Pressure Vessel Update (NB-132, Revision 8)

In order to protect the public from boiler and pressure vessel explosions, guidelines must be in place to ensure proper construction, installation, inspection, operation, maintenance, alterations, and repairs. However, these guidelines do little to protect the public unless they are mandated by law.  In order to encourage the development of essential safety laws in jurisdictions that have no laws, rules, or regulations in the area of boiler and pressure vessel safety, the National Board published NB-131, Recommended Boiler and Pressure Vessel Safety Legislation, and NB-132, Recommended Administrative Boiler and Pressure Vessel Safety Rules and Regulations. These documents may be used as guidelines to update a jurisdiction’s existing requirements and also provide a VERY NICE summary of some basics for pressure vessel safety. 

NOTE:  This is a sunmary of the highlights of this document.  If you are interested in the full document, please download NB-132 Recommended Administrative Boiler and Pressure Vessel Safety Rules and Regulations.

The first thing to establish are the “official” definitions.

Definitions

ALTERATION – any change in the item described on the original Manufacturer’s Data Report which affects the pressure-containing capability
of the boiler or pressure vessel. Nonphysical changes such as an increase in the maximum allowable working pressure (internal or external) or design temperature of a boiler or pressure vessel shall be considered an alteration. A reduction in minimum temperature such that additional mechanical tests are required shall also be considered an alteration.

ANSI – American National Standards Institute

API CERTIFIED INSPECTOR – an inspector who is certified by the American Petroleum Institute to perform functions specified in API-510 or API-570.

API-510, PRESSURE VESSEL INSPECTION CODE – the code for maintenance inspection, repair, alteration, and re-rating procedures for pressure vessels used by the petroleum and chemical process industries. API-510 is published by the American Petroleum Institute and is an approved ANSI standard.

API-570, PIPING INSPECTION CODE – the code for maintenance inspection, repair, alteration, and re-rating procedures for process piping used by the petroleum and chemical process industries. API-570 is published by the American Petroleum Institute and is an approved ANSI standard.

API-RP 579, FITNESS-FOR-SERVICE – A recommended practice that describes standardized fitness-for-service assessment techniques for pressurized equipment used in the petrochemical industry. Fitness-for-service is defined as the ability to demonstrate the structural integrity of an in-service component containing a flaw.

API/ASME CODE – the American Petroleum Institute (API), in conjunction with the ASME Code, as used in these rules and regulations shall mean the Code for Unfired Pressure Vessels for Petroleum Liquids and Gases, that existed from 1934-1956, and is no longer in use.

APPROVED – approved by the Board of Boiler and Pressure Vessel Rules.

ASME – the American Society of Mechanical Engineers.

ASME CODE – The Boiler and Pressure Vessel Code published by the American Society of Mechanical Engineers, including addenda and code cases approved by the council of that Society.

AUTHORIZED INSPECTION AGENCY – one of the following:

New Construction: An Authorized Inspection Agency is one that meets the qualification and definition of NB-360, Criteria for Acceptance of Authorized Inspection Agencies for New Construction.

Inservice: An Authorized Inspection Agency is either:

A. a jurisdictional authority as defined in the National Board Constitution, or
B. an entity that is accredited in accordance with NB-369, Qualifications and Duties for Authorized Inspection Agencies (AIAs) Performing Inservice Inspection Activities and Qualifications for Inspectors of Boilers and Pressure Vessels.

BOARD – the Board of Boiler and Pressure Vessel Rules created by the Act and empowered to make, alter, amend, and interpret rules and regulations for the safe construction, installation, inspection, alteration, and repair of boilers and pressure vessels.

BOILER – a closed vessel in which water or another liquid is heated, steam or vapor is generated, steam or vapor is superheated, or any combination thereof, under pressure or vacuum, for use external to itself, by the direct application of energy from the combination of fuels or from electricity, solar or nuclear energy. The term “boiler” includes fired units for heating or vaporizing liquids other than water but does not include fired process heaters and systems. The term boiler also shall include the apparatus by which heat is generated as well as all controls and safety devices associated with such apparatus or the closed vessels.

1. Power Boiler – a boiler in which steam or other vapor is generated at a pressure of more than 15 psig for use external to itself.
2. High-Temperature Boiler – a boiler in which water or other fluid is heated and intended for operation at pressures in excess of 160 psig and/or temperatures in excess of 250°F. 
3. Heating Boiler – a steam or vapor boiler operating at a pressure not exceeding 15 psig or a boiler in which water or other fluid is heated and intended for operation at pressures not exceeding 160 psig or temperatures not exceeding 250°F. 
4. Electric Boiler – a power boiler or heating boiler in which the source of heat is electricity.
5. Miniature Boiler – a power boiler or high-temperature boiler which does not exceed the following limits: 
6. 16 inches inside diameter of shell; 
7. 20 square feet heating surface (not applicable to electric boilers); 
8. 5 cubic feet gross volume exclusive of casing and insulation; 
9. 100 psig maximum allowable working pressure. 
10. Unfired Boiler – an unfired steam or other vapor-generating system using heat from the operation of a processing system or other indirect heat source. NB-132, Revision 8 4 
11. Hot Water Supply Boiler – a boiler completely filled with water that furnishes hot water to be used externally to itself at pressures not exceeding 160 psig or at temperatures not exceeding 250°F at or near the boiler outlet.
12. Portable Boiler – a boiler which is primarily intended for temporary location, and the construction and usage permits it to be readily moved from one location to another.

CERTIFICATE OF COMPETENCY – a certificate issued to a person who has passed the examination prescribed by the Board.

CERTIFICATE OF INSPECTION – a certificate issued by the chief inspector for the operation of a boiler, pressure vessel, or nuclear system as required by the Act.

CERTIFICATE INSPECTION – an inspection, the report of which is used by the chief inspector as justification for issuing, withholding, or revoking the inspection certificate. This certificate inspection shall be an internal inspection when required; otherwise, it shall be as complete an inspection as possible. 

1. INTERNAL INSPECTION – as complete an examination as can reasonably be made of the internal and external surfaces of a boiler, pressure vessel, or nuclear component while it is shut down, and manhole plates, handhole plates or other inspection-opening closures are removed as required by the inspector. 
2. EXTERNAL INSPECTION – an inspection made when a boiler, pressure vessel, or nuclear component is in operation, if possible.

