DESIGN AND APPLICATION
PG-60 REQUIREMENTS FOR MISCELLANEOUS PIPE, VALVES, AND FITTINGS
Piping referred to in this paragraph shall be designed in accordance with the applicable requirements of ASME B31.1.
PG-60.1 Water Level Indicators. All boilers having a fixed water level (steam and water interface) shall have at least one gage glass (a transparent device that permits visual determination of the water level). Boilers not having a fixed water level, such as forced-flow steam generators and high-temperature water boilers of the forced circulation type, are not required to have a gage glass. The lowest visible water level in a gage glass shall be at least 2 in. (50 mm) above the lowest permissible water level, as determined by the boiler Manufacturer. Electrode-type electric boilers are required to have only one gage glass, regardless of MAWP.
Gage glasses having multiple tubular sections shall have a minimum of 1 in. (25 mm) overlap of the sections in which the water level may be visible. Segmented gage glasses, such as ported or end-connected strip gages, shall be equipped to provide obvious visual discrimination between water and vapor in the individual sections.
PG-60.1.1 Boilers having a maximum allowable working pressure exceeding 400 psi (3 MPa) shall have two gage glasses. Instead of one of the two required gage glasses, two independent remote water level indicators (two discrete systems that continuously measure, transmit, and display water level) may be provided.
PG-60.1.1.1 When the water level in at least one gage glass is not readily visible to the operator in the area where control actions are initiated, either a fiber optic cable (with no electrical modification of the optical signal) or mirrors shall be provided to transfer the optical image of the water level to the control area. Alternatively, any combination of two of the following shall be provided:
(a) an independent remote water level indicator
(b) an independent continuous transmission and display of an image of the water level in a gage glass.
PG-60.1.1.2 When two independent remote water level indicators are in reliable operation (continuously indicating water level), the one required gage glass may be shut off, but shall be maintained in the serviceable condition.
PG-60.1.1.3 The display of a remote water level indicator shall have a clearly marked minimum water level reference at least 2 in. (50 mm) above the lowest permissible water level, as determined by the Manufacturer.
PG-60.1.6 Each gage glass shall be fitted with a drain cock or valve having an unrestricted drain opening of not less than ¼
in. (6 mm) diameter to facilitate cleaning. When the boiler MAWP exceeds 100 psi (700 kPa), the gage glass shall be furnished with a connection to install a valved drain to a point of safe discharge.
Each gage glass shall be equipped with a top and a bottom shutoff valve of such through-flow construction as to prevent stoppage by deposits of sediments. If the bottom valve is more than 7 ft (2 m) above the floor or platform from which it is operated, the operating mechanism shall indicate by its position whether the valve is open or closed. The pressure—temperature rating of valves, fittings, and piping shall be at least equal to the boiler MAWP and the corresponding saturated-steam temperature.
Straight-run globe valves shall not be used on such connections. Automatic shutoff valves, if permitted to be used, shall conform to the requirements given in A-18.
PG-60.2 Water Columns
PG-60.2.1 A water column shall be so mounted that it will be correctly positioned, relative to the normal water level under operating conditions.
PG-60.2.3 Each water column shall be furnished with a connection of at least NPS ¾ (DN 20) to install a valved drain to a safe point of discharge.
PG-60.2.4 The design and material of a water column shall comply with the requirements of PG-8.2, PG-8.3, and PG-42.
PG-60.3 Connections.
PG-60.3.1 Gage glasses that are required by PG-60.1 shall be connected directly to the shell or drum of the boiler or to an intervening water column. When two gage glasses are required, both may be connected to a single water column.
PG-60.3.2 The lower edge of the steam connection between a water column or gage glass in the boiler shall not be below the highest visible water level in the gage glass. There shall be no sag or offset in the piping that will permit the accumulation of water.
PG-60.3.3 The upper edge of the water connection between a water column or gage glass and the boiler shall not be above the lowest visible water level in the gage glass. No part of this pipe connection shall be above the point of connection at the water column.
