 2.25 = 0.843 sq in. Hr 2.25 6.0-- =--------------- = Tr 0.375 22 L/D0 = -- = 0.734 30 30 DJt = = 60 0.500 (f) Determination of Is (Second Trial). From Fig. HG-312.2, 199 R8-003203 1/17/02 NUECES C-101 Factor B = 13,250 1995 SECTION IV Factor A = 0.00041 C-101 Pa = 13,250/60 = 221 psi I = 0.356 in.4 (as above) A, = 0.843 in.2 (as above) 100x30 Factor B = ---------------- = 5573 0.843 0.500 +-----22 From Fig. HG-312.2, 302 x 22 (0.500 + 0.843/22) 0.00041 = 0.312 in.4 Since /, is less than I (0.356 in.4), the assumed reinforcing ring is acceptable. 200 RS-003204 1/17/02 NUECES APPENDIX D EXAMPLES OF METHODS OF COMPUTATION OF OPENINGS IN BOILER SHELLS D-100 PAD REINFORCED OPENING (a) Design Data. A boiler shell has a 6 in. connection as shown in Fig. D-100. The shell has an inside diameter of 60 in., a thickness of 9/16 in. and a working pressure of 160 psi. The shell and pad material are in accordance with SA-285 Grade C. (b) Wall Thickness Required (See HG-301) *n -2d dP "'1 1 |_,L| w7 PxR tr ~ S x E - 0.6P 160x30 = ------------------------------ = 0.440 in. 11,000 x 1.0 - 0.6 x 160 FIG. D-100 COMPUTATION OF TYPICAL PAD REINFORCEMENT (c) Size of Welds Required (See HW-731) Inner fillet weld = 1.41 x 0.7 x tr = wi = 1.41 x 0.440 = 0.434 in. Outer fillet weld = 1.41 x 0.5 x tr = h>2 w2 = 1.41 x 0.5 x 0.440 = 0.310 in. A '/2 in- inner fillet weld and a 7/)6 in. outer fillet weld meet these minimum requirements. (d) Area of Reinforcement Required (See HG-321) Ai = tt(d,, - d0) = 0.437(12.50 - 6.00) = 2.841 sq in. Aj = 2 x '/; x + 2 x '/2 x w22 = 2 x `/: x 0.5002 + 2 x `/2 x 0.4372 A = d x trx F -- 7.50 x 0.440 x 1.0 = 3.300 sq in. (e) Area of Reinforcement Provided (See HG-326) 0.441 sq in. Total area provided 4.204 sq in. A, = (Eit - Ftr)d = (1.0 x 0.563 - 1.0 x 0.440) 7.5 = 0.922 sq in. (f) Load to Be Carried by Welds (See HG-327.2) 201 RS-003206 1/17/02 NUECES D-100 1995 SECTION IV PR h~SE- 0.6P D-I01 160 x 18 = ------------------------------ = 0.264 in. 11.000 x 1.0-0.6 x 160 (c) Nozzle Thickness Required FIG. D-101 COMPUTATION OF A TYPICAL NOZZLE FITTING PR 160 x 1.913 ---------------------------- = 0.032 in. 9600 x 1.0 - 0.6 x 160 W = (dxtr-Ai)xS = (7.50 x 0.440 - 0.922) x 11,000 = 26,160 lb (g) Unit Stresses (See HW-730.2) Shear in fillet weld = 0.49 x 11,000 = 5390 psi = S, (h) Strength of Connection Elements (!) Inner Weld W] in Shear -d x w, x S, = 1.57 x 7.50 x 0.500 x 5390 2 = 31,750 lb (2) Outer Weld vv2 in Shear (d) Size Weld Required (See HW-731) tc -- tniin * 0.7 = 0.337 x 0.7 = 0.236 in. (e) Area of Reinforcement Required (See HG-321) A = dtrF+2tntrF{l - j) = 3.826 x 0.264 x 1.0 / 9600 \ + 2 (0.337)(0.264)(1.0) \ 1 ---1--1-,-0-0--0/ = 1.033 sq in. (f) Area of Reinforcement Provided (See HG-326) ^dp x w2 x S, = 157 x 12.50 x 0.437 x 5390 = 46,200 lb D-101 NOZZLE REINFORCED OPENING (a) Design Data. A 4 in. SA-53 schedule 80 pipe is welded into a shell as shown in Fig. D-101. The shell has an inside diameter of 36 in., a thickness of 7/16 in., and a working pressure of 160 psi. The shell material is in accordance with SA-285 Grade C. (b) Wall Thickness Required (See HG-301) = (]t - Ftr)d - 2t,, (f - Ftr) (l - ' Jy' = (1.0 x 0.438 - 1.0 x 0.264) 3.826 - 2.0 x 0.337 (1.0 x 0.438 - 1.0 x 0.264)(0.127) = 0.651 sq in. = (f,, - ,rn) (5;,, + 2r,) = (0.337 - 0.032) (5.0 x 0.337 + 2.0 x 0)(0.873) = 0.449 sq in. 202 RS-003206 1/17102 NUECES D-101 APPENDIX D D-101 A3= leg2 = 0.337 x0.337 = 0.114 sq in. At = total reinforcement = 1.214 sq in. = 7700 psi = S,, (i) Strength of Connection Elements (See HW-730.I) (1) Fillet Weld in Shear At>A (opening is reinforced) (g) Load to Be Carried by the Welds (See HG-327.2) W = [(<L x V - (24, - d,,)(t - fr)] S(shell) = .[(4.50 x 0.264) - (2.0 x 3.826 - 4.50) x (0.437 - 0.264)] 11,000 = 7035 lb (h) Unit Stresses (See HW-730.2) Shear in fillet weld = 0.49 x 11,000 = 5390 psi = S, Tension in groove weld = 0.74 x 11,000 = 8140 psi = S, Shear in nozzle wall = 0.70 x 11,000 -- x dm x weld leg x S', = 1.57 x 4.5 x 0.337 x 5390 2 = 12,833 lb (2) Groove Weld in Tension v -xd,,xtxS, = 1.57 x 4.5 x 0.437 x 8140 2 = 25,100 lb (3) Nozzle Wall Shear IT -- x mean nozzle diam. x r, x Sn = 1.571 x 4.163 x 0.337 x 7700 = 16,971 lb Possible paths of failure are: (a) through (1) and (2) above with a strength of 37,933 lb; (b) through (1) and (3) above with a strength of 29,804 lb. Both paths are stronger than the required strength of 7035 lb. A96 203 RS-003207 1/17/02 NUECES * A95 APPENDIX E TERMINOLOGY E-100 TERMS RELATING TO DESIGN Action, Popping, or Pop -- The action of a safety or safety relief valve when it opens under steam pres sure. The disk of the valve is designed so that the force of the steam lifting the disk is increased when the disk is lifted slightly off its seat. The increase in force accelerates the rising action of the disk to the wide open position at or near the opening pressure. Blowdown -- The difference between the opening and closing pressures of a safety or relief valve. Boiler, Automatically Fired -- A boiler equipped with a means of introducing, heat or of causing fuel, whether solid, liquid, gaseous, or electric, to be intro duced into the boiler or boiler furnace, the means being so regulated by the rate of flow, the generating pressure, or temperature of the boiler fluid or of a vessel or space being heated as to maintain a determined, desired condition within a designated tolerance. Boiler, Electric, Resistance Heating Element Type -- Electric boilers of the resistance heating element type are either. (a) of a design where the electric resistance element is directly attached to the external surface of the pressure vessel; or (b) an immersed type where the electric resistance element is inserted through an opening in the pressure vessel so that the element is in direct contact with the water. Boiler, Horizontal-Return Tubular -- A firetube boiler consisting of a cylindrical shell, with tubes inside the shell attached to both end closures. The products of combustion pass under the bottom half of the shell and return through the tubes. Boiler, Hot Water Heating -- A boiler designed to heat water for circulation through an external space heating system. Boiler, Hot Water Supply -- A boiler used to heat water for purposes other than space heating. Boiler, Modular -- A steam or hot water heating assembly consisting of a grouping of individual boilers called modules, intended to be installed as a unit. Modules may be under one jacket or may be individually jacketed. Boiler, Steam Heating -- A boiler designed to convert water into steam which is supplied to an external space heating system. Boiler, Vacuum -- A factory-sealed steam boiler that is operated below atmospheric pressure. Bottom Blowoff Valve -- A valve or cock located in the bottom blowoff connection of a boiler which, when opened, permits free passage of scale and sediment during the blowoff operation. Column, Fluid Relief -- That piping, connected to the top of a hot water heating boiler, which is provided for the thermal expansion of the water. It will connect to either an open or a closed expansion tank. Drain Valve -- A valve or cock located in a boiler connection which, when opened, will drain the lowest water space practicable. Electric Boiler, Submerged Electrode Type -- A submerged electrode type electric boiler incorporates a design wherein two or more metallic electrodes are directly suspended in the boiler water. When a source of electric power is connected to the electrodes, current will flow between the electrodes and through the water, thus raising the temperature of the water to produce '.team. Feedwater -- Water introduced into a boiler during operation. Includes makeup and return condensate or return water. Flue -- Passage through which gases pass from the combustion chamber or furnace to the venting system. Furnace -- That part of a boiler in which combustion of fuel takes place or in which primary furnace gases are conveyed. Gases, Primary Furnace -- Gases in a zone where the anticipated temperature of the gas exceeds 850F. Joints, Swing -- Threaded, flanged, welded, or brazed pipe and fittings so arranged that the piping system which they comprise, when connected to a boiler, can A97 204 RS4)0W8 1I1W* E-100 APPENDIX E E-101 A95 expand and contract without imposing excessive force on it Makeup Water -- Water introduced into the boiler to replace that lost or removed from the system. Pressure, Accumulation Test -- That steam pressure at which the capacity of a safety, safety relief, or a relief valve is determined. It is 33'/3% ova- the steam safety valve set pressure and 10% ova the safety relief valve set pressure. Pressure, Design -- The pressure used in the design of a boiler for the purpose of calculating the minimum permissible thickness or physical characteristics of the different parts of the boiler. Pressure, Maximum Allowable Working -- The maxi mum gage pressure permissible in a completed boiler. The MAWP of the completed boila shall be less than or equal to the lowest design pressure determined for any of its parts. This pressure is based upon eitha proof tests or calculations for every pressure part of the boila using nominal thickness exclusive of allow ances for corrosion and thickness required for loadings other than pressure. Pressure, Operating -- The pressure of a boila at which it normally operates. It shall not exceed the maximum allowable working pressure and it is usually kept at a suitable level below the setting of the pressure relieving devices to prevent their frequent opening. Rated, Officially -- A safety, safety relief, or relief valve for use on a heating boiler which has been capacity rated in accordance with HG-402. Stress, Maximum Allowable -- The maximum unit stress permitted in a given material used under these rules. Siphon -- A bent pipe or tube, between a steam pressure gage and the steam connection on a boiler, so fabricated that it contains a water seal which prevents steam entering the Bourdon tube of the gage. Surface, Heating, Square Feet of -- That area of the boila surface exposed to the-products of combustion. In computing the heating surface for the purpose of determining the safety or relief valve requirements, only the tubes, fireboxes, shells, tubesheets, and the projected area of the headers need be considered, except that for vertical firetube boilers only that portion of the tube surface up to the middle point of the gage glass is to be computed. Thickness, Required -- The minimum thickness deter mined by the formulas in this Code. Tube, Fire -- A hollow cylinder used for the convey ance of gases, flame, or hot air. Tube, Water -- A hollow cylinder used for the conveyance of liquids. Valve, Pressure-Temperature Relief-- An automatic relieving device actuated by die static pressure upstream of the valve (which opens further with increase in the pressure ova the opening pressure) or by the tempera ture of the fluid. It is used primarily fa liquid service. Valve, Safety -- An automatic pressure relieving device actuated by the static pressure upstream of the valve and characterized by full-opening pop action. It is used for gas or vapor service. Valve, Safety, Lift of -- The movement of the disk off the seat of a safety, safety relief, or relief valve when the valve is opened. It normally refers to the amount of movement of the disk off the seat when the valve is discharging at rated pressure. Valve, Safety Relief -- An automatic pressure reliev ing device actuated by the pressure upstream of the valve and characterized by opening pop action with further increase in lift with an increase in pressure ova popping pressure. Water Heater -- A vessel in which potable wata is heated by the combustion of fuel, by electricity, or by any other source, and withdrawn for external use. Water Heater, Lined -- A water heata with a corrosion resistant lining designed to heat potable wata. Water Heater, Unlined -- A wata heata made from corrosion resistant materials designed to heat potable water. Wet-Bottom Boiler -- Any type of boila which has a stayed or self-supporting, partially or fully watercooled, shell or furnace bottom. E-101 TERMS RELATING TO WELDING Arc Stud Welding -- An arc welding process wherein coalescence is' produced by heating with an arc drawn between a metal stud, or similar part, until the surfaces to be joined are properly heated, when they are brought together under pressure. Partial shielding may be ob tained by the use of a ceramic ferrule surrounding the stud. Shielding gas or flux may or may not be used. Arc Welding -- A group of welding processes wherein coalescence is produced by heating with an electric arc or arcs, with or without the application of pressure and with or without the use of filler metal. Atomic Hydrogen Welding -- An arc welding process wherein coalescence is produced by heating with an electric arc maintained between two metal electrodes in an atmosphere of hydrogen. Shielding is obtained 205 RS-003209 1/17/02 NUECES E-101 1995 SECTION IV E-101 from the hydrogen. Pressure may or may not be used and filler metal may or may not be used. Automatic Welding -- Welding with equipment which performs the entire welding operation without constant observation and adjustment of the controls by an opera tor. The equipment may or may not perform the loading and unloading of the work. Backing -- Material (metal, weld metal, asbestos, carbon, granular flux, etc.) backing up the joint during welding to facilitate obtaining a sound weld at the root. Base Metal -- The metal to be welded or cut. Brazing -- A group of metal-joining processes wherein coalescence is produced by heating to suitable temperatures above 800F and by using a nonferrous filler metal, having a melting point below that of the base metals. The filler metal is distributed between the closely fitted surfaces of the joint by capillary attraction. Butt Joint -- A joint between two members lying approximately in the same plane. Comer Joint -- A joint between two members located approximately at right angles to each other in the form of an L. Double-Welded Butt Joint -- A butt joint welded from both sides. Double-Welded Lap Joint -- A lap joint in which the overlapped edges of the members to be joined are welded along the edges of both members. Edge Joint -- A joint between the edges of two or more parallel or nearly parallel members. Filler Metal -- Metal to be added in making a weld. Fillet Weld -- A weld of approximately triangular cross section joining two surfaces approximately at right angles to each other in a lap joint, tee joint, or comer joint. Flux Cored Arc Welding (FCAW) -- A gas metal arc welding process which produces coalescence of metals by heating them with an arc between a continuous filler metal (consumable) electrode and the work. Shielding is provided by a flux contained within the tubular electrode: Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. Flux Cored Arc Welding-Electrogas (FCAW-EG) -- A variation of the flux cored arc welding process in which molding shoes are used to confine the molten weld metal for vertical position welding. Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. Flux Cored Electrode -- A composite filler metal electrode consisting of a metal tube or other hollow configuration containing ingredients to provide such functions as shielding atmosphere, deoxidation, arc sta bilization, and slag formation. Alloying materials may be included in the core. External shielding may or may not be used. Full Fillet Weld -- A fillet weld whose size is equal to the thickness of the thinner member joined. Gas Metal Arc Welding-Electrogas (GMAW-EG) -- A variation of the gas metal arc welding process using molding shoes to confine the molten weld metal for vertical position welding. Gas Tungsten-Arc Welding -- An arc welding process wherein coalescence is produced by heating with an electric arc between a single tungsten (nonconsumable) electrode and the work. Shielding is obtained from a gas or gas mixture (which may contain an inert gas). Pressure may or may not be used. Filler metal may or may not be used. (This process has sometimes been called TIG Welding.) . ....... Gas Welding -- A group of welding processes wherein coalescence is produced by heating with a gas flame or flames with or without the application of pressure, and with or without the use of filler metal. Joint Efficiency -- The efficiency of a welded joint is expressed as a numerical (decimal) quantity and is used in the design of a joint as a multiplier of the appropriate allowable stress taken from Tables HF300.1 and HF-300.2. Joint Penetration -- The minimum depth a groove weld extends from its face into a joint, exclusive of reinforcement. Lap Joint -- A joint between two overlapping members. Machine Welding -- Welding with equipment which performs the welding operation under the observation and control of an operator. The equipment may or may not perform the loading and unloading of the work. Manual Welding -- Welding wherein the entire weld ing operation is performed and controlled by hand. Oxyacetylene Welding -- A gas welding process wherein coalescence is produced by heating with a gas flame or flames obtained from the combustion of acetylene with oxygen, with or without the application of pressure and with or without the use of filler metal. Oxygen Cutting -- A group of cutting processes wherein the severing of metals is effected by means of the chemical reaction of oxygen with the base metal at elevated temperatures. In the case of oxidation resistant metals, the reaction is facilitated by use of a flux or metal powder. Oxyhydrogen Welding -- A gas welding process wherein coalescence is produced by heating with a gas flame or flames obtained from the combustion of hydrogen with oxygen, without the application of pres sure and with or without the use of filler metal. 206 R8-003210 1/17/02 NUECES E-101 APPENDIX E E-101 Plasma Arc Welding -- A gas tungsten arc welding process wherein coalescence is produced by heating with a constricted arc between an electrode and workpiece (transferred arc) or the electrode and the constricting nozzle (nontransferred arc). Shielding is obtained from hot ionized gas issuing from the orifice which may be supplemented by an auxiliary source of shielding gas. Shielding gas may be an inert gas or a mixture of gases, pressure may or may not be used, and filler metal may or may not be used. Pressure Gas Welding -- A gas welding process wherein coalescence is produced simultaneously over the entire area of abutting surfaces, by heating with a gas flame or flames obtained from combustion of hydro gen with oxygen, without the application of pressure, and with or without the use of filler metal. Pressure Welding -- Any welding process or method wherein pressure is used to complete the weld. Projection Welding (PW) -- A resistance welding process that produces coalesence by the heat obtained from the resistance of the flow of welding current. The resulting welds are localized at predetermined points by projections, embossments, or intersections. The metals to be joined lap over each other. Reinforcement of Weld -- Weld metal on the face of a groove weld in excess of the metal necessary for the specified weld size. Resistance Seam Welding (RSEW) -- A resistance welding process that produces coalesence of overlapped parts at the faying surfaces progessively along the length of a joint. The weld may be made with overlap ping nuggets, a continuous weld nugget, or by forging the joint as it is heated to the welding temperature by resistance to the flow of welding current. Resistance Spot Welding (RSW) -- A resistance weld ing process that produces coalesence at the faying surfaces of overlapped parts by the heat obtained from resistance of the work to the flow of welding current in a circuit of which the work is a part, and by the application of pressure. Resistance Stud Welding -- A resistance welding process wherein coalescence is produced by the heat obtained from resistance to electric current at the inter face between the stud and the work piece, until the surfaces to be joined are properly heated, when they are brought together under pressure. Resistance Welding (RW) -- A group of welding processes that produces coalescence of overlapping faying surfaces with the heat obtained from resistance of the work to the flow of current in a circuit of which the work is a part, and by the application of pressure. Seal Weld -- Any weld used primarily to obtain tightness. Semiautomatic Arc Welding -- Arc welding with equipment which controls only the filler metal feed. The advance of the welding is manually controlled. Shielded Metal-Arc Welding -- An arc welding pro cess wherein coalescence is produced by heating with an electric arc between a covered metal electrode and the work. Shielding is obtained from decomposition of the electrode covering. Pressure is not used and filler metal is obtained from the electrode. Single-Welded Butt Joints -- A butt joint welded from one side only. Single-Welded Lap Joint -- A lap joint in which the overlapped edges of the members to be joined are welded along the edge of one member. Size of Weld (a) Groove Weld -- The joint penetration (depth of chamfering plus the root penetration when specified). (b) Fillet Weld (1) For Equal-Leg Fillet Welds. The leg length of the largest isosceles right triangle which can be inscribed within the fillet weld cross section. (2) For Unequal-Leg Fillet Welds. The leg lengths of the largest right triangle which can be inscribed within the fillet weld cross section. Submerged Arc Welding -- An arc welding process wherein coalescence is produced by heating with an electric arc or arcs between a bare metal electrode or electrodes and the work. The welding is shielded by a blanket of granular, fusible material on the work. Pressure is not used and filler metal is obtained from the electrode and sometimes from a supplementary welding rod. Tee Joint -- A joint between two members located approximately at right angles to each other in the form of a T. Thermit Welding -- A group of welding processes wherein coalescence is produced by heating with super heated liquid metal and slag resulting from a chemical reaction between a metal oxide and aluminum, with or without the application of pressure. Filler metal, when used, is obtained from the liquid metal. Throat of a Fillet Weld (a) Theoretical. The distance from the beginning of the root of the joint perpendicular to the hypotenuse of the largest right triangle that can be inscribed within the fillet weld cross section. (b) Actual. The shortest distance from the root of a fillet weld to its face. Undercut -- A groove melted into the base metal adjacent to the toe of a weld and left unfilled by weld metal. Weld -- A localized coalescence of metal wherein coalescence is produced by heating to suitable tempera- 207 r8jOO^ nuece E-101 1995 SECTION IV tures, with or without the application of pressure and with or without the use of filler metal. The filler metal has a melting point approximately the same as the base metals. Weld Metal -- That portion of a weld which has been melted during welding. Welded Joint -- A union of two or more members produced by the application of a welding process. Welder -- One who is capable of performing a manual or semiautomatic welding operation. Welding Operator -- One who operates machine or automatic welding equipment E-101 208 R8-003212 1/17/02 NUECES APPENDIX F QUALITY CONTROL SYSTEM F-100 GENERAL F-100.1 Quality Control System. The manufacturer or assembler shall have and maintain a quality control system which will establish that all Code requirements including material, design, fabrication, examination (by the manufacturer), and inspection (by the Authorized Inspector) for boilers and water heaters constructed primarily of wrought materials will be met. Provided that Code requirements are suitably identi fied, the system may include provisions for satisfying any requirements by the manufacturer or user which exceed minimum Code requirements and may include provisions for quality control of non-Code work. In such systems, the manufacturer may make changes in parts of the system which do not affect the Code requirements without securing acceptance by the Au thorized Inspector. Before implementation, revisions to quality control systems of manufacturers and assemblers of safety and safety relief valves shall have been found acceptable to the ASME Designee if such revisions affect Code requirements. The system that the manufacturer uses to meet the requirements of this Section must be one suitable for his own circumstances. The necessary scope and detail of the system shall depend upon the complexity of the work performed and upon the size and complexity of the manufacturer's organization. A written description of the system the manufacturer will use to produce a Code item shall be available for review. Depending upon the circumstances, the description may be brief or voluminous. The written description may contain information of a proprietary nature relating to the manufacturer's pro cesses. Therefore, the Code does not require any distri bution of this information, except for the Authorized Inspector or ASME Designee, as covered by F-202.10. It is intended that information learned about the quality control system in connection with evaluation will be treated as confidential and that all loaned descriptions will be returned to the manufacturer upon completion of the evaluation. F-202 OUTLINE OF FEATURES TO BE INCLUDED IN THE WRITTEN DESCRIPTION OF THE QUALITY CONTROL SYSTEM The following is a guide to some of the features which should be covered in the written description of the quality control system and which is equally applicable to both shop and field work. F-202.1 Authority and Responsibility. The authority and responsibility of those in charge of the quality control system shall be clearly established. Persons performing quality control functions shall have sufficient and well defined responsibility, the authority, and the organizational freedom to identify quality control prob lems and to initiate, recommend and provide solutions. F-202.2 Organization. An organization chart show ing the relationship between management and engi neering, purchasing, manufacturing, field assembling, inspection, and quality control, is required to reflect the actual organization. The purpose of this chart is to identify and associate the various organizational groups with the particular function for which they are responsible. The Code does not intend to encroach on the manufacturer's right to establish, and from time to time, alter whatever form of organization the manufac turer considers appropriate for its Code work. F-202.3 Drawings, Design Calculations, and Speci fication Control. The manufacturer's or assembler's quality control system shall provide procedures which will insure that the latest applicable drawings, design calculations, specifications, and instructions required by the Code, as well as authorized changes, are used for manufacture, assembly, examination, inspection, and testing. 209 RS-003213 1117/02 NUECES F-202.4 1995 SECTION IV F-202.11 F-202.4 Material Control. The Manufacturer or assembler shall include a system of receiving control that requires verification that the material received conforms to order requirements and that the identifica tion of the materials corresponds to the material certifi cations or material test reports. The system shall ensure that only the intended material is used in Code con struction. F-202.5 Examination and Inspection Program. The Manufacturer's quality control system shall describe the fabrication operations, including examinations, suf ficiently to permit the Authorized Inspector to determine at what stages specific inspections are to be performed. F-202.6 Correction of Nonconformities. There shall be a system agreed upon with the Authorized Inspector for correction of nonconformities. A nonconformity condition which does not comply with the applicable rules of this Section. Nonconformities must be corrected or eliminated in some way before the completed compo nent can be considered to comply with this Section. F-202.7 Welding. The quality control system shall include provisions for indicating that welding conforms to requirements of Section IX as supplemented by this Section. F-202.8 Calibration of Measurement and Test Equipment The Manufacturer or assembler shall have a system for the calibration of examination, measuring, and test equipment used in fulfillment of requirements of this Section. F-202.9 Sample Forms. The forms used in the quality control system and any detailed procedures for their use shall be available for review. The written description shall make necessary references to these forms. F-202.10 Authorized Inspector F-202.10.1 The Authorized Inspector is the ASME Code Inspector defined in HG-515.3. F-202.10.2 The written description of the quality control system shall include reference to the Authorized Inspector. F-202.10.2.1 The Manufacturer shall make avail able to the Authorized Inspector at the Manufacturer's plant a copy of the written description of the quality control system. F-202.10.2.2 The Manufacturer's quality control system shall provide for the Authorized Inspector at the Manufacturer's plant to have access to all drawings, calculations, specifications, procedures, process sheets, repair procedures, records, test results, and any other documents as necessary for the Authorized Inspector to perform his duties in accordance with this Section. The Manufacturer may provide such access either to his own files of such documents or by providing copies to the Authorized Inspector. F-202.11 Inspection During Manufacture of Safety and Safety Relief Valves. See HG-401.3. 