COMMISSION; NATIONAL BOARD – the commission issued by The National Board of Boiler and Pressure Vessel Inspectors to a holder of a certificate of competency who desires to make shop inspections or field inspections in accordance with the National Board bylaws and whose employer submits the inspector’s application to the National Board for such commission.

COMMISSIONER – the Commissioner (or other appropriate title) of …..

CONDEMNED BOILER, PRESSURE VESSEL, OR NUCLEAR COMPONENT – a boiler, pressure vessel, or nuclear component that has been inspected and declared unsafe or disqualified by legal requirements by an inspector, and a stamping or marking has been applied by the chief or a deputy inspector designating its condemnation.

EXISTING INSTALLATION – includes any boiler, pressure vessel, or nuclear component constructed, installed, placed in operation, or contracted for before (date of passage of Act).

HOT WATER STORAGE TANK – a closed vessel connected to a water heater used exclusively to contain potable water.

INSPECTOR – the chief inspector, or any deputy inspector, special inspector or, owner-user inspector. 

1. CHIEF INSPECTOR – the Chief Boiler and Pressure Vessel Inspector appointed under the Act. 
2. DEPUTY INSPECTOR – any inspector appointed by the Commissioner under the provisions of the Act. 
3. SPECIAL INSPECTOR – an inspector holding a certificate of competency, and who is regularly employed by an authorized inspection agency. 
4. OWNER-USER INSPECTOR – an inspector who holds a valid National Board Owner-User Commission who has passed the examination prescribed by the Board or is an API Certified Inspector under a jurisdictionally approved owner-user inspection organization.

LINED POTABLE WATER HEATER – a water heater with a corrosion resistant lining used to supply potable hot water.

MODIFICATION/NUCLEAR COMPONENT – the process of changing an item that requires revision of the existing design requirements and may also require a revision to the design specification.

NATIONAL BOARD – The National Board of Boiler and Pressure Vessel Inspectors (NB), 1055 Crupper Avenue, Columbus, Ohio 43229, whose membership is composed of the chief inspectors of jurisdictions who are charged with the enforcement of the provisions of the Boiler and Pressure Vessel Safety Act.

NATIONAL BOARD INSPECTION CODE ANSI/NB-23 – the code for jurisdictional authorities, inspectors, users, and organizations performing repairs and alterations to pressure-retaining items. It is published by the National Board.

NATIONAL BOARD COMMISSION – A certificate issued by the National Board to an individual who has passed the National Board Examination, who holds a valid certificate of competency and who is regularly employed by an Authorized Inspection Agency.

NATIONAL BOARD COMMISSIONED INSPECTOR – An individual who: 

• holds a valid Certificate of Competency to perform inservice, repair and alteration inspections as defined by the National Board Inspection Code; 
• holds a National Board commission; and is regularly employed as an inspector by an Authorized Inspection Agency.

NEW BOILER, PRESSURE VESSEL, OR NUCLEAR COMPONENT INSTALLATION – includes all boilers, pressure vessels, and nuclear components constructed, installed, placed in operation or contracted for after (fill in the date).

NONSTANDARD BOILER, PRESSURE VESSEL, OR NUCLEAR COMPONENT – a boiler, pressure vessel, or nuclear component that does not bear a stamp acceptable to the jurisdiction, or otherwise does not comply with the Act or stated rules and regulations of this jurisdiction.

NUCLEAR COMPONENT – the items in a nuclear power plant such as vessels, piping systems, pumps, valves, and component supports.

NUCLEAR POWER PLANT – one or more nuclear power systems and containment systems.

NUCLEAR SYSTEM – a system comprised of nuclear components which collectively serve the purpose of producing and controlling an output of thermal energy from nuclear fuel and includes those associated systems essential to the function and overall safety of the power system.

ORIGINAL CODE OF CONSTRUCTION – documents promulgated by recognized national standards-writing bodies that contain technical requirements for construction of pressure-retaining items or equivalent to which the pressure-retaining item was certified by the original manufacturer.

OWNER OR USER – any person, firm, or corporation legally responsible for the safe installation, operation, and maintenance of any boiler, pressure vessel, or nuclear component within the jurisdiction.

OWNER-USER INSPECTION ORGANIZATION – an owner or user of pressure-retaining items who maintains a regularly established inspection department, whose organization and inspection procedures meet the requirements of the National Board rules or API-510, as applicable, and are acceptable to the Board.

PRESSURE VESSEL – a vessel in which the pressure is obtained from an external source, or by the application of heat from an indirect source, or from a direct source other than those boilers defined in item 14.

PRESSURE-RETAINING ITEM (PRI) – Any boiler, pressure vessel, piping, or material used for the containment of pressure, either internal or external. The pressure may be obtained from an external source, or by the application of heat from a direct source, or any combination thereof.

PSIG – pounds per square inch gage.

REINSTALLED BOILER, PRESSURE VESSEL, OR NUCLEAR COMPONENT – a boiler, pressure vessel, or nuclear component removed from its original setting and reinstalled at the same location or at a new location without change of ownership.

RELIEF VALVE – a pressure relief valve actuated by inlet static pressure having a gradual lift generally proportional to the increase in pressure over opening pressure. It may be provided with an enclosed spring housing suitable for closed discharge system application and is primarily used for liquid service.

REPAIR – the work necessary to restore a pressure-retaining item to a safe and satisfactory operating condition.

REPAIR/NUCLEAR COMPONENT – the work necessary to restore a nuclear component or system to a safe and satisfactory operating condition, provided there is no deviation from the original design requirements.

REPAIR/PRESSURE RELIEF VALVE – the replacement, remachining, or cleaning of any critical part, lapping of seat and disk, or any other operation which may affect the flow passage, capacity function, or pressure-retaining ability of the valve. Disassembly, reassembly, and/or adjustments which affect the pressure relief valve function are also considered a repair.

REPLACEMENT/NUCLEAR COMPONENT – the installation of renewal components, appurtenances and subassemblies or parts of a component or system not affecting existing design requirements.

SAFETY RELIEF VALVE – a pressure relief valve characterized by rapid opening or pop action, or by opening in proportion to the increase in pressure over opening pressure, depending on application.

