Water-tube boilers and auxiliary installations - Part 5: Workmanship and construction of pressure parts of the boiler

This European Standard specifies requirements for the workmanship and construction of water-tube boilers as defined in EN 12952-1:2001.

Wasserrohrkessel und Anlagenkomponenten - Teil 5: Verarbeitung und Bauausführung für drucktragende Kesselteile

Diese Europäische Norm legt Anforderungen für die Verarbeitung und Bauausführung von Wasserrohrkesseln fest, die in EN 12952-1:2001 festgelegt sind.

Chaudières à tubes d'eau et installations auxiliaires - Partie 5: Fabrication et construction des parties sous pression de la chaudière

La présente Norme européenne spécifie les règles de fabrication et de construction des chaudières à tubes
d'eau telles que définies dans l'EN 12952-1:2001.

Vodocevni kotli in pomožne napeljave - 5. del: Izdelava in izvedba tlačno obremenjenih delov kotla

Ta dokument določa zahteve za izdelavo in izvedbo vodocevnih kotlov, kot so opredeljeni v EN 12952-1.

General Information

Status
Withdrawn
Publication Date
01-Nov-2011
Withdrawal Date
21-Dec-2021
Current Stage
9960 - Withdrawal effective - Withdrawal
Completion Date
22-Dec-2021

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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Wasserrohrkessel und Anlagenkomponenten - Teil 5: Verarbeitung und Bauausführung für drucktragende KesselteileChaudières à tubes d'eau et installations auxiliaires - Partie 5 : Fabrication et construction des parties sous pression de la chaudièreWater-tube boilers and auxiliary installations - Part 5: Workmanship and construction of pressure parts of the boiler27.060.30Grelniki vode in prenosniki toploteBoilers and heat exchangersICS:Ta slovenski standard je istoveten z:EN 12952-5:2011SIST EN 12952-5:2012en,fr,de01-januar-2012SIST EN 12952-5:2012SLOVENSKI

STANDARDSIST EN 12952-5:20021DGRPHãþD
SIST EN 12952-5:2012
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 12952-5
November 2011 ICS 27.040 Supersedes EN 12952-5:2001English Version

Water-tube boilers and auxiliary installations - Part 5: Workmanship and construction of pressure parts of the boiler

Chaudières à tubes d'eau et installations auxiliaires - Partie 5: Fabrication et construction des parties sous pression de la chaudière

Wasserrohrkessel und Anlagenkomponenten - Teil 5: Verarbeitung und Bauausführung für drucktragende Kesselteile This European Standard was approved by CEN on 10 September 2011.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,

B-1000 Brussels © 2011 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 12952-5:2011: ESIST EN 12952-5:2012

EN 12952-5:2011 (E) 2 Contents Page Foreword ..............................................................................................................................................................41Scope ......................................................................................................................................................62Normative references ............................................................................................................................63Terms and definitions ...........................................................................................................................74Symbols and abbreviations ..................................................................................................................85General ....................................................................................................................................................86Pressure part ..........................................................................................................................................86.1Drums, headers and similar pressure parts .......................................................................................86.2Material identification ............................................................................................................................96.3Material marking ....................................................................................................................................96.4Marking during manufacture ................................................................................................................97Cutting, forming and fabrication tolerances .................................................................................... 107.1Cutting material ................................................................................................................................... 107.2Forming of drums, headers and ends .............................................................................................. 117.3Forming of tube bends ....................................................................................................................... 117.4Drum and header fabrication tolerances .......................................................................................... 198Welding ................................................................................................................................................ 218.1Design and other requirements specific to welding ....................................................................... 218.2Welding consumables ........................................................................................................................ 248.3Welding approvals .............................................................................................................................. 248.4General production requirements for welding ................................................................................ 258.5Repairs to welds ................................................................................................................................. 268.6Pre-heating .......................................................................................................................................... 278.7Post-weld heat treatment ................................................................................................................... 278.8Welding subsequent to final post-weld heat treatment .................................................................. 278.9Welded joints, connections and production test plates ................................................................. 288.10Attachment of non-pressure parts to drums and headers by welding ......................................... 318.11Welding of tubes ................................................................................................................................. 328.12Flash butt welding of tubes ............................................................................................................... 348.13Welded tube water walls .................................................................................................................... 348.14Arc stud welding ................................................................................................................................. 349Mechanical connections .................................................................................................................... 359.1General ................................................................................................................................................. 359.2Access openings ................................................................................................................................ 35SIST EN 12952-5:2012