PG-60.3.4 Connections from the boiler to the water column shall be at least NPS 1 (DN 25). Connections for gage glasses connected directly to the boiler or to an intervening water column shall be at least NPS ½ (DN 15). Connections from the boiler to the remote level indicator shall be at least NPS ¾
(DN 20) to and including the isolation valve and from there to the remote level indicator at least ½ in. (13 mm) O.D. tubing.
PG-60.3.5 When the boiler MAWP exceeds 400 psi (3 MPa), lower connections to drums for water columns and remote level indicators shall be provided with shields, sleeves, or other suitable means to reduce the effect of temperature differentials in the shells or heads.
PG-60.3.6 The steam and water connections to a water column or a gage glass shall be readily accessible for internal inspection and cleaning. Some acceptable methods of meeting this requirement are by providing a cross or fitting with a back outlet at each right-angle turn to permit inspection and cleaning in both directions, or by using pipe bends or fittings of a type that does not leave an internal shoulder or pocket in the pipe connection and with a radius of curvature that will permit the passage of a rotary cleaner. Screwed plug closures using threaded connections as allowed by PG-39.5.3 are acceptable means of access for this inspection and cleaning. When the boiler MAWP exceeds 400 psig (3 MPa), socket-welded plugs may be used for this purpose in lieu of screwed plugs. If the water connection to the water column has a rising bend or pocket that cannot be drained by means of the water-column drain, an additional drain shall be placed on this connection so that it may be blown off to clear any sediment from the pipe.
PG-60.3.7 Shutoff valves, if provided in the pipe connections between a boiler and a water column or between a boiler and the shutoff valves required for the gage glass (PG-60.1.6), shall be of such through-flow construction as to prevent stoppage by deposits of sediment and shall indicate whether they are in open or closed position of the operating mechanism.
Some examples of acceptable valves are:
(a) outside-screw-and-yoke type gate valve
(b) lever-lifting-type gate valve with permanently fastened lever
(c) stopcock with the plug held in place by a guard or gland
(d) ball valve
Such valves shall be locked or sealed open except under the following additional conditions:
(1) The boiler MAWP shall not exceed 250 psig (1.7 MPa).
(2) The boiler shall not be hand fired or fired with solid fuel not in suspension.
(3) Interlocks between the valve and the burner control system shall stop fuel supply and prevent firing whenever the valve between the drum and the water column is not in the fully open position.
(4) The minimum valve size shall be NPS 1 (DN 25).
PG-60.3.8 Except for control devices such as damper regulators and feedwater regulators, drains, steam pressure gages, or apparatus of such form as does not permit the escape of an appreciable amount of steam or water therefrom, no outlet connections shall be placed on the piping connecting a water column or gage glass to a boiler. No outlet connections shall be placed on the piping connecting a remote level indicator to the boiler or to a water column for any function other than water level indication.
PG-60.3.9 An acceptable arrangement is shown in Fig. PG-60.3.9
PG-60.4 Gage Cocks. Not required.
PG-60.5 Water Fronts. Each boiler fitted with a water jacketed boiler-furnace mouth protector, or similar appliance having valves on the pipes connecting them to the boiler shall have these valves locked or sealed open. Such valves, when used, shall be of the straightway type.