SAFETY VALVE – a pressure relief valve actuated by inlet static pressure and characterized by rapid opening or pop action.

SECONDHAND BOILER, PRESSURE VESSEL, OR NUCLEAR COMPONENT – a boiler, pressure vessel, or nuclear component which has changed both location and ownership since primary use.

STANDARD BOILER, PRESSURE VESSEL, OR NUCLEAR COMPONENT – a boiler, pressure vessel, or nuclear component which bears the stamp of this
jurisdiction, the ASME stamp, the API/ASME stamp, both the ASME and National Board stamp, or the stamp of another jurisdiction which has adopted a standard of construction equivalent to that required by the Board.

WATER HEATER – a closed vessel used to supply potable hot water which is heated by the combustion of fuels, electricity, or any other source and withdrawn for use external to the system at pressures not exceeding 160 psig, or a heat input of 200,000 BTU per hour, and shall include all controls and devices necessary to prevent water temperatures from exceeding 210°F.

MINIMUM CONSTRUCTION STANDARDS FOR BOILERS, PRESSURE VESSELS, OR OTHER PRESSURE-RETAINING ITEMS 

A. ALL new boilers, pressure vessels, or other pressure-retaining items installed and operated in this jurisdiction unless otherwise exempted, shall be designed and constructed in accordance with the ASME Code or a nationally recognized Code of Construction accepted by this jurisdiction.  ALL new pressure-retaining items installed in this jurisdiction shall be marked in accordance with the Code of Construction and shall be registered with the National Board in accordance with NB-264, Criteria for Registration of Boilers, Pressure Vessels and Other Pressure-Retaining Items, or listed in accordance with NB-265, Criteria for Listing of Boilers, Pressure Vessels and Other Pressure-Retaining Items Not Registered with the National Board. Pressure-relieving devices shall be constructed to the ASME Code and certified by the National Board in accordance with NB-500, Criteria for Certification of Pressure Relief Devices. Copies of registration or listing documents shall be provided to the chief inspector when requested.

B. State Special – If, due to a valid impediment to compliance with the original code of construction, a boiler, pressure vessel, or nuclear component cannot bear the required construction code and National Board stamping, details in the English language and United States customary units of the proposed construction, material specifications and calculations, approved by a registered professional engineer experienced in boiler, pressure vessel and nuclear systems design, shall be submitted to the chief inspector by the owner or user and approval as “State Special” obtained from the Board before construction is started.

C. Before a secondhand boiler, pressure vessel, or nuclear component is installed, application for permission to install it shall be filed by the owner or user with the chief inspector and his/ her approval obtained.

D. The following shall be exempt from these rules: 

1. Boilers and pressure vessels under federal control or regulation; 
2. Pressure vessels used for transportation and storage of compressed gases when constructed in compliance with specifications of the U.S. Department of Transportation and, when charged with gas, marked, maintained, and periodically requalified for use, as required by appropriate regulations of the U.S. Department of Transportation; 
3. Pressure vessels located on vehicles operating under the rules of other jurisdictional authorities and used for carrying passengers or freight; 
4. Pressure vessels installed on the right-of-way of railroads and used directly in the operation of trains; 
5. Pressure vessels having an internal or external operating pressure not exceeding 15 psig with no limit on size; 
6. Pressure vessels having an inside diameter, width, height, or crosssection diagonal not exceeding 6 inches with no limitation on length of the vessel or pressure; 
7. Pressure vessels for containing water under pressure, including those containing air, the compression of which serves only as a cushion, when none of the following limitations are exceeded: 
   1. a design pressure of 300 psig 
   2. a design temperature of 210°F 
8. Pressure vessels containing water heated by steam or any other indirect means when none of the following limitations are exceeded: 
   1. a heat input of 200,000 BTU per hour 
   2. a water temperature of 210°F provided such pressure vessels shall be equipped with an ASME-NB-stamped safety relief valve; 
9. Hot water supply boilers used exclusively for supplying hot water which are directly fired with oil, gas, or electricity, when none of the following limitations are exceeded: 
   1. a heat input of 200,000 BTU per hour 
   2. a water temperature of 210°F NB-132, Revision 8 10 
   3. a nominal water capacity of 120 gallons 
   • It being further provided that this exemption shall not apply to hot water supply boilers that exceed 50 gallons in volume or 100,000 BTU per hour when installed in a place of public assembly. These exempt hot water supply boilers shall be equipped with ASME/NB-stamped safety relief valves; 
10. Potable water heaters and hot water storage tanks for operations at a pressure not exceeding 160 psig where none of the following limitations are exceeded: 
    1. a heat input of 200,000 BTU per hour 
    2. a water temperature of 210°F 
    3. a nominal water capacity of 120 gallons except that they shall be equipped with safety devices in accordance with HLW-800. 
    • It being further provided that this exemption shall not apply to water heaters and hot water storage tanks that exceed 50 gallons in volume or 100,000 BTU per hour when installed in a place of public assembly; 
11. Pressure vessels which may be classified as pressure containers which are integral parts of components of rotating or reciprocating mechanical devices such as pumps, compressors, turbines, generator engines, and hydraulic or pneumatic cylinders where the primary design considerations and stresses are derived from the functional requirements of the device; 
12. Continuous coil-type hot water boilers used only for “steam vapor” cleaning of such things as machinery and buildings when none of the following limitations are exceeded: 
    1. 3/4-inch diameter tubing or pipe size with no drums or headers attached; 
    2. nominal water-containing capacity does not exceed six gallons; 
    3. water temperature does not exceed 35°F; 
    4. steam is not generated within the coil.
    • Exempted continuous coil-type hot water boilers shall be provided with one or more relief valves meeting the requirements of EBO-6, Part III of NB-132. 

E. The following boilers, pressure vessels and piping shall be exempt from the requirements of inservice inspections and certificate inspections as required by Section XIII, XIV, XV, and XVI of the Act:

1. Pressure vessels not exceeding the following limitations:
   1. 5 cubic feet in volume and 250 psig 
   2. 1-1/2 cubic feet in volume and 600 psig 
2. Heating boilers or pressure vessels which are located in private residences or in apartment houses of fewer than six family units; 
3. Pressure vessels operated entirely full of water or liquid which is not materially more hazardous than water, provided the temperature of the vessel’s contents does not exceed 140°F or a pressure of 200 psig; 
4. Power piping and process piping beyond the scope of the ASME Boiler and Pressure Vessel Code (also referred to herein as the ASME Code); 
5. Boilers or pressure vessels located on farms and used solely for agricultural or horticultural purposes; 
6. Pressure vessels used as an external part of an electrical circuit breaker or transformer. 

