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GB/T 16508.4-2013 English PDF (GBT16508.4-2013)

GB/T 16508.4-2013 English PDF (GBT16508.4-2013)

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GB/T 16508.4-2013: Shell boilers -- Part 4: Fabrication, inspection and acceptance

This Part of GB/T 16508 specifies the requirements for fabrication, inspection and test, delivery information and nameplate of stationary shell boilers. This Part is applicable to the shell boilers defined within the scope of GB/T 16508.1.
GB/T 16508.4-2013
NATIONAL STANDARD OF THE
PEOPLE REPUBLIC OF CHINA
ICS 27.060.30
J 98
Partially replacing GB/T 16507-1996
Shell Boilers -- Part 4: Fabrication, Inspection and
Acceptance
ISSUED ON: DECEMBER 31, 2013
IMPLEMENTED ON: JULY 1, 2014
Issued by: General Administration of Quality Supervision, Inspection and Quarantine of the PRC;
Standardization Administration of the PRC.
Table of Contents
Foreword ... 3
1 Scope ... 6
2 Normative References ... 6
3 Terms and Definitions ... 7
4 Fabrication ... 8
5 Inspection and Test ... 33
6 Delivery Information and Nameplate ... 41
Appendix A (Normative) Welded Tube Orifice of Boiler ... 44
Foreword
GB/T 16508 Shell Boilers comprises the following eight parts:
-- Part 1: General Requirements;
-- Part 2: Material;
-- Part 3: Design and Strength Calculation;
-- Part 4: Fabrication, Inspection and Acceptance;
-- Part 5: Safety Appurtenances and Instruments;
-- Part 6: Combustion Systems;
-- Part 7: Installation;
-- Part 8: Operation.
This Part is Part 4 of GB/T 16508.
This Part was drafted according to the rules given in GB/T 1.1-2009.
This Part replaces the relevant contents such as fabrication, inspection, and acceptance in GB/T 16507-1996 Rules for Construction of Stationary Boilers. Compared with GB/T 16507-1996, the main technical changes are as follows: a) ADD Chapter 3 "Terms and Definitions";
b) Chapter 4:
-- ADD management requirements for the use of new process, new technique, and new method;
-- ADD requirements for butt welds of flat tube plate and arched tube plate; -- ADD requirements for dimension deviation of corrugated furnace;
-- ADD requirements for dimension deviation of tube orifice center distance and dimension deviation of tube orifice;
-- ADD forming requirements of threaded flue;
Shell Boilers -- Part 4: Fabrication, Inspection and
Acceptance
1 Scope
This Part of GB/T 16508 specifies the requirements for fabrication, inspection and test, delivery information and nameplate of stationary shell boilers.
This Part is applicable to the shell boilers defined within the scope of GB/T 16508.1. 2 Normative References
The following referenced documents are indispensable for the application of this document. For dated reference, only the edition cited applies. For undated reference, the latest edition of the normative document (including any amendments) applies. GB 146.1 Rolling Stock Gauge for Standard Gauge Railways
GB 191 Packaging - Pictorial Marking for Handling of Goods
GB/T 1804 General Tolerances - Tolerances for Linear and Angular Dimensions without Individual Tolerance Indications GB/T 2652 Tensile Test Methods on Weld and Deposited Metal
GB/T 16507.5 Water-Tube Boilers - Part 5: Fabrication
GB/T 16508.1 Shell Boilers - Part 1: General Requirements
GB/T 16508.2 Shell Boilers - Part 2: Material
GB/T 16508.3 Shell Boilers - Part 3: Design and Strength Calculation
GB/T 19293 Method of X-Ray Radioscopy for Butt-Weld
GB/T 25198 Heads for Pressure Vessels
4 Fabrication
4.1 Basic requirements
4.1.1 Qualifications of boiler fabrication organization and operation personnel shall meet those specified in GB/T 16508.1.
4.1.2 Materials for boiler fabrication shall meet the requirements of design document and GB/T 16508.2.
4.1.3 Fabrication, inspection and acceptance of boilers shall meet the requirements of TSG G0001 Boiler Safety Technical Supervision Administration Regulation, design documents and this Part.
