Water-tube boilers and auxiliary installations - Part 4: In-service boiler life expectancy calculations

This European Standard is applicable to water-tube boilers as defined in EN 12952-1:2001.
This European Standard specifies procedures for calculating the creep and/or the fatigue damage of boiler components during operation. These calculations are not required to be carried out by the manufacturer as part of his responsibilities within this European Standard.

Wasserrohrkessel und Anlagenkomponenten - Teil 4: Betriebsbegleitende Berechnung der Lebensdauererwartung

Diese Europäische Norm gilt für Wasserrohrkessel wie in EN 12952 1:2001 definiert.
Diese Europäische Norm legt Verfahren zur Berechnung der Kriech- und/oder Ermüdungsschädigung von Kessel¬bauteilen während des Betriebs fest. Die Durchführung dieser Berechnungen ist nicht Teil der Verant-wort¬lichkeiten des Herstellers innerhalb dieser Europäischen Norm.

Chaudières à tubes d'eau et installations auxiliaires - Partie 4: Calculs de la durée de vie prévisible des chaudières en service

La présente Norme européenne s’applique aux chaudières à tubes d’eau telles que définies dans
l’EN 12952-1:2001.
La présente Norme européenne décrit des procédures de calcul des dommages liés au fluage et/ou à la fatigue des composants de chaudières au cours du fonctionnement. Il n'est pas requis que ces calculs soient menés par le fabricant dans le cadre de sa mission au titre de la présente Norme européenne.

Vodocevni kotli in pomožne napeljave - 4. del: Izračun pričakovane življenjske dobe obratovanja

Ta evropski standard velja za vodocevne kotle, kot so opredeljeni v EN 12952-1:2001. Ta evropski standard določa postopke za izračun poškodbe zaradi lezenja in/ali utrujenosti sestavnih delov kotlov med obratovanjem. Teh izračunov proizvajalcu ni treba opraviti kot del odgovornosti v okviru tega evropskega standarda.

General Information

Status
Withdrawn
Publication Date
30-Oct-2011
Withdrawal Date
30-Jan-2012
Current Stage
9060 - Closure of 2 Year Review Enquiry - Review Enquiry
Start Date
02-Dec-2022
Completion Date
02-Dec-2022

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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Wasserrohrkessel und Anlagenkomponenten - Teil 4: Betriebsbegleitende Berechnung der LebensdauererwartungChaudières à tubes d'eau et installations auxiliaires - Partie 4 : Calculs de la durée de vie prévisible des chaudières en serviceWater-tube boilers and auxiliary installations - Part 4: In-service boiler life expectancy calculations27.060.30Grelniki vode in prenosniki toploteBoilers and heat exchangersICS:Ta slovenski standard je istoveten z:EN 12952-4:2011SIST EN 12952-4:2011en,fr,de01-november-2011SIST EN 12952-4:2011SLOVENSKI

STANDARDSIST EN 12952-4:20011DGRPHãþD
SIST EN 12952-4:2011
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 12952-4
July 2011 ICS 27.040 Supersedes EN 12952-4:2000English Version

Water-tube boilers and auxiliary installations - Part 4: In-service boiler life expectancy calculations

Chaudières à tubes d'eau et installations auxiliaires -Partie 4: Calculs de la durée de vie prévisible des chaudières en service

Wasserrohrkessel und Anlagenkomponenten - Teil 4: Betriebsbegleitende Berechnung der Lebensdauererwartung This European Standard was approved by CEN on 18 June 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 12952-4:2011: ESIST EN 12952-4:2011

EN 12952-4:2011 (E) 2 Contents Page Foreword ............................................................................................................................................................. 31Scope ...................................................................................................................................................... 52Normative references ............................................................................................................................ 53Terms and definitions ........................................................................................................................... 54Symbols and abbreviations .................................................................................................................. 55General ................................................................................................................................................... 56Calculations ........................................................................................................................................... 5Annex A (informative)

Calculation of in-service creep damage ................................................................... 6Annex B (informative)

Calculation of in-service fatigue damage ............................................................... 10Annex C (informative)

Significant technical changes between this European Standard and the previous edition ................................................................................................................................... 20Bibliography ...................................................................................................................................................... 21 SIST EN 12952-4:2011