F. In ALL circumstances, the owner or user shall confer with the chief inspector regarding exemption or nonexemption.

FREQUENCY OF INSPECTIONS OF BOILERS AND PRESSURE VESSELS
A. Except as permitted in (1) below, power boilers and high-temperature water boilers shall receive a certificate inspection annually which shall be an internal inspection where construction permits; otherwise, it shall be as complete an inspection as possible. Such boilers shall also be inspected externally annually while under normal operating conditions.

1. Alternative internal inspection requirements:
   1. Fully attended power boilers and high-temperature boilers may be extended to thirty-six (36) months if the following requirements are met: 
      1. Continuous boiler water treatment under the direct supervision of persons trained and experienced in water treatment for the purpose of controlling and limiting corrosion and deposits. 
      2. Recordkeeping available for review, showing: 
         1. The date and time the boiler is out of service and the reason therefore. 
         2. Daily analysis of water samples that adequately show the conditions of the water and elements or characteristics that are capable of producing corrosion or other deterioration to the boiler or its parts. 
      3. Controls, safety devices, instrumentation, and other equipment necessary for safe operation are up-to-date, inservice, calibrated, and meet the requirements of an appropriate safety code for that size boiler, such as NFPA 85, ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers, National Board Inspection Code ANSI/NB-23, jurisdictional requirements, and are not compromised. 
2. Inspection intervals beyond thirty-six (36) months may be granted at the discretion of the Board. 

B. Low-pressure boilers, water heaters, and hot water storage tanks covered by these rules and regulations shall receive a certificate inspection BIENNIALLY, except boilers located in places of public assembly shall receive a certificate of inspection ANNUALLY, with an internal inspection at least every TWO (2) years where construction permits. 

1. Steam or vapor boilers shall have an external inspection and an internal inspection every two years where construction permits;
2. Hot water heating and hot water supply boilers shall have an external inspection biennially and, where construction permits, an internal inspection at the discretion of the inspector; 
3. Water heaters, including hot water storage tanks, shall have an external inspection every two years which shall include the function of all controls and devices. 

C. Except as provided for in (D) and (E) below, pressure vessels subject to internal corrosion shall receive a certificate inspection BIENNIALLY. This inspection shall be internal where construction permits. Pressure vessels not subject to internal corrosion shall be inspected externally BIENNIALLY.

D. Pressure vessels and unfired boilers that are under the supervision of an owner-user inspection organization shall be inspected at intervals required by NB-23 or API-510, as applicable.

E. Nuclear components shall be inspected as provided by Section XI of the ASME Code.

F. Based upon documentation of such actual service conditions by the owner or user of the operating equipment, the Board may, in its discretion, permit variations in the inspection frequency requirements as provided in the Act.

G. Historical boilers, defined as steam boilers of riveted construction, preserved, restored, or maintained for hobby or demonstration use, shall be subjected to an initial inspection followed by a certificate inspection every three (3) years thereafter if stored inside a shelter and annually if stored outdoors. The initial inspection shall include ultrasonic thickness testing of all pressure boundaries. All thinned areas shall be monitored and recorded on the inspection report.

NOTIFICATION OF INSPECTION

Certificate inspection, as required in Section 2 above, shall be carried out prior to the expiration date of the certificate and at a time mutually agreeable to the inspector and owner or user. External inspections may be performed by the inspector during reasonable hours and without prior notification. When, as a result of external inspection or determination by other objective means, it is the inspector’s opinion that continued operation of the boiler, pressure vessel, or nuclear system constitutes a menace to public safety, the inspector may request an internal inspection or an appropriate pressure test, or both, to evaluate conditions. In such instances, the owner or user shall prepare the boiler, pressure vessel or nuclear system for such inspections or tests as the inspector may designate.

EXAMINATION FOR AN INSPECTOR’S CERTIFICATE OF COMPETENCY – CLICK HERE to see this material in the full document

EXAMINATION FEES – CLICK HERE to see this material in the full document

CERTIFICATE OF COMPETENCY AND IDENTIFICATION CARD – CLICK HERE to see this material in the full document

CONFLICT OF INTEREST – CLICK HERE to see this material in the full document

INSPECTION REPORTS TO BE SUBMITTED BY INSPECTORS – CLICK HERE to see this material in the full document

NOTIFICATION TO CHIEF INSPECTOR – CLICK HERE to see this material in the full document

SPECIAL INSPECTORS TO NOTIFY CHIEF INSPECTOR OF UNSAFE BOILERS, PRESSURE VESSELS, AND NUCLEAR COMPONENTS – CLICK HERE to see this material in the full document

OWNER-USER INSPECTION ORGANIZATIONS – CLICK HERE to see this material in the full document

DEFECTIVE CONDITIONS DISCLOSED AT TIME OF EXTERNAL INSPECTION

If, upon an external inspection, there is evidence of a leak or crack, sufficient covering of the boiler, pressure vessel, or nuclear component shall be removed to permit the inspector to satisfactorily determine the safety of the boiler, pressure vessel, or nuclear component. If the covering cannot be removed at that time, he/she may order the operation of the boiler, pressure vessel, or nuclear component stopped until such time as the covering can be removed and proper examination made.

13. OWNER OR USER TO NOTIFY CHIEF INSPECTOR OF ACCIDENT

When an accident occurs to a boiler, pressure vessel, power piping, process piping or nuclear system, the owner or user shall promptly notify the chief inspector and submit a detailed report of the accident. In the event of a personal injury or any explosion, notice shall be given immediately by telephone, or accepted means of electronic communication, and neither the boiler, pressure vessel, power piping, process piping or nuclear system, nor any parts thereof, shall be removed or disturbed before permission has been given by the chief inspector, except for the purpose of saving human life and limiting consequential damage.