210 R8-0032'4 NUECES  A96 A97 APPENDIX H LIST OF ABBREVIATIONS AND ADDRESSES ANSI American National Standards Institute 11 West 42nd Street, 13th Floor, New York, NY 10036 ASHRAE American Society of Heating, Refrigerating and Air Conditioning Engineers 1791 Tullie Circle NE, Atlanta, GA 30329 UL Underwriters' Laboratories, Inc. 333 Pfingston Road, Northbrook, EL 60062 CGA Canadian Gas Association 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3 NEC National Electric Code NFPA 70 National Fire Protection Association International Batterymarch Park, Quincy, MA 02269 AGA American Gas Association 1515 Wilson Blvd., Arlington, VA 22209 American Gas Association Laboratories 8501 East Pleasant Valley Road, Cleveland, OH 44131 NSFI NSFI (National Sanitation Foundation International) 3475 Plymouth Road Ann Arbor, MI 48105 ASTM American Society for Testing and Materials 100 Barr Harbor Drive West Conshohocken, PA 19428 211 RS4103218 1/17/02 NUECES_ APPENDIX I SPECIFICATION FOR TEST METHOD FOR WATER ABSORPTION OF PLASTICS A96 SD-570 (Identical to ASTM Specification D 570-81 (Reapproved 1988)) 1. Scope 1.1 This test method covers the determination of the relative rate of absorption of water by plastics when immersed. The test method is intended to apply to the testing of all types of plastics, including cast, hotmolded, and cold-molded resinous products, and both homogeneous and laminated plastics in rod and tube form and in sheets 0.13 mm (0.005 in.) or greater in thickness. 1.2 The values stated in SI units are to be regarded as the standard. The values stated in parentheses are for information purposes only. 13 This standard may involve hazardous materials, operations, and equipment This standard does not purport to address all of the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 2. Referenced Document 2.1 ASTM Standard: D 647 Design of Molds for Test Specimens of Plastic Molding Materials 3. Significance and Use 3.1 The test method for rate of water absorption has two chief functions: first, as a guide to the proportion of water absorbed by a material and consequently, in those cases where the relationships between moisture and electrical or mechanical properties, dimensions, or appearance have been determined, as a guide to the effects of exposure to water or humid conditions on such properties; and second, as a control test on the uniformity of a product. This second function is particu larly applicable to sheet, rod, and tube arms when the test is made on the finished product. 3.2 Comparison of water absorption values of various plastics can be made on the basis of values obtained in accordance with 7.1 and 7.4. 33 The moisture content of a plastic is very intimately related to such properties as electrical insulation resist ance, dielectric losses, mechanical strength, appearance, and dimensions. The effect upon these properties of change in moisture content due to water absorption depends largely on the type of exposure (by immersion in water or by exposure to high humidity), shape of the part, and inherent properties of the plastic. With nonhomogeneous materials, such as laminated forms, the rate of water absorption may be widely different through each edge and surface. Even for otherwise homogeneous materials, it may be slightly greater through cut edges than through molded surfaces. Conse quently, attempts to correlate water absorption with the surface area must generally be limited to closely related materials and to similarly shaped specimens: For materi als of widely varying density, relation between waterabsorption values on a volume as well as a weight basis may need to be considered. 212 RS-003218 1/17/02 NUECES 4. Apput m>.< 4.1 Balance--An analytical balance capable of read ing 0.0001 g. 4.2 Oven, capable of maintaining uniform tempera tures of 50 3C (122 5.4F) and of 105 to 110C (221 to 230F). 5. Test Specimen 5.1 The test specimen for molded plastics shall be in the form of a disk 50.8 mm (2 in.) in diameter and 3.2 mm (Vg in.) in thickness (Note 1). Permissible variations in thickness are 0.18 mm (0.007 in.) for hot-molded and 0.30 mm (0.012 in.) for coldmolded or cast materials. NOTE 1--The disk mold prescribed in the Molds for Disk Test Specimens Section of Practice D 647 is suitable for molding disk test specimens of thermosetting materials but not thermoplastic materials. 5.2 The test specimen for sheets shall be in the form of a bar 76.2 mm (3 in.) long by 25.4 mm (1 in.) wide by the thickness of the material. When comparison of absorption values with molded plastics is desired, specimens 3.2 mm ('/8 in.) thick should be used. Permissible variations in thickness shall be 0.20 mm (0.008 in.) except for asbestos-fabric-base phenolic laminated materials or other materials which have greater standard commercial tolerances. 53 The test specimen for rods shall be 25.4 mm (1 in.) long for rods 25.4 mm (1 in.) in diameter or under, and 12.7 mm (V2 in.) long for larger-diameter rods. The diameter of the specimen shall be the diameter of the finished rod. 5.4 The test specimen for tubes less than 76 mm (3 in.) in inside diameter shall be the full section of the tube and 25.4 mm (1 in.) long. For tubes 76 mm (3 in.) or more in inside diameter, a rectangular specimen shall be cut 76 mm (3 in.) in length in the circumferential direction of the tube and 25.4 mm (1 in.) in width lengthwise of the tube. 5.5 The test specimens for sheets, rods, and tubes shall be machined, sawed, or sheared from the sample so as to have smooth edges free from cracks. The cut edges shall be made smooth by finishing with No. 0 or finer sandpaper or emery cloth. Sawing, machining, and sandpapering operations shall be slow enough so that the material is not heated appreciably. NOTE 2--If there is any oil on the surface of the specimen when received or as a result of machining operations, wash the specimen with a cloth wet with gasoline to remove oil, wipe with a dry cloth, and allow to stand in air for 2 h to permit evaporation of the 5.6 The dimensions listed in the following table for the various specimens shall be measured to the nearest 0.025 mm (0.001 in.). Dimensions not listed shall be measured within 0.8 mm ( V32 in.). Type of Specimen Molded disk Sheet Rod Tube Dimensions Co be Measured to the Nearest 0.025 mm (0,001 in.) thickness thickness length and diameter inside and outside diameter, and wall thickness 6. Conditioning 6.1 Three specimens shall be conditioned as follows: 6.1.1 Specimens of materials whose water-absorp tion value would be appreciably affected by tempera tures in the neighborhood of 110C (230F), shall be dried in an oven for 24 h at 50 3C (122 5.4F), cooled in a desiccator, and immediately weighed to the nearest 0.001 g. NOTE 3--If a static charge interferes with the weighing, lightly rub the surface of the specimens with a grounded conductor. 6.1.2 Specimens of materials, such as phenolic laminated plastics and other products whose waterabsorption value has been shown not to be appreciably affected by temperatures up to 110C (230F), shall be dried in an oven for 1 h at 105 to 110 C (221 to 230 F). 6.13 When data for comparison with absorption values for other plastics are desired, the specimens shall be dried in an oven for 24 h at 50 3C (122 5.4F), cooled in a desiccator, and immediately weighed to the nearest 0.001 g. 7. Procedure 7.1 24-h Immersion--The conditioned specimens shall be placed in a container of distilled water maintained at a temperature of 23 1C (73.4 1.8F), and shall rest on edge and be entirely immersed. At the end of 24, +V2, -0 h, the specimens shall be removed from the water one at a time, all surface water wiped off with a dry cloth, and weighed to the nearest 0.001 g immediately. If the specimen is ]/]6 in. or less in thickness, it shall be put in a weighing bottle immedi ately after wiping and weighed in the bottle. 213 RS-00M17 1/17/oa NUECES 7.2 1995 SECTION IV 9.1.6 7.2 2-h Immersion--For all thicknesses of materials having a relatively high rate of absorption, and for thin specimens of other materials which may show a significant weight increase in 2 h, the specimens shall be tested as described in 7.1 except that the time of immersion shall be reduced to 120 4 min. 73 Repeated Immersion--A specimen may be weighed to the nearest 0.001 g after 2-h immersion, replaced in the water, and weighed again after 24 h. NOTE 4--In using this method the amount of water absorbed in 24 h may be less than it would have been had the immersion not been interrupted. 7.4 Long-Term Immersion--To determine the total water absorbed when substantially saturated, the condi tioned specimens shall be tested as described in 7.1 except that at the end of 24 h they shall be removed from the water, wiped free of surface moisture with a dry cloth, weighed to the nearest 0.001 g immediately, and then replaced in the water. The weighings shall be repeated at the end of the first week and every two weeks thereafter until the increase in weight per twoweek period, as shown by three consecutive weighings, averages less than 1% of the total increase in weight, or 5 mg, whichever is greater, the specimen shall then be considered substantially saturated. The difference between the substantially saturated weight and the dry weight shall be considered as the water absorbed when substantially saturated. 73 2-h Boiling Water Immersion--The conditioned specimens shall be placed in a container of boiling distilled water, and shall be supported on edge and be entirely immersed. At the end of 120 4 min, the specimens shall be removed from the water and cooled in distilled water maintained at room temperature. After 15 1 min, the specimens shall be removed from the water, one at a time, all surface water removed with a dry cloth, and the specimens weighed to the nearest 0.001 g immediately. If the specimen is V16 in. or less in thickness, it shall be weighed in a weighing bottle. 7.6 V2-h Boiling Water Immersion--For all thick nesses of materials having a relatively high rate of absorption, and for thin specimens of other materials which may show a significant weight increase in '/2 h the specimens shall be tested as described in 7.5, except that the time of immersion shall be reduced to 30 1 min. 7.7 Immersion at 50C--The conditioned specimens shall be tested as described in 7.5, except that the time and temperature of immersion shall be 48 1 h and 50 1C (122.0 1.8F), respectively, and cooling in water before weighing shall be omitted. 7.8 When data for comparison with absorption values for other plastics are desired, the 24-h immersion procedure described in 7.1 and the equilibrium value determined in 7.4 shall be used. 8. Reconditioning 8.1 When materials are known or suspected to contain any appreciable amount of water-soluble ingredients, the specimens, after immersion, shall be weighed, and then reconditioned for the same time and temperature as used in the original drying period. They shall then be cooled in a desiccator and immediately reweighed. If the reconditioned weight is lower than the conditioned weight, the difference shall be considered as watersoluble matter lost during the immersion test. For such materials, the water-absorption value shall be taken as the sum of the increase in weight on immersion and of the weight of the water-soluble matter. 9. Calculation and Report 9.1 The report shall include the values for each specimen and the average for the three specimens as follows: 9.1.1 Dimensions of the specimens before test, measured in accordance with 5.6, and reported to the nearest 0.001 in., 9.1.2 Conditioning time and temperature, 9.13 Immersion procedure used, 9.1.4 Time of immersion (long-term immersion procedure only), 9.13 Percentage increase in weight during immer sion, calculated to the nearest 0.01% as follows: wet wt - conditioned wt Increase in weight, % ------------------------------- x 100 conditioned wt 9.1.6 Percentage of soluble matter lost during immersion, if determined, calculated to the nearest 0.01% as follows (Note 5): Soluble matter lost, % conditioned wt - reconditioned wt = ---------------------------------------- x 100 conditioned wt 214 RS-003218 9.1.6 APPENDIX I 10.2 NOTE 5--When the weight on reconditioning the specimen after immersion in water exceeds the conditioned weight prior to immersion, report "none" under 9.1.6. 9.1.7 The percentage of water absorbed, which is the sum of the values in 9.1.5 and 9.1.6, and 9.1.8 Any observations as to warping, cracking, or change in appearance of the specimens. three laboratories and three materials. Analysis of this data yields the following coefficients of variation (aver age of three replicates). Average absorption above 1% (2 materials) Average absorption below 0.2% (1 material) Within Laboratories 2.33% Between Laboratories 4.89% 9.01% 16.63% 10. Precision and Bias 10.2 Bias--No justifiable statement on the bias of this test method can be made, since the true value of 10.1 Precision--An interlaboratoiy test program was the property cannot be established by an accepted carried out using the procedure outlined in 7.1, involving referee method. J VJ f ) 215 R8-003218 1/17/02 NUECES APPENDIX K GUIDE TO INFORMATION APPEARING ON CERTIFICATE OF AUTHORIZATION ITEM 0 i DESCRIPTION a. The name of the Manufacturer or Assembler; this description could include "doing business as" (DBA) or an abbreviation of the name, b. The full street address, city, state or province, country, and zip code. This section describes the scope and limitations if any, on use of the Code symbol stamps, as illustrated below. Field site Certificate of Authorization applies to items which are fabricated or assembled at a field site and is not intended to apply to items at any shop location. H Code Symbol Stamp 1. Heating boilers, except cast iron, at the above location only. 2. Heating boilers, except cast iron, at the above location only. (This authorization includes multiple duplicate heating boilers.) 3. Heating boilers, except cast iron, at the above location. (This authorization does not cover welding or brazing.) 4. Heating boilers, except cast iron, at the above location and field sites controlled by that location. 5. Heating boilers, cast iron only, at the above location only. HLW Code Symbol Stamp 1. Potable water heaters at the above location only. 2. Potable water heaters at the above location only. (This authorization includes multiple duplicate lined potable water heaters.) HV Code Symbol Stamp 1. Manufacturer of heating boiler safety valves and safety relief valve at the above location only. 2. Manufacturer of heating boiler safety valves and safer/ relief valve at the above location only. (This authorization does not cover welding or brazing.) 0 The date authorization was granted by the Society to use the appropriate Code Symbol Stamp. The date authorization to use the appropriate Code Symbol Stamp will expire. A95 216 RS-003220 1/17/02 NUECES APPENDIX K A unique Certificate number assigned by the Society. Code Symbol granted by the Society, i.e., H Heating Boilers; HLW Water Heat ers; and HV Safety Valves. , The signature of the current Chairman of the Boiler and Pressure Vessel Commit tee and the Director of Accreditation. 217 RS-003221 1/17/02 NUECES A95 APPENDIX L GUIDE TO MANUFACTURER'S DATA REPORT FORMS Introduction ......................................................................................................................................... 221 Instructions for Preparation of Section IV Manufacturer's Data Report Forms ......................................... 222 Form H-2 Form H-3 Form H*4 _ Form H-5 Form HLW-6 Form HLW-7 Form HLW-8 Manufacturer's Data Report for All Types of Boilers Except Watertube and Those Made of Cast Iron.......................................................................... Manufacturer's Data Report for Watertube Boilers................................................ Manufacturer's Partial Data Report..................................................................... Manufacturer's Master DataReport for Boilers Constructed From CastIron............ Manufacturer's Data Report for Water Heaters or Storage Tanks........................... Manufacturer's Partial Data Report for Water Heaters and Storage Tanks.............. Manufacturer's Master DataProof Test Report for Water Heaters or Storage Tanks................................................................................................ 225 227 229 231 233 235 237 sJ 219 RS-003222 1/17/02 NUECE8 INTRODUCTION The following pages are a guide for completing the Manufacturer's Data Report Forms. Forms and guides are keyed in the following manner Circled numbers refer to the guide for required subject material. 1. Numbers without circles appearing in the guide material identify specific lines on the Manufacturer's Data Report Forms. Forms appearing in this Section may be obtained from the Order Dept., ASME, 22 Law Drive, Box 2300, Fairfield, N.J. 07007-2300. 221 RS-003223 1/17/02 NUECES Instructions 1995 SECTION IV A95 A95 H-2 H-3 XX XX XX XX XX XX XX XX XX X XX X X X X X X X X X X X X X XX XX X X X XX XX XX INSTRUCTIONS FOR THE PREPARATION OF SECTION IV MANUFACTURER'S DATA REPORT FORMS Applies to Form H-5 HLW-6 HLW-7 HLW-8 Note No. Instruction: XXX X ... X ... X X XX 0 Name and address of manufacturer (i.e., maker of all components not covered by Partial Data Reports.) X 0 Name and address of purchaser and/or owner. 0 Name and address of location where unit is to be installed. If not known, so indicate (e.g., "not known--built for stock.") X X X. X X X X X X X X XX X X XX X ... XX X X X X X 0 Show type or model of unit documented by this data report. X 0 Identification of unit by applicable numbers. If intended for installation in Canada, indicate the Canadian design registration number and drawing number. X 0 Year in which fabrication was completed in shop. X 0 Date (year) of Section IV edition under which boiler or part was constructed. X 0 Issue date of most recent addenda to Section IV under which boiler or part was constructed (e.g., "Summer 1982.") 0 Code Case number, if applicable. 0 Show quantity and inside dimensions in inches. If more than two shells or drums are used, enter data in line 14. X X 0 Show the complete ASME material specification number and grade as listed in the appropriate stress allowance table in Section IV (e.g., "SA-285-B") Ex ception: A specification number for a material not identical to an ASME Spec ification may be shown only if such material has been approved for Section IV construction by an ASME interpretation case ruling and provided the applicable case number is also shown. X Indicate type of joint(s). X 0 Show joint efficiency for welded joints. 0 Show number of furnaces in boiler. For cylindrical furnaces of the Adamson, ring-reinforced, and combined types, show total length only. 0 For stayed (firebox) type furnace, complete line 12 also. 0 If threaded, show diameter at root of thread. 0 Minimum cross-sectional area after deducting for telltale hole. 0 Maximum allowable working pressure for the stayed area calculated according to the rules contained in Part HG of Section IV. 0 Type of stay or brace (e.g., diagonal, gusset, girder, through, etc.) 0 Minimum cross-sectional area of the stay or brace multiplied by the number of stays or braces supporting the area under consideration. @ See applicable paragraphs and figures in Part MG of Section IV. 0 List parts not covered elsewhere on the data report. If insufficient space, attach a supplementary sheet. 0 Tabulate data for parts listed on line 14. 0 Show data for main and auxiliary inlets and outlets, nozzles, inspection openings, safety valve openings, drains and blowoffs. This does not apply to small openings for water column, controls, vents, etc. 0 Maximum allowable working pressure. @ Show Section IV paragraph which applies to the weakest part of the unit as established by calculation or deformation test. 0 Boiler heating surface calculated in accordance with HG-403 of Section IV or kW. 0 Hydrostatic pressure applied in accordance with HG-510 and witnessed by the Authorized Inspector. X 0 To be completed when one or more components comprising the unit are furnished by others and certified by the applicable Partial Data Report(s). X X 0 The manufacturer's ASME Certificate of Authorization number and date of expiration of said authorization. X X 0 This line is to be completed and signed by an authorized representative of the manufacturer. 222 RS-003224 1/17/02 NUECES APPENDIX L Instructions H-2 H-3 XX XX XX XX XX XX XX XX XX XX ... X X X X X X X X X X X XX INSTRUCTIONS FOR THE PREPARATION OF SECTION IV MANUFACTURER'S DATA REPORT FORMS (CONT'D) Applies to Form H-4 H-5 HLW-6 HLW-7 HLW-B Note No. Instruction: X ... X X X X ... X X X X X X t.. X X X X XXX X X X X X X X X X X X X X X X X 0 This certificate to be completed by the Authorized Inspection Agency repre sentative who performs the in-shop inspection. 0 To determine what goes in this space, you should be guided by the following: National Board stamped boilers and pressure vessels After "and state or province" in the certification blocks -- if the Inspector has a valid Certificate of Competency for the state or province where the manu facturer's shop is located, insert the name of that state or province. If the manufacturer is located in a non-Code jurisdiction, insert the name of the state or province where the inspector took his original examination to obtain his National Board Commission provided that Certificate of Competency is still valid. If not, show the name of the state or province where he has a valid Certificate of Competency authorizing him to make the shop inspection. Boilers and pressure vessels stamped only ASME Follow the above procedure. However, in this case do not list any National Board Commission number after the inspector's signature at the bottom of the block. 0 Indicate the data items covered on the applicable form by line numbers. 0 Indicate by line numbers those items furnished by others and for which the applicable Partial Data Reports have been examined. 0 The inspector's National Board Commission number and the state or province Certificate of Competency number must be shown when the boiler is stamped National Board. The inspector shall use his jurisdictional Certificate of Com petency and National Board Commission number on Partial Data Report Forms. If the boiler or vessel is not to be registered with the National Board, the inspector shall use only his state or province Certificate of Competency number. 0 The assembler's ASME Certificate of Authorization number and date of expi ration of said authorization. & This line to be completed, when applicable, and signed by an authorized rep resentative of the organization responsible for field assembly of the boiler. 0 This certificate to be completed by the Authorized Inspection Agency repre sentative who performs the field assembly inspection. 0 Indicate by line numbers from the applicable form those items inspected in the field that were not inspected in the shop. 0 Nominal thickness of plate. 0 Minimum thickness after forming. 0 Radius on concave side of dish. 0 Shop hydrostatic test, if any, applied to individual part prior to test applied to the assembled boiler. (See lines 33 and 35.) & This line for headers not covered as items 7 through 10. It is intended primarily for sectional headers on straight tube watertube boilers. Indicate shape as flat, dished, ellipsoidal or hemispherical. 0 Use inside dimensions for size. 0 Indicate shape as square, round, etc. 0 Outside diameter. 0 Minimum thickness of tubes. 0 Size is nominal pipe size. 0 Describe type as flanged, welding neck, etc. 0 Show name of part (e.g., steam drum, waterwall header, etc.) 0 Show data line number on applicable form for the named part. 0 Any additional information to clarify the report should be entered here. @ List each individual section which makes up boiler assembly. Show pattern and / or part number for each section. Show drawing number for each section. Show metal thickness for each section as indicated on the drawings. List each section of the complete boiler. 0 Show bursting pressure of each section of boiler in pounds per square inch. Show thickness in inches measured at the break or fracture of each section. Indicate weight in pounds of each section. 223 3840322* 1/17/02 NUECES Instructions 1995 SECTION IV INSTRUCTIONS FOR THE PREPARATION OF SECTION IV MANUFACTURER'S DATA REPORT FORMS (CONT'D) Appfrrs to Form Note (W Hki Jm Si HLW-6 HLW-7 HLW-8 No. Instruction: X X X X X ................. X XX XX XX XX XX ................ X .................. X A95 X X X .............................. 0 Indicate minimum specified tensile strength in pounds per square inch for the class of iron as set forth in Table HC-300. 0 Indicate sections of boiler which represent specimen test bars. Show results of each specimen tested (tensile strength) in pounds per square inch. 0 Show maximum allowable working pressure in pounds per square inch as deter mined by Formula HC-402 and by values allowed by Formula HC-402. X 0 The individual designated to conduct tests, the designated manufacturer's rep resentative who witnesses test and date or dates on which destruction tests were conducted. 0 Designated responsible engineering head certifying the tests and date. 0 Show quantity and dimensions. 0 Type of lining, if applicable. X 0 Maximum allowable working pressure established in accordance with HLW-300 or HLW-500 of Section IV. @ Indicate maximum allowable input,___ Btu/hr, or kW. For tanks used for storage, indicate `storage only.' 0 Maximum temperature in accordance with HLW-300 of Section IV. 0 Hydrostatic pressure applied in accordance with HLW-50S of Section IV and witnessed by the Authorized Inspector. X 0 Part of vessel yielding first should be indicated. X 0 Pressure at which yielding occurs as evidenced by flaking of the brittle coating or by appearance of strain lines. X 0 Show yield strength in psi for each of the three specimens and average of the three. 0 This ID number is a unique identifying number for this form which may be assigned by the Certificate Holder, if desired. @ Maximum water temperature. R8-003226 224 1/17/02 NUECES APPENDIX L Form H-2 FORM H-2 MANUFACTURER'S DATA REPORT FOR ALL TYPES OF BOILERS EXCEPT WATERTUBE AND THOSE MADE OF CAST IRON As Required by the Provisions of the ASME Code Rules, Section IV 1. Manufactured and certilied by 2. Manufactured for___________ 3. Location of installation______ 4. Unit identification (compaeie better. superheater ataman. aconommr. etc t ___ 0___ mti i tviui not O____________ (fteme end sddftlt f manufaciuran ama address of purchased _Q_____ ineme end eddressi (CflNi (drawing no I .irMre0wnt S. The chemical and physical properties ol all parts meet the requirements of material specifications of the ASME BOILER AND PRESSURE VESSEL CODE. The design, construction and workmanship conform to ASME Code. Section IV Q ______ _____0______ ivmo (addwitfa MaMS ICotf* Cam no.) Manufacturer's Partial Data Reports property Identified and of this report:_______________ ________________@_______ by Commissioned Inspectors have been furnished for the foltowing Kerns (noma of port. Mom numbor, mb's, urns and Mortifying stomp) (no) imsti smc gn -dong (seamless. wttdtdi _____ ______ (0<a ti 0 H (fangih lovanitn ____ iti> tas tompjrtd to seamiest* igirtn istjrnicst watdadH (man apoc. grad*) O tube*- No___ (mat t spac. grade) (tn*c*nessi Tube holes isir*gnt or m*mi Dia (AO idol Lenath (H venous gre* m* A min | (a (10 (tongth (ovoraUM (no O( Shod couraot) Gauge (or Ifucfcnesa) (man speciircatron no i (mal l, spac^ grj (INefcneasi 12 Staybnllv (no | (am tde M lin.cftnei%i ii*t dnd etipo*dot| (radtus of dssh) <2__________ _____ Seams:! (no.) {N(O0 or W k HM (langth iaach aacuong noted (type (piam. corrugated. etc* (type (aamwtaaa. wildm (mat > spoc gr tsuet (tetttaiei (not areat _______ ________ (pitch (hor and van | (MAWP (psip 13. Stays or braces: Localson (a) F.H. above tubes (b) R.H. above tubes (c) F.H. below tubes (d) R.H. below tubes (e) Through stays MaM Spac Type NO A S-/P Pitch Tout Nat Are* Fig HG 30 L/t Oist Tubas toShatt Area lobe Stayed MAWP oat. 14. Other parts 1S323. <pfi*l OtCiDiiO<* -- dom* boner piping ale I 1. _____________Q_________________________ _____________________ 2. _________________________________________________________________________________ 3. ________________________________________________________________________________________ tmai i %D*C grao* malar.