4.1.4 Adoption of new process, new technique and new method for boiler fabrication and inspection unlisted in this Part shall be in accordance with relevant provisions of TSG G0001 Boiler Safety Technical Supervision Administration Regulation. 4.2 Mark and mark transplantation
4.2.1 Material marks for pressure parts and main loaded non-pressure parts (hanger/support and brace) shall have traceability. In the process of fabrication, if the original mark is cut off or the material is divided into several pieces, the fabrication organization shall specify the expression mode of the mark and complete mark transplantation prior to the material cutting.
4.2.2 Weld of pressure part, weld of product welding specimen and surrounding fillet weld between the pressure parts and the main loaded non-pressure parts shall be printed with steel seal of welder code, or the welder code shall be recorded in the welding record including weld map.
4.2.3 Non-destructive testing mark shall meet the requirements of NB/T 47013 (JB/T 4730).
4.2.4 In the area of inner and outer arcs of tube bend, hard imprint mark is not allowed to be used.
4.3 Material cutting
4.3.1 Material cutting method is selected according to steel characteristics and specification. The adopted cutting method shall ensure machining precision. 4.3.2 During thermal cutting, the material may be pre-heated according to the type flange/boiler furnace hole flange on the tube plate to the starting point of the flange bending is greater than 5mm may be polished or soldered according to 4.4.2.2. 4.4.2.4 Any crack and rip due to unsatisfied steel plate quality and over-burning, shall not be subjected to repair welding.
4.4.3 Weld layout
4.4.3.1 The longitudinal welds of two adjacent shell sections at the shell (except that with unequal wall thickness), shell and boiler furnace as well as the butt welds at the head, tube plate, boiler furnace top or foot ring and the longitudinal weld at adjacent shell sections shall not be connected with each other. The distance between the centerlines of the welds (arc length of the excircle) is at least three times the thickness of the thicker steel plate and greater than or equal to 100mm.
4.4.3.2 The distance (L) between centerlines of the butt welds at the boiler heating surface tube (except the dissimilar steel joint) and the straight section of the tubing shall meet the following requirements:
a) The outside diameter is less than 159mm and L is greater than or equal to 2 times of the outside diameter;
b) The outside diameter is greater than or equal to 159mm and L is greater than or equal to 300mm.
Where the boiler structure is difficult to meet the requirements of this article, the heat- affected zone of butt welds shall not be overlapped, and L shall be greater than or equal to 50mm.
4.4.3.3 Boiler heating surface tube and tubing butt weld position shall meet the following requirements:
a) The butt weld at the heating surface tube and tubing (except coil tube and molded tube fittings) shall be located at the straight section of the tube; b) The distance between the centerline of the butt weld at the heating surface tube and the external wall of the shell and header, starting point of the tube bending and the edges of the tube supports and hangers is at least 50mm; for boilers with rated operating pressure of greater than or equal to 3.8MPa, the distance is at least 70mm and that for the tubing shall not be less than 100mm.
4.4.3.4 Main welds at the pressure parts and the neighboring areas shall be kept clear of the welded attachments. If impossible, the weld at the welded attachments may be penetrated through the main weld, but shall not be ended at the main weld and the neighboring areas.
4.4.3.5 Tube orifices in expansion connection shall not be arranged at the longitudinal weld of the shell and also shall avoid being arranged at the circumferential weld as much as possible.
4.4.3.6 The orifice of common down-comer shall not be made at the weld, and other welded tube orifices also shall avoid being made at the weld and its heat-affected zone. 4.4.3.7 For the shell with nominal inside diameter of greater than 1800mm, quantity of longitudinal butt welds at each section of the shell shall not be greater than 3 pieces; for the shell and boiler furnace with the nominal inside diameter of not greater than 1800mm; quantity of longitudinal butt welds at each section of the shell shall not be greater than 2. Arc length of the excircle between the longitudinal welds at each section of the shell shall not be less than 300mm.
4.4.3.8 During shell splicing, length of any shell section at the shell and the boiler furnace shall not be less than 300mm and that of any shell section at the header shell shall not be less than 500mm.
4.4.3.9 Quantity of butt welds at the tube sheet and head with the nominal inside diameter of greater than 2200mm shall not be greater than 2; that of the butt welds at the tube sheet and head with the nominal diameter of not greater than 2200mm shall not be greater than 1.
4.4.3.10 The distance from the butt weld of the head to the centerline of the head shall not be greater than 30% of the nominal bore of the end, furthermore, the weld shall not pass through the flange manhole or arranged on the circular arc of the plate edge of manhole.