14. INSPECTION CERTIFICATE AND INSPECTION FEES
…

4. Pressure vessels

Certificate Inspections

Fees to be based on the maximum length of the vessel times the maximum width or diameter thereof in feet.
Each pressure vessel subject to inspection having a product as determined above 50 sq. ft. or less $_________
For each additional 100 sq. ft., or portions thereof, of area in excess of 50 sq. ft. $_________
Not more than $ ____ shall be paid for each inspection on any one vessel.

A group of pressure vessels, such as the rolls of a paper machine or dryer operating as a single machine or unit, shall be considered as one pressure vessel. Not more than one fee shall be charged or collected for any and all inspections as above of any pressure vessels in any required inspection period except as provided in paragraphs 5 and 6 below.

6. Pressure tests
When it is necessary to make a special trip to witness the application of a pressure test, an additional fee based on the scale of fees applicable to a certificate inspection of the boiler or pressure vessel shall be charged.

7. All other inspections, including shop inspections, special inspections, certificate reinspections, and inspections of secondhand or used boilers, pressure vessels, or nuclear components made by the chief or deputy inspector, shall be charged for at the rate of not less than $ _____ for one-half day of four hours or any portion thereof, or $ _____ for one full day at four to eight hours, including travel time, plus all expenses, including traveling, meals and lodging.

…

15. STAMPING/RESTAMPING OF BOILERS, PRESSURE VESSELS OR OTHER PRESSURE-RETAINING ITEMS

A. The stamping shall not be concealed by lagging or paint and shall be exposed at all times unless a suitable record is kept of the location of the stamping so that it may be readily uncovered at any time this may be desired.

B. When the stamping on a boiler, pressure vessel, or nuclear component becomes indistinct, the inspector shall instruct the owner or user to have it restamped. Request for permission to restamp the boiler, pressure vessel, or nuclear component shall be made to the chief inspector and proof of the original stamping shall accompany the request. The chief inspector may grant such authorization. Restamping authorized by the chief inspector shall be done only in the presence of a deputy inspector, and shall be identical with the original stamping except for the ASME Code symbol stamp. Notice of completion of such stamping shall be filed with the chief inspector by the inspector who witnessed the stamping on the boiler, pressure vessel, or nuclear component together with a facsimile of the stamping applied.

16. PENALTY FOR OPERATION OF UNSAFE BOILERS, PRESSURE VESSELS, OR NUCLEAR COMPONENTS 

A. If, upon inspection, a boiler, pressure vessel, or nuclear component is found to be in such condition that it is unsafe to operate, the inspector shall notify the chief inspector and the inspection certificate may be suspended by the chief inspector. 

B. Any person, firm, partnership, or corporation causing such objects to continue to be operated shall be subject to the penalty provided in the Act.

17. CONDEMNED BOILERS, PRESSURE VESSELS, AND NUCLEAR COMPONENTS 

A. Any boiler, pressure vessel, or nuclear component having been inspected and declared unfit for further service by an inspector shall be stamped by the chief inspector or a deputy inspector on either side of the jurisdiction number with the letters “XXX” as shown by the preceding facsimile, which will designate a condemned boiler, pressure vessel, or nuclear component. 

B. Any person, firm, partnership, or corporation using or offering for sale a condemned boiler, pressure vessel, or nuclear component for operation within this jurisdiction shall be subject to the penalties provided by the Act.

18. REINSTALLATION OF BOILERS, PRESSURE VESSELS, OR NUCLEAR COMPONENTS MOVED OUTSIDE THE JURISDICTION 

When a standard boiler, pressure vessel, or nuclear component located within this jurisdiction is to be moved outside the jurisdiction for temporary use or for repair, alteration, or modification, application shall be made by the owner or user to the chief inspector for permission to reinstall the boiler, pressure vessel, or nuclear component in this jurisdiction. When a nonstandard boiler, pressure vessel, or nuclear component is removed from this jurisdiction, it shall not be reinstalled within this jurisdiction.

19. INSTALLATION, OPERATION, SALE, OR OFFERING FOR SALE OF NONSTANDARD BOILERS, PRESSURE VESSELS, OR NUCLEAR COMPONENTS 

The installation, operation, sale, or the offering for sale of nonstandard boilers, pressure vessels, or nuclear components in this jurisdiction without prior permission from the Board is prohibited.

20. INSTALLATION OF USED OR SECONDHAND BOILERS, PRESSURE VESSELS, OR NUCLEAR COMPONENTS 

Before a used or secondhand boiler, pressure vessel, or nuclear component may be shipped for installation in this jurisdiction, an inspection must be made by an inspector qualified by this jurisdiction or by an inspector holding a valid National Board commission, and data submitted by him/her shall be filed by the owner or user of the boiler or pressure vessel with the chief inspector for his/her approval. Such boilers, pressure vessels, and nuclear components, when installed in the jurisdiction, shall be equipped with fittings and appurtenances that comply with the rules and regulations for new installations.

21. REINSTALLED BOILERS, PRESSURE VESSELS, OR NUCLEAR COMPONENTS 

When a stationary boiler, pressure vessel, or nuclear component is moved and reinstalled within this jurisdiction, the attached fittings and appurtenances shall comply with these rules and regulations for NEW installations.

22. WORKING PRESSURE FOR EXISTING INSTALLATIONS 

Any inspector may decrease the working pressure on any existing installation if the condition of the boiler, pressure vessel, or nuclear component warrants it. If the owner or user does not concur with the inspector’s decision, the owner or user may appeal to the Board, which may request a joint inspection by the chief inspector or a deputy inspector and the inspector. The chief inspector shall render a report to the Board and the Board shall render the final decision, based upon the data contained in the inspector’s reports.

23. REPAIRS AND ALTERATIONS TO BOILERS AND PRESSURE VESSELS 

Repairs and alterations to boilers and pressure vessels shall be made in accordance with the latest edition of the National Board Inspection Code, or the API Pressure Vessel Inspection Code, as applicable.

24. REPAIRS TO PRESSURE RELIEF VALVES 

A. Repairs to pressure relief valves except as in (B) below, shall be made in accordance with the latest edition and addenda of the National Board Inspection Code by an organization which holds a valid Certificate of Authorization for use of the National Board Pressure Relief Valve Repair “VR” symbol stamp. At the approval of the Board, owner-user inspection organizations may test and repair pressure relief devices in accordance with the requirements of API-510. The initial installation, testing and adjustments of a new pressure relief valve on a boiler, pressure vessel, or nuclear component are not considered a repair if made by the manufacturer or assembler of the valve. 