PG-60.6 Pressure Gages
PG-60.6.1 Each boiler shall have a pressure gage so located that it is easily readable. The pressure gage shall be installed so that it shall at all times indicate the pressure in the boiler. Each steam boiler shall have the pressure gage connected to the steam space or to the water column or its steam connection. A valve or cock shall be placed in the gage connection adjacent to the gage. An additional valve or cock may be located near the boiler providing it is locked or sealed in the open position. No other shutoff valves shall be located between the gage and the boiler. The pipe connection shall be of ample size and arranged so that it may be cleared by blowing out. For a steam boiler the gage or connection shall contain a syphon or equivalent device that will develop and maintain a water seal that will prevent steam from entering the gage tube. Pressure gage connections shall be suitable for the maximum allowable working pressure and temperature, but if the temperature exceeds 406°F (208
°C), brass or copper pipe or tubing shall not be used. The connections to the boiler, except the syphon, if used, shall not be less than NPS ¼ (DN 8) but where steel or wrought iron pipe or tubing is used, they shall not be less than ½ in. (13 mm) inside diameter. The minimum size of a syphon, if used, shall be ¼ in. (6 mm) inside diameter. The dial of the pressure gage shall be graduated to approximately double the pressure at which the safety valve is set, but in no case to less than 1 ½ times this pressure.
PG-60.6.2 Each forced-flow steam generator with no fixed steam and waterline shall be equipped with pressure gages or other pressure measuring devices located as follows:
PG-60.6.2.1 At the boiler or superheater outlet (following the last section which involves absorption of heat), and
PG-60.6.2.2 At the boiler or economizer inlet (preceding any section that involves absorption of heat), and
PG-60.6.2.3 Upstream of any shutoff valve that may be used between any two sections of the heat absorbing surface.
PG-60.6.3 Each boiler shall be provided with a valve connection at least NPS ¼ (DN 8) for the exclusive purpose of attaching a test gage when the boiler is in service, so that the accuracy of the boiler pressure gage can be ascertained.
PG-60.6.4 Each high-temperature water boiler shall have a temperature gage so located and connected that it shall be easily readable. The temperature gage shall be installed so that it at all times indicates the temperature in degrees Fahrenheit (Celsius) of the water in the boiler, at or near the outlet connection.
PG-61 FEEDWATER SUPPLY
PG-61.1 Except as provided for in PG-61.2 and PG-61.4, boilers having more than 500 ft2 (47 m2) of water-heating surface shall have at least two means of feeding water. Except as provided for in PG-61.3, PG-61.4, and PG-61.5, each source of feeding shall be capable of supplying water to the boiler at a pressure of 3% higher than the highest setting of any safety valve on the boiler. For boilers that are fired with solid fuel not in suspension, and for boilers whose setting or heat source can continue to supply sufficient heat to cause damage to the boiler if the feed supply is interrupted, one such means of feeding shall not be susceptible to the same interruption as the other, and each shall provide sufficient water to prevent damage to the boiler.
PG-61.2 Except as provided for in PG-61.1, a boiler fired by gaseous, liquid, or solid fuel in suspension, or heated by combustion turbine engine exhaust, may be equipped with a single means of feeding water, provided means are furnished for the shutting off of its heat input prior to the water level reaching the lowest permissible level established by PG-60.
PG-61.3 For boilers having a water-heating surface of not more than 100 ft2 (9.3 m2) the feed connection to the boiler shall not be smaller than NPS ½ (DN 15). For boilers having a water-heating surface more than 100 ft2 (9.3 m2) the feed connection to the boiler shall not be less than NPS ¾ (DN 20).
PG-61.4 High-temperature water boilers shall be provided with means of adding water to the boiler or system while under pressure.
PG-61.5 A forced-flow steam generator with no fixed steam and waterline shall be provided with a source of feeding capable of supplying water to the boiler at a pressure not less than the expected maximum sustained pressure at the boiler inlet, as determined by the boiler Manufacturer, corresponding to operation at maximum designed steaming capacity with maximum allowable working pressure at the superheater outlet.
OVERPRESSURE PROTECTION REQUIREMENTS
PG-67 BOILER
PG-67.1 Each boiler shall have at least one pressure relief valve and if it has more than 500 ft2 (47 m2) of bare tube water-heating surface, or if an electric boiler has a power input more than 1,100 kW, it shall have two or more pressure relief valves. For a boiler with combined bare tube and extended water-heating surface exceeding 500 ft2 (47 m2), two or more pressure relief valves are required only if the design steam generating capacity of the boiler exceeds 4,000 lb/hr (1 800 kg/hr). Organic fluid vaporizer generators require special consideration as given in Part PVG.