EN 12952-4:2011 (E) 3 Foreword This document (EN 12952-4:2011) 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 January 2012, and conflicting national standards shall be withdrawn at the latest by January 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 12952-4:2000. Annex C provides details of significant technical changes between this European Standard and the previous edition. The European Standard 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;  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;  Part 14: Requirements for flue gas DENOX-systems using liquified 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. SIST EN 12952-4:2011

EN 12952-4:2011 (E) 4 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 water-tube boilers requires the application of more than one part in order for the requirements of this 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 12952-4:2011

EN 12952-4:2011 (E) 5 1 Scope This European Standard is applicable to water-tube boilers as defined in EN 12952-1:2001. This European Standard specifies procedures for calculating the creep and/or the fatigue damage of boiler components during operation. These calculations are not required to be carried out by the manufacturer as part of his responsibilities within this European Standard. 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 12952-1:2001, Water-tube boilers and auxiliary installations — Part 1: General EN 12952-3:2011, Water-tube boilers and auxiliary installations — Part 3: Design and calculation for pressure parts 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 12952-1:2001 apply. 4 Symbols and abbreviations For the purposes of this document, the symbols and abbreviations given in EN 12952-1:2001, Table 4-1 apply. 5 General The calculations may be carried out, using transposed design equations. The measured (actual) wall thickness of the components shall be used in the calculations, i.e. taking into account any wall thickness reduction that may have occurred due to corrosion or erosion during the service life up to the time of the analysis, see EN 12952-3:2011, 5.7. Operating temperature, pressure and especially the magnitude of load changes often differ from the estimations used for the design. Thus, these calculations may help to prevent unexpected early failure of components. The results may be used as a guideline for the decision to inspect a component for fatigue cracks or to inspect for creep pores by the replica method or any other suitable method. NOTE In some cases, the influence of both creep and fatigue damage will be significant. It is normally conservative to combine the creep and fatigue damage mechanisms by adding the calculated usage factors. If necessary, more detailed methods of assessment may be used (see [1] PD 7910 Published by British Standardization Institute, London, UK). Thus, the components are not necessarily to be replaced, if the calculated usage factor exceeds the value of 1. The highest loaded components shall be chosen for monitoring purposes. 6 Calculations Annex A describes the creep damage calculation. Annex B describes the fatigue damage calculation. SIST EN 12952-4:2011

EN 12952-4:2011 (E) 6 Annex A (informative)

Calculation of in-service creep damage A.1 General This annex describes a procedure for calculating the creep damage of a boiler and its major components during operation. It is based on measured values of pressure and temperature, from which the actual primary stress and the expected lifetime at these conditions may be determined. Design lifetime is not necessarily identical with the operating lifetime. It is therefore necessary to make projections at various stages throughout the operating lifetime of the boiler to determine its expected lifetime. A.2 Symbols and abbreviations In addition to the symbols given in EN 12952-1:2001, Table 4-1, the symbols given in Table A.1 apply. Table A.1 — Symbols Symbol Description Unit fop Membrane stress at operating conditions N/mm2 Top Operated time at operating conditions h Tal Time to reach the theoretical rupture by creep h Dc Creep damage – A.3 Calculation of in-service lifetime and creep damage A.3.1 General The calculation of the usage factor due to creep is a method that retrospectively takes into consideration the previous modes of operation. It is carried out for highly loaded components on the basis of the measured operating temperatures and gauge pressures. In order to limit the number of the required calculations and to more clearly present the results, the pressure and temperature range over which the component has been operated, shall be broken down into increments. The membrane stress fop at the highest loaded point in the component shall be obtained by transposing the design formula using the mean pressure of each pressure increment. If the operating pressure is not measured continuously during operation the separation into increments is not valid and under such circumstances the operating pressure for 100 % load may be used, thus resulting in more conservative predictions. If available, the measured minimum wall thickness may be used. If this was not measured, the guaranteed minimum wall thickness of the material as delivered shall be used. The theoretical lifetime Tal shall be calculated for each rating temperature/pressure. According to Figure A.1, Tal is obtained at the intersection of the stress line fop and the lower limit curve of the scatter band of the creep rupture strength (= 0,8 Rm T tc) at the mean temperature of each temperature increment. The respective portion of the creep damage ûDci k for each incremental temperature/pressure is obtained by the ratio of the operating time Top for this increment divided by the theoretical lifetime Tal for the same increment. SIST EN 12952-4:2011