B. The Board may authorize properly trained and qualified employees of boiler, pressure vessel, and nuclear component users or their designees to make adjustments to set pressure and/or blowdown to pressure relief valves owned by them, provided the adjusted settings and/or capacities and the date of the adjustment are recorded on a metal tag secured to the seal wire. All external adjustments shall be resealed showing the identification of the organization making the adjustments. A record of all external adjustments shall be maintained and made available to the inspector. 

25. REPAIR, MODIFICATION, OR REPLACEMENT OF NUCLEAR COMPONENTS 

Repair, modification, or replacement of nuclear components shall be made only by an organization which holds a valid Certificate of Authorization for use of the National Board nuclear “NR” symbol stamp. Repair, modification, or replacement of ASME stamped “NR” pressure relief valves shall be made only by an organization which holds valid National Board Certificates of Authorization for use of the “NR” and “VR” symbol stamps.

26. RIVETED PATCHES 

In applying riveted patches, the design of the patch and method of installation shall be in accordance with the National Board Inspection Code, 1973 edition. 

27. SAFETY APPLIANCES 

A. NO person shall attempt to remove or do any work on any safety appliance prescribed by these rules and regulations while the appliance is subject to pressure. 

B. Should any of these appliances be removed for repair during an outage of a boiler or pressure vessel, they MUST be reinstalled and in proper working order BEFORE the object is again placed in service. 

C. NO person shall alter any safety or safety relief valves or pressure relief devices in any manner to maintain a working pressure in excess of that stated on the boiler or pressure vessel inspection certificate.

28. APPLICATION OF SERIAL NUMBERS 

A. Upon completion of the installation of a boiler, pressure vessel, or nuclear system, or at the time of the initial certificate inspection of an existing installation, each boiler or pressure vessel shall be identified by a number unique to that item. 

B. All cast-iron, low-pressure heating boilers shall have securely attached to the front of the boiler a corrosion-resistant metal tag of not less than one inch by four inches in size, which shall have the serial number of the jurisdiction stamped thereon. All pressure vessels constructed of cast iron, or of material of such thickness that it should not be stamped, shall have securely attached a corrosion-resistant metal tag not less than one inch by four inches in size, which shall have the serial number of the jurisdiction stamped thereon.

29. VARIATIONS 

A. Any person who believes the rules and regulations promulgated by the Board are unreasonable or impose an undue burden upon the owner or variation shall be in writing and shall specify how equivalent safety is to be maintained. The Board, after investigation and such hearing as it may direct, may grant such variation from the terms of any rule or regulation provided such special conditions as may be specified are maintained in order to provide equivalent safety.

B. When there is a reason to believe, or upon receipt of a complaint that a variation does not provide freedom from danger equivalent to the published rule or regulation, the Board, after notice to the owner or user and complainant after such hearing and investigation as it may direct, may continue to reaffirm, suspend, revoke, or modify the conditions specified in any variation. No declaration, act, or omission of the Board, or of the chief inspector, deputy inspectors, or special inspectors, other than a written order authorizing a variation as permitted above, shall be deemed to exempt, either wholly or in part, expressly or implied, any owner or user from full compliance with the terms of any rule or regulation.

30. PENALTIES 

Any person, firm, or corporation violating any of the provisions of these rules and regulations shall be guilty of a misdemeanor and subject to a fine to be collected by suit or through compromise as provided for in Section XV of the Act. Each day of such operation in violation of the provisions shall be considered a separate offense.

PART III EXISTING INSTALLATION

SECTION 3 — PRESSURE VESSELS

EPV-1 Maximum Allowable Working Pressure for Standard Pressure Vessels

The maximum allowable working pressure for standard pressure vessels shall be determined in accordance with the applicable provisions of the edition of the ASME Code or the API-ASME Code under which they were constructed and stamped.

EPV-2 Maximum Allowable Working Pressure for Nonstandard Pressure Vessels, Except as Provided in EPV-3

A. The maximum allowable working pressure of a nonstandard pressure vessel shall be determined by the strength of the weakest course computed from the thickness of the plate, the tensile strength of the plate, the efficiency of the longitudinal joint, the inside diameter of the course, and the factor of safety set by these rules.

TStE
RFS = maximum allowable working pressure, psig

where:
TS = specified minimum tensile strength of shell plate material, psi (When the tensile strength of carbon steel plate is not known, it may be taken as 55,000 psi for temperatures not exceeding 650°F. For other materials, use the lowest stress values for that material from Section VIII of the ASME Code.)

t = minimum thickness of shell plate of weakest course, inches

E = efficiency of longitudinal joint depending upon construction

Use the following values: for riveted joints – calculated riveted efficiency; for fusion welded and brazed joints.

Percent

Single lap weld              40
Double lap weld             50
Single butt weld             60
Double butt weld            70
Forge weld                    70
Brazed steel                  80

R = Inside radius of weakest course of shell (inches) provided the thickness does not exceed 10 percent of the radius. If the thickness is over 10 percent of the radius, the outer radius shall be used

FS = factor of safety allowed by these rules

B. The minimum factor of safety shall in no case be less than 5 for existing installations. The working pressure shall be decreased when deemed necessary by the inspector to ensure the operation of the vessel within safe limits. The condition of the vessel and the particular service to which it is subject will be the determining factors.

C. The maximum allowable working pressure permitted for formed heads under pressure shall be determined by using the appropriate formulas from ASME Code Section VIII, Div. 1, and the tensile strength and factors of safety given in Paragraphs EPV-1 and EPV-2(A) and (B).

D. The maximum allowable working pressure for nonstandard pressure vessels subjected to external pressure shall be determined by the rules of Section VIII, Div.1, of the ASME Code.

EPV-3 Formulas 

Pressure vessels that were not ASME Code-stamped but which were constructed of known materials and were designed and constructed in accordance with sound engineering standards, formulas, and practices that provide safety equivalent to the intent of the Code shall be calculated on the same basis as used in the original design.