PG-67.2 The pressure relief valve capacity for each boiler (except as noted in PG-67.4) shall be such that the pressure relief valve, or valves will discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 6% above the highest pressure at which any valve is set and in no case to more than 6% above the maximum allowable working pressure.
PG-67.2.1 The minimum required relieving capacity of the pressure relief valves for all types of boilers shall be not less than the maximum designed steaming capacity at the MAWP of the boiler, as determined by the Manufacturer and shall be based on the capacity of all the fuel burning equipment as limited by other boiler functions.
PG-67.2.2 The minimum required relieving capacity for a waste heat boiler shall be determined by the Manufacturer. When auxiliary firing is to be used in combination with waste heat recovery, the maximum output as determined by the boiler Manufacturer shall include the effect of such firing in the total required capacity. When auxiliary firing is' to be used in place of waste heat recovery, the minimum required relieving capacity shall be based on auxiliary firing or waste heat recovery, whichever is higher.
PG-67.2.3 The minimum required relieving capacity for electric boilers shall be in accordance with PEB-15.
PG-67.2.4 The minimum required relieving capacity in lb/hr (kg/hr) for a high-temperature water boiler shall be determined by dividing the maximum output in Btu/hr (W) at the boiler nozzle, produced by the highest heating value fuel for which the boiler is designed, by 1,000 (646).
PG-67.2.5 The minimum required relieving capacity for organic fluid vaporizers shall be in accordance with PVG-12. The minimum required relieving capacity for miniature boilers shall be in accordance with PMB-15.
PG-67.2.6 Any economizer that may be shut off from the boiler, thereby permitting the economizer to become a fired pressure vessel, shall have one or more pressure relief valves with a total discharge capacity, in lb/hr (kg/hr), calculated from the maximum expected heat absorption in Btu/hr (W), as determined by the Manufacturer, divided by 1,000 (646). This absorption s shall be stated in the stamping (PG-106.4). For overpressure conditions where the fluid relieved is water, the discharge capacity of the pressure relief valve, or valves shall be sufficient to prevent the pressure from exceeding the limits of PG-67.2.
PG-67.2.7 The steam generated when all pressure relief valves are relieving at full lift on a boiler that has a steam-generating surface located downstream in the gas stream of a superheater and/or reheater surface may exceed the maximum designed steaming capacity at the MA WP of the boiler. The Manufacturer shall address this by one of the following methods:
PG-67.2.7.1 The minimum required relieving capacity of the pressure relief valves shall not be less than the steam that may be generated with all pressure relief valves relieving at full lift. For boilers that use auxiliary firing in combination with the primary heat source, the Manufacturer shall include the effect of such firing in the total required capacity.
PG-67.2.7.2 The minimum required relieving capacity of the pressure relief valves shall not be less than the maximum designed steaming capacity at the MAWP of the boiler, and the boiler shall be provided with controls responsive to steam pressure, which include not less than the following:
(a) a control that reduces that total heat input to the boiler such that the steam generated does not exceed the maximum designed steaming capacity at the MAWP of the boiler
(b) a control that trips the heat input to the boiler if the pressure reaches 106% of the MAWP of the boiler.
PG-67.3 One or more pressure relief valves on the boiler proper shall be set at or below the maximum allowable working pressure (except as noted in PG-67.4). If additional valves are used the highest pressure setting shall not exceed the maximum allowable working pressure by more than 3%. The complete range of pressure settings of all the saturated-steam pressure relief valves on a boiler shall not exceed 10% of the highest pressure to which any valve is set. Pressure setting of pressure relief valves on high-temperature water boilers
8 may exceed this 10% range. Economizer pressure relief devices required by PG-67.2.6 shall be set as above using the MAWP of the economizer.