EN 12952-4:2011 (E) 7

Key a) lg (Rm) b) lg (T), h Figure A.1 — Diagram for the determination of Tal The operating times in the temperature/pressure increment shall be summarized, taking into account the temperature allowances for measuring uncertainties and for temperature asymmetries in due consideration at this classification. The usage portion for each increment is given by alopkciTTD=û (A.1) The creep damage Dc during the evaluated period shall be obtained from the linear damage rule by summing up the values ûDci k for all temperature increments and, if any, pressure as follows: ∑∑=ikkcicDDû (A.2) A.3.2 Online computerized data storage In the case of on-line data storage by means of a data processing system a separation into increments may be waived. For calculation of the theoretical lifetime Tal the on-line measured values of pressure and temperature including the above mentioned allowances shall be used instead of the mean values of the increments. The increase of creep damage is obtained in this case from the measured time divided by the theoretical lifetime (see Tables A.2 and A.3). The computer programme used shall permit the results to be verified by at least a random test. SIST EN 12952-4:2011

EN 12952-4:2011 (E) 8 Table A.2 — Summation of data for the calculation of in-service creep damage User and boiler plant: XY Power station: XY Boiler: 3 Works-No.: 12345 Year built: 2003 Maximum allowable pressure HP: 84 bar Reheater: – bar Superheated steam temperature: HP: 525 °C Reheater: – °C Steam output: 128 t/h 1 2 3 4 5 67 8 9 10 11 12 13 No. Component Material; Steel group a

mm c

es mm ers mm pc bar to °C tc °C fap N/mm2 Tal 103 h 1 HP-line 13CrMo44; 5.1 m AB292,0o24,021,075,5525 530 48,7 208 2 Superheater 2 – header 13CrMo44; 5.1 n AB419,0o39,039,075,5510 525 56,3 186 3 Superheater 2 – outlet line 13CrMo44; 5.1 n AB241,0o17,517,575,5510 525 48,2 304 4 Superheater 2 – outlet header 16CrMo44; 5.1 n AB250,0i 20,028,075,5510 525 47,1 329 7 Fitting at control 20Mo3; 1.2 m AB225,0i 28,020,080,4460 465 86,6 > 500 11 Superheater 1 – outlet line 16Mo3; 1.1 n AB241,0o14,014,080,4460 475 65,2 > 500 12 Superheater 1 – outlet header 20Mo3; 1.2 n AB250,0i 22,022,080,4460 475 67,0 > 500 a Column 3:

Temperature allowances according to EN 12952-3:2011, Table 6.1-1
unheated = mixed or controlled (+ 5 °C)
unheated (+ 15 °C) b Column 4: A
Nominal or design values
Operational or actual values
c Column 6:
Inside diameter
Outside diameter
SIST EN 12952-4:2011

EN 12952-4:2011 (E) 9 Table A.3 — Summation of data for the calculation of in-service creep damage User and boiler plant: XY Power station: XY Boiler: 6 Works-No.: 12345 Component: Connecting pipes between primary super heater and secondary

super heater ∅ 90 × 8 Commissioning: 2003 Material: Steel group 5.1 (13CrMo44) Calculation pressure pc: 100 bar Mean wall temperature tc: 530 °C Stress at pc: 57,5 N/mm2 Evaluated period: from

to 1 2 3 4 5 6 7 Evalu-ation range At outlet of component Calculation pressure Calculation temperature Related to mean wall temperature Elapsed operating time Creep damage for evaluated period

to pc tc Tal Top ûDc
From to mean
°C bar °C 103 h h % 1

< 500 < 500 100 515 430 1 250 0,29 2 500 510 505 100 520 260 820 0,31 3 510 515 512,5 100 527,5 162 6 800 4,20 4 515 520 517,5 100 532,5 106 5 760 5,45 5 520 525 522,5 100 537,5 80 610 0,76

Sum for evaluated period 15 240 11,01 Sum prior to evaluated period 20 000 14,00 Total 35 240 25,01

SIST
...

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