EN 12952-5:2011 (E) 3 9.3Branches and nozzles mechanically connected to the main pressure parts ............................... 369.4Tube connections ................................................................................................................................ 3710Thermal treatment ............................................................................................................................... 3910.1General ................................................................................................................................................. 3910.2Heating cycles and heat treatment(s) associated with plate forming operations ........................ 3910.3Pre-heating for welding and thermal cutting .................................................................................... 4110.4Post weld heat treatment .................................................................................................................... 4210.5Heat treatment of production test plates .......................................................................................... 51Annex A (normative)

Tube bending procedure tests .................................................................................... 52Annex B (informative)

Welded pressure connections and non-pressure containing attachments ......... 61Annex C (normative)

Manufacture of welded tubewalls ............................................................................... 62Annex D (normative)

Coiled boilers and coiled superheaters ..................................................................... 69Annex E (normative)

Special requirements for composite tubes ................................................................ 70Annex F (informative)

Guidelines for the determination of the competency of boiler manufacturers ...................................................................................................................................... 72Annex G (informative)

Significant technical changes between this European Standard and the previous edition ................................................................................................................................... 85Annex ZA (informative)

Relationship between this European Standard and the Essential Requirements of EU Directive 97/23/EC ............................................................................................ 87Bibliography ...................................................................................................................................................... 88 SIST EN 12952-5:2012

EN 12952-5:2011 (E) 4 Foreword This document (EN 12952-5:2011) has been prepared by Technical Committee CEN/TC 269 “Shell and water-tube boilers”, the secretariat of which is held by DIN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by May 2012, and conflicting national standards shall be withdrawn at the latest by May 2012. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights. This document supersedes EN 12952-5:2001. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). For relationship with EU Directive 97/23/EC, see informative Annex ZA, which is an integral part of this document. Annex G provides details of significant technical changes between this European Standard and the previous edition. The European Standard series EN 12952 concerning water-tube boilers and auxiliary installations consists of the following parts:  Part 1: General;  Part 2: Materials for pressure parts of boilers and accessories;  Part 3: Design and calculation for pressure parts of the boiler;  Part 4: In-service boiler life expectancy calculations;  Part 5: Workmanship and construction of pressure parts of the boiler;  Part 6: Inspection during construction; documentation and marking of pressure parts of the boiler;  Part 7: Requirements for equipment for the boiler;  Part 8: Requirements for firing systems for liquid and gaseous fuels for the boiler;  Part 9: Requirements for firing systems for pulverized solid fuels for the boiler;  Part 10: Requirements for safeguards against excessive pressure;  Part 11: Requirements for limiting devices of the boiler and accessories;  Part 12: Requirements for boiler feedwater and boiler water quality;  Part 13: Requirements for flue gas cleaning systems; SIST EN 12952-5:2012

EN 12952-5:2011 (E) 5  Part 14: Requirements for flue gas DENOX-systems using liquefied pressurized ammonia and ammonia water solution;  Part 15: Acceptance tests;  Part 16: Requirements for grate and fluidized-bed firing systems for solid fuels for the boiler;  CR 12952 Part 17: Guideline for the involvement of an inspection body independent of the manufacturer. NOTE 1 A Part 18 on operating instructions is currently in preparation. Although these parts may be obtained separately, it should be recognized that the parts are inter-dependent. As such, the design and manufacture of boilers requires the application of more than one part in order for the requirements of the European Standard to be satisfactorily fulfilled. NOTE 2 Part 4 and Part 15 are not applicable during the design, construction and installation stages. NOTE 3 A "Boiler Helpdesk" has been established in CEN/TC 269 which may be contacted for any questions regarding the application of European Standards series EN 12952 and EN 12953, see the following website: http://www.boiler-helpdesk.din.de. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom.