*! |ivt** MAWPl IS. Noulas, inspection and salety valve openings: @ Purpoaa (tniaf. pvt/at. dram, ate / NO 0*a or Sue Type MOW Atitchoo Mat Nom Thickness Handhole up to 3' x 4* Manhole NA ft Aamforcement Mali. NA Location This form (E00101) may be obtained from the Order Dept., ASME, 22 Law Drive, Box 2300, Fairfield, N.J. 07007-2300. 225 RS-003227 1/17/02 NUECES Form H-2 1995 SECTION IV FORM H-2 (Back) 16. Boiler supports: 1*0 ttyp* wod-es **g 'uqiii <nac***Ai ibo*id o< weidedN 17. MAWP _ @___ Based on________ _________ Healing surface . ... @_______ Shop hydro leaf___________ 0_______ IP**/ IS. Maximum water temperature fj *F. ICO*!* M> MV o'rn.MI laq l o# *1111 llelvill (0I icomptata DOilvm A95 CERTIFICATE OF SHOP COMPLIANCE We certify that the statement* made m this data report are correct and that all details of design, material, construction, and workmanship of this boiler conform lo Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. *H* Certificate of Authorization no.__________ expires, 19 Date________________ SignedName (by representative) (manufacturer that constructed end certified boilet) CERTIFICATE OF SHOP INSPECTION Boiler constructed by__________ ____________ ;___________________________________________________ at________ I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the state or prov ince of Q___________ and employed by ______ have inspected parts of this boiler relerred to as data items .and have examined Manufacturers' Partial Data Reports lor items and state that, to the best of my knowledge and belief, the manufacturer has constructed this boiler in accordance with the applicable sec tions of the ASME BOILER AND PRESSURE VESSEL CODE. By signing tills certificate neither the inspector nor his employer makes any warranty, expressed or implied, concerning Ihe boiler described In this Manufacturers' Data Report. Furthermore, neither the inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of sny kind arising Irom or connected with this inspection. DateSignedCommissions (Authorized inspector) (Net i 04 (ioci endorsements) state. pro* and no i CERTIFICATE OF FIELD ASSEMBLY COMPLIANCE We certify that the field assembly construction of an parts of this boiler conforms with the requirements of SECTION IV of Ihe ASME BOILER AND PRESSURE VESSEL CODE. _ 'H' Ceniftcate of Authorization no. Date________ 2)Signed. .expires. , 19 Name (by reprosonUltvo) (assembler that certified and constructed field assembly) CERTIFICATE OF FIELD ASSEMBLY INSPECTION I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the state or prov ince of_________ and employed by_______________________________________________________________________________________ __________have compared statements in this Manufacturers' Data Report with the described boiler and state that the parts referred to as data itemsQ________________________ not In cluded In the certlllcate ol shop Inspection, have been inspected by me and that to the best of my knowledge and belief Ihe manufacturer and/or Ihe assembler has constructed and assembled this boiler in accordance with the applicable sections of the ASME BOILER AND PRESSURE VESSEL CODE. The described boiler was inspected and subjected to a hydrostatic test ofpal. By signing this certificate neither the inspector nor his employer makes any warranty, expressed or implied, concerning Ihe boiler described In this Manufacturers' Data Report. Furthermore, neither Ihe Inspector nor his employer shall be liable In any manner for any personal Injury or property damage or a loss of any kind arising from or connected with this inspection. Date. .Signed. (Authorized Inspector) .Commissions. JL Nan Bd line) andoraamenlal slxta prov ana no I 226 RS-003228 1/17/02 NUECES APPENDIX L FORM H-3 MANUFACTURER'S DATA REPORT FOR WATERTUBE BOILERS As Required by the Provisions of the ASME Code Rules, Section IV Form H-3 1. Manufactured and certified by 2 (noma end addieat of manufacturer) 2. Manufactured lot__________________________________________________________________________________________________ (name and address cH purchaser) 3. Location of installation_________________________________________________________________________________________ _ (name and addretti 4. Unit identification:______________________________ (complete boiler, superheater waltrwaii. etc ) _____________ _______________ ________________ (mil s tanai no l (CRN) (drawing no i (NaO Bd no.) (year bmiq 5. The chemical and physical properties of all parts meet the requirements of material specifications of Ihe ASME BOILER AND PRESSURE VESSEL CODE. The design, construction and workmanship conform to ASME Code. Section iv ______ ______ iron Mdowida Maws (Coo* Cam no ) 8. (a) Drums: Inside NO Diameter. In inside length Ft in 1 2 Shii Ptates Tube Sheets Mat i Spec Grade Thickness In inside Radius in 1 jsLT -- ThscknesS In Inside Radius in Tube Hoie Ugamonl Efficiency, % longitu dinal Circum ferential longitudinal Circum Joints Joints No No A Typo* Effi ciency No A Typ# EH. Ciency 1 2 'Indicate <f IU seamless. |2| fusion welded --- 6. (b) Boiler tubes: Diameter Thickness Mai t Spec No . Grade Mat f Spec Grade Heads Th<kness In Type*' Radius of Oish Hydro static Test, pet Mow NO Attached * 'indicate <i| tiai. (2) dished, p) ellipsoidal. (4) hemispherical. 6 (c) Headers no .............................. _______ ^Q (boa or sinuous or round, men spec no. thickness) Heads or ends @ ._ Hydro, test, psi__ (Shape mai I spec no . m.ckneisi 6 (d) Siayboirs (mat i spec no. diameter. sue temaie. net areal 6. (e) Mud drum: o' (lor sect header ooiiee state we shape mat t spec no tn.cknessi 7. Waterfall headers: Heads or ends Pilch_____ m Net areasq. in. (supported by one both Design pressurepsi Q Q______ ____Hydro test, psi ____________@ tsnaoe met spec nc m*ckne*M No Sue end Shape Maienai Spec No Gf Thickness In Shaoe Thtckne^ in Meier.*i Spec No Gf Hyd'O Test osi Diameter in Thickness In Material Spec No . Gr 1 or 2 3 8. (a) Other parts (1)12)(318 (b) Tubes lor other parts . ) This form (E00102) may be obtained from the Order Dept., ASME, 22 Law Drive. Box 2300, Fairfield, NJ. 07007-2300. 227 RS-003229 1/17/02 NUECES Form H-3 1995 SECTION IV FORM H-3 (Back) Boiler b Waterwall e Superheater d Other parts MAWP Maximum water temp. Sfioo H^dfo Tost pa* Hooting Swrfoeo so ft H10aOaoimsgtatmurpfeadc* on drum floods Thu nooiing so loes not to 00 usod for dotor- V mining mini mum sof#l|r voivo capacity 12. Manufacturer's Partial Data Reports property Identified and signed by Commissioned Inspectors have been furnished for me following Rems of this report: Q______________________________________________________________ @___________________________ _____________________ (ram* of part, itom numb*, mfr**, namo, and Identifying stamp) A95 CERTIFICATE OF SHOP COMPLIANCE We certify that the statements made In this data report are correct and thal all details of design, material, construction, and workmanship of this boiler conform to Section IV of the ASME BOILER AND PRESSURE VESSEL CODE *H" Certiflcale of Authorization no. exolres .19 nata Signed Name (by representative) (manufacturer that constructed and certified boRef) @ CERTIFICATE OF SHOP INSPECTION Hollar constructed by at L the undersigned, holding a valid commission Issued by tne National Board of Boiler and Pressure Vessel Inspectors and/or the stale or province of and employed bv have inspected parts of mis boiler referred to as data Rems and have examined Manufacturer's Partial Data Reports for Rems and state that, to the best of my knowledge and belief, the manufacturer has constructed this boiler In accordance with Section IV of the ASME BOILER AND PRESSURE VESSEL CODE By signing this certificate neither the inspector nor his employer makes any warranty, expressed or implied, concerning the boiler described in this Manufacturers' Data Report. Furthermore, neither the inspector nor his employer shall be liable in any manner tor any personal injury or property damage or a loss of any kind arising from or connected with this inspection. Dale Signed (Awttwtad tnwctfXl Commissions <N*l i B6 cndOMmafti*) atata. pfov ft0 no > CERTIFICATE OF FIELD ASSEMBLY COMPLIANCE We certify that the field assembly construction ol all parts ol this boiler conforms with the requirements of SECTION IV of the ASME BOILER AND PRESSURE VESSEL CODE. "H" Certificate of Authorization no exoires ____ _ 19 Date Stoned . <Dv rpfa*nuii*Bi Name latsampitf inat criif*d and f-.onsifuciad tac aaaampty) @ CERTIFICATE OF FIELD ASSEMBLY INSPECTION 1, the undersigned, holding a valid commission Issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the stale or province of @ and emoioved bv the Darts referred to as data Items have comDared Ihe statements In this Manufacturer's Data Report with the described boiler and stale that not Included In Ihe certificate of shop Inspection, have been Inspected bv me and thal to the best of my knowledge and belief the manufacturer and/or Ihe assembler has constructed and assembled this boiler In accordance with Section IV of the ASME BOILER AND PRESSURE VESSEL CODE The desertbed boiler was inspected and subjected to a hydrostatic test Of DSl. >, signing this certificate neither the inspector nor his employer makes any warranty, expressed or implied, concerning Ihe boiler described in this Manufacturers' Data Report. Furthermore, neither Ihe inspector nor his employer shall be liable in any manner lor any personal iniury or property damage or a loss of any kind arising from or connected with this inspection. Date Sinned Commissions (AulNNizttf lAtptctoO (Han 8d (irtO ndofMmtnia) ttata. pro* and no) 228 RS-003230 1/17102 NUECES o APPENDIX L FORM H-4 MANUFACTURER'S PARTIAL DATA REPORT As Required by the Provisions of the ASME Code Rules Attach to the applicable Data Report, Section^ IV_ 1. Manufactured and certified byO _______________________________________________ H-4 in* (name end MOftn o* menuiecivreri 2. Manufactured lor@ Iname end add*ess o< purchaser) 3. Location of installation______________________ ______________________________ mam# and address) 4. Identification of part(s): Name of Part @ Ima No 0 Mir s Sara< No Mtt Drawing No CRN Nat i 8e No Form H-4 Year wStull 5. The chemical and physical properties of all parts meet the requirements of material specifications of the ASME BOILER AND PRESSURE VESSEL CODE. The design, construction and workmanship conform to ASME Code. Section IV. _Q_ . _______ _ (addenda (daitii (Code Case no) 6. (a) Drums: insida No Dfmeter. in inside Length Ft in 1 2 $hii Pistes Mat Spec No C>ao 0 7nrcnest Rad* In Twoe Sheets Thickness in <ns*de Rad*ws in Tuba Ho*# Ugamani Efficlancy, % tongitu d*naf Circum ferential Longtlwdmai Jomts No No 4 Type* EH. c*ency C*Cum Joints No 4 Typa EH. Ciencr 1 2 *indcate < Pi seamless 1?) igson etded 6. (0) Boiler tubes: Otantotar ThCknes Mat i Spac No Grade Mat So*c Nn 0 HO* NO Attached Heads Thickness in 0 Tfpe* Rad<vt o> D>sh __ 52___ Hydrostatic Test pa. `-w-si* >i o* tiai tjio.sneo 1)) s">oso<dai i*| hemispherical 6 (Cl Headers no_____2>" too* at a* m^nd mat 1 spec no. thickness) Heads or ends 000 .Hydro, test, psi__ 0 IS"*Df mjl 1 )pec ">0 in.cknessi 6 (01 Slaybolls52 tmat oec no 0>amis< < tetiiaie net srssi Pitch in Net area so in Design pressure supoo'fed br on* POM! pat 6. (e) Mud drum- Q *0 Heads or ends (io< sect rteade* bo<'*'s state s>/t nape, man spac no thicn#*sr ______0 rshape mat 1 me no m>ckne*j Hydro test, psi52. 7. Walerwall headers: NO Sue and Shape 10 2 3 Material Spec No G' O Th^fcness in '0 Shape 0 Tftrcness in 0 Mart"*' Spec No G' 0 Hydro T**l os. D'jmeter In Thrcaness In @ Maier*a/ Spec No Gr 0 8. (a) Other parts (1)(2)13)8 (b| Tubes lor other parts 1 2 J____________________ ______________________________ ___________________________ ______________I_____________ ______________L This form (E00103) may be obtained from the Order Dept., ASME, 22 Lew Drive, Box 2300, Feirfield, N.J. 07007*2300. 229 R8-003231 1/17/02 NUECES Form H-4 1995 SECTION IV FORM H-4 (Back) 9. Nozzles, Inspection and safety valve openings: Purpoee Oa (MM, OuttOI. dem. t > N Sac Handhole up to 3* x4* @ Typo $ Mow Allochod Mon NA Nom ThtcknoM Remtorcemeni Mon NA LOCOIlOA A95 a Boiler b Watarwatf c Other parts 12. Remarks: . MAWP Maximum water temp. Shoe Hydro Tool P** HOOIehg Surface se fi ! HOfokoWting10twMrioce OotrawmmpMeoooont IThi* hooting turface not to M used tor Ooiormmsng minimum Mtoly otvo copecity 8 Field Hydro Toot pM CERTIFICATE OF SHOP COMPLIANCE We certify that the statements made In this partial data report are correct and that an details of design, material, construction, and workmanship of these parts conform to Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. H* Certificate of Authorization no._________ ______ expires. 19 Dale__________ SignedName (by reprosontoirvo} (manufacturer that constructed and certified boiler) @ CERTIFICATE OF SHOP INSPECTION L the undersigned, holding a valid commission Issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the state or province of__________________________ and employed by ____________________________________________________________ have Inspected the pari of a boiler described In this Manufacturer's Partial Data Report on. 19, and stale that to the best of my knowledge and belief, the manufacturer has constructed this part In accordance with Section IV of the ASME BOILER AND PRESSURE VESSEL CODE By signing this certificate, neither the Inspector nor his employer makes any warranty, expressed or Implied, concerning the part described in this Manufacturer's Partial Data Report Furthermore, neither the inspector nor his employer shall be liable in any manner for any personal Injury or property damage or a loss of any kind arising from or connected with this Inspection. DaleSignedCommissions (Authorized Inspector) (Nan Bd (incl. endorsements) stats, prov. and no.) 230 RS-003232 1/17/02 NUECES APPENDIX L FORM H-5 MANUFACTURER'S MASTER DATA REPORT FOR BOILERS CONSTRUCTED FROM CAST IRON As Required by the Provisions of the ASME Code Rules, Section IV 1. Manufactured and certified by -------__----------- ------------------------Q------------------------------- (w>w end Mom o* (ftHeyfry emrfeeioni 2. Boiler type or modal no. 3. Boiler aacllon data: Section Designation (Hat each individual section In ooiler assembly) (a)------------------------------------------------- <b)--------------------------------(0--------------------------------- (d)--------------------------------------------- (a)------------------------------------- 4. Boiler section bursting data: Section Designation (a) ----------------------------------------------- (b) ---------------------------- ------------------- (c) ----------------------------------------- <d)--------------------------------------------------- (a)-------------------------------------------------------- 5. Minimum specitied tensile strength_________ 6 Tensile strength ot associated test bars Section Designation (a) . (b) . (e). <d), <e). T Specification no and class ot gray iron Pattern and/or Part No Metal Thickness According to Orawing Bursting Pressure. Metal Thickness Measured at Break or fracture, and Weight of Section Test No. 1 ___ ................ OB) in lb oai m lb OSl m m pst in - lb ost in . lb. Test No. 2 oai in. tb. oai in lb oai in. lb pai in lb. In lb Test No. 3 oai In lb. n*i th oal in. lb. oai in lb DSi In. lb. Bar lor Test No 1 Bar lor Test No 2 psi -----------------ps> ---------psi .PSI psi oai PS) pst ..... ................. .. psi Bar for Test No. 3 osl psi oai oai psi 8 Maximum Allowable working pressure ot boiler* -PSI Determined by using formula in MC-402 and by selection of lowest values ot bursting pressure Irom tests recorded in item 4 ot this report This form (E00041) may be obtained from the Order Dept., ASME, 22 Law Drive, Box 2300, Fairfield, NJ. 07007-2300. 231 RS-003233 i/ir/oa NUECES FORM H-5 (Back) 9. Sketch of section with lowest bursting pressure Show location of (allure and indicate whether principally in bending or tension 10. Examination data: (a) Test engineer._______ __ \ (b) Witness of fstimi (c) Oatefs) of destruction tests <na**w> -----------------------------(-n-xnwl it Manufacturer's certification: (5) Date19. Certified to be true record Note: Signature of designated responsible engineering head of the manufacturer must be notarized. 12. ASME Certificate of Authorization no--------------------------------------------- 3______________________ Certificate expires19 to use the "H" symbol (cast iron). 232 RS-00323* 1/17/02 NUECES FORM HLW-6 MANUFACTURER'S DATA REPORT FOR WATER HEATERS OR STORAGE TANKS As Required by the Provisions of the ASME Code Rules 1. Manufactured and certified by............................................................. .................... Q____________________________________________ (name ana addrass ol ma/Hitactwao 2. Manufactured for-----------------------------------------------------------------------------------------------------------------------------------------------------------------------wm ana unu el wwiiel 3. Location of Inataltation------------------------------------------------------ ________ foam# and addfosat 4. Identification.' _________ a______________________________________________________________________________________ pa*r`*. aartal *o) (CRN) (drawing no.) (Nan ftd 1*04 (year 5. The chemical and physical properties of all parts meet the requirements ol material specifications of the ASME BOILER AND PRESSURE VESSEL CODE. The design, construction, and workmanship conform to Part HLW. Section IV ___________ 0___________ Irewt laaetnaa tastes (Code Case imj Q6. Shell'__ ____________f$ (ml) OMNI, apac., grj (ttucfcnass (nvj| fwwgt (do. (m.| (tangtn {ft. 4 M4 (oacaiH 7. Joints-____ Q pong. fiaarwfata, aiWid> {oft. fcomparad 10 saamiassa (qwia (saamtaas. wloads (no of thaw court#*} taeafton Man 4pac..Gr . Thtefcnats Crown Radio* Knock* Hidui Etfcptieai Ratio Hamtspftancat Radius FwOa. Sda Pvasawra pawaa, cawwi 9. TubMh--tL- Q Tubes_____ {man. apac. grj (no4 (MiapAJ 10. Noclw, Inspection and safety valve openings: Q (Mat, awdat, drawi, alej No Cha. pSin Typo Handhole up to 3* x 4* NA pangmm l HOw Attached _____ 2_____ (man spec. gr) pmcknaM <* {roUod or wafOad) Nom Rawtforcamant Mart Ttwcknasa Man location NA NA .... 11. MAWP_________ @_________ MAX input___________________ (pad (Btw/iv. or kW) Mss temp-------------- Q (*F) Hyrimte.i Q (psi) 12. Manufacturer's Partial Data Reports property identified and signed by Commissioned inspectors have been furnished for the lotlovring Rems of this report: Q Q_______ _ (name el pan. Ram no, mtr*t nama, IdantRlen stampa) This form (E00105) may be obtained from the Order Oept., ASME, 22 Law Drive, Bo* 2300, Fairfield, N.J. 07007-2300, 233 RS403236 1/17/02 NUECES Form HLW-6 A97 1995 SECTION IV FORM HLW-6 (Back) CERTIFICATE OF SHOP COMPLIANCE We certify that the statements made in this data report are correct and that all details of design, material, construction, and workmanship of this water heater or storage tank conform to Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. 'HLW* Certificate of Authorization no-----------------------------------------------------------expiration date---------------------------------------------------------- Date Name Signed --------------------------------------------------------------------------------------------------------------------------------------------------------- (manufacturar dial conabuciad and certified vmmt haaiar or atoraga tank) (by raptatantariva)* I, CERTIFICATE OF SHOP INSPECTION Constructed byat------------------------------------------------------------------------------I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the state or province ofand employed by---------------------------------------------------------------------------------------------------------------have inspected parts referred to as data items________________________________________________________ and have examined Manufacturer's Partial Data Reports for items------------------------------------------------------------------ and state that to the best of my knowledge and belief, the manufacturer has constructed this water heater or storage tank in accordance with Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. By signing this certificate, neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the water heater or storage tank described in this Manufacturer's Data Report Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from or connected with this inspection. Date Signed Commissions (Aurhorind InapactDr) INaTI Bd. (bid. andoraamanta) atata. pray, and no.| 234 RS-003236 1/17/02 NUECES . .wwvuc OUIC5 Attach to the applicable Form HLW-6 Data Report 1. Manufactured and cartifiad by2.----------------------------------------------------------------------------------------------------------------------- HLW-7 IOi (nama enfl add*ta ot manutactwror? 2. Manufactured for______________________2D------------------------------------------------------------------------------------------------------------------------- mama and o* purehaeen 3. Identification of part(s): Nomoof Ron tma No tOamitying No Q Manu*aeiuror a Drawing No YaarB ______ 4. The chemical and physical properties of an parts meet the requirements of malarial spedflcallons of (he ASME BOILERAND PRESSUF CODE The design, construction, and workmanship conform to Part HLW, Section IV______ Q and Addenda lo( 5. Shen: 220Sfi (no.| (mel'I. spec., gt.) (thtolmesa .)) (lining) (die. (in.|) (length (TL 4 n 6. Joints:222121 (tong, (seamless, welded)) (eff. (compand to seamless)) (girth (seamless, welded)) (no. of shen courses 7. Heads: Location MaTntMScpxoncoa.Ct r. O Crown RadsvB Knwcaia Rad</ EMrphCal Ratio Hamiaohrai RadHa Fiat Ota $da (concav*. co> * Tubesheet:_________________________ _________ Imat i ipec . or I . Tubes: $i*ein. Length (no) 10. Connections: Rurpood NO Suaorpta J t._ Tube holes. too and Oia) _m. Material spec., gr.. - Thickness___ Maianai SpaC. Gr Thtcknaa* Ratnlorcam*i Matariai 11. MAWP. 12. Remartta:. .Max input. JL o* >Wi .Max remp_ Hydrostatic test This form (E00106) may be obtained from the Order Dept.. ASME, 22 Law Drive, Box 2300, Fairfield, N.J. 07007-230 235 og-0032^ NinUEriCwES Form HLW-7 1995 SECTION IV FORM HLW-7 (Back) CERTIFICATE OF SHOP COMPLIANCE We certify me statements In this Manufacturer's Partial Data Report to be correct and that all details of material, construction, and workmanship of this water healer or storage lank conform to Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. - CetWcale of Authorization no.____________ lo use the "HLW symbol expires. 19________________________________________________ . Oats______ ________ Signedby * * imanvfacivw mai coa i vci ano cartifiM pan*) (aw'ftoruMi rtprasanialt**! * @ CERTIFICATE OF SHOP INSPECTION L the undersigned, holding a valid commission Issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the slate or province of__________ and employed >y___________________________________________________________________________________________________ have Inspected the part described In this Manufacturer's Partial Data Report on . 19, and state that to the best of my knowledge and belief, the manufacturer has constructed this part In accordance with Section IV of me ASME BOILER AND PRESSURE VESSEL CODE. By signing this certificate, neither the inspector nor his employer makes any warranty, expressed or implied, concerning the part described in this Manufacturer^ Partial Data Report Furthermore, neither the inspector nor his employer shall be liable in any manner for personal in jury or property damage or a loss ol any kind arising from or connected with this inspection DateSignedCommissions <Aw1*O't0 <N*1 l B4 (inci nttorMmpfUa) pro* and no ) 236 RS-003238 1/17102 NUECES GUIDE TO FORMS FORM HLW-8 MANUFACTURER'S MASTER DATA PROOF TEST REPORT FOR WATER HEATERS OR STORAGE TANKS As Required by the Provisions of the ASME Code Rules, Section IV 1. Manufactured and certified by 2. Vessel type or model no. (HLW-500): 3, Vessel proof test data: Vassal Parts Description or P8rt No. 2. Material Spec. Gr. Thickness According to Drawing Specified Yield Strength, psi Form HLW-8 A97 Minimum Tensile, psi H 4. Type of coating: S. Test data to determine yielding: Part Designation Yielding (Amt wash or othsr brtttls costing) Yielding Pressure by Flaking of Coating or by Strain Lines Location of Yielding Whether Bending or Tension (indicate on sketch) 6. Yield strength of test specimens [HLW-502.1(c)(: (a) __ _ psi (b)psi (c)psi Averagepsi 7. Maximum allowable working pressure of vessel: ________ ________ psi [determined by formulas in HLW-502.1(d)| 8. Examination data: (a) Test engineer_____ (b) Witness of test____ (c) Date(s) of proof test MANUFACTURER'S CERTIFICATION We certify that the above data is correct and that the proof test procedure conforms with HLW-500 of Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. ASME Certificate of Authorization no________ _______ to use the "HLW symbol expiration date Date_______ _______ Certified to be true record (authorized reprwantativa)* (manufacturer) Note: Signature of manufacturer's designated responsible engineering representative is required.* I, PROOF TEST CERTIFICATE I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the state or province ofSand employed by have witnessed the proof test and the procedures conforming to HLW-500 of Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. By signing this certificate, neither the inspector nor his employer makes any warranty, expressed or implied, concerning the water heater or storage tank described in this Manufacturer's Proof Test Report Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from or connected with the witnessing of this proof test Date Signed Commissions (Authorized Inspector) latata. province, and no.| This form (E00107) may be obtained from the Order Department ASME, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300. 237 RS-003239 1/17/02 NUECES SI UNITS The 1995 Edition of the Boiler and Pressure Vessel Code is based on U.S. Customary (ft-lb) units of measurement which are to be regarded as the standard. This supplement is provided as a convenience to the Code user and contains SI conversion factors for units contained in the Code. 239 R8-003240 1/17/02 NUECE8 LIST OF SI UNITS FOR USE WITH ASME BOILER AND PRESSURE VESSEL CODE1 Quantity Other Units or Unit Symbol Limitations Space and Time plane angle length area volume time radian meter square meter cubic meter second rad degree (decimalized) m m2 m2 liter (L) for liquid only (use without prefix other than in milliliter, mL) s minute (min), hour (h), day (d), week, and year Periodic and Related Phenomena frequency rotational frequency hertz revolutions per second Hz revolutions per second (r/s) s-i revolutions per minute (r/m) Mechanics mass density moment of inertia force moment of force (torque) pressure and stress energy, work power impact strength section modulus moment of section (second moment of area) fracture toughness kilogram kilogram per cubic meter kilogram meter2 newton newton-meter pascal joule watt joule meter2 meter4 Pa s/m k9 kg/m*2 *1 kg m2 N Nm Pa J W J m2 m4 (pascal = newton per square meter) kilowatt-hour (kW h) Heat temperature -- thermodynamic [Note (2)] temperature -- other than thermodynamic linear expansion coefficient quantity of heat heat flow rate thermal conductivity thermal diffusivity specific heat capacity kelvin degree Celsius meter per meter-kelvin joule watt watt per meter-kelvin square meter per second joule per kilogram-kelvin K c K> J W W/(m K) m2/s J/(kg K) degree Celsius (*C) kelvin (K) c> W/(m *C) J/(kg *C) Electricity and Magnetism electric current electric potential current density magnetic field strength ampere volt ampere per meter2 ampere per meter A V A/m2 A/m NOTES: (1) Conversion factors between SI units and U.S. customary are given in SI-1, "ASME Orientation and Guide for Use of SI (Metric) Units," and ASTM E 380. (2) Preferred use for temperature and temperature interval is degrees Celsius (*C), except for thermodynamic and cryogenic work where kelvins may be more suitable. For temperature interval, 1 K = l'C exactly. 