4.4.3.11 The whole piece of the butt weld of the flat tube plate shall not be arranged at the flange arc, or penetrate through the flange hole.
4.4.3.12 Distance from the butt weld of the arched tube plate to the intersecting line of the straight part and the raised part shall not exceed 30% of equivalent inside diameter (centerline is counted from that of edge flue row).
4.4.3.13 The butt weld of the foot ring shall be arranged in radial direction, the minimum excircle arc length between centerlines of two welds shall not be less than 300mm.
4.4.4 Groove preparation
4.4.4.1 The groove type, dimension and assembling gap of welded joints shall meet 4.6 Welding
4.6.1 General requirements
4.6.1.1 The welder shall conduct welding as per welding procedure specification prepared according to welding procedure that passes the evaluation and make the welding record well.
4.6.1.2 Welding procedure qualification other than this Organization shall not be used for welding work of pressure part products of this Organization.
4.6.1.3 The fabrication organization shall create technical files of welders, and inspect and evaluate the actual welding procedure parameters and weld quality as well as the welder's conformity with the procedure discipline.
4.6.2 Pre-welding preparation and welding environment
4.6.2.1 The storage house for electrodes, welding fluxes and other welding materials shall be kept dry, and its relative humidity shall not be greater than 60%. 4.6.2.2 Without effective protection measures, the welding must not be conducted under one of the following welding environments:
a) Wind speed is greater than 10m/s at shielded metal arc welding;
b) Wind speed is greater than 2m/s at gas metal arc welding (GMAW);
c) The relative humidity is greater than 90%;
d) Rain and snow environment;
e) The weldment temperature is lower than -20??C.
4.6.2.3 Where the weldment temperature is -20??C~0??C, the weldment shall be preheated to 15??C above within 100mm of the initial welding.
4.6.3 Welding procedure qualification
4.6.3.1 Before welding of the boiler product, the following welded joints shall be subjected to welding procedure qualification:
a) Butt welded joint between pressure parts;
b) Full-penetration T-shaped joint or fillet joint between the pressure parts or structure that exceeds the limit, another heat treatment is allowed to be conducted for the inspected specimen and then double specimen are taken for the re-inspection (after the qualification, the mechanical property still shall be re-inspected) and all the specimens may be deemed as acceptable after they pass the re-inspection.
4.6.3.4 Welding procedure qualification document shall meet the following requirements:
a) The welding organization shall, according to the product welding requirements and welding procedure qualification standard, prepare preliminary welding procedure specification (PWPS) for evaluation and form a welding procedure qualification report (PQR) after the qualification in the welding procedure qualification and may carry out welding after formulating the welding procedure specification (WPS);
b) Welding procedure specification shall at least include welding method and degree of mechanization, material, thickness range, welding groove, welding specification, welding position, preheating temperature, number of welding layers (number of beads), welding material, heat treatment requirements and welding technical requirements etc.;
c) After completion of the welding procedure qualification, the welding procedure qualification report and welding procedure specification shall be approved by the welding engineer from the fabrication organization and may be kept in the technical files after the approval by the technical principal. The technical files shall be kept until the procedure qualification is invalid. The welding procedure qualification specimen shall be at least kept for 5 years. Upon approval, the technical contents of welding procedure qualification shall not be modified and only editorial modification and supplement are allowed.
4.6.4 Welding procedure
4.6.4.1 No arc ignition is allowed on non-welded surface of the weldment; any crater, if any, shall be polished or soldered. For materials with crack tendency, surface non- destructive testing shall be carried out after polishing or soldering.
4.6.4.2 Run-on plate, run-off plate or product welding specimen on both ends of the longitudinal weld of the weldment must not be dismantled by hammering.
4.6.4.3 During assembling, the weldment shall not be aligned in a forced way. The welding may be carried out only after the weldment assembling and tack welding quality meet the requirements of the procedure documents.
d) Where combined welding procedure is adopted, if preheating is required, preheating requirements shall be determined for each procedure respectively; e) The temperature of the weldment joint requiring preheating shall not be less than the preheating temperature in the whole process of welding.