SIST EN 12952-5:2012

EN 12952-5:2011 (E) 6 1 Scope This European Standard specifies requirements for the workmanship and construction of water-tube boilers as defined in EN 12952-1:2001. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 287-1:2011, Qualification test of welders — Fusion welding — Part 1: Steels EN 473, Non-destructive testing — Qualification and certification of NDT personnel — General principles EN 571-1:1997, Non destructive testing — Penetrant testing — Part 1: General principles EN 1092-1:2007, Flanges and their joints — Circular flanges for pipes, valves, fittings and accessories, PN designated — Part 1: Steel flanges EN 1418:1997, Welding personnel — Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanized and automatic welding of metallic materials EN 1759-1:2004, Flanges and their joints — Circular flanges for pipes, valves, fittings and accessories, Class designated — Part 1: Steel flanges, NPS 1/2 to 24 EN 10025-2, Hot rolled products of structural steels — Part 2: Technical delivery conditions for non-alloy structural steels EN 10028-2, Flat products made of steels for pressure purposes — Part 2: Non-alloy and alloy steels with specified elevated temperature properties EN 10204:2004, Metallic products — Types of inspection documents EN 10216-2, Seamless steel tubes for pressure purposes — Technical delivery conditions — Part 2: Non-alloy and alloy steel tubes with specified elevated temperature properties EN 10253-2:2007, Butt-welding pipe fittings — Part 2: Non alloy and ferritic alloy steels with specific inspection requirements EN 10253-4:2008, Butt-welding pipe fittings — Part 4: Wrought austenitic and austenitic-ferritic (duplex) stainless steels with specific inspection requirements EN 12952-1:2001, Water-tube boilers and auxiliary installations — Part 1: General EN 12952-2:2011, Water-tube boilers and auxiliary installations — Part 2: Materials for pressure parts of boilers and accessories EN 12952-3:2011, Water-tube boilers and auxiliary installations — Part 3: Design and calculation for pressure parts EN 12952-6:2011, Water-tube boilers and auxiliary installations — Part 6: Inspection during construction; documentation and marking of pressure parts of the boiler EN 12952-7:2002, Water-tube boilers and auxiliary installations — Part 7: Requirements for equipment for the boiler SIST EN 12952-5:2012

EN 12952-5:2011 (E) 7 EN ISO 148-1:2010, Metallic materials — Charpy pendulum impact test — Part 1: Test method

(ISO 148-1:2009) EN ISO 4759-1:2000, Tolerances for fasteners — Part 1: Bolts, screws, studs and nuts — Product grades A, B and C (ISO 4759-1:2000) EN ISO 5817, Welding — Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) — Quality levels for imperfections (ISO 5817:2003, corrected version:2005, including Technical Corrigendum 1:2006) EN ISO 6520-1, Welding and allied processes — Classification of geometric imperfections in metallic materials — Part 1: Fusion welding (ISO 6520-1:2007) EN ISO 6892-1:2009, Metallic materials — Tensile testing — Part 1: Method of test at room temperature

(ISO 6892-1:2009) EN ISO 14555:2006, Welding — Arc stud welding of metallic materials (ISO 14555:2006) EN ISO 15609 (all parts), Specification and qualification of welding procedures for metallic materials — Welding procedure specification

EN ISO 15613, Specification and qualification of welding procedure for metallic materials — Qualification based on pre-production welding test (ISO 15613:2004) EN ISO 15614-1:2004, Specification and qualification of welding procedures for metallic materials — Welding procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys

(ISO 15614-1:2004) EN ISO 17638:2009, Non-destructive testing of welds — Magnetic particle testing (ISO 17638:2003) EN ISO 17663:2009, Welding — Quality requirements for heat treatment in connection with welding and allied processes (ISO 17663:2009) EN ISO 23277:2009, Non-destructive testing of welds — Penetrant testing of welds — Acceptance levels (ISO 23277:2006) EN ISO 23278:2009, Non-destructive testing of welds — Magnetic particle testing of welds — Acceptance levels (ISO 23278:2006) CEN ISO/TR 15608, Welding — Guidelines for a metallic material grouping system (ISO/TR 15608:2005) 3 Terms and definitions For the purposes of this document the terms and definitions given in EN 12952-1:2001 and the following apply. 3.1 cold forming for ferritic steels, it is forming at temperatures below the maximum permissible temperature for post-weld heat treatment and for austenitic materials it is forming at temperatures below 300 °C NOTE See Table 10.4-2. 3.2 hot forming for ferritic steels, it is forming at temperatures at or above the maximum permissible temperature for post-weld heat treatment SIST EN 12952-5:2012