240 RS-003241 1/17/02 NUECE8 COMMONLY USED CONVERSION FACTORS (For Others See ASTM E 380) (See Note 1) Quantity plane angle To Convert From degree Multiply by To [Note (2)1 rad 1.745 329 E-02 length in ft yd m 2.54* E-02 m 3.048* E-Ol m 9.144* E-Ol area volume in2 ft* yd* in5 ft* US gallon Imperial gallon liter m* 6.451 6* E-04 m* 9.290 304* E-02 m2 8.361 274 E-Ol m3 1.638 706 E-05 m3 2.831 685 E-02 m3 3.785 412 E-03 m3 4.546 09 E-03 m3 1.0* E-03 mass Ibm ton (metric) (mass) ton (short 2000 Ibm) k9 kg kg 4.535 924 1.000 00* 9.071 847 E-Ol E + 03 E + 02 force -- kgf Ibf N 9.806 65* E + 00 N 4.448 222 E + 00 bending, torque kgf m Ibf in Ibf ft Nm N m N m 9.806 65* 1.129 848 1.355 818 E + 00 E-Ol E + 00 pressure, stress kgf/m* Ibf/ft* Ibf/in* (psi) kips/in* bar Pa 9.806 65* E + 00 Pa 4.788 026 E + 01 Pa 6.894 757 E + 03 Pa 6.894 757 E + 06 Pa. 1.0* E + 05 energy, work Btu (IT) [Note (3)1 ft Ibf J J 1.055 056 1.355 818 E + 03 E + 00 power hp (550 ft Ibf/s) W 7.456 999 E + 02 fracture toughness ksi vTn Pa i/m 1.098 843 E + 06 temperature *C *F *F K t,, = tc + 273.15 K t. = (tF + 459.671/1.8 c tc = (tF- 321/1.8 temperature interval c F K K or `C 1.0* 5.555 555 E + 00 E-01 NOTES: (1) Care should be taken when converting formulas or equations that contain constant terms or factors. The value of these terms must be understood and may also require conversion. (2)<a> Relationships that are exact in terms of the base units are followed by a single asterisk. (b) The factors are written as a number greater than 1 and less than 10 with 6 or less decimal places. The number is followed by the letter E (for exponent), a plus or minus symbol, and two digits which indicate the power of 10 by which the number must be multiplied to obtain the correct value. For example: 3.523 907 E-02 is 3.523 907 x 10 * or 0.035 239 07. (3) International Table 241 RS-003242 1/17/02 NUECES INDEX A ASME Designee .................................................. HC-502.11 Abbreviations and addresses .............................. Appendix H Acceptance of unidentified materials (see Unidentified materials) Access doors.........................................HG-330.1, HG-330..5 Access openings.....................HG-330, HG-330.1, HG-330.4, HG-330.5, HG-720 Accumulation test of safety and safety relief valve capacity.................................................HG-512 Addresses and abbreviations .............................. Appendix H Adjusted pressure ratings for flanges and fittings......................................................... HG-370.2 Admiralty plate ........................ HF-301.2, Tables HF-300.2, HF-301.2 Admiralty tubes ...............................HG-315.2, HG-315.3, Table HF-300.2 Air cushion in closed type expansion system ............... HG-709.2 Airtight tank in closed type expansion system .........................................................HG-709.2 Alignment (see Welded joints) Allowable stress values (see Stresses) Allowable working pressures (see Working pressures) Alloy steel (see Steel) Altitude gages for hot water boilers .......................... HG-611 American National Standard cast iron pipe flanges and flanged fittings ........................HC-310.1 American National Standard steel pipe flanges and fittings .................................... HG-370.2 Anchorage, steam and hot water mains .................HG-703.1, Figs. HG-703.1, HG-703.2 Application of Code ................................................ Preamble Approval of new materials under Code .................................................... A-100-A-105 Assemblers and welders authorized ...................... HG-533.1, HG-533.2, HW-610 Assembly, boiler and boiler parts, by other than manufacturer ...................................... HG-533.2 in field................................. HG-532, HG-533.1, HW-810 of nonferrous tubes and fittings by welding ...................................................... HG-315.2 of parts to be welded ............................................HW-810 Associated test bars (see Tests) Atmospheres and fluxes ........................................... HB-1103 Atmospheric pressure ............................................HG-300(b) Attachment material, strength of............................ HG-327.1, HG-327.2 Attachments, of crown sheet to head or tubesheet ............................HW-712.1, HW-712.2 of firetubes and tube ends ..................................HG-360.2 of furnaces to head or tubesheet.......................... HW-712, HW-715 of head to shell ...................................HW-715, HLW-415 of tubes attached by rolling................................HLW-309 of tubesheets to shells...........................................HW-711,HLW-411 of tubes to tubesheets ..........................HW-713, HLW-413 strength .........................................HW-703.1, HLW-430.1 watertube ............................................................HW-731.8 Attachments by welding (see Welding) Attachment welds (see Welds) Authorization for use of Code symbol.......................................................... HG-540,HG-540.1 Authorization for use of materials not found in Section II .....................................HG-200.3 Authorized Inspector............. HG-515.2, HG-515.3, HG-540 Automatically fired boilers, hot water ......................HG-613, HG-614 (see also Stamping) vertical firetube type, handholes or washout plugs for ..................................HG-330.4(c) stand/or water feeding device............... HG-605, HG-614 Automatic resetting pressure-temperature relief valve ................................................. HG-400.2 B Back strips, nozzles abutting boiler shell .................. HW-731.2(a), Fig. HW-731 nozzles inserted in boiler shell .................... Fig. HW-731, HW-731.3(a) welded butt joints .................. HW-701.1, Fig. HW-701.1, HLW-401.1 Baffles, materials for............................HG-200.7, HF-202(b) Bars, associated test (see Tests) for alignment of welded parts ...........................HW-810(b) specifications for ...................... HF-202, Tables HF-300.1, HF-300.2 stress values, maximum allowable ...................Tables HF- 300.1, HF-300.2 Base metal, preparation for welded joint .................. HW-801 Basis for establishing stress values.................... Footnotes to Tables HF-300.1, HF-300.2 Battery, boilers installed in ................................... HG-703.1, Figs. HG-703.1, HG-703.2 Beading of firetubes ............................................... HG-360.2 Blind flanges (see Flanges) Blowdown for safety and safety relief valves tests to determine pressures ........... HG-402.3(a) (see 243 R8-003243 1/17/02 NUECES 1995 SECTION IV also Tests) {see also Joints) {see also Safety and safety relief valves) Brazers and brazing operators, Blowoff cocks ............................................................ HG-715 certification of ............................................. HB-1502 Blowoff piping............................................................ HG-715 no production without qualification of............. HB-1202.3 Blowoff valves {see Valves) qualification of, by tests...............HB-1202.2, HB-1202.4 Boilers, compact type, stamping of.................HG-530.2(aX2) records of qualifications and identifying firetube type, manholes for ............................HG-330.1(b) marks of ............................HB-1202.4, HB-1502(b) for service in excess of limits of this responsibility of manufacturers for...................... HB-1001, Section.................................................. HG-101.3 HB-1202.2, HB-1202.4 horizontal tubular flue type, manholes symbol to identify work of ............................... HB-1202.4 for ....................................................... HG-330.2 Brazing, filler metal, design of joint to provide stamping of..................................... HG-530.1(b)(1) for application of..........................................HB-1304 inspection and certification of............. HG-515 {see also flow of .............................................................. HB-1304 Certification; Inspection) manual application of..................................HB-1304(a) locomotive firebox type, handholes preplacement of............................................ HB-1304(b) or washout plugs for...........................HG-330.4(a) materials, Code qualification of .......... HB-1100-HB-1103 stamping of ........................................... HG-530.2(a) Code specifications and limitations of..............HB-1100 scotch type, handholes or washout dissimilar, combinations of ...............................HB-1101 plugs for ...........................................HG-330.4(b) fiUer metals ..................................... HB-1102, HB-1304 stamping of ......................................HG-530.1(b)(5) fluxes and atmospheres .................................... HB-1103 service restrictionsand exceptions ...................... HG-101, procedures. Code qualification and HG-101.1, HG-101.2 specifications of........................ HB-1001, HB-1202, setting, for wet-bottom type boilers .................... HG-720 HB-1202.1, HB-1303 outside suspension type ...............HG-725.2-HG-725.4 combination of welding and brazing in split section and sectional firebox type, from same assembly ............................................. HB-1201 wrought materials, stamping of............HG-530.1(b)(4) for each different type of joint ......................... HB-1201 stamping of........................ HG-530 {see also Stamping) inspection of...................................................... HB-1501 vertical firetube type, handholes or washout no production without Code qualification plugs for ........................................... HG-330.4(c) of ............................................................. HB-1202.3 stamping of .................................. .. HG-530.1(b)(2) recommended form of recording....................... HB-1201 watertube type, stamping of..................... HG-530.1(b)(3) records of.........................................HB-1201, HB-1202 wet-bottom type................................................HG-720 responsibility of manufacturer..........................HB-1001, Bolted covers and heads (spherically dished) HB-1202.1 covers)................ HG-309, HG-309.1, Fig. HG-309 Bolting flanges {see Flanges) service temperature, permissible....................... HB-1303 tests, qualification ........................ HB-1001, HB-1202.1 Bolt loads ....................................... HG-307.1, HG-307.2 processes................................................................HB-1200 Bolt moments................................HG-307.2(b), HG-307.4 Bosses, cast iron, radii of...................................... HC-320 sequence ................................................................HB-1201 Brittle coating of critical area in proof Bottom blowoff piping and valves, size of ..............HG-715 tests .........................................HG-501.5, HG-502.4 Braces, as supports for heads or tubesheets.............HW-711 Brittle fracture, material submitted for Code materials for................................................. HF-202(a) approval ..........................................................A-103 Brackets for supporting boilers ............. HG-725, HG-725.6 Bronze casting materials................................Table HF-300.2 Brass, casting material .............................. Table HF-300.2 Brown furnaces ....................................................... HG-312.6 pipe .....................................................Table HF-300.2 Btu of various fuels........................................................B-102 plates ..................HF-301.2, Tables HF-300.2, HF-301.2 Bursting pressure tests for pressure parts................ HG-502.3 seamless condenser tubes...................................... TableHF-300.2 {see also Tests) tubes .................................. HG-315.2, Table HF-300.2 Butt joints {see Welded joints) Brazed connections and fittings............................ HB-1307 Brazed joints, cleaning .........................HB-1400, HB-1401 clearance..............................HB-1305, Table HB-1305 C efficiency factors ..................... HB-1301, HB-1304(a)(b) "C" factors, values of, for unstayed heads, lap, testing of........................................... HB-1202.1(b) cover plates and blind flanges................... HG-307.1, post operations on ........................................... HB-1401 HG-307.2(b), HG-307.3, rejection of............................................... HB-1503(d) HG-307.4, Fig. HG-307 repair of defective ............................HB-1402, HB-1503 Capacities, of bottom blowoff piping........................HG-715, strength of...................................................... HB-1300 Table HG-715 visual examination of ...................................... HB-1503 of expansion tanks................................................HG-709.3 244 RS-003244 1/17/02 NUECES INDEX in forced hot water systems................. Table HG-709.2 in gravity hot water systems ............... Table HG-709.1 relieving, of safety and safety relief valves Csee Safety and safety relief valves; Valves) Capacity tests (see Tests; Valves) Carbon steel .................................................. Table HF-300.1 bars and stays.............................. HF-202, Table HF-300.1 bolting..........................................HF-202, Table HF-300.1 castings ................... HF-203.1, HF-203.2, Table HF-300.1 electric resistance welded pipe and tubes...........................................Table HF-300.1 forgings................... HF-203.1. HF-203.2, Table HF-300.1 furnaces, horizontal cylindrical .................Figs. HG-312.1, HG-312.2 permissible carbon content in weldments........................................... HW-500(a) plate........................................HF-205, Table HF-300.1 seamless pipe and tubes ............HF-205, Table HF-300.1 Castings, boiler, stamping of...............................HG-530.2 pumps ...........................................................HF-203.1 Casting, parts formed by ....................HF-203.1, HF-203.2 Castings, brass and bronze.........................Table HF-300.2 steel ........... 7....... HF-203.1, HF-203.2, Table HF-300.1 Cast iron, boilers, certifying tests ...........................HC-403 Code requirements.............................................HC-100 design of................ HC-300, HC-310, HC-311, HC-315, HC-320, HC-325 inspection ........................................................ HC-501 marking requirements for................................ HG-530.2 quality control ..................................................HC-501 recording of tests.............................................. HC-403 washout openings for ........................................HC-325 washout openings used as return pipe connections.............................................. HC-325 washout plugs ................................................. HC-325 witnessing tests for ...........................................HC-403 circular spherically shaped covers or heads, with bolting flanges................. HC-311, HC-311.1, Fig. HC-311 classes of ...............................................Table HC-300 facings and drillings of flanges ........................ HC-311.1 flanges.......................HC-311, HC-311.1, Fig. HC-311, HC-315(b) for boilers and boiler parts.................. HC-100, HC-200, HC-300, Table HC-300 heads ................................................. HC-310, HC-311 minimum tensile strength values......... Table HC-300 nozzles ........................................................... HC-315 openings in cast iron boilers ..............................HC-315 pressure parts ................................. HF-203.1, HF-203.2 reinforcement of openings in cast iron boilers .............................................. HC-315 stress values, maximum allowable .....................HC-300, washout openings in steam and hot Table HC-300 water boilers............................................ HC-325 Cast nonstandard pressure parts............................HF-203.2 Cast standard pressure parts......................................HF-203.1 Cast steel (see Castings, steel) Cement lined water heaters .....................................HLW-200 Certificate of Authorization to use Code Symbol Stamps, application for.................. HG-402.2 authorization by Society.....................HG-402.2, HG-540, HG-540.1, HG-540.2(b) cancellation of certificate.............. HG-402.2, HG-540.2(c) expiration of certificate..................HG-402.2, HG-540.2(c) fee paid by applicants....................HG-402.2, HG-540.2(c) new regulations for, by Boiler and Pressure Vessel Committee .................... HG-402.2, HG-540.2 purchase of symbol from Society .......................HG-402.2, HG-540.2 refusal to renew............................. HG-402.2, HG-540.2(c) renewal of............................................................HG-402.2,HG-540.2 Certification, of brazers and brazing operators qualification test records, by manufacturers ................................... HB-1502(b) of field assemblies, by assemblers ......................HG-533.2 by inspectors ................................................... HG-533.2 of shop assemblies by manufacturers and inspectors.............................................HG-515.3,HG-532.2 of welders and welding procedure qualifications by manufacturers................... HW-910, HW-911 of work done by other than manufacturers..............................'............. HG-515.1 Certification by manufacturers, of records of Code qualification tests of brazers, of records of performance tests of welders and welding operators.......................... HW-911(a) of records of welding procedures and welders, welding operators and their identification marks............................................................ HW-613 of standard pressure parts as to material and service rating .....................HF-203.1, HF-203.2 of tests of cast iron boilers and boiler parts to establish pressure rating............................ HC-403 of tests of nonidentified material ........................ HF-205.3 Chambers, float ..................................................... HG-606(a) of fuel cutoff and water feeding devices ........... HG-606(c) rear combustion...............................................HG-330.4(b) Check valves in feed pipes..............................Fig. HG-703.1 Circuit breakers and shutdown switches, location of...................................................... HG-634 Circuitry, type of electric control .............................. HG-632 Circular cast iron spherically shaped covers (see Covers) Circular furnaces, plain type ...................................HG-312.1 Circular sections, plain, of combination type furnace .................... HG-312.6, Fig. HG-312.6 Circular spherically dished heads (see Covers) Circulating system of boiler, standard pressure parts for.................................... HF-203.1(a) Circumferential joints (see Joints) Clamps for aligning parts to be welded............... HW-810(b) 245 RS-00#*6 1995 SECTION IV Cleaning, of surfaces to be brazed ........................ HB-1400, HB-1401 openings for ...................... HG-330.1, HG-330.4, HC-325 return piping.................................................... HG-703.2(d) water column piping.......................................... HG-604(a) water gage glasses.............................................. HG-603(a) Clearance, brazed joint .............................................HB-1305 Cocks, blowoff............................................................HG-715 gage........................................................HG-601, HG-611 stop valve ............................................................ HG-710.4 Code, jurisdictional limits.................... HG-101.1, HG-101.2, HG-101.3 stamps (see Stamping; Stamps) Code compliance, electric wiring ............. HG-631, HG-640 Code policy on new materials...................................... A-100 Coefficient method, capacity relieving tests (see Tests) Coils, pipe, for heating hot water supply .................................................... HG-400.3(a) in heat exchangers...................................... HG-400.3(b)(c) Cold bending and close coiling, materials suitable for ~..........................................HF-205.2(b) Collapse tests of pressure parts (see Tests) Columns, fluid relief.................................................. HG-709 water ..............................HG-603, HG-604(a)(b), HG-705 Combination type furnaces, requirements for...............HG-312.7, Fig. HG-312.6 (see also Furnaces) Common connections of two or more valves, requirements for.......................... HG-701.2 (see also Safety and safety relief valves) Compensation, limits in cylindrical shells .................................................... Fig. HG-320 Component parts requiring proof testing (see Tests) Cones, openings in ............................................ HG-321.2(b) thicknesses of...................................................HG-321.2(b) Conical portions of boilers, openings in..................HG-320.1 Connections, area of, for two or more safety valves .................................................... HG-701.2(a) attached to shells, drums, headers by welding (see Welded connections) blowoff ...........................................HG-705, HG-715(a)(b) bolted............................ HG-309, Fig. HG-309, HG-370.2, HC-310.1, HC-311, Fig. HC-311 bottom blowoff and/or bottom drain (see Connections, blowoff) brazed .................................................. HB-1306, HB-1307 common, for separate combustion controls .........................................HG-605, HG-613 for two or more safety relief valves, requirements of ..........................................HG-701.2 couplings, pipe, welded to brazed boilers ..................................................... HB-1306(b) discharge or drain piping .............HG-715, Table HG-715 elbows, to safety or safety relief valve discharge pipe ............................................HG-701.6 expanded..................................HG-320.3(c), HG-360.1, HG-360.2 external piping, flanged .................................HG-370.2 threaded ..........................HG-370.1, Table HG-370 feedwater ........................................................HG-705 flanged, for external piping ............................. HG-370.2 flared, for nonferrous assemblies ..................... HG-315.2 for tube ends........................... HG-360.1, HG-360.2 flow, of hot water boilers...............................HG-611(a) for altitude gages....................................HG-611(a), (c) for controls.......................HG-605, HG-605(c), HG-613 for pressure gages ............................. HG-605, HG-611 for steam gages .................................. HG-601-HG-604 for test gages ...................................HG-505, HC-402.1 fuel cutoff, to boilers .................................. HG-606(b) inlet, of safety valves ..................................... HG-701.2 nozzles (see Nozzles) of piping to boilers ....................... HG-370.1, HG-370.2, Table HG-370, HG-703.1, HG-703.2, HG-705, HG-707 outlet, for damper or feedwater regulator ................................................. HG-604 return pipe or piping..........HG-703.2, HG-705, HG-710, HG-710.2, HG-710.3, HC-325 saddle type fittings (see Fittings) saddle type pads, welded ............................... HW-731.5 Fig. HW-731(k) studded ........................................................ HG-320.3 supply pipe, for multiple boilers............. Figs. HG-703.1, HG-703.2; HG-710.3 for single hot water boilers........................ HG-710.2 for single steam boilers............................. HG-710.1 threaded, for external piping .............HG-370, HG-370.1, Table HG-370 for valves................................................ HG-701.3 size of............................................. HG-320.3(c)(l) to safety and safety relief valves..........HG-701, HG-705 to tapped openings ........................................ HG-370.1 water column ..................................... HG-604, HG-705 water equalizing pipe .. HG-606(c) water feeding devices ....................................HG-606(b) water gage glass ................................HG-603, HG-604, HG-705 water level control piping ...................HG-604, HG-605, HG-705 water treatment ................................................HG-705 welded........................ HW-730, HW-731.1, HW-731.5, Fig. HW-731 location and minimum size of .................. HW-731.1 maximum size of unreinforced........... HG-320.3(c)(2) Contraction, provision for (see Expansion and contraction) Contractor's responsibility (see Manufacturer's responsibility Control panel frame (control circuitry).......................HG-632 (see also Electric wiring) Controls, altitude gage, for hot water boilers ........... HG-611 246 jss* INDEX automatic low-water fuel cutoff HG-606 combustion, for steam boilers and multiple boiler installations ......................................... HG-605 damper regulator .................................................... HG-602 electric.................................................... HG-631, HG-632 limit ................................................................. HG-633 feedwater regulator .................................................HG-604 flame safeguard ...................................................... HG-640 low-water fuel cutoff .............................................HG-614 mounted inside boiler jackets ................................ HG-621 operating, for automatically fired boilers .................... HG-605(a), (b); HG-613(a), (b) piping, water level.................................................. HG-604 pressure................................................................... HG-605 operating ..................................................... HG-605(b) pressure-actuated combustion .................... HG-605(a), (b) primary safety ........................................................HG-640 safety, for heat generating apparatus .....................HG-640 temperature-actuated combustion ............. HG-613(a), (b); HLW-801.1 Copper, fittings, assembled with copper or copper alloy tubes .......................... HG-315.2(b) parts, maximum allowable stress values . .7........................................Table HF-300.2 minimum thicknesses of ...................HF-301.2, Table HF-301.2, HB-1302 staybolts........................ HG-342.6 tubes, thicknesses of .................................... HG-315.2 Copper alloy (see Copper) Copper lined water heaters......................................HLW-200 Copper-nickel (see Copper) Cored sections of cast iron boilers stamping of....................... HG-530.2(a) Comer or tee joints (see Joints) Comer radius .................... HG-307.1, HG-307.4, HG-340.1 Comers and fillets, cast iron boilers...........................HC-320 Comer welds (see Welds) Corrugated furnaces................ HG-312.6 (see also Furnaces) Corrugated sections................ HG-312.7 (see also Furnaces) Counterboring of tube holes.................................... HG-360.1 Couplings, pipe (see Connections) Courses in steel plate boilers......... HG-320.2(c), HW-701.1 Cover plates, minimum thicknesses of (see Covers) Covers ......... HG-307.1, HG-307.2(b), HG-307.3, HG-307.4, Fig. HG-307, HG-309, Fig. HG-309 Crimping.......................................... HG-307.4, HB-1305(b) Critical areas, pressure parts .................................. HG-501.5 Crown radius ........................HG-305.3, HG-305.6, HG-309 Crown sheets .....................................HW-712.1, HW-712.2 external pressure ................................................. HG-312.7 Curves, plotted during displacement pressure measurement tests ........... HG-502.2 (see also Tests) plotted during strain pressure measurement tests ............................HG-502.1(c) (see also Tests) Cutoff, automatic low-water fuel...............HG-606, HG-614 Cutting, flame, for test specimens.......................HG-501.6(b) of base metal .........................................................HW-801 oxygen, of text specimens ......... HG-501.6(a), HW-500(a) thermal, of plates..................................HW-500, HW-801 Cylindrical parts under external pressure...................HG-312 furnaces.......................... HG-312.1-HG-312.3, HG-312.5, HG-312.6, Figs. HG-312.1, HG-312.2 (see also Furnaces) Cylindrical portions of boilers............. HG-320.1, HG-320.2 Cylindrical pressure parts, groups of openings in..................................................HG-350.1 Cylindrical shells, alignment tolerances of plate edges ....................................................HW-812 joined to stayed wrappers....................................HW-701.2 openings in..................................HG-320.2, HG-321.1(a) under internal pressure ........................................... HG-301 D Damper regulators in water piping ............................ HG-604 Data Reports, assemblers' ...................HG-533.2, HG-533.3 for field assembled wrought boilers .................... HG-532, HG-532.1, HG-532.2, Forms H-2, H-3 Forms, manufacturer's Data Reports for all types of boilers except watertube and cast iron.............................. Form H-2 manufacturer's Data Report for lined water heaters ...............Form HLW-6, HLW-601.1 manufacturer's Data Reports for watertube boilers ....................................... Form H-3 manufacturer's master, for cast iron boilers ..........................HC-403, HC-405, Form H-5 manufacturer's master Data Proof Test Report for lined water heaters............. Form HLW-8 manufacturer's master, for wrought boilers .......................................HG-520, HG-520.1, Forms H-2, H-3 manufacturer's master Data Reports for boilers constructed from cast iron............. Form H-5 manufacturer's Partial Data Reports...................Form H-4 manufacturer's Partial Data Report for lined water heaters Form HLW-7 partial ..........................HG-520.2, Form H-4, HLW-601.2 not required.................. HF-203, HF-203.1-HF-203.3 for safety and safety relief valve tests ................ HG-402.9 Deadweight tester, standard .................................. HG-505(c), (see also Tests) Defects, in brazed joints........................ HB-1402, HB-1501, HB-1503 in welds and welded joints.................................... HW-830 Definitions ....................................................... E-100, E-101 Deformation, radial, in threaded joints....................HG-307.4 tests ........................................................................ HG-503 Design pressure ..................................................... HG-300(a) Design stress criterion............................Footnotes to Tables HF-300.1, HF-300.2 Design stresses........... Article 3, Tables HF-300.1, HF-300.2 Destruction tests......................................................... HC-402 247 RS-003247 1/17/02 NUECES 1995 SECTION IV Deterioration, internal parts subject to ................... HG-200.2 Devices, automatic low-water fuel cutoff and/or water feeding..................................... HG-606 lifting, for safety and safety relief valve disks (see Disks) Diagonal lines, holes along ......... HG-350.4, Fig. HG-350.4 (see also Holes; Openings) Diagonal pitch, of adjacent openings ................... HG-350.1 (see also Holes; Openings) Diagonal stays, area required of ............................HG-343.1 dimensions of..................................HG-343, Fig. HG-343 for segments of tubesheets...................................HG-343.2 welding of............................................................HW-710.4 Dials, graduated for gages (see Gages) Die formed nonstandard pressure parts .................. HF-203.2 Die formed standard pressure parts.......................... HF-203.1 Die forming process ..............................HF-203.1, HF-203.2 Dip brazing........................................... HB-1200, HB-1202.2 Discharge capacities, safety and safety relief valves......................................... HG-402 discharge in Btu (safety relief valves ................................................ Table HG-715 identifying markings ...........................................HG-402.1 tests, pressure and relieving capacity ................. HG-402.3, HG-402.5 coefficient method ....................................HG-402.3(a) curve method............................................. HG-402.3(b) fluid medium for .......................................... HG-402.7 pressures at which conducted........................HG-402.4 three-valve method.................................... HG-402.3(c) where and by whom conducted ....................HG-402.8 Discharge piping, blowoff ......................................... HG-715 safety and safety relief valves, arrangement to prevent scalding of attendants ............. HG-701.6(b), HLW-801.7 draining of.................................................HG-701.6(b) elbows, location of.................................... HG-701.6(a) internal cross-sectional area of................. HG-701.6(a) shutoff valves in............................................ HG-701.5 size and arrangement of .......................... HG-701.6(b) Dished heads (see Heads) Disks, safety and safety relief valve lifting devices for, of corrosion resistant Displacement measurement tests of pressure parts ..............................................HG-502.2 Dissimilar metals, brazing of....................................HB-1101 Distortion .................................................................. HW-813 Doors, access ....................................HG-330.1(b), HG-330.5 Double-welded butt joints (see Welded joints) Double-welded lap joints (see Welded joints) Drain cocks................................................................. HG-715 Drain connections ......................................................HG-715 Draining of single hot water heatingboilers............ HG-710.2 Drain pipe connections....... HG-606(c), HG-715, HLW-810 Drains, open gravity, in safety valves .................. HG-400.1 Drain valves, in bottom blowoff pipe connections in boilers..................................... HG-715, HLW-810 in water column piping.......................................HG-604(a) Drilled holes in furnace sheets ............................... HG-312.6 Drilled telltale holes in solid staybolts....................HG-341.1 Dr./led tube holes ...................................................... HG-360 Drilling and facing of flanges ............... HG-309, HC-312.1, Fig. HC-311 (see also Flanges) Drillings, chemical composition ................................ HC-202 Drums, circular or noncircular plates welded to inside of .....................................HG-307.4 connections to, welded ..................................Fig. HW-731 fusion welded boiler........................ HG-307.4, HW-701.1 Ductility of material submitted for Code approval ........................................................... A-103 Duplicate pressure parts, hydrostatic tests of................................................................... HG-504 Dye penetrant inspection of brazed joints ..........HB-1503(c) E Edges, of tube holes ......................................HG-360.1(b) of plates offset from each other ........................ HW-812 Efficiencies, joint.................. HG-301, HG-305.1, HW-702 brazed ........................................................... HB-1301 welded............................................................ HW-702 Efficiency, ligament ........... HG-301, HG-350.1-HG-350.4 Efficiency factors of brazed joints in design of boilers ................ HB-1301, HB-1304, HB-1503(a) Elbows, in safety or safety relief valve discharge pipes...................................HG-701.6(a) Electrical code compliance............. HG-631, HG-632(a)(l), HG-640, HLW-704.1 Electrically heated boilers ...............HG-101.2, HG-640(a) Electric resistance brazing process .......................HB-1200, HB-1202.2 Electric resistance welded pipe and tubes......................................Table HF-300.1 Electric wiring, field or factory mounted, circuitry for...............;........... HG-632, HLW-704 compliance with National Electric Code and/or local codes............... HG-631, HLW-704.1 for controls, heat generating apparatus, and other boiler appurtenances ..................HG-631, HLW-703 limit controls .................................. HG-633, HLW-702 shutdown switches and circuit breakers............... HG-634 Elements, thermal, for pressure-temperature relief valves .............................................HG-405 Ellipsoidal formed heads (see Heads) Elliptical flat unstayed heads, covers, and blind flanges ..................... .. HG-307.3 Elliptical manholes (see Manholes) Elongation in material submitted for Code approval .................... ___A-101(a) Ends, of firetubes in contact with primary furnace gases .......................... HG-360.2(a) 248 RS-009248 1/17/02 NUECES INDEX of firctubes not in contact with primary furnace gases ..........................................HG-360.2(b) of nipples ............................................................HG-606(b) of plates, forming .................................................. HW-800 of staybolts, fitted with nuts ............................... HG-341.3 of steel stays, upset for threading........................HG-341.2 of through-stays with washers............................ HG-340.2, Fig. HG-340.2 of tubes, flared to fit tube holes ..........................HG-360.1 Examination of cast iron boilers ................................HC-510 Examination, visual, of brazed joints .....................HB-1301, HB-1304, HB-1503 Examples of methods, of calculating a welded ring reinforced furnace for steam or hot water boilers ..................................C-100, C-101 of checking safety and safety relief valve capacity by measuring minimum amount of fuel that can be burned .................. B-101 of computation of openings in boiler shells ................................D-100, Fig. D-100, D-101 Exchanges, heat, safety valve requirements for ............................................................. HG-400.3 Expanded connections................................... HG-320.3(c)(l) Expanding of tube ends ..............HG-360.1(a), HG-360.2(a) Expansion, thermal, in hot water systems ....................................... HG-709, HG-709.2 Expansion and contraction, in piping connected to boilers..............................HG-703.1, HLW-809.2, Figs. HG-703.1, HG-703.2, HLW-809, HLW-809.1 Expansion tanks.......................................HG-709, HLW-809 capacity of closed ...............HG-709.3, Tables HG-709.1, HG-709.2 closed ..................................................................HG-709.3 draining provisions ..............................................HG-709.2 open, overflow for............................................... HG-709.1 External piping connections....................................... HG-370 flanged ................................................................ HG-370.2 threaded................................................................ HG-370.1 External pressure, crown sheets............................... HG-312.8 materials for,submitted for Code approval........... A-101(b) semicircular furnaces ......... HG-312.8 (see also Pressure) External supports.....................................HG-200.7, HF-202 External type oil heater...............................................HG-707 F F values of, in calculating required reinforcement .......................................Fig. HG-321 Fabrication of boilers and boiler parts by brazing.................................................... HB-1000 by welding ............................................................ HW-400 Facings and drillings of flanges, cast iron, conforming to American National Standards..................................................... HC-311.1 steel, conforming to American National Standards....................................................HG-309.1 Fee, for use of Code Symbol............................ HG-402.2, HG-540.2(b) Feedwater, connections.......................... HG-606, HG-705 devices ........................................................... HG-606 introduced directly to boiler through independent connections.................. Fig. HG-703.1 (Note) introduced through return piping or through independent connections............................ HG-705 regulators ........................................................ HG-604 Ferrous materials, maximum allowable stresses ........................ Tables HF-300.1, HC-300 specifications for....................Tables HF-300.1, HC-300 Field assembled boilers and boiler parts inspection, stamping and Data Reports ............HG-532.1, HG-532.3, HG-533.1, HG-533.2, HG-533.3, HG-533.6 inspection and certification of........ HG-533.3, HG-533.6 Filler metals, for brazing, application of ............... HB-1304 control of, in repair of brazed joints...................HB-1402 defects in................................................. HG-1503 distribution of, by capillary attraction.......... HB-1305 face feeding of, in brazed joints...............HB-1304(a) in construction of brazed boilers, Code requirements of ...................................... HB-1103 preplacement of .................................. HB-1304(b) qualification of ......................................... HB-1303 service temperature of................................HB-1303 strength of................................................ HB-1300 for welding (see Weld metal) Fillets, and comers, cast iron............................... HC-320 and transition section ........................................HC-320 rough, in brazed joints .................................... HB-1503 Fillet-welded lap joints (see Welded joints) Fillet welds (see Welded joints. Welds) Finish of material submitted for Code approval ................................................A-105(d) Fireboxes, pitch of staybolts ....................... Fig. HG-340.1 Firebox type boilers........................................... HG-330.4 locomotive ................................................... HG-530.2 Fire doors ................... HG-330.5(b) Firetube boilers, location of manholes ................. HG-330.2 use of ferrous and nonferrous tubes in............. HG-315.1, HG-315.2 Firetubes, thicknesses of....................HG-315.1, HG-315.2, Table HG-315 Firetube vertical boilers, handholes and washout plugs in ..................................HG-330.4 Fittings, attached by brazed lap joints .............. HB-1307(a) couplings, pipe, welded, in brazed boilers ..............................................HB-1306(b) crosses.........................................................HG-604(a) dimensions ........... HG-370.2, HG-602-HG-606, HG-611, HG-701.2, HW-731, Fig. HW-731, HB-1306, HC-320, HC-325 elbows on safety and safety relief discharge pipe ....................................... HG-701.6(a) 249 R8-003249 1/17/02 NUECES 1995 SECTION IV external piping connections, flanged and threaded................................................... HG-370 flanged external piping connections ................. HG-370.2 for hot water boilers ............................ HG-610-HG-615 for steam heating boilers ......................HG-601-HG-607 inside boiler jackets............................HG-620, HG-621 internal threads............................................ HLW-431.5 in water piping connections to boilers............. HG-604(a) material of ....................... HG-200.1, HG-201, HG-315, HF-202, HF-203. l-HF-203.3, Table HC-300 nipples, for safety valve mountings ................. HG-701.1 reaming of............................................. HG-606(b) nonferrous, assembled with tubes.....................HG-315.2 tees and Y's between boilers and water glasses ...........................................HG-606 nozzles, cast, forged, rolled, or die formed.................................................. HF-203.1 cast iron, cast integrally............. HC-315(b), HC-320 strength of, and added material ................. HG-327.1 welded, abutting boiler well ......................HW-731.2 attached by arc or gas welding .............. HW-730.1, HW-731.1, Fig. HW-731 attachment welds for, location and size ...................................................HW-731.1 attachment welds for, stress values of............................HG-327.1, HW-730.2 inserted, with added reinforcement......... HW-731.4, HLW-431.3 inserted, without reinforcement.............. HW-731.3, HLW-431.2 material requirements ............................. HG-203.3 some acceptable types of .................. Fig. HW-731 with integral reinforcement .................. HW-731.5, HLW-431.2 with bolting flanges or integral flanges to be brazed ....................................... HB-1307(b) saddle type, for outwardly flanged openings in brazed vessel wall.......................... HB-1307(a) steel ............................................................ HF-203.1 threaded plugs in bottom of corrugated furnace.............................. HG-312.6(c) valved, to connect water glasses to steam boiler water columns................................. HG-602 washout plugs, dimensions and locations of.......................... HG-330.1, HG-330.4, HC-325 water glasses, attached directly to boiler....................................... HG-603, HG-606 welded, internally threaded .......HW-731.6, Fig. HW-731 material requirements.................................HF-203.3 Fit-up and welding of stays ............................... HW-710.3 Flange, bolted, connections ................................ HG-370.2 Flanged heads............................. Fig. HG-307, HG-345.2, HW-711.1 Flanged-in manhole openings ......................... HG-323.3(a) gasket bearings surface................................... HG-323.5 in heads in horizontal firetube boilers .......... HG-345.1(d) Flanged-in openings in formed heads......................HG-323 Flanged openings, connected to safety and safety relief valves........................... HG-701.1 Flanged plates, screwed over end of shell, pipe, or header, thickness of .........................HG-307.4, Fig. HG-307 Flange rings ........................................................ HF-202 for spherically dished covers (bolted heads)........ HG-309 Flanges, blind, thickness of ............... HG-307.2-HG-307.4; Figs. HG-307(j), (k) cast integrally with cast iron boilers.................. HC-315, HC-320 in brazed connections to boilers .................. HB-1307(b) integral ........................ HG-309, Fig. HG-309, HC-310, HC-315, HC-320 welded......................................................... HF-203.1 Flanging, outward, of vessel walls ........................HB-1307 Flared connections............................................. HG-315.2 Flared rings...............................HG-312.4, Fig. HG-312.3 Flaring of firetubes ........................................... HG-360.2 Flash welding process...................................... HW-600(b) Flat heads {see Heads) flat plates, edges of stayed, flanged .................HG-340.5(c) staybolts, for....................................HG-341, HG-342.6 with stays ..................................................... HG-340.1 Flat spots on formed heads ................................ HG-305.9 Flat surfaces, on dished heads............................. HG-305.9 . on formed or flat heads, permissible diameters of .......................................... HG-305.9 on stayed formed heads ..................................HG-305.5 to be stayed .......................... HG-340.1, Fig. HG-340.1 welded joints in, between two rows of stays ................................................ HG-340.5 Float chambers.................................................HG-606(a) Flow, connections on hot water boilers ............. HG-611(a) of brazing filler metal into or across joints ................... HB-1304 steam, actual, formula for coefficient of discharge ...................................... HG-402.3(a) steam, theoretical, formula for coefficient of discharge ...................................... HG-402.3(a) Flowmeter, steam............................................... HG-402.7 Flues, as stays of flanged-in openings ............. HG-323.3(a) circular, in water heaters ............................. HLW-307.1 in horizontal tubular flue type boilers, stamping of....................................HG-530.2(a)(l) Fluid medium, for capacity tests of safety relief valves .......................................... HG-402.7 Fluid relief columns, in hot water heating systems ................................................... HG-709 Fluing operation.................................. HG-305.1 (Note 1) Fluorocarbon polymer lined water heaters............ HLW-200 Fluxes and atmospheres ......................................HB-1103 residue, removal of..................... HB-1401, HB-1503(a) Forced hot water systems........... HG-709, Table HG-709.2 Forging materials..................................... Table HF-300.1 250 RS-0032S0 1/17/02 NUECES INDEX Forgings, carbon steel, specifications and Tables HF-300.1, HF-301.1 material properties.........................Table HF-300.1 nonferrous ............HF-300, HF-301.2, nonstandard pressure parts............................... HF-203.2 Tables HF-300.2, HF-301.2 standard pressure pa ^s .................................... HF-203.1 Morrison, corrugated type ...............................HG-312.6 Formed heads (see Hoads) plain circular type, requirements for..................HG-312.1 Forming, die, of non^mdard pressure flared-end assembly of...........................HG-312.1(d) parts.............................................................. HF-203.2 thickness of wall and procedure for of standard pressure parts .......................... HF-203.1 determining..................... HG-312.1(d), HG-312.2, fabrication practice, on material submitted for Figs. HG-312.1, HG-312.2 Code approval ...........................................A-103 Purves, corrugated type .................................HG-312.6 Forms, Data Report, manufacturer's, for all ribbed type, thickness, calculation of...........HG-312.6(c) types of boilers, except hot watertube ring reinforced type................ HG-312.4, Fig. HG-312.3 and cast iron......................................... Form H-2 design temperature................................ HG-312.4(f) for lined water heaters.....................................FormHLW-6 examples of methods of calculating for watertube boilers ............................... Form H-3 welded............................................ C-100, C-101 master, for cast iron boilers.............................Form H-5 replacement of ................ HG-312.4, Fig. HG-312.3 partial ......................................................... Form H-4 stiffening rings, requirements for............... HG-312.4, for lined water heaters.................................... FormHLW-7 HG-312.5, Figs. HG-312.1, HG-312.2 proof test report for lined water tubes, attached to tubesheets ............................. HW-713 heaters........................................................ FormHLW-8 wall thicknesses, corrugated or ribbed (see also Data Reports) types ............................................... HG-312.6(c) recommended for recording brazing procedures-.............................................. HB-1201 Fox furnaces, corrugated type .............................HG-312.6 Fracture, brittle, of material submitted for Code plain types.......HG-312.1, Figs. HG-312.1, HG-312.3 procedure for determining..........................HG-312.3 ring reinforced types ..................... HG-312.4(a), (h) Furnace sheets ...............................HW-712.1, HW-712.2 Fuses, time delay, in control circuitry ............ HG-632(a)(3) approval .................. A-103 Fusion of base metal............................................HW-701 Frames, for reinforced openings ..................HF-202, Tables Fusion welding (see Welding) HF-300.1, HF-300.2 Fuel, burning of........................................... B-100-B-102 Fuel burning equipment ............. HG-330.5(b), HG-400.1(e), G HG-400.2(f) Fuel cutoffs, automatic low-water ......................HG-604(a), HG-606, HG-614 high-limit temperature actuated .......................... HG-613 Fuels, heats of combustion of ..................................B-102 Furnace brazing ................................................. HB-1200 Furnaces, access doors ................... HG-330, HG-330.1(c), HG-330.5 access openings, fire doors ............................ HG-330.5 inspection............................................ HG-330.4(b) attachments.................. HG-312.4, HW-712.1, HW-712.2 Code stamping of ........................ HG-530.1, HG-530.2 combination type, for external pressure............ HG-312.7 corrugated type ..................... HG-312.6, Fig. HG-312.6 drilled holes in, to determine thickness ........... HG-312.6 fire door openings in.................................. HG-330.5(b) flared end assembly of plain type.....................HG-312.1 Fox, corrugated type...................................... HG-312.6 horizontal cylindrical type, carbon steel charts for determining wall thicknesses Gage cocks, for pressure or altitude gages ........ HG-611(a) for steam gages ............................................HG-602(a) Gage connections............................................. HG-602(a) Gage piping ....................................................HG-602(a) Gage pressure, definition ..................................HG-300(b) Gage tubes and tubing ..................................... HG-602(a) Gages, altitude .................................................... HG-611 compound steam ..............................................HG-601 deadweight tester for................ HG-505(c), HC-402.1(c) master, calibrated.....................HG-505(c), HC-402.1(c) pressure or altitude, for hot water boilers ................ HG-611, HG-621, HG-705 steam.......................... .......................... HG-602 strain .......................... ....................HG-502.1(a) temperature.................. HG-612, HG-621, HG-705 test, deadweight tester for .. HG-505(c), HC-402.1(c) indicating.............. ..........HG-505, HC-402.1 master................... .. HG-505(c), HC-402.1(c) recording, for larger vessels and pressure parts ..................HG-505(a), HC-402.1 (a) of ...............................Figs. HG-312.1, HG-312.2 inspection openings for, in scotch type boilers....................................... HG-330.4(b) strain..................................................... HG-502.1 water gage glasses for electric boilers ................................. HG-603(c)(e) Leeds suspension bulb, corrugated type........... HG-312.6 resistance heating .............................. HG-603(d) materials ...............................HG-201, HF-201, HF-203 submerged electrode............................HG-603(c) ferrous ..................................... HF-300, HF-301.1, for steam boilers ..................................HG-603(a) 251 RS-003261 1/17102 NUECES 1995 SECTION IV fittings ..........HG-603(a), HG-604(a), HG-606(b) lowest visible part of ..........................HG-603(b) material of ........................................ HG-603(b) piping for..........HG-604(a), HG-606(b), HG-705 water gages, mounted inside boiler jackets .....................................................HG-621 (see alsoSteam gages; Test gages; Water gage glasses) Galvanized water heaters ................................... HLW-200 Gases, primary furnace, firetubes in contact with .................................................... HG-360.2 furnaces or crown sheets in contact with..........HW-712.2 shells in contact with ..................HW-711.1, HW-711.2 Gas, natural, fired boilers......................................HG-640 Gaskets, for manholes, bearing surfaces .............. HG-323.5 thicknesses of............................................ HG-330.3(d) full face, for bolting flanges ..........HG-309.1, HC-311.1 for circular and noncircular covers .............HG-307.4 moment arms of............................................. HG-307.1 rings, for bolting flanges..........HG-309.1, HC-311.1 tightness of ......................................... HG-307.2(b) Gas tungsten arc welding..................................... HW-600 Gas welding ....................................................... HW-600 Glands, for plug cocks ...................................... HG-710.4 Glass-lined water heaters ................................... HLW-200 Gravity drains, open, in safety valve casings.............................................. HG-400.1(a) Gravity hot water systems, expansion tank capacities ............................Table HG-709.1 Gravity return steam heating systems.................. HG-703.2, Fig. HG-703.1 Grinding, of base metal before welding.......HLW-801(a)(d) of ends of tack welds after welding ...............HW-810(c) Groove welds (see Welds) Ground conductors, in control circuitry .................. HG-632 Guards, for plugs of plug cocks ..........................HG-710.4 H H, authorized Code Symbol for stamping of both steam and water boilers.................. HG-530.2, Figs. HG-530.1-HG-530.3 Hand-fired boilers ......................................... HG-703.2(b) Handholes, in all boilers, for inspection................ HG-330.1 in boilers designed for steam service, for in bottom of shells, for inspection............HG-330.4(b) in front heads of scotch type boilers ............HG-330.4(b) in locomotive or firebox type boilers, location of ...................................... HG-330.4(a) in scotch and scotch marine boilers ................. HG-330.4 in vertical firetube or similar type boilers .............................................. HG-330.3(c) in size of....................................................HG-330.4(f) Handles, T- or lever .......................HG-602(a), HG-611(a) Hangers to support boilers ................ HG-725.1, HG-725.6 Headers .........................HG-301, HG-307.4, Fig. HG-307, HG-530.2, HG-604(b), HG-701.1, HW-731.2(b) Heads, area of, to be stayed.......................... HG-345.1(c), Fig. HG-345.1, HG-345.2, HG-345.3 blank (see Heads, flat) concave and convex ........ HG-305, HG-305.1, HG-305.8, HG-309.1, HW-715, HC-310.1, HC-310.2 cone (see Heads, conical) conical......................................................... HG-305.1 dished (see Covers) ellipsoidal (see Heads, formed) flanged ..................HG-307.4, Fig. HG-307, HG-345.2, Fig. HG-345.2, HW-711.1, HLW-411.2 flanged-in openings (see Heads, formed) flat, acceptable types of ...............HG-307, Fig. HG-307 area to be stayed in ..........HG-345.1, Fig. HG-345.1 circular..................................... HG-307.2, HG-325 noncircular.................................HG-307,3, HG-325 openings in ................................................ HG-325 reinforcement requirements...........................HG-325 unstayed....................................HG-307, HLW-305 flat spots on formed ......................................HG-305.9 formed, attachment by welding..........HW-712, HW-715 built up of several shapes ..........................HG-305.7 concave to pressure .................. HG-305, HG-309.1, HW-715, HC-310.1 convex to pressure ...... HG-306, HW-715, HC-310.2 dished (bolted) (see Covers) ellipsoidal .............HG-305.1, HG-305.2, HG-305.9, HG-323.1, HG-323.2, HW-715, HW-715(a), HW-715(b), HLW-305.2 flanged-in openings ....................HG-323, HG-345.2 hemispherical ........ HG-305.1, HG-305.4, HG-305.9, HG-323.1, HG-323.2, HW-715, HW-715(c), HW-812(b), HLW-305.5, HLW-306.2 manholes in............................................ HG-323.2 openings in ................... HG-320, HG-321, HC-315 . reinforcement for,...............HG-320.3(a), HG-321 pressure, maximum allowable working............................... HG-305.2-HG-305.4 skirts, length of........................ HG-305.8, HW-715 stayed as flat surfaces ....................HG-305, HG-345 staying of............................................... HG-305.5,HG-345 torispherical........... HG-305.1, HG-305.3, HG-305.5, HG-305.6, HG-305.9, HG-323.1, HG-323.2, HG-345, HW-715(a), HW-715(b), HLW-305.3 unstayed........... HG-305.6, HLW-305.4, HLW-306.1 integral ................... HG-307.4, Fig. HG-307, HC-310.1 noncircular ...............................HG-307.4, Fig. HG-307 nonstandard pressure parts..............................HF-203.2 openings in (see Heads, formed) segments of areas to be stayed ...............HG-345.2, Fig. HG-345.2, HG-345.3 252 RS4032S2 1/17/02 NUECES INDEX skirts, length of (.see Heads, formed) stamping of................................................HG-530.2(a) (see also Boilers, stamping) staying of (see Heads, formed) thickness of .................. HG-305, HG-307, Fig. HG-307, HG-309, HF-301.1, HF-301.2, Tables HF-301.1, HF-301.2, HW-703, HB-1302, HC-310, HC-311 unflanged ..............................HG-345.1, Fig. HG-345.1, HG-345.3, HW-711.2 unstayed ....................HG-305.6, HG-307, Fig. HG-307, HG-345.1(b) Head-to-shell attachments................................... HLW-415 Heat, direct radiant, onstaybolt nuts .....................HG-341.3 Heaters, oil .......................................................... HG-707 Heat exchangers, safety and safety relief valves .................................................. HG-400.3 Heat generating apparatus, field wiring for .................................HG-631, HG-634 oil and gas-fired, and electrically heated boilers, safety equipment for..................HG-640(a) symbol of certifying organization affixed to ......................... HG-640(b), HLW-602.3 water heaters ..............................................HLW-602.3 Heating, space .............................................. HG-400.3(b) Heating boilers.......................................HG-100, HC-100 Heating surfaces.................. I...............................HG-403 of boilers, for determining safety valve capacities...............................................HG-400.1 Heating systems, hot water ...................................HG-709 closed ......................................... HG-709.2, HG-709.3 forced ............................................... Table HG-709.2 gravity.......................... ............Table HG-709.1 open expansion tank....... ...................... HG-709.1 steam............................ ...................... HG-703.2 Heating values of fuel........ HG-512(b), B-100, B-102 Heat or heat treatment lots .. HF-205.2(b)(c), HF-205.3 Heats of combustion of fuels ............................B-102 Heat treatment of material submitted for Code approval ........... A-101, A-103, A-105(d) High-limit pressure-actuated combustion controls (see Controls) Holes, drain, in safety valves........................ HG-400.1 (a) drilled bolt, in flanged connections................ HG-309.1, HG-370.2, HC-311.1 drilled in corrugated or ribbed furnaces....................................HG-312.6(c) drilled or punched tube................................... HG-360.1 elliptical (Footnote 5) .....................................HG-320.1 flanged, in boilers, for direct attachment of safety or safety relief valves................HG-701.1 outwardly.................................... HB-1307(a) for nozzles and nozzle fittings........................HW-731.3, HB-1306(a), HB-1307(b) for pipe connections in brazed boilers ..........HB-1306(b) handholes (see Handholes) in welded joints ...............................................HW-720 ligament efficiency of........................................HG-350 multiple, reinforcement for ............................... HG-328 obround (Footnote 6) ..................................... HG-320.1 punched tube ................................................ HG-360.1 reinforcement of (see Reinforcements) screw or threaded (see Holes, threaded) shape of, in boilers or formed heads .................. HG-320 spacing of...............HG-350.4, Fig. HG-350. l-HG-350.3 strength and design of finished....................... HG-320.3 tapped, for attachment of safety valves ........... HG-701.1 for attachment of water gage glasses........ HG-606(b) for threaded connections to boilers ............HG-370.1 telltale .........................................HG-341.1, HW-730.3 threaded (screwed) ..................HG-305.5(c), HG-340.2, HG-341.1, HG-370, HG-370.1, HG-701.3 tube (see Tube holes) with removable covers in boiler jackets............HG-530.2 (see also Openings) Horizontal firetube boilers ........... HG-343.2, HG-345.1(c), HG-604(b) Horizontal return tubular boilers..........HG-330.2, HG-725, HW-711.1 Horizontal tubular flue type boilers ....................HG-530.2 Hot leg, in control circuitry ...........................HG-632(b)(2) Hot water boilers (see Heating boilers; Hot water systems) Hot water heaters, installation requirements of .........................HG-700 (see also Heating boilers; Hot water systems) Hot water supply, heated by high temperature water ..............................HG-400.3(b) heated indirectly by steam coils or pipes ................................................HG-400.3(a) Hot water supply boilers, outside Code jurisdiction ........................................... HG-101.2 Hot water systems, closed type expansion tanks ................................................... HG-709.2 minimum capacity............. HG-709.3, Tables HG-709.1, HG-709.2 expansion, thermal, provisions for ..................... HG-709 fluid relief columns...........................................HG-709 hot water tanks................................................. HG-709 open type expansion tanks.............................. HG-709.1 (see also Heating boilers) Hydrostatic tests, bursting, for cast iron boilers or boiler parts ............. HG-501.1, HC-400, HC-401, HC-402 rating of boilers based on ............................ HC-404 test gages for........................................... HC-402.1 for wrought boilers ...............HG-501.1, HG-502.3 witnessing, recording, and certifying..............HC-403 of all completed boilers, welded or brazed ..........HG-510 of all completed cast iron boilers ....................... HC-410 of all completed water heaters......................... HLW-505 proof, of wrought boiler parts ...............HG-501-HG-506 test gages for.......................... HG-505, HLW-502.2 253 RS-003263 1/17/02 NUECES 1995 SECTION IV (see also Gages) types of .................................................HG-501.1 I Identification markings, arrangement of..........HG-530, HG-531, HG-533.5, Figs. HG-530.2, HG-530.3, Forms H-2-H-5 for material.......................................................HF-210 for nonidentified material............. HG-200.7, HF-202(b), HF-203.1(b), HF-205.3 for nonstandard pressure parts...................... HF-203.3(a) for safety and safety relief valves.....................HG-402.1 for shutdown switches and circuit breakers................................................... HG-634 for standard pressure parts...............HF-203.1, HF-203.3 for stop valves ...............................................HG-710.5 for welded standard pressure parts ................HF-203.3(a) Identifying marks, for brazers or brazing operators ............................................HB-1202.4 for welders or welding operators ...................... HW-613 Increments of pressure applied in hydrostatic proof tests........... HG-501.4, HG-502.1, HG-502.2, HG-502.4 Indicating gages, attached to test pressure parts .......................... HG-505, HC-402.1 (see also Gages; Test gages) Indicating pressure gages (see Gages) Indoor overflow of open expansion tank systems..........................................HG-709.1 Induction brazing process..................HB-1200, HB-1202.2 Inertia, moment of, for circumferential stiffening...............................................HG-312.5 Inlet area of safety valves ............................. HG-701.2(b) Inlet connections for safety valves .................. HG-701.2(a) Inlet openings, of safety valves....................... HG-400.1(c) of safety-relief valves ................................. HG-400.2(d) Inlet valves, in water feeding devices..................HG-606(a) Input, heat, of boilers ...............HG-101.2(a), HG-400.2(d) Insertion of stays in holes to be welded ............................................ HW-710.1 {see also Stays; Welded stays) Inside nuts, for attachment of through-stays to ................................. HG-305.5(c) Inspection, dye penetrant .................................... HB-1503 not required for standard pressure parts ........................ HF-203.1, HF-203.3 of boiler parts...................................................HG-515 of boiler parts requiring Partial Data Reports..........................................HG-520.2 of brazing procedures .......................HB-1500, HB-1501 of cast iron boilers or boiler parts..........HC-410, HC-501 of critical openings .................................... HG-320.2(c) of field assembled boilers and parts..................................... HG-533, HG-533.3, HG-533.4, HG-533.6 of hot water heaters........................................HLW-600 of prefabricated or preformed pressure parts........................................................ HF-203 of proof tests ...................................................HG-506 of welded boilers or other parts during fabrication............................................... HW-900 of welder and welding operator performance qualifications .........................................HW-911 of welding procedure qualifications ................... HW-910 openings ........................ HG-330, HG-330.1, HG-330.4, HG-705, HG-720 visual........... HW-731.2, HW-731.3, HB-1304, HB-1503 {see also Visual examination) Inspectors, authorized .......................HG-515.2, HG-515.3, HG-533.3, HG-533.4, HG-533.6, HLW-600.1 Inspector's duties.......................... HG-515.4, HLW-600.3 Inspector's responsibilities ................ HG-501.5, HG-515.3, HG-520.2, HG-533.1, HG-532.2, HG-532.3, HG-533.3, HG-533.4, HG-533.6, HF-203.1, HF-205.1-HF-205.3, HF-210, HW-900, HW-910, HW-911, HB-1202.4, HB-1501, HB-1502 Installation requirements, boilers............................ HG-700 bottom blowoff or drain valves.......................... HG-715, Table HG-715 feedwater connections....................................... HG-705 hot water heaters ..............................HG-700, HLW-800 oil heaters........................................................HG-707 piping ............................. HG-703 safety and safety relief valves........ HG-701, HLW-800.1 settings ........................................................... HG-720 stop valves ...................................................... HG-710 supports........................................................... HG-725 Instruments, for hot water boilers...........................HG-610 pressure or altitude gages...................................HG-611 {see also Gages) thermometers ...................................................HG-612 for steam boilers, steam gages............................ HG-601 {see also Gages) water gage glasses HG-602 {see also Water gage glasses) Insulating rings..................................................HG-200.7 Integral cast iron bolted flanges ..........................HC-310.1 Integral flanges on nozzle fittings..................... HB-1307(b) Integral forged circular and noncircular heads ....................................................HG-307.4 Integral reinforcement, areas ...........................HG-327.2(2) nozzles with ................................. HG-327.1, HW-731.5 Interchange of qualifying tests...............................HW-612 Internal cross-sectional areas of discharge pipes .................................................. HG-701.6 Internally fired boilers, furnace access doors for .......................................... HG-330.1(c) Internally threaded fittings, attached by welding ................................................HW-731.6 Internal parts, subject to deterioration ..................HG-200.2 Internal pipes, in boilers, connections to ............. HG-701.4 Internal pressure.................................. HG-301, HG-321.2, 254 R8-003264 1/17/02 NUECES INDEX HG-502. l-HG-502.4, HF-203 (see also Pressure) Internal volume, of cast iron boilers....................... HC-325 of vertical firetube boilers .......................... HG-330.4(c) Inwardly extending nozzles ............................ HG-326.4(c) Inwardly flanged heads or tubesheets.................. HW-711.1 Iron, and steel bodied valves.......................... HG-400.1(a) cast (see Cast iron) wrought (see Wrought iron) Isolation transformers ...........................................HG-632 J Jackets, boiler.....................................HG-530.4, HG-621 Jacks .............................................................HW-810(b) Joints, blind (see Joints, brazed) bolted, cast iron, circular .................. HC-310.1, HC-311, Fig. HC-311 circular and noncircular............ HG-307.2-HG-307.4, Fig. HG-307 flanged connections for external piping ___ HG-370.2 nozzle fittings .......................................HB-1307(b) spherically dished covers with flanges ......... HG-309, Fig. HG-309 brazed, applying filler metal to.........................HB-1304 cleaning of................................HB-1400-HB-1402 clearances .......................HB-1305, Table HB-1305 combination of dissimilar materials in .........HB-1101 connections ................................ HB-1307 defective....................HB-1402, HB-1501, HB-1503 dip brazing of...........................................HB-1200 efficiency factors of...................HB-1301, HB-1304 face-feeding of ..................................... HB-1304(a) filler metals for......................... HB-1102, HB-1304 fluxes and atmospheres for.........................HB-1103 flux residue removal from.......HB-1401, HB-1503(a) inspection...................................HB-1501-HB-1503 lap.................................HB-1202.1(b), HB-1300(b) materials for ..............................HB-1100-HB-1103 metals, base.............................. HB-1300, HB-1400 repair of................................... HB-1402, HB-1503 socket type........................................... HB-1304(a) strength of............................................... HB-1300 temperature, permissibleservice ..................HB-1303 visual examination of.................................HB-1503 butt welded, circumferential butt....................HW-701.1 HW-812, HLW-401.1 (see also Welded joints) double welded butt................ HW-701.1, HW-820.1, HLW-401.1 (see also Welded joints) electric resistance, carbon steel pipes and tubes..................................... Table HF-300.1 head-to-shell attachments ..........................HW-715 longitudinal ........ HW-701.1 (see also Welded joints) openings in ................................ HG-321, HW-720 steel pipes and tubes ...................... Table HF-300.1 wrought iron, pipes and tubes ..........Table HF-300.1 (see also Welded joints) comer, welded .......................HG-340.5, Fig. HG-340.3, HG-345.1, HW-701.3, Fig. HW-701.3, HLW-401.2 double full fillet lap welded.......................... HW-702(d) efficiencies (see Joints, brazed; Welded joints) fillet welded ............................HG-307.4, Fig. HG-307, HG-725.6, HW-701.2, HW-701.3, HW-710.4, HW-711.1, HW-712.1, HW-730.1, HW-730.2, HW-731.4-HW-731.7 full penetration welded.................. HG-312.4, HG-312.7, HW-701.3. Fig. HW-701.3, HW-711.2, HW-712.2, HW-731. l-HW-731.6, Fig. HW-731 fusion welded...............HG-307.4, HG-312.6, HG-725.6, HW-701.1 gasketed ....................................... HG-307.2 (footnote) groove welded ...........................HW-730.1, HW-730.2, HW-731.7, Fig. HW-731 lap welded .................................................. HW-701.2 longitudinal butt welded............... HG-312.6, HW-701.1, HW-800, HW-812, HLW-401.1 partial penetration welded ........... HW-731.3, HW-731.6, Fig. HW-731 single-bevel welded..................... HW-731.4, HW-731.5, Fig. HW-731 single full fillet welded.................................. HW-701.3 single-J welded .......................... HW-731.3, HW-731.4, HW-731.5, Fig. HW-731 socket type (see Joints, brazed) strain absorbing, in piping ..................... HG-703.1, Figs. HG-703.1, HG-703.2 swing.................. HG-703.1, Figs. HG-703.1, HG-703.2 tee .......................................... HW-701.3, HLW-401.2 threaded............... HG-307.4, Fig. HG-307, HG-320.3(c), HG-341. l-HG-341.3, HG-370.1, HG-701.3 welded, efficiencies (efficiency factors).............. HW-702 pipe connections, in brazed boilers ......... HB-1306(b) preparation................................................ HW-801 repair of defective . v. ........................ HW-830 requirements for ........... HW-700, HW-701, HW-820 single-welded butt (see Welded joints) single-welded lap (see Welded joints) weld metal, stress values of ......................HW-730.2 (see also Welded joints) Jurisdiction, outside of Code ................... HG-101.2 Knuckles radius K HG-305.6 L Lap joints, welded.......... Lap welded pipe and tubes ............. HW-701.2 (see also Joints, lap) ...... Table HF-300.1 255 R8-003266 1/17/02 NUECE8 1995 SECTION IV Leeds suspension bulb type furnaces ................... HG-312.6 Lever handles for cocks ..................... HG-602(a), HG-611 Licenses, patented materials..................................... A-104 Lifting levers on safety valves.............................HG-4Q2.1 Lift pressure of safety valves...........................HG-402.3(a) Ligaments and ligament efficiencies....................... HG-350 Limit controls, electrical.......................HG-633, HLW-702 Limits, Code service for boilers ............................ HG-101 of metal available for reinforcing ....................... HG-S26 of reinforcement for multiple openings ............ HG-328.1 Lined potable water heaters controls ........................................................ HLW-700 design of weldments ...................................... HLW-400 general material requirements ......................... HLW-200 inspection and stamping................................. HLW-600 installation requirements................................. HLW-800 pressure relieving devices .............................. HLW-300 Loading, plane of greatest ..................................HG-321.1 types of....................................................... HG-501(a) Loads, bolt ...................................................HG-307.2(b) carried by welds ....................................D-100, D-101 on hangers ....................................................HG-725.1 on stays..........HG-340, HG-340.4, HG-342.1, HG-342.2 radial membrane ..............................HG-309, HG-309.1 Locking arrangement, mechanical....................... HG-307.4, Fig. HG-307 Locomotive type boilers....................HG-330.4, HG-530.2 Longitudinal axis of boilers ................................ HG-350.4 Longitudinal center line of diagonal stays.................................................HW-710.4(c) Longitudinal joints (see Welded joints) Longitudinal pitch of openings ....................... HG-350.1(a) Low-alloy steel.........................................Table HF-300.1 Lowest permissible water level .........................HG-603(b), HG-614(b) Low-water fuel cutoff........... HG-604(a), HG-606, HG-614 Lugs.................................................. HG-725.6, HC-320 M Machining, for joint preparation ........................... HW-801 of test bars ...................................................... HC-402 Mains, steam and hot water boiler ..................... HG-703.1, Fig. HG-703.1 Manholes........................ HG-323.5, HG-330.1-HG-330.3, HG-345.1(g), HF-203.1 Manual application of brazing filler metal........ HB-1304(a) Manually operated shutdown switches .................... HG-634 Manual welding .................................................. HW-701 Manufacturer's, Data Report (see Manufacturer's, master Data Reports) design or type numbers ..............................HG-402.1(b) identification marks (marking) (see Identification markings; Markings; Stamping) master Data Reports .......................HG-520, HG-520.1, HG-532.1, HG-532.2, HG-533.2, HG-533.3, HC-403, Forms H-2-H-5 nameplates ....................................................HG-530.2 names .......................HG-402.1(a), HG-531, HG-533.4, HF-203.1, HF-203.2 Partial Data Reports ..................... HG-520.2, HF-203.1, Form H-4 reports on tests < f nonidentified materials .......................HF-205.3 (see also Tests) serial numbers, on all boilers....................... HG-530.1(a) on boiler parts and accessories.................HG-531 (a) stamping, of boiler ........ HG-530 (see also Identification symbols; Identification markings; Stamping) trademarks ................ HG-402.1(a), HF-203.1-HG-203.3 Manufacturer's (or contractor's) responsibilities for brazing .............................................HB-1001 certifying others' work...................................... HG-515 compliance with Code ...................................... HG-515 conducting qualifying tests................ HW-401, HB-1001 establishing fabrication procedures.................... HW-401, HB-1001 executing Data Reports....................HG-520, HG-532.1, HG-532.2, HG-533.2, HG-533.3, HC-403 inspecting and certifying ................................ HG-515.3 providing design details ................................... Preamble quality control ..................................................HC-501 recording test results........ HW-613, HB-1202.4, HC-403 submitting parts for inspection .......................... HW-900 testing safety and safety relief valves................ HG-402.3 welding ...........................................................HW-401 Markings, arrangement of....................................HG-530.2 transfer of................. HF-210 (see also Identification markings; Stamping) Master gages...............................HG-505(c), HC-402.1(c) Materials, acceptable for fusion welding ................ HW-500 approval of new.......................HG-200.3, A-100-A-105 bolting................................................. Table HF-300.1 chemical composition ........................................ HC-202 combination, of different specifications of, joined by welding .................................... HW-501 of dissimilar, joined by brazing................. HB-1101 duplicate parts of same ...................................... HG-504 ferrous, maximum allowable stress values ............................HF-300, Table HF-300.1 specifications .............HF-200, HF-201, Table HF-300.1 tensile strength......................................Table HF-300.1 tubes, minimum thickness of . ....................... HG-315.1, Table HG-315 for brazing ........................ ......................... HB-1100 for cast iron boilers............. ... HC-200, Table HC-300 for filler metals .................. ..........HW-500, HB-1102 for lined potable water heaters ........................ HLW-200 for welding........................ .......................... HW-500 general requirements........... HG-200, HF-200, HW-500, HB-1100, HC-200 identification ...............HF-210 maximum allowable stress values, cast iron .......................... HC-300, Table HC-300 ferrous ............................. HF-300, Table HF-300.1 256 RS-0032S6 1/17/02 NUECE8 INDEX nonferrous ...................... HF-300, Table HF-300.1, HB-1100 (see also Stress values) metallic enclosures, control circuitry ................. HG-632 metals (see Filler metals; Metals; Weld metal) nonferrous, nameplates.................. HG-530.1, HG-530.2 pipes and tubes....................HG-602(a), HG-604(a), HG-605(c), HG-611 plates ............................ HF-301.2, Table HF-301.2 specifications of ............................. Table HF-300.2 stress values, maximum allowable...............HF-300, Table HF-300.2 tensile strength ............................... Table HF-300.2 nonidentified (see Materials, not identified) nonstandard pressure parts...............................HF-203.2 not found in Section II ................................... HG-200.3 not fully identified............................................. HF-205 not identified by mill test reports ....................HG-200.7, HF-203.1, HF-203.2 of bars....................HF-202, Tables HF-300.1, HF-300.2 of rods.................. HG-202, Tables HF-300.1, HF-300.2 of shapes................ HF-202, Tables HF-300.1, HF-300.2 of small parts of unidentified........ HF-203.1(b), HW-502 of standard pressure parts............ HF-203.1 (a), HF-203.3 of stays and staybolts ........ HF-202(a), Tables HF-300.1, HF-300.2 of structural quality, for partsnot directly subjected to pressure................ HF-202(b) of weldable quality, for nonpressure parts....................................HG-200.7, HF-202(b) patented............................................................ A-104 plate, for pressure containing parts..............................HF-201, HF-203, HF-205, Tables HF-300.1, HF-300.2 prefabricated or preformedpressure parts ............. HF-203 specifications for.................... HF-200, HF-203, HF-205, Tables HF-300.1, HF-300.2; HW-500, HB-1100, HB-1102, HC-200 specific requirements for ................... HG-201, HF-201, HF-202, HF-203 subject to deterioration................................... HG-200.2 suitable for welding, cold bending, close coiling ..................................................HG-205.2 test bars................................ HC-205, HC-206, HC-207 tests, yield and tensile..................... HG-501.6, HC-203, HC-204, HC-208 thickness, exceeding specification limits ...........HG-200.6 gasket.................................................HG-330.3(d) minimum ........... HG-315, Table HG-315; HF-301.1, HF-301.2, Tables HF-301.1, HF-301.2; HW-703 transparent, for water gages................ HG-603(b) (Note) unidentified................ HG-200.3, HG-200.7, HF-202(b), HF-205, HF-205. l-HF-205.3 use, not limited by production methods............ HG-200.5 not limited by specification title................. HG-200.4 Maximum allowable stress values (see Stress values) Maximum allowable working pressures (see Working pressures) Maximum pitch of stays....................HG-340.1, HG-340.3 Maximum thicknesses of materials (see Materials) Mechanical locking arrangements........................ HG-307.4 Mechanical properties of materials...............A-101, A-103 Membrane loads.................................. HG-309, HC-311.1 Membrane stresses.................................. HG-501.5 (Note) Metals, base, preparation for welding.....................HW-801 filler, brazing ..................HB-1102, HB-1300, HB-1301, HB-1303-HB-1305, HB-1402, HB-1503 weld ......................................................HW-701.1 weld, as reinforcement ................................... HG-327.1 in butt joints ........... HW-701.1, HW-820, HW-820.1 specifications of ....................................... HW-500 stress values for .....................................HW-730.2 Methods, of calculating ring reinforced furnaces.......................................... C-100, C-101 of checking capacity of safety valves........ B-100, B-101, B-102 of computing openings in shells ...............D-100, D-101 of determining capacity of safety valves ..........HG-402.3 of determining net area, irregular segments of heads..........................................Fig. HG-345.2 Mill test reports .................................. HG-200.7, HF-203 Modular steam heating boilers ............................... HG-607 Moment, arm .................................................. HG-307.1 edge............................................. HG-307.2, HG-307.3 of inertia..................................HG-312.3(i), HG-312.5 total ............................. HG-309, HC-311, Fig. HC-311 Morison type furnaces.......................................HG-312.6 Mounting, safety and safety relief valves HG-701 (see also Safety and safety relief valves) Multiple boiler installation............. HG-605(b), HG-613(b), HG-710.3 Multiple duplicate construction.......................... HG-515.3 Multiple openings, reinforcement for..................... HG-328 .N Nameplates, manufacturer's............................... HG-402.1, HG-530.2, HB-1510 (see also Identification markings) Names, manufacturer's (see Identification markings) Necks, extended integrally as reinforcement........ HW-731.5 New materials, approval of........... HG-200.3, A-100-A-105 Nipples, short..................................... HG-606, HG-701.1 Nominal head thicknesses ................................... HW-715 Noncircular flat heads, covers and flanges Nonferrous fittings........................................... HG-606(b) Nonferrous materials (see Materials) Nonferrous tubes, assembled with fittings............ HG-315.2 Nonferrous tubes, thickness............................. HLW-307.2 Nonpressure parts, welded to pressure parts ..................................... HF-202, HW-610 Nonstandard pressure parts.................................. HF-203.2 257 RS-0032S7 1/17/02 NUECES 1995 SECTION IV Not fully identified materials (see Materials) Not identified materials (see Materials) Nozzles ........... HG-326.4(c), HG-237.1, HF-203, HW-730, HW-731, Fig. HW-731, HB-1307(b), HC-315(b), HC-320, HLW-431.2-HLW-431.6. D-100, D-101, Ftg. D-101 Numbers, manufacturer's, design or type ................................................ HG-402.1(b) material serial S............................................ HF-205.3 serial .................................. HG-530.1(a)(5), HG-530.2, Figs. HG-530.2, HG-530.3 of threads in threaded openings for staybolts of connections ..................... HG-341.1, HG-370.1 part manufacturer's serial...................................HG-531 specification ...................................................HF-205.3 Nuts, staybolts fitted with................................... HG-341.3 through-stays with...................................... HG-305.5(c) O Obround flat heads, covers and blind flanges.................................................. HG-307.3 Obround shaped openings .................HG-320.1, HG-327.2 Offset of plate edges at butt joints ........................ HW-812 OG rings, flared or welded ............................HG-312.4(g) Oil fired boilers ....................................... HG-640, B-101 Oil heaters............................. HG-707 Open expansion tanks........................................ HG-709.1 Opening test of pressure-temperature relief valves ..........................................HG-402.5 Openings and reinforcements................... HG-320-HG-328, HC-315, HLW-308 feedwater ........................................................HG-705 fire door ................................ HG-330.5 flanged, in boilers, for valve connections ......... HG-701.1 outwardly............................................. HB-1307(a) flanged-in .................. HG-323 (see also Heads, formed) for gravity drains........................................HG-400.1(a) for inlet boiler piping ................................. HG-400.2(a) for outlet connections ........................................HG-604 for outlet piping..........................................HG-400.1(f) for pipe connections ..................... HG-400.1, HG-400.2, HB-1306, HB-1307 frames for reinforced .................................... HF-202(a) handholes (see Handholes; Openings, inspection and access) in drain valves ..............................................HG-603(a) in furnace sheets ........................................... HG-312.6 in heads.......................... HG-320.1, HG-320.3, HG-321, HG-323, HG-325, HG-328.2(c), HG-330.4(b) in shells, examples of computation of ................................................. D-100, D-101 inspection and access..................................HG-330 multiple ................................ HG-350.1 -HG-350.4, Figs. HG-350. l-HG-350.4 reinforcement of circular and elliptical.......... HG-321 inspection and access ..................... HG-330, HG-330.5, HG-705, HG-720 in welds......................................... HW-720, HLW-420 larger than covered by rules ....................... HG-320.2(c) manholes (see Manholes) multiple.......................... HG-328, HG-350. l-HG-350.4 (see also Holes) nozzle ........................ HW-731, HW-731.2-HW-731.4, Fig. HW-731, HB-1306, HB-1307 parallel to shell axis ...................................... HG-350.2 reinforcement requirements for............HG-320, HG-321, HG-323, HG-325-HG-328, HLW-308 screwed (threaded) (see Openings, threaded) shape of....................................... HG-320.1, HG-327.2 size of...........................................................HG-320.2 spacing of........... HG-350. l-HG-350.4, Figs. HG-350.1- HG-350.4 (see also Holes) strength, and design of finished .......................HG-320.3 of welded................................................ HW-730.1 tapped .................. HG-370.1, Table HG-370, HG-400.1, HG-606, HW-701.1 threaded..........HG-320.3, HG-370, HG-370.1. HG-701.3 transverse to shell axis ....................................HG-350.3 unreinforced .................................HG-320.2, HG-320.3 vent, in open expansion tanks .......................... HG-709.1 washouts..................... HG-330.1(a), HG-330.4, HC-325 (see also Openings, inspection and access) (see also Heads; Holes; Reinforcements) Operation of boilers............. Preamble, HG-101, HG-300(c) ' ..................(see also Boilers, service) Operators, brazing, identifying symbols...............HB-1202.4 qualification of............HB-1001, HB-1202.2, HB-1202.3 Operators, welding, identifying symbols . HW-613 qualification of....................HW-401, HW-610-HW-612 Orifice sizes ..................................................HG-402.3(b) Outlet, connections ...............................................HG-604 piping ......................................... HG-400.1, HG-701.1 Outside-screw-and-yoke top valves.......................HG-710.4 Outside suspension type boiler setting .................................. HG-725.1-HG-725.3 Oxyacetylene welding process ............. HW-600(a)(b) (see also Welding) Oxygen cutting.................................................. HG-501.6 Oxyhydrogen welding process........................... HW-600(a) P P-numbers, for welding materials .......................... HW-500 Pad reinforced openings ..................... D-100, Fig. D-100 Pads, reinforcement............................................ HG-327.1 saddle type, as integral nozzle reinforcement........................................ HW-731.5 Pad-to-nozzle attachment weldmetal ................... HG-327.1 Partial Data Reports ............. HG-520.2, HF-203, HF-203.1 (see also Data Reports; Manufacturer's Data Reports) Pam, cast .........................................HG-203.1, HF-203.2 INDEX cylindrical, openings in........... .................... HG-350.1 under external pressure __ .......................HG-3I2 designed for external pressure . ....FF-203.1, HF-203.2 die formed ............................ __ HF-203.1, HF-203.2 duplicate, tests of................... .......................HG-504 forged .................................. __ HF-203.1, HF-203.2 internal, subject to deterioration .................... HG-200.2 material for (see Materials) nonpressure.......................... .................... HG-200.7 prefabricated or preformed----- ....................... HF-203 pressure, containing............... ....................... HF-201 nonstandard.................... .....................HF-203.2 standard ......................... ....HF-203.1, HF-203.2 rolled................................... ....HF-203.1, HF-203.2 small .................................. .. HF-203.1(b), HW-502 strength of, not computable __ ........................ Preamble subject to collapse................ ....................... HG-503 tests of (see Tests) welded, nonpressure ............. .. .HG-200.7, HF-202(b) standard pressure ........... ................... HF-203.3 Penetration, of brazing filler metal .....................HB-1301, HB-1304, HB-1503 welds, into base metal .......... ...... HW-701, HW-820 (see also Welded joints) Personnel, safety of.................. .HG-501.3, HG-701.6(b) Pinholes, in brazed joints__ ',.. ...... HB-1503 (see also Joints, brazed) in welded joints ....................... HW-830 (see also Holes; Welded joints) Pipe, piping and pipe connections, Admiralty .................... ........................HG-315.2 altitude gage......................... .......................... HG-611 blowoff............................... .......................... HG-715 brass .................................. ........................HG-315.2 brazed ................................. ..........HB-1306, HB-1307 coils.................................... ........ HG-400.3, HF-203.2 copper ................................. ........................HG-315.2 copper-nickel ....................... ........................HG-315.2 couplings............................. ................... HB-1306(b) discharge, pump.................... ..Figs. HG-703.1, HG-705 discharge, safety valve .......... .......................HG-701.6 drain .................................. .......................... HG-715 expansion and contraction ---- .......................HG-703.1, Figs. HG-703.1, HG-703.2 external ................... ... HG-370, Table HG-370 feedwater ............. ........... HG-604, HG-705 ferrous.................. HG-602, HG-604, HG-605 fittings.................. HG-603, HG-605, HG-606, HG-701, HG-703 flanged ................ ........................HG-370.2 low-water fuel cutoff .......................... HG-606 nonferrous............. ........................... HG-611 nozzles D-101, Fig. D-101 pressure gage .................................................. HG-611 return....................HG-703.2, Figs. HG-703.1, HG-703.2 safety and safety relief valve............................. HG-701 steam gage ......................................................HG-602 steel (see Steel) supply ....................HG-710, Figs. HG-703.1, HG-703.2 threads.................................. HG-370.1, Table HG-370 used as tubes .......................................HG-301 (Note) water column ...................................................HG-604 water gage glass ..............................................HG-603 waterlevel control ............................................ HG-604 wrought iron (see Iron) Pitch, of openings ........................... HG-350.1, HG-350.2 of stays and staybolts ..................... HG-340, HG-340.1, HG-340.3, HG-340.5, Fig. HG-340.1, Table HG-340 Plain sections, combination type furnaces ............ HG-312.7 Plastics, water absorption of ............................... Appendix I Plate, ends, forming of........................................ HW-800 for pressure containing parts .............................. HF-201 not fully identified.............................................HF-205 specifications ........... HF-201, Table HF-300.1, HF-300.2 Plates, alignment of edges ................... HW-810, HW-820 beveling (see Welding) connected by stays ................................... HG-340.1(a) cover ............................................HG-307.1, HF-203.2 cutting ........................ HG-501.6, HW-500(a), HW-801 ends, forming of .............................................HW-800 ferrous................ HF-301.1, Tables HF-300.1, HF-301.1 flat stayed...................................HG-340, HW-701.2 identification of (see Identification markings) nonferrous........... HF-301.2, Tables HF-300.2, HF-301.2 preparation of..................................................HW-801 reinforcement............................. HW-730.3, HW-731.4 shell................... HF-301.1, Table HF-301.1, .HF-301.2, Table HF-301.2 steel (see Steel plate) thickness (see Plates, shell) Plug cocks........................................................HG-710.4 Plugs, threaded..............................................HG-312.6(c) washout.......................... HG-330.1, HG-330.4, HG-325 Postbrazing operations ....................................... HB-1401 Postwelding operations.................................... HW-810(c) Preamble Prefabricated and preformed ~ pressure parts ................... HG-203 (see also Parts) Pressure, application of (see Tests) atmospheric ................................................ HG-300(c) blowdown, safety valve ............................. HG-402.3(a) controls (see Controls) design ........................................................ HG-300(a) external ............. HG-312, HG-503, HW-702.1, A-101(b) forming of plate ends ...................................... HW-800 gage........................................................... HG-300(c) gages (see Gages) internal .......................................... HG-301, HG-321.2 lift, safety valve.........................................HG-402.3(a) parts, nonstandard (see Parts) standard (see Parts) popping, safety valve .................................HG-402.3(a) relieving devices ............................................. HG-400 259 RS-003268 1/17/02 NUECES 1995 SECTION IV relieving valve requirements ..............................HG-400 setting, tolerances for, safety and safety relief valves ............................................ HG-401 stress, materials object to................................ HG-200.1 temperature relief valves ...............HG-400.2, HG-402.5 temperature relief valve tests (see Tests) tests, hydrostatic (see Hydrostatic tests) welding processes ............................................HW-600 Procedures, brazing (see Qualification) for tests (see Tests) welding (see Qualification) Processes, brazing .............................................. HB-1200 welding ...........................................................HW-600 Production, method of, material not limited by ............................................. HG-200.5 ratings of boilers, based on tests......................... HC-404 work ........................................... HW-611, HB-1202.3 Proof tests........................................... HG-500, HLW-502 (see also Tests) Pump discharge, piping............. Figs. HG-703.1, HG-703.2 Pumps, casing of................................................HF-203.1 Purves type furnaces'.......................................... HG-312.6 Q Qualification, brazing operators..........HB-1001, HB-1202.2 brazing procedures .......... HB-1001, HB-1100-HB-1103, HB-1202, HG-1305 requalification ...........................................HB-1305(b) welding operator .................HW-401, HW-610, HW-612, HW-711, HW-713, HLW-450 welding procedure...............HW-401. HW-600, HW-610, HW-611, HW-613, HLW-450, HLW-460 Quality, structural, rods, bars, shapes................ HF-202(b) weldable .................... HF-202(b), HF-202.3(c), HW-502 Quality control of castings....................................HC-501 Quality control, outline of features............. HC-502, F-202 Quality control system .................................. Appendix F Quality factors, ferrous castings ................ Table HF-300.1 [Note (5)] nonferrous castings ..................Table HF-300.2 [Note(4)J R Radial deformation, threaded joint ...................... HG-307.4 Radii, inside ........................................HG-301, HG-305.1 comer ..........................................HG-307.1, HG-307.4 crown..............................HG-305.1. HG-305.6, HG-309 knuckle ..............................HG-305.6, HG-309, HC-311 spherical ......................................... HG-305.1, HG-309 values of factor ............................Table HG-321 of fillets and transition sections.......................... HC-320 Ratings, of boilers, based on tests.......................... HC-404 Recessing, holes for nozzles ........................ HW-731.2(b) tube holes ....................................................... HW-713 Records, of brazer and brazing operator identifying marks.........................................HB-1202.4 of brazer and brazing operator qualification tests .................................. HB-1202.4 of brazing procedure qualification tests ..............HB-1201 of capacity tests of relieving devices................ HG-402.8 of tests of associated test bars.............................HC-402 of tests of unidentified materials...................... HF-205.1, HF-205.3 of tests to establish maximum allowable working pressure ...................................... HC-403 of welder and welding operator identifying marks......................................HW-613, HLW-453 of welder and welding operator qualification tests......................HW-613, HLW-453 of welding procedure qualification tests .......................................HW-613, HLW-453 Rectangular flat heads........................................ HG-307.3 Reexamination of repaired welded joints................ HW-830 Refractory materials, protecting furnace extensions ............................................... HW-712 Regulators, damper .............................................. HG-604 feedwater ........................................................HG-604 Reinforced openings, for pipe connections........................ HW-731.1, HW-731.6 frames for.....................................................HF-202(a) in flat heads .....................................................HG-325 in formed (dished) heads ....................HG-321, HG-323 in shells....................................HG-321, Table HG-321 in welds.......................................................... HW-720 (see also Heads; Openings) Reinforcements, area of ................ HG-321, D-100, D-101 configurations, representative ....................Fig. HG-326 integral .........................................HW-731.5, HC-315 metal available for............................................ HG-326 of butt welds ............................................... HW-701.1 of multiple openings......................................... HG-328 pad...................................................HW-731.5, D-100 plates........................................................... HW-730.3 provisions of.............................. HG-321.1 saddles..........................................................HW-730.3 strength of........................................................ HG-327 (see also Openings) Rejection of brazed joints.....................................HB-1503 Repair, of brazed joints........................................HB-1503 of welded joints............................................... HW-830 Reports, Master and Partial Data............................ HG-520 Reports, of tests of unidentified materials .............HG-205.3 (see also Data Reports; Manufacturer's, master Data Reports; Manufacturer's, Partial Data Reports; Records) Requirements for safety and safety relief valves .............................................HG-401 Resistance welding ............................................. HW-600 Retests of pressure parts (see Tests) Return, pipe connections (see Pipe) piping (see Pipe) Rewelding defective joints....................................HW-830 260 R8-003260 1/17/02 NUECES Ring gaskets . HG-309, Fig. HG-309, HC-311.1, Fig. HC-311 Rings, flange, from rods, bars, shapes .................HF-202(a) flange, of spherically dished or shaped covers..............................HG-309, HC-311 insulating .....................................................HG-200.7 OG (Ogee) .........................HG-312.4(g), Fig. HG-312.3 reinforcing (see Rings, stiffening) stiffening...............HG-312.3, Fig. HG-312.3, HG-312.4, HF-202(a), C-100, C-101 Rivets, controlling brazed joint tolerance........... HB-1305(b) Rods, for nonpressure parts ............................... HF-202(b) for pressure parts........................................... HF-202(a) specifications for ....................HF-202, Tables HF-300.1, HF-300.2 stay .......................................................... HG-345.1(c) unidentified....................................................... HF-205 Rolled nonstandard pressure parts.........................HF-203.2 Rolled standard pressure parts............................. HF-203.1 Rolling, direction of .......................................HF-205.2(a) of plain type furnaces................................. HG-312.1(c) S S maximum allowable stress values'.........................Tables HF-300.1, HF-300.2 Saddles, as reinforcement...................................HW-730.3 Saddle type fittings (see Fittings) Saddle type pads, as reinforcement......................HW-731.5 Safety, strength of parts not computable for ........................................................Preamble Safety and safety relief valves...............HG-400, HLW-800 accumulation tests.......................HG-512, B-100-B-102 additional existing installations.......HG-400.1, HG-400.2 adjusted and sealed .................................... HG-400.1(a) capacity, discharge ............................HG-400, HG-402, Table HG-715 examples of checking ....................................B-101 methods of checking .............HG-512, B-100, B-102 relieving......................................HG-400, HG-402 required .................................................... HG-400 casings...................................................... HG-400.1(a) connections for................................................. HG-701 common.......................................... . HG-701.2 data sheets, test record ................................... HG-402.9 discharge, capacity (see Safety and safety piping ....................................... HG-701.6 disk ................................................................HG-401 lifting devices............................................ HG-401.1(g) manufacturer's test reports.............................. HG-402.9 markings required .........................................HG-402.1 marking to constitute guarantee.......................HG-402.1, HG-402.3 maximum rise in pressure __ HG-400.1(e), HG-400.2(f), HG-400.3, HG-401 mounting......................................................... HG-701 officially rated .......................HG-400.1(a), HG-400.2(a) popping point tolerances..................... relieving capacity (see Safety and safety relief) required, on boilers................ HG-400.1(a), HG-400.2(a) on hot water tanks ...............................HG-400.3(a) on steam heat exchangers ..................... HG-400.3(c) on water heat exchangers ......................HG-400.3(b) seals.......................................................... HG-400.1(a) seats.......................................................... HG-400.2(c) set pressure.......................................................HG-401 setting ......................................... HG-400.1. HG-400.2 size.................................................... HG-400.1(b), (c) spring loaded ............................................ HG-400.2(a) spring pop type ......................................... HG-400.1(a) stamping with Code Symbol .......... HG-402.1, HG-402.2 (see also Stamping) testing and stamping............HG-402 (see also Stamping; Tests) test record data sheets..................................... HG-402.8 tests, accumulation ..........HG-512. B-100, B-101, B-102 (see also Tests) to determine capacity........ HG-402.3 (see also Tests) coefficient method.............................. HG-402.3(a) curve method .................................... HG-402.3(b) fluid medium used in tests.......................HG-402.7 pressures ............................................... HG-402.4 three-valve method ............................ HG-402.3(c) where and by whom conducted................HG-402.8 threaded connections.......................................HG-701.3 twin ............................................................HG-701.2 Y-bases for................................ HG-701.1, HG-701.2 Safety controls, primary .................................. HG-605(a) Safety devices ................................................. HG-101.2 design requirements........................................ HG-401.5 manufacturer's testing..................................... HG-401.4 manufacture and inspection ............................HG-401.3 material selection............................................HG-401.2 mechanical requirements ............................... HG-401.1 Safety factors ..................... HG-307.4, HG-320 [Note (1)], Tables HF-300.1, HF-300.2 (see also Design, stress criterion) Safety limit switches.........................................HG-640(a) Scope, of Code...................................................Preamble of Part HLW ................................................ HLW-100 Screwed fittings or valves ...............HG-320.3(c), HG-370, HG-701.3, HW-73I.6 (see also Fittings; Safety and safety relief valves; Valves) Screwed stays and staybolts........ HG-340.2, Fig. HG-340.2, HG-341.1, HG-341.2, HG-342.5 Seals, safety valves ....................................... HG-400.1(a) water .......................................................... HG-605(c) Seal welding..................................................... HG-307.4 Seats in tube holes.............................................HG-360.1 Selection of materials ...............HG-200, HF-200, HW-500, HB-1100, HC-200 Semiautomatic arc welding process ...................... HW-701 Semicircular furnaces ........................................ HG-312.8 261 ftS-003281 uirm NUECES 1995 SECTION IV Serial Numbers, manufacturer's ................ HG-530.1(a)(5), of openings and tube holes ..................... HG-305, Figs. HG-530.2, Figs. HG-530.2, HG-530.3 HG-350. l-HG-350.4 Service, exceptions, hot water supply of stays and staybolts ............HG-340, HG-341, HG-343 boilers ..................................................HG-101.2 Specifications for materials (see Materials) lined potable water heaters.............................. HLW-101 Specification tide, materials not limited by........... HG-200.4 restrictions, boilers ....................................... HG-101.1 Spherically dished covers (bolted heads)................ HG-309, temperatures, furnaces, plain type.................HG-312.1(b) HC-311 ring reinforced type ............................. HG-312.4(f) Spherically dished heads....................... HG-309, HC-311.1 hot water boilers.................................. HG-101.1(b) Spherically shaped covers .....................................HC-311 hot water supply boilers .......HG-lOl.l(c), HG-101.2 Spherical radius factor K\............................ Table HG-321 water heaters ................................................HLW-101 Spring loading of safety relief valves............... HG-400.2(a) water storage tanks ........................................HLW-101 Spring pop type safety valves ............................. HG-400.1 Services in excess of Code limits ........................HG-101.3 Stamping, arrangement............. HG-530.4, Figs. HG-530.2, Setting, of boilers .................................HG-720, HG-725 HG-530.2 (see also Markings, of safety valves .............................................HG-400.1 arrangement of) of safety relief valves .....................................HG-400.2 location, brazed boilers.....................................HB-1510 Shapes .................................................. HF-202, HF-205 cast boilers............................................... HG-530.2 Shear, in brazed joints .................................. HB-1307(a) valves, safety and safety relief -................... HG-402.I in welded joints..........HW-710.1, HW-730.1, HW-730.2 wrought boilers........................................... HG-532 Sheets, attached to shell ................... HW-711.1, HW-711.2 nameplates ..........HG-402.1, HG-530.1(a), HG-530.2(a), crown.......................................................... HW-712.1,HW-712.2 Figs. HG-530.2-HG-530.7; HB-1510, diagonal stays for tube ................................... HG-343.2 HLW-602.1, Fig. HLW-602.2 furnace ..........r.........................HW-712.1, HW-712.2 requirements, all boilers.....................HG-530, HG-530.1 tube, classified as shell plates, ferrous...........HF-301.1(b) boiler parts and accessories............HG-531, HF-203, nonferrous ........................................... HF-301.2(b) HF-205, HF-210 wrapper........................................................HW-711.2 brazed boilers ........................................... HB-1510 Shell axis, openings parallel to ........................... HG-350.2 cast iron boilers .......................................HG-530.2 openings transverse to.....................................HG-350.3 field assembled boiler pressure parts............. HG-533 Shells, allowable working pressure.........................HG-301 field assembled wrought boilers.................... HG-532 circumferential joints of.................................... ..!.....HW-701.1` ' of hot water heaters ...:;....... HLW-602 computation of openings in ..................... D-100, D-101, other than cast iron .................................HG-530.1 Figs. D-100, D-101 valves............................... HG-402.1, Fig. HG-402 design pressure............................................. HG-300(a) symbols..................HG-402.1, Fig. HG-402, HG-530.2, extended ..................................... HW-711.1, HW-711.2 Figs. HG-530. l-HG-530.3; HG-533.5 heads attached to............. HG-305.7, HG-307.4, HW-715 transferring of (see Markings) longitudinal joints of......................................HW-701.1 Stamps, administrative fee for......................... HG-540.2(b) materials for (see Materials; Plates) ASME official Symbols ............HG-402.1, Fig. HG-402, minimum thickness of.................................... HF-301.1, HG-530.2, Figs. HG-530.1-HG-530.3; Table HF-301.1, HF-301.2, HLW-602.1, HLW-602.2 Table HF-301.2, HLW-301 authorization to use....................................... HG-402.2,HG-402.9, openings, computations (see Shells, computation HG-533, HG-540, HG-540.1 of openings in) Certificates of Authorization to use .................HG-402.2, reinforcement of openings in (see Openings and HG-530.2, HG-533.5, HG-540.2(b), reinforcements, reinforcement requirements HLW-602.1 for) application for .......................... HG-402.2(a), HG-533.4, staying of ...................................................... HG-340 HG-540.2(a) welded to heads or tubesheets.......................... HW-711 cancellation of ...........................................HG-540.2(c) Shielded carbon arc welding process ................. HW-600(a) regulations concerning use of ..........................HG-540.2 Shielded metal arc welded process....................HW-600(a) renewal of................................................. HG-540.2(b) Shutoff valves prohibited ........ HG-604, HG-605, HG-701.5 Stayed heads....................................... HG-305.5, HG-345 Siphons, in pressure control connections .................HG-605 Stayed shells..................................................... HG-340.4 in steam gage connections ................................. HG-602 Stayed surfaces................... HG-340, HG-341.1, HG-343.1 Skirts, nonstandard pressure pans....................... HF-202(b) Stayed tubesheets.................................HG-343.2, HG-346 on heads ..................... HG-305.1, HG-305.2, HG-305.6, Stayed wrapper sheets........................................HW-701.2 HG-305.8, HW-715, HC-310.2 Stays, staybolts, stay rods and stay tubes, Socket type joints .........................................HB-1304(a) adjacent to upper comers of Spacing, of brackets, lugs, hangers......................... HG-725 fireboxes ....................................... Fig. HG-340.1 262 RS-003262 1/17/02 NUECES INDEX allowable stress on Table HF-300.1 area supported by .........................HG-342.2, HG-345.1, HG-345.2, Fig. HG-345.2 cross-sectional area, minimum.............. HG-342.1, HG-342.5 diagonal........................................................... HG-343 acceptable and unacceptable types---- Fig. HW-710.4 diameters, minimum .......................................HG-342.6 dimensions of.................................... HG-342, HG-343 distance to comer joints, etc..............................HG-340.5 ends riveted over............................................HG-341.1 ends welded over........................................HG-345.1(b) fabricated by welding ..................................... HG-342.4 hollow .......................................................... HG-341.1 load carried by...............................................HG-342.2 location .........................................................HG-340.5 material ...............HG-342.6, Tables HF-300.1, HF-300.2 pitch..................... HG-340.3, HG-340.6, Fig. HG-340.1, Table HG-340 proportions ....................................................HG-340.2 telltale holes in............................................... HG-341.1 threaded......................................... HG-341.1-HG-341.3 unsymmetrical ..............................................HG-340.4 upset ............................................................HG-341.2 welded-in ..................................... HG-341.4, HW-710 Steam flowmeters, calibrated...............................HG-402.7 Steam gages ............................... HG-601 (see also Gages) Steam generating capacity .............................B-100-B-102 Steam heating boilers, in battery.................. Fig. HG-703.1 safety valve requirements............................ HG-400.1(a) service restrictions and exceptions ............... HG-lOl.l(a) Steam mains..................................................... HG-703.1 Steam pipe, valveless ........................................ HG-701.1 Steam piping........................................................HG-703 Steel, alloy .....................................................HW-500(a) bars .................................................................HF-202 bolting................................................. Table HF-300.1 carbon ........ Figs. HG-312.1, HG-312.2; Table HF-300.1, HW-500(a) cast.......................HF-203.1, HF-203.2, Table HF-300.1 fittings.......................... HF-203.1, HF-203.3, HF-300.1 flanges..................HF-203.1, HF-203.3, Table HF-300.1 forgings................ HF-203. l-HF-203.3, Table HF-300.1 pipe, butt welded..................................Table HF-300.1 electric resistance welded ................Table HF-300.1 lap welded..................................... Table HF-300.1 seamless.........................................Table HF-300.1 plate.................................. HF-201, HF-205, HF-301.1, Tables HF-300.1, HF-301.1 stays.......................HG-345.2, HF-202, Table HF-300.1 tubes ....................................HG-315.1, Table HG-315 Stiffening rings...............................HG-312.4, HF-202(a), HG-312.5, C-101 Stop valves (see Valves) Strain measurement tests ........... HG-502.1 (see also Tests) Strength in reinforcements, of added materia] ............................................... HG-327.1 of attachment material ....................................HG-327.2 of nozzles ......................................................HG-327.1 of weld metal.................................................HG-327.1 Stresses, maximum allowable, in ferrous materials ....................... Tables HF-300.1, HC-300 in nonferrous materials.......................... Table HF-300.2 for lined materials............................... Table HLW-300 Stress values for weld metal .......... HW-730.2, HLW-430.2 Strips, backing ............. HW-701.3, HW-702, HW-731.2(a) Structural shapes .................................................. HF-202 procedure and performance qualification tests for.......... HW-820.5, HLW-460.6 Stud welding.................................. HW-802.4, HW-820.6, HLW-431.7, HLW-460.5 material requirements for............................... HW-820.5 Studded connections .................................. HG-320.3(c)(l) Studs ........................................................... HG-326.4(d) Submerged arc welding process ........................HW-600(a) Supply pipe connections........ ............................ HG-710 Supports .......................HG-200.7, HF-202(b), HW-711.1, HW-711.2, HC-320 for boilers over 72 in. in diameter .................. HG-725.2 for boilers between 54 in. and 72 in. in diameter ...............................................HG-725.3 for boilers up to 54 in. in diameter................... HG-725.4 Surfaces, brazed..................................................HB-1400 gasket (see Gaskets) on heads (see Heads, flat) stayed (see Stayed surfaces) to be welded......... ..........................................HW-801 (see also Welded joints) Suspension, outside, type of boiler setting............... HG-725 Switches, safety limit ....................................... HG-640(a) shutdown......................................................... HG-634 Systems, hot water, closed type........................... HG-709.2 tank capacity ................................................ HG-709.3 open type ..................................................... HG-709.1 thermal expansion in......................................... HG-709 T T- or lever handles for gage cocks ..........HG-602, HG-611 Tack welds .................................................... HW-810(c) Tanks for hot water systems ..................... HG-709, Tables HG-709.1, HG-709.2 Tapped holes HG-370.1, HG-400.1(a), HG-606(b), HG-701.1 Tee joints ..........................HW-701.3(a) (see also Joints) Tees............................. HG-330.4(e), HG-606(b), HC-325 Telltale holes .................HG-341.1, HW-730.3, HLW-801 Temperature, controls .......................... HG-613, HLW-701 design .................................. HG-312.1(b), HG-312.3(f) gages ........................... ..................................HG-705 maximum water...............HG-101.1, HG-101.2, HG-613 pressure, ratings for flanges............................HG-370.2 pressure, relief valves...............HG-400.2(a), HG-402.5, 263 R8-003283 1/17/02 NUECES 1995 SECTION IV HC-402 HG-320.3, HG-370.1, Table HG-370, service, permissible.......................... HG-101, HB-1303 HG-701.3, HW-731.7, Fig. HW-731 Tensile strength, of cast iron .......................Table HC-300 Threads ..........................HG-307.4, HG-341.1, HG-370.1 of ferrous materials............................................. TableHF-300T.1hroats of fillet welds..................... HW-701.2, HW-711.1, of nonferrous materials......................................... TableHF-300.2 HW-712.1, HW-731.4, HW-731.5 tests to determine................HG-501.6, HG-502, HC-402 (see also Welds; Welding) Tension, in groove welds ..................................... HW-730 Through-stays................ HG-305.5(c), HG-340.2, HW-710, maximum allowable stress values in ..................HC-300, Fig. HG-340.2 (see also Stays) Table HC-300 Time delay fuses ..................................................HG-632 Test gages.......................................... HG-505, HC-402.1 Tolerances, alignment, buttjoints.................. HW-812 Tests, clearance, for brazed joints .........................HB-1305(b), accumulation .................................................. HG-512 Table HB-1305 air................................................................ HW-730.3 set pressure...................................................... HG-401 blowdown pressure ........................................ HG-402.3 Torch brazing.....................................................HB-1200 brittle coating................................................ HG-502.4 Torispherical heads (dished) (see Heads) bursting.......................................... HG-502.3, HC-402 Trademarks (see Identification markings; capacity, discharge ........................ HG-402.3, HG-402.6 Stamping) displacement measurement.............................. HG-502.2 Transfer of markings on plate ................................ HF-210 hydrostatic .......................... HG-503, HG-504, HG-510, Transformer, isolation........................................... HG-632 HC-410, HLW-505 leakage .......................................................... HW-830 lift pressure................................................... HG-402.3 of associated test bars..................................... HC-402.2 Tube ends, beading ............................................HG-360.2 expanding...................................... HG-360.1, HG-360.2 firetube boilers................................... HG-360.2(a) extension of................................. HG-360.2(b) flaring .......................................... HG-360.1, HG-360.2 of completed boilers ............................HG-510, HC-410 recessed....................................HW-713, HW-731.2(b) of duplicate parts.............................................. HG-504 welding of......................................HG-360.2, HW-713 of individual sections ........ .............................. HC-410 extension of............................................... HW-713 of materials not fully identified........................... HF-205 Tube holes ..........HG-320.3, HG-321, HG-330.1, HG-350, of parts subject to collapse................................HG-503,HLW-503 HG-360, HW-713, HW-731.2 of safety valves after design changes................HG-402.8 (see also Holes) opening test ..................................................HG-402.5 Tubes, as stays.................................................. HG-345.1 physical......................................................... HF-205.2 as supports ..........................HW-711.1(a), HW-711.2(a) popping pressure ........................................... HG-402.3 attached bywelding ......................... HW-713, HLW-413 pressure application........................................ HG-501.4 attachment of.................................HG-360.2, HLW-309 proof .................................HG-500-HG-503, HLW-502 in heat exchangers.......................................... HG-400.3 qualification ..................... HW-600, HW-610-HW-613, integrally finned.............................................. HF-204.1 HB-1001, HB-1102, HB-1103, thickness, minimum ..............HG-315.1, Table HG-315, HB-1201, HB-1202 HG-315.2, HLW-307 strain measurement ....................................... HG-502.1 Tubesheets ........... HG-343.2, HG-346, HG-360, HF-301.1, tensile strength...............................................HG-501.6 HF-301.2, Tables HF-301.1, HF-301.2; to establish design pressure ................................HC-400 . .. HW-711, HB-1302, HLW-411 transverse test..................................... HC-209, HC-210, Tube spacing ...................................................... HG-350 HC-211, HC-212 Tubing....................................HG-602, HG-605, HG-611 types of.........................................................HG-501.1 Two-wire control circuits........................ HG-632(b) yield strength ................................................ HG-501.6 Thermal cutting .............................................. HW-801(b) Thermal elements................................................. HG-405 U Thermal expansion ..............................HG-709, HLW-809 Thermal gouging .............................................. HW-820.1 Thermit welding.................................................. HW-600 Unequal spacing of openings...........................HG-350.4(a) Unflanged heads ............. HG-345.1, HG-345.3, HW-711.2 Unfianged manhole rings ............................... HG-323.3(b) Thermometers.......................HG-612, HG-621, HLW-820 Unidentified materials....................... HG-200.3, HF-200.7, Thicknesses, exceeding specification limits...........HG-200.6 HF-202(b), HF-203 maximum, of materials................................... HG-200.6 Unreinforced openings ...................... HG-305, HG-320.3 (see also Materials) Unstayed flanged-in openings ......................... HG-323.3(b) minimum, of materials ........... HG-200.6, HG-315, Table Unstayed heads ...............HG-305.5, HG-305.6, HG-307.1, HG-315, HF-301.1, Table HF-301.1 HG-307.2, Fig. HG-307, HG-320.3(c), Threaded connections ....................... HG-307.4, HG-312.6, HG-345.1 264 rRs1-/0107130** * NUECES INDEX Unstayed noncircular covers and blind flanges..............................HG-307.3, Fig. HG-307 Unsymmetrical spacing of staybolts ....................HG-340.4 V Vacuum boilers ................................................HG-300.1 V-Symbol, authorized Code Stamp for valves ........................ HG-402.1, Fig. HG-402 Values, of C in flat head design .........................HG-307.4 of F in determining area of reinforcement ................... HG-321.2, Fig. HG-321 of K\, spherical radius factor....................Table HG-321 Valves, blowoff..........Figs. HG-703.1, HG-703.2; HG-715, Table HG-715 bottom drain (see Valves, blowoff) capacity tests, safety valves (see Tests) check...................................................... Fig. HG-703.1 drain ......................................... HG-603(a), HG-604(a) (see also Valves, blowoff) feedwater (see Valves, supply; Valves, water inlet pressure reducing^..................................... Fig. HG-703.2 pressure-temperature relief............... HG-400.2, HG-402.5 safety and safety-relief (see Safety and safety relief valves) shutoff, prohibited.........................HG-605(c), HG-701.5 stop ................................................................HG-710 supply ............................................................ HG-710 swing check ........................................... Fig. HG-703.1 water inlet........................................................HG-606 (see also Identification markings; Materials; Mountings; Stamping) Valved fittings .................................................... HG-603 Valveless headers.............................................. HG-701.1 Valveless steam pipe between boilers ................. HG-701.1 Vents, open, in open expansion tank systems ................................................ HG-709.1 Vertical firetube boilers ................... HG-330.2, HG-330.4, HG-350.2 Visibility of instruments.......................................HG-621 Visual examination of joints ............................ HW-731.2, HW-731.3(b), HB-1301, HB-1304, HB-1503 W Washout openings ........... HG-330.1, HG-330.4(e), HC-325 Washout plugs ..................................................HG-330.4 Water columns........ HG-602(a), HG-603, HG-604, HG-705 Water equalizing pipe connections .....................HG-606(c) Water, feed, connections....................................... HG-705 Water feeding devices.......................................... HG-606 Water gage glasses ..................HG-603, HG-604, HG-606 Water heaters, lined potable...............................Part HLW definitions of ...............................................HLW-100 glass lined ..................................... HLW-100(b)(1) galvanized ......................................HLW-100(b)(2) cement lined ...................................HLW-100(b)(3) copper lined..................................... HLW-100(b)(4) polymer lined ................................. HLW-100(b)(5) Water level control pipes .................................. HG-604(a) Waterlegs ....................................... HG-330.4, HG-341.1 Water, low, fuel cutoffs .........................HG-606, HG-614 Water outlets on boilers ..................................... HG-701.1 Water seals, for pressure controls.......................HG-605(c) for steam gages ............................................ HG-602(a) Water supply connections................................... HLW-805 Watertube boilers...............................HG-315, HG-530.2 Weld defects.................................... HW-830, HLW-460.4 Welded connections..........HW-730, HW-731, Fig. HW-731 Welded-in staybolts............................................HG-341.1 Welded joints, alignment tolerances.......................HW-812 assembly of......................................................HW-810 butt.................................HW-701.1, HW-702, HW-812, HW-820, HLW-401.1 circumferential ............................... HW-701.1, HW-812 comer ......................................HW-701.3, HLW-401.2 defects in ...................................................... HW-830 design of..........................HW-700, HW-701, HLW-400 double-welded butt ....................... HW-701.1, HW-702, HW-820.1, HLW-460.1 double-welded lap.......................................... HW-702 efficiencies .......................HW-702, HW-703, HLW-402 fillet.................................HW-710, HW-711, HW-730, HW-731, HW-820.2, HLW-460.2 for stays ....................HG-341.4, Fig. HG-343, HW-710 full fillet ....................................HW-701.2, HW-701.3, Fig. HW-701.3, HW-712 full penetration..................... HW-701.3, Fig. HW-701.3, HW-712.2, HW-731 fusion (see Welding) groove...........................................HW-730, HW-731.2 inspection during fabrication ............................. HW-900 lap .............................................................. HW-701.2 longitudinal.................................... HW-701.1, HW-812 openings in..................................................... HW-720 partial penetration .......................................... HW-731 repair of defective............ HW-830 requirements for.................. HW-700, HW-701, HW-820 single-bevel .................................................. HW-731 single-J .........................................................HW-731 single-welded butt.......................... HW-701.1, HW-702 single-welded lap.................. HW-701.2, Fig. HW-701.3 tee ................... HW-701.3, Fig. HW-701.3, HLW-401.2 (see also Joints) Welded parts, minimumthicknesses of ...................HW-703 Welded standardpressure parts ......................... HF-203.3 Welded stays ..................HG-340.3, HG-342.4, HG-342.5, HG-345.1(b), HW-710 Welders and welding operators ........... HG-533.1, HW-401, HW-610, HW-611, HW-612, HW-613, HW-911 Welding, caps................................................ HF-203.3(a) 265 RS-003285 1/17/02 NUECES 1995 SECTION IV fusion.......................... HG-307.4, HG-312.6, HG-342.5, tack ............................................................... HW-810 HW-701.1 tightness tests of ........................................... HW-730.3 necks .........................................................HF-203.3(a) Wet-bottom boilers .............................................. HG-720 nozzles ....................................HW-731, Fig. HW-731 Wiring, electric, circuit breakers .............................HG-634 of boilers with two or more courses.............HW-701.1(a) electrical code compliance..................................HG-631 of circumferential joints, corrugated flame safeguard controls.....................................HG-640 furnaces................................................ HG-312.6 limit controls ................................................... HG-633 of crown sheets to heads ..................................HW-712 safety controls for heat generating of furnace sheets to heads ................................ HW-712 apparatus..................................................HG-640 of heads of shells............................................ HW-711,HW-715 shutdown switches............................................. HG-634 of internally threaded fittings..........................HW-731.6, Fig. HW-731 of longitudinal joints, corrugated furnaces................................................ HG-312.6 of nonpressure parts to pressure parts, type circuitry ................................................... HG-632 Working pressures, allowabledefinition of..........HG-300(c) for heads and covers...........................HG-305, HG-307, HG-309, HLW-305 for hot water heating boilers ...........................HG-101.1 for hot water supply boilers............................. HG-101.1 posthydrotest ........................................HLW-454 for shells, pipe and headers............... HG-301, HLW-300 of stays ..........HG-341.4, HG-342.4, HG-342.5, HW-710 for stayed surfaces............................................. HG-340 of tubes.......................................................... HW-713 for steam boilers ............................................ HG-101.1 of tubesheets....................................................HW-711 for steel flanges and fittings ............. HG-307, HG-370.2 pipe couplings .......................................... HB-1306(b) maximum ........................................................ HG-300 plasma arc...........................................................E-100 tests to establish.................... HG-501-HG-504, HC-400, processes....................................... HW-600, HLW-440 HC-401, HLW-300 specific requirements for ..................................HW-820 Wrapper sheets..................................................HW-701.2 spot ......................................................... HG-1305(b) Wrought iron pipe or tube .......... HG-315.1, Table HG-315, test................................................................HW-910,HW-911 HG-602(a), HG-604, HG-605, Weld metal (filler metal) allowable Table HF-300.1 stress values ......................................... HW-730.2 Wrought materials...................................HF-100, HF-200, as reinforcement ........................................... HG-326.4 Tables HF-300.1, HF-300.2 depositing of................................................ HW-701.1.HW-820 {see also Metals) Welds, attachment, requirements for......................HW-731, Y HLW-431, HLW-431.1 Y-fittings and bases HG-606(b), HG-701.1, openings in..................................................... HW-720 HG-701.2 strength of.................................................... HW-730.1 Yield point .......... .................HG-501.6 repair of defects in ..........................................HW-830 Yield strength...... .................HG-501.6 266 RS-003266 1/17/02 NUECES