4.6.5.2 Post-heating shall meet the following requirements:
a) Post-heating measures shall be taken for the low alloy steel with relatively large sensitivity to cold crack and the weldment with larger restraint degree, which shall meet the requirements of the procedure documents;
b) Post-heating temperature is generally 200??C~350??C; holding time, in relation to post-heating temperature and weld metal thickness, is generally not less than 30min;
c) Post-heating shall be carried out immediately after welding and post-heating may be omitted if heat treatment is carried out immediately after welding. 4.6.6 Appearance inspection on welded joints of pressure parts
Welded joints of pressure parts (including those between pressure parts and main loaded non-pressure parts) shall be subjected to appearance inspection according to the following requirements:
a) Overall dimension of the weld shall meet the requirements of design drawing and procedure document;
b) Weld height of butt joint shall not be less than that of the base material surface; the weld and the base materials shall have smooth transition; the weld and the heat-affected zone surface is free from crack, incomplete fusion, slag inclusion, crater and gas cavity;
c) Longitudinal and circumferential welds of the shell, boiler furnace, header or tubing and butt welds of the head, tube plate and foot ring shall be free from undercut and undercut depth of other welds shall not exceed 0.5mm. Total undercut length on both sides of the tube weld shall not exceed 20% the perimeter of the tube or 40mm;
d) Connecting weld and base material between pressure parts and loaded non- pressure parts shall have smooth transition and continuous weld; weld and heat-affected zone surface shall be free from crack, incomplete fusion, slag inclusion, crater and gas cavity etc. and the undercut depth is not greater than 0.5mm.
4.6.7 Repair welding
4.6.7.1 Where the weld requires repair, causes of defects shall be found out and repair procedure shall be established according to the requirements of 4.6.1. 4.6.7.2 Before repair welding, the defect shall be thoroughly eliminated and repair shall not be carried out in exposure to water.
4.6.7.3 After repair welding, the repair welding area shall be subjected to appearance and non-destructive testing inspection. The parts requiring post-weld heat treatment shall be subjected to post-weld heat treatment after repair welding.
4.6.7.4 The same position should not be repaired over 2 times; if over 2 times, it shall be approved by the technical director of the organization and the repair positions, times and conditions shall be kept in the technical files of the boiler product. 4.7 Heat treatment
4.7.1 Basic requirements
4.7.1.1 The fabrication organization shall prepare heat treatment procedure prior to heat treatment according to corresponding standard and drawing requirements and shall put forward procedure requirements for specific on-site heat treatment for conditions requiring on-site heat treatment.
4.7.1.2 Coal-fired furnace shall not be used for post-weld heat treatment. 4.7.1.3 Heat treatment equipment shall be equipped with such device that automatically records heat treatment time and temperature curve. The temperature measuring device shall be able to reflect the actual temperature of the workpiece accurately.
4.7.1.4 In the process of post-weld heat treatment, various parameters of heat treatment specification shall be recorded in detail. After heat treatment, relevant responsible personnel shall check, in detail, whether each record index is in accordance with the procedure requirements.
4.7.2 Heat treatment for restorability of formed pressure parts
4.7.2.1 Where cold forming is adopted for the carbon steel and low-alloy steel plate, their deformation rate shall not be greater than 5%. The deformation rate is calculated according to Formulas (1) and (2) (see Figure 9):
shall be carried out for the carbon steel and alloy steel; solution treatment shall be carried out for the austenitic stainless steel.
4.7.2.3 During step-by-step cold forming, if intermediate heat treatment is not carried out, the deformation rate of the formed parts is the sum of the forming deformation rates in each step; if intermediate heat treatment is carried out, sum of deformation rates of the formed parts before and after the intermediate heat treatment shall be calculated respectively.
4.7.2.4 Elimination of deformation and residual stress of warm forming workpieces, if required, shall refer to cold forming conditions and requirements stated in 4.7.2.1 and 4.7.2.2.
4.7.2.5 If hot forming or warm forming destroys the material supply heat treatment state, heat treatment shall be carried out again to restore the material supply heat treatment state.
4.7.2.6 Any special requirements for heat treatment of forming temperature and restoring the material supply heat treatment state, if any, shall comply with relevant standards, specifications or design documents.
4.7.3 Post-weld heat treatment
4.7.3.1 It is determined whether the pressure parts is subjected to post-weld heat treatment according to the material, post-weld heat treatment thickness ??PWHT and design requirements.
4.7.3.2 The pressure parts may be subjected to post-weld heat treatment only after all the welding (including welding of non-pressure parts and their connection) work is finished and passes the inspection.
4.7.3.3 Post-weld heat treatment shall be carried out before pressure test. 4.7.3.4 Post-weld heat treatment thickness ??PWHT...

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