EN 12952-5:2011 (E) 8 NOTE See Table 10.4-2. 4 Symbols and abbreviations For the purposes of this European Standard, the symbols given in EN 12952-1 shall apply. Throughout this European Standard, additional terminology and symbols have been included, where necessary, to meet the requirements of the specific text concerned. It should also be noted that in some clauses the same additional symbol is used in different equations to represent different terms. However, in all such cases, the special meaning of each symbol is indicated for each equation. 5 General Water-tube boilers shall be manufactured and assembled in accordance with approved drawings, procedures and specifications and good engineering practice. The workshops and sites associated with the construction of water-tube boilers shall be properly equipped and have suitable provisions for all the inspection and testing specified in EN 12952-6. The relevant manufacturing procedures shall be adequate and manufacturing personnel shall be competent and properly qualified for their assigned tasks. The procedures for the approval of welding and NDE personnel are given respectively in EN 12952-6:2011, Clause 7 and 9.2. Appropriate records of manufacturing operations shall be maintained. 6 Pressure part 6.1 Drums, headers and similar pressure parts 6.1.1 Principles for manufacturing Drums, headers and similar pressure parts shall be constructed from tubes, forgings, plates or castings. Drums and headers shall be in a suitably clean condition, both internally and externally, to enable proper visual inspection of the surface to be carried out before drilling of holes for tube stubs, branches, etc. and before welding of any permanent connections. 6.1.2 Manufacturing process for header ends The ends of forged or other seamless steel tube headers shall be carried out by any one of the following methods: a) forging or spinning; b) welding in accordance with Clause 8, see also EN 12952-3:2011, Figure 10.3-1; c) bolted flanges in accordance with relevant European Standards e.g. EN 1092-1:2007 or

EN 1759-1:2004. Bolted flanges in accordance with c) shall not be used where the bolts would be exposed to gases of combustion. 6.1.3 Material for header ends Header ends shall be forged or machined from steel of a grade compatible with the bodies of the headers and profiled as shown in EN 12952-3:2011, Figure 10.3-1. SIST EN 12952-5:2012

EN 12952-5:2011 (E) 9 6.2 Material identification The manufacturer shall maintain a system of material identification for all pressure parts and drum lifting lugs. The system shall be such that material used in major pressure parts (drums, tubes for header shells with do > 142 mm) can be traced back to its origin. The identification of tubes which are not used for header shells and tubes for header shells with do ≤ 142 mm shall be controlled by a system which permits positive identification of cast, on receipt into the manufacturer's works and maintenance of the material type identification throughout manufacturing operations by marking. 6.3 Material marking 6.3.1 General The marking of materials shall be maintained throughout the process of manufacture. If original markings are discarded or parts without markings could be created by dividing up parts during the course of manufacture, markings shall be transferred, normally before fabrication. Appropriate measures shall be taken to ensure that there is no possibility of confusion in the transfer of markings. 6.3.2 Responsible personnel Marking transfer shall be performed by the manufacturer's nominated representative(s) except for materials for which an inspection certificate (3.2) to EN 10204:2004 is required and also not for components classified as small parts. In the case of materials for which an inspection certificate (3.2) to EN 10204:2004 is required, the markings shall be transferred in accordance with the requirements of EN 12952-6:2011. NOTE This does not apply to small parts which are those made from certified products, such as nipples, nozzles, flanges, compensating rings, with outside diameters equal to or less than 142 mm. 6.3.3 Method of marking In general, material marking should be done by hard stamping using a low stress type metal stamp or etching. NOTE Other marking methods may be used if the manufacturer can ensure that their use will not impair the safety of the boiler. 6.3.4 Marking of non-pressure parts For welded non-pressure parts, marking need only be transferred if the identification of materials is not evident from the drawing or parts list. 6.3.5 Marking of bolts and nuts Bolts and nuts for pressure purposes shall be marked with the manufacturer's brand mark and property class symbol, or the steel grade code number in accordance with EN ISO 4759-1:2000. 6.4 Marking during manufacture 6.4.1 Temporary marking Temporary marks for the purpose of identification during manufacture e.g. parts numbers, welder numbers, radiograph numbers, etc. shall be made by any one, or a combination, of the following methods: SIST EN 12952-5:2012