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PG-67.4 For a forced-flow steam generator with no fixed steam and waterline (Fig. PG-6704), equipped with automatic controls and protective interlocks responsive to steam pressure, pressure relief valves may be provided in accordance with the above paragraphs or the following protection against overpressure shall be provided:
PG-67.4.1 One or more power-actuated pressure relieving valves
9 shall be provided in direct communication with the boiler when the boiler is under pressure and shall receive a control impulse to open when the maximum allowable working pressure at the superheater outlet, as shown in the master stamping (PG-106.3), is exceeded. The total combined relieving capacity of the power-actuated relieving valves shall be not less than 10% of the maximum design steaming capacity of the boiler under any operating condition as determined by the Manufacturer. The valve or valves shall be located in the pressure part system where they will relieve the overpressure.
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An isolating stop valve of the outside-screw-and-yoke or ball type may be installed between the power-actuated pressure relieving valve and the boiler to permit repairs provided an alternate power-actuated pressure relieving valve of the same capacity is so installed as to be in direct communication with the boiler in accordance with the requirements of this paragraph.
The isolating stop valve port area shall at least equal the area of the inlet of the power-actuated pressure relieving valve. If the isolating stop valve is of the ball type, the valve shall include a means to clearly identify whether the valve is in the open or closed position. If the isolating stop valve is power actuated (air, motor, hydraulic, etc.), a manual override mechanism shall be provided.
Power-actuated pressure relieving valves discharging to intermediate pressure and incorporated into bypass and/or startup circuits by the boiler Manufacturer need not be capacity certified. Instead, they shall be marked by the valve manufacturer with a capacity rating at a set of specified inlet pressure and temperature conditions. Power-actuated pressure relieving valves discharging directly to atmosphere shall be capacity certified. This capacity certification shall be conducted in accordance with the provisions of PG-69.3. The valves shall be marked in accordance with the provisions of PG-69.4.
PG-67.4.2 Pressure relief valves shall be provided, having a total combined relieving capacity, including that of the power-actuated pressure relieving capacity installed under PG-67.4.l, of not less than 100% of the maximum designed steaming capacity of the boiler, as determined by the Manufacturer, except the alternate provisions of PG-67.4.3 are satisfied. In this total, no credit in excess of 30% of the total required relieving capacity shall be allowed for the power-actuated pressure relieving valves actually installed. Any or all of the pressure relief valves may be set above the maximum allowable working pressure of the parts to which they are connected, but the set pressures shall be such that when all of these valves (together with the power-actuated pressure relieving valves)are in operation the pressure will not rise more than 20% above the maximum allowable working pressure of any part of the boiler, except for the steam piping between the boiler and the prime mover.
PG-67.4.3 The total installed capacity of spring loaded safety valves may be less than the requirements of PG-67.4.2 provided all of the following conditions are met.
PG-67.4.3.1 The boiler shall be of no less steaming capacity than 1,000,000 lb/hr (450 000 kg/hr) and installed in a unit system for power generation (i.e., a single boiler supplying a single turbine-generator unit).
PG-67.4.3.2 The boiler shall be provided with automatic devices, responsive to variations in steam pressure, which include not less than all the following:
PG-67.4.3.2.1 A control capable of maintaining steam pressure at the desired operating level and of modulating firing rates and feedwater flow in proportion to a variable steam output.
PG-67.4.3.2.2 A control that overrides PG-67.4.3.2.1 by reducing the fuel rate and feedwater flow when the steam pressure exceeds the maximum allowable working pressure as shown in the master stamping (PG-106.3) by 10%; and
PG-67.4.3.2.3 A direct-acting overpressure-trip-actuating mechanism, using an independent pressure sensing device, that will stop the flow of fuel and feedwater to the boiler, at a pressure higher than the set pressure of PG-67.4.3.2.2, but less than 20% above the maximum allowable working pressure as shown in the master stamping (PG-106.3).