EPV-4 Inspection of Inaccessible Parts 

Where, in the opinion of the inspector, as the result of conditions disclosed at the time of inspection, it may be necessary to remove interior or exterior lining, covering or brickwork to expose certain parts of the vessel not normally visible, the owner or user shall remove such material to permit proper inspection and to determine remaining thickness.

EPV-5 Overpressure Protection

Each pressure vessel shall be provided with pressure relief devices which are ASME-NB-stamped and certified or indicating and controlling devices as necessary to protect against overpressure. These devices shall be so constructed, located, and installed that they cannot readily be rendered inoperative. The relieving capacity of such pressure relief devices shall be adequate to prevent a rise in pressure in the vessel of more than 10 percent or 3 psig, whichever is greater, above the maximum allowable working pressure except when multiple relieving devices are provided, they shall prevent the pressure from rising more than 16 percent or 4 psig, whichever is greater, above the maximum allowable working pressure. When multiple pressure relieving devices are provided, at least one device shall be set at or below the maximum allowable working pressure and the additional devices shall be set no higher than 105 percent of the maximum allowable working pressure. Where an additional hazard is involved due to fire or other unexpected sources of external heat, the pressure relief devices shall meet the requirements of ASME Code Section VIII, Div. 1, Paragraph UG-125, or Div. 2, Paragraph AR-130, whichever is applicable.

EPV-6 Repairs and Renewals of Fittings and Appliances 

Whenever repairs are made to fittings and appliances or it becomes necessary to replace them, the work must comply with the requirements for new installations.

PART IV GENERAL REQUIREMENTS

GR-1 Inspection of Boilers and Pressure Vessels

All boilers and pressure vessels not exempted by the Act or by rules and regulations promulgated under the Act and which are subject to regular inspections shall be prepared for such inspections as required in GR-2.

GR-2 Preparation for Inspection

The owner or user shall prepare each boiler or pressure vessel for inspection, and shall prepare for and apply a hydrostatic or pressure test, whenever necessary, on the date arranged by the inspector which shall not be less than seven (7) days after the date of notification.

A. Boilers – The owner or user shall prepare a boiler for internal inspection in the following manner:

1. Water shall be drawn off and the boiler washed thoroughly;
2. Manhole and handhole plates, washout plugs, and inspection plugs in water column connections shall be removed as required by the inspector. The furnace and combustion chambers shall be cooled and thoroughly cleaned; 
3. All grates of internally fi red boilers shall be removed; 
4. Insulation or brickwork shall be removed as required by the inspector in order to determine the condition of the boiler, headers, furnace, supports, or other parts; 
5. The pressure gage shall be removed for testing as required by the inspector; 
6. Any leakage of steam or hot water into the boiler shall be prevented by disconnecting the pipe or valve at the most convenient point or any appropriate means approved by the inspector; 
7. Before opening the manhole or handhole covers and entering any parts of the steam generating unit connected to a common header with other boilers, the non-return and steam stop valves must be closed, tagged, and padlocked, and drain valves or cocks between the two valves opened. The feed valves must be closed, tagged, and padlocked, and drain valves or cocks located between the two valves opened. After draining the boiler, the blowoff valves shall be closed, tagged, and padlocked. Blowoff lines, where practicable, shall be disconnected between pressure parts and valves. All drains and vent lines shall be opened.

B. Pressure Vessels – Pressure vessels shall be prepared for inspection to the extent deemed necessary by the inspector and the applicable
procedures outlined in (A) above.

GR-3 Boilers and Pressure Vessels Improperly Prepared for Inspection

If a boiler or pressure vessel has not been properly prepared for an internal inspection, or if the owner or user fails to comply with the requirements for a pressure test as set forth in these rules, the inspector may decline to make the inspection or test and the inspection certificate shall be withheld or right-to operate revoked, until the owner or user complies with the requirements.

GR-4 Removal of Covering to Permit Inspection

If, upon an external inspection, there is evidence of a leak or crack, sufficient covering of the boiler or pressure vessel shall be removed to permit the inspector to satisfactorily determine the safety of the boiler or pressure vessel.

GR-5 Lap Seam Crack

The shell or drum of a boiler or pressure vessel (in which a lap seam crack is discovered along a longitudinal riveted joint) shall be immediately discontinued from use. Patching is prohibited. (Lap seam crack refers to a crack found in lap seams extending parallel to the longitudinal joint, and located either between or adjacent to rivet holes.)

GR-6 Pressure Test

A pressure test, when applied to boilers or pressure vessels, need not exceed the maximum allowable working pressure or the setting of the lowest set safety valves. The pressure shall be under proper control so that in no case shall the required test pressure be exceeded. During a pressure test the safety valve or valves shall be removed or each valve disk shall be held to its seat by means of a testing clamp and not by screwing down the compression screw upon the spring. A plug device designed for this purpose may be used. It is suggested that the minimum metal temperatures during a pressure test shall be not less than 70°F, and that the maximum metal temperature during inspection shall not exceed 120°F. When a pressure test is applied to determine tightness, the pressure shall be equal to the normal operating pressure but need not exceed the release pressure of the safety valve having the lowest release setting. When the contents of the vessel prohibit contamination by any other medium or when a water pressure test is not possible, other testing media may be used providing the precautionary requirements of the applicable section of the ASME Code are followed. In such cases, there shall be agreement between the owner and the inspector.

GR-7 Automatic Low-Water Fuel Cutoff and/or Water Feeding Device

Each automatically fired steam or vapor system boiler shall be equipped with an automatic low-water fuel cutoff so located as to automatically cut off the fuel supply when the surface of the water falls to the lowest safe waterline. If a waterfeeding device is nstalled, it shall be so constructed that the water inlet valve cannot feed water into the boiler through the fl oat chamber and so located as to supply requisite feedwater. The lowest safe waterline should not be lower than the lowest visible part of the water glass.  Hot water heating boilers shall be equipped with a Low Water Fuel Cutoff with a manual reset function. Such fuel or feedwater control devices may be attached directly to a boiler or for low pressure boilers, to the tapped openings provided for attaching a water glass directly to a boiler, provided that such connections from the boiler are nonferrous tees or Ys not less than 1/2 in. pipe size between the boiler and the water glass, so that the water glass is attached directly and as close as possible to the boiler; the straightway tapping of the Y or tee to take the water glass fittings, the side outlet of the Y or tee to take the fuel cutoff or water-feeding device. The ends of all nipples shall be reamed to full size diameter.  Designs embodying a float and float bowl shall have a vertical straightaway valve drain pipe at the lowest point in the water equalizing pipe connections by which the bowl and the equalizing pipe can be flushed and the device tested.