EN 12952-5:2011 (E) 10 a) painting or pen, provided they are compatible with the material being marked; b) vibro etching or other etching tool; c) metal stamps of the low stress type. 6.4.2 Permanent marking Permanent marks complying with the requirements of 6.2 shall be made by any one or a combination, of the following methods: a) vibro etching or other etching tools; b) metal stamps of the low stress type; c) stamped data plates welded directly to the component using an approved welding procedure specification. 6.4.3 Tube bends Metal stamping shall not be permitted on the curved area of tube bends. 6.4.4 Location drawings Location drawings may be provided in the case of welders marks, radiographs, etc. 7 Cutting, forming and fabrication tolerances 7.1 Cutting material 7.1.1 Methods for cutting Steel shall be cut by thermal means, shearing, sawing, machining or a combination of these methods. Thermal cutting may necessitate the use of preheating, depending on the type of steel and the thickness in question, which shall be applied in accordance with 10.3.3. It is recognized that the cold worked zone resulting from the shearing process need not be eliminated before welding if this zone will be fused during welding. 7.1.2 Post-cutting measures Any material damaged metallurgically in the process of cutting to size or forming the edge or end preparation shall be removed by machining, grinding, chipping or thermal-cutting back to sound metal. Surfaces that have been thermally cut shall be cut back by machining or grinding so as to remove all burnt metal, harmful notches, slag and scale, but slight discoloration of machine thermally cut edges on mild steel shall not be regarded as detrimental. If alloy steels are prepared by thermal cutting, the surface shall be dressed back by grinding or machining for a distance of at least 1,5 mm, unless it can be shown that the material has not been damaged by the cutting process. NOTE These requirements for dressing do not apply to surfaces that are prepared for electro-slag welding, where a thermally cut surface is generally acceptable without further treatment. After the edges of the material have been prepared for welding, they shall be visually examined for flaws, cracks, laminations, slag inclusions or other defects before further work is carried out. Any weld repairs that are required to materials damaged as a result of thermal cutting shall be to an approved welding procedure specification. SIST EN 12952-5:2012

EN 12952-5:2011 (E) 11 7.2 Forming of drums, headers and ends 7.2.1 General Drums, headers and ends shall be rolled or pressed from plate, solid forged, drawn or extruded, or made by a combination of these processes. Components made by a forging, drawing or extrusion process shall be produced in accordance with the forgemaster's specification, as agreed with the boiler manufacturer. Components formed from ferritic steel plate shall be heat treated in accordance with 10.2.2 to 10.2.4 inclusive. The heating associated with forming operations and the heat treatment requirements after forming are given in 10.2. The forming requirements applicable to austenitic steel plate are the subject of development. In the meantime, the methods used shall be in accordance with the manufacturer's own proven procedure which shall ensure that, by their use, the safety of the boiler is not impaired. 7.2.2 Drum and header shells Shell plates shall be formed, either hot or cold, to ensure compliance with the tolerances specified in 7.4. Each shell plate shall be formed to the correct contour up to the extreme edges of the plate. The bending or pressing shall be done entirely by machine. The definitions of hot and cold forming are given in 3.1 and 3.2. Local heating and hammering shall not be employed. 7.2.3 Ends Dishing and peripheral flanging, either hot or cold, shall be carried out to ensure compliance with the tolerances specified in 7.4. The operations shall be performed by machine. Sectional flanging shall not be employed. 7.2.4 Plates welded prior to hot or cold forming Where practicable, shells and ends shall be rolled or pressed from one piece of plate. Where this is impracticable, butt welding of plate, prior to forming shall be permitted, provided that the welded joints are non-destructively examined after forming in accordance with the requirements of EN 12952-6:2011, and a welding procedure qualification test has been performed to EN ISO 15614-1:2004 taking into account any heat treatment cycles involved. A production test plate as specified in 10.2.5 shall be provided. 7.2.5 Extruded openings in headers Extruded openings in headers shall have a fillet with a radius not less than the thickness of the neck of the extrusion. 7.3 Forming of tube bends 7.3.1 General Tubes which are bent hot or cold shall conform to 7.3.2 to 7.3.12. This subclause does not apply to fittings in accordance with EN 10253-2:2007 and EN 10253-4:2008. NOTE Annex A requires procedure tests to be carried out on tube bends. Attention is drawn to the fact that not all the combinations of materials and bending processes permitted, and the associated thermal treatments nominated in Table 7.3-2, will satisfy the requirements for the procedure test given in 7.3.2 to 7.3.13 and Annex A. The manufacturer should ensure that any combination of material, bending process and the chosen bend geometry will produce bends that satisfy the requirements of 7.3. If a chosen bend geometry is found not to comply with the requirements of 7.3, the manufacturer should adjust the design to enable the requirements to be met. SIST EN 12952-5:2012

EN 12952-5:2011 (E) 12 7.3.2 Tube bending procedure test It shall be demonstrated by means of a tube bending procedure test (see Annex A) that tubes can be satisfactorily bent to the requirements of 7.3.1. The tests

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