GR-8 Pressure Reducing Valves

Where pressure reducing valves are used, one or more safety or safety relief valves shall be provided on the low-pressure side of the reducing valve when the piping or equipment on the low pressure side does not meet the requirements for the full initial pressure. The safety or safety relief valves shall be located adjoining or as close as possible to the reducing valve. Proper protection shall be provided to prevent injury or damage caused by the escaping fluid from the discharge of safety or safety relief valves if vented to the atmosphere. The combined discharge capacity of the safety or safety relief valves shall be such that the pressure rating of the lower pressure piping or equipment shall not be exceeded in case the reducing valve fails in the open position.

The use of hand-controlled bypasses around reducing valves is permissible. If a bypass is used around the reduction valve, the safety valve required on the low pressure side shall be of sufficient capacity to relieve all the fluid that can pass through the bypass without over-pressuring the low pressure side. A pressure gage shall be installed on the low-pressure side of a reducing valve.

GR-9 Boiler Blowoff Equipment

The blowdown from a boiler or boilers that enters a sanitary sewer system or blowdown which is considered a hazard to life or property shall pass through some form of blowoff equipment that will reduce pressure and temperature as required hereinafter. The temperature of the water leaving the blowoff equipment shall not exceed 140°F. The pressure of the blowdown leaving any type of blowoff equipment shall not exceed 5 psig. All blowoff equipment shall be fitted with openings to facilitate cleaning and inspection. Blowoff equipment shall conform to the provisions set forth in the recommended rules for Sizing Blowoff Vessels 2004 Edition.

GR-10 Location of Discharge Piping Outlets

The discharge of safety valves, blowoff pipes, and other outlets shall be located and supported as to prevent injury to personnel.

GR-11 Supports

Each boiler and pressure vessel shall be supported by masonry or structural supports of sufficient strength and rigidity to safely support the boiler or pressure vessel and its contents. There shall be no excessive vibration in either the boiler, pressure vessel, or its connecting piping.

GR-12 Boiler Door Latches

A watertube boiler shall have the firing doors of the inward opening type, unless such doors are provided with substantial and effective latching or fastening devices or otherwise so constructed as to prevent them, when closed, from being blown open by pressure on the furnace side. These latches or fastenings shall be of the positive self-locking type. Friction contacts, latches, or bolts actuated by springs shall not be used. The foregoing requirements for latches or fastenings shall not apply to coal openings of downdraft or similar furnaces.  All other doors, except explosion doors, not used in the firing of the boiler, may be provided with bolts or fastenings in lieu of self-locking latching devices. Explosion doors, if used and if located in the setting walls within 7 ft. of the firing floor or operating platform, shall be provided with substantial deflectors to divert the blast.

GR-13 Clearance

When boilers are replaced or new boilers are installed in either existing or new buildings, a minimum height of at least 3 ft. shall be provided between the top of the boiler proper and the ceiling, and at least 3 ft. between all sides of the boiler and adjacent walls or other structures. Boilers and pressure vessels having manholes shall have 5 ft. clearance from the manhole opening and any wall, ceiling or piping that will prevent a person from entering the boiler or vessel. All boilers and pressure vessels shall be so located that adequate space will be provided for the proper operation of the boilers and pressure vessels and their appurtenances, for the inspection of all surfaces, tubes, waterwalls, economizers, piping, valves and other equipment, and for their necessary maintenance and repair and replacement of tubes.

GR-14 Ladders and Runways

When necessary for safety, there shall be a steel runway or platform of standard construction installed across the tops of adjacent boilers or pressure vessels or at some other convenient level for the purpose of affording safe access. All walkways shall have at least two means of exit, each to be remotely located from the other.

GR-15 Exit from Boiler Room

All boiler rooms exceeding a 500 sq. ft. floor area and containing one or more boilers having a fuel burning capacity of 1,000,000 BTU, or equivalent electrical heat input, shall have at least two means of exit. Each exit shall be remotely located from the other. Each elevation in such boiler room shall have two means of exit, each remotely located from the other.

GR-16 Suggestions for Operations

It is suggested that the Recommended Rules for Care of Power Boilers, Section VII, and the Recommended Rules for Care and Operation of Heating Boilers, Section VI, of the ASME Code be used as a guide for proper and safe operating practices.

GR-17 Air and Ventilation Requirements – Combustion Air Supply and Ventilation of Boiler Room

A permanent source of outside air shall be provided for each boiler room to permit satisfactory combustion of the fuel as well as proper ventilation of the boiler room under normal operating conditions.

A. The total requirements of all burners for all fired pressure vessels and air compressors or other air-consuming equipment in the boiler room must be used to determine the net louvered area in square feet:

INPUT BTU/HOUR	REQUIRED AIR CU/FT/MIN	MIN. NET LOUVERED AREA, SQ. FT.
500,000	125	1.0
1,000,000	250	1.0
2,000,000	500	1.6
3,000,000	750	2.5
4,000,000	1,000	3.3
5,000,000	1,250	4.1
6,000,000	1,500	5.0
7,000,000	1,750	5.8
8,000,000	2,000	6.6
9,000,000	2,250	7.5
10,000,000	2,500	8.3

B. When mechanical ventilation is in lieu of paragraph (A), the supply of combustion and ventilation air to the boiler room and the fi ring device will not operate with the fan off. The velocity of the air through the ventilating fan shall not exceed 500 feet per minute and the total air delivered shall be equal to or greater than shown in paragraph (A) above.

GR-18 Gas Burners

For installations which are gas-fired, the burners used shall conform to the applicable requirements of nationally recognized standards.
GR-19 Conditions Not Covered by These Rules and Regulations For any conditions not covered by these requirements, the applicable provisions
of the ASME Code, the National Board Inspection Code, or the American Petroleum Institute Pressure Vessel Inspection